New Holland TT3840,TT3840F,TT4030,TT3880F Tractor Service Repair Manual (47921938) - PDF Download by www.heydownloads.com

SERVICE MANUAL

SERVICE MANUAL TT3840 / TT3840F / TT4030 / TT3880F Tractor

TT3840 TT3840F TT4030 TT3880F Tractor

1/1 Part number 47921938

Part number 47921938 English February 2017

SERVICE MANUAL TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017 EN

Link Product / Engine Product TT3840 Sem cabine, 8x2, TIER 2, atualizaĂ§ĂŁo, modelo ano 2016 TT3840F Sem cabine, 8x2, modelo ano 2016 TT3880F Sem cabine, 8x2, modelo ano 2016 TT3880F Sem cabine, 12x3, modelo ano 2016 TT4030 Sem cabine, 8x2, 2WD, modelo ano 2016 TT4030 Sem cabine, 8x2, 4WD, modelo ano 2016

Market Product Latin America

8035.05.716

Latin America

8035.05.716

Latin America

8045.05.716

Latin America

8045.05.716

Latin America

8045.05.716

Latin America

8045.05.716

47921938 07/02/2017

Engine

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

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

Transmission.............................................................................. 21 [21.114] Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.130] Mechanical transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.140] Mechanical transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3

Four-Wheel Drive (4WD) system .................................................. 23 [23.304] Four-Wheel Drive (4WD) gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1

47921938 07/02/2017

[23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2

Front axle system ....................................................................... 25 [25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 [25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3 [25.310] Final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4 [25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.5

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 [31.101] Rear mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 [31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2

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

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.100] Main lift system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.116] Three-point hitch cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.114] Three-point hitch control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7

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

Steering..................................................................................... 41 47921938 07/02/2017

[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

Wheels ...................................................................................... 44 [44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1

Electrical systems ....................................................................... 55 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5

Platform, cab, bodywork, and decals ............................................. 90 [90.151] Cab interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1

47921938 07/02/2017

INTRODUCTION

47921938 07/02/2017

Contents INTRODUCTION Advice (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 International symbols (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety rules (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Basic instructions Hardware (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 General specification - Biodiesel Fuels (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Consumables LoctiteÂŽ Product Chart (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

(*) See content for specific models 47921938 07/02/2017

INTRODUCTION

Advice TT3840F TT3840 TT3880F TT4030

LA LA LA LA

BT09A213

47921938 07/02/2017

INTRODUCTION

International symbols TT3840F TT3840 TT3880F TT4030

LA LA LA LA

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. Thermostart Start-up help

Radio

PTO

Control Control

Alternator charging

Keep alive memory

Transmission in neutral

Check Control

Fuel level

Turn signals

Creeper gears

Accessory socket

Auto Fuel shut-off

Turn signals -one trailer

Slow or low setting

Implement socket

Turn signals -two trailers

Fast or high setting

%age slip

Ground speed

Hitch raise (rear)

Differential lock

Hitch lower (rear)

rear axle temperature rear axle

Hitch height limit (rear)

Engine speed(rev/ min x 100) Hours recorded Engine oil pressure Engine coolant temperature

Windshield front wash/wipe Windshield front wash/wipe Temperature control erature control

Coolant level

Heater fan

Transmission oil pressure

Hitch height limit (front)

Tractor lights

Air COND.

FWD engaged

Hitch disabled

Head Light main beam

Air filter plugged

FWD disengaged

Head Light dipped beam

Parking sw

Warning!

Remote valve extend

Work lamps

Brake fluid level

Hazard warning lights

Remote oscillating

valve retraction lamps

Trailer sw

Variable control

Remote valve float

Klaxon

Roof beacon

Pressurized! Open carefully

Warning! Corrosive substance

47921938 07/02/2017

Filter transmission system

Malfunction! See Operatorâ&#x20AC;&#x2122;s manual Malfunction! (alternative symbol)

INTRODUCTION

Safety rules TT3840F TT3840 TT3880F TT4030

LA LA LA LA

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.

47921938 07/02/2017

INTRODUCTION

Basic instructions Hardware TT3840F TT3840 TT3880F TT4030

LA LA LA LA

General The TT tractor has been built using metric hardware. NOTE: Be sure to use the hardware specified when using tapped holes, as trying to install ametric bolt in an inch thread, or an inch bolt in a metric thread, will damage the thread. Certain hardware must be tightened to specific torque specifications. If specific torque specifications are not noted, tighten the hardware to the standard torque chart specification listed in this manual.

Plating Hardware used on New Holland balers is plated with zinc chromate (gold color). Gold colored hardware has different torquing requirements from unplated or zinc plated (silver color) hardware because of the difference in the coefficient of friction of the plating material. The torque charts in this manual list the correct specifications for gold, silver, and unplated bolts.

Nut Tightening Whenever possible, the nut should be tightened, not the head of the bolt. When tightening using the bolt head, the clamp load can be lost because some of the torque applied twists the bolt instead of tensioning (stretching) it. The tension on the bolt is what holds the joint together. Approximately 90% of the torque applied during assembly goes to overcoming friction between the parts. The other 10% is used to tension (stretch) the bolt. After assembly, the frictional forces disappear, which is the basis for the saying 'If it does not fail during assembly, it will not fail in service.' The bolt may later fail due to other factors, but not from being over tightened.

Locknuts Most locknuts are coated with a special lubricant that is dry to the touch. Anytime a locknut is used, a lower than normal torque is required. Refer to the torque charts in this manual for specific values.

Jam Nuts When using a jam nut to lock a regular nut, the jam nut should be installed first and tightened to one half the recommended torque, then held in place while installing a regular nut to the recommended torque.

Thread Lubrication The addition of antiseize compound, Molykote, oil, graphite, or any other lubricant to a bolt decreases the friction between it and a nut. This makes it necessary to reduce the recommended torque to prevent over tensioning of the bolt. When using the torque charts in this manual, decrease the value by 20% whenever a lubricant is used.

47921938 07/02/2017

INTRODUCTION

General specification - Biodiesel Fuels TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with methyl esters. NOTICE: Biodiesel Fuel blends are approved for your engine only if they comply with EN14214 Specification Standards or ASTM D6751. NOTICE: It is imperative that you check which blend is approved for your engine with your NEW HOLLAND dealer. Be aware that the use of Biodiesel Fuel that does not comply with the Standards mentioned above could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved may void NEW HOLLAND Warranty coverage.

Biodiesel Fuel Usage Conditions NOTICE: The Biodiesel Fuel must meet the fuel Specification mentioned above. Biodiesel Fuel must be purchased from a trusted supplier that understands the product and maintains good fuel quality. Biodiesel Fuel must be pre-blended by the supplier. Mixing Biodiesel Fuels on-site can result incorrect mixture that can lead to problems with both engine and fuel system. Engine performance is affected by the use of Biodiesel Fuel. There may be up to 12% reduction in power or torque depending on the blend used. NOTICE: DO NOT modify the engine and/or injection pump settings to recover the reduced performance. The reduced power must be accepted if using any Biodiesel Fuel blend. Some modification may be required to allow your engine to run Biodiesel Fuel. Consult you dealer for complete information on these modifications. Biodiesel Fuel has a higher cloud point than Diesel Fuel. NOTICE: The use of high Biodiesel Fuel blends are not recommended in cold weather conditions. With Biodiesel Fuels, it may be necessary to change the engine oil, engine oil filter and fuel filter elements more frequently than with Diesel Fuels. Biodiesel Fuel can remove rust and particles from the inside of on-site fuel storage tanks that would normally adhere to the sides of the tank. Like particle deposits that commonly occur with Diesel Fuel, these particles can become trapped by the machine fuel filters, causing blockage and shortening filter life. In cold weather, this is more likely to happen. Consult your NEW HOLLAND dealer for information on cold weather operation and proper maintenance intervals when using any Biodiesel Fuel blend. When handling Biodiesel Fuel, care must be taken not to allow water into the fuel supply. Biodiesel Fuel will actually attract moisture from the atmosphere. Fuel tanks must be kept as full as possible to limit the amount of air and water vapors in them. It may be necessary to drain the fuel filter water tap more frequently. Potential oxidation and stability could be a problem with the fuel stored in the machine. NOTICE: Machines must not be stored for more than three months with Biodiesel Fuel blends in the fuel system. If long storage periods are necessary, the engine must run on Diesel Fuel for 20 hours to flush the Biodiesel Fuel out of the engine fuel system prior to storage. NOTICE: Biodiesel Fuel must not be stored in on-site storage tanks for more than three months. Any spillage of Biodiesel Fuel must be cleaned up immediately before it can cause damage to the environment and the paint finish of the machine. Before using Biodiesel Fuel blends you should consult with your dealer to receive full information about the approved blend for your machine and any detailed conditions of its usage. 47921938 07/02/2017

INTRODUCTION

NOTICE: Be aware that not fulfilling the requirements and conditions of Biodiesel Fuel usage will void your machineâ&#x20AC;&#x2122;s NEW HOLLAND Warranty coverage.

47921938 07/02/2017

INTRODUCTION

Consumables Loctite® Product Chart TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Bonding Adhesives Product

Color

Strength

Fixture/Full Cure (Steel/ Steel) Time

312

Clear

9.8 – 17.2 MPa 2 min/24 hrs (1421 – 2495 psi)

324

Light amber

34 – 614 MPa (4932 – 89061 psi)

326

Yellow 34 – 300 MPa to light (4932 – amber 43515 psi)

3 min/6 hrs

380

Black

26 MPa (3770 psi)

2 min/24 hrs

409

Clear to slightly cloudy Black

18 – 26 MPa (2611 – 3771 psi)

2 min/24 hrs

426

454

455

4.8 – 20.7 MPa 10 sec/40 sec. none (696 – 3003 psi) none Clear 19 – 28 MPa 1 min/72 hrs (2756 – to slightly 4061 psi) cloudy Clear 9.7 MPa 30 sec/24 hrs none to light (1407 psi) yellow

480

Black

495

Clear to straw colored Pale 29.8 MPa yellow (4322 psi)

E60HP

30 min/24 hrs

Description Recommended Primer or Activator 736 Typical applications include bonding dissimilar materials such as metals, glass or ceramics and where fast fixturing is required between close fitting parts. 7075 Is used to bond flat parts together. Especially suitable for joining dissimilar materials, e.g. ferrite to plated materials in electric motors, loudspeakers, etc. This product is specifically formulated for toughness and impact strength. 7649 Typical applications include bonding ferrites to on one plated materials in electric motors, loudspeaker surface hardware and jewelry where fast fixturing is required. none Is a rubber toughened adhesive with increased flexibility and peel strength along with enhanced resistance to shock. none Is a general purpose cyanoacrylate adhesive gel. The gel consistency prevents adhesive flow even on vertical surfaces.

22 – 30 MPa (3191 – 4352 psi) 12 – 26 MPa (1741 – 3771 psi)

2 min/24 hrs

none

10 sec/30 sec. none

3 hrs/24 hrs

none

Is an adhesive gel toughened with elastomers for impact and peel strength along with improved resistance to heat and humidity. Is particularly suited for bonding porous or absorbent materials such as wood, paper, leather and fabric. Is a general purpose cyanoacrylate adhesive gel with low odor and low blooming properties and is particularly suitable for applications where vapor control is difficult. Is a rubber toughened adhesive with increased flexibility and peel strength along with enhanced resistance to shock. Is a general purpose cyanoacrylate instant adhesive.

Is a toughened, mediumviscosity, industrial grade epoxy adhesive with extended work life. Once mixed, the two-component epoxy cures at room temperature to form a tough, off-white, bond line which provides high peel resistance and high shear strengths. The fully cured epoxy is resistant to a wide range of chemicals and solvents, and acts as an excellent electrical insulator.

47921938 07/02/2017

INTRODUCTION

Surface Preparation Product 7380

7471

7649

Color Yellow to light amber Yellow to light amber

Green

Description Active (Steel/Steel) Time 6 hours Is designed to initiate the cure of Loctite toughened acrylic adhesives. 30 to 70 seconds

30 to 70 seconds

Is used where increased cure speed of LOCTITE® anaerobic products is required. It is especially recommended for applications with passive metals or inert surfaces and with large bond gaps. Is particularly recommended when prevailing temperature is low < 15 °C (60 °F). Is used where increased cure speed of LOCTITE® anaerobic products is required. It is especially recommended for applications with passive metals or inert surfaces and with large bond gaps. Is particularly recommended when prevailing temperature is low < 15 °C (60 °F).

Retain, Cylindrical Assemblies Product

Color

Strength

603

Green

13.5 – 22.5 MPa (1958 – 3264 psi)

609

Green

10.3 – 15.8 MPa (1494 – 2292 psi)

620

Green

17.2 – 24.1 MPa (2495 – 3496 psi)

635

Green 13.8 – opaque 31.0 MPa (2002 – 4497 psi)

Description Recommended Primer or Activator 7471 or Is designed for the bonding of cylindrical fitting 7 min/6 hrs 7469 parts, particularly where consistently clean surfaces cannot be assured. The product cures when confined in the absence of air between close fitting metal surfaces and prevents loosening and leakage from shock and vibration. Typical applications include retaining roller bearings or oil impregnated bushings into housings. 7471 or Is designed for the bonding of cylindrical fitting 25 min/6 hrs 7469 parts. The product cures when confined in the absence of air between close fitting metal surfaces and prevents loosening and leakage from shock and vibration. Typical applications include rotor to shafts in fractional and subfractional horsepower motors. Locks bushings and sleeves in housings on shafts. Augments press fits. 1 hr 10 min/18 7471 or Is designed for the bonding of cylindrical fitting 7469 hrs parts. The product cures when confined in the absence of air between close fitting metal surfaces and prevents loosening and leakage from shock and vibration. Typical applications include locating pins in radiator assemblies, sleeves into pump housings and bearings in auto transmissions. Particularly suitable for applications where temperature resistance up to 200 °C (395 °F) is required. 30 min/72 hrs 7471 or Is designed for the bonding of cylindrical fitting 7469 parts. The product cures when confined in the absence of air between close fitting metal surfaces and prevents loosening and leakage from shock and vibration. Typical applications include rotor to shafts in fractional and subfractional horsepower motors. Locks bushings and sleeves in housings on shafts. Augments press fits. Fixture/Full Cure (Steel/ Steel) Time

47921938 07/02/2017

INTRODUCTION

Retain, Cylindrical Assemblies Product

Color

Strength

Fixture/Full Cure (Steel/ Steel) Time

638

Green

13.5 – 4 min/6 hrs 25.0 MPa (1958 – 3626 psi)

648

Green

13.5 – 4 min/1.5 hrs 25.0 MPa (1958 – 3626 psi)

660

Metallic 17.2 MPa grey (2495 psi)

680

Green

15 min/1.5 hrs

19.3 – 20 min/1.1 hrs 24.1 MPa (2799 – 3496 psi)

Description Recommended Primer or Activator 7471 or Is designed for the bonding of cylindrical fitting 7469 parts, particularly where bond gaps can approach 0.25 mm (0.01 in.) and where maximum strength at room temperature is required. The product cures when confined in the absence of air between close fitting metal surfaces and prevents loosening and leakage from shock and vibration. Typical applications include locking bushings and sleeves into housings and on shafts. 7471 or Is designed for the bonding of cylindrical fitting 7469 parts. The product cures when confined in the absence of air between close fitting metal surfaces and prevents loosening and leakage from shock and vibration. Typical applications include holding gears and sprockets onto gearbox shafts and rotors on electric motor shafts. 7471 or Is designed for the bonding of cylindrical fitting 7469 parts, particularly where bond gaps can approach 0.50 mm (0.02 in). The product cures when confined in the absence of air between close fitting metal surfaces and prevents loosening and leakage from shock and vibration. This product possesses excellent gap cure characteristics. Typical applications include restoring correct fits on worn shafts, spun bearings, and damaged keyways. 7471 or Is designed for the bonding of cylindrical fitting 7469 parts, particularly where low viscosity is required. The product cures when confined in the absence of air between close fitting metal surfaces and prevents loosening and leakage from shock and vibration.

RTV Sealants Product

Color

Strength

Fixture/Full Cure (Steel/ Steel) Time 30 min/14 days

5699

Grey

1.3 – 2.1 MPa (189 – 305 psi)

587

Blue

2 hrs/24 hrs

593

Black

1.5 MPa (218 psi)

5 min/24 hrs

Description

Is designed primarily for flange sealing with excellent oil resistance on rigid flange sealing for example on transmissions and cast metal housings. Forms tough, flexible gaskets directly on the flange. Sensor-safe, low odor, non-corrosive. Excellent oil resistance and joint movement values. Eight times more flexible than cork/composite gaskets; three times more oil resistant than conventional silicones. Temperature range -59 – 260 °C (-75 – 500 °F) intermittent; resists auto and shop fluids. Is designed for superior bonding and sealing properties to most surfaces (not recommended for concrete). This product resists aging, weathering and thermal cycling without hardening, shrinking or cracking. It is formulated to withstand extreme temperature cycling, UV light and ozone. The thixotropic nature reduces the migration of liquid product after application to the substrate.

47921938 07/02/2017

INTRODUCTION

RTV Sealants Product

Color

Strength

595

Clear

1.5 MPa (218 psi)

596

Red

Fixture/Full Cure (Steel/ Steel) Time 5 min/24 hrs

5 min/24 hrs

Description

Is designed for superior bonding and sealing properties to most surfaces (not recommended for concrete). This product resists aging, weathering and thermal cycling without hardening, shrinking or cracking. It is formulated to withstand extreme temperature cycling, UV light and ozone. The thixotropic nature reduces the migration of liquid product after application to the substrate. Is specifically formulated for gasketing and sealing where high temperatures 315 °C (600 °F) are experienced such as exhaust manifolds - crossovers, high temperature ovens and furnaces. Applications where sealing and bonding are required under frequent exposure to temperatures above 235 – 315 °C (450 – 600 °F).

Gasket Sealants Product

Color

Strength

Fixture/Full Cure (Steel/ Steel) Time

509

Blue to 8 – 9 MPa green- (1160 – 1305 psi) ish paste

1 hr/72 hrs

515

Opaq- 6 – 14 MPa ue, dark (870 – purple 2031 psi)

30 min/18 hrs

518

Red

7.5 – 8.5 MPa (1088 – 1233 psi)

30 min/8 hrs

542

Brown

9 – 25 Nm (80 – 222 lb in)

20 min/8 hrs

545

Purple

2 Nm (20 lb in) 30 min/24 hrs

567

Off white Brown

0.3 – 1.7 Nm (3 4 hrs/72 hrs – 15 lb in) 1.1 – 2.8 Nm 2 hr/24 hrs (10 – 25 lb in)

569

Description Recommended Primer or Activator 7471 or Provides resistance to low pressures immediately 7469 after assembly of flanges. It seals close fitting joints between rigid metal faces and flanges. Typically used as a form-in-place gasket on rigid flanged connections, e.g. gearbox and engine casings, etc. The thixotropic nature reduces the migration of liquid product after application to the substrate. 7471 or It seals close fitting joints between rigid metal 7469 faces and flanges and will flex with minor flange movements. Provides resistance to low pressures immediately after assembly of flanges. Typically used as a form-in-place gasket for pumps, thermostats, compressors, transmission housings and axle covers. 7471 or Typical applications include sealing close fitting 7469 joints between rigid metal faces and flanges. Provides resistance to low pressures immediately after assembly of flanges. Typically used as a form-in-place gasket on rigid flanged connections, e.g. gearbox and engine casings, etc. 7471 or Is designed for the locking and sealing of metal 7469 pipes and fittings. The product cures when confined in the absence of air between close fitting metal surfaces and prevents loosening and leakage from shock and vibration. 7471 or Is designed for the locking and sealing of metal 7469 pipes and fittings. The product cures when confined in the absence of air between close fitting metal surfaces and prevents loosening and leakage from shock and vibration. This product is specially formulated to offer lubricity for easy assembly. 7471 or Is designed for the locking and sealing of metal 7469 tapered threads and fittings. 7471 or Is designed for the locking and sealing of plastic 7469 and metal pipes and fittings.

47921938 07/02/2017

INTRODUCTION

Gasket Sealants Product

Color

Strength

592

White

0.113 – 0.330 Nm (1 – 3 lb in)

598

Metallic 1.31 MPa black (190 psi)

Fixture/Full Cure (Steel/ Steel) Time 72 hrs

25 min/72 hrs

Description Recommended Primer or Activator none Is a medium strength anaerobic sealant with Teflon® for tapered pipe threads. The high lubricating properties of this compound prevent galling on pipe threads and fittings. It will provide immediate low pressure sealing and allow the readjustment of fittings shortly after assembly. After 72 hours the joint is sealed to pipe burst pressure. none This product resists aging, weathering and thermal cycling without hardening, shrinking or cracking. Typical applications include oil pans, transmission pans, valve covers, valves and guides, timing gear covers, and differential covers. This product is typically used in applications with an operating range of -54 – 260 °C (-65 – 500 °F).

Thread Locker and Sealing Product

Color

Strength

Fixture/Full Cure (Steel/ Steel) Time

204

Pink

12.4 – 24.9 Nm 10 min/72 hrs (110 – 220 lb in)

222

Purple

4 – 14 Nm (35 – 124 lb in)

242

Blue

5.6 – 17 Nm (50 3 min/6 hrs – 150 lb in)

243

Blue

7 – 24 Nm (62 – 212 lb in)

246

Blue

2 – 5.7 Nm (18 10 min/6 hrs – 50 lb in)

262

Red

271

Red

277

Red

22 – 40 Nm (195 – 354 lb in) 16.9 – 34 Nm (150 – 300 lb in) 32 – 40 Nm (283 – 354 lb in)

20 min/3 hrs

10 min/1 hr

15min/7 hrs

Description Recommended Primer or Activator none Is a dry-to-the-touch, preapplied film for threaded fasteners. It remains inert on the fastener until assembly of the threads releases a quick curing resin. The resin fills all the voids in the threads and cures to securely lock and seal the assembly. 7471 or Is designed for the locking and sealing of threaded 7469 fasteners which require easy disassembly with standard hand tools. 7471 or Is designed for the locking and sealing of threaded 7469 fasteners which require normal disassembly with standard hand tools. 7471 or Is designed for the locking and sealing of threaded 7469 fasteners which require normal disassembly with standard hand tools. 7471 or Is designed for the locking and sealing of threaded 7469 fasteners which require normal disassembly with standard hand tools. The product cures when confined in the absence of air between close fitting metal surfaces and prevents loosening and leakage from shock and vibration. Particularly suitable for heavy duty applications such as bolts used in transmissions, construction equipment or railroad assemblies where resistance to heavy shock, vibration and stress level is required along with exposure to elevated temperatures. 7471 or Is designed for the permanent locking and sealing 7469 of threaded fasteners.

10 min/24 hrs

7471 or 7469

Is designed for the permanent locking and sealing of threaded fasteners.

30 min/7 hrs

7471 or 7469

Is designed for the permanent locking and sealing of threaded fasteners.

47921938 07/02/2017

INTRODUCTION

Thread Locker and Sealing Product

Color

Strength

Fixture/Full Cure (Steel/ Steel) Time

290

Green

10 – 40 Nm (90 20 min/4 hrs – 355 lb in)

425

Dark blue

0.23 – 8.5 Nm (2 – 75 lb in)

2 min/24 hrs

Description Recommended Primer or Activator 7471 or Is designed for the locking and sealing of threaded 7469 fasteners. Because of its low viscosity and capillary action, the product wicks between engaged threads and eliminates the need to disassemble prior to application. 7113 Is designed as a fast curing, low strength adhesive for locking metal and plastics fasteners. The product is designed for pre- or post-application. LOCTITE® 425™ cures quickly on plated metal and plastics fasteners; fixturing is achieved in less than 2 minutes and full strength within 24 hours.

47921938 07/02/2017

SERVICE MANUAL Engine TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017

Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

47921938 07/02/2017

CONSUMABLES INDEX Consumable Loctite速 Loctite速 NEW HOLLAND AMBRA AGRIFLU NEW HOLLAND AMBRA AGRIFLU Loctite速 242速

Reference

PAGE

Engine - Install Engine - Install Engine cooling system - Dynamic description

10.1 / 51 10.1 / 51 10.13 / 5

Engine cooling system - Dynamic description

10.13 / 5

Water pump - Overhaul

10.13 / 14

47921938 07/02/2017

Engine - 10 Engine and crankcase - 001

TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017

10.1 [10.001] / 1

Contents Engine - 10 Engine and crankcase - 001

TECHNICAL DATA Engine General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

FUNCTIONAL DATA Engine Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SERVICE Engine Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Compression test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Crankcase Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Liner - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

DIAGNOSTIC Engine Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

(*) See content for specific models 47921938 07/02/2017

10.1 [10.001] / 2

CONSUMABLES INDEX Consumable Loctite® Loctite®

Reference Engine - Install Engine - Install

PAGE 10.1 / 51 10.1 / 51

47921938 07/02/2017

10.1 [10.001] / 3

Engine - Engine and crankcase

Engine - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

TT3840 Number of rolls Loop Injection Piston diameter Piston stroke Injection Sequence Engine speeds Idle speed Maximum RPM without load Nominal speed Total cylinder capacity Compression ratio Maximum Power Rotation for maximum power Rotation for maximum torque Number of main bearing housings Crankcase Maximum working inclination, transverse, and longitudinal Rev counter Acionamento Gauge calibrated for engine at Sistema de distribuição Spread

TT3840F 3

TT3880F 4

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

1–2–3 650 RPM +/- 25 RPM 2750 – 2790 RPM 2500 RPM +/- 50 RPM 2931 cm³ 18:01 Aspirated 16.5:1 Turbo 40.45 kW (55 Hp) 2500 RPM 1500 RPM 4 Cast iron

3908 cm³

56 kW (76.14 Hp) 1500 RPM 5

35° Incorporated in control panel Originated from the distribution shaft gear 1800 RPM 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.

Aspiration Start: End: Discharge 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

12° before TDC 31° after BDC 50° before BDC 16° 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 47921938 07/02/2017

10.1 [10.001] / 4

Engine - Engine and crankcase

TT3840

TT3840F 53.875 – 53.930 mm

Back Interference between the bushes (control shaft) and the housings in the block External diameter of seats on the control shaft: Front Middle Back Internal diameter of the bushes on the control shaft (installed and finished in the block): Front Middle Back Play between the seats and bushes Maximum acceptable play from wear Longitudinal play of control shaft Bloco 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 Back Diameter of tappet housings Tappet oversize Main bearing seat bore diameter Virabrequim e mancais 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

TT3880F

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 0.070 – 0.220 mm 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 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 47921938 07/02/2017

10.1 [10.001] / 5

Engine - Engine and crankcase

TT3840 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) Bielas 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 Pistões Pistons 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 Clearance between piston pin and bushing

TT3840F 0.082 – 0.334 mm 0.400 mm

TT3880F

0.010 mm 0.050 mm 0.100 mm 0.250 mm

±0.100 mm

0.025 mm

0.040 mm

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 ± 0.070 mm

25 g

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

47921938 07/02/2017

10.1 [10.001] / 6

Engine - Engine and crankcase

TT3840

TT3840F 0.090 – 0.122 mm 0.060 mm

TT3880F 0.105 – 0.155 mm

Play in piston ring groove (upper) Maximum acceptable play from wear Maximum difference in piston weight in 20 g the same engine Play between the rings and piston channels (vertically): 1st Ring 0.090 – 0.122 mm 2nd Ring 0.060 – 0.092 mm 3rd Ring 0.040 – 0.075 mm Maximum admitted play from wear (between rings and channels) 1st Ring 0.500 mm 2nd Ring 0.200 mm Play between ring ends (installed) 1st Ring 0.400 – 0.650 mm 2nd Ring 0.300 – 0.550 mm 3rd Ring 0.300 – 0.600 mm Maximum acceptable play between ends 1.200 mm from wear Tuchos Diameter of housing in the block 15.000 – 15.018 mm Standard tappet external diameter 14.950 – 14.970 mm Play between tappet and block 0.030 – 0.068 mm Maximum acceptable play from wear 0.15 mm Tappet oversize 0.100 mm - 0.200 mm - 0.300 mm Balancins - Válvulas Rocker arm hole diameters 18.016 – 18.031 mm 17.982 – 18.000 mm Rocker arm holder shaft diameters 0.016 – 0.052 mm Play between shaft and rocker arm holders 0.15 mm Maximum acceptable play from wear Characteristics of rocker arm separation spring 59.5 mm Rated length of free spring 44 mm Length of spring with a load of 46 – 52 N (10.34 – 11.69 lb) 0.45 mm Valve play for synchronization (diagram) Valve play for engine operation (cold) Intake valve 0.30 mm Exhaust Valve 0.30 mm Path of tappet (from control shaft) Intake valve 5.955 mm Exhaust Valve 6.027 mm 21.006 – 21.031 mm External diameter of rocker arm bush Balanceador dinâmico com contrapeso rotativo, consulte Balancer - Sectional view (10.110) para as referências. – – 0.063 – 0.140 mm Interference between the bushes (28) and the seat on the gear (26) – – Play between the transmission gear 0.050 – 0.100 mm bearing seat (27) and bushes (28) – – 0.063 – 0.140 mm Interference of installation between the bushes and support seat (20) – – 0.050 – 0.100 mm Play between the gear shaft (22) and the related bushes – – 0.038 – 0.106 mm Play between the teeth of the sleeve (17) that interlinks the gear (22) and the gear counterweight (13)

47921938 07/02/2017

10.1 [10.001] / 7

Engine - Engine and crankcase

Interference between the front bush (16) and seat on the casing (12) Play between the control shaft (13) and the front bush (16) Interference between the gear counterweight rear bush (13) and the support seat (6) Play between the control shaft (13) and the related rear bush Interference between the bushes and the related casing on the counterweights (8) Play between the counterweight revolution shaft (4) and the related bushes Interference between the transmission gear bush (9) and related seat in the casing (12) Play between the transmission gear shaft (10) and the related bush Play between the gear teeth (of counterweights) Cabeçote 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

TT3840 –

TT3840F –

TT3880F 0.063 – 0.140 mm

–

0.050 – 0.100 mm

–

0.037 – 0.101 mm

–

0.013 – 0.061 mm

–

0.040 – 0.100 mm

–

0.020 – 0.073 mm

–

0.037 – 0.101 mm

–

0.013 – 0.061 mm

–

0.080 mm

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 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

47921938 07/02/2017

10.1 [10.001] / 8

Engine - Engine and crankcase

TT3840

TT3840F

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. 4800031and 4800032 Valve synchronization Inlet opening (before TDC) Inlet closing (after BDC) Exhaust opening (before BDC) Exhaust closing (after TDC)

TT3880F

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°

Engine - Torque TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Angular tightening torque Part to tighten Head fixing bolts (2), Engine - Sectional view (10.001) Main journal fixing bolts (4), Engine - Sectional view (10.001) of the crankshaft Connecting rod journal bolts (5), Engine - Sectional view (10.001) Engine flywheel fixing bolts (3), Engine - Sectional view (10.001)

Turnbuckle

Tightening torque

Angle 130 ± 5° + 140 ± 5°

M12 x 1.25

70 N·m (51.63 lb ft)

M14 x 1.5

80 N·m (59.00 lb ft)

90°

M11 x 1.25

40 N·m (29.50 lb ft)

60°

M12 x 1.25

40 N·m (29.50 lb ft)

60°

Tightening torques Parts Fixing bolts of the rocker shaft supports Hub fixing nut on the crankshaft Fan and alternator drive pulley fixing bolts (6), Engine - Sectional view (10.001) Dynamic balancer fixing bolts for the four-cylinder models Intake manifold fixing bolts Alternator and belt tensioner fixing nut Water pump to engine fixing bolts Nuts for injector fixing stud Valve cover fixing nuts

Turnbuckle M8 X 1.25 M30 x 1.5

Torque value 25 N·m (18.44 lb ft) 300 N·m (221.3 lb ft)

M12 x 1.25

49 N·m (36.1 lb ft)

M12 x 1.25

110 N·m (81.13 lb ft)

M8 X 1.25 M12 x 1.25 M10 X 1.25 M8 X 1.25 M8 X 1.25

25 N·m (18.44 lb ft) 55 N·m (40.57 lb ft) 55 N·m (40.57 lb ft) 25 N·m (18.44 lb ft)(*) 15 N·m (11.06 lb ft)

47921938 07/02/2017

10.1 [10.001] / 9

Engine - Engine and crankcase

Parts Fixing bolts of the rocker shaft supports Oil pump and respective cover fixing bolts Distribution box and cover fixing bolts Flanged intermediate pin fixing bolts Control shaft retaining plate bolts Nuts for valve play adjustment bolts Exhaust manifold fixing bolts Injection pump fixing bolts Engine sump fixing bolts to: Front and rear distribution cover Engine flywheel and cylinder block cover:

Torque value 25 N·m (18.44 lb 25 N·m (18.44 lb 25 N·m (18.44 lb 55 N·m (40.57 lb 35 N·m (25.81 lb 22 N·m (16.23 lb 25 N·m (18.44 lb 25 N·m (18.44 lb

Turnbuckle M8 X 1.25 M8 X 1.25 M8 X 1.25 M10 X 1.25 M8 X 1.25 M8 x 1 M8 X 1.25 M8 X 1.25 M10 X 1.25 M10 X 1.25

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

39 – 49 N·m (28.76 – 36.14 lb ft) 49 – 59 N·m (36.14 – 43.52 lb ft)

(*) Tighten the nuts in two phases

Engine - Special tools TT3840F TT3840 TT3880F TT4030

LA LA LA LA

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. X X

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

380000569 290740 380000301 292870 293240 293679 296118 380000221 380000994 380000304 380000226 380000232 291046 380000222 294028 380000242 292177 380003037 380003042 380000223 380000549 380000292

Tractor Separation Stand Hook to lift the engine Rotary trestle to service the engine Universal manometers, seals, and tubes for lubricating pressure control kit Kit to control engines with turbo charger Wrench to disassemble the oil filters Device to control the engine belt tension Pliers to assemble the piston rings Belt to assemble pistons on the cylinders Device for angular tightening of engine bolts Crankshaft pulley hub puller Wrench to adjust valve play Mandrel to assemble and disassemble the valve guides Valve guide countersinker The reamer to make the lower opening on the exhaust valve guides Bush to assemble the valve guides (with 380000219) Set of reamers for the valve guide Valve spring compressor Kit to assemble and grind the injector holder sleeve in the head Extractor for the water pump turbine Punch to assemble the cooling water pump turbine seal (repair) Sliding Hammer Transmission clutch and PTO centralizer

Testing the injection pump on the bench X X X

380000228 380000229 380000322

Dial gauge ( 1/100 mm scale, 5 mm travel, 40 mm with 380000229) Device to synchronize the BOSCH injection pump to the engine Extractor for the injection pump drive gear 47921938 07/02/2017

10.1 [10.001] / 10

Engine - Engine and crankcase

380000215

Hand pump to test the injector nozzles

Tools for the injector nozzles X X X X X X X X

380000829 380000830 380000831 75297687 380000833 380000834 75290944 380000322

Screw tap to install tool 75297687 Milling cutter guide for injector nozzles Reamer for the injector nozzle sleeve Injector nozzle sleeve extractor Milling cutter to adjust injector nozzle protection Device to install the injector nozzle sleeves Valve guide reamer Injection pump gear extractor

50075: Hook to lift the engine. Dimensions in mm. Material: UNI C40.

LAIL11TL1103A0A

LAIL11TL1296B0A

86512999: Crankshaft front retainer installer. Dimensions In mm. Material: UNI C40.

47921938 07/02/2017

10.1 [10.001] / 11

Engine - Engine and crankcase

50139: Crankshaft rear retainer installer. Dimensions In mm. Material: UNI C40.

LAIL11TL1297B0A

LAIL11TL1302F0A

50131: Supports for lifting the hood: special tool (two units). Dimensions in mm. Material: UNI Fe 42C .

47921938 07/02/2017

10.1 [10.001] / 12

Engine - Engine and crankcase

50132: Front hook for lifting the hood. Dimensions in mm. Material: UNI C40.

LAIL11TL1298B0A

47921938 07/02/2017

10.1 [10.001] / 13

Engine - Engine and crankcase

Engine - Sectional view TT3840F TT3840 TT3880F TT4030

LA LA LA LA

47921938 07/02/2017

10.1 [10.001] / 14

Engine - Engine and crankcase

Longitudinal section of the 3 cylinder engine

LAIL11TL1307H0A

47921938 07/02/2017

10.1 [10.001] / 15

Engine - Engine and crankcase

Cross-section of the 3 cylinder engine

LAIL11TL1308H0A

47921938 07/02/2017

10.1 [10.001] / 16

Engine - Engine and crankcase

Longitudinal section of the aspirated 4 cylinder engine

LAIL11TL1309H0A

47921938 07/02/2017

10.1 [10.001] / 17

Engine - Engine and crankcase

Cross-section of the aspirated 4 cylinder engine

LAIL11TL1310H0A

47921938 07/02/2017

10.1 [10.001] / 18

Engine - Engine and crankcase

Engine - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

The engines feature cross-flow heads, with the intake manifold and exhaust manifold on opposite sides of the head. The fuel and air combustion process takes place in the specifically designed combustion chamber inside the piston head.

Head The cylinder head incorporates valves and springs, with the valve rocker arm shaft assembly bolted to the cylinder block through the cylinder head. The retaining bolts are evenly spaced with a six-point pattern around each cylinder which ensures an even clamping load across the head. The intake manifold and exhaust manifold are screwed to the head. The intake manifold is mounted on the right-hand side of the engine. The diesel fuel injectors are installed on top of the engine head. The exhaust manifold is mounted on the left side of the engine. The water outlet connections and thermostat are attached to the front of the cylinder block directly behind the radiator. Valve guides are inserted into the cylinder head, and are replaceable. Special replaceable cast alloy valve seats are pressed into each valve port during manufacturing. No oversize valve seats on guides are available. All the valves rotate clockwise. The valve clearance is maintained by adjusting the locking bolt installed on each of the rockers.

Camshaft assembly The camshaft runs in three replaceable bushings. The camshaft drive gear is in contact with (and driven by) the camshaft idler gear, which is driven by the crankshaft timing gear. The camshaft longitudinal play is controlled by a thrust plate bolted to the block, which is located between the shaft gear and the front shaft journal.

Cylinder block assembly The cylinder block is made of steel alloy with deep cylinder skirts and water jackets for cooling the cylinders. The internal diameters of the cylinders are machined along with the cylinder block during the manufacturing process. The cylinders are arranged vertically in a row and numbered from 1 to 4, from the front of the engine to the rear. The oil sump, which is attached to the bottom of the cylinder block, is the oil reservoir for the engine oil lubrication system. A cast iron engine front cover and front plate are attached to the front of the engine, covering the entire timing gear assembly.

Crankshaft The crankshaft is supported in the cylinder block by five main bearings mounted in the engine. The crankshaft is made of steel with machined crank arms. The longitudinal play is controlled by an axial journal built into the main central bearing of the crankshaft. A dynamic balancer is fitted and driven by the crankshaft to ensure smooth operation. Front and rear crankshaft oil sealing is effected by one piece seals that are designed for long and durable service life.

Link conrods Connecting rods ĂŹWedgeĂŽ shaped at the small end have been designed to reduce the reciprocating weight at the piston end. The connecting rods are heavy beam construction and are assembled as a matched set to each engine, attached to the crankshaft, by means of insert type bearings. They are retained in position by the connecting rod big end cap and secured by two bolts per rod. The small end of the connecting rod is fitted with a replaceable bronze bushing, through which the free floating piston pin is fitted. The steel pin being held in place within the piston by two snap rings.

The figure above shows the location of the fastening holes for auxiliary implements on tractors with platforms. The pistons are made of aluminum-silicon alloy with a slotted combustion chamber set back in the piston crown. Each piston has two compression rings and one oil control ring, to reduce friction and increase positive seating. All rings are located above the piston pin. 47921938 07/02/2017

10.1 [10.001] / 19

Engine - Engine and crankcase

Manifolds The cross-flow-design aluminum intake manifold and the cast iron exhaust manifold are on opposite sides of the head. This is to maintain balanced heat distribution within the head. The configuration of the manifolds also ensures minimum heat transfer to the intake manifold. The intake tube is connected to the air filter via a hose.

Timing gears The crankshaft timing gear is heated and press-fitted on to the front of the crankshaft, with a high degree of accuracy during manufacturing. This is to maintain precise timing during the life of the engine. The crankshaft gear drives the idler gear, which is attached to the front of cylinder block. The idler gear drives the camshaft and the injection pump via the connection between the helical gears. The camshaft is fixed via screws to the front of the shaft and is locked to maintain the position of the gear on the camshaft.

47921938 07/02/2017

10.1 [10.001] / 20

Engine - Engine and crankcase

Engine - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Disconnect the negative battery cable. 2. Drain the oil from the transmission box/gear box. 3. Drain the engine coolant. 4. Disassemble the tool holder box and remove the respective support bracket (1).

LAIL11TL1104A0A

LAIL11TL1105A0A

LAIL11TL1106A0A

5. Remove the fixing cotter pin (1) from the counterweight lock pin.

6. Remove the pin (1) and remove the front counterweight package (2).

47921938 07/02/2017

10.1 [10.001] / 21

Engine - Engine and crankcase

7. Disconnect the connections (1) from the headlights (2).

LAIL11TL1107A0A

LAIL11TL1108A0A

LAIL11TL1109A0A

LAIL11TL1110A0A

8. Remove the shock absorber (1) from the hood.

9. Remove the four bolts (1) holding the hood support articulations.

10. Remove the exhaust pipe and remove the hood (1).

47921938 07/02/2017

10.1 [10.001] / 22

Engine - Engine and crankcase

11. Remove the guard screen (1) from the right-hand blower.

LAIL11TL1111A0A

LAIL11TL1112A0A

12. Remove the metal blocking clamp (1) from the rigid oil pipes for the hydraulic lift pump intake and pressure.

13. Remove the hydraulic hose (1) from the hydraulic pump suction tube.

LAIL11TL1113A0A

LAIL11TL1114A0A

14. Remove the hydraulic hose (1) from the lift pump suction tube.

47921938 07/02/2017

10.1 [10.001] / 23

Engine - Engine and crankcase

15. Disconnect the lift pump pressure pipe (1).

LAIL11TL1115A0A

LAIL11TL1116A0A

LAIL11TL1117A0A

LAIL11TL1118A0A

16. Disconnect the pre-heating plug fuel pipe (1) . 17. Disconnect the injector fuel return pipe and the connection pipe from the tank to the decanter filter. 18. Remove the complete fuel filter support. 19. Disconnect the support bracket from the flexible brake lines. 20. Disconnect the electric connection from the engine coolant sensor. 21. Disconnect the electric connections located between the cab and the engine on the left-hand side. 22. Disconnect the electric connection from the engine oil pressure sensor. Disconnect the rev counter control and remove the fixing support.

23. Remove the fixing clamp (1) from the pipes to the steering cylinder.

47921938 07/02/2017

10.1 [10.001] / 24

Engine - Engine and crankcase

24. Disconnect the flexible oil pressure and return lines (1) to the steering cylinders.

LAIL11TL1119A0A

LAIL11TL1120A0A

LAIL11TL1121A0A

LAIL11TL1122A0A

25. Remove the front, central and rear fixing bolts from the front shaft drive prop shaft and disassemble the guard.

26. Remove the lock ring (2), and, as shown by the arrow, move the sleeve (1) to uncouple it from the pinion.

27. Remove the lock ring (2) and, as shown by the arrow, move the sleeve (1) to uncouple it from the transfer box shaft.

47921938 07/02/2017

10.1 [10.001] / 25

Engine - Engine and crankcase

28. Remove the prop shaft central support fixing bolts (1) and remove the complete shaft with the support.

LAIL11TL1123A0A

LAIL11TL1124A0A

LAIL11TL1125A0A

LAIL11TL1126A0A

29. Disconnect the rigid oil pressure line to the transfer box control.

30. Remove the four knobs and remove the two linings (1) from the tool box support.

31. Release the differential lock pedal drive, remove the pedal and release the carpet.

47921938 07/02/2017

10.1 [10.001] / 26

Engine - Engine and crankcase

32. Remove the covers (1) to access the engine fixing upper bolts.

LAIL11TL1127A0A

LAIL11TL1128A0A

LAIL11TL1129A0A

LAIL11TL1130A0A

33. Disconnect the control pedal throttle cable.

34. Loosen the two front bolts (one on each side) holding the cab (1) to the respective supports.

35. Lift the front of the cab approximately six centimetres.

47921938 07/02/2017

10.1 [10.001] / 27

Engine - Engine and crankcase

36. Loosen the two fixing nuts and two bolts from the engine to the transmission. Gain access through the two split openings.

LAIL11TL1131A0A

LAIL11TL1132A0A

LAIL11TL1133A0A

LAIL11TL1134A0A

37. Loosen the four lower bolts (1) holding the engine to the transmission.

38. Place the tool (trolley) under the tractor and put two wedges on the front shaft to prevent swaying. 39. Place a wooden shim (1) on the contact points between the trestles and the tractor.

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

47921938 07/02/2017

10.1 [10.001] / 28

Engine - Engine and crankcase

41. Remove the support clamp (1) from the cab heating pipes.

LAIL11TL1135A0A

LAIL11TL1136A0A

LAIL11TL1137A0A

LAIL11TL1138A0A

42. Loosen the last four fixing bolts from the engine to the transmission. 43. Disconnect the three electrical connectors (1) from their support. 44. Separate the engine from the transmission.

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

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

47921938 07/02/2017

10.1 [10.001] / 29

Engine - Engine and crankcase

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

LAIL11TL1139A0A

LAIL11TL1140A0A

LAIL11TL1141A0A

LAIL11TL1142A0A

48. Remove the fixing bolt (2) from the engine tubing and remove the low pressure hydraulic circuit tubing. 49. Remove the radiator fixing bolt. 50. Hitch the engine to the winch with the chain, fixing it to the engine supports intended for this purpose.

51. Remove the lift pump (1) with its filter by loosening the four fixing bolts. 52. Disconnect all electric connectors and remove the entire cable assembly.

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

47921938 07/02/2017

10.1 [10.001] / 30

Engine - Engine and crankcase

54. Remove the guard screen (1) from the left-hand engine blower.

LAIL11TL1143A0A

LAIL11TL1144A0A

LAIL11TL1145A0A

LAIL11TL1146A0A

55. Remove the clamp and disconnect the tube (1) that connects the engine to the radiator.

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

57. Loosen the three nuts (2) that hold the silencer to the manifold and remove the assembly.

47921938 07/02/2017

10.1 [10.001] / 31

Engine - Engine and crankcase

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

LAIL11TL1147A0A

LAIL11TL1148A0A

LAIL11TL1149A0A

LAIL11TL1150A0A

59. Remove the clamp and disconnect the radiator lower hose (1). 60. Loosen the four engine fixing bolts (2), remove the engine from the axle support, and prop it on a wooden block.

Separating the front axle from the engine 61. Loosen the radiator hose (1) and drain the coolant.

62. Loosen the fixing clamps (1) and (2) and disconnect the pipe (3) from the air filter and the radiator hose (4).

47921938 07/02/2017

10.1 [10.001] / 32

Engine - Engine and crankcase

63. Remove the bolt that holds the radiator support bracket (5).

LAIL11TL1151A0A

LAIL11TL1152A0A

LAIL11TL1153A0A

LAIL11TL1154A0A

64. Cut the plastic clamps and remove all the central wiring from the front part. 65. Remove the wiring connections to the alternator, sensor, WT relay, OPS, FIP and starter solenoid. 66. Support the front axle using a suitable stand. 67. Connect the engine to a suitable hoist.

68. Remove the 4 levelling bolts (1) that couple the engine and the front axle support.

69. Detach the engine from front axle carefully and mount it on the engine stand (Special Tool No. 293860minimum).

Next operation: Removing the engine: see the procedures in Engine - Disassemble (10.001)

47921938 07/02/2017

10.1 [10.001] / 33

Engine - Engine and crankcase

Engine - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

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

Removal of the front axle support, front axle assembly, radiator and support 1. Release the radiator hose (1) and drain the coolant.

LAIL11TT0003A0A

LAIL11TT0004A0A

LAIL11TT0005A0A

2. Loosen the retaining clamps (1) and (2) and disconnect the pipe (3) from the air filter and the hose (4) from the radiator.

3. Remove the bolt that holds the radiator support bracket (5).

47921938 07/02/2017

10.1 [10.001] / 34

Engine - Engine and crankcase

4. Cut the plastic clips. Remove all of the central wiring from the front. 5. Remove the alternator and connections for the starter solenoid wiring. 6. Support the front axle using a suitable stand. 7. Connect the engine to a suitable hoist.

LAIL11TT0006A0A

BRAG12TRLUE0381

LAIL11TT0008A0A

8. Remove the four buckle-up bolts (1) coupling the engine and the front axle support.

9. Detach the engine from front axle carefully and mount on engine stand (Special Tool No. 293860).

47921938 07/02/2017

10.1 [10.001] / 35

Engine - Engine and crankcase

Engine - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Engine removal: see the procedures in Engine - Remove (10.001).

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. Remove the front and rear fixing bolts from the hood bracket support. 2. Remove the hood opening lever fixing bolt (1) and keep the lever together with the hood bracket support. 3. Loosen the lower alternator fixing bolt. 4. Loosen the belt tension adjustment bolt (1). 5. Loosen the belt adjustment support, removing the fixing nut. 6. Remove the alternator and water pump drive belt. LAIL11TL1155A0A

LAIL11TL1156A0A

LAIL11TL1157A0A

7. Remove the fan and pulley fixing bolts (1) on the water pump and remove the two parts.

8. Loosen the connection (1) from the water flow rigid pipe to the cab heating.

47921938 07/02/2017

10.1 [10.001] / 36

Engine - Engine and crankcase

9. Loosen the clamp, remove the water pump hose (1) and remove the curved pipe and the flexible tubes to the cab heating.

LAIL11TL1158A0A

LAIL11TL1159A0A

LAIL11TL1160A0A

LAIL11TL1161A0A

10. Remove the spout (1) for accessing the pump fixing bolt.

11. Remove the water pump fixing bolts (1) and remove all the parts.

12. Remove the pump support fixing bolts (1) and the muffler bracket fixing bolt and remove the parts.

47921938 07/02/2017

10.1 [10.001] / 37

Engine - Engine and crankcase

13. Fit the support (1) from series no. 380000804 to hold the engine on the rotating trestle 380000301.

LAIL11TL1162A0A

LAIL11TL1163A0A

14. Assemble a hook with eye bolt (1) on the front engine wall in the place of the muffler bracket support. 15. Lift the engine from the wooden platform, transport it, position it and locate it on rotating trestle no. 380000301 (2) using the support (3) from series no. 380000804bolt.

16. Remove the alternator support fixing bolts (1) on the base and remove the entire group.

LAIL11TL1164A0A

LAIL11TL1165A0A

17. Remove the exhaust manifold fixing bolts (1) from the head and remove the part.

47921938 07/02/2017

10.1 [10.001] / 38

Engine - Engine and crankcase

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

LAIL11TL1166A0A

LAIL11TL1167A0A

LAIL11TL1168A0A

LAIL11TL1169A0A

19. Remove the thermostat support fixing bolts (1) and remove the group.

20. Loosen the nuts (1) on the injection pump to injector connecting pipes and remove the pipes.

21. Remove the intake manifold fixing bolts (1) from the head and remove the part.

47921938 07/02/2017

10.1 [10.001] / 39

Engine - Engine and crankcase

22. Loosen the supply pump nuts (1) and remove the pipes.

LAIL11TL1170A0A

LAIL11TL1171A0A

LAIL11TL1172A0A

LAIL11TL1173A0A

23. Remove the injection pump fixing nuts (1) from the distribution box.

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

25. Loosen the lock nut (1) fixing the injection pump shaft to the related drive gear.

47921938 07/02/2017

10.1 [10.001] / 40

Engine - Engine and crankcase

26. Extract the injection pump drive gear using tool no. 380000322 (1) and remove the injection pump with the related wrench.

LAIL11TL1174A0A

LAIL11TL1175A0A

LAIL11TL1176A0A

LAIL11TL1177A0A

27. Loosen the fixing connections (1) from the fuel pipes to the sludge deposit.

28. Remove the fixing bolts (1) holding the sludge deposit support to the block, and remove the entire group from the filter.

29. Remove the fixing nuts (1), disassemble the complete supply pump support and remove the interface lining below.

47921938 07/02/2017

10.1 [10.001] / 41

Engine - Engine and crankcase

30. Remove the fixing bolts (1) and remove the complete steering pump with the filter and output pipe.

LAIL11TL1178A0A

LAIL11TL1179A0A

LAIL11TL1180A0A

31. Remove the separator (3), the joint (2) and the sleeve (1).

32. Remove the fixing bolts (1) and remove the starter motor.

33. Remove the fixing nuts from the supports, the ball washers below, then the supports and the injectors. 34. Remove the fixing bolts (1) and the washers with the sealing lining and remove the rocker arms housing cover (2) complete with the sealing lining.

47921938 07/02/2017

10.1 [10.001] / 42

Engine - Engine and crankcase

35. Remove the fixing bolts (2) and extract the complete rocker arm holder shaft (1).

LAIL11TL1181A0A

LAIL11TL1182A0A

LAIL11TL1183A0A

LAIL11TL1184A0A

36. Remove the tabs (1) from the valves and remove the rods (2).

37. Loosen the head fixing bolts (1) and extract the head with the winch and hook no. 290740bolt. 38. Remove the gasket installed between the head and the block.

39. Turn the rotary trestle 180Â° and remove the fixing bolts, the sump (1) and the related lining (2).

47921938 07/02/2017

10.1 [10.001] / 43

Engine - Engine and crankcase

40. Remove the fixing bolts and remove the engine lubrication oil suction pipe (1) complete with the sealing lining. 41. Remove the fixing bolts (2), remove the dynamic balancer (3) and remove the hose (4) and the box (3). NOTE: Operations 39 - 40 - 41 are only for 4-cylinder engines. For the dynamic balancer Disassembly - Installation operations, see Balancer - Disassemble (10.110) and Balancer - Timing adjust (10.110), respectively.

LAIL11TL1185A0A

LAIL11TL1186A0A

LAIL11TL1187A0A

LAIL11TL1188A0A

42. Remove the fixing bolts (4) and the sump with a winch, hood 290740 and chain with eye bolts. 43. Remove the half-linings (1) and (3) for the sump base interface and the lining (2) for the sump interface and front distribution support.

44. Remove the lining (1) for the interface between the sump and the rear engine flywheel support. NOTE: When fitting the linings ( (1), Fig. 33 and (2), Fig. 31), apply silicone THREE BOND 1207G or anaerobic sealant LOCTITE ULTRABLACK to the housings.

45. Remove the dynamic balancer gear lubrication oil sealing O-ring (1) installed on the interface between the sump and the engine block.

47921938 07/02/2017

10.1 [10.001] / 44

Engine - Engine and crankcase

46. Remove the fixing bolts (1) and remove the complete engine lubrication oil pump. NOTE: For TT3880 models, see Figure 53.

LAIL11TL1189A0A

LAIL11TL1190A0A

LAIL11TL1191A0A

LAIL11TL1192A0A

47. Remove the fixing bolts (2) and extract the fan and alternator drive pulley (1).

48. Unscrew the nut (1) and remove it, holding the crankshaft appropriately.

49. Extract the pulley hub from the crankshaft using tool no. 380000226 (1) and remove the wrench.

47921938 07/02/2017

10.1 [10.001] / 45

Engine - Engine and crankcase

50. Remove the fixing bolts (1), distribution box cover and lining for the interface with the base support.

LAIL11TL1193A0A

LAIL11TL1194A0A

LAIL11TL1195A0A

LAIL11TL1196A0A

51. Remove the fixing bolts, then the hydraulic lift pump drive gear support (1).

52. Remove the lock ring (1) and remove the transmission spacer and gear (2). NOTE: To reinstall the gear, see Crankcase gears - Timing adjust (10.114).

53. Remove the fixing bolts (1) and extract the transmission gear pin.

47921938 07/02/2017

10.1 [10.001] / 46

Engine - Engine and crankcase

54. Remove the fixing bolts (2) and remove the complete control shaft (3) from the drive gear (1) and lock plate (4).

LAIL11TL1197A0A

LAIL11TL1198A0A

LAIL11TL1199A0A

LAIL11TL1200A0A

55. Remove the lock ring (1) and the separator, removing from the opposite side of the gear with the supply pump drive eccentric shaft (2). NOTE: This gear transmits movement to the injection pump gear. To reinstall the gear, see Crankcase gears - Timing adjust (10.114).

56. Remove the fixing bolts (1) and the distribution gear box.

57. Replace the sealing ring (1) installed at the lift pump drive shaft lubrication oil outflow. 58. Remove the sealing lining installed between the distribution support and the engine block.

47921938 07/02/2017

10.1 [10.001] / 47

Engine - Engine and crankcase

59. Turn the engine 90Â°, remove the bolts from the link conrod bushings (2) and keep the bolts from the link conrod bushings with the related bushes.

LAIL11TL1201A0A

LAIL11TL1202A0A

LAIL11TL1203A0A

LAIL11TL1204A0A

60. Remove the pistons (1) together with the rings, pins and link conrods.

61. Bring the engine back to the horizontal position, turning it 90Â° on the trestle, remove the fixing bolts and remove the engine flywheel using the winch and hook 290740. 62. Remove the fixing bolts and the rear cover (1) complete with the sealing lining.

63. Remove the fixing bolts (1) and extract the fixed bushings with the related bushes, removing the thrust bushes installed on the penultimate bush indicated in Figure 51. 64. Extract the crankshaft with the winch and the nylon cord, removing the bearings, separators and tappets.

47921938 07/02/2017

10.1 [10.001] / 48

Engine - Engine and crankcase

65. Turn the block 180Â° on the rotary trestle 380000301 (2), fasten the chain with eye bolts to the block as indicated in the figure, slightly lift with the winch and hook 290740 and remove the bolts fixing the engine to the rotary trestle (2) and the support (3) from series 380000804. 66. Lift the engine block clearing it from the rotary trestle.

LAIL11TL1205A0A

LAIL11TL1206A0A

67. Remove the fixing bolts and extract the block rear support (1) complete with the sealing lining. NOTE: Oil pump for TT3880 models. 68. Remove the fixing bolts (4) and remove the washers (3) and the engine lubrication oil pump (2) complete with the overpressure valve (1).

Next operation: Installing tappets, crankshaft, bushings and separators; see the procedures in Crankshaft - Assemble (10.103).

47921938 07/02/2017

10.1 [10.001] / 49

Engine - Engine and crankcase

Engine - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

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

NOTICE: Raise and handle all heavy parts using lifting equipment with sufficient lifting capacity. Make sure all the units and parts are supported by appropriate belts and hooks. Make sure that there is no one around the load that is to be lifted. Proceed as follows: 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

LAIL11TL1141A0A

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

47921938 07/02/2017

10.1 [10.001] / 50

Engine - Engine and crankcase

7. Place the air passage rigid pipe (1) to the intake manifold and fasten with the relative clamp. 8. Connect all the disassembled electric connections: heater plug, water temperature sensor, clogged air filter sensor, sound alarm, earth (negative) front axle support, engine stop cable in the injection pump, alternator and relay cables, engine oil pressure sensor, starter motor connection, decanter fuel filter. Fasten the entire set of cables with plastic clamps (belts).

LAIL11TL1142A0A

LAIL11TL1139A0A

LAIL11TL1138A0A

9. Install the clutch using tool no. 380000292 (1)monitor. Lock the clutch on the engine flywheel fastening it with the six bolts (2). 10. Assemble the oil pressure pipe to the front wheel drive distributor. 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.

47921938 07/02/2017

10.1 [10.001] / 51

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 RH 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 tool no. 292320 and the trestle 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

LAIL11TL1119A0A

LAIL11TL1135A0A

24. Reconnect the pipe to the heater plug and lastly to the drying filter. 25. Reassemble the fuel filter support, fastening it to the engine. Connect the two semi-rigid pipes to the support. 26. Connect the two steering distributor oil pressure and return pipes (1). 27. Reassemble the rigid oil suction pipes to the pumps and fasten the rubber hose with clamps. 28. Reassemble all the electric connections to the vertical connector support.

29. Reassemble the cab heating pipe gasket in the engine spacer in the clutch housing. Fasten with the clamp (1). Assemble the flexible rubber pipes with the gasket. 30. Assemble the two steering valve flexible pipes to the gasket stuck on the front left side axle. Fasten the two pipes with a special clamp; lock the latter with a bolt to the tractor body. 31. Reassemble the rev counter and fasten the sleeves with the related clamp.

47921938 07/02/2017

10.1 [10.001] / 52

Engine - Engine and crankcase

32. Assemble the muffler on the exhaust manifold tightening the bolts (1) and inserting the sealing gasket. Fasten the muffler inlet with the vertical support clamp. Assemble the dust ejector flexible pipe. 33. Fasten the hood support clamp with the radiator clamp. 34. Fasten the oil pressure rigid pipe to the front wheel drive control distributor and rear differential lock.

LAIL11TL1145A0A

35. Assemble the front wheel drive prop shaft with its respective latch rings and assemble the guard plate tightening the front, central, and lower bolts. 36. Reassemble the throttle cable on the pedal. If necessary, adjust the cable on the lever installed in the injection pump. 37. Assemble the clutch cable to the control pedal. Lock the sleeve on the stop support.

LAIL11TL1120A0A

LAIL11TL1127A0A

LAIL11TL1111A0A

38. Reassemble the plastic covers (1) on the openings installed on the cab floor. Reinstall the floor mat. 39. Reassemble the guard panels next to the steering wheel.

40. Reassemble the engine fan guard screens (1).

47921938 07/02/2017

10.1 [10.001] / 53

Engine - Engine and crankcase

41. Assemble the hood using the procedure followed for removal. Tighten the hood articulation bolts (1) to the relative support clamp.

LAIL11TL1109A0A

LAIL11TL1108A0A

LAIL11TL1106A0A

42. Assemble the pneumatic piston to lift and lower the hood to the headlight connections and remove the belts. 43. Reassemble the secondary clamp (battery support) to the clutch housing.

44. Reassemble the front weights (2) and fasten them with the vertical pin (1). 45. Reassemble the tool holder box support clamp, then fasten the box to the clamp.

47921938 07/02/2017

10.1 [10.001] / 54

Engine - Engine and crankcase

Engine - Compression test TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Procedure: 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, presuming that each cylinder has injected the same amount of fuel in each stroke. Low compression not only reduces engine performance, it also does not allow for the fuel being totally burnt, since there will be lack of air required for a perfect combustion. Thus, the engine is inefficient and consumes excessive fuel, with resulting smoke from the exhaust and a reduction in the exhaust chambers. Compression depends on engine temperature and must only be measured when the engine is at operating temperature. Compression values will be lower when the engine is cold and, logically, higher when the engine is hot. 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 ignition key from the contact. 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 9977364 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. 10. Start the engine (starter motor only) and note the meter reading. Repeat the procedure for all the engine cylinders.

47921938 07/02/2017

10.1 [10.001] / 55

Engine - Engine and crankcase

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 a 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.

47921938 07/02/2017

10.1 [10.001] / 56

Engine - Engine and crankcase

Crankcase - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Roll diameter 1. Cylinder block plugs and senders require changing if leaking and rusty, and must be replaced. Clean the old sealant of the block, and fit new plugs with sealer.

LAIL11TL1241A0A

LAIL11TL1242A0A

2. Check the cylinder bore for scuffing or rings around the ring frame area. To check roundness, wear, and conicalness. Use a dial diameter gauge immediately to perform the evaluation.

47921938 07/02/2017

10.1 [10.001] / 57

Engine - Engine and crankcase

Crankcase Liner - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Installation of new sleeves 1. Preparation for fitting new sleeves: • After the old sleeves have been removed, the bore must be thoroughly cleaned, both at the top access to the sleeve flange and inside the bore itself. • A check must be made to ensure that all areas of contact with the sleeves in the cylinder block are free from burrs, corrosion, or damage. Remove any burrs present. • Check the ovalization of the inside diameter of the engine block and if necessary, machine it to 106.850 – 106.900 mm. • Check whether the outer diameter of the cylinder liner is 107.020 – 107.050 mm. NOTE: The cylinder liners are delivered as spare parts with an outer diameter greater than 0.2 mm. 2. Lubricate the outside diameter of the sleeves with clean oil using spray. It is not recommended to use a steel brush. 3. Install a new sleeve ( 0.2 mm bigger if necessary) through the top of the block, as follows. • Adjust the liner and start forced fitting. After force fitting 70 – 90 mm, check that the load is greater than 5000 N·m and less than 23.000 N·m. Continue force fitting and stop for 5 min with an adjustment load greater than 50.000 N·m. • After installation, the liners must be drilled and polished on the surface. Cylinder liners are delivered as spare parts with an inner diameter slightly below nominal diameter in order to be able to correct possible deformation appearing during mounting. 4. Sand the face of the block and the top of the sleeves in order to achieve the desired flatness. 5. A chamfer in the internal diameter at the top of the sleeve, of 30° x 0.5 mm, should be maintained, to prevent piston damage on assembly. NOTE: The new pistons should be of the same type as those that were removed and they should have the same identification letters and numbers embossed on the piston.

LAIL11TL1243A0A

47921938 07/02/2017

10.1 [10.001] / 58

Engine - Engine and crankcase

Engine - Troubleshooting TT3840F TT3840 TT3880F TT4030

Problem Engine will not start

LA LA LA LA

Possible Cause Partly run down batteries Connections to battery terminals corroded or loose Engine injection pump out of point Build up of impurities or water in the fuel lines Tank out of fuel Injection pump lacking supply Presence of air in the fuel circuit

Faulty starter motor Thermostat inefficient The engine shuts off

Idling speed too low Irregular injection pump adjustment Build up of impurities or water in the fuel lines Fuel filter clogged Abnormal play between valves and rockers Burnt or cracked valves Presence of air in the fuel circuit

Engine overheats

Damaged injection pump controls Inefficient cooling circuit centrifugal pump Thermostat inefficient

Radiator partly inefficient

Correction Check voltage and recharge the batteries. Replace them if necessary Clean, examine, and tighten the nuts. Replace the corroded terminals and nuts Perform correct placement of injection pump on point Disconnect the piping, injection pump, and clean thoroughly. If necessary, clean and drain the fuel tank Fill the deposit Check and, if necessary, replace the supply pump Check the piping and gaskets, supply pump, filters and injection pump to check for the presence of air. Lastly, bleed the circuit Repair or replace the starter motor Check and replace the thermostat if necessary Adjust the idle speed Send the pump to an authorized BOSCH or DELPHI shop Disconnect the piping, injection pump, and clean thoroughly. If necessary, clean and dry the fuel tank Replace the integral filters Adjust the play between valves and rockers You may need to lift and lower the front three-point hitch to loosen the turnbuckle. Check the piping and gaskets, supply pump, filters and injection pump to check for the presence of air. Lastly, bleed the circuit Replace defective parts Check the pump and if necessary replace it When using biodiesel, consult your dealer to perform the fuel system preparation procedure for machines in storage for longer than one month. Remove any eventual crusts through washing. Check and repair any leaks Wash thoroughly

Crusts in the coolant passage gaps in the head and block Insufficient water pump and fan drive belt Check and adjust belt tension tension Top up the level in the expansion tank with Coolant level low the indicated liquid Engine timing is incorrect Check and adjust Injection pump out of calibration Send to an authorized BOSCH or DELPHI shop Air filter blocked Clean it and, if necessary, change the filter element Engine lacking power and Incorrect timing of injection pump on engine Perform the correct synchronization with irregular operation

47921938 07/02/2017

10.1 [10.001] / 59

Engine - Engine and crankcase

Problem

Possible Cause Correction Automatic advance variator on injection Send to an authorized BOSCH or DELPHI pump faulty shop Distributor pin worn Send to an authorized BOSCH or DELPHI shop Irregular injection pump capacities Send to an authorized BOSCH or DELPHI shop Speed governor at all speeds damaged Send to an authorized BOSCH or DELPHI shop Partially clogged or damaged injectors Clean, service, and perform correct calibration of the injectors Build up of impurities or water in the fuel Disconnect the lines, injection pump, and clean thoroughly and, if necessary, clean lines and dry the fuel tank Replace supply pump Supply pump damaged Incorrect play between valves and rockers Adjust the clearance between valves and rockers Low cylinder compression Test compression and if necessary check the engine Air filter blocked Clean it and, if necessary, change the filter element Length of the tie rod, between the throttle Adjust the length of the tie rod and injection pump, out of adjustment Injection pump with maximum bolt not ad- Adjust the maximum bolt to obtain justed 2500 RPM rpm (without load) Abnormal engine noise Partially clogged or damaged injectors Clean, service, and perform correct injector calibration Build up of impurity in the fuel lines Clean the lines and replace those with heavy smashing. If necessary, clean the injection pump Incorrect timing of injection pump on engine Time the injection pump correctly on the engine Crankshaft strikes caused by excess play Grind the crankshaft and replace the bushon one or more connecting rod bushings or ings excess longitudinal play Crankshaft unbalanced Check alignment and balancing, if necessary, replace it Replace loose bolts and tighten all bolts to Flywheel fixing bolts loose the prescribed torque and angle Connecting rod with shafts not parallel Grind the connecting rods, check shaft parallelism and, if necessary, replace the connecting rods Piston pins noisy due to excess play in pis- Replace the necessary parts ton hubs and connecting rod bushing Noise from the head Inspect for broken springs, excess play between the rods and guides, tappets and seats. Adjust the clearance between valves and rockers Engine producing excess Excess maximum capacity of injection Send the pump to an authorized BOSCH or black or dark gray smoke pump DELPHI shop The injection pump is excessively delayed Time the injection pump correctly on the enor the automatic advance variator is dam- gine or have the automatic advance variator inspected at an authorized shop aged Injection pump excessively advanced Time the injection pump correctly on the engine Injectors partly and/or totally clogged or out Clean, check, and perform correct calibraof calibration tion of injectors, if necessary, replace them Air filter blocked Clean it and, if necessary, change the filter element

47921938 07/02/2017

10.1 [10.001] / 60

Engine - Engine and crankcase

Problem

Blue, gray-blue, or gray smoke tending to white

The engine continues running after being turned off

Possible Cause Correction Engine compression leaking due to: Replace damaged parts or, if necessary, Stuck rings check the engine Deteriorated valves or valves out of adjustment Damaged injection piping Check the conditions of the piping and replace it, if necessary The injection pump is excessively delayed Time the injection pump correctly on the enor the automatic advance variator is dam- gine or check the automatic advance variator aged Clogged or damaged injectors Clean, check, and perform correct calibration of injectors, if necessary, replace them Passage of oil in the piston rings caused by Replace damaged parts or, if necessary, stuck rings check the engine Passage of oil through intake valve guides Check the engine head due to valve guide or rod wear Engine does not reach operating tempera- Replace thermostatic valve ture Replace the solenoid Stopping solenoid damaged Speed governor at all speeds damaged

47921938 07/02/2017

10.1 [10.001] / 61

Send the pump to an authorized BOSCH or DELPHI shop

Index Engine - 10 Engine and crankcase - 001 Crankcase - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Liner - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Engine - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Engine - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

10.1 [10.001] / 62

Engine - 10 Pan and covers - 102

47921938 07/02/2017

10.2 [10.102] / 1

Contents Engine - 10 Pan and covers - 102

SERVICE Engine oil pan Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(*) See content for specific models 47921938 07/02/2017

10.2 [10.102] / 2

Engine - Pan and covers

Engine oil pan - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

NOTICE: Due to the weight of the oil pan, it is recommended that a hydraulic jack is used to support and lower the oil pan to the ground. 1. Drain the engine oil through oil pan plug and remove the oil level indicator.

LAIL11TL1359A0A

LAIL11TL1360A0A

2. Remove the oil pan bolts including those through the timing cover and lower the oil pan to the ground.

Inspecting and repairing Clean the gasket material from the oil pan face, clean the pan with a suitable solvent and inspect the pan for cracks or damaged threads on the pan face.

47921938 07/02/2017

10.2 [10.102] / 3

Engine - Pan and covers

Engine oil pan - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Installation is the reverse of removal, but with the following requirements: 1. Ensure block face is clear and free of gasket material. Install a new gasket on the oil pan. 2. Position the oil pan and install a bolt at each corner, finger-tighten to hold in position, then install the remaining bolts and tighten to the specified torque. 3. Reinstall the oil strainer and the oil pan bottom cover plate.

LAIL11TL1359A0A

47921938 07/02/2017

10.2 [10.102] / 4

Index Engine - 10 Pan and covers - 102 Engine oil pan - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pan - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

10.2 [10.102] / 5

47921938 07/02/2017

10.2 [10.102] / 6

Engine - 10 Valve drive and gears - 106

47921938 07/02/2017

10.3 [10.106] / 1

Contents Engine - 10 Valve drive and gears - 106

TECHNICAL DATA Camshaft Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tappets - Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Rocker arm Adjust the clearance between the valves and rockers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Camshaft Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Camshaft bushings Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

(*) See content for specific models 47921938 07/02/2017

10.3 [10.106] / 2

Engine - Valve drive and gears

Camshaft - Service limits TT3840F TT3840 TT3880F TT4030

LA LA LA LA

LAIL11TL1394G0A

Dimensions (mm) of the control shaft seats and respective housings in the block A. B.

Mod. 3 cylinder Mod. 4 cylinder

NOTE: The internal diameter of bushes refers to the assembled part.

Camshaft Tappets - Service limits TT3840F TT3840 TT3880F TT4030

LA LA LA LA

47921938 07/02/2017

10.3 [10.106] / 3

Engine - Valve drive and gears

Ensure that the tappets slide smoothly in their housing without excessive clearance. If excessive tappet clearance is detected, exchange for larger tappets and open out the associated housing internal diameters. See the standard dimension in Figure 1.

LAIL11TL1351A0A

Larger tappets are available in oversizes of 0.1 mm, 0.2 mm and 0.3 mm. The rods must be perfectly straight and the rocker screw seat must not show signs of undue wear or locking. NOTE: Do not repair warped rods; replace them with new ones.

47921938 07/02/2017

10.3 [10.106] / 4

Engine - Valve drive and gears

Rocker arm - Adjust the clearance between the valves and rockers TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Installation and synchronization of the distribution gears, see the procedures in Crankcase gears - Timing adjust (10.114). 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 NÂˇm (18.44 lb ft).

7. Adjust the clearance between the valves and the rockers using: feeler gauge, key (1) and special tool 291883 (2).

47921938 07/02/2017

10.3 [10.106] / 5

Engine - Valve drive and gears

Camshaft - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

To check the camshaft, place it onto two V-shaped supports and with a centesimal gauge, check that the eccentricity between the support seats and the rotation shaft does not exceed 0.02 mm. Straighten the shaft with a press, if the eccentricity does not exceed 0.2 mm. In case of higher values, otherwise, the shaft needs to be replaced. Check with a centesimal gauge the raising of the lugs, which should be: • 5.97 mm intake lug. • 6.25 mm exhaust lug. Replace the worn bushes using the appropriate extractors and punches and grind the internal diameter of the bushings to the sizes indicated in Camshaft - Service limits (10.106). Check the rocker shaft for signs of wear or damage to the diameter. Replace with a new part. If re-used, before assembly, clean thoroughly in solvent, making sure all oil passages are clear. NOTE: When it becomes necessary to plane the rockers and screw working surfaces, remove as little material as possible. Refer to more specifications and wear limits. Length of rocker spacer spring length should be checked on both free length and load length. Free length – 59.5 mm Load length – 44 mm with a weight of 4.7 – 5.3 kg

47921938 07/02/2017

10.3 [10.106] / 6

LAIL11TL1352A0A

Engine - Valve drive and gears

Camshaft bushings - Replace TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Check the clearance between the camshaft and the bushing. If there is any excess, or, if there are deep scratches, change the bushing. 2. Use a suitable mandrel in order to dismount and mount the bushes. NOTE: When mounting the bushings, pay attention to the alignment of the oil holes (1), which must be aligned to the crankcase oil holes for the supply of the lubricating oil.

LAIL11TL1353A0A

LAIL11TL1354A0A

LAIL11TL1355A0A

3. After mounting, grind all the bushings using a mandrel, a milling cutter, and grind bushings, in order to obtain the prescribed diameter.

4. Mount the cover (1) completely with a sealing ring and secure it together with the corresponding plate on the rear side of engine. Refer to the maximum dimensions of the camshaft in Camshaft - Service limits (10.106).

47921938 07/02/2017

10.3 [10.106] / 7

Index Engine - 10 Valve drive and gears - 106 Camshaft - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft - Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft Tappets - Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft bushings - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rocker arm - Adjust the clearance between the valves and rockers (*) . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

10.3 [10.106] / 8

Engine - 10 Cylinder heads - 101

47921938 07/02/2017

10.4 [10.101] / 1

Contents Engine - 10 Cylinder heads - 101

TECHNICAL DATA Valves Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Valve seat Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Cylinder head Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Injector cup - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Valves Adjust of the gap (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Valve guide Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Valve seat Regrind (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

(*) See content for specific models 47921938 07/02/2017

10.4 [10.101] / 2

Engine - Cylinder heads

Valves - Service limits TT3840F TT3840 TT3880F TT4030

LA LA LA LA

When disassembling and assembling the valves, use tool No. 380003037monitor. For small sealing imperfections it is possible to grind down the valves and seats on the head with a pneumatic grinder or a small universal vise. In case of deeper sealing faults, grind the seat on the head and grind the valves as shown in Valve seat - Regrind (10.101). NOTE: The seats are directly on the head. After the grinding operation, check that the thickness of the valve head edge is not less than 0.5 mm. Measure the depth of the valves in relation to the head face. Dimensions (mm) of valves and related guides. A – Intake B – Size to obtain after grinding with guide - valve assembled in the head S – Exhaust

LAIL11TL1350A0A

Valves - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

TT 3840

TT 3840F

Intake valve clearance

TT 3880F 0,30 mm

47921938 07/02/2017

10.4 [10.101] / 3

TT 4030

Engine - Cylinder heads

Exhaust valve clearance

0,30 mm

47921938 07/02/2017

10.4 [10.101] / 4

Engine - Cylinder heads

Valve seat - Service limits TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Dimensions (mm) of housings (seats) for the valves and valve guides.

LAIL11TL1300B0A

A. B. R.

Intake Size of end for conical grinding on heads for engines with 3 and 4 cylinders Exhaust

47921938 07/02/2017

10.4 [10.101] / 5

Engine - Cylinder heads

Cylinder head - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Disassembling and assembling the valve springs, use tool no. 380003037bolt. 1. Before performing any operation, thoroughly clean the parts. 2. Check the head support surface in the block using ruler (2) check with the calibrator (1). 3. If you note surface warping greater than 0.15 mm, grind the head. NOTE: Remove as little material as possible. The maximum amount of material removed from the head is 0.5 mm. LAIL11TL1261A0A

LAIL11TL1262A0A

4. Use a comparing gauge (1) with magnetic base to control centring and play between the valve rod (2) and the respective housing. 5. If you note excessive play, consult the table in Engine - General specification (10.001), replace the valves and, if necessary, the valve guides.

Next operation: To fit the head, see the procedures in Cylinder head - Install (10.101).

47921938 07/02/2017

10.4 [10.101] / 6

Engine - Cylinder heads

Cylinder head - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Installing the cylinder head is the reverse of the removal procedure described in Engine - Disassemble (10.001), but please observe the following: 1. Clean the splice surfaces well and refit the cylinder head gasket with the word “TOP” facing upwards.

LAIL11TL1258A0A

LAIL11TL1259A0A

LAIL11TL1257A0A

2. Replace the head and tighten the bolts in the sequence shown in the drawing, and in four phases, as shown on the side. Install new inlet and exhaust collector gaskets. NOTE: Lightly lubricate the bolts prior to assembly and tighten to the torque specification, with the engine cold.

NOTE: Before reusing the bolts, check that diameter "d" as shown is no less than 11.5 mm. If it is, change the bolt(s).

Tightening sequence 1st phase 40 N·m 2nd phase Check the initial torque 3rd phase 130° 4th phase 140°

47921938 07/02/2017

10.4 [10.101] / 7

Engine - Cylinder heads

3. Adjust the valves following the procedures in Valves Adjust of the gap (10.101). 4. Before installing the fuel injectors, run the tests described in Fuel injectors - Leakage test (10.218). If the injectors show results suitable for use, install them with new seat washers and cork seals. 5. Install the high pressure fuel lines between the injectors and fuel injector pump. 6. Install a return line with new washers.

BRAG11TR0102LUE

47921938 07/02/2017

10.4 [10.101] / 8

Engine - Cylinder heads

Cylinder head Injector cup - Replace TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Grinding the head valve housing: see procedures in Valve seat - Regrind (10.101).

Replacement 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

Check whether the injector lug (lobe) is within the values indicated in the table in Engine - General specification (10.001). Checking the injector and valve height relative to the head plane: to. Checking injector lug. b. Checking the distance between the head face and the valve: 0.7 â&#x20AC;&#x201C; 1.0 mm (max. permitted distance = 1.3 mm). If the injector lug exceeds the indicated limit, replace the injector sleeve using tool kit 380003042 and proceed as follows: 1. Establish distance "A" in tool (3) 292240 with a value of 9 mm via the ring (5) and block it with the bolt (4). 2. Make an internal thread in the sleeve to be disassembled using tool 292240 (M 12 x 1.75), ensuring that the thread is only cut into the sleeve. 3. Adjust the tool ( (2), Fig. 3) 293784 to the injector bolts in the head via nuts (3) (M8 x 1.25).

LAIL11TL1273A0A

LAIL11TL1274A0A

4. Tighten the part ( (11), Fig. 3) totally in the thread made previously in the sleeve and tighten the nut ( (1), Fig. 3) to remove the injection sleeve ( (12), Fig. 3) from the head. 5. Remove any copper residue from inside the head using tool 292243. 6. Fit new seals ( (6), Fig. 3) to the new injector sleeve and adjust the head to the holes, ensuring the head is touching the lower part of the head housing and press in with punch 293861 (5).

47921938 07/02/2017

10.4 [10.101] / 9

Engine - Cylinder heads

7. Place the sleeve ( (12), Fig. 3), on the bush 293746 (10), fix it into its housing tightening the bush ring (9) clockwise, put the enlarger 293747 (7) into the bush (10) and enlarge the inner part of the sleeve. 8. Remove the enlarger ( (7), Fig. 3) and loosen the bush (9) by approximately 10 mm. 9. Tighten the bush ( (9), Fig. 3) manually, or with light taps with a plastic hammer until the internal body of the bush (10) 293746 unblocks. 10. Disassemble the bushing, insert the grinder 293790 ( (8), Fig. 3) into the bushing, place the latter in the sleeve (12) and fasten by tightening the bushing (9) clockwise. 11. Move the bit ( (8), Fig. 3) extracting material until the housing is perfectly smooth. 12. Assemble the injector holder and check the projection in relation to the head face.

Disassembly, extraction of residual material, assembly and grinding injector holder sleeve in head with kit 380003042

LAIL11TL1306F0A

1-2-11. 3. 4. 5. 6.

Injector holder sleeve extractor 293784 Injector fixing nuts M 8 x 1.25. Tool to extract residual material 292243 Tool to assemble the injector sleeve 293861 O-ring linings

47921938 07/02/2017

10.4 [10.101] / 10

7. 8. 9-10 11. 12.

Enlarger 293747 Grinder 293790 Bushes for guide 293746 Rod Liner

Engine - Cylinder heads

Valves - Adjust of the gap TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Adjustment of the intake and exhaust valves Adjust the clearance of the intake and exhaust valves with the engine cold. Use special tool 380000232. The valve clearance values are described in Valves - General specification (10.101).

LAIL11TL1347A0A

LAIL11TL1348A0A

LAIL11TL1349A0A

3-cylinder engine Install piston no. 1 at Top Dead Center (TDC) in compression stroke and adjust the clearance of valves A, B, C, and F. Rotate the crankshaft one turn and adjust valves D and E.

4-cylinder engine Install piston no. 1 at TDC in compression stroke and adjust the clearance of valves A, B, D, and E. Rotate the crankshaft one turn and adjust valves C, F, G, and H.

47921938 07/02/2017

10.4 [10.101] / 11

Engine - Cylinder heads

Valve guide - Replace TT3840F TT3840 TT3880F TT4030

LA LA LA LA

NOTICE: Raise and handle all heavy parts using lifting equipment with sufficient lifting capacity. Make sure all units and parts are supported by appropriate belts and hooks. Make sure that there is no one around the load that is to be lifted. With the head on the bench, proceed as follows: 1. With the helical tip 380000222, ream the hole for the valve guide to be assembled. 2. Position the head on a suitable support and extract the valve guide to be replaced using a punch 291046 (1).

LAIL11TL1263A0A

LAIL11TL1264A0A

LAIL11TL1265A0A

3. Turn the head and install the new guide with the widened hole, using punch 291046 (1) and bushing 293231 (2).

4. With the aid of a reamer 292177 (1) grind the guide hole (2).

NOTE: Whenever you replace the exhaust valve guides, perform the following operations:

47921938 07/02/2017

10.4 [10.101] / 12

Engine - Cylinder heads

5. Measure the distance "L" between the base of the head and the base of the valve guide using a pachymeter and plate (1) of tool No. 294028monitor. The depth for grinding is given by: B–L = C where: B = Size of end for conical grinding ( Valve seat - Service limits (10.101)). L = Dimension measured between the head base and the valve guide base. C = Depth of conical grinding to be performed.

LAIL11TL1266A0A

LAIL11TL1267A0A

LAIL11TL1268A0A

LAIL11TL1269A0A

Example (for 4-cylinder model) B = 43.1 – 43.6 mm L = 34 mm (measured dimension) C = ( 43.1 – 43.6 mm) - 34 mm = 9.1 – 9.6 mm Depth of conical grinding to be performed. 6. Insert, on the top side of the head, the bushing (1) of tool 294028 in the valve guide (2).

7. Install the grinder (1) of tool 294028 with the limiter (2), in the bushing positioned in the previous operation until the grinder makes contact with the valve guide.

8. Position plate (3) of tool 294028 in contact with the head base. Support the limiter (2) against the same plate and measure the distance "A" between the limiter ends and grinder end (1).

47921938 07/02/2017

10.4 [10.101] / 13

Engine - Cylinder heads

9. Move the limiter (1) to distance D = 35.9 – 36.4 mm from the end of the grinder and lock it with the appropriate screw. Distance "D" is obtained from: D = A–C where: D = Size that determines the end of conical grinder. A = Distance between the end of the grinder and the end of the limiter with the plate making contact with the head. C = Depth of conical grinding to be performed.

LAIL11TL1270A0A

LAIL11TL1271A0A

Example: A = 45.5 mm C = 9.1 – 9.6 mm D = 45.5 mm -( 9.1 – 9.6 mm) = 35.9 – 36.4 mm 10. Turn the grinder (2) until the limiter (1) makes contact with the plate (3). NOTE: Before assembling the head it must be thoroughly cleaned to eliminate all work residues.

47921938 07/02/2017

10.4 [10.101] / 14

Engine - Cylinder heads

Valve seat - Regrind TT3840F TT3840 TT3880F TT4030

LA LA LA LA

â&#x20AC;&#x153;Trimâ&#x20AC;? 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. If the valve support (seat) requires grinding to improve the valve sealing, use the universal valve grinder 294006 (1) and remove the smallest amount of material possible.

LAIL11TL1272A0A

Refer to the maximum and minimum acceptable dimensions of the valve seat in Valve seat - Service limits (10.101).

47921938 07/02/2017

10.4 [10.101] / 15

Index Engine - 10 Cylinder heads - 101 Cylinder head - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder head - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder head Injector cup - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve guide - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve seat - Regrind (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve seat - Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves - Adjust of the gap (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves - Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

10.4 [10.101] / 16

Engine - 10 Connecting rods and pistons - 105

47921938 07/02/2017

10.5 [10.105] / 1

Contents Engine - 10 Connecting rods and pistons - 105

TECHNICAL DATA Connecting rod and piston Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Connecting rod and piston Connecting rod - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Piston Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Ring - Backlash (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

(*) See content for specific models 47921938 07/02/2017

10.5 [10.105] / 2

Engine - Connecting rods and pistons

Connecting rod and piston - Service limits TT3840F TT3840 TT3880F TT4030

LA LA LA LA

LAIL11TL1305F0A

Dimensions (mm) of standard pistons, relative pins, and rings. A.

Size to be measured with the rings introduced in the cylinders.

Piston diameter measured at 57 mm from the skirting base.

47921938 07/02/2017

10.5 [10.105] / 3

Engine - Connecting rods and pistons

LAIL11TL1299B0A

Maximum and minimum connecting rod dimensions

47921938 07/02/2017

10.5 [10.105] / 4

Engine - Connecting rods and pistons

Connecting rod and piston Connecting rod - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Before performing any operation, thoroughly clean the parts. Refer to the maximum and minimum dimensions of the connecting rod in Connecting rod and piston - Service limits (10.105). Check if the link conrod bushes (on the piston pin) did not undergo loosened fastenings and that they are aligned with the side surfaces. If necessary, replace the bushes and grind them to the value of size A. Dimensions (mm) of link conrods, bush bushings and standard pins. Size to obtain with grinding after assembling the bushings - L, M. Lubrication holes. Check that the link conrod shafts are parallel, the maximum acceptable tolerance is Âą 0.07 mm measured at 125 mm on the link conrod longitudinal axis. Smooth deformations may be eliminated with the aid of a press, otherwise, replace the link conrod. The new link conrods must be marked with the numbers that refer to the cylinders onto which they will be assembled, making sure that the difference in link conrod weights within the same engine does not exceed 25 g. Also check that the lubrication holes (L and M) of the connecting rod are free from encrustations or impurities. LAIL11TL1256A0A

47921938 07/02/2017

10.5 [10.105] / 5

Engine - Connecting rods and pistons

Piston - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Before performing any operation, thoroughly clean the parts. Check the wear to the cylinders and pistons using as reference the values in the table in Engine - General specification (10.001), as well as the figures below. When replacing pistons, ensure that the weight difference between pistons in the same engine does not exceed 20 g. Check the play in the rings in the piston housings (b, Fig. 1) and the gap between the points (c, Fig. 1), see the values in the table in Engine - General specification (10.001). If the play between the ring ends is lower than the normal value, it may be increased through grinding.

LAIL11TL1301E0A

Measuring pistons and relative rings a.

Measure a piston's diameter using size "L" at the skirting base (b = 57 mm).

Checking play between one ring and the respective housing.

Trac- Checking the play between the ends of a ring tors introduced in the cylinder. with turbocharged engines

Consult the maximum and minimum dimensions that the piston can have in Connecting rod and piston Service limits (10.105).

47921938 07/02/2017

10.5 [10.105] / 6

Engine - Connecting rods and pistons

For repair operations where new piston rings (1) need to be removed/fitted, use pliers 291160 (2). Assemble the link conrods on the pistons ensuring the coupling play between the pin and the housing in the piston is between 0.095 – 0.171 mm.

LAIL11TL1247A0A

LAIL11TL1248A0A

LAIL11TL1249A0A

LAIL11TL1245A0A

Check for perfect alignment between the link conrods and pistons. If this is not the case, replace the parts causing the problem.

• Lubricate the pistons, rings, and cylinders before assembling the pistons in the cylinder. • Also remember that before fitting the belt 380000994 (1) to put the pistons (2) in the cylinder, you must check that the ring points in the pistons are 180° out of alignment with each other. This will assure better compression and better oil seal.

Link conrod cover fixing bolts If the bolts are being reused, check that diameter "d", measured at the point indicated by letter "a", is greater than 10.5 mm: if not, replace the bolts. NOTE: We advise replacing the bolts every time the conrod covers are removed.

Next operation: 47921938 07/02/2017

10.5 [10.105] / 7

Engine - Connecting rods and pistons

Checking the play in the ring housings: see the procedures in Piston Ring - Backlash (10.105).

47921938 07/02/2017

10.5 [10.105] / 8

Engine - Connecting rods and pistons

Piston Ring - Backlash TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To check the piston measurement, see the procedures in Piston - Inspect (10.105).

Check the play in the ring housings 1. Clean the rings in the grooves and, using a new ring and feeler gauges, check if there is wear to the radius of the piston ring (gap between the ring and the groove).

• Upper compression ring: 0.090 – 0.122 mm • 2nd compression ring: 0.060 – 0.092 mm • Oil control ring: 0.040 – 0.075 mm

LAIL11TL1250A0A

LAIL11TL1251A0A

Maximum groove wear clearance: • Upper compression ring: 0.050 mm • 2nd compression ring and oil control ring: 0.020 mm 2. Place a new ring into the cylinder bore and check the piston ring gap width at the top, middle and bottom of the bore.

• Top ring 0.40 – 0.65 mm • Second ring 0.30 – 0.55 mm • Third ring 0.30 – 0.60 mm • Maximum wear gap – 1.20 mm NOTE: In a worn cylinder, ring gap should be checked at the bottom of cylinder. Next operation: To fit the pistons in their liners, see the procedures in Piston - Assemble (10.105).

47921938 07/02/2017

10.5 [10.105] / 9

Engine - Connecting rods and pistons

Piston - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Checking the play in the ring housings: see the procedures in Piston Ring - Backlash (10.105). Proceed as follows: 1. Lubricate the pistons, rings, and cylinders with engine oil before performing the assembly. 2. Using pliers 291160, fit the rings in the piston housing and once the pistons are assembled, ensure that the ends are 180° out of alignment. 3. Assemble tool number 380000994 (1) (belt) and use to fit the pistons (2) into the cylinders, taking care not to change the alignment of the ring points mentioned in the previous paragraph. 4. Mount the pistons complete with the conrods in the base, checking that the number of the conrod corresponds to the number of the cylinder and that the number marked on the conrod is facing the opposite side with regard to the camshaft.

LAIL11TL1252A0A

LAIL11TL1253A0A

LAIL11TL1254A0A

5. Position the conrod covers (1) complete with the respective bushings and tighten the fixing bolts (2) to a torque of 40 N·m (29.50 lb ft).

6. Using tool number 380000304 (1), tighten each screw (2) securing the covers of the conrods another 60°.

47921938 07/02/2017

10.5 [10.105] / 10

Engine - Connecting rods and pistons

Check the piston projection in relation to the block. Using a calibration gauge with magnetic base (1), check if the projection of the upper plane of the pistons (2) in relation to the face of the block is within the tolerance specified in 0.355 â&#x20AC;&#x201C; 0.761 mm (pistons above the block).

LAIL11TL1255A0A

47921938 07/02/2017

10.5 [10.105] / 11

Index Engine - 10 Connecting rods and pistons - 105 Connecting rod and piston - Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting rod and piston Connecting rod - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Ring - Backlash (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

10.5 [10.105] / 12

Engine - 10 Crankshaft and flywheel - 103

47921938 07/02/2017

10.6 [10.103] / 1

Contents Engine - 10 Crankshaft and flywheel - 103

TECHNICAL DATA Crankshaft Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine flywheel Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Crankshaft oil seal Front seal - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Front seal - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Crankshaft Journal - Backlash (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

(*) See content for specific models 47921938 07/02/2017

10.6 [10.103] / 2

Engine - Crankshaft and flywheel

Crankshaft - Service limits TT3840F TT3840 TT3880F TT4030

LA LA LA LA

LAIL11TL1303F0A

Maximum acceptable tolerances on the main bushings and link conrods a. 3-cylinder engine b. 4-cylinder engines Tractors with turboc- Connecting rod seat radius harged engines

d. e.

Main seat radius Thrust bushing seat radius

47921938 07/02/2017

10.6 [10.103] / 3

Engine - Crankshaft and flywheel

LAIL11TL1304F0A

Maximum tolerances for aligning the main bushing seats relative to those of the link conrod b.

Mod. 3 cylinder

Trac- Mod. 4 cylinder tors with turbocharged engines

A. and B. D.

Support positions for the comparing gauge to check perpendicularity and centering of the flywheel coupling flange. Maximum permissible difference of crankshaft warping, supported on the end seats.

47921938 07/02/2017

10.6 [10.103] / 4

Engine - Crankshaft and flywheel

Engine flywheel - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Assembling tappets, crankshaft, bushings, and separators: see the procedures in Crankshaft - Assemble (10.103) . The flywheel is fastened to the crankshaft with self-locking bolts and on the engine side contains the starter ring gear (rack), hot-fastened. If necessary, replace the rack. To refit it, heat it in oil at a temperature of 80 – 90 °C and guide the angle of the teeth from inside (starter motor side). Assembly of the flywheel on the crankshaft has a fixed position; the holes for the fixing bolts are rightly out of alignment. • Lubricate the bolts that fix the flywheel to the engine with engine oil and tighten them with a torque meter to the torque indicated in Engine - Torque (10.001) .

Engine flywheel fixing bolts If the bolts are being reused, check that diameter "d" (measured at point "a") is greater than 11.5 mm: if not, replace them.

LAIL11TL1221A0A

LAIL11TL1213A0A

Rear cover with the seal joint and the engine flywheel Proceed as follows: 1. Fit the rear cover (3) with the respective external seal joint, tighten the fixing bolts (2) with a torque of 25 N·m (18.44 lb ft), ensuring with feeler gauges (1), that the crankshaft flange is coaxial with the cover.

47921938 07/02/2017

10.6 [10.103] / 5

Engine - Crankshaft and flywheel

2. Install the rear retainer with tool no. 50139monitor.

LAIL11TL1214A0A

LAIL11TL1215A0A

LAIL11TL1216A0A

3. Fit the flywheel and tighten the fixing bolts (1) with a torque of 40 N·m (29.50 lb ft).

4. Then, using tool no. 380000304 (1), tighten each flywheel fixing bolt (2) a further 60°.

47921938 07/02/2017

10.6 [10.103] / 6

Engine - Crankshaft and flywheel

Crankshaft oil seal Front seal - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Front crankshaft oil retainer 1. Remove the air filter following procedures described in Air cleaner - Remove (10.202). 2. Remove the radiator following the procedures described in Radiator - Remove (10.400). 3. Remove the fan following the procedures described in Fan and drive - Remove (10.414). 4. Loosen the retention bolts (1) and remove the pulley from the crankshaft.

LAIL11TL1237A0A

LAIL11TL1238A0A

LAIL11TL1239A0A

5. Straighten the projection on the back-up washer, securing the crankshaft against rotation and loosen the nut (1).

6. Remove the pulley hub from the crankshaft with tool 380000226 (1) and extract the woodruff key.

47921938 07/02/2017

10.6 [10.103] / 7

Engine - Crankshaft and flywheel

7. Remove the oil seal from its seat.

LAIL11TL1240A0A

Next operation: Installation of the front crankshaft retainer: see procedures in Crankshaft oil seal Front seal - Install (10.103).

47921938 07/02/2017

10.6 [10.103] / 8

Engine - Crankshaft and flywheel

Crankshaft oil seal Front seal - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Install the oil seal following the reverse order of procedures described in Crankshaft oil seal Front seal Remove (10.103). 2. Reinstall the crankshaft hub and the retention nut using tool 380000226 (1). Incline the projection on the safety nut. 3. Reinstall the fan following the reverse order of procedures described in Fan and drive - Remove (10.414). 4. Reinstall the control belt and adjust the tension following the procedures described in Fan and drive - Tension adjust (10.414). 5. Install the radiator following the reverse order of procedures described in Radiator - Install (10.400). LAIL11TL1239A0A

47921938 07/02/2017

10.6 [10.103] / 9

Engine - Crankshaft and flywheel

Crankshaft Journal - Backlash TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Check if the existing play between the seats and relative bushes with calibrated wire proceeding as follows: 1. Make sure all parts are perfectly clean and have no oil marks. 2. Place the bushings in the housings (5). 3. Install the crankshaft according to the procedures in Crankshaft - Assemble (10.103). 4. Arrange a piece of calibrated wire (6) on the seats (4) of the crankshaft parallel to the longitudinal axis. 5. Assemble the covers (1) complete with bushings (2) in the block.

LAIL11TL1218A0A

LAIL11TL1219A0A

LAIL11TL1220A0A

6. Lubricate the bushing cover fixing bolts with engine oil and tighten them with a torque meter to the indicated torque Engine - Torque (10.001).

Bushing cover fixing bolts If reusing the bolts, check that diameter "d" (measured as indicated in Fig. 2, region "a") is greater than 13.5 mm: if not, replace the bolts. 1. Disassemble the bushing covers and determine the existing play between the cover and the seats comparing the width of the calibrated wire at the point of highest crushing with the graded scale on the envelope ( (3), Fig. 1) containing the wire. 2. After refitting the crankshaft in the block and fixing it with the bearings, use a calibrator gauge (1) to check the axial play at the penultimate bearing. â&#x20AC;˘ If the clearance exceeds that indicated in Engine General specification (10.001), replace the thrust bushing.

47921938 07/02/2017

10.6 [10.103] / 10

Index Engine - 10 Crankshaft and flywheel - 103 Crankshaft - Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Journal - Backlash (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft oil seal Front seal - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft oil seal Front seal - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine flywheel - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

10.6 [10.103] / 11

47921938 07/02/2017

10.6 [10.103] / 12

Engine - 10 Balancer and damper - 110

47921938 07/02/2017

10.7 [10.110] / 1

Contents Engine - 10 Balancer and damper - 110

FUNCTIONAL DATA Balancer Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Balancer Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Timing adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

(*) See content for specific models 47921938 07/02/2017

10.7 [10.110] / 2

Engine - Balancer and damper

Balancer - Sectional view TT3840F TT3840 TT3880F TT4030

LA LA LA LA

LAIL11TL1393E0A

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Separators Locking ring Bushing (28) lubrication tube Counterweight support shaft Shaft retention spring pin Counterweight drive gear (13) support Separator Counterweights Counterweight drive gear Fixing bolts from the counterweight box to the block Locking ring Counterweight box Counterweight drive gear Suction tube

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

Suction pipe fixing bolt Bushing Connection sleeve Locking ring Separator Gear (22) support Separator Counterweight drive movement take off gear Seal cover O-Ring

25. 26. 27. 28.

Locking ring Transmission gear Gear (26) support shaft Bushing

47921938 07/02/2017

10.7 [10.110] / 3

Engine - Balancer and damper

Balancer - Service instruction TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Checks, measurements, and repairs 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

Before performing any operation, thoroughly clean the parts. Check component wear and replace the damaged ones. In case of replacement, the rotary counterweight bushings must be fastened to their respective housings after heating the counterweights in oil at a temperature of 140 â&#x20AC;&#x201C; 160Â°. Grind the inside of the replaced bushings using wideners with expansible blades. Note the play indicated in table Engine - General specification (10.001).

47921938 07/02/2017

10.7 [10.110] / 4

Engine - Balancer and damper

Balancer - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Dynamic balancer with rotating counterweights To remove the balancer assembly with the engine fitted on the tractor, proceed as follows: 1. Remove the oil pump along with the strainer. 2. Loosen the bolts securing the balancer assembly and slide the assembly towards the flywheel side until the shaft (1) moves away from the fixed coupling (2). 3. Remove the balancer assembly.

LAIL11TL1356A0A

Next operation: Removing the dynamic balancer, see the procedures in Balancer - Disassemble (10.110).

47921938 07/02/2017

10.7 [10.110] / 5

Engine - Balancer and damper

Balancer - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

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: Removing the dynamic balancer, see the procedures in Balancer - Remove (10.110). 1. Remove the cotter pins (1) and disassemble the weight shaft through punch blows. 2. Disassemble the drive gear (2) by removing the circlip (3) and the bolts (4) that secure the housing. 3. Disassemble the idler gear (5) by removing the circlip (6).

LAIL11TL1357A0A

Mounting 1. To assemble, follow the steps for disassembly in the reverse order.

47921938 07/02/2017

10.7 [10.110] / 6

Engine - Balancer and damper

Balancer - Timing adjust TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Check the parts for wear, replacing damaged parts, and remove burrs from the exchanged bushings. Weight bushings must be fitted in their housings after heating the weights in oil at a temperature of 140 – 160 °C. 2. When reassembling the part, the gear (5) and the weights (8) must be positioned according to the marks indicated by the arrows. Observe that: • The weight drive idler gear (5) must have the longer part of the hub facing the case wall. • The holes for the pins, made on the shaft (7), must be aligned with the corresponding holes on case. When refitting the contra-rotating mass unit, timing is undertaken as follows: 1. Position piston No. 1 at top dead center. 2. Secure the mechanical transmission (9), matching the reference marks as shown in Figure 1. 3. Lock the weights in the correct installation position with the pin (1), checking the correspondence of the reference marks. 4. Fit the transmission coupling (2) and lock the assembly, tightening the bolts to the specified torque.

47921938 07/02/2017

10.7 [10.110] / 7

LAIL11TL1358A0A

Index Engine - 10 Balancer and damper - 110 Balancer - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Balancer - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Balancer - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Balancer - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Balancer - Timing adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

10.7 [10.110] / 8

Engine - 10 Pump drives - 114

47921938 07/02/2017

10.8 [10.114] / 1

Contents Engine - 10 Pump drives - 114

SERVICE Crankcase gears Gear tooth contact (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Timing adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Check synchronization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(*) See content for specific models 47921938 07/02/2017

10.8 [10.114] / 2

Engine - Pump drives

Crankcase gears - Gear tooth contact TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Before removing the timing gear, use a calibration gauge or feeler gauge to measure the backlash between each set of gears. Rotate the gears and check the backlash at four equal points on the gears. If the backlash exceeds 0.160 mm, the gears need to be replaced.

LAIL11TL1338A0A

Next operation: To remove the idler shaft gear, see the procedures in Crankcase gears - Remove (10.114).

47921938 07/02/2017

10.8 [10.114] / 3

Engine - Pump drives

Crankcase gears - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To check the gear teeth contact, see the procedures in Crankcase gears - Gear tooth contact (10.114). 1. Remove the lock ring and the spacer (1) and the (3). Hub idler gear (2).

LAIL11TL1339A0A

LAIL11TL1340A0A

2. Remove three bolts (1) and the cap hub.

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

47921938 07/02/2017

10.8 [10.114] / 4

Engine - Pump drives

Crankcase gears - Timing adjust TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To remove the idler shaft gear, see the procedures in Crankcase gears - Remove (10.114). 1. If the rear cover was removed, thoroughly clean the mating surfaces between the cover and engine block, using a suitable solvent cleaner and apply a thin coat of grease to the engine block and assemble the cover to the engine and tighten the retaining bolts to the specified torque. 2. Rotate the flywheel to PMS1 position before assembling the timing gears. 3. Assemble the camshaft, thrust washer, flange, and camshaft gear and tighten the two bolts to specified torque. LAIL11TL1341A0A

LAIL11TL1342A0A

4. Install the Feed Pump Drive Gear by following the removal procedure in reverse. 5. Install the idler gear on the block, aligning the timing marks 1-1, 2-2, and 3-3 to the crankshaft gear, the camshaft drive gear, and the supply pump drive gear respectively. NOTE: Ensure that the flywheel is positioned at the PMS1 mark while aligning the timing marks. 6. Install the fuel injection pump drive gear by aligning mark 4-4 to the supply pump drive gear when the idler gear is aligned with other gears as mentioned in step 5. 7. Tighten the fuel injection pump drive gear bolt to the specified torque. Install the hydraulic drive gear by inverting the removal procedure. 8. Replace new gaskets between timing cover and hydraulic and power steering pump flange before installing pump.

Next operation: For the play between the valves and rocker arms, see the procedures in Rocker arm - Adjust the clearance between the valves and rockers (10.106).

47921938 07/02/2017

10.8 [10.114] / 5

Engine - Pump drives

Crankcase gears - Check synchronization TT3840F TT3840 TT3880F TT4030

LA LA LA LA

If after installing, removing, or servicing the distribution assemblies, you need to check the distribution diagram, follow the steps below: 1. Check synchronization of the distribution gears indicated in topic: Crankcase gears - Timing adjust (10.114). 2. Temporarily adjust the play between the valves and the rocker arms to 0.45 mm. 3. Keep turning the crankshaft on a graduated scale until valve opening and closing match the angle values shown in Fig. 1. 4. Adjust the operating play between the valves and rocker arms as indicated on Rocker arm - Adjust the clearance between the valves and rockers (10.106).

Distribution diagram A. Fixed anticipation (*) (start of injection) 1.

T.D.C.

B.D.C.

Intake

Exhaust

Fuel injection

* Consult the table in Engine - General specification (10.001) on the base for the type of engine and pump installed in the tractor.

47921938 07/02/2017

10.8 [10.114] / 6

BRAG11TR0106LUE

Index Engine - 10 Pump drives - 114 Crankcase gears - Check synchronization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase gears - Gear tooth contact (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase gears - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase gears - Timing adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

10.8 [10.114] / 7

47921938 07/02/2017

10.8 [10.114] / 8

Engine - 10 Lift pump and lines - 210

47921938 07/02/2017

10.9 [10.210] / 1

Contents Engine - 10 Lift pump and lines - 210

SERVICE Fuel lift pump Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(*) See content for specific models 47921938 07/02/2017

10.9 [10.210] / 2

Engine - Lift pump and lines

Fuel lift pump - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

NOTE: Before removing the pump, check that the areas around the feed pump are clean. 1. Close the fuel entry recorder (1).

BRAG11TR0099LUE

BRAG11TR0100LUE

2. Disconnect the fuel intake and return lines from the feed pump. 3. Loosen the two nuts (1) securing the feed pump to the mounting bracket and remove the feed pump. Remove the gasket between the feed pump and mounting bracket.

Installation 4. To install the transfer pump, follow the procedures for its removal in reverse order. Next operation: Feed pump disassembly: see procedures in Fuel lift pump - Disassemble (10.210).

47921938 07/02/2017

10.9 [10.210] / 3

Engine - Lift pump and lines

Fuel lift pump - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Removing the transfer pump, see procedures in Fuel lift pump - Remove (10.210). 1. Loosen the butterfly nut, open the screen cap (1) and remove the screen (2).

LAIL11TL1290A0A

LAIL11TL1291A0A

LAIL11TL1292A0A

2. Loosen the screws and remove the supply pump head (1).

3. Remove the nylon cup (1) using the appropriate tool.

47921938 07/02/2017

10.9 [10.210] / 4

Engine - Lift pump and lines

4. Remove the diaphragm assembly by pressing and turning 90Â° clockwise or anti-clockwise.

LAIL11TL1293A0A

LAIL11TL1294A0A

5. Remove the spacer (1) from the diaphragm assembly.

Mounting For assembly, follow the disassembly procedure in reverse. Next operation: Inspecting the fuel transfer pump, see the procedures in Fuel lift pump - Inspect (10.210).

47921938 07/02/2017

10.9 [10.210] / 5

Engine - Lift pump and lines

Fuel lift pump - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To remove the transfer pump, see procedures in Fuel lift pump - Disassemble (10.210). 1. Check diaphragm for damage, cuts, or cracks. Replace diaphragm assembly if necessary. 2. Check the rubber valves and nylon cup O-ring and head for damage. If necessary, replace the nylon cup and O-ring.

LAIL11TL1295A0A

Next operation: Assembling the transfer pump, see procedures in Fuel lift pump - Disassemble (10.210).

47921938 07/02/2017

10.9 [10.210] / 6

Index Engine - 10 Lift pump and lines - 210 Fuel lift pump - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel lift pump - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel lift pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

10.9 [10.210] / 7

47921938 07/02/2017

10.9 [10.210] / 8

Engine - 10 Fuel injection system - 218

47921938 07/02/2017

10.10 [10.218] / 1

Contents Engine - 10 Fuel injection system - 218

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

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

SERVICE Rotary injection pump Bleed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Timing adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Timing adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Fuel injectors Replace injector sleeves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

(*) See content for specific models 47921938 07/02/2017

10.10 [10.218] / 2

Engine - Fuel injection system

Fuel injection system - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

TT3840 Turbocompressor GARRET type

TT3840F

TT3880F

TT4030

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

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

4800029 4791124 4800030

KBEL83S35

3 0.350 mm 230 – 242 bar

5 0.230 mm

0.250 mm

258.3 – 268.5 bar

BOSCH pump injection piping Type

4797506 -

Tube size

6 mm x 1.5 mm x 475 mm

Bomba da alimentação Control shaft eccentricity Control shaft diameter corresponding to the bushes Internal diameter of bushes installed and finished in the housing Interference between bushes and the housings Assembly play between the shaft and bushings Internal washer thickness External washer thickness

47921938 07/02/2017

10.10 [10.218] / 3

FPT/Cartec FPT/Cartec FPT/Cartec ( (504388200) (504388201) 5801445643) 6 mm x 6 mm x 6 mm x 1.5 mm x 1.5 mm x 1.8 mm x 540 mm 540 mm 540 mm 3.000 mm 31.975 – 32.000 mm 32.050 – 32.075 mm 0.063 0.050 1.450 2.930

– – – –

0.140 mm 0.100 mm 1.500 mm 3.000 mm

Engine - Fuel injection system

Fuel injection system - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

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.

47921938 07/02/2017

10.10 [10.218] / 4

Engine - Fuel injection system

Rotary injection pump - Bleed TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Synchronisation of injection pump, see procedures in Rotary injection pump - Timing adjust (10.218). 1. Loosen the plug (1) in 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).

47921938 07/02/2017

10.10 [10.218] / 5

Engine - Fuel injection system

Rotary injection pump - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

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).

47921938 07/02/2017

10.10 [10.218] / 6

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).

47921938 07/02/2017

10.10 [10.218] / 7

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

47921938 07/02/2017

10.10 [10.218] / 8

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 TT3840 and TT3840F models the fuel filter has to be removed before the injection pump.

47921938 07/02/2017

10.10 [10.218] / 9

Engine - Fuel injection system

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

LAIL11TL1289A0A

Next operation: To remove the transfer pump, see procedures in Fuel lift pump - Disassemble (10.210).

47921938 07/02/2017

10.10 [10.218] / 10

Engine - Fuel injection system

Rotary injection pump - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Removal of fuel injection pump, see procedures in Rotary injection pump - Remove (10.218). 1. Reassemble the injection pump drive gear matching the synchronisation references marked on the gears and fasten with the correct nut. Fix the pump to the support with the three nuts. 2. Reassemble the gear cover. 3. Reassemble the two semi-rigid tubes connecting the injection pump/filter and supply pump/filter. 4. To make it easier, first fasten the connections to the filter. 5. Assemble the engine stopping cable. Reassemble the high pressure tubes to the pump and injectors. 6. Reassemble the injection pump throttle control lever articulation spring. Reassemble all the flexible tubes that were disassembled before. 7. Reinstall the access cover to the flywheel rack. 8. Reassemble the protection screen on the RH side of the fan. 9. Reconnect the negative battery cable. 10. Close the hood and reassemble the exhaust tube. Next operation: Adjust synchronization of injection pump, see procedures in Rotary injection pump - Timing adjust (10.218).

47921938 07/02/2017

10.10 [10.218] / 11

Engine - Fuel injection system

Rotary injection pump - Timing adjust TT3840F TT3840 TT4030

LA LA LA

Prior operation: Installation of injection pump, see procedures in Rotary injection pump - Install (10.218).

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 synchronised as follows: 1. Loosen the connections from the injection pump to injector connecting tubes and remove the tubes.

LAIL11TL1099A0A

LAIL11TL1100A0A

LAIL11TL1101A0A

2. Remove injection pump gear cover.

3. Check the reference numbers marked on gears (1) and (2) match. 4. Remove the flywheel inspection cover (1).

47921938 07/02/2017

10.10 [10.218] / 12

Engine - Fuel injection system

5. Turn the crankshaft so it lifts cylinder no. 1 to TDC (compression phase).

LAIL11TL1102A0A

LAIL11TL1311A0A

LAIL11TL1312A0A

LAIL11TL1313A0A

6. Check through the flywheel inspection hole that the alignment of the reference arrow with the degree mark is of: Motor TT 3840/3840F (3 cilindros) = 5 – 7° 7. With the injection pump installed in the respective housing and fixing bolts loose, remove the plug (1) installed in the pump body. 8. Install the calibrator 380000228 ( (1), Fig. 7) and the tool 380000229 (2), pre-loading the calibrator to approximately 2.5 mm. 9. 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). 10. 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. 11. Check on the calibrator gauge if the pumping element travel is 1 mm, if not, loosen the pump fixing bolts. 12. Turn the pump anti-clockwise if travel is lower and clockwise if travel is higher until obtaining the specified travel. 13. Once these conditions have been reached, tighten the pump fixing nuts ( (1), Fig. 12, Rotary injection pump - Remove (10.218)) with a torque of 25 N·m (18.44 lb ft). 14. Mark pump point references ( (1), Fig. 1) on the housing, on the pump and on the interface spacer. 15. Remove the calibrator 380000228 (1) and the tool 380000229 (2), refit the cover, tightening it to a torque of 8 – 10 N·m (5.90 – 7.38 lb ft). 16. Reassemble the other parts proceeding in the inverted order in relation to the operations.

Next operation: Bleeding injection pump, see procedures in Rotary injection pump - Bleed (10.218).

47921938 07/02/2017

10.10 [10.218] / 13

Engine - Fuel injection system

Rotary injection pump - Timing adjust TT3840 TT4030

LA LA

1. Make a plate (1) to hold the injection pump in a vice. Use a metal sheet 6 mm thick, 126 mm wide and 200 mm long. 2. Make a 50 mm diameter hole, 63 mm from the point and 63 mm from the sides, 3. Insert the front (shaft point) of the injection pump into the 50 mm hole in the plate. Using the installation holes as a template, make three marks on the plate 4. Drill three holes 9.5 mm in diameter in the plate.

BRAG11TR0110LUE

BRAG11TR0111LUE

BRAG11TR0112LUE

5. Fix the fitting plate (1) in the vice. Fix the injection pump (2) onto the bolt using the three bolts 5/16 x 1 in and nuts. 6. Put the Woodruff key on a firm surface on the bench. Using a punch, make a small mark on both sides of the key. This will guarantee the pump shaft is firmly fixed and prevent the key coming out of the shaft when installing the pump on the engine. 7. Install the Woodruff key in the channel in the pump shaft, ensuring it is correctly and firmly positioned.

8. Power the KSB solenoid to remove the cold start synchronization advance as follows: 9. Using a battery 12 V and power cables, connect the positive terminal of the battery to the KSB solenoid (1) (cold start advance) and the negative terminal of the battery to a clean unpainted part of the body or the manufactured support plate. (2)

47921938 07/02/2017

10.10 [10.218] / 14

Engine - Fuel injection system

10. At this point the advance arm of the KSB on the side of the sump (1) will be positioned on the rear part of the pump, away from the limiter (2). When the advance arm is in this position, the cam ring on the advance pump 6Â° prevents cold start. The KSB solenoid must remain powered at 12 V until the synchronisation advance is clear, before proceeding. With the battery totally charged this will take about 5 min to happen.

BRAG11TR0113LUE

BRAG11TR0114LUE

BRAG11TR0115LUE

BRAG11TR0116LUE

11. After 5 min, the advance arm (1) will have moved forwards in the pump, almost reaching the limiter (2). The KSB solenoid should remain powered at 12 V during the rest of the adjustment procedure. The cold start advance is now totally clear, and you can proceed with the rest of the test.

12. Obtain two tightening nuts M14x1.50 mm locally. Thread both the nuts (1) onto the pump shaft (2), then tighten them using two 22 mm spanners.

13. Using the same spanner as on the internal nut, turn the pump shaft anti-clockwise (starting form the front of the pump) until the Woodruff key (1) is aligned slightly before the synchronisation mark on the piston (1) in the body of the pump (2). NOTE: On turning the pump shaft there will be a restriction on the piston in the pump that raises and lowers the cam lobes on the cam plate. The pump shaft will stop and there will be no restriction in it when turned to the correct position with the key positioned slightly before the synchronisation mark. It is very important to turn the pump shaft anti-clockwise when adjusting this pump.

47921938 07/02/2017

10.10 [10.218] / 15

Engine - Fuel injection system

14. Using a spanner 12 mm remove the piston access plug (1) from the centre of the pump rear cover.

BRAG11TR0117LUE

BRAG11TR0118LUE

15. Install the adapter in the synchronisation tool (1) into the injection pump and the pin 380001601 in the access point to the piston. Tighten the adapter using a spanner 16 mm.

16. Insert the calibration gauge 380000228 (1), into the adapter in the synchronisation tool (2). Pre-load the calibration gauge to 2.5 mm and turn the adjustment ring on the calibration gauge (3) to zero. NOTE: At this point the pump shaft is positioned withe the Woodruff key slightly before the synchronisation mark on the case. On turning the shaft slightly back you may see the gauge needle move to zero, but this should not happen. If the needle falls to zero, readjust the ring to zero with the shaft in this position. This will guarantee that the piston inside the pump is at the dead point, halfway between the cam lobes. BRAG11TR0119LUE

47921938 07/02/2017

10.10 [10.218] / 16

Engine - Fuel injection system

17. Using a 10 mm, loosen the locking bolt (1) from the shaft, located in the side of the injection pump. Remove the shim plate (2) from behind the head of this bolt. NOTE: Keep the shim for reinstallation behind the synchronisation adjustment bolt after the pump is installed in the motor. Leave the synchronisation adjustment bolt loose for now. 18. Install a 10 mm socket in the activator and tighten to a torque of 34 N·m. 19. While watching the gauge needle, slowly turn the pump shaft anti clockwise. The pump piston will start to raise the cam lobe and the calibration gauge will go to zero. When the comparison gauge reaches the correct synchronisation mark (check the following table), hold the shaft carefully in position and tighten the synchronisation bolt, without locking it, to a torque of 34 N·m. Model TT3840

BRAG11TR0120LUE

BRAG11TR0121LUE

TDC Synchronisation 1.44 – 1.50 mm

20. Remove the lightening nuts (1) from the point of the shaft while checking that the comparison gauge needle does not move. If this happens it means the shaft turns and needs to be readjusted. The synchronisation bolt (2) will hold the pump shaft in the correct place for the time needed to install the pump in the engine. 21. Disconnect the power cables from the battery 12 V. 22. Remove the comparison gauge and the synchronisation tool adapter. Without tightening it, install the piston access outlet now, because the engine synchronisation pump will need to be checked after the pump is installed in the engine.

23. Remove the injection pump from the support plate. Install the pump following the procedures in Rotary injection pump - Install (10.218).

47921938 07/02/2017

10.10 [10.218] / 17

Engine - Fuel injection system

Fuel injectors - Replace injector sleeves TT3840F TT3840 TT3880F TT4030

LA LA LA LA

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.

47921938 07/02/2017

10.10 [10.218] / 18

Engine - Fuel injection system

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.

47921938 07/02/2017

10.10 [10.218] / 19

Engine - Fuel injection system

4. Insert the injector in the sleeve and check that the projection is between 0.05 â&#x20AC;&#x201C; 0.7 mm.

LAIL11TL1390B0A

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

47921938 07/02/2017

10.10 [10.218] / 20

Engine - Fuel injection system

Fuel injectors - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

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 and assemble the base ball washers.

BRAG11TR0102LUE

LAIL11TL1337A0A

3. Tighten the nuts (1) manually until they touch the ball washers and 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.

47921938 07/02/2017

10.10 [10.218] / 21

Index Engine - 10 Fuel injection system - 218 Fuel injection system - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

Rotary injection pump - Timing adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

10.10 [10.218] / 22

Engine - 10 Air cleaners and lines - 202

47921938 07/02/2017

10.11 [10.202] / 1

Contents Engine - 10 Air cleaners and lines - 202

SERVICE Air cleaner Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47921938 07/02/2017

10.11 [10.202] / 2

Engine - Air cleaners and lines

Air cleaner - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

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

LAIL11TL1371A0A

LAIL11TL1372A0A

LAIL11TL1373A0A

4. Remove the hose clamp, separate the lower hose from the radiator (1) and drain the coolant.

5. Remove the ground cable fixing screw from the front axle (1). 6. Disconnect the electrical leads from the horn.

47921938 07/02/2017

10.11 [10.202] / 3

Engine - Air cleaners and lines

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

LAIL11TL1374A0A

LAIL11TL1375A0A

LAIL11TL1376A0A

LAIL11TL1377A0A

8. Remove the intake manifold hose clamp (1).

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

10. Remove the air filter restriction sensor (1) and retrieve the tubing.

47921938 07/02/2017

10.11 [10.202] / 4

Engine - Air cleaners and lines

11. Loosen the clamp and disconnect the tube (1) which connects the air filter to the exhaust aspirator.

LAIL11TL1378A0A

47921938 07/02/2017

10.11 [10.202] / 5

Index Engine - 10 Air cleaners and lines - 202 Air cleaner - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

10.11 [10.202] / 6

Engine - 10 Intake and exhaust manifolds and muffler - 254

47921938 07/02/2017

10.12 [10.254] / 1

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

TECHNICAL DATA Intake and exhaust manifolds and muffler General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47921938 07/02/2017

10.12 [10.254] / 2

Engine - Intake and exhaust manifolds and muffler

Intake and exhaust manifolds and muffler - General specification TT3840F TT3840 TT3880F TT4030

Air filtering Feed Pump Fuel filtering Minimum fuel capacity with rotary control shaft at 1600 RPM Cam controlled BOSCH injection pump Speed regulator, at all speeds, incorporated into BOSCH and DELPHI pumps Automatic speed variator, incorporated in BOSCH and DELPHI pump

LA LA LA LA

TT3840 TT3840F TT3880F TT4030 Through dry air filter with dual cartridge, light indicator for clogged centrifugal pre-filter and automatic dust discharge With dual membrane Through screen filter at the feeding pump, one filter with replaceable cartridge at the injection pump feed 100 l/hour Driven by the engine distribution With rotary distributor With centrifugal mass Hydraulic

47921938 07/02/2017

10.12 [10.254] / 3

Index Engine - 10 Intake and exhaust manifolds and muffler - 254 Intake and exhaust manifolds and muffler - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

10.12 [10.254] / 4

Engine - 10 Engine cooling system - 400

47921938 07/02/2017

10.13 [10.400] / 1

Contents Engine - 10 Engine cooling system - 400

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

FUNCTIONAL DATA Engine cooling system Engine cooling system - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Water pump Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Radiator Cap - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Water pump Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Overhaul (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Coolant thermostat Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

(*) See content for specific models 47921938 07/02/2017

10.13 [10.400] / 2

CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA AGRIFLU NEW HOLLAND AMBRA AGRIFLU Loctite® 242®

Reference

PAGE

Engine cooling system - Dynamic description

10.13 / 5

Engine cooling system - Dynamic description

10.13 / 5

Water pump - Overhaul

10.13 / 14

47921938 07/02/2017

10.13 [10.400] / 3

Engine - Engine cooling system

Engine cooling system - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

TT3840

Cooling Radiator type Fan fastened to the water pump pulley Water pump Engine rpm and water pump ratio Temperature control Water thermometer Definition of each section: Start band (blue) Central band (green) End band (red) Interference between the shaft and water pump turbine Interference between the shaft and fan hub Interference between the bush with front sealant and the turbine Radiator cover pressure relief valve Válvula termostática Valve opening temperature Thermostat valve closing temperature Valve travel when fully open

TT3840F TT3880F TT4030 Water circulation Three rows of vertical tubes with Four rows of vertical copper tubes copper fins Aspiration, with 4 steel blades Centrifugal with blades 1:16/1.03:1 With thermostat With colour scale divided into 3 sections. 30 °C : 65 °C 65 °C : 105 °C 105 °C : 115 °C 0.017 – 0.059 mm 0.024 – 0.058 mm 0.012 – 0.058 mm 0.9 Kg/cm² ( 13 psi) 79 °C 94 °C 7,5 mm

47921938 07/02/2017

10.13 [10.400] / 4

Engine - Engine cooling system

Engine cooling system - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

The function of the water pump mounted at the front of the engine, is to maintain a continuous flow of water around the cooling system. This is essential to ensure the correct engine temperature and performance during vehicle operation. The pump is driven by a ëVí belt from the crankshaft pulley, when the engine is running. The cooling system for the new generation of engines is of the recirculating by-pass type with full-length water-jackets for the bottom tank of the radiator by the water pump, which transfers the coolant to the cylinder block. This coolant then flows through cored passages to cool the cylinder walls. Passages in the cylinder head gasket allow coolant to flow from the cylinder block, into the cylinder head cored passages also conduct the coolant to the fuel injector nozzle locations before re-entering the water pump below the thermostat. The thermostat is located at the top of the water pump body, and controls the water flow as required by changes in temperature. NOTE: A faulty thermostat may cause the engine to operate at too high (hot) or low (cold) a temperature. If not replaced this could result in a damaged engine or impaired engine performance. When the thermostat is closed a recirculating by-pass is provided to allow the coolant to recirculate from the head to the block to effort a faster warm-up. Once the engine has reached its normal operating temperature, the thermostat will open and allow water to be drawn through the radiator by the pump action. Cooled water then returns to the engine system. Cooling occurs as the coolant passes down through the radiator cores, which are exposed to the air as it is drawn through the radiator by the fan. NOTE: Do not operate the engine without a thermostat. The cooling system incorporates a drain plug, on the left hand side of the cylinder block. The cap on the radiator is a system pressure cap and should not be removed unless refilling the system from empty. The engine cooling fan is mounted on a pump pulley which is belt driven from the crankshaft.

Coolant Clean all of the parts thoroughly before proceeding with repair operations. The cooling system is filled with a permanent coolant mixture that consists of water and NEW HOLLAND AMBRA AGRIFLU anti-freeze (up to 50% in volume). This mixture prevents freezing below the temperatures indicated in the table: This mixture also has anti-oxidizing, anti-corrosion, anti-foam, and anti-sediment properties to ensure long-term protection of the cooling system. The same mixture can be used in the system for up to two years or 1600 h of use, whichever comes first, after which the mixture must be changed. Engine coolant -8 °C (17.60 °F) -15 °C (5.00 °F) -25 °C (-13.00 °F) -35 °C (-31.00 °F)

% by volume of NEW HOLLAND AMBRA AGRIFLU 20% 30% 40% 50%

47921938 07/02/2017

10.13 [10.400] / 5

Engine - Engine cooling system

Water pump - Component localization TT3840F TT3840 TT3880F TT4030

LA LA LA LA

LAIL11TL1395G0A

a. Water circulation with thermostat closed b. Water circulation with thermostat open Trac- 3 cylinder model tors with turbocharged engines

1. 2. 3.

Thermostat Pump Engine water electric thermometer

47921938 07/02/2017

10.13 [10.400] / 6

Engine - Engine cooling system

4-cylinder model

4. 5. 6.

Temperature transmitter Fan Radiator

47921938 07/02/2017

10.13 [10.400] / 7

Engine - Engine cooling system

Radiator Cap - Service instruction TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Radiators – Circulation and checks The radiator cap has two valves, a pressure valve and a pressure relief valve. Periodically check that they are working properly. Remove impurities from the radiator using a solution of water and descaling agent in the proportions indicated on the packaging. To not limit the circulation of the radiator, we advise always extending the circulation around the cooling circuit and filling the engine with the solution mentioned above. Turn the engine for one hour. With the engine off, drain the solution by opening the drain. In case of leaks, the radiator can be cooled by immersion in a tank of water at a temperature of 20 – 40 °C (68 – 104 °F), introducing air with a pressure of 0.98 bar (14.21 psi) for approximately two minutes (repeat the test at least three times).

Repair and inspection The radiator cap has two valves: a pressure relief valve (1) set to 0.9 Kg/cm² or 13 psi and a vacuum relief valve. Periodically check that valves operate correctly. On overhaul, eliminate scale in radiator as follows: 1. Prepare the quantity of warm water and bicarbonate of soda solution indicated on the container ( 30 g/L). 2. Pour the solution into radiator. Drain and rinse with plenty of water.

LAIL11TL1383A0A

To check for radiator leaks, immerse it in a tank of water at 10 °C and apply an air pressure of 1 Kg/cm² for two minutes. Repeat the test at least three times. When flushing the radiator, also flush the rest of the cooling system using the solution and procedures indicated above. Run the engine for about 1 h before draining the solution with the engine off.

47921938 07/02/2017

10.13 [10.400] / 8

Engine - Engine cooling system

Radiator - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Remove the air filter following procedures described in Air cleaner - Remove (10.202). 2. Loosen the hose clamp (1) and remove the upper radiator hose.

LAIL11TL1379A0A

LAIL11TL1380A0A

LAIL11TL1381A0A

3. Loosen the clamp and remove the radiator cover line (1).

4. Loosen the two bolts (1) that secure the radiator to the front shaft support and remove the bolts, rubber mounts and spacers.

47921938 07/02/2017

10.13 [10.400] / 9

Engine - Engine cooling system

5. Remove the radiator (1) and the upper rubber mounts. To install the radiator, see the procedures described in Radiator - Install (10.400).

LAIL11TL1382A0A

47921938 07/02/2017

10.13 [10.400] / 10

Engine - Engine cooling system

Radiator - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Put it back in place and tighten the two bolts (1). 2. Connect the two rubber hoses to the cooling pump and the thermostat housing. Connect the tubing to the radiator cap. 3. Reconnect the hood support to the support on the radiator and replace the retaining bolts.

LAIL11TL1381A0A

LAIL11TL1378A0A

LAIL11TL1374A0A

4. Reconnect the hose (1) to the exhaust aspirator. 5. Connect the hose between the air cleaner and the intake manifold. Install the air filter restriction sensor.

6. Reconnect the electrical leads to the horn, the air filter restriction sensor and the front axle earth discharge. 7. Reconnect the two guards to the sides of the fan. 8. Fill the radiator with coolant. 9. Reconnect the negative cable on the battery and close the hood.

47921938 07/02/2017

10.13 [10.400] / 11

Engine - Engine cooling system

Water pump - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Drain the refrigerant from the engine block 2. Remove the radiator as described in Radiator - Remove (10.400). 3. Remove the cooling fan. 4. Remove the hoses and remove the bolts securing the water pump. 5. Disassemble the oil pump according to the procedures described in Water pump - Disassemble (10.400).

BRAG11TR0091LUE

Installation 1. Installation of the water pump is the removal operation in reverse. As a precaution after installing the radiator, refill the cooling system and run the engine to check for leaks.

47921938 07/02/2017

10.13 [10.400] / 12

Engine - Engine cooling system

Water pump - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Remove the cover (8) and retaining screw (3) from the shaft bearing (2). 2. Tap the end of the shaft lightly to break the oxide film between the shaft and the impeller and remove the impeller using the puller 291182/1. 3. Using a suitable puller, withdraw shaft complete with bearing and fun hub. 4. Only remove the seal (5) if replacement is necessary, i.e. when the graphite surface in contact with the impeller bushing is no longer smooth enough to prevent leakage. LAIL11TL1365A0A

LAIL11TL1366A0A

Mounting Assembly is the inverse of removal. Do not forget the following points: 1. The bearing (2) does not require any lubrication. 2. The impeller (7) must be fitted flush with the end of the drive shaft.

Next operation: To service the water pump, see the procedures in Water pump - Overhaul (10.400).

47921938 07/02/2017

10.13 [10.400] / 13

Engine - Engine cooling system

Water pump - Overhaul TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: For disassembly of the water pump, see the procedures in Water pump - Disassemble (10.400).

Service NOTE: The bearing (9) forms a single part with the control shaft (10): it is a sealed group and therefore does not require lubrication during operation. Service the pump as follows: 1. Remove the cover (4) and the fixing bolt (2) for the shaft (10) and the bearing (9). 2. Tap lightly on the end of the shaft ( (1), Figure 1) on the side of the turbine (5) to break the oxide film formed between the shaft and the turbine: use the extractor 380000223 ( (1), Figure 2) and remove the turbine. 3. Remove the front retention bush ( (7), Figure 1). 4. Use a punch to extract the pump body ( (6), Figure 1) of the whole shaft (10) with the bearing (9) and the fan hub (1). NOTE: Only remove the seal (repair) ( (8), Figure 1) when it needs to be replaced. Check the state of component wear and replace the damaged ones. Reassemble the parts proceeding as follows:

LAIL11TL1367A0A

LAIL11TL1368A0A

LAIL11TL1369A0A

5. Fit the whole shaft ( (10), Fig. 1) with the bearing (9) and the hub (1) on the pump body (6) and lock it using the fixing bolt (2) , after passing LOCTITEÂŽ 242ÂŽ. 6. In the event of a replacement, place the seal ( (8), Figure 1) into the appropriate housing, using tool no. 293280 ( (1), Figure 3).

47921938 07/02/2017

10.13 [10.400] / 14

Engine - Engine cooling system

7. Warm the rotor (1) in a hot air oven until there is a temperature difference of 130 – 150 °C in relation to the shaft (2). 8. Fit the rotor (1) on the shaft (2), supporting the end of it so that the bearing is not damaged, until you get working clearance G = 0.5 – 0.7 mm (see Fig. 1). 9. Install the lining ( (3), Figure 1) for the seal and cover (4), fixing it with screws.

LAIL11TL1370A0A

47921938 07/02/2017

10.13 [10.400] / 15

Engine - Engine cooling system

Coolant thermostat - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Drain the cooling system below the level of the thermostatic valve housing. 2. Remove the hoses (1) and bolts securing the bracket (2).

BRAG11TR0092LUE

LAIL11TL1384A0A

3. Remove the top flange (1) by loosening the bolts. 4. Remove the thermostat (3) from the housing with the gasket (2). 5. Test the valve according to the procedures described in Coolant thermostat - Test (10.400).

Install 1. Apply sealant on a new gasket (2). Install the new gasket in the thermostatic valve housing. 2. Position the recess on the thermostatic valve housing. Coat the edge of the thermostatic valve with grease. 3. Install the thermostatic valve. Reinstall the thermostatic valve housing.

47921938 07/02/2017

10.13 [10.400] / 16

Engine - Engine cooling system

Coolant thermostat - Test TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Removal of the oil pump, see the procedures in Coolant thermostat - Remove (10.400). Place the thermostatic valve in a container with water at a temperature up to 100 Â°C. If the thermostat fails to open when heated, or does not close properly when cooled, it must be replaced.

LAIL11TL1385A0A

47921938 07/02/2017

10.13 [10.400] / 17

Index Engine - 10 Engine cooling system - 400 Coolant thermostat - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant thermostat - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine cooling system - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Radiator - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator Cap - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water pump - Component localization (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water pump - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water pump - Overhaul (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

10.13 [10.400] / 18

Engine - 10 Fan and drive - 414

47921938 07/02/2017

10.14 [10.414] / 1

Contents Engine - 10 Fan and drive - 414

SERVICE Fan and drive Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(*) See content for specific models 47921938 07/02/2017

10.14 [10.414] / 2

Engine - Fan and drive

Fan and drive - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Loosen the alternator pivot bolt.

LAIL11TL1234A0A

LAIL11TL1235A0A

LAIL11TL1236A0A

2. Loosen the belt tension adjustment bolt (1) and remove the belt.

3. Remove the fan from the radiator (1).

47921938 07/02/2017

10.14 [10.414] / 3

Engine - Fan and drive

Fan and drive - Tension adjust TT3840F TT3840 TT3880F TT4030

LA LA LA LA

To check the fan, water pump and alternator drive belt, apply a load of 8 â&#x20AC;&#x201C; 10 kg on the belt section between the alternator and water pump pulleys. There should be a 10 â&#x20AC;&#x201C; 11 mm deformation in the belt. If needed, adjust as follows: 1. Loosen the nut (1) securing the alternator to the belt tensioner. 2. Move the alternator on the tensioner support in order to obtain the specified tension. Retighten the nut (1).

LAIL11TL1235A0A

47921938 07/02/2017

10.14 [10.414] / 4

Index Engine - 10 Fan and drive - 414 Fan and drive - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fan and drive - Tension adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

10.14 [10.414] / 5

47921938 07/02/2017

10.14 [10.414] / 6

Engine - 10 Engine lubrication system - 304

47921938 07/02/2017

10.15 [10.304] / 1

Contents Engine - 10 Engine lubrication system - 304

TECHNICAL DATA Engine lubrication system General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine lubrication system Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Oil pressure valve Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Engine oil pump Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SERVICE Engine oil filter Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Engine oil pump Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

(*) See content for specific models 47921938 07/02/2017

10.15 [10.304] / 2

Engine - Engine lubrication system

Engine lubrication system - General specification TT3840F TT3840 TT3880F TT4030

Lubrication system/Model Lubricate Pump control Engine rpm and oil pump ratio Oil filtering Normal oil pressure with engine hot and running at maximum rpm Pressure limiting valve Initial valve opening pressure Play between the drive shaft and the oil pump bush Play between the shaft and the relative driven gear Play between the drive and driven gear teeth Radial play between the drive and driven gears and the pump body Drive and driven gear thickness Height of gears in the valve body Longitudinal play between the pump body and the gears Characteristics of the pressure limiting valve spring Length of free spring Length of spring with a load of 45 – 49 N (10.12 – 11.02 lb) Length of spring with a load of 88 – 94 N (19.78 – 21.13 lb) Length of spring with a load of 127.8 – 141.2 N (28.73 – 31.74 lb) Length of spring with a load of 133.4 – 258 N (29.99 – 58.00 lb)

LA LA LA LA

TT3840

TT3840F TT3880F TT4030 Forced, with gear pump From the distribution shaft 2:1 Through screen filter for aspiration and cartridge for output 2.9 – 3.9 bar (42.05 – 56.55 psi)

Located on the pump body 3.5 bar (50.75 psi) 0.016 – 0.055 mm

0.033 – 0.066 mm

0.100 mm 0.060 – 0.170 mm

40.961 – 41.000 mm 41.025 – 41.087 mm 0.025 – 0.126 mm

45 mm 37.5 mm

35.9 mm -

30.5 mm

29 mm

23.2 mm

47921938 07/02/2017

10.15 [10.304] / 3

Engine - Engine lubrication system

Engine lubrication system - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Lubrication of the engine ( Engine lubrication system - Overview (10.304) and Engine lubrication system Overview (10.304)) is maintained by a gear type oil pump mounted in the rear of the engine block, forward of the flywheel on the left-hand side viewed from rear side of the engine. The oil pump is driven from the rear of the camshaft and drains oil from the engine oil sump through a tube and screen assembly. A spring loaded relief valve is integral with the oil filter and prevents over pressurization of the system. A spin on type oil filter is mounted externally to its support housing on the left-hand side of the engine. Oil flows from the filter to the main oil gallery, which runs the length of the cylinder block, which also intersects the camshaft follower chamber. The main gallery also supplies oil to the crankshaft main bearings, connecting rods both big and small ends and timing gear bushes. The underside of the pistons and pins are lubricated by oil pressure jets. Timing gears are lubricated by splashed oil from the cam follower chamber and the pressure lubricated camshaft drive gear bushing. An intermittent flow of oil is directed to the value rocker arm shaft assembly via a drilled passage in the cylinder block. It is located vertically above bearing No. 3 of the camshaft and aligns with a hole in the head. The rotation of the camshaft allows a controlled intermediate flow of lubrication.

47921938 07/02/2017

10.15 [10.304] / 4

Engine - Engine lubrication system

Engine lubrication system - Overview TT3840F TT3840 TT3880F TT4030

LA LA LA LA

47921938 07/02/2017

10.15 [10.304] / 5

Engine - Engine lubrication system

3 cylinder engine lubrication schematics

LAIL11TL1396H0A

47921938 07/02/2017

10.15 [10.304] / 6

Engine - Engine lubrication system

1. 2.

3. 4.

Oil filler cap Filter safety valve (intervenes when the oil pressure at the filter input exceeds the output pressure by 1.5 â&#x20AC;&#x201C; 1.7 bar) Filter Illuminated switch to indicate low engine lubrication oil pressure (located on the panel)

5. 6.

Oil dipstick Pump

7. 8.

Oil pressure limiter valve Filter with screen in aspiration

47921938 07/02/2017

10.15 [10.304] / 7

Engine - Engine lubrication system

Engine lubrication system - Overview TT3840F TT3840 TT3880F TT4030

LA LA LA LA

47921938 07/02/2017

10.15 [10.304] / 8

Engine - Engine lubrication system

Aspirated 4 cylinder engine lubrication schematics

LAIL11TL1397H0A

47921938 07/02/2017

10.15 [10.304] / 9

Engine - Engine lubrication system

1. 2.

3. 4.

5. 6.

Oil dipstick Pump

7. 8.

Oil pressure limiter valve Filter with screen in aspiration

47921938 07/02/2017

10.15 [10.304] / 10

Engine - Engine lubrication system

Oil pressure valve - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Insufficient oil pressure signal Functional checks The signal comprises a control switch and a red light situated on the panel, which illuminates in the following cases: 1. Low oil pressure (the signal illuminates normally, without any problems, even with the engine hot and at low speed). 2. Control switch not working. If, with the engine off and the key on, the red light does not illuminate, the possible causes are: • Blown fuse. • Lamp burnt out. • Connection wire interrupted.

47921938 07/02/2017

10.15 [10.304] / 11

Engine - Engine lubrication system

Engine oil pump - Sectional view TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Aspirated engine oil pump

LAIL11TL1392B0A

1. External control gear 2. Bushing 3. Control shaft and gear

4. Driven shaft and gear 5. Pressure limiting valve

47921938 07/02/2017

10.15 [10.304] / 12

Engine - Engine lubrication system

Turbine engine oil pump

LAIL11TL1361A0A

1. 2.

Pressure limiting valve Spring

3. 4.

Pump body Internal gears

47921938 07/02/2017

10.15 [10.304] / 13

Engine - Engine lubrication system

Engine oil filter - Replace TT3840F TT3840 TT3880F TT4030

LA LA LA LA

The rotary-type oil filter (1) is a full-flow unit fitted on the outlet side of the pump. A by-pass valve will enable unfiltered oil to enter the engine, if the filter becomes obstructed. Every 300 h hours of service, change the cartridges noting the following points: 1. Apply engine oil to the external seal. 2. Fit the cartridge by turning it until contact with the mounting flange is established. 3. Turn the cartridge an additional 3/4 of a turn.

BRAG11TR0093LUE

Replace the cartridge periodically (every 400 h of use), remembering to: • Lubricate the outside of the seal in contact with the mounting base of the crankshaft sump. • Screw in the new cartridge until the seal touches the mounting base. • Adjust the cartridge, by hand only, just over 3/4 of a turn.

47921938 07/02/2017

10.15 [10.304] / 14

Engine - Engine lubrication system

Engine oil pump - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Oil pan removal: see the procedures in Engine oil pan - Remove (10.102). 1. Remove the bolt from the suction pipe strainer support (1) on the balancer

BRAG11TR0097LUE

BRAG11TR0098LUE

2. Loosen the screws and remove suction pipe (1) . 3. Loosen the two bolts that fasten the oil pump to the housing and remove the pump from the engine.

Next operation: Oil pump disassembly following the procedures described in Engine oil pump - Disassemble (10.304).

47921938 07/02/2017

10.15 [10.304] / 15

Engine - Engine lubrication system

Engine oil pump - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Oil pump removal: see procedures in Engine oil pump - Remove (10.304).

Aspirated engines 1. Loosen the two Allen screws and the two bolts retaining the pump face plate to the body.

BRAG11TR0095LUE

LAIL11TL1392B0A

2. Remove the driven gear (4) from its corresponding shaft. 3. Remove the pin that fastens the external control gear (1) and remove the gear. 4. Remove the drive shaft (3) and the corresponding gear. 5. Remove the pressure relief valve (5), loosening the cap screw.

Next operation: Oil pump inspection following the procedures described in Engine oil pump - Inspect (10.304).

47921938 07/02/2017

10.15 [10.304] / 16

Engine - Engine lubrication system

Engine oil pump - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Oil pump disassembly: see procedures in Engine oil pump - Disassemble (10.304).

Before performing any operation, thoroughly clean the parts.

Service To gain access to the oil pump, it is necessary to disassemble the engine pan, as indicated in Engine oil pan - Remove (10.102). During servicing, control pump part wear checking the sizes indicated in the table. In case of replacement, remember that the drive shaft and the relative gear are supplied coupled, with the latter being hot fitted onto the shaft.

Repair Fasten the pump body assembly on a vice and place the drive and driven gears. Placing a ruler across the top, slide a feeler gauge, between the ruler and the inner rotor. The backlash should be between 0.025 â&#x20AC;&#x201C; 0.126 mm. If it is greater, the pump must be replaced.

LAIL11TL1362A0A

47921938 07/02/2017

10.15 [10.304] / 17

Engine - Engine lubrication system

Check drive and driven gear clearance in the pump body, by inserting a feeler gauge. If the value exceeds 0.030 â&#x20AC;&#x201C; 0.170 mm, the pump must be replaced. NOTE: If not to specification, replace the oil pump, as reduced pump pressure through wear could result in reduced engine life. NOTE: Having loosened the bolts, manually check that the gears turn freely. If not, disassemble and repeat the procedure.

LAIL11TL1363A0A

Next operation: Oil pump assembly following the procedures described in Engine oil pump - Assemble (10.304).

47921938 07/02/2017

10.15 [10.304] / 18

Engine - Engine lubrication system

Engine oil pump - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Oil pump inspection: see the procedures in Engine oil pump - Inspect (10.304). 1. Clean and coat parts in new engine oil. Place the gears in the pump body and ensure that they are rotating freely. Insert the pump plate into the body and ensure that the shaft is fully seated in the plate. 2. Tighten the Allen screws and the other bolts securing the plate to the specified torque. NOTE: After tightening the bolts, manually check that the gears can rotate freely. If not, disassemble and repeat the procedure.

BRAG11TR0095LUE

Next operation: Oil pump installation: see the procedures in Engine oil pump - Install (10.304).

47921938 07/02/2017

10.15 [10.304] / 19

Engine - Engine lubrication system

Engine oil pump - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Oil pump assembly: see the procedures described in Engine oil pump - Assemble (10.304). 1. Install the pump on the engine block and fit the suction pipe and strainer.

BRAG11TR0098LUE

BRAG11TR0097LUE

2. Place the suction pipe strainer support bolt (1) in the balancer. 3. Check the free and loaded lengths of the relief valve: Free length: 45 mm Length under a load of 9 â&#x20AC;&#x201C; 9.6 kg ( 88 â&#x20AC;&#x201C; 94 N): 30.5 mm If not to specification, replace the relief valve spring.

Next operation: Oil pan installation: see the procedures described in Engine oil pan - Install (10.102).

47921938 07/02/2017

10.15 [10.304] / 20

Index Engine - 10 Engine lubrication system - 304 Engine lubrication system - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Engine lubrication system - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil filter - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pump - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pump - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pump - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pump - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil pressure valve - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

10.15 [10.304] / 21

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.

47921938 07/02/2017 EN

SERVICE MANUAL Clutch TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017

Contents Clutch - 18

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

47921938 07/02/2017

CONSUMABLES INDEX Consumable LOCTITE® 574 Loctite® 242

Reference Clutch - Sealing Clutch - Sealing

PAGE 18.2 / 6 18.2 / 6

47921938 07/02/2017

Clutch - 18 Clutch hydraulic release control - 104

47921938 07/02/2017

18.1 [18.104] / 1

Contents Clutch - 18 Clutch hydraulic release control - 104

SERVICE Clutch hydraulic release control Clutch hydraulic release control - Remove Clutch pedal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjust Transmission clutch pedal Free - travel and Adjustment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(*) See content for specific models 47921938 07/02/2017

18.1 [18.104] / 2

Clutch - Clutch hydraulic release control

Clutch hydraulic release control - Remove Clutch pedal TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Remove brake pedal spring, (1). 2. Remove split pin, (2), and disconnect linkage, (3). 3. Remove circlip, (4), and pull out right-hand brake pedal.

20098362

20098363

20098364

4. Loosen lock screw, (1), and remove left-hand brake pedal, (2).

5. Remove spring, (1), to split pin and disconnect lefthand brake linkage, (2), at left-hand side of the tractor.

47921938 07/02/2017

18.1 [18.104] / 3

Clutch - Clutch hydraulic release control

6. Remove clutch pedal spring, (1).

20098364

20098365

20096210

20098366

7. Remove split pin, (1), and disconnect linkage, (2), from clutch cross shaft.

8. Jack-up rear left-hand side of tractor and remove lefthand rear wheel, (1).

9. Pull out clutch/brake pedal support rod, (1), from the rear axle housing. 10. Retrieve clutch pedal, (2), from the support shaft.

47921938 07/02/2017

18.1 [18.104] / 4

Clutch - Clutch hydraulic release control

Clutch hydraulic release control - Adjust Transmission clutch pedal Free - travel and Adjustment TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Free-travel is the distance the clutch pedal will travel from the rest (unapplied) position to the moment of resistance. The free-travel distance feels loose on the pedal to the operator and ends when the pedals become more difficult to move, as when the clutch is applied. It may be necessary to seek assistance when checking the clutch pedal free-travel. To check the clutch pedal free-travel proceed as follows. 1. Measure the distance from the bottom of the clutch pedal to the platform. 2. Slowly depress the clutch pedal until feeling resistance and record the amount of travel. The resultant should be 35 â&#x20AC;&#x201C; 40 mm (1.38 â&#x20AC;&#x201C; 1.57 in) . If free-travel is less than 35 mm (1.38 in) proceed with the remaining steps. 3. Loosen the lock nut, (1), on the pedal control rod, (2), located on the left-hand side of the platform under the clutch pedal. 4. Remove the pin and clevis on the rod end (not shown) and turn the rod end counterclockwise to increase freetravel. One complete turn adjusts the clutch pedal freetravel by 10 mm (0.39 in). 5. Reinstall the clevis and pin. Repeat until obtaining the specified free-travel.

47921938 07/02/2017

18.1 [18.104] / 5

20098367

Index Clutch - 18 Clutch hydraulic release control - 104 Clutch hydraulic release control - Remove Clutch pedal (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch hydraulic release control - Adjust Transmission clutch pedal Free - travel and Adjustment (*)

(*) See content for specific models 47921938 07/02/2017

18.1 [18.104] / 6

Clutch - 18 Clutch and components - 110

47921938 07/02/2017

18.2 [18.110] / 1

Contents Clutch - 18 Clutch and components - 110

TECHNICAL DATA Clutch General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sealing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Clutch Sectional view Clutch assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Sectional view Clutch plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Clutch Remove Clutch assy (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble Clutch Assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Inspect Clutch assy (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assemble Clutch Assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install Clutch Assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

DIAGNOSTIC Clutch Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

(*) See content for specific models 47921938 07/02/2017

18.2 [18.110] / 2

CONSUMABLES INDEX Consumable LOCTITE® 574 Loctite® 242

Reference Clutch - Sealing Clutch - Sealing

47921938 07/02/2017

18.2 [18.110] / 3

PAGE 18.2 / 6 18.2 / 6

Clutch - Clutch and components

Clutch - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Specifications TT3840 Type Control Release mechanism Plate material Plate Thickness: Transmission PTO Wear Limit Plate with Pressure Springs Transmission Clutch Control Sleeve Working Clearance PTO Clutch Control Sleeve Working Clearance PTO clutch lever play adjustment Transmission clutch pedal free play adjustment Transmission pedal requirements Pedal Pin Diameter Internal diameter of support bushing (fitted, not dressed) Pin/bush play Pedal Bracket Internal Diameter Bush Outer Diameter Pedal bracket/bush interference adjustment

TT3840F TT3880F Double, dry plate, torsion spring Mechanical pedal for transmission Hand lever for PTO Dished Spring Organic Compound

8.8 – 9.6 mm 8.3 – 8.9 mm See the values in Clutch - Inspect Clutch assy (18.110). Tangential Springs 0.050 – 0.151 mm 0.072 – 0.205 mm 2.5 – 5 mm 45 – 50 mm 27.948 – 28.000 mm 28.020 – 20.072 mm 0.020 32.927 33.009 0.043

Clutch - Torque TT3840F TT3840 TT3880F TT4030

TT4030

LA LA LA LA

47921938 07/02/2017

18.2 [18.110] / 4

– – – –

0.124 mm 32.966 mm 33.030 mm 0.103 mm

Clutch - Clutch and components

20097611

Description Transmission housing to flywheel housing bolts, (C1) Clutch assembly mounting bolts, (C2) Release fork bolts, (C3)

Thread Size (mm) M12 X 1.25 X 45

Torque N⋅⋅m (lb ft) 75 N·m (55 lb ft)

M8 X 1.25 X 45 M16 X 1.5 X 32

26 N·m (19 lb ft) 160 N·m (118 lb ft)

Clutch - Special tools TT3840F TT3840 TT3880F TT4030

LA LA LA LA

47921938 07/02/2017

18.2 [18.110] / 5

Clutch - Clutch and components

Special tools Tool description Clutch centralizer and finger height setting gauge Clutch finger height adjusting wrench (set of 3) Clutch pedal free play setting tool

No. of the tool 291184 293763 9971365

Clutch - Sealing TT3840F TT3840 TT3880F TT4030

LA LA LA LA

20097530

Operation Description Engine to transmission buckle up, (S1) Release fork bolts, (S2)

Sealants Specification LOCTITE® 574 LOCTITE® 242

47921938 07/02/2017

18.2 [18.110] / 6

Clutch - Clutch and components

Clutch - Sectional view Clutch assembly TT3840F TT3840 TT3880F TT4030

LA LA LA LA

20097531

1. 2. 3. 4. 5. 6.

Dish Spring PTO clutch release fingers Transmission clutch release fingers Release control sleeves with thrust bearings PTO clutch release lever locknuts & adj. link PTO clutch plate

7. 8. 9. 10. 11.

Transmission clutch plate Flywheel bearing PTO clutch release fork Transmission clutch release fork Transmission clutch release lever locknut, adjusting screw and lever

47921938 07/02/2017

18.2 [18.110] / 7

Clutch - Clutch and components

Clutch - Sectional view Clutch plate TT3840F TT3840 TT3880F TT4030

LA LA LA LA

20097591

1. 2. 3. 4.

Clutch facing Facing rivet Segment rivet Hub

5. 6. 7.

Segment Idle damper spring Main damper spring

47921938 07/02/2017

18.2 [18.110] / 8

Clutch - Clutch and components

Clutch - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Description The clutch system is double clutch mechanical type. It includes two dry clutch discs with non-asbestos, organic material pads. One clutch disc is to connect transmission to engine and another for connecting PTO directly to engine, independent of transmission. As usual, the clutch is located in front of the transmission. The transmission (main) clutch is operated by means of foot pedal and PTO clutch is operated by hand lever located on right side below rear hood panel. The clutch system is composed of the clutch housing, clutch pressure plate, disc ring clutch release fingers, clutch release bearings and clutch discs.

Operation When both the clutches are engaged, the PTO clutch pressure plate pushes the PTO clutch disc against engine flywheel and transmission presure plate pushes the clutch housing by the spring action of dish ring. The friction between the clutch disc, flywheel and clutch housing transmits the engine power to the transmission drive shaft and PTO drive shaft independently. The clutch pedal is connected to the main clutch release bearing by means of mechanical linkage components. When the clutch pedal is pressed, the clutch release bearing moves forward and discharges the main clutch fingers. Consequently, the clutch pressure plate backs off and releases the clutch disc from the clutch housing. The transfer of engine power to the transmission is stopped. When the clutch pedal is released, the main clutch release bearing disengages the main clutch finger which acts on the clutch pressure plate and causes the clutch housing, main clutch discs and pressure plates to come in contact. The flow of power from the engine and transmission is re-established. Similarly PTO clutch is engaged and disengaged independent of transmission clutch by operating PTO clutch control lever.

47921938 07/02/2017

18.2 [18.110] / 9

Clutch - Clutch and components

Clutch - Remove Clutch assy TT3840F TT3840 TT3880F TT4030

LA LA LA LA

NOTE: It is necessary to split the tractor between Engine and Transmission housing to gain access to the clutch. 1. Separate the Transmission housing from Engine as described in Engine - Remove (10.001).

20097512

20097525

20097526

2. Remove the four of the six capscrews, (1), that retain the clutch assembly to the engine fly wheel.

3. Insert the double clutch aligning arbor # 380002740 into the clutch disc splines. Remove the two remaining capscrews that retain the clutch assembly to the flywheel. Then remove the clutch assembly with the PTO clutch disc from the flywheel.

Next operation: For removing the engine, see the procedures in Clutch - Disassemble Clutch Assembly (18.110).

47921938 07/02/2017

18.2 [18.110] / 10

Clutch - Clutch and components

Clutch - Disassemble Clutch Assembly TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Loosen the PTO clutch release lever locknuts, (1). NOTE: Since the locknuts are under the load of disk ring, loosen all these gradually and evenly by rotating 1/4 to 1/2 turns.

20097536

20097537

20097538

2. Remove PTO pressure plate, (1).

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

47921938 07/02/2017

18.2 [18.110] / 11

Clutch - Clutch and components

4. Extract the spring retaining pins, (1), from the seats.

20097539

20097540

20097553

20097541

5. Remove disk ring, (1), and lock ring, (2).

6. Loosen lock nut, (1).

7. Remove transmission clutch pressure plate, (1),

47921938 07/02/2017

18.2 [18.110] / 12

Clutch - Clutch and components

8. Remove transmission clutch disc, (1), from the housing.

20097542

47921938 07/02/2017

18.2 [18.110] / 13

Clutch - Clutch and components

Clutch - Inspect Clutch assy TT3840F TT3840 TT3880F TT4030

LA LA LA LA

20097548

H - Ø 300 mm (11.8 in) G - 2 mm (0.1 in)

1. Check clutch driven discs for wear and replace if rivets, (2), ( Clutch - Sectional view Clutch plate (18.110)) are near or flush with top facing. 2. Discs are also to be replaced if the organic facings are found to be soaked with oil. 3. Check condition of clutch housing and pressure plate friction surfaces. If necessary dress, noting that dimensions of pressure plates and clutch housing must not be reduced below the limits described below, otherwise replace as necessary. • Fly wheel, (1), under cut - 'A' = 2 mm (0.0787 in). • PTO clutch pressure plate, (2), thickness - 'B' = 22 mm (0.866 in). • Transmission clutch pressure plate, (3), thickness - 'C' = 24 mm (0.945 in). • Clutch housing, (4), under cut - 'E' = 2.5 mm (0.0984 in). • Dressing allowance - 'F' = 70 mm (2.8 in) ± 0.15 mm (0.00591 in) • Calculate Dimension 'F' as follows F=A+B+C+S1+S2+P Where S1 = PTO clutch disc thickness S2 = Transmission clutch disc thickness P = Spring dimensions to restore original load = 4.5 mm (0.177 in) (fixed). • Check that value 'F' is equal to 70 mm (3 in) ± 0.15 mm (0.00591 in) • In restoring value 'F' check that clutch housing thickness 'E' does not fall below 17 mm (0.669 in). i.e., D-F = E > 17 mm (0.669 in).

47921938 07/02/2017

18.2 [18.110] / 14

Clutch - Clutch and components

â&#x20AC;˘ Check that the undercut 'E' on clutch housing is deeper than 2.5 mm (0.0984 in) and restore as necessary. â&#x20AC;˘ If necessary dress friction face on flywheel and restore external undercut 'A' of 2 mm (0.0787 in).

47921938 07/02/2017

18.2 [18.110] / 15

Clutch - Clutch and components

Clutch - Assemble Clutch Assembly TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Clutch - Inspect Clutch assy (18.110). 1. Install the main clutch disk, (1), into the housing. NOTE: Install clutch disc with flange facing towards the release fingers.

20097549

20097550

20097551

2. Install the inner clutch pressure plate, (1), with contact surface facing the main clutch disc. 3. Install the large ring, (2), as shown. The ring will start and stop at pin in plate.

4. Install the set screw and lock nut assembly, (1), into the pressure plate for the release fingers.

47921938 07/02/2017

18.2 [18.110] / 16

Clutch - Clutch and components

5. Install the large spring plate, (1), onto pressure plate. NOTE: The slots in spring plate must engage the locating pin in pressure plate.

20097552

20097539

20097554

20097555

6. Install the large C-Clamps, (1), around the spring plate in 120Â° increments. 7. Install the retaining plate, (2), around the spring plate as shown. The plate will engage into a slot in the housing assembly. 8. Remove the C-Clamps, (1), after all retaining plates are installed in the clutch housing.

9. Install the springs, (1), around each release lever. 10. Install the pressure plate, (2), with clutch disc face towards the flywheel.

11. Secure the pressure plate to the release fingers with lock nuts, (1).

47921938 07/02/2017

18.2 [18.110] / 17

Clutch - Clutch and components

12. Install the PTO clutch disc, (1), onto clutch aligning arbor tool, 380002740 (2), and insert assembly into bearing in flywheel. NOTE: When installing the clutch disc, make sure the flange, (3), on disc is facing away from the flywheel.

20097527

20097533

13. Install the clutch assembly, (1), over the special tool, (2), still in the flywheel. 14. Install the M8 x 1.25 x 45 mm bolts with lock washers, (3) and tighten in a star pattern to avoid breaking components. Torque the hardware to 26 NÂˇm (19 lb ft). 15. Perform clutch release finger adjustments as described in Clutch hydraulic release control - Adjust (18.104). 16. Install the transmission to the engine.

Next operation: Clutch - Install Clutch Assembly (18.110).

47921938 07/02/2017

18.2 [18.110] / 18

Clutch - Clutch and components

Clutch - Install Clutch Assembly TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Install the PTO clutch disc, (1), onto clutch aligning arbor tool, 380002740 (2), and insert assembly into pilot bearing in the flywheel. NOTE: When installing the clutch disc, make sure the flange, (3), on disc is facing away from the flywheel.

20097527

20097533

20097534

2. Install the clutch assembly, (1), over the special tool, (2), still in the flywheel. 3. Install the M8 x 1.25 x 45 mm bolts with lock washers, (3) and tighten in a star pattern to avoid damaging components. Torque the hardware to 26 NÂˇm (19 lb ft) 4. Install the transmission to the engine.

Install the clutch assembly back on flywheel taking care of the following: 5. Check condition of pilot bearing, (1), pressed in flywheel. Replace in the event of excessive noise or binding. 6. Install old/new bearing packing the seat with grease. â&#x20AC;˘ Before securing the transmission housing and engine, thoroughly clean and degrease mating surfaces and apply a bead of silicone sealer of approximately. 2 mm (0.08 in) of diameter following pattern shown in Figure 4.

47921938 07/02/2017

18.2 [18.110] / 19

Clutch - Clutch and components

20097535

47921938 07/02/2017

18.2 [18.110] / 20

Clutch - Clutch and components

Clutch - Troubleshooting TT3840F TT3840 TT3880F TT4030

Problem The clutch slips

LA LA LA LA

Possible Cause Clutch disc, pressure plate and/or flywheel wear. Damaged, bent or broken fingers. Oil or grease on friction material.

Correction Replace the clutch disk. Replace the clutch if necessary and grind the flywheel. Replace the finger assembly. Replace the clutch disk. Repair the leak of lubricant into the clutch housing. Thoroughly clean friction surfaces. Clutch grabs. Stiff external control linkage. Check and lubricate linkage pivot points. Warped clutch disk. Replace the clutch disk. Clutch disk with damaged damper springs Replace the clutch disk. or loose hub. Replace the clutch disk. Repair the leak Oil or grease on friction material. of lubricant into the clutch housing. Thoroughly clean friction surfaces. Finger springs broken. Replace finger springs. Replace clutch disc Clutch fails to disengage Warped clutch disk. and drags. Damaged clutch release bearing Replace clutch release bearing. Damaged finger spring. Replace finger springs. Hard pedal Clutch control pedal Check and lubricate linkage. hardness Broken or disconnected clutch return Replace or hook â&#x20AC;&#x201C; up clutch return spring. spring. Warped clutch disc. Replace clutch disc Clutch noise during engagement and/or disengagement. Damaged clutch disc damper springs. Replace clutch disc Excess backlash on clutch disc to hub Replace clutch disc and shaft, as necesmeshing splines. sary. Worn clutch release bearing. Replace the bearing. Clutch noise at disengagement.

47921938 07/02/2017

18.2 [18.110] / 21

Index Clutch - 18 Clutch and components - 110 Clutch - Assemble Clutch Assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Disassemble Clutch Assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Clutch - Inspect Clutch assy (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Clutch - Sealing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Clutch - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Clutch - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

18.2 [18.110] / 22

47921938 07/02/2017

18.2 [18.110] / 23

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

47921938 07/02/2017 EN

SERVICE MANUAL Transmission TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017

Contents Transmission - 21

[21.114] Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.130] Mechanical transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.140] Mechanical transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3

47921938 07/02/2017

CONSUMABLES INDEX Consumable Loctite® 518 Loctite® 518 Loctite® 243 NEW HOLLAND AMBRA MULTI G 134™ HYDRAULIC TRANSMISSION OIL

Reference Mechanical Mechanical Mechanical Mechanical

transmission transmission transmission transmission

Sealing Sealing Sealing Install

47921938 07/02/2017

PAGE 21.1 / 5 21.1 / 5 21.1 / 5 21.1 / 14

47921938 07/02/2017

Transmission - 21 Mechanical transmission - 114

47921938 07/02/2017

21.1 [21.114] / 1

Contents Transmission - 21 Mechanical transmission - 114

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

FUNCTIONAL DATA Mechanical transmission Dynamic description 8 + 2 Transmission (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Mechanical transmission Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DIAGNOSTIC Mechanical transmission Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

(*) See content for specific models 47921938 07/02/2017

21.1 [21.114] / 2

CONSUMABLES INDEX Consumable Loctite® 518 Loctite® 518 Loctite® 243 NEW HOLLAND AMBRA MULTI G 134™ HYDRAULIC TRANSMISSION OIL

Reference Mechanical Mechanical Mechanical Mechanical

transmission transmission transmission transmission

Sealing Sealing Sealing Install

47921938 07/02/2017

21.1 [21.114] / 3

PAGE 21.1 / 5 21.1 / 5 21.1 / 5 21.1 / 14

Transmission - Mechanical transmission

Mechanical transmission - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Specifications Component Type Gears Divider – Reduction ratio Transmission and splitter controls External diameter of the driven gear bushing Internal diameter of the driven gear Bushing clearance in gear Driven shaft diameter Bushing inside diameter Shaft clearance in bushing PTO clutch shaft diameter Internal diameter of the fitted bushing PTO Shaft Clearance in Bushing Bushing Interference Fit with Drive Shaft Shim thickness for adjusting the end float of driven gears Flat washer thickness and inboard and outboard baulk rings for driven gears and planetary gear splitter supports Gear selector shaft detent ball spring length: - Free - With load of 5.1 kg to 5.7 kg Gear selector shaft detent ball spring length: - Free - With load of 5.15 kg to 5.25 kg Gear selector shaft detent ball spring length (splitter only): - Free - With load of 11.7 kg to 12.9 kg

TT3840 TT3840F TT3880F TT4030 8 forward speeds and 2 reverse speeds Sprocket wheel Planetary, with three sprocket wheel pinions 20 : (20 + 52) = 1 : 3.6 Separate levers 49.925 mm@ 49.950 mm 50.050 mm@ 50.089 mm 0.100 mm@ 0.164 mm 39.166 mm@ 39.191 mm 39.200 mm@ 39.239 mm 0.009 mm@ 0.073 mm 24.964 mm@ 24.985 mm 25.040 mm@ 25.092 mm 0.055 mm@ 0.128 mm 0.037 mm@ 0.091 mm 3.7 mm - 4 mm - 4.3 mm 1.470 mm@ 1.530 mm

61.5 mm 48 mm 35.5 mm 31.5 mm 35.5 mm 31.5 mm

Mechanical transmission - Torque TT3840F TT3840 TT3880F TT4030

Description Transmission housing to Engine Nut Driven Gear Shaft Lock--Nut Transmission Shaft Bearing Cover Nut Transmission Housing Cover Bolts Spacer to Transmission Housing and Power Train Nuts Planetary Reduction Fixed Gear Bolts Splitter Shift Fork Rod Bracket Bolts

LA LA LA LA

Thread Size M12 X 1.25 M24 X 1.50 M8 X 1.25

Torque Nm (lb ft) 100 N·m (74 lb ft) 255 N·m (188 lb ft) 18 N·m (13 lb ft)

M8 X 1.25 M10 X 1.25

25 N·m (18 lb ft) 60 N·m (44 lb ft)

M12 X 1.50 M10 X 1.25

75 N·m (55 lb ft) 60 N·m (44 lb ft)

47921938 07/02/2017

21.1 [21.114] / 4

Transmission - Mechanical transmission

Mechanical transmission - Sealing TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Operation Description Rear axle to transmission housing, (S1) Transmission to Engine, (S2) Gear shift cover to transmission housing, (S3) Pinion shaft front cover hardware, (S4)

Sealant Specification LOCTITE® 518 LOCTITE® 518 Silicone Sealer LOCTITE® 243

20099001

Mechanical transmission - Special tools TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Special tools Tool description Sling hook, gear box Gear box stand Remover, drive shaft Remover, reverse gear shaft Puller, needle bearing reverse gear 18 – 25 mm jaw.

N°. of the tool 291517 270086 9971348 9971347 292909 292907

47921938 07/02/2017

21.1 [21.114] / 5

Transmission - Mechanical transmission

Mechanical transmission - Dynamic description 8 + 2 Transmission TT3840F TT3840 TT3880F TT4030

LA LA LA LA

WARNING Unexpected machine movement! Engage the parking brake and put all levers in neutral before leaving the machine to make the connections. Failure to comply could result in death or serious injury. W0425A

The transmission has eight forward and two reverse gears. The main gearshift lever (the right hand lever) is used to select any one of the four forward gears or one reverse gear. The Hi-Low selector lever is used to select the high (H) or low (L) range, which gives double the number of available gears. To change gear range; depress the clutch pedal, stop the tractor and move the Hi-Low selector lever, 1, backward for high or forward for low. To change the gears in the selected range; depress the clutch pedal and shift the main gear lever, 2, as normal. Third and fourth gears in both ranges are synchronized in the TT3880F/TT4030 models and optional in the TT3840/ TT3840F models. To select reverse gear (R), first stop the tractor.

BRAG12TRLUE0273

NOTE: A neutral start switch is provided to prevent operation of the starter motor unless the transmission range lever is in neutral position. NOTICE: If it is necessary to tow the tractor, both the Hi-Low selector and main gearshift levers must be in neutral.

20099909

47921938 07/02/2017

21.1 [21.114] / 6

Transmission - Mechanical transmission

The constant-mesh transmission has parallel shafts with gear in constant mesh. In the collar shift version, shifting is accomplished by locking free-running gears to their shaft with sliding collars. In the synchromesh version, gears can be selected without clashing by synchronising the speeds of mating gears before they engage. This is possible by adding an extra device, called a “Sychronizer” to equalise the speed of the mating points before they engage. It permits gear shifting while the tractor is moving. The range gears is a planetary type work much like the solar system. Each of the “Pinions” on planet gears, turns on its own axis and at the same time, rotates around the sun gear.

20099910

AW.B CDEF-

Sun Planets Planet Pinion Carrier Ring gear Sun Gear Planet Pinion

47921938 07/02/2017

21.1 [21.114] / 7

Transmission - Mechanical transmission

Mechanical transmission - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

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: To remove the Transmission, separate engine with front axle from transmission housing and rear axle housing from transmission housing. Follow the below steps for removal procedure. 1. Separate the engine with the front axle from the transmission housing following the procedure Engine - Remove (10.001).

20098370

20098382

2. Drain the lubrication oil from transmission housing by opening drain plugs, (1), and (2).

47921938 07/02/2017

21.1 [21.114] / 8

Transmission - Mechanical transmission

3. Install a mechanical stand under the rear axle housing.

20093443A

20098947

20098365

20098948

4. Remove right-hand and left-hand foot boards, (1).

5. Disconnect clutch pedal, (1), and PTO clutch, (2), lever linkages.

6. Disconnect rear electric connection and safety start switch electric connections. 7. Remove the clamps and release the electric wires from the transmission and rear axle housing.

47921938 07/02/2017

21.1 [21.114] / 9

Transmission - Mechanical transmission

8. Loosen the clamp, (1), to drain the steering oil and remove the pipes. 9. Loosen steering assembly securing bolts and remove steering assembly with spindle.

20098800

20098949

20098950

10. Loosen the bolts and remove both the gear shift covers, (1) and (2).

11. Remove all rail pins and forks, (1), to ease the splitting.

12. Attach lift hooks, (1), to the transmission housing and connect it to a suitable hoist. 13. Loosen the bolts and stud nuts securing transmission and rear wheel drive housings together. 14. Remove the transmission housing from rear axle housing by moving it forward sufficiently to clear the PTO shaft and rail shafts.

20098951

47921938 07/02/2017

21.1 [21.114] / 10

Transmission - Mechanical transmission

15. Attach the transmission housing on a rotary stand or bench for further inspection and disassembly , if required.

20098952

47921938 07/02/2017

21.1 [21.114] / 11

Transmission - Mechanical transmission

Mechanical transmission - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

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. Reinstall the transmission to the engine observing the following.

20099003

2. Clean both surfaces and apply a 2 mm (5/64 in) bead of sealant according to figure 1. 3. Use an appropriate lifting device to install transmission to the rear wheel drive housing. NOTE: Be careful not to damage the rails while sliding the two housings together. 4. Install the M12 x 1.5 x 40 bolts, M12 x 1.5 x 60 bolts, washers and nuts to secure the two housings together. Torque the hardware to 75 NÂˇm (55 lb ft). 20098951

47921938 07/02/2017

21.1 [21.114] / 12

Transmission - Mechanical transmission

5. Reinstall the rail pins, (1), and forks.

20098950

20098949

20098800

20098948

6. Reinstall gear shift covers, (1) and (2).

7. Install steering assembly with spindle. Secure hardware. 8. Reinstall pipes, (1) and replenish fluids.

9. Install clamps from removal and secure the wire harness. 10. Connect the rear electric connection and safety start switch connections.

47921938 07/02/2017

21.1 [21.114] / 13

Transmission - Mechanical transmission

11. Attach the clutch pedal lever linkage, (1). 12. Attach the PTO clutch lever linkage, (2).

20098365

20099890

20098947

13. Remove fill plug, (1). 14. Fill the transmission housing with NEW HOLLAND AMBRA MULTI G 134â&#x201E;˘ HYDRAULIC TRANSMISSION OIL hydraulic oil. 15. While filling the unit, check the level on the right side of the rear axle housing, (2).

16. Install the left hand and right hand foot boards, (1).

17. Attach engine, (1), to transmission assembly, (2). Refer to Engine - Install (10.001) for the assembly procedure.

20098370

47921938 07/02/2017

21.1 [21.114] / 14

Transmission - Mechanical transmission

Mechanical transmission - Troubleshooting TT3840F TT3840 TT3880F TT4030

Problem Difficult engagement of speed and range gears

Speed and range gears disengage themselves

LA LA LA LA

Possible Cause External levers misadjusted External levers stiff or seized Internal control components (shafts, forks, and sleeves) slide with difficulty External linkage poorly adjusted and levers poorly adjusted. Faulty retaining springs on the control shaft Partial engagement travel

Correction Adjust properly Check pivot points and correct Service the control components Adjust properly

Replace the springs Correct reasons for problem and restore full travel Noisy operation with Input and output shaft support bearing mis- Remove transmission housing and adjust bearings. range in neutral and main adjusted. lever engaged Remove housing, overhaul transmission Faulty or defective inner components. and replace faulty parts. Internal component seizure due to poor lu- Overhaul transmission and top up oil to corbrication. rect level. Noisy operation with Faulty clutch plate springs Replace clutch plates tractor stationery, idling engine and transmission in neutral

47921938 07/02/2017

21.1 [21.114] / 15

Index Transmission - 21 Mechanical transmission - 114 Mechanical transmission - Dynamic description 8 + 2 Transmission (*) . . . . . . . . . . . . . . . . . . . . . . . .

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

Mechanical transmission - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Sealing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Mechanical transmission - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

21.1 [21.114] / 16

Transmission - 21 Mechanical transmission external controls - 130

47921938 07/02/2017

21.2 [21.130] / 1

Contents Transmission - 21 Mechanical transmission external controls - 130

SERVICE Mechanical transmission external controls Mechanical transmission external controls - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(*) See content for specific models 47921938 07/02/2017

21.2 [21.130] / 2

Transmission - Mechanical transmission external controls

Mechanical transmission external controls - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Loosen the bolts (1) and remove the top cover (2) from the transmission housing.

LAIL11TT0015A0A

LAIL11TT0016A0A

LAIL11TT0017A0A

2. Remove the spring pin (1). 3. Remove the washer (2) and the spring (3). 4. Remove the spring pin (4) using a suitable magnetic tool. 5. Loosen the rubber boot clamps (5).

6. Withdraw the levers from the cover plate. 7. Follow the same procedure for the other lever.

47921938 07/02/2017

21.2 [21.130] / 3

Transmission - Mechanical transmission external controls

Mechanical transmission external controls - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Assemble the levers in the cover plate and reinstall the cover plate on the transmission housing, observing the following: 1. inspect the rubber boot (1) for cracks or damage and replace if necessary. 2. Re-installation follows the removal procedure in reverse, from step 7 to 1 described in Mechanical transmission external controls - Disassemble (21.130). 3. Before fixing the cover plate, thoroughly clean and degrease the mating surface and apply a 2 mm bead of sealant, following the pattern shown in Figure 2. 4. Tighten to the correct torques as detailed in Mechanical transmission - Torque (21.114). LAIL11TT0223A0A

LAIL11TT0231F0A

47921938 07/02/2017

21.2 [21.130] / 4

Index Transmission - 21 Mechanical transmission external controls - 130 Mechanical transmission external controls - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission external controls - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

21.2 [21.130] / 5

47921938 07/02/2017

21.2 [21.130] / 6

Transmission - 21 Mechanical transmission internal components - 140

47921938 07/02/2017

21.3 [21.140] / 1

Contents Transmission - 21 Mechanical transmission internal components - 140

SERVICE Transmission shaft Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassemble Reverse gears and drive shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassemble Driven gears and drive shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspect Driven gears and drive shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble Driven gears and drive shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Assemble Drive shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Transmission internal parts Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Gears, shaft, and bearings Remove Range gear assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Disassemble Range gear assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Assemble Range gear assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

(*) See content for specific models 47921938 07/02/2017

21.3 [21.140] / 2

Transmission - Mechanical transmission internal components

Transmission shaft - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

WARNING Always use suitable tools to align holes. DO NOT USE HAND OR FINGERS. Failure to comply could result in death or serious injury. B020A

WARNING Lift and handle all heavy components using lifting equipment of appropriate lifting capacity. Ensure that units or parts are supported by suitable slings or hooks. Ensure that no persons or pets are in the vicinity of the load to be lifted. Failure to comply could result in death or serious injury. M1258

1. To facilitate disassembly, install the transmission housing on rotary stand as shown, or place on a bench.

20098952

20098372

2. Remove transmission and PTO clutch forks locking screws, (1).

47921938 07/02/2017

21.3 [21.140] / 3

Transmission - Mechanical transmission internal components

3. Remove transmission and PTO clutch forks shafts, (1), and remove associated forks from the housing.

20098965

20098371

20097515

20098949

4. Retrieve locking pins, (1), from the housing.

5. Slide out both transmission and PTO clutch release bearings, (1).

6. Loosen the bolts and remove both the gear shift covers, (1) and (2).

47921938 07/02/2017

21.3 [21.140] / 4

Transmission - Mechanical transmission internal components

7. Remove the dowel pins, (1), from each range gear rail shaft, (2).

20098953

20098954

20098955

8. Straighten the locking plates and remove the gear rail support bracket bolts, (1).

9. Loosen nuts, (1) and remove oil seal cover, (2). 10. Loosen the screws, (3) and remove front bearing cover, (4).

11. Remove the circlip, (1) and shims, (2). If necessary pull out the seal, (3), from its seat on the shaft.

20098956

47921938 07/02/2017

21.3 [21.140] / 5

Transmission - Mechanical transmission internal components

12. Using a suitable punch and mallet, remove the drive shaft out of the housing by hammering gently towards the engine mounting side.

20098957

20098958

13. Retrieve the gears inside the housing. 14. Remove the bearing from the shaft using suitable puller. 15. Remove shift forks.

47921938 07/02/2017

21.3 [21.140] / 6

Transmission - Mechanical transmission internal components

Transmission shaft - Disassemble Reverse gears and drive shaft TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Remove the range gear assembly as detailed in Gears, shaft, and bearings - Remove Range gear assembly (21.140).

20098966

20098968

20098969

2. Using a suitable pry bar, remove reverse gear shaft, (1), with outer ball bearing.

3. Retrieve the reverse gears, (1), in transmission housing.

47921938 07/02/2017

21.3 [21.140] / 7

Transmission - Mechanical transmission internal components

4. Retrieve pin, (1), from the gears. 5. Using suitable puller remove ball bearing, (2), from the reverse gear shaft.

20099043

20098970

6. Using a pair of hooks with a sliding hammer, (1), remove reverse gear shaft needle bearing from the housing.

47921938 07/02/2017

21.3 [21.140] / 8

Transmission - Mechanical transmission internal components

Transmission shaft - Disassemble Driven gears and drive shaft TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Remove range gear assembly from the housing as described earlier.

20098966

20098961

20098958

2. Lock the gears and remove the driven gear shaft retaining nut, (1).

3. Remove the drive shaft from its housing and remove the gears, as described in Transmission shaft - Disassemble Reverse gears and drive shaft (21.140).

47921938 07/02/2017

21.3 [21.140] / 9

Transmission - Mechanical transmission internal components

4. Remove reverse gear and shaft from the housing as explained earlier.

20098969

20098973

5. Remove the shaft from rear axle housing mounting side by gently hammering using suitable punch and mallet. 6. Retrieve the gears couplers / synchromesh from inside the housing.

47921938 07/02/2017

21.3 [21.140] / 10

Transmission - Mechanical transmission internal components

Transmission shaft - Inspect Driven gears and drive shaft TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Transmission shaft - Disassemble Driven gears and drive shaft (21.140). • Check sychromesh assembly, spring, ball and cage for damage and wear. If necessary, replace. • Check the bearings and bushings, if replacement is required, remove the bearing from their seats using suitable pullers. • Check gears for wear, damage, fittings etc. if necessary replace the gears with new one. Remove small dents on teeth by rubbing with abrasive paper.

20098974

Next operation: Transmission shaft - Assemble Driven gears and drive shaft (21.140).

47921938 07/02/2017

21.3 [21.140] / 11

Transmission - Mechanical transmission internal components

Transmission shaft - Assemble Driven gears and drive shaft TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Transmission shaft - Inspect Driven gears and drive shaft (21.140). Refer to the Figures throughout the procedure and fit the 3rd and 4th gear synchronizer. The 3rd /4th synchromesh:

• Insert the toothed sector, (1), into the baulk ring, matching the cuts of ring and sector.

20098975

20098976

20098977

• Put the cage on the slotted hole, followed by a spring, (1).

• Press the ball, (1), with the help of a screwdriver, (2). • Insert toothed sector partially into the ring. • Repeat the same procedure for other cages, springs and balls and then insert completely.

47921938 07/02/2017

21.3 [21.140] / 12

Transmission - Mechanical transmission internal components

• Put the synchro cone on to the synchronizer ring, (1), and pick up the gear, (2), and place it inside the ring.

20098978

20098979

20098980

20098981

1. Insert the 3rd and 4th driven gear synchro assembly as shown, into the upright transmission housing. NOTICE: Make sure the gear bushings stay with each gear. Also, make sure groove in sliding sleeve, (3), is facing the front of the transmission. The gears are in order as follows: • 4th Driven Gear (32 teeth), (1). • Clutch Body ring (36 teeth), (2). • Gear engage Sliding sleeve (includes two Synchro rings [24 teeth], Hub Synchro w/spring [33 internal teeth], poppel and ball), (3). • Clutch Body ring (36 teeth), (4). • 3rd Driven Gear (36 teeth), (5). • Washer, (6). 2. Insert next set of gears as shown. NOTICE: Make sure the gear bushings stay with each gear. The gears are in order as follows: • 2nd Driven Gear (41 teeth), (1). • Clutch Body ring (36 teeth), (2).

3. Insert next set of gears as shown. The gears are in order as follows: • Synchro Hub (27 teeth), (1). • Sliding Sleeve (46 teeth), (2). NOTE: The synchro hub sits inside of the sliding sleeve.

47921938 07/02/2017

21.3 [21.140] / 13

Transmission - Mechanical transmission internal components

4. Insert the last set of gears as shown. NOTICE: Make sure the gear bushings stay with each gear. The gears are in order as follows: â&#x20AC;˘ Clutch Body ring (36 teeth), (1). â&#x20AC;˘ 1st Driven Gear (46 teeth), (2).

20098982

20098983

5. Insert the spacer with raised lip facing up, (1).

6. Install shaft, (1), with new bearing, (2), into the gears.

20098973

20098984

7. Set transmission into a horizontal position. 8. Insert spacer, (1), with raised lip facing forward.

47921938 07/02/2017

21.3 [21.140] / 14

Transmission - Mechanical transmission internal components

9. Install the remaining gears with their shafts, as described earlier in each of the appropriate sections.

20098953

20098963

10. Lock the gears and install nut, (1). Torque the M24 x 1.50 retaining nut to 255 NÂˇm (188 lb ft). 11. Lock the nut by punching locking plate. 12. Install the cover with a new seal, not shown. Torque the bolts 18 NÂˇm (13 lb ft).

47921938 07/02/2017

21.3 [21.140] / 15

Transmission - Mechanical transmission internal components

Transmission shaft - Assemble Drive shaft TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Re-install drive shaft in transmission housing observing the following: • Refer to figure for correct orientation of the different gears, bearings and shims.

20098959

20098960

20098961

• Install bushing, (1), if removed using suitable tool. • Install new seal, if removed using suitable tool.

1. Install bearing with snap ring, (1), into housing.

47921938 07/02/2017

21.3 [21.140] / 16

Transmission - Mechanical transmission internal components

2. Install the gears into the housing as shown. Gears shown: • 4th Driven Gear (31 Teeth), (1). • Spacer, (2). • 3rd and Reverse Driven Gear (27 Teeth), (3). • 1st (16 Teeth) and 2nd (21 Teeth) Driven Gear, (4). 3. Install shaft (not shown) through the gears and spacer.

20098962

20098963

20098964

20098985

4. Install snap ring, (1), onto shaft. NOTE: If there is not enough space to install ring, gently hit the back side of shaft with a rubber mallet. Install snap ring and then hit the shaft with rubber mallet in the front, until ring is flush with bearing. 5. Remove seal shim, (2), if applicable and install onto the shaft cover, not shown.

6. Install a new bearing, (1), into rear of the housing until bearing is flush with the rear housing. NOTE: Make sure the inner race of the bearing, (2), is installed with the larger face against the driven gears.

7. Install washer, (1), followed by snap ring, (2). NOTE: If there is not enough room to install the snap ring, (2), use a mallet at the front of the shaft to push the shaft rearward and allow snap ring to fit in place. 8. Adjust the end play by shimming with washer, (1). End Play Specification • 0 – 0.127 mm (0 – 0.0050 in) Shim Sizes • 3.7 mm (0.146 in) • 4 mm (0.157 in) • 4.3 mm (0.169 in)

47921938 07/02/2017

21.3 [21.140] / 17

Transmission - Mechanical transmission internal components

9. Install the front oil seal cover, (1), complete with gasket/ sealants, making sure that the rear bearing is in perfect alignment. NOTE: Check oil seal for damage before installing front cover.

20098955

47921938 07/02/2017

21.3 [21.140] / 18

Transmission - Mechanical transmission internal components

Transmission internal parts - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Gear forks shaft 1. Remove all shaft pins (1) and forks.

LAIL11TT0422A0A

LAIL11TT0423A0A

LAIL11TT0424A0A

NOTE: Shafts can be distinguished as shown in the figure. (1) Gear I/II forks shafts (2) Gear III/IV forks shafts NOTE: I/II and III/IV gear fork shafts are similar. The only difference is that III/IV gear fork shaft has a bore (5) to accommodate interlock capsules. (3) Reverse gear forks shaft (4) High/low gear forks shaft

2. Remove shafts 1, 2 and 3 from the housing. 3. Remove the interlock (1) from the intermediate shaft (2). 4. Using a screw driver push the remaining two interlocking balls (3) after removing the plug (4). NOTE: Interlocks are of different sizes. Two are in the shape of a ball and the rest are in the shape of a capsule.

47921938 07/02/2017

21.3 [21.140] / 19

Transmission - Mechanical transmission internal components

5. Remove the high-low shaft locking capsules (1) using a suitable magnetic tool after removing the neutral switch.

LAIL11TT0425A0A

LAIL11TT0426A0A

LAIL11TT0450A0A

LAIL11TT0451A0A

6. Remove the spring pin from the shaft and fork.

7. Straighten the lock-plate.

8. Remove the bracket (1) to retrieve the ball and spring (2) from the support bracket, if the shifter rod is to be removed from the bracket.

47921938 07/02/2017

21.3 [21.140] / 20

Transmission - Mechanical transmission internal components

Transmission internal parts - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Reassembly follows the procedure for removing the shaft from the gear forks. 1. Press the ball as shown in the figure and fit both shafts into the bracket using Tool No. 9971346. 2. Insert the high low shaft also as explained above.

LAIL11TT0452A0A

47921938 07/02/2017

21.3 [21.140] / 21

Transmission - Mechanical transmission internal components

Gears, shaft, and bearings - Remove Range gear assembly TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Straighten the locking plate at each bolt, (1). 2. Remove the bolts, (2), that secure the assembly, (3), to the transmission housing.

20098966

Next operation: To disassemble the range gears, see the procedures in Gears, shaft, and bearings - Disassemble Range gear assembly (21.140).

47921938 07/02/2017

21.3 [21.140] / 22

Transmission - Mechanical transmission internal components

Gears, shaft, and bearings - Disassemble Range gear assembly TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To remove the range gears, see the procedures in Gears, shaft, and bearings - Remove Range gear assembly (21.140). 1. Remove pins, (1), to remove the planetary gears, (2), from the carrier. Retrieve the brass washers, (3).

20098967

Next operation: To inspect the range gears, see the procedures in Gears, shaft, and bearings - Inspect (21.140).

47921938 07/02/2017

21.3 [21.140] / 23

Transmission - Mechanical transmission internal components

Gears, shaft, and bearings - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

20099046

1. Inspect each component and replace each component that has damage or excessive wear. Refer to figure for component breakdown. Ref.# 1. Planetary Splitter Sun Gear (52 Teeth) 2. Planet Gears Support 3. Splitter Planet Gear (16 Teeth) 4. Needle Roller 5. Planet Gear Thrust Washer 6. Pin 7. Inner Planet Gear Support Plate 8. Roll Pin 9. Inner Planet Gear Thrust Washer 10. Outer Planet Gear Thrust Washer 11. Outer Gear Support Thrust Plate 12. Cap Screw, M12 x 1.50 x 60 mm 13. Lock Plate 14. Sleeve Sliding

47921938 07/02/2017

21.3 [21.140] / 24

Transmission - Mechanical transmission internal components

Gears, shaft, and bearings - Assemble Range gear assembly TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To inspect the range gears, see the procedures in Gears, shaft, and bearings - Inspect (21.140). 1. Reassemble the range gear components and install the range gear assembly, (1), onto the transmission. NOTE: Make sure thrust washers are seated correctly on the dowel pins. 2. Install theM12 x 1.50 x 60 mm bolts, (2), with the locking plates, (3), and torque the bolts to 75 NÂˇm (55 lb ft).

20098967

47921938 07/02/2017

21.3 [21.140] / 25

Index Transmission - 21 Mechanical transmission internal components - 140 Gears, shaft, and bearings - Assemble Range gear assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gears, shaft, and bearings - Disassemble Range gear assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

Gears, shaft, and bearings - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gears, shaft, and bearings - Remove Range gear assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission internal parts - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission internal parts - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission shaft - Assemble Drive shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission shaft - Assemble Driven gears and drive shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission shaft - Disassemble Driven gears and drive shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission shaft - Disassemble Reverse gears and drive shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission shaft - Inspect Driven gears and drive shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission shaft - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

21.3 [21.140] / 26

47921938 07/02/2017

21.3 [21.140] / 27

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

47921938 07/02/2017 EN

SERVICE MANUAL Four-Wheel Drive (4WD) system TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017

Contents Four-Wheel Drive (4WD) system - 23

[23.304] Four-Wheel Drive (4WD) gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 [23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2

47921938 07/02/2017

Four-Wheel Drive (4WD) system - 23 Four-Wheel Drive (4WD) gearbox - 304

47921938 07/02/2017

23.1 [23.304] / 1

Contents Four-Wheel Drive (4WD) system - 23 Four-Wheel Drive (4WD) gearbox - 304

TECHNICAL DATA Gearbox General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Gearbox Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Gearbox Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

(*) See content for specific models 47921938 07/02/2017

23.1 [23.304] / 2

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Gearbox - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Main Specifications Component Reduction ratio Relay lever pad width Pad seat width in driven gear Pad clearance in seat Relay lever pivot diameter Pivot housing internal diameter in casing Pivot clearance in housing Relay lever detent spring length Free Less than 178.2 – 197.8 N (40 – 44 lb)

TT3840

TT3840F TT3880F TT4030 34/24x24/34 = 1 to 1 7.978 – 8.000 mm (0.3141 – 0.3150 in) 8.280 – 8.370 mm (0.3260 – 0.3295 in) 0.280 – 0.460 mm (0.0110 – 0.0181 in) 15.973 – 16.000 mm (0.6289 – 0.6299 in) 16.016 – 16.059 mm (0.6306 – 0.6322 in) 0.016 – 0.086 mm (0.0006 – 0.0034 in) 130 mm (5.1181 in) 142.5 mm (5.6102 in)

Gearbox - Torque TT3840F TT3840 TT3880F TT4030

LA LA LA LA

LAIL11TT0398F0A

47921938 07/02/2017

23.1 [23.304] / 3

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Part to be torqued Transmission shaft central support retaining bolt (C12) Drive gear housing retaining bolt (C13)

Turnbuckle

Torque setting

M12 x 1.5

98 N·m (867.37 lb in)

M12 x 1.25

98 N·m (867.37 lb in)

Gearbox - Special tools TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Tools 293836 Drive shaft seal key

47921938 07/02/2017

23.1 [23.304] / 4

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Gearbox - Sectional view TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Sectional views of transfer box

LAIL11TT0397F0A

C12 = Drive shaft center bearing fixing screw C13 = Drive shaft housing fixing screw X = When assembling, thoroughly clean and degrease mating surface X. 1. 2. 3. 4. 5. 6. 10. 11. 12.

Brake driven disks Brake linings Brake shoe Driven gear Idler gear Needle roller bearing Driven shaft Dowel Bolts Fourâ&#x20AC;&#x201C;wheel drive engagement sleeve

22. 25. 26. 27. 28. 29. 30. 39. 56.

Detent plunger Snap pin Idler shaft Dust excluder Seal Retaining ring Splined driven shaft Drive shaft guard Center bearing

47921938 07/02/2017

23.1 [23.304] / 5

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Gearbox - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

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: To remove the axle guard, see the procedures in Drive shaft - Remove (23.314). To remove, proceed as follows: 1. Remove the plug (1) and drain the oil from the gearbox/ switch box.

LAIL11TT0178A0A

LAIL11TT0157A0A

LAIL11TT0158A0A

2. Remove the drive gear engagement control lever (1).

3. Remove the screws (1) that secure the drive gear housing (transfer box) to the transmission housing. 4. Remove the drive gear housing from the transmission housing.

Next operation: To remove the transfer case, see the procedures in Gearbox - Disassemble (23.304). 47921938 07/02/2017

23.1 [23.304] / 6

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Gearbox - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

With the transfer box on the bench, proceed as follows: 1. Carry out operation Gearbox - Remove (23.304).

LAIL11TT0018A0A

LAIL11TT0019A0A

LAIL11TT0020A0A

2. Use the special punch to extract the snap ring (1) and the pin (2). Remove the roller bearing, the spacer, the thrust washers and the intermediate gear (3). 3. Remove the parking brake control lever.

4. Use a screwdriver to remove the dust ring (1). 5. Remove the splined driven shaft, complete with parts, parking brake disks and the driven gear.

Next operation: To assemble the transfer box, see procedures in Gearbox - Assemble (23.304).

47921938 07/02/2017

23.1 [23.304] / 7

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Gearbox - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To remove the transfer box, see procedures in Gearbox - Disassemble (23.304). 1. To refit the transfer box, proceed as follows:

LAIL11TT0224A0A

LAIL11TT0225A0A

2. Insert the shaft in the housing, then assemble the gear unit, washer and lock ring. 3. Fit the internal lever ,the external lever, the coupling pad and secure in position using the washer and corresponding lock ring. Fit the bearing and corresponding lock rings. 4. Using the tool 293836, fit the seal and dust ring (use the spacer to fit the dust ring).

Next operation: To install the transfer box, see procedures in Gearbox - Install (23.304).

47921938 07/02/2017

23.1 [23.304] / 8

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Gearbox - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To assemble the transfer case, see the procedures in Gearbox - Assemble (23.304) . 1. Check Gearbox - Torque (23.304) for the tightening torques. 2. Carefully clean the mating surfaces. 3. Apply a bead of approximately 2 mm of anaerobic sealant to the mating surface of the drive gear housing. 4. Fit the drive gear housing into the transmission housing. 5. Connect the drive gear engagement control lever. 6. Replace the drain plug for the transmission oil. 7. Fit the transmission shaft and the related guard. Follow the procedures in Drive shaft - Install (23.314).

BRAG12TRLUE0342

47921938 07/02/2017

23.1 [23.304] / 9

Index Four-Wheel Drive (4WD) system - 23 Four-Wheel Drive (4WD) gearbox - 304 Gearbox - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

23.1 [23.304] / 10

Four-Wheel Drive (4WD) system - 23 Drive shaft - 314

47921938 07/02/2017

23.2 [23.314] / 1

Contents Four-Wheel Drive (4WD) system - 23 Drive shaft - 314

TECHNICAL DATA Drive shaft General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Drive shaft Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(*) See content for specific models 47921938 07/02/2017

23.2 [23.314] / 2

Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Main specifications of drive shaft Component Front drive sleeve adjustment Front drive sleeve shim thickness

TT3840 TT3840F TT3880F TT4030 Consult the procedures in Drive shaft - Remove (23.314) . 2.2 mm (0.0866 in)– 2.5 mm (0.0984 in) – 2.8 mm (0.1102 in) – 3 mm (0.1181 in) – 3.3 mm (0.1299 in) – 3.7 mm (0.1457 in) – 4 mm (0.1575 in) – 4.3 mm (0.1693 in)

47921938 07/02/2017

23.2 [23.314] / 3

Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

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. Disconnect the negative battery cable (1).

BRAG12TRLUE0356

LAIL11TL0473A0A

LAIL11TL0474A0A

2. Remove the front, middle and rear drive shaft protection fastening bolts.

3. Remove the retaining lock ring (2) and wiggle the sleeve (1) as shown in the diagram to loosen the fitting on the transfer box shaft body.

Next operation: To install the drive shaft, see the procedures in Drive shaft - Install (23.314).

47921938 07/02/2017

23.2 [23.314] / 4

Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To remove the drive shaft, see the procedures in Drive shaft - Remove (23.314). 1. Fit and secure the transmission shaft in the correct position. 2. Move the front splined sleeve (27) against the retaining ring (28). Using a feeler, measure the clearance between the sleeve and the retaining ring (26). Fit the shim (S5) to obtain a clearance of 1 â&#x20AC;&#x201C; 1,5 mm in the sleeve (L). Refer to the references in Gearbox - Sectional view (23.304). 3. Fit and secure the guard.

LAIL11TL0474A0A

47921938 07/02/2017

23.2 [23.314] / 5

Index Four-Wheel Drive (4WD) system - 23 Drive shaft - 314 Drive shaft - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

23.2 [23.314] / 6

47921938 07/02/2017

23.2 [23.314] / 7

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

47921938 07/02/2017 EN

SERVICE MANUAL Front axle system TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017

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 [25.310] Final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4 [25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.5

47921938 07/02/2017

CONSUMABLES INDEX Consumable Loctite® 510™ Loctite® 270 Loctite® 638™ NEW HOLLAND AMBRA GR-9 MULTI-PURPOSE GREASE Loctite® 518™ Loctite® 518™ Loctite® 638™ Loctite® 638™

Reference Powered Powered Powered Powered

front front front front

axle axle axle axle

Sealing Sealing Sealing Grease

Differential - Service instruction Differential - Gear tooth contact - 4WD Ring/pinion adjustment Non-powered front axle - Sealing Non-powered front axle - Sealing

47921938 07/02/2017

PAGE 25.1 25.1 25.1 25.1

/ / / /

12 12 12 22

25.2 / 27 25.2 / 29 25.5 / 6 25.5 / 6

47921938 07/02/2017

Front axle system - 25 Powered front axle - 100

47921938 07/02/2017

25.1 [25.100] / 1

Contents Front axle system - 25 Powered front axle - 100

TECHNICAL DATA Powered front axle General specification (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General specification (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Torque (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Torque (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Special tools (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Special tools (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Sealing (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Dimension (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

FUNCTIONAL DATA Powered front axle Component identification (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Dynamic description (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Dynamic description - Narrow axle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Overview of the toe-in angle (narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Axle housing Exploded view (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Axle support Sectional view (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SERVICE Powered front axle Grease (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Adjust - 4WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Remove - 4WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Disassemble - 4WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Inspect - 4WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Assemble - 4WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Install - 4WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Change fluid (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 (*) See content for specific models 47921938 07/02/2017

25.1 [25.100] / 2

Toe in adjust (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Adjust the steering angle (narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Test after assembly (narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Axle housing Disassemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Assemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

DIAGNOSTIC Powered front axle Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

(*) See content for specific models 47921938 07/02/2017

25.1 [25.100] / 3

CONSUMABLES INDEX Consumable Loctite® 510™ Loctite® 270 Loctite® 638™ NEW HOLLAND AMBRA GR-9 MULTI-PURPOSE GREASE

Reference Powered Powered Powered Powered

front front front front

axle axle axle axle

Sealing Sealing Sealing Grease

47921938 07/02/2017

25.1 [25.100] / 4

PAGE 25.1 25.1 25.1 25.1

/ / / /

12 12 12 22

Front axle system - Powered front axle

Powered front axle - General specification (Standard shaft) TT3840 TT4030

LA LA

See the references in Differential lock - Sectional view (Standard shaft) (25.102) and Final drive - Sectional view (Standard shaft) (25.310). Component Type Pair of bevel gears - differential Pinion/crown gear ratio: Clearance between teeth: Pinion position adjustment shim thickness (11)

TT3840 TT4030 Steering, load support structure, central articulation

10/35 = 1:3.5 0.18 - 0.23 2.5 mm - 2.6 mm - 2.7 mm - 2.8 mm - 2.9 mm - 3.0 mm 3.1 mm - 3.2 mm - 3.3 mm - 3.4 mm - 3.5 mm - 3.6 mm - 3.7 mm 2.5 mm - 2.55 mm - 2.6 mm - 2.65 mm - 2.7 mm - 2.75 mm Thickness of the adjustment shim for the preload of - 2.8 mm - 2.85 mm - 2.9 mm - 2.95 mm - 3.0 mm the pinion bearings (12) 3.05 mm - 3.1 mm - 3.15 mm - 3.2 mm - 3.25 mm - 3.3 mm - 3.35 mm - 3.4 mm - 3.45 mm - 3.5 mm - 3.55 mm 3.6 mm - 3.65 mm - 3.7 mm - 3.75 mm - 3.8 mm - 3.85 mm - 3.9 mm - 3.95 mm - 4.0 mm - 4.05 mm - 4.1 mm 4.15 mm - 4.2 mm - 4.25 mm - 4.3 mm - 4.35 mm - 4.4 mm - 4.45 mm - 4.5 mm - 4.55 mm - 4.6 mm - 4.65 mm 4.7 mm - 4.75 mm - 4.8 mm 0.9 mm - 1 mm - 1.1 mm - 1.2 mm - 1.3 mm - 1.4 mm Crown adjustment shim thickness (4) 1.5 mm - 1.6 mm - 1.7 mm - 1.8 mm - 1.9 mm - 2 mm 0.15 mm Clearance between planetary and satellite (gear) teeth 1.470 – 1.530 mm Planetary shim thickness (1) 1.4 mm - 1.5 mm - 1.6 mm - 1.7 mm - 1.8 mm Satellite shim thickness 21.939 – 21.960 mm Transverse pin diameter (14) to satellites 22.040 – 22.061 mm Diameter of satellite cross holes (3): 0.080 – 0.122 mm Clearance between transversal pins and holes Differential lock 75 mm Free length of the spring (5): Spring under tension of: 41 mm - 1370 – 1566 N (308.0 – 352.1 lb) Shafts and Turning Housings 44.975 – 45.000 mm Diameter of the outer shaft (7) in relation to the bushings (8): 45.100 – 45.175 mm(1) Internal diameter of the installed bushing (8): 0.100 – 0.200 mm Clearance between the shafts and bushes 0.064 – 0.129 mm Interference between bushes and the respective holes 0.10 mm - 0.15 mm - 0.20 mm - 0.25 mm - 0.30 mm Pin adjustment shim thickness (10) Final epicyclic transmission Gear ratio: 12: (12 + 60) = 1 : 6 0.77 – 0.83 mm Gear shim thickness (9) Axle articulation 0.3 – 1.1 mm Clearance of end between axle housing and bearings Maximum admissible clearance 2 mm 52.652 – 52.671 mm Articulated axle front pin diameter (3) 52.720 – 52.790 mm(1) Internal diameter of the installed front bushing (1) 0.049 – 0.138 mm Clearance between the pin (3) and-bushing (1) 99.020 – 99.050 mm External diameter of the rear bushing (6) installed in the bevel pinion support 99.146 – 99.221 mm(1) Internal diameter of the rear bushing (5) installed in the articulated axle support 0.096 – 0.201 mm Clearance between the two bushes and pins 47921938 07/02/2017

25.1 [25.100] / 5

Front axle system - Powered front axle

4.90 – 5.00 mm

Shim thickness of the front axle front backing (2) and rear backing (4) (1)

Measurement to be achieved without enlargement

Powered front axle - General specification (Narrow shaft) TT3840F TT3880F

LA LA

TT3840F

Characteristic

TT3880F Values 572890 20.09/F Limited slip 3.55:1 5.00 / 1 17.77:1 167 kg

Code Model Differential type Bevel gear ratio Epicyclic reduction gear ratio Overall ratio Dry weight Input rotation Clockwise Counter clockwise Steer angle Toe-in Bevel gear set backlash Pinion bearings preload (measured in D = 30.5 mm without seals) Pinion-crown gear bearing total preload (measured in D = 30.5 mm without seals) Differential Oil Capacity Epicyclic reduction gear oil capacity each side Oil specification: Use recommended additive-enriched oil. Pinion-drive shaft interface Ø = 100 mm

42° 0-2 0 – 2 mm 0.17 – 0.23 mm P = 10.5 – 15.7 kgf T = (P+5.8) – (P+8.7) kgf 4l 0.5 l API GL-5 SAE 1310

Powered front axle - Torque (Standard shaft) TT3840 TT4030

LA LA

See the part references in Differential lock - Sectional view (Standard shaft) (25.102), Final drive - Sectional view (Standard shaft) (25.310) and Axle support - Sectional view (Standard shaft) (25.100). Description Front bridge Crown fixing bolt (C1) Lock cover fixing bolt (C2) Pinion fixing nut (C3) Axle housing steering assembly fixing nut (C4) Steering support pin fixing nut (C5) Wheel hub bearings fixing nut (C6) Hub cover fixing bolt (C7) Upper engine fixing nut (C8) Bearing fixing bolt (C9) Differential cover bolt (C10)

Turnbuckle

TT3840

TT4030 Torque

M12 X 1.25 M10 X 1.25 M35 x 1.5

113 N·m 64 N·m 294 N·m

11.5 kgm 6.5 kgm 30 kgm

M12 X 1.25

113 N·m

11.5 kgm

M10 X 1.25 M70 x 2 M10 X 1.25 M18 x 1.5 M18 x 1.5 M12 X 1.25

64 N·m 392 N·m 64 N·m 314 N·m 314 N·m 113 N·m

6.5 kgm 40 kgm 6.5 kgm 32 kgm 32 kgm 11.5 kgm

47921938 07/02/2017

25.1 [25.100] / 6

Front axle system - Powered front axle

Wheel rim fixing bolt nut

M16 X 1.5

245 NÂ·m

Powered front axle - Torque (Narrow shaft) TT3840F TT3880F

LA LA

47921938 07/02/2017

25.1 [25.100] / 7

25 kgm

Front axle system - Powered front axle

LAIL11TT0170H0A

47921938 07/02/2017

25.1 [25.100] / 8

Front axle system - Powered front axle

Powered front axle - Special tools (Standard shaft) TT3840 TT4030

LA LA

ATTENTION: 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.

Special tools List of specific tools needed to perform the different operations described in this Section.

X X X X X X X X

X X X

293460 291517 293743 293878 293391 293510 292903 293782 293400 293544 295030 293882 292888 293812 293857 292161 292220 292870

Trestle for servicing the front bridge. Hook for lifting the differential support. Support for servicing the differential. Wrench for bevel pinion nut. Template for adjusting the tapered bearings Universal indicator for adjusting the pinion bearing. Disassembly pliers. Wrench for locking the bevel pinion. Universal calibrator for bevel pinion positioning. Wrench for the adjustment nut for the differential bearing pre-load. Wrench for the wheel hub nut. Pair of hooks for extracting the internal ring of the conical bearing of the wheel hub. Guide pins (M12x1.25) for the epicyclical reducer cover. Guide pins (M16x1.25) for the installing the wheels. Extractor for the hinge pin of the wheel hub articulated seal. Extractor for the turning housing pin bushings. Adaptor for measuring the turning housing pre-load. Universal kit containing manometers, gaskets and tubes for front shaft pressure control.

The tool to be manufactured for adjusting the bevel pinion is used together with tool 293391(models TT3840 and TT4030) (tool no. 50118 - dimensions in mm). Made using UNI C40.

LAIL11TT0107A0A

Powered front axle - Special tools (Narrow shaft) TT3840F TT3880F

LA LA

The special drifts/pads used to assemble the seals, bearings and bushings should always be used with the interchangeable handle; its use is recommended together with a suitable safety handle in order to protect the hands.

47921938 07/02/2017

25.1 [25.100] / 9

Front axle system - Powered front axle

LAIL11TT0474G0A

47921938 07/02/2017

25.1 [25.100] / 10

Front axle system - Powered front axle

LAIL11TT0475H0A

47921938 07/02/2017

25.1 [25.100] / 11

Front axle system - Powered front axle

Powered front axle - Sealing (Narrow shaft) TT3840F TT3880F

LA LA

Adhesive/Sealant Application (see figure 1) Apply on the contact surfaces Apply on bolts thread / on pins Gasket sealant Referr

Presence

Adhesive make and type LOCTITE® 510™ Superbond® 529

A1 Gasket sealant Manufacturer reference

Presence

Adhesive make and type LOCTITE® 270 Superbond® 331

B2 Gasket sealant Manufacturer reference

Presence

Adhesive make and type LOCTITE® 638™ Superbond® 433

See the technical characteristics of each compound in Consumables Loctite® Product Chart.

47921938 07/02/2017

25.1 [25.100] / 12

Front axle system - Powered front axle

Sealing compounds and adhesives

LAIL11TT0399H0A

47921938 07/02/2017

25.1 [25.100] / 13

Front axle system - Powered front axle

Powered front axle - Dimension (Narrow shaft) TT3840F TT3880F

LA LA

47921938 07/02/2017

25.1 [25.100] / 14

Front axle system - Powered front axle

Total dimensions (millimeters)

LAIL11TT0234F0A

47921938 07/02/2017

25.1 [25.100] / 15

Front axle system - Powered front axle

Powered front axle - Component identification (Narrow shaft) TT3840F TT3880F

LA LA

LAIL11TT0166F0A

1. 2. 3. 4. 5. 6.

Axle type Customer ref. Manufacturer S/N Total transmission ratio Differential type Differential Oil Capacity

7. 8. 9. 10. 11.

Epicyclic reduction gear oil capacity Epicyclic reduction gear oil type Differential oil type Input rotation Manufacturer No.

47921938 07/02/2017

25.1 [25.100] / 16

Front axle system - Powered front axle

Powered front axle - Dynamic description (Standard shaft) TT3840 TT4030

LA LA

Description and operation TT3840/TT4030 models have a central front wheel drive and a coaxial drive shaft in the longitudinal direction of the tractor. The drive shaft has no universal joints. The differential has two planetary gears and movement is transmitted to the lateral epicyclic final units (installed in the wheel hubs) through universal joints that do not require any maintenance.

47921938 07/02/2017

25.1 [25.100] / 17

Front axle system - Powered front axle

Powered front axle - Dynamic description - Narrow axle TT3840F TT3880F

LA LA

BRAG12TRLUE0363

• Steering Cylinder (1) • Differential (2) • Differential support (3) • Pinion (4) • Epicyclic reduction gear (5) • Wheel hub (6) • Axle case (7)

47921938 07/02/2017

25.1 [25.100] / 18

Front axle system - Powered front axle

Powered front axle - Overview of the toe-in angle (narrow shaft) TT3840F TT3880F

LA LA

LAIL11TT0344G0A

1. 2. 3.

Guide rod Locking nut Union

4. 5.

Stop bolt Lock ring

47921938 07/02/2017

25.1 [25.100] / 19

Front axle system - Powered front axle

Axle housing - Exploded view (Narrow shaft) TT3840F TT3880F

LA LA

Front axle housing

LAIL11TT0172F0A

1. 2. 3. 4. 5.

Axle case Top link cover Ball bearing cup Bushing Bushing

6. 7. 8. 9. 10.

Retainer Half-shaft Rear retainer Rear bushing Front retainer

47921938 07/02/2017

25.1 [25.100] / 20

Front axle system - Powered front axle

Axle support - Sectional view (Standard shaft) TT3840 TT4030

LA LA

Cross-section of front axle pivot

BRAG12TRLUE0382

H L S5 C9 C10 C11 1. 2. 3.

1 mm (0.0394 in) 1 – 1.5 mm (0.0394 – 0.0591 in) Coupling sleeve shim Support bolt for axle pivot Differential journal bolt Fixing bolt to attach the front axle support to the engine Axle pivot front support Front backing washer Front bushing

47921938 07/02/2017

25.1 [25.100] / 21

4. 5. 6. 7. 8. 9. 10. 11.

Rear backing washer Rear bushing Axle pivot rear support Lock ring Front splined sleeve Lock ring Propeller shaft protection Propeller shaft

Front axle system - Powered front axle

Powered front axle - Grease (Narrow shaft) TT3840F TT3880F

LA LA

Applying grease to the assembly NEW HOLLAND AMBRA GR-9 MULTI-PURPOSE GREASE

LAIL11TT0227F0A

47921938 07/02/2017

25.1 [25.100] / 22

As Required As Required

Front axle system - Powered front axle

Powered front axle - Adjust - 4WD TT3840 TT4030

LA LA

When travelling forward in a straight path, the wheels of four-wheel drive tractors must be parallel to the longitudinal axis of the tractor, alternatively a slight toe-in of the front wheels is permissible up to a maximum of 6 mm (0.24 in) as measured at the edges of the wheel rims. To check the exact value of the toe-in setting of fourwheel drive tractors, proceed as follows. 1. Inflate the front tires to the prescribed pressure. 2. Position the steering at the straight ahead position (along the longitudinal axis of the tractor). 3. Check if the wheels are parallel with the longitudinal axis of the tractor. 4. Make a chalk mark on the front inside edges of both wheel rims, at the height of the wheel hub centers. Measure the distance, (1), between the chalk marks. 5. Move the tractor forward to turn the front wheels through 180°. The chalk marks will now measure between the rear inside edges of the wheel rims at the height of the wheel hub centers. Now measure the distance, (2), checking that this new measurement is equal to or greater than the distance, (1), by a maximum or 6 mm (0.24 in). The rotation of the wheels through 180° is necessary to eliminate the effect of wear, misalignment or distortion of the wheel rims on the measurements obtained. 20097715

20097716

6. If it is necessary to correct the wheel alignment, remove nut, (1), and pull the tie rod end out of its housing. Loosen the locknut, (2), and screw the tie rod end, (3), in or out to increase or decrease the distance, (2), Reposition the tie rod end in its housing and re-check alignment. After having adjusted the toe in to within the prescribed limits, tighten locknut, (2), to a torque of 180 N·m (133 lb ft) and nut, (1), to 100 N·m (74 lb ft). NOTE: The self-locking nut, (1), must be replaced each time it is removed or partially unscrewed.

47921938 07/02/2017

25.1 [25.100] / 23

Front axle system - Powered front axle

Powered front axle - Remove - 4WD TT3840 TT4030

LA LA

Proceed as follows: NOTE: The front axle assembly can be removed from the tractor either with or without previously removing the drive shaft. The description below refers to removal of the front axle with the drive shaft installed on the tractor. 1. Disconnect the negative cable, (1), from the battery and insulate it.

BRAG12TRLUE0356

20097655

96096504

2. Attach nylon slings to the front weights, (1). Loosen the locking screw from each weight, lift the weights clear of the tractor and place them in a safe position.

3. Remove the bolts, (1), and remove the drive shaft guards, (2).

47921938 07/02/2017

25.1 [25.100] / 24

Front axle system - Powered front axle

4. Remove the snap ring, (1), from the front and rear of the drive shaft. 5. Remove the bolts from the drive shaft support. 6. Remove the drive shaft from the front axle input shaft and drop box output shaft by sliding the two couplers onto the drive shaft.

20097657

20097658

20099978

96096507

7. Attach nylon slings around the front axle and attach them to a hoist.

8. Lift the tractor with the hoist and place a stand under the lower portion of the front axle.

9. Remove the power steering hoses, (1), from the power steering tubes.

47921938 07/02/2017

25.1 [25.100] / 25

Front axle system - Powered front axle

10. Remove the front wheels.

20097661

96096504

11. Remove the front axle rear support retaining bolts, (1).

12. Remove the front axle front support retaining bolts, (1).

96096506

20097664

13. Using a hoist and nylon cables (one for each side) detach the front axle from the tractor.

47921938 07/02/2017

25.1 [25.100] / 26

Front axle system - Powered front axle

Powered front axle - Disassemble - 4WD TT3840 TT4030

LA LA

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: To remove the front axle, see the procedures in Powered front axle - Remove - 4WD (25.100). With the front axle on a workbench, proceed as follows:

20097665

96096503

20097667

1. Remove plug, (1), and drain the oil from the axle casing.

2. To drain the final drive oil, remove plug, (1), on the left-hand final drive casing; repeat the same operation on the right-hand casing.

47921938 07/02/2017

25.1 [25.100] / 27

Front axle system - Powered front axle

3. Remove the rear support, (1), off the front axle; remove the front support and the thrust washer.

20097668

20097669

20097670

96096507

4. Remove the tie rod retaining nuts, (1).

5. Using a removal tool, remove the tie rod ends from their bores in the stub axle housing.

6. Remove the snap ring from the bottom of the cylinder rod pivot pin, (1), remove the pin retaining bolt, (2), from the pin. Remove the pins and detach the cylinder.

47921938 07/02/2017

25.1 [25.100] / 28

Front axle system - Powered front axle

7. Unscrew the retaining bolts off the left-hand final drive casing cover, (1). Screw in the two M10 x 100 dowels tool no 380002813, (2), and, using a slide hammer puller screwed into the oil drain plug, detach the cover, (1), from the casing.

20097672

20097673

8. Remove the snap ring, (1), securing the driving gear, (2), and remove the gear.

9. Remove the snap ring, (1), securing the driving gear.

20097674

20097675

10. Remove the staking, (1), on the wheel hub bearing lock ring, (2).

47921938 07/02/2017

25.1 [25.100] / 29

Front axle system - Powered front axle

11. Remove the wheel hub bearing lock ring using tool no 380000295, (1).

20097676

20097677

20097678

20097679

12. Remove the wheel hub, (1), with the ring gear, (2).

13. Remove the retaining bolts, (1), of the lower pivot pin of the stub axle housing. Remove the lower pivot pin and the relative adjustment shims.

14. Remove the retaining bolts of the upper pivot pin. 15. Withdraw the upper pivot pin, (1), and detach the stub axle housing, (2).

47921938 07/02/2017

25.1 [25.100] / 30

Front axle system - Powered front axle

16. Remove the retaining bolt, (1), of the axle shaft, (2).

20097680

20097681

20097682

20097683

17. Using a prybar, pull the axle shaft out of the casing. 18. To disassemble the right-hand final drive unit, repeat the above steps 7 to 17.

19. Remove the bolts fixing the bevel drive-differential support to the axle casing. Screw in the M12 x 100 dowels, tool no 380002814, (1). Remove the remaining bolts and separate the bevel drive-differential support from the axle casing. Attach a chain, (2), to the support and take up the weight with the hoist. Remove the bevel drive-differential support, (3), from the axle casing.

20. Remove the two bolts, (1), from the two ring gear differential support caps, (2). Remove the crown wheeldifferential assembly from the housing.

47921938 07/02/2017

25.1 [25.100] / 31

Front axle system - Powered front axle

21. Remove the snap ring, (1), from the splined shaft, (2).

20097684

20097685

20097686

20097687

22. Straighten the locking tab on the splined shaft lock nut, (1).

23. Remove the nut using wrench, tool no 380000268, (1), while holding the bevel drive pinion shaft against rotation with wrench, tool no 380000257.

24. Remove the splined shaft detent ball, (1).

47921938 07/02/2017

25.1 [25.100] / 32

Front axle system - Powered front axle

25. Remove the bevel drive pinion shaft, (1), from the rear of the casing and remove the spacer, the adjustment shims and the bearing. NOTE: Observe the quantity and the size of the shims removed from the pinion shaft.

20097688

20097689

26. Using a screwdriver, remove the dust seal, seal ring, (1), and rear bearing.

Next operation: To inspect the front axle, see the procedures in Powered front axle - Inspect - 4WD (25.100).

47921938 07/02/2017

25.1 [25.100] / 33

Front axle system - Powered front axle

Powered front axle - Inspect - 4WD TT3840 TT4030

LA LA

Prior operation: Powered front axle - Disassemble - 4WD (25.100). 1. Wash all parts in a suitable solvent and allow to air dry. 2. Inspect the gears for excess wear or damage. Replace as necessary. 3. Check all the bearings for wear or roughness. Rotate the bearings by hand and replace as necessary. 4. Inspect the axle shafts and pinion shaft for wear or damage. Replace as necessary. 5. Inspect the front axle housing for any damage. Replace as necessary. Next operation: Powered front axle - Assemble - 4WD (25.100).

47921938 07/02/2017

25.1 [25.100] / 34

Front axle system - Powered front axle

Powered front axle - Assemble - 4WD TT3840 TT4030

LA LA

Prior operation: Powered front axle - Inspect - 4WD (25.100). 1. Reassemble the front axle adhering to the following instructions: • Refer to the tightening torques Powered front axle - Torque (Standard shaft) (25.100). • Install the rear bearing, the seal, the dust seal, the adjustment shims, the spacer and the bevel drive pinion shaft complete with front bearing. • Position the detent ball, screw in the bevel drive pinion lock nut and secure in position by staking. Finally, replace the snap ring. • Install the ring gear differential assembly, the support caps and tighten the relative bolts. • Install the bevel drive-differential housing on the front axle casing. • Install the axle shaft and relative bolt. • Install the stub axle, the adjustment shims, the upper and lower pivot pins. • Install the wheel hub, the ring gear of the final drive unit and the lock ring and tighten to the prescribed torque value, while simultaneously turning the wheel hub to ensure that the bearings are correctly seated. • Install the securing and stop snap rings, the driving gear and the cover of the final drive unit. • Install the pins, washers, spacers and steering cylinders. • Install the track rod, the front and rear supports and the oil drain plugs. Next operation: Powered front axle - Install - 4WD (25.100).

47921938 07/02/2017

25.1 [25.100] / 35

Front axle system - Powered front axle

Powered front axle - Install - 4WD TT3840 TT4030

LA LA

Prior operation: Powered front axle - Assemble - 4WD (25.100). 1. Refit the front axle following the instructions below. • Install the axle and bolt the front and rear supports in position. • Reconnect the power steering hoses. • Install the front wheels. • Raise the front of the tractor using the hoist. • Remove the fixed stand. • Detach the nylon cables. • Reconnect the drive shaft and install the drive shaft guard. • Attach a nylon cable to the front weights, lift, install to the tractor and secure with the locking screws. • Reconnect the negative battery lead. • Refer to the tightening torques Powered front axle - Torque (Standard shaft) (25.100).

47921938 07/02/2017

25.1 [25.100] / 36

Front axle system - Powered front axle

Powered front axle - Change fluid (Narrow shaft) TT3840F TT3880F

LA LA

LAIL11TT0444F0A

Position 1 2 3 4 5

Description Oil filling and level plug Oil drain plug Oil breather Filling, drain and level plug of epicyclic reduction gear oil Grease points

47921938 07/02/2017

25.1 [25.100] / 37

Front axle system - Powered front axle

ATTENTION: To drain and fill the oil and to check the oil level, the axle must be horizontal. ATTENTION: Risk of violent oil ejection. Carefully follow all the safety procedures in this manual and in the tractor manual

LAIL11TT0445A0A

LAIL11TT0446A0A

LAIL11TT0447A0A

LAIL11TT0448A0A

1. Before draining the oil from the axle housing, use the breather (1) to release possible internal pressure. 2. To drain the oil, remove the level plug (2) and the drain plug (3). ATTENTION: Risk of violent oil ejection.

3. See point one. 4. Drain all oil. 5. Clean the plug (3). Tighten the plug to the prescribed torque (Tightening torque â&#x20AC;&#x201C; Powered front axle Torque (Narrow shaft) (25.100). 6. Always use the breather (1) to release possible internal pressure. 7. Unscrew the oil fill plug (2). Fill up to the bottom of the level plug hole with the specified oil. 8. Wait to allow the oil to flow through the axle. 9. Check oil level and fill to the specified level if necessary. 10. Tighten the plug (2) to the prescribed torque (Tightening torque â&#x20AC;&#x201C; Powered front axle - Torque (Narrow shaft) (25.100). ATTENTION: To drain and fill the oil and to check the oil level, the axle must be horizontal. 11. Before draining the oil from the wheel end, rotate the wheel end so that the plug (4) is in the highest position [position A] and partially unscrew to release possible pressure. 12. Rotate the wheel end so that the plug (4) is toward the ground [position B]. Remove the plug and drain the oil.

47921938 07/02/2017

25.1 [25.100] / 38

Front axle system - Powered front axle

13. Rotate the wheel end so that the hole (4) is in the position shown in the figure. Fill up to the bottom of the fill plug hole with the specified oil (Technical specifications Powered front axle - General specification (Narrow shaft) (25.100). 14. Tighten the plug (4) to the prescribed torque (Tightening torque â&#x20AC;&#x201C; Powered front axle - Torque (Narrow shaft) (25.100).

LAIL11TT0449A0A

47921938 07/02/2017

25.1 [25.100] / 39

Front axle system - Powered front axle

Powered front axle - Toe in adjust (Narrow shaft) TT3840F TT3880F

LA LA

Adjusting the toe in Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. See the general diagram of the system in Powered front axle - Overview of the toe-in angle (narrow shaft) (25.100). 1. Put two equal one-meter-long linear bars on the wheel sides and lock them with two nuts on the wheel hub stud bolt. NOTICE: The two bars should be fixed on their middle so that they are perpendicular to the supporting surface and parallel to the pinion shaft axis; align the two bars. LAIL11TT0511A0A

LAIL11TT0499A0A

2. Measure the distance in mm M between the bars ends with a tapeline. NOTE: Keep the minimum value, swinging the measurement point.

47921938 07/02/2017

25.1 [25.100] / 40

Front axle system - Powered front axle

3. Check that the difference of the measurements between the wheel hubs diameters ends is within the requested tolerance range.

LAIL11TT0406B0A

LAIL11TT0512A0A

See the permissible toe-in values in Powered front axle - General specification (Narrow shaft) (25.100). 4. The nominal toe-in value (A) is referred to the external diameter of the wheel hub flange; therefore the measured value (M) at the bar ends must be related to the ratio between length of the bar and flange diameter. Nominal toe-in = (A) 0 â&#x20AC;&#x201C; 2 mm. Measured toe-in = (M) 0 â&#x20AC;&#x201C; 5 mm. 5. If the toe-in is incorrect, adjust the two guide rods (1) by tightening and loosening the two joint link rods (3) equally till the toe-in is within the required range.

47921938 07/02/2017

25.1 [25.100] / 41

Front axle system - Powered front axle

6. After adjusting, tighten the lock nuts (2) of the guide rods (1) to the torque specified in Powered front axle - Torque (Narrow shaft) (25.100).

LAIL11TT0513A0A

Next operation: To adjust the steering angle, see the procedures in Powered front axle - Adjust the steering angle (narrow shaft) (25.100).

47921938 07/02/2017

25.1 [25.100] / 42

Front axle system - Powered front axle

Powered front axle - Adjust the steering angle (narrow shaft) TT3840F TT3880F

LA LA

Prior operation: To adjust the toe-in, see the procedures in Powered front axle - Toe in adjust (Narrow shaft) (25.100). Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. 1. Use the same bars assembled for the toe-in adjustment and a long bar perfectly leaned over the machined part of the central body (pinion side), so that the two bars form an acute angle at the maximum steering.

LAIL11TT0506A0A

LAIL11TT0507A0A

LAIL11TT0508A0A

2. Set a protractor to the angle specified in Powered front axle - General specification (Narrow shaft) (25.100) and position it on the long bar. Move a wheel side till it forms, with the two bars, the angle fixed by the protractor.

3. Adjust the mechanical steering stop. Tighten or loosen the stop bolt (4) and lock it at the torque specified in Powered front axle - Torque (Narrow shaft) (25.100) with the lock nut (5).

47921938 07/02/2017

25.1 [25.100] / 43

Front axle system - Powered front axle

4. Rotate completely toward the other side and repeat the same operations.

LAIL11TT0509A0A

Next operation: To test after fitting, see the procedures in Powered front axle - Test after assembly (narrow shaft) (25.100).

47921938 07/02/2017

25.1 [25.100] / 44

Front axle system - Powered front axle

Powered front axle - Test after assembly (narrow shaft) TT3840F TT3880F

LA LA

Prior operation: To adjust the toe-in, see the procedures in Powered front axle - Toe in adjust (Narrow shaft) (25.100).

Test methods Step 1: With the engine off, lift the axle so that the tires are off the ground. Step 2: Engage the gear so that the pinion is locked. Step 3: With the help of another person standing on the opposite side, begin the assembly testing by rotating both the wheels forward as much as possible. Both the wheels should lock after a while. Step 4: Keeping the pinion locked, free the right wheel and rotate the left wheel in the direction of travel. Rotate the right wheels in the opposite direction. The wheel will move freely without difficulty and the right wheel will move in the opposite direction if the assembly has been carried out correctly. Repeat the same operation in the opposite direction (reverse gear). if one wheel does not rotate freely in both directions, then check step by step all assembly operations. Check and see that the brakes are regulated correctly and functioning properly.

47921938 07/02/2017

25.1 [25.100] / 45

Front axle system - Powered front axle

Axle housing - Disassemble (Narrow shaft) TT3840F TT3880F

LA LA

WARNING Avoid injury! Use Personal Protective Equipment (PPE), including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W1036A

Disassembling the axle housing Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. 1. Remove the two axle shafts (7) from the axle housing (1).

LAIL11TT0182A0A

LAIL11TT0491A0A

LAIL11TT0066A0A

2. Remove the retainers (6) from the axle housing (1). NOTE: This operation destroys the retainers. 3. Only remove bushings (4) and (5) from the axle housing (1) if they are worn enough to require it. ATTENTION: Be careful not to damage the brush seat.

4. Only remove the top link cover (2) and the ball bearing cup (3) from the link pin seats if they are worn enough to require it. Use a suitable extractor to do so.

47921938 07/02/2017

25.1 [25.100] / 46

Front axle system - Powered front axle

5. Remove the rear and front retainers (8) and (10) from the pivot using a suitable tool. NOTE: This operation destroys the retainers. 6. Remove the rear and front bushings (9) from the axle beam pivot using a suitable extractor. NOTE: This is a destructive operation for the bushings. Use new retainers for assembly.

LAIL11TT0067A0A

Next operation: To remove the axle housing, see the procedures in Axle housing - Assemble (Narrow shaft) (25.100).

47921938 07/02/2017

25.1 [25.100] / 47

Front axle system - Powered front axle

Axle housing - Assemble (Narrow shaft) TT3840F TT3880F

LA LA

WARNING Avoid injury! Use Personal Protective Equipment (PPE), including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W1036A

Prior operation: To remove the axle housing, see the procedures in Axle housing - Disassemble (Narrow shaft) (25.100).

Fitting the axle housing Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. Cool the top link pin cover (2) and the ball bearing cup (3) to a temperature below -100 Â°C with liquid nitrogen. 1. Mount the top brush (2) on the top link pin seat with special tool CA119220 and a hammer. Mount the ball bearing cup (3) on the bottom link pin seat with special tool CA715451 and a hammer.

LAIL11TT0068A0A

LAIL11TT0069A0A

2. Cool the bushing (5) to a temperature below 100 Â°C with liquid nitrogen. NOTE: Bushing (5) includes bushing (4). 3. Fit bushing (5) in the axle housing (1) with special tool CA715452 and a hammer. 4. Fit the retainer (6) on the axle housing with special tool CA715453 and a hammer.

47921938 07/02/2017

25.1 [25.100] / 48

Front axle system - Powered front axle

NOTE: Carefully apply petroleum jelly to the seal rings.

LAIL11TT0070A0A

LAIL11TT0182A0A

LAIL11TT0071A0A

5. Insert the axle shaft (7) into the axle housing (1).

6. Fit two new bushings (9) on the axle housing pivot with special tool CA715475. 7. Fit two new retainers (8) and (10) on the axle housing pivot using special tools CA715562 and CA715573. NOTE: See the information about oil changes in Powered front axle - Change fluid (Narrow shaft) (25.100).

47921938 07/02/2017

25.1 [25.100] / 49

Front axle system - Powered front axle

Powered front axle - Troubleshooting TT3840F TT3880F

Problem No differential action; jamming during steering

LA LA

Possible Cause Incorrect installation / defective axle

Overloading / incorrect weight distribution Different rotation radius of the tires

Broken axle shaft

Bent axle shaft Incorrect wheel adjustment Contamination in the axle box or incorrect assembly of parts Incorrect use of the product Pinion teeth pitting

Excessive use Insufficient lubrication

Incorrect installation / defective axle Steering is difficult; vehicle continues in a straight line while turning Overloading / incorrect weight distribution Different rotation radius of the tires

Broken axle shaft

Incorrect use of the product Friction noise

Incorrect installation / defective axle

Broken axle shaft

Bent axle shaft Spoiled or worn out axle parts Contamination in the axle box or incorrect assembly of parts 47921938 07/02/2017

25.1 [25.100] / 50

Correction Correct installation or repair or replace the differential in case it does not survive any one of the test phases. Remove excessive weight and redistribute load. Follow the vehicle-related instructions. If one tire has a smaller radius, it will cause partial wheel slipping whenever force is applied. The other tire with bigger radius will have to support all the work. Replace the tire or adjust the pressure so that both tires have the same radius. It is not advisable to operate the vehicle with a broken axle shaft. The tractor (engine off and tractor unloaded) may only be moved a few meters. Replace axle shaft. Verify group integrity and wheel side bearings. Adjusting according. Look for foreign particles. Check assembly of the various parts of the axle. Consult the tractor manufacturerâ&#x20AC;&#x2122;s instructions. Replace bevel gear set Use correct lubrication fill up, to the right level and replace at recommended intervals Correct the installation. Repair or replace the differential if it does not survive any one of the test stages. Remove excessive weight and redistribute load. Follow the vehicle-related instructions. If one tire has a smaller radius, it will cause partial wheel slipping whenever force is applied. The other tire with bigger radius will have to support all the work. Replace the tire or adjust the pressure so that both tires have the same radius. It is not advisable to operate the vehicle with a broken axle shaft. The tractor (engine off and tractor unloaded) may only be moved a few meters. Consult the tractor manufacturerâ&#x20AC;&#x2122;s instructions. Correct the installation. Repair or replace the differential if it does not survive any one of the test stages. It is not advisable to operate the vehicle with a broken axle shaft. The tractor (engine off and tractor unloaded) may only be moved a few meters. Replace axle shaft Check the condition of the ring gear, pinion gear, bearings etc. Replace as needed Look for foreign particles. Check the assembly of the various parts of the axle

Front axle system - Powered front axle

Problem

Possible Cause Correction Incorrect adjustment of bevel gear assem- (transmission gears, Universal joints etc.) bly: worn transmission parts Replace or adjust as required Incorrect use of the product Consult the tractor manufacturerâ&#x20AC;&#x2122;s instructions. Ring gear tooth broken at Excessive gear load compared to the one Replace bevel gear set the outer side foreseen Incorrect gear adjustment (excessive back- Carefully follow the recommended operalash) tions for the adjustment of bevel gear set clearance. Pinion nut loose Carefully follow the recommended operations for the adjustment of bevel gear set clearance. Bent axle housing body Vehicle overloaded Replace the axle housing body Vehicle's accident Replace the axle housing body Load bump Replace the axle housing body Bent or broken halfshaft Vehicle operated intensively or overloaded Replace Pinion and ring teeth Crash load of differential components Check and/or replace other differential breakage components Incorrect installation / defective axle Correct the installation. Repair or replace Wheel vibration; front the differential if it does not survive any one tire resistance; axle shaft of the test stages. breakage Overloading / incorrect weight distribution Remove excessive weight and redistribute load. Follow the vehicle-related instructions. Different rotation radius of the tires If one tire has a smaller radius, it will cause partial wheel slipping whenever force is applied. The other tire with bigger radius will have to support all the work. Replace the tire or adjust the pressure so that both tires have the same radius. Bent axle shaft Replace axle shaft Incorrect use of the product Consult the tractor manufacturerâ&#x20AC;&#x2122;s instructions. Vibration during forward Incorrect installation / defective axle Correct the installation. Repair or replace drive, intermittent noise the differential if it does not survive any one of the test stages. Overloading / incorrect weight distribution Remove excessive weight and redistribute load. Follow the vehicle-related instructions. Different rotation radius of the tires If one tire has a smaller radius, it will cause partial wheel slipping whenever force is applied. The other tire with bigger radius will have to support all the work. Replace the tire or adjust the pressure so that both tires have the same radius. Bent axle shaft Replace axle shaft Incorrect adjustment of bevel gear assem- (transmission gears, universal joints, etc.). bly: worn transmission parts Replace or adjust, as required Prolonged operation at high temperatures Replace bevel gear set Overheated ring and pinion teeth Incorrect lubrication Use appropriate lubricant See if gear teeth have faded Low oil level Fill to the correct level Replace according to the recommended Contaminated Oil schedule Oil leakage form gaskets Prolonged functioning at high temperature Replace the gasket or seal and corresponding surface, if damaged. and seals of the oil Use the correct lubrication and replace it at Oil gasket assembled incorrectly recommended intervals. Use the correct lubrication and replace it at Seal lip damaged recommended intervals. 47921938 07/02/2017

25.1 [25.100] / 51

Front axle system - Powered front axle

Problem Uneven tire wear.

Possible Cause Contaminated Oil Incorrect installation / defective axle

Overloading / incorrect weight distribution Different rotation radius of the tires

Broken axle shaft

Bent axle shaft Blocked differential

Incorrect wheel adjustment Pinion or ring gear teeth or worn

Insufficient lubrication

Contaminated Oil

Incorrect lubrication or depleted additives

Worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring.

47921938 07/02/2017

25.1 [25.100] / 52

Correction Use the correct lubrication and replace it at recommended intervals. Correct installation or repair or replace the differential in case it does not survive any one of the test phases. Remove excessive weight and redistribute load. Follow the vehicle-related instructions. If one tire has a smaller radius, it will cause partial wheel slipping whenever force is applied. The other tire with bigger radius will have to support all the work. Replace the tire or adjust the pressure so that both tires have the same radius. It is not advisable to operate the vehicle with a broken axle shaft. The tractor (engine off and tractor unloaded) may only be moved a few meters. Replace axle shaft. Differential is not working properly or control device is broken/blocked. Verify assembly and all components. Tractors with wide steering angle may move jerkily and have difficulty steering, or tires may be worn when taking sharp bends. Reduce the steering angle to the minimum and slow down when the vehicle starts moving jerkily. Verify group integrity and wheel side bearings. Adjusting according. Replace bevel gear set. Carefully follow the recommended operations for the adjustment of bevel gear set clearance. Use correct lubricants, fill up to the right levels and replace according to the recommended program. Replace bevel gear set. Carefully follow the recommended operations for the adjustment of bevel gear set clearance. Use correct lubricants, fill up to the right levels and replace according to the recommended program. Replace bevel gear set. Carefully follow the recommended operations for the adjustment of bevel gear set clearance. Use correct lubricants, fill up to the right levels and replace according to the recommended program. Replace bevel gear set. Carefully follow the recommended operations for the adjustment of bevel gear set clearance. Use correct lubricants, fill up to the right levels and replace according to the recommended program.

Front axle system - Powered front axle

Problem Possible Cause Excessive wearing out of Exhaustive use input flange spline

Correction • Replace the flange. • Check that the pinion spline is not excessively worn out. • Replace bevel gear set if required. • Replace the flange.

Pinion nut loose

• Check that the pinion spline is not excessively worn out. Pinion axle backlash

• Replace bevel gear set if required. • Replace the flange. • Check that the pinion spline is not excessively worn out.

Fatigue failure of pinion Exhaustive use teeth See if the fracture line is well defined (wave lines, beach lines) Continuous overload Excessive use Side gear spline worn out. Replace all scratched washers (Excessive backlash) Thrust washer surface Insufficient lubrication worn out or scratched.

• Replace bevel gear set if required. Replace bevel gear set

Replace bevel gear set • Replace differential gear assy. • Replace halfshaft if required • Use the correct lubrication and fill up to the right level. • Replace at intervals recommended.

Incorrect lubrication

• Replace all scratched washers and those with 0,1mm thickness lower than the new ones. • Use the correct lubrication and fill up to the right level. • Replace at intervals recommended. • Replace all scratched washers and those with 0,1mm thickness lower than the new ones. • Use the correct lubrication and fill up to the right level.

Contaminated Oil

• Replace at intervals recommended. • Replace all scratched washers and those with 0,1mm thickness lower than the new ones. • Replace the bearing.

Inner diameter of tapered Excessive use roller bearing worn out.

• Check pinion axial backlash.

Excessive axial pinion backlash

• Use proper lubrication, fill up to right level and replace at recommended intervals. • Replace the bearing. • Check pinion axial backlash. • Use proper lubrication, fill up to right level and replace at recommended intervals.

47921938 07/02/2017

25.1 [25.100] / 53

Front axle system - Powered front axle

Problem

Possible Cause Insufficient lubrication

Correction • Replace the bearing. • Check pinion axial backlash. • Use proper lubrication, fill up to right level and replace at recommended intervals. • Replace the bearing.

Contaminated Oil

• Check pinion axial backlash.

Premature tyre wear

Drive by noise

Noise while driving in neutral

Intermittent noise Constant noise

Noise while steering

Low tractor stability

• Use proper lubrication, fill up to right level and replace at recommended intervals. Incorrect inflation pressure To inflate the tires to the correct pressure, see the values suggested in the operator’s manual. Always comply with the values specified by the tire manufacturer. Incorrect front wheel toe-in. Adjust the toe-in (see procedures in Powered front axle - Toe in adjust (Narrow shaft) (25.100)). Excessive backlash between pinion and Adjust ring gear Worn out pinion and gear ring Replace Worn pinion bearings Replace Pinion bearings loose Adjust Excessive axial pinion backlash Adjust Replace Worn differential bearings Adjust Differential bearings loose Replace Ring gear out of roundness Low lubricant level Oil level Poor or wrong lubricant Replace Replace Bent axle shaft Noise coming from axle are usually heard Replace or adjust (see above) when vehicle moves in neutral gear but are not loud. Incorrect clearance between pinion and Replace ring (sound heard while decelerating disappears when increasing the speed) Adjust Pinion or input flange worn out Ring gear damaged Replace bevel gear set Tighten to torque Differential case bolts loose Ring gear teeth or pinion damaged Replace bevel gear set Worn bearings Replace Worn pinion spline Replace Replace Bent axle shaft Replace Worn differential gears Replace Worn differential case or crosshead Replace Differential thrust washers worn Replace Half shaft spline worn out Fill tires to correct pressure Incorrect inflation pressure

47921938 07/02/2017

25.1 [25.100] / 54

Index Front axle system - 25 Powered front axle - 100 Axle housing - Assemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle housing - Disassemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle housing - Exploded view (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle support - Sectional view (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Adjust - 4WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Adjust the steering angle (narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Assemble - 4WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Change fluid (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Component identification (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Dimension (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Disassemble - 4WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Dynamic description (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Dynamic description - Narrow axle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - General specification (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - General specification (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Grease (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Inspect - 4WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Install - 4WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Overview of the toe-in angle (narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Remove - 4WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Sealing (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Special tools (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Special tools (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Test after assembly (narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Toe in adjust (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Torque (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Torque (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

25.1 [25.100] / 55

47921938 07/02/2017

25.1 [25.100] / 56

Front axle system - 25 Front bevel gear set and differential - 102

47921938 07/02/2017

25.2 [25.102] / 1

Contents Front axle system - 25 Front bevel gear set and differential - 102

TECHNICAL DATA Differential Service limits (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Differential Exploded view (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Exploded view (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Differential housing Exploded view (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Exploded view (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Differential lock Sectional view (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Differential Preload (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Adjust (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Disassemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Assemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Input shaft assembly - Disassemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Input shaft assembly - Assemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Input shaft assembly - Assemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Input shaft assembly - Disassemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Service instruction (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Gear tooth contact - 4WD Ring/pinion adjustment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Differential housing Disassemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Assemble - Narrow shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Gear tooth contact (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

(*) See content for specific models 47921938 07/02/2017

25.2 [25.102] / 2

CONSUMABLES INDEX Consumable Loctite® 518™ Loctite® 518™

Reference Differential - Service instruction Differential - Gear tooth contact - 4WD Ring/pinion adjustment

47921938 07/02/2017

25.2 [25.102] / 3

PAGE 25.2 / 27 25.2 / 29

Front axle system - Front bevel gear set and differential

Differential - Service limits (Narrow shaft) TT3840F TT3880F

LA LA

Limited slip differential disks specifications

BRAG12TRLUE0353

1. 2. 3.

Friction disk thickness = 1,497 – 1,503 mm Minimum thickness = 1,4 mm. Quantity: 10 Friction disk thickness ( 1,597 – 1,603 mm. Minimum thickness = 1,45 mm. Quantity: 8 Friction disk thickness ( 2,797 – 2,803 mm. Minimum thickness = 2,7 mm. Quantity: 2

47921938 07/02/2017

25.2 [25.102] / 4

Front axle system - Front bevel gear set and differential

Differential - Exploded view (Narrow shaft) TT3840F TT3880F

LA LA

Differential group

LAIL11TT0468F0A

1. 2. 3. 4. 5. 6.

Fixing bolt Bevel gear Ball Bearings Half box Lock disk Lock disk

7. 8. 9. 10. 11. 12.

Lock disk Planetary Gears Crossheads Satellite gears Thrust washers Half box

47921938 07/02/2017

25.2 [25.102] / 5

Front axle system - Front bevel gear set and differential

Differential - Exploded view (Narrow shaft) TT3840F TT3880F

LA LA

Pinion group

LAIL11TT0492F0A

1. 2. 3. 4. 5.

Bevel pinion Adjustment shim Bearing Cup Flat washer Spacer

6. 7. 8. 9. 10.

Flat washer Differential support Bearing Retaining washer Lockwasher

47921938 07/02/2017

25.2 [25.102] / 6

Front axle system - Front bevel gear set and differential

Differential housing - Exploded view (Narrow shaft) TT3840F TT3880F

LA LA

Differential support group

LAIL11TT0343G0A

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

Differential support Mounting bolts for differential support Ring nut Bearing Cup Casing Bearing Cup Ring nut

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

Ring nut tighteners Screws Guide Journal Screws Positioning pins Axle housing

47921938 07/02/2017

25.2 [25.102] / 7

Front axle system - Front bevel gear set and differential

Differential housing - Exploded view (Narrow shaft) TT3840F TT3880F

LA LA

BRAG12TRLUE0354

1. 2. 3.

Spring-ring Flange Retainer

4. 5.

O-Ring Flat washer

47921938 07/02/2017

25.2 [25.102] / 8

Front axle system - Front bevel gear set and differential

Differential lock - Sectional view (Standard shaft) TT3840 TT4030

LA LA

Cross-section of front axle differential

LAIL11TT0168G0A

S1 S2 C1 C2 C3 Gd, Gs 1. 2.

= = = = = =

Pinion bearing shim Pinion positioning shim Pinion bearing lock nut Differential assembly fixing bolt Crown fixing bolt Lock nuts for the right- and left-hand differential bearings Pinion Seal

3. 4. 5. 6. 7. 8.

Pinion bearing spacer Ring gear Axle shaft with universal joint Planetary washer Satellite washer Satellite box mounting bolt

60. Planetary 61. Planetary 62. Satellite

47921938 07/02/2017

25.2 [25.102] / 9

Front axle system - Front bevel gear set and differential

63. Satellite shaft NOTE: During assembly, apply sealant to the surfaces (X).

47921938 07/02/2017

25.2 [25.102] / 10

Front axle system - Front bevel gear set and differential

Differential - Preload (Standard shaft) TT3840 TT4030

LA LA

Bevel pinion adjustments Check out the procedure for removing the front axle differential in Powered front axle - Disassemble - 4WD (25.100), from step 19. Proceed as follows: 1. Fix the tool 293391 (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. NOTE: For models TT3840/TT4030, insert tool 50118 (see Powered front axle - Special tools (Standard shaft) (25.100)) between the tool 293391 (1) and the bearing (2).

LAIL11TT0335A0A

LAIL11TT0336A0A

LAIL11TT0337A0A

2. Use a micrometer to measure the distance (H1) between the top surface and the pin of tool 293391. (1) 3. Disassemble the above parts, lubricate the bearings with engine oil and then reinstall the parts, excluding the bearing spacer ( (3), Fig. 1), of the differential shaft housing, complete with the external races of the bearings, and kept in place with the aid of tool 293743. 4. Tighten the tool nut 293391 (1) (see note above) 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. 6. The thickness required for the adjustment shim is determined by: S = Hâ&#x201A;&#x201A; - Hâ&#x201A; + 0.05 mm.

47921938 07/02/2017

25.2 [25.102] / 11

Front axle system - Front bevel gear set and differential

If necessary, round up the value obtained to the next 0.05 mm. NOTE: When adjustment is complete, do not remove the adjustment tool from the axle housing differential. Leave it to adjust the pinion position.

Bevel pinion adjustments (projection) Proceed as follows: 7. Attach tool 293400 (1) to the differential housing only and with the journal caps fitted. 8. Tighten the cones (3) of tool 293400 (1) inside or outside, so as to direct the micrometer shaft toward the inner bearing race and to prevent the end between the cones and the bearings from moving. 9. Adjust the micrometer so that the axis is in contact with the inner bearing race and measure the distance (H 3 ) obtained. 10. Determine the corrected distance (H5) between the center of the differential and the support base of the bearing in the pinion: H₅ = H₄ + C where: H₄ = 95 mm for TT3840/TT4030 models. Nominal distance between the center of the differential and the support base of the bearing in the pinion. C = Correction value written on the pinion, preceded by the + or – sign (if not zero), to be added or subtracted from the nominal distance (H4), according to the sign. LAIL11TT0338A0A

11. The shim thickness will be determined by: S = H₃- H₅ where: H₃ = Distance measured with the micrometer. H₅ = Corrected nominal distance between the center of the differential and the support base of the bearing in the pinion. Examples:

47921938 07/02/2017

25.2 [25.102] / 12

Front axle system - Front bevel gear set and differential

• Distance measured with micrometer H5 = 98 mm. • Nominal distance between the center of the differential and the support base of the bearing in the pinion H4 = 95 mm • Correction value C = + 0.2 mm. • Nominal corrected H5 distance = 95 mm + 0.2 mm = 95.2 mm. • S Shim Thickness = 98 mm – 95.2 mm = 2.8 mm. • Correction value C = - 0.2 mm. • Nominal corrected H5 distance = 95 mm + 0.2 mm = 94.8 mm. • Thickness of adjustment shim S = 98 mm – 94.8 mm = 3.2 mm. • Correction value C = 0 mm. • Nominal corrected H5 distance = H4 = 95 mm. • Thickness of adjustment shim S = 98 mm – 95 mm = 3 mm. 12. Remove tools 293391 and 293400 from the bevel pinion housing. 13. Install the complete bevel pinion with internal bearing race, spacer, and adjustment shim ( (11) and (12)) with the previously determined thicknesses. 14. Fit the O-ring sealing (1) onto the pinion shaft. 15. Next, insert the retainer race and afterwards the ball, after having carefully lubricated the external surface.

LAIL11TT0339A0A

LAIL11TT0340A0A

16. Install pinion lock key 293782. (2) 17. Install key 293878 in the pinion nut.

47921938 07/02/2017

25.2 [25.102] / 13

Front axle system - Front bevel gear set and differential

18. Using a key, lock the pinion (2), and using a torque meter positioned on nut (1) exactly as shown in Fig. 6, fasten the nut (C₃, Powered front axle - Torque (Standard shaft) (25.100)) to a torque of 294 N·m (217 lb ft), and simultaneously turn the pinion to ensure that the bearings are correctly seated. 19. Using a torque wrench 293952 (1) and pinion lock wrench 293782 (2), check that the pinion’s swing torque is 0.5 – 1 N·m (0.369 – 0.738 lb ft) without the retainer and the dust guard.If the swing torque value is lower than recommended, fit a thinner adjustment shim. If the torque value is higher than recommended, fit a thicker adjustment shim.

LAIL11TT0341A0A

20. Loosen the nut and fit the retainer and the corresponding dust guard ring. Fasten the nut to a torque of 294 N·m (217 lb ft) and simultaneously turn the pinion to ensure that the bearings are correctly seated. 21. Using torquemeter 293952 (1) and pinion lock wrench 293782 (2), check that the pinion’s swing torque is < 0.50 N·m (0.369 lb ft) with the retainer fitted, for models TT3840/ TT4030. Finally, carefully lock the nut and install the lock ring.

47921938 07/02/2017

25.2 [25.102] / 14

Front axle system - Front bevel gear set and differential

Differential - Adjust (Standard shaft) TT3840 TT4030

LA LA

End Play Adjustment In case of differential assembly overhaul it is necessary to adjust the backlash between the teeth of the planet pinions and side gears. Proceed as follows: 1. Thoroughly clean the components of the differential to remove any traces of oil which would otherwise prevent accurate backlash measurement. 2. Install the two side gears without thrust washers. 3. Install the planet pinions complete with thrust washers and pins and screw the pin retaining bolts in by a few turns to hold the pins in place. 4. Position a dial gauge on the differential housing. 5. Move the left-hand side gear to bring it into full contact with the planet pinion and then push it up against the differential housing, reading the end play (GL) on the dial gauge.

20097712

20097713

20097714

6. Repeat the above operations to measure the end play on the right-hand side gear (GR). Axial clearance should be 0.25 mm (0.010 in). Therefore the shims to be inserted in the differential housing are given by: Shim (left) = GL - 0.25 mm (0.010 in) for the left-hand side gear. Shim (right) = GR - 0.25 mm (0.010 in) for the righthand side gear.

7. Install shims, (1), as near as possible to the calculated value. Use a dial gauge and following the procedure described above, check that the end float of the left and right-hand side gears is approximately 0.25 mm (0.010 in).

47921938 07/02/2017

25.2 [25.102] / 15

Front axle system - Front bevel gear set and differential

Differential side gear shim sizes Available Shim Sizes mm (inches) 1.0 mm (0.039 in) 1.6 mm (0.063 in) 1.1 mm (0.043 in) 1.7 mm (0.067 in) 1.2 mm (0.047 in) 1.8 mm (0.071 in) 1.3 mm (0.051 in) 1.9 mm (0.075 in) 1.4 mm (0.055 in) 2.0 mm (0.039 in) 1.5 mm (0.059 in)

47921938 07/02/2017

25.2 [25.102] / 16

Front axle system - Front bevel gear set and differential

Differential - Disassemble (Narrow shaft) TT3840F TT3880F

LA LA

Prior operation: When removing the differential support, see the procedures in Differential housing - Disassemble (Narrow shaft) (25.102). Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. Proceed as follows: See the exploded view of the assembly in Differential - Exploded view (Narrow shaft) (25.102). 1. Lock the differential with a clamp. Unscrew the mounting bolts (1) and remove the bevel gear (2). ATTENTION: This will make both differential half boxes (4) and (12) free, so take care not to drop the internal components.

LAIL11TT0494A0A

LAIL11TT0183A0A

LAIL11TT0184A0A

2. Disassemble the differential housing into two half cases (4) and (12) with the related components. NOTE: Make alignment marks on the half cases before dividing them. Disassemble all the components. 3. Check the operating and wear conditions of the components.

4. Remove the bearings (3), and the half cases (4) and (12) using a three point extractor.

Next operation: For fitting the differential, see the procedures in Differential - Assemble (Narrow shaft) (25.102).

47921938 07/02/2017

25.2 [25.102] / 17

Front axle system - Front bevel gear set and differential

Differential - Assemble (Narrow shaft) TT3840F TT3880F

LA LA

Prior operation: When removing the differential, see the procedures in Differential - Disassemble (Narrow shaft) (25.102). Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. See the exploded view of the assembly in Differential - Exploded view (Narrow shaft) (25.102). 1. Fit the bearing cones (3) on half boxes (4) and (12), using special tool CA715083 and a hammer.

LAIL11TT0476A0A

LAIL11TT0392A0A

LAIL11TT0477A0A

2. Position part (4) or (12) in a vise and assemble all the internal components (lock disks (5), (6) and (7), the planetary gears (8), crossheads (9), satellite gears (10) and thrust washers (11)) as shown. NOTE: The first disk (7) must be fitted with friction material next to the disks and the smooth surface on the planetary gear side (8). 3. Join the two half boxes aligning the reference marks made during disassembly. See the specifications of the differential lock disks in Powered front axle - General specification (Narrow shaft) (25.100). 4. Position the crown gear (2) on the differential housing. Apply the indicated sealant to the bolt threads (1). 5. Fit the bolts (1) and tighten them to the torque given in Powered front axle - Torque (Narrow shaft) (25.100).

47921938 07/02/2017

25.2 [25.102] / 18

Front axle system - Front bevel gear set and differential

Differential Input shaft assembly - Disassemble (Narrow shaft) TT3840F TT3880F

LA LA

Disassembly 1. See the exploded view of the system in Differential housing - Exploded view (Narrow shaft) (25.102). Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. 2. Remove the spring-ring (1) from the end of the pinion. 3. Remove the flange (2).

LAIL11TT0208A0A

LAIL11TT0209A0A

4. Remove the retainer (3) from the differential support. NOTE: This operation destroys the retainer. Remove the O-ring (4) and the washer (5). Fit a new O-ring and washer.

Next operation: For the differential flange, see the procedures described in Differential Input shaft assembly - Assemble (Narrow shaft) (25.102).

47921938 07/02/2017

25.2 [25.102] / 19

Front axle system - Front bevel gear set and differential

Differential Input shaft assembly - Assemble (Narrow shaft) TT3840F TT3880F

LA LA

Prior operation: When removing the flange assembly, see the procedures in Differential Input shaft assembly - Disassemble (Narrow shaft) (25.102). Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. See the exploded view of the system in Differential housing - Exploded view (Narrow shaft) (25.102) 1. Fit the flat washer (5) and the new O-ring (4) on the end of the pinion. Fit the new retainer (3) on the differential support with special tool CA715165 and a hammer.

LAIL11TT0021A0A

LAIL11TT0022A0A

2. Fit the flange (2). Fit the lock ring (1) on the end of the pinion.

47921938 07/02/2017

25.2 [25.102] / 20

Front axle system - Front bevel gear set and differential

Differential Input shaft assembly - Assemble (Narrow shaft) TT3840F TT3880F

LA LA

Prior operation: To remove the pinion assembly, see the procedures in Differential Input shaft assembly - Disassemble (Narrow shaft) (25.102). Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. See the exploded view of the assembly in Differential - Exploded view (Narrow shaft) (25.102). 1. Place the differential support (7) on a workbench. 2. Fit bearing races (3) and (8) using special tool CA119068 and a hammer.

LAIL11TT0094A0A

LAIL11TT0095A0A

LAIL11TT0096A0A

3. Prepare the kit consisting of the special tools called the “false pinion” CA715084 and the “false differential box” CA119205, as well as a depth gauge .

4. Insert the bearing cones (3) and (8) into their housings. Assemble the "false pinion" and its ring nut (10). Tighten without exceeding the ring nut, till the backlash is eliminated.

47921938 07/02/2017

25.2 [25.102] / 21

Front axle system - Front bevel gear set and differential

5. Install the "false differential box" special tools into the differential group support (7) and lock it with the half collars.

LAIL11TT0097A0A

LAIL11TT0098A0A

LAIL11TT0099A0A

6. Assembly diagram of the "false differential box" tools (on the left). Use a depth gauge to measure the distance "X" (distance between the axis of the differential bearings and the point at which the pinion head is supported, or base of the bearing).

7. In order to determine the necessary thickness value (S) between the pinion and the bearing, subtract the value (V), stamped on the pinion head ( V = requested conical distance), from the measured value â&#x20AC;&#x153;Xâ&#x20AC;?. S = X-V mm

Thick.

2.5 mm

2.6 mm

Shim range 2.7 mm 2.8 mm 2.9 mm

3.0 mm

3.1 mm

3.2 mm

3.3 mm

3.4 mm

8. Select the shim (2) of thickness value (S) from the available shims.

LAIL11TT0100A0A

47921938 07/02/2017

25.2 [25.102] / 22

Front axle system - Front bevel gear set and differential

9. Remove the “false differential box” special tool from the differential support (7). Remove the ring nut (10), the “false pinion”, and bearing cones (3) and (8).

LAIL11TT0101A0A

LAIL11TT0102A0A

10. Insert the chosen shim (2) with the chamfer facing the gear inside the pinion shaft (1). 11. Force the bearing (3) into the pinion shaft (1) with special tool CA715082 under a press, making sure that it is well seated. 12. Insert shims (4) and (6) and a new removable spacer (5). NOTE: Always use a new removable spacer (5).

13. Insert the bevel pinion (1) unit into the differential support housing (7) and the bearing cone (8) into the pinion shaft, as shown in the figure. 14. Use special tool CA715082 and a hammer to guide the bearing (8).

LAIL11TT0103A0A

LAIL11TT0104A0A

15. Insert the ring nut washer (9) and screw a new lock ring nut (10) onto the pinion end.

47921938 07/02/2017

25.2 [25.102] / 23

Front axle system - Front bevel gear set and differential

16. Screw the ring nut (10) in, using the wrench for ring nut CA715080 and for pinion retainer CA715081. NOTE: If it is too tight, the removable spacer (5) must be replaced and the procedure repeated. When you check the preload, it is advisable to hit both ends of the pinion (1) gently with a rubber hammer to help to set bearings (3) and (8). ATTENTION: The torque setting is given by the preloading measurement on bearings (3) and (8); tighten the ring nut (10) gradually.

LAIL11TT0105A0A

LAIL11TT0106A0A

LAIL11TT0498A0A

17. Measure the preload of the pinionâ&#x20AC;&#x2122;s beveled roller bearings (3) and (8), using a dynamometer whose cord is wound around the splined end of the pinion (1). 18. The adjustment is carried out by increasing the ring nut (10) torque gradually, being careful not to exceed the maximum torque. ATTENTION: All preloadings must be measured without the seal ring.

P = 10.5 â&#x20AC;&#x201C; 15.7 kgf 19. Once the requested preload value is achieved, stake the ring nut (10), using a hammer and a chisel.

47921938 07/02/2017

25.2 [25.102] / 24

Front axle system - Front bevel gear set and differential

Differential Input shaft assembly - Disassemble (Narrow shaft) TT3840F TT3880F

LA LA

Prior operation: When removing the differential support, see the procedures in Differential housing - Disassemble (Narrow shaft) (25.102).

Disassembly Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. See the exploded view of the assembly in Differential - Exploded view (Narrow shaft) (25.102). 1. Secure the differential support in a vise. Unscrew the auto-lock nut (10) using special tools CA715080 and CA715081. NOTE: This operation will irretrievably damage the autolock nut (10).

LAIL11TT0089A0A

LAIL11TT0090A0A

LAIL11TT0091A0A

2. Remove the ring nut (10) and remove its retaining washer (9).

3. Tap the shaft with a rubber hammer to remove the bevel pinion (1). NOTICE: Take care not to drop the bevel pinion (1). 4. Collect flat washers (4) and (6), the omega spacer (5) and the bearing cone (8).

47921938 07/02/2017

25.2 [25.102] / 25

Front axle system - Front bevel gear set and differential

5. Place the differential support (7) on a flat surface and remove the bearing races (3) and (8) using a displacer and a hammer.

LAIL11TT0092A0A

LAIL11TT0093A0A

LAIL11TT0493A0A

6. To remove the bearing cone (3) of the bevel pinion (1), use a standard extractor. Collect the bearing cone (3) and the adjustment shim (2).

7. Check all pinion components for wear. NOTICE: The ring nut (10) and the collapsible spacer (5) must be replaced when reassembling the unit.

Next operation: To fit the pinion assembly, see the procedures in Differential Input shaft assembly - Assemble (Narrow shaft) (25.102).

47921938 07/02/2017

25.2 [25.102] / 26

Front axle system - Front bevel gear set and differential

Differential - Service instruction (Standard shaft) TT3840 TT4030

LA LA

1. Application diagram for the gasket eliminator LOCTITEÂŽ 518â&#x201E;˘ for mounting the bevel drive unit and the planetary final drive unit.

20097711

47921938 07/02/2017

25.2 [25.102] / 27

Front axle system - Front bevel gear set and differential

Differential - Gear tooth contact - 4WD Ring/pinion adjustment TT3840 TT4030

LA LA

Adjustment of the ring gear bearings and checking the backlash between the pinion and ring gear Proceed as follows: 1. Install the differential assembly complete with ring gear and inner ring gear bearing rings in the bevel drive/ differential housing.

20097705

20097706

20097707

2. Insert the outer bearing rings in the differential housing, install the differential support caps, tighten the bolts to a torque of 59 N·m (44 lb ft), then loosen and re-tighten to a torque of 20 N·m (15 lb ft).

3. With the bearings lubricated, rotate the ring gear and at the same time tighten the threaded adjustment ring using wrench, tool no 380000252, (1), to a torque of 39 – 59 N·m (29 – 44 lb ft) to take up the axial play between the components.

47921938 07/02/2017

25.2 [25.102] / 28

Front axle system - Front bevel gear set and differential

4. Use a dial gauge (1) to measure the clearance between the pinion and crown gear. Place the dial gauge perpendicular to the outer edge of a crown gear tooth (2). 5. Repeat the measurement in two other positions 120° apart and compare the average of the three values (Gm) with the prescribed normal backlash specification of: 0.18 mm (0.007 in) - 0.23 mm (0.009 in) average value 0.20 mm (0.008 in). If the measured backlash exceeds the prescribed value, adjust the threaded adjustment rings by screwing one of the rings in and the other out by the same amount to correct the axial preload and thus obtain the prescribed backlash. 20097708

20097707

20097709

6. Position a dial gauge perpendicular to the outside edge of one of the crown gear teeth. Check that the clearance between the pinion and crown gear is within the tolerance limits of 0.18 mm (0.007 in) - 0.23 mm (0.009 in).

7. Using a wrench, tool number 380000252, (1), turn the threaded adjustment ring and check, using torque wrench, (2), that the combined rolling resistance torque of the ring gear and pinion bearings is: A2 = A1 + 1.0 N·m (0.74 lb ft) to 1.5 N·m (1.11 lb ft). where: A2 = combined ring gear/pinion rolling resistance torque; A1 = rolling resistance torque of pinion, as measured previously. 1.0 N·m (0.74 lb ft) to 1.5 N·m (1.11 lb ft) = rolling resistance torque of crown wheel only measured at the end of the pinion using wrench, tool number 380000257 and a torque wrench. 8. Torque the cap screws to 113 N·m (83 lb ft). 9. Install the safety plate, screwing the threaded adjustment ring in or out up to the nearest notch. 10. Attach the bevel drive/differential to the axle casing after having carefully cleaned and degreased the mating surfaces and applied a bead of gasket eliminator LOCTITE® 518™, approx. 2 mm (0.08 in) wide along the line shown in the figure. 11. See Differential - Service instruction (Standard shaft) (25.102) for the type of sealant and where to apply the sealant when mounting the bevel drive and the final drive unit.

47921938 07/02/2017

25.2 [25.102] / 29

Front axle system - Front bevel gear set and differential

Differential housing - Disassemble (Narrow shaft) TT3840F TT3880F

LA LA

Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. See the exploded view of the assembly in Differential housing - Exploded view (Narrow shaft) (25.102). 1. Drain the oil completely from the differential. NOTE: See Powered front axle - Change fluid (Narrow shaft) (25.100) for information about changing fluid. 2. Loosen and remove the bolts (2) on the differential support (1). 3. Remove the differential support (1) from the axle housing (14).

LAIL11TT0400A0A

LAIL11TT0401A0A

LAIL11TT0402A0A

ATTENTION: Support the differential support with a rope or other appropriate means 4. Loosen and remove the bolts (9) to remove the two ring nut retainers (8).

5. Before removing the bolts, mark both journals (11) and the differential support with permanent reference marks to avoid inverting them during re-assembly. Mark the area between ring nuts (3) and (7), and the differential support (1) as well.

47921938 07/02/2017

25.2 [25.102] / 30

Front axle system - Front bevel gear set and differential

6. Unscrew the nuts of bearings (3) and (7) using the tools (a1) and a wrench.

LAIL11TT0403A0A

LAIL11TT0404A0A

LAIL11TT0405A0A

7. Remove the 4 bolts (12) and remove both journals (11). NOTE: Check that the guides (10) are still in their housings.

8. Remove the housing (5). 9. Bearing races (4) and (6) are removed together with the differential housing. ATTENTION: Do not invert the bearing cups if the bearings have not been replaced.

Next operation: To fit the engine flywheel, see the procedures in Differential housing - Assemble - Narrow shaft (25.102).

47921938 07/02/2017

25.2 [25.102] / 31

Front axle system - Front bevel gear set and differential

Differential housing - Assemble - Narrow shaft TT3840F TT3880F

LA LA

Prior operation: Differential housing - Disassemble (Narrow shaft) (25.102). 1. Fit bearing races (4) and (6) in the differential housing (5). NOTE: Do not invert the bearing races. If necessary, replace the entire assemblies (bearing and race).

LAIL11TT0072A0A

LAIL11TT0073A0A

LAIL11TT0074A0A

2. Position the entire differential assembly on the support (1).

3. Rotate the ring gear assembly until the gears click into place. 4. Make sure that the guides (10) are correctly installed. 5. Install the journals (11) and their respective screws (12). NOTE: Do not invert the journals and screws.

47921938 07/02/2017

25.2 [25.102] / 32

Front axle system - Front bevel gear set and differential

6. Fit the nuts (3) and (7) onto the differential support. 7. Tighten both bearing nuts (3) and (7) until the clearance is eliminated and the differential bearings are slightly preloaded.

LAIL11TT0075A0A

LAIL11TT0076A0A

LAIL11TT0077A0A

LAIL11TT0078A0A

8. Check that the differential bearings are properly seated. If necessary, disassemble and reassemble the assembly. 9. Place a clock gauge on the housing. Adjust the clock gauge feeler at an angle of 90° with the gear teeth. 10. Lock the pinion.

11. Move the ring gear and record the clearance. Repeat this process three times to find the average clearance. NOTE: The value of the average clearance should be between 0.17 mm and 0.23 mm 12. To adjust the clearance, rotate the adjustment nuts (3) and (7) closer or further away from the pinion ring gear.

Adjust the ring nuts (3) and (7), remembering that: • “A” if the measured play is above the given tolerance range, unscrew nut (7) and tighten nut (3) by the same amount; • “B” if the measured play is below the given tolerance range, unscrew nut (3) and tighten nut (7) by the same amount.

47921938 07/02/2017

25.2 [25.102] / 33

Front axle system - Front bevel gear set and differential

Bearing preload of the ring gear and pinion 13. Apply lubricant oil to the bearings. Rotate the assembly so that the fluid lubricates the bearings. 14. Install a dynamometric scale on the pinion shaft.

LAIL11TT0082A0A

LAIL11TT0080A0A

15. Measure the dynamic swing torque of the ring gear and pinion assembly (T). T = (P + 58.0 N (13.0 lb)) ÷ (P + 87.0 N (19.6 lb)) CA144567. T = (P + 43.0 N (9.7 lb)) ÷ (P + 64.0 N (14.4 lb)) CA135403 - CA139788 Where P is the effectively measured pinion preload. NOTE: All preloads must be measured without the pinion retainer. 16. To adjust the preload, rotate the adjustment nuts (3) and (7). Proceed as follows: • “A” if the preload total is below the given range, tighten nuts (3) and (7) on the adjustment tool ring by the same amount, keeping the pinion-crown gear play value unchanged. • “B” if the preload total is above the given range, tighten both nuts by the same amount, keeping the pinion-crown gear play value unchanged.

17. Fit the fasteners (8) and the nuts (9). Apply the specified torque.

LAIL11TT0081A0A

47921938 07/02/2017

25.2 [25.102] / 34

Front axle system - Front bevel gear set and differential

18. Tighten the screws on both journals to the torque specified in Powered front axle - Torque (Narrow shaft) (25.100).

LAIL11TT0083A0A

LAIL11TT0084A0A

LAIL11TT0085A0A

19. Fit the fasteners (8) and the nuts (9). Apply the specified torque. 20. Install the guide pins (12) and (13) .

21. Install the differential assembly (1) on the front axle housing (14). Secure using the screws (2). Apply the specified torque.

Next operation: Differential housing - Gear tooth contact (Narrow shaft) (25.102).

47921938 07/02/2017

25.2 [25.102] / 35

Front axle system - Front bevel gear set and differential

Differential housing - Gear tooth contact (Narrow shaft) TT3840F TT3880F

LA LA

Prior operation: To fit the engine flywheel, see the procedures in Differential housing - Assemble - Narrow shaft (25.102).

Bevel gear marking test 1. To test the marks of the bevel gear teeth, paint the ring gear with red lead paint. The marking test should be always carried out on the ring bevel gear teeth and on both sides.

LAIL11TT0086A0A

LAIL11TT0087A0A

LAIL11TT0088A0A

OK » Correct contact: If the bevel gear is well adjusted, the mark on the teeth surfaces will be regular. Z » Excessive contact at the tooth tip: Bring the pinion to the ring bevel gear and then move the ring bevel gear away from the pinion in order to adjust the clearance. X » Excessive contact at the tooth base: Move the pinion away from the ring bevel gear and then bring the ring bevel gear to the pinion in order to adjust the clearance.

Movements to correct: 2. Move the pinion to adjust type “X” contact. 3. Move the pinion to adjust type “Z” contact.

47921938 07/02/2017

25.2 [25.102] / 36

Index Front axle system - 25 Front bevel gear set and differential - 102 Differential - Adjust (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Assemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Disassemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Exploded view (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Gear tooth contact - 4WD Ring/pinion adjustment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Preload (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Service instruction (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Service limits (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential Input shaft assembly - Assemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential Input shaft assembly - Disassemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential housing - Assemble - Narrow shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential housing - Disassemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential housing - Exploded view (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential housing - Gear tooth contact (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential lock - Sectional view (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

25.2 [25.102] / 37

47921938 07/02/2017

25.2 [25.102] / 38

Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

47921938 07/02/2017

25.3 [25.108] / 1

Contents Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

FUNCTIONAL DATA Steering knuckle and king pin Exploded view (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Steering knuckle and king pin Disassemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Assemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Replace - 4WD Steering knuckle pins and bearings (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Adjust (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

(*) See content for specific models 47921938 07/02/2017

25.3 [25.108] / 2

Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Exploded view (Narrow shaft) TT3840F TT3880F

LA LA

LAIL11TT0391F0A

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Lock ring Flat washer Flat washer Collet Fixing bolt Guide bushing Wheel flange Lock ring Bearing Cup Wheel hub Bearing Cup seal

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

Fixing bolt Top link pin Collet Bottom link pin Casing Bushing Retainer Bellville Washer Bellville Washer Half-shaft Stop nut Stop bolt

47921938 07/02/2017

25.3 [25.108] / 3

Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Disassemble (Narrow shaft) TT3840F TT3880F

LA LA

Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. See the exploded view of the assembly in Steering knuckle and king pin - Exploded view (Narrow shaft) (25.108). 1. Insert a lever between the housing (17) and the axle beam and fit it into the universal joint. With the lever, push the universal joint toward the wheel hub to enable removal of the lock ring (1). ATTENTION: Do not damage the universal joint.

LAIL11TT0509A0A

LAIL11TT0510A0A

LAIL11TT0511A0A

2. Pull the lock ring (1) off the universal joint shaft. Remove washers (2) and (3).

3. Remove the mounting bolts (5) from the hub assembly.

47921938 07/02/2017

25.3 [25.108] / 4

Front axle system - Final drive hub, steering knuckles, and shafts

4. To remove the hub (7), screw two of the newly removed bolts (4) into the threaded holes. 5. Remove the hub (7) and the planetary ring gear (4).

LAIL11TT0512A0A

LAIL11TT0513A0A

LAIL11TT0514A0A

LAIL11TT0515A0A

6. Remove the lock ring (8).

7. Only if necessary, remove the guide bushings (6) from the wheel flange (7) with a hammer and the special tool.

8. Remove the wheel hub (10) using levers and a hammer to facilitate the operation. NOTE: Remove the bearing cone (9).

47921938 07/02/2017

25.3 [25.108] / 5

Front axle system - Final drive hub, steering knuckles, and shafts

9. Position the wheel hub (10) on a flat surface. Remove bearing races (9) and (11) using a hammer and a suitable displacer.

LAIL11TT0516A0A

LAIL11TT0517A0A

10. Unscrew and remove the mounting bolts (13) from the upper (14) and lower (16) link pins. NOTICE: Before removing link pins (14) and (16), attach the housing (17) to a hoist or any other supporting device with a belt or a cord. Follow all current safety regulations to guarantee operator safety. 11. Remove link pins (14) and (16).

12. Remove the housing (17) from the axle beam and from the stub shaft of the universal joint. Remove Belleville washers (20) and (21).

LAIL11TT0518A0A

LAIL11TT0519A0A

13. Position the housing (17) on a flat surface and remove the seal ring (12) with a lever. NOTE: This operation destroys the retainer (12). Remove the bearing cone (11) from the end of the housing (17) using a suitable extractor.

47921938 07/02/2017

25.3 [25.108] / 6

Front axle system - Final drive hub, steering knuckles, and shafts

14. Position the housing (17) on a flat surface and remove the retainer (19) with a lever. NOTE: This operation destroys the seal ring. 15. Turn the housing and remove the bushing (18) using a suitable displacer and hammer.

LAIL11TT0520A0A

Next operation: For fitting the steering knuckle and king pin, see the procedures in Steering knuckle and king pin - Assemble (Narrow shaft) (25.108).

47921938 07/02/2017

25.3 [25.108] / 7

Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Assemble (Narrow shaft) TT3840F TT3880F

LA LA

Prior operation: Disassembly of the steering knuckle and king pin, see the procedures in Steering knuckle and king pin - Disassemble (Narrow shaft) (25.108). Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. See the exploded view of the assembly in Steering knuckle and king pin - Exploded view (Narrow shaft) (25.108). 1. If it has been previously removed, reassemble the steering stop comprising the bolt (24) and nut (23). NOTE: Do not tighten the nut (23) until you have adjusted the steering angle. See: Convergence â&#x20AC;&#x201C; Steering knuckle and king pin Adjust (25.108). LAIL11TT0061A0A

LAIL11TT0485A0A

LAIL11TT0062A0A

2. Mount the bushing (18) inside the housing (17) with special tool CA715104 and a hammer or a press. 3. Fit the retainer (19) in the housing (17) with special tool CA715402 and a hammer. Carefully grease the seal ring (19). See the technical characteristics in Powered front axle - General specification (Narrow shaft) (25.100).

4. Fit the retainer (12) in the housing (7) with special tool CA715367 and a hammer.

47921938 07/02/2017

25.3 [25.108] / 8

Front axle system - Final drive hub, steering knuckles, and shafts

If the cone (15) of the ball joint has previously been removed, fit it to the lower king pin (16) using special tool CA715451 under a press. Carefully grease the seats of the link pins (16) and (14) with the specific grease. See the technical characteristics in Powered front axle - General specification (Narrow shaft) (25.100). Place the Belleville washers (20) and (21) on the link pin seats.

LAIL11TT0486A0A

LAIL11TT0500A0A

LAIL11TT0501A0A

LAIL11TT0487A0A

5. NOTICE: Secure the housing (17) to a hoist or any other supporting device using a belt or a cord. 6. Protect the splined end of the axle shaft by winding it with an adhesive tape to avoid damage to the retainer (19). Fit the housing (17) on the axle beam. NOTE: Completely remove the adhesive tape.

7. Fit the lower (14) and upper (16) link pins, and tighten the mounting bolts (13) to the torque specified in Powered front axle - Torque (Narrow shaft) (25.100). NOTE: Ensure that the Belleville washers (20) and (21) remain in their positions.

8. Force both bearing cups (9) and (11) into their wheel hub housings (10) using the special tool under a press or with a hammer.

47921938 07/02/2017

25.3 [25.108] / 9

Front axle system - Final drive hub, steering knuckles, and shafts

9. Fit the bearing cone (11) on the end of the housing (17). 10. Mount the wheel hub (10) in the swivel housing (17) and fit the bearing cone (9).

LAIL11TT0488A0A

LAIL11TT0063A0A

11. Position the flange (7) on a workbench and use the special tool to fit the guide bushings (6) at the level of the flange surface.

NOTE: At least two bushings (diametrically opposed) should be set slightly higher than the flange surface level to be used as positioning pins.

LAIL11TT0497A0A

LAIL11TT0064A0A

12. First fit the flange and the (7) toothed crown gear (4) with the lock ring (8).

47921938 07/02/2017

25.3 [25.108] / 10

Front axle system - Final drive hub, steering knuckles, and shafts

13. Mount the flange assembly on the wheel hub using the two boss bushings (6) as positioning pins and tighten the corresponding bolts (5) to make contact between the bearings and the wheel hub.

LAIL11TT0489A0A

LAIL11TT0490A0A

LAIL11TT0065A0A

LAIL11TT0483A0A

14. Force all the hub bushings (6) all the way down with the special tool and a hammer. Apply sealant to the thread of the mounting bolts (5). Fit the mounting bolts (5) and tighten them to the torque specified in Powered front axle - Torque (Narrow shaft) (25.100).

15. The special “Set Right” operation for bearings (9) and (11) does not require preloading or play adjustment. Anyway, before assembling new components check the indicated dimensions. A = 11.975 – 12.025 mm B = 52.230 – 52.280 mm C = 20.000 – 20.100 mm

16. Insert a lever between the housing (17) and the axle beam and fit it into the universal joint. With the lever, push the universal joint toward the wheel hub to make it easier to insert the lock ring (1).

47921938 07/02/2017

25.3 [25.108] / 11

Front axle system - Final drive hub, steering knuckles, and shafts

17. Slide thrust washers (3) and (2) onto the end of the axle shaft (22). 18. Insert the lock ring (1) on the end of the sun gear and push it into its groove. NOTE: Check that the lock ring (1) is properly seated in the groove. Push the universal joint all the way down.

LAIL11TT0484A0A

47921938 07/02/2017

25.3 [25.108] / 12

Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Replace - 4WD Steering knuckle pins and bearings TT3840 TT4030

LA LA

In the event that the steering knuckle pins prove difficult to remove, proceed as follows. 1. Remove the grease nipples and the steering knuckle pin retaining bolts. 2. Install the bolts, (1), from tool number 380000265. 3. Install the plate, (2), from the tool and retain it to the three bolts with nuts, (3). 4. Install the central tie bolt, (4), screwing it fully into the grease nipple bore on the pin, (5). 5. Screw in the nut, (6), to drive the pin out of its bore.

20097690

20097691

6. Using extractor tool, tool number 380000234, (1), remove the steering knuckle bearings. 7. Re-install the steering knuckle bearings using a suitable drift.

47921938 07/02/2017

25.3 [25.108] / 13

Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Adjust (Standard shaft) TT3840 TT4030

LA LA

Install the front axle on a stand and proceed as follows. 1. Smear grease on the outer races of the bearings and fit the upper cover, without the adjustment plate, but with tool number 380000235, (1). Tighten the retaining bolts to a torque value of 64 N·m (47 lb ft).

20097692

20097693

20097694

2. Install the lower cover without adjustment plate, lubricate the three retaining bolts with oil. 3. Gradually tighten the lower cover bolts in sequence, while simultaneously rotating the casing to allow the excess grease to escape.

4. Using a torque wrench, tool number 380000235, (1), check that the torque required to rotate the casing is 2.9 N·m (25.7 lb in),without considering the peak starting value. If not, adjust by way of the lower cover bolts. 5. Measure the gap (H) created between the low cover and the casing in correspondence with the three bolts.

6. Calculate the average of the three measured values. The total thickness of the adjustment shims to be fitted under the lower cover is to be calculated as follows: S3= H If necessary, round up the value to the next 0.05 mm (0.002 in). 7. Partially unscrew the bolts of the lower cover, insert the shims and tighten the bolts to a torque value of 64 N·m (47 lb ft). 47921938 07/02/2017

25.3 [25.108] / 14

Front axle system - Final drive hub, steering knuckles, and shafts

8. After having rotated the casing a few times to allow the components to bed down, check that the torque necessary to rotate the casing is 2.9 NÂˇm (25.7 lb in) - 7.8 NÂˇm (69 lb in), without considering the initial peak torque. 9. If the torque value measured is greater than the prescribed value, increase the thickness of the shims, if the measured value is less than the prescribed value, reduce the thickness of the shims. 10. Install the grease nipples in the upper and lower covers and grease the assembly.

20097695

47921938 07/02/2017

25.3 [25.108] / 15

Index Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108 Steering knuckle and king pin - Adjust (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering knuckle and king pin - Assemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering knuckle and king pin - Disassemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering knuckle and king pin - Exploded view (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering knuckle and king pin - Replace - 4WD Steering knuckle pins and bearings (*) . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

25.3 [25.108] / 16

Front axle system - 25 Final drives - 310

47921938 07/02/2017

25.4 [25.310] / 1

Contents Front axle system - 25 Final drives - 310

FUNCTIONAL DATA Final drive Sectional view (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Exploded view (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Final drive Disassemble - Narrow axle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

(*) See content for specific models 47921938 07/02/2017

25.4 [25.310] / 2

Front axle system - Final drives

Final drive - Sectional view (Standard shaft) TT3840 TT4030

LA LA

Cross section of the stub shaft and front hubs

LAIL11TT0041G0A

S₃. C₄. C₅. C₆. C₇. 5. 9. 10. 11. 12.

Master pin bearing shim King pin bolt Stub axle bolt Lock nut for hub crown gear Bolt on final drive housing Half-shaft Journal fixing bolt Seal Master pin bearing Seal

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

Seal End-of-shaft bushing Spacer Thrust Washer Planetary shaft Planetary shim Sun gear

47921938 07/02/2017

25.4 [25.310] / 3

Front axle system - Final drives

NOTE: During assembly, apply sealant to the surfaces (X).

47921938 07/02/2017

25.4 [25.310] / 4

Front axle system - Final drives

Final drive - Exploded view (Narrow shaft) TT3840F TT3880F

LA LA

Epicyclic reduction gear group

LAIL11TT0226F0A

1. 2. 3. 4. 5. 6.

Plug Plug ring Fixing bolt Hub cap O-Ring Thrust Washer

7. 8. 9. 10 11.

Needle bearing Flat washer Pin Planetary Gears Lock ring

47921938 07/02/2017

25.4 [25.310] / 5

Front axle system - Final drives

Final drive - Disassemble - Narrow axle TT3840F TT3880F

LA LA

Disassembly 1. Drain the oil fully from the final drive. See the procedure in: Powered front axle - Change fluid (Narrow shaft) (25.100) 2. Remove the cap screws (3). 3. Remove the cover (4).

LAIL11TT0522A0A

LAIL11TT0523A0A

LAIL11TT0524A0A

4. Remove the ring (5).

Disassembling the gears from the reducer cover 5. Position the cover on a workbench. 6. Remove the lock ring (11) 7. Remove the pins (9) 8. Remove the planetary gears (10) 9. Remove the thrust washers (6) 10. Remove the needle bearings (7) and check their condition 11. Remove the flat washers (8)

Next operation: Final drive - Assemble (Narrow shaft) (25.310).

47921938 07/02/2017

25.4 [25.310] / 6

Front axle system - Final drives

Final drive - Assemble (Narrow shaft) TT3840F TT3880F

LA LA

Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. See the exploded view of the assembly in Final drive - Exploded view (Narrow shaft) (25.310). 1. Collect all the parts of the planetary reduction gear: the hub cover (4), the lock ring (11), the pins (9), the thrust washer (6), the planetary gear (10) with needle bearings (7) and flat washers (8). NOTE: Note: with new planetary gears (10) it is advisable to fit new needle bearings (7).

LAIL11TT0502A0A

LAIL11TT0480A0A

LAIL11TT0479A0A

LAIL11TT0481A0A

2. Position the hub cover (4) on a workbench. NOTE: Note: grease the needle bearings (7) thoroughly. Insert the flat washers (8) and the needle bearings (7) into the epicyclic gears (10). Fit the thrust washers (6) onto the planetary gears (10). Insert the planetary gears inside the hub cover (4).

3. Insert the pins (10). 4. Assemble the lock ring (11). NOTE: Check that the lock ring (11) is correctly fitted in its seat.

5. Fit a new O-ring (5) on the wheel hub (1). Assemble the epicyclic reduction gear on the wheel hub.

47921938 07/02/2017

25.4 [25.310] / 7

Front axle system - Final drives

6. Attach the bolts (3) and tighten them to the torque specified in Powered front axle - Torque (Narrow shaft) (25.100).

LAIL11TT0482A0A

LAIL11TT0496A0A

Top up the oil in the wheel hub. See the information about oil changes in Powered front axle - Change fluid (Narrow shaft) (25.100). Fit the oil plug (1) on the hub cover (4) and tighten to the torque specified in Powered front axle - Torque (Narrow shaft) (25.100).

47921938 07/02/2017

25.4 [25.310] / 8

Index Front axle system - 25 Final drives - 310 Final drive - Assemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive - Disassemble - Narrow axle (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive - Exploded view (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive - Sectional view (Standard shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

25.4 [25.310] / 9

47921938 07/02/2017

25.4 [25.310] / 10

Front axle system - 25 Non-powered front axle - 400

47921938 07/02/2017

25.5 [25.400] / 1

Contents Front axle system - 25 Non-powered front axle - 400

TECHNICAL DATA Non-powered front axle General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sealing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Non-powered front axle Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Axle support Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Axle wheel hub Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Non-powered front axle Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Toe in adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Axle wheel hub Remove - 2WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

DIAGNOSTIC Non-powered front axle Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

(*) See content for specific models 47921938 07/02/2017

25.5 [25.400] / 2

CONSUMABLES INDEX Consumable Loctite® 638™ Loctite® 638™

Reference Non-powered front axle - Sealing Non-powered front axle - Sealing

47921938 07/02/2017

25.5 [25.400] / 3

PAGE 25.5 / 6 25.5 / 6

Front axle system - Non-powered front axle

Non-powered front axle - General specification TT3840

TT3840

Component Type Tread settings Wheel camber Wheel toe-in Swivel pin assembly Diameter of the bushings of the swivel pin (3) Pressed bushing (4) internal diameter Clearance between the swivel pin and the bushing Fitting the pivot pin Diameter of the pivot pin Internal diameter of the pressed bushing Clearance between the pivot pin and the bushing Thrust washer thickness Thickness of the steel washer

TT4030 Measurement U-profile center pivot – center beam with telescopic end sections 1390 mm – 1490 mm – 1590 mm – 1690 mm – 1790 mm – 1890 mm 2° Corresponds approximately to 15 mm with 16 in rims 0 – 5 mm 37.96 mm / 38.00 mm 38.05 mm / 38.14 mm 0.05 mm / 0.179 mm 37.96 mm / 38.00 mm 38.05 mm / 38.14 mm 0.05 mm / 0.179 mm 3.935 mm / 4.065 mm 3.925 mm / 4.00 mm

Refer to the references in Axle support - Sectional view (25.400).

Non-powered front axle - Torque TT3840

47921938 07/02/2017

25.5 [25.400] / 4

Front axle system - Non-powered front axle

LAIL11TT0002G0A

Description Bolt, front axle support to engine (C₁) Bolt, pivot shaft (C₂) Bolt, wheel to hub (C₃) Nut, steering adjustment, ball joint (C₄) Nut, RH and LH control lever (C₅) Bolts securing the axle extension (C6)

Thread size M18 x 1.5 M10 x 1.25 M18 x 1.5 M14 x 1.5 M14 x 1.5 M16 x 1.5

Non-powered front axle - Special tools TT3840

Tool description Slide hammer for center pin Adapter for slide hammer

Tool no. 292927 290793

47921938 07/02/2017

25.5 [25.400] / 5

Torque 320 N·m 60 N·m 320 N·m 100 N·m 150 N·m 118 N·m

Front axle system - Non-powered front axle

Non-powered front axle - Sealing TT3840

Operation description Front wheel hub bushing Thrust washer of the main pin

Specification LOCTITE® 638™ LOCTITE® 638™

47921938 07/02/2017

25.5 [25.400] / 6

Front axle system - Non-powered front axle

Non-powered front axle - Dynamic description TT3840

Description and operation The front axle is composed of an inverted U-type center beam (2) with telescopic sections (1) at each end. A number of holes at intervals of 50 mm (2.0 in) are provided on the telescopic sections to adjust the tread. You can adjust the tread setting for the front wheels equally on both ends. The center beam is fixed to the front axle housing by means of a single pivot shaft which allows oscillation on both sides. The front axle is controlled by assisted/manual steering by means of a lever for controlling the swivel pin. The two swivel pins are connected by control bars with telescopic rails, which have toe-in adjustment.

47921938 07/02/2017

25.5 [25.400] / 7

Front axle system - Non-powered front axle

Axle support - Sectional view TT3840

BRAG12TRLUE0345

TT4030

BRAG12TRLUE0343

TT3840 1. Grease fitting 2. Pivot shaft bushing 3. Axle pivot pin

4. Front axle housing 5. Keeper 6. Thrus washer

47921938 07/02/2017

25.5 [25.400] / 8

Front axle system - Non-powered front axle

Axle wheel hub - Sectional view TT3840

LAIL11TT0179F0A

1. 2. 3. 4.

Retainer assembly Retainer assembly Thrus washer Thrus washer

5. 6. 7.

Retainer anti-dust collar Retainer lower anti-dust collar Retainer upper anti-dust collar

47921938 07/02/2017

25.5 [25.400] / 9

Front axle system - Non-powered front axle

LAIL11TT0393A0A

1. 2. 3.

Inner bearing Outer bearing Hub cap

4. 5. 6.

Hexagonal nut Washer O-ring

47921938 07/02/2017

25.5 [25.400] / 10

Front axle system - Non-powered front axle

Non-powered front axle - Remove TT3840

Remove the front axle assembly as follows: 1. Open and raise the front hood. 2. Disconnect the negative cable (1) from the battery and insulate the cable.

BRAG12TRLUE0356

LAIL11TT0408A0A

LAIL11TT0409A0A

3. Lock the rear wheels. 4. Remove the front weights (1) and support for the weights (2), if installed.

5. Lift the front of the tractor and place a fixed stand (1) beneath the engine crankcase.

47921938 07/02/2017

25.5 [25.400] / 11

Front axle system - Non-powered front axle

6. Loosen the retaining bolts (1) and remove the front wheels.

LAIL11TT0410A0A

LAIL11TT0411A0A

LAIL11TT0412A0A

LAIL11TT0413A0A

7. Remove the linkage joint nut (1) and disconnect the suspension arm (2) of the control lever.

8. Loosen nuts (2) and (3). Remove the hydraulic cylinder (1).

9. Remove the retaining bolt from the axle pivot pin (1).

47921938 07/02/2017

25.5 [25.400] / 12

Front axle system - Non-powered front axle

10. Using a pulley extractor (special tool no. 292927) with an adapter (special tool no. 292927), remove the pivot pin (1). Retrieve the thrust washers and shims between the center beam and axle housing. 11. Remove the front axle from the tractor using a suitable hoist.

LAIL11TT0470A0A

Next operation: To remove the front axle, see the procedures in Non-powered front axle - Disassemble (25.400).

47921938 07/02/2017

25.5 [25.400] / 13

Front axle system - Non-powered front axle

Non-powered front axle - Disassemble TT3840

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: To remove the non-powered front axle, see the procedures in Non-powered front axle - Remove (25.400).

Axle-end assembly You can remove and service the swivel pins with the front axle on the tractor. Proceed as follows for each wheel: 1. Lock the rear wheels. 2. Lift the front of the tractor and place a fixed stand (1) beneath the crankcase.

LAIL11TT0159A0A

LAIL11TT0192A0A

LAIL11TT0193A0A

3. Loosen the retaining bolts and remove the front wheels.

4. Remove the retaining pin from the control lever for the swivel pin (1). 5. Remove the control lever (2) from the swivel assembly.

47921938 07/02/2017

25.5 [25.400] / 14

Front axle system - Non-powered front axle

6. Remove the swivel axle and the hub assembly (1) from the axle outer section.

LAIL11TT0160A0A

LAIL11TT0194A0A

LAIL11TT0161A0A

7. Loosen the bolts that are securing the axle outer section (1).

8. Remove the axle outer section (1).

Next operation: To overhaul the components of the non-powered front axle, see the procedures in Non-powered front axle - Check (25.400).

47921938 07/02/2017

25.5 [25.400] / 15

Front axle system - Non-powered front axle

Non-powered front axle - Check TT3840

Prior operation: To disassemble the non-powered front axle, see the procedures in Non-powered front axle - Disassemble (25.400). 1. Secure the axle outer section in a vise. Remove the upper retainer using a suitable tool.

LAIL11TT0162A0A

LAIL11TT0163A0A

2. Remove the lower retainer using a suitable tool and retrieve the thrust washer. 3. Check the swing bearing bushings for wear. See specifications in Non-powered front axle - General specification (25.400). If the bushing requires replacing, remove the bushing using a suitable tool. 4. Using a suitable punch, install the new bushing on the axle outer section. 5. Check the swing pin for wear. If necessary, replace the axle end. 6. Ream the new bushing to fit the swing pin.

Next operation: To assemble the non-powered front axle, see the procedures in Non-powered front axle - Assemble (25.400).

47921938 07/02/2017

25.5 [25.400] / 16

Front axle system - Non-powered front axle

Non-powered front axle - Assemble TT3840

Prior operation: To overhaul the components of the non-powered front axle, see the procedures in Non-powered front axle - Check (25.400). 1. Re-install the axle end assembly onto the front axle by following the disassembly procedure in reverse order. NOTE: Ensure that the groove (1) on the thrust washer fits into the fly on the outer section of the axle.

LAIL11TT0164A0A

Next operation: To install the non-powered front axle, see the procedures in Non-powered front axle - Install (25.400).

47921938 07/02/2017

25.5 [25.400] / 17

Front axle system - Non-powered front axle

Non-powered front axle - Install TT3840

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: To mount the non-powered front axle, see the procedures in Non-powered front axle - Assemble (25.400) .

Installation Fit the front axle assembly in the housing. Observe the following: 1. Installation follows the removal procedure in reverse from step 10 to step 1. 2. Check the clearance of the pivot pin. The clearance must not exceed 0.25 mm. If the clearance is greater, add shims between the center beam and the axle housing. 3. Tighten all the fixings to the correct torques detailed in Non-powered front axle - Torque (25.400). Next operation: To adjust the wheel toe-in, see the procedures in Non-powered front axle - Toe in adjust (25.400).

47921938 07/02/2017

25.5 [25.400] / 18

Front axle system - Non-powered front axle

Non-powered front axle - Toe in adjust TT3840

Wheel tilt test Check the front wheel tilt. Take into account that when the tractor moves along a straight line, the wheels must be at an angle of 2° from the ground. This corresponds to a difference “X” of approximately 15 mm between the edges of the rims.

LAIL11TT0394A0A

LAIL11TT0395A0A

LAIL11TT0396A0A

Front Wheel Toe–in Test When the tractor is moving in a straight line, the wheels must be parallel to the center line of the tractor or slightly toed-in. The maximum toe-in is 0.5 mm, measured between the edges of the rims.

Toe-in checking procedure: 1. Fill the front wheels to a pressure of 25 psi. 2. Place the steering wheels in the straight-ahead position, with the radius of the wheel along the centerline of the tractor. 3. Check that the wheels are parallel to the center line of the tractor. 4. Measure the distance “B” between the inside of the wheel rims at hub height and the front of the tires. 5. Measure the distance between the inside of the wheel rims at hub height and the rear of the wheels. The measurement taken must be equal to “B” or up to a maximum of 5 mm more. 6. If necessary, adjust the toe-in of the front wheels as follows: 7. Loosen the clamp (1) at both ends of the tread control bar. 8. Rotate the tread control bar (2) to increase or decrease the length of the tread control bar. Do this until you achieve a toe-in of 0.5 mm. 9. Tighten the clamp (1). 47921938 07/02/2017

25.5 [25.400] / 19

Front axle system - Non-powered front axle

Axle wheel hub - Remove - 2WD TT3840

Wheel hubs can be removed with the front axle on the tractor. Proceed as follows for each hub: 1. Safely block rear wheels. 2. Use a floor jack to raise the front of the tractor and place a stationary stand, (1), under the sump.

20097801

20099931

20096266

3. Loosen retaining bolts, (1),and remove front wheels.

4. Remove wheel hub bearing grease cup, (1).

47921938 07/02/2017

25.5 [25.400] / 20

Front axle system - Non-powered front axle

5. Remove the cotter pin, (1).

20096267

20096268

20096269

20096270

6. Using the socket spanner loosen the wheel hub bearing. Remove castle nut.

7. Remove wheel hub, (1), and recover bearing, (2), and (3).

8. Remove seal, (1), and nyloc ring, (2), using suitable tool.

47921938 07/02/2017

25.5 [25.400] / 21

Front axle system - Non-powered front axle

Next operation: When fitting the wheel hub, see the procedures in Axle wheel hub - Install (25.400).

47921938 07/02/2017

25.5 [25.400] / 22

Front axle system - Non-powered front axle

Axle wheel hub - Install TT3840

Prior operation: To remove the wheel hub, see the procedures in Axle wheel hub - Remove - 2WD (25.400). 1. Replace faulty seals and worn bearing using suitable pullers and drifts. 2. Fill the wheel hub with specified grease. 3. Re-assemble the wheel hub, (1), complete with the bearings, (2), and (3). NOTE: Image is for reference only.

20096269

20096271

20096267

4. Using a torque wrench, (1), and socket spanner, (2), tighten the castle nut while turning the wheel hub, to settle the bearing. Tighten the nut until wheel hub gets slightly tight to rotate. 5. Loosen the castle nut and torque it again to 9.8 NÂˇm (7.2 lb ft) continuing to turn the wheel hub.

6. Insert a new cotter pin, (1).

47921938 07/02/2017

25.5 [25.400] / 23

Front axle system - Non-powered front axle

7. Reassemble the wheel hub dust cap, (1). NOTE: Check the O-ring provided on the dust cap for any cut or damage. If required replace the O-ring.

20096272

20099931

8. Reinstall the front wheels and torque the hardware to 333 N·m (246 lb ft) ± 19 N·m (14 lb ft) 9. Remove jack and/or stands from underneath the tractor.

47921938 07/02/2017

25.5 [25.400] / 24

Front axle system - Non-powered front axle

Non-powered front axle - Troubleshooting TT3840

Problem Premature tyre wear

Possible Cause Incorrect inflation pressure Incorrect front wheel toe-in.

Low tractor stability

Incorrect inflation pressure

47921938 07/02/2017

25.5 [25.400] / 25

Correction Fill the front tires to the specified pressure. Pay attention to the pressure specified by the tire manufacturer. Adjust the tire toe-in as per the procedures described in Non-powered front axle Toe in adjust (25.400). Fill tires to correct pressure

Index Front axle system - 25 Non-powered front axle - 400 Axle support - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle wheel hub - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle wheel hub - Remove - 2WD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle wheel hub - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Sealing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Toe in adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

25.5 [25.400] / 26

47921938 07/02/2017

25.5 [25.400] / 27

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

47921938 07/02/2017 EN

SERVICE MANUAL Rear axle system TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017

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

47921938 07/02/2017

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

518 518 270 518 518 270 518™ 270 242® 518™

Reference Powered rear axle - Sealing Powered rear axle - Sealing Powered rear axle - Sealing Powered rear axle - Sealing Powered rear axle - Sealing Powered rear axle - Sealing Rear axle housing - Install Differential - Assemble Differential - Adjust Ring gear bearings Planetary and final drives - Sealing

47921938 07/02/2017

PAGE 27.1 / 6 27.1 / 6 27.1 / 6 27.1 / 6 27.1 / 6 27.1 / 6 27.1 / 16 27.2 / 22 27.2 / 32 27.3 / 6

47921938 07/02/2017

Rear axle system - 27 Powered rear axle - 100

47921938 07/02/2017

27.1 [27.100] / 1

Contents Rear axle system - 27 Powered rear axle - 100

TECHNICAL DATA Powered rear axle General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sealing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Powered rear axle Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Rear axle housing Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

DIAGNOSTIC Powered rear axle - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

(*) See content for specific models 47921938 07/02/2017

27.1 [27.100] / 2

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

518 518 270 518 518 270 518™

47921938 07/02/2017

27.1 [27.100] / 3

PAGE 27.1 / 6 27.1 / 6 27.1 / 6 27.1 / 6 27.1 / 6 27.1 / 6 27.1 / 16

Rear axle system - Powered rear axle

Powered rear axle - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Specifications Bevel drive and differential Component Bevel drive ratio Beveled pusher play Differential Differential lock (mm) Internal diameter of differential pinion Diameter of the differential pinion journal Differential pinion clearance on journal Diameter of the housing for the side gear hub on the differential case Side gear hub diameter Clearance for side gear hub in the case Bevel pinion bearing shim thickness availability

TT3840

TT3840F TT3880F 14/47 = 1:3.35 0.15 – 0.20 mm 2 mm pinions Pedal–controlled 24.040 – 24.061 mm 23.939 – 23.960 mm 0.080 – 0.122 mm

TT4030

44.080 – 44.119 mm 43.961 – 44.000 mm 0.080 – 0.158 mm 1.0 mm – 1.05 mm – 1.10 mm – 1.15 mm – 1.20 mm – 1.40 mm – 1.50 mm – 1.70 mm – 1.75 mm – 1.85 mm – 1.90 mm – 1.95 mm – 2.0 mm – 2.10 mm – 2.2 mm Bevel pinion bearing shim thickness availability 1.0 mm – 1.05 mm – 1.10 mm – 1.15 mm – 1.20 mm – 1.40 mm – 1.50 mm – 1.70 mm – 1.75 mm – 1.85 mm – 1.90 mm – 1.95 mm – 2.0 mm – 2.05 mm – 2.10 mm – 2.2 mm 0.15 mm Differential pinion play and side gear play 1.5 – 1.6 mm Availability of thrust washer thickness on side gear Thrust washer thickness for differential pinion 1.5 mm Side gear end float adjustment Differential lock fork spring length 188 mm free with 28.5 – 31.5 kg load 126.5 mm

Powered rear axle - Torque TT3840F TT3840 TT3880F TT4030

Description Self-locking nuts for Bolts securing ring gear, (C1) Nut locking bevel pinion shaft, (C2) Bolts securing differential assembly/bearing supports, (C3) Bolts securing differential lock pedal bracket, (C4) Bolts securing final drive housing to rear wheel drive housing, (C5) Bolts securing mechanical lift housing on rear wheel drive housing, (C6)

LA LA LA LA

Thread size

Torque

M12 x 1.25

85 N·m (63 lb ft)

M40 x 13

300 N·m (221 lb ft)

M10 x 1.25

60 N·m (44 lb ft)

M12 x 1.25

75 N·m (55 lb ft)

M12 x 1.50

85 N·m (63 lb ft)

M14 x 1.50

136 N·m (100 lb ft)

47921938 07/02/2017

27.1 [27.100] / 4

Rear axle system - Powered rear axle

20098873

47921938 07/02/2017

27.1 [27.100] / 5

Rear axle system - Powered rear axle

Powered rear axle - Sealing TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Operation Description Final drive housing to rear wheel drive housing, (S1) PTO rear cover plate, (S2) Ring gear bolts Mechanical lift housing to rear wheel drive housing, (S3) Transmission top cover, (S4) Locking plate allen screws

Sealant Specification LOCTITE® 518 LOCTITE® 518 LOCTITE® 270 LOCTITE® 518 LOCTITE® 518 LOCTITE® 270

20098904

Powered rear axle - Special tools TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Special tools Tool description Sling hook, gear box Pinion bearing installer and extractor Bearing adjuster for the bevel pinion Tool for adjustment of the mounting distance Spring scales, pre-loading of ring gear pinion from ring gear-pinion assembly Wrench, bevel pinion nut Pinion Locking Tool 47921938 07/02/2017

27.1 [27.100] / 6

No. of the tool 291517 292911 293101 293400 82834306 293342 9971366

Rear axle system - Powered rear axle

Tool description Spring compressor for the differential lock

No. of the tool 290870

47921938 07/02/2017

27.1 [27.100] / 7

Rear axle system - Powered rear axle

Powered rear axle - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Rear wheel drive assembly transfers drive from the transmission to the outboard final drive through a bevel pinion and ring gear coupling. The bevel gears are spiral type, supported by roller bearings. The differential is fitted with two planetary, two side gears and a mechanical lock. The differential lock is operated by foot pedal located below operatorâ&#x20AC;&#x2122;s seat at right hand side. The differential is necessary on tractors, to permit steering without wheelslip consequent to the different wheel speeds.

47921938 07/02/2017

27.1 [27.100] / 8

Rear axle system - Powered rear axle

Rear axle housing - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

To remove the rear wheel drive housing the final drive housing, mechanical lift assembly, ROPS, fenders, three point linkage, draw bars and PTO assemblies have to be removed. Proceed as follows: 1. Detach the negative cable, (1), from the battery and insulate.

BRAG12TRLUE0356

20098948

2. Remove guard and detach rear electric connections, (1), under rear hood.

47921938 07/02/2017

27.1 [27.100] / 9

Rear axle system - Powered rear axle

3. Detach electric connections, (1), for left-hand fender. 4. Detach electric connections for brake switch below right-hand platform. 5. Remove the electric cables from the transmission and rear wheel drive housing.

20093437

20093438

20098688

20098867

6. Loosen the bolts, (1), and remove operator seat.

7. Remove three point linkages, (1), from the tractor.

8. Loosen the nuts, (1), and remove the ROPS and both left-hand and right-hand fenders from the tractor.

47921938 07/02/2017

27.1 [27.100] / 10

Rear axle system - Powered rear axle

9. Remove both left-hand and right-hand foot rest, (1), from the tractor. NOTE: Disconnect foot accelerator linkage before removing right-hand foot rest.

20098947

20098695

20093443A

10. Loosen Mechanical lift housing bolts, (1), disconnect vent lines, (2), and remove housing using a suitable hoist.

11. Place the wedges at front and back on both sides of the front tires. 12. Drain oil from the transmission housing. 13. Jack up rear tractor and place two suitable stands, (1), under the transmission housing to raise the wheels off the ground. 14. Position a suitable splitting trolley under the tractor supporting transmission housing and rear wheel drive housing.

15. Remove both left and right side wheels.

20093444

47921938 07/02/2017

27.1 [27.100] / 11

Rear axle system - Powered rear axle

16. Disconnect all hydraulic connections to remote control valve and remove remote control valve. NOTE: If remote control valve is not fitted, then disconnect pipe connecting pump and mechanical lift housing.

20099010

20098777

20098876

20098871

17. Wrap suitable chain on the final drive housing, (1), and connect it to a hoist. Loosen attaching bolts and remove the entire final drive. 18. Repeat for the final drive housing on the other side.

19. Remove circlip, (1), and disconnect clutch pedal linkages, (2).

20. Remove the brake pedal and the brake links as per the procedures described in Brake control pedals and shafts - Remove Brake pedals and external linkages (33.120). 21. Connect the rear wheel drive housing, (1), to a suitable hoist using chain with hooks, (2). 22. Loosen the bolts and nuts securing the rear wheel drive housing to transmission housing and detach slowly with all due care to avoid damaging the PTO drive shaft. Place the housing on a flat wooden surface or mount it on rotary stand.

23. Remove the PTO housing as per the procedures described in Front drive shaft - Remove PTO Shaft Assembly (31.114). 47921938 07/02/2017

27.1 [27.100] / 12

Rear axle system - Powered rear axle

Next operation: Rear axle housing - Inspect (27.100).

47921938 07/02/2017

27.1 [27.100] / 13

Rear axle system - Powered rear axle

Rear axle housing - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: When removing the drive housing on the rear wheel, see the procedures in Rear axle housing - Remove (27.100). 1. Clean all parts in a suitable solvent and allow to air dry. 2. Check all parts for damage or excessive wear. Repair replace as required. Next operation: When fitting the drive housing on the rear wheel, see the procedures in Rear axle housing - Install (27.100).

47921938 07/02/2017

27.1 [27.100] / 14

Rear axle system - Powered rear axle

Rear axle housing - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Rear axle housing - Inspect (27.100) 1. Reinstall the PTO assembly into the rear wheel drive housing as described in Front drive shaft - Install PTO Shaft Assembly (31.114). 2. Connect the rear wheel drive housing, (1), to a suitable hoist using chain with hooks, (2). NOTE: Before reassembling housings, supports, and covers, thoroughly clean and degrease mating surfaces. 3. Replace the two gaskets between the transmission and rear axle housing. 4. Carefully join the rear wheel drive housing to the transmission housing slowly, taking care to avoid damaging the PTO drive shaft. 5. Secure the two housings together using the M12 x 60 mm bolts, the M12 x 40 mm bolts and the M12 washers and nuts. Tighten to a torque of 75 NÂˇm (55 lb ft).

20098871

20098876

6. Reinstall the brake linkage and brake pedals. Consult the procedures in Brake control pedals and shafts Assemble (33.120). 7. Reconnect the clutch pedal linkage, (1), and secure with circlip, (2).

47921938 07/02/2017

27.1 [27.100] / 15

Rear axle system - Powered rear axle

8. Insert a single brake disk, (1), allowing it to rest on the ears of the differential bearing support, (2).

20098778

20098408

20097446

9. Insert brake disc alignment arbor, (1), (Special Tool No.380002743) through brake discs and stators, (2), into the differential unit splines.

10. Press brake pedals to engage actuator plates, and set the parking brake, (1). 11. Remove brake disc alignment arbor (Special Tool No.380002743), from within the rear wheel drive housing.

NOTICE: Before reinstalling the rear axle housing, thoroughly clean and degrease mating surfaces. 12. Apply a bead of LOCTITEÂŽ 518â&#x201E;˘ sealant, approximately 2 mm (0.079 in) in width following the pattern shown. Refer to Powered rear axle - Sealing (27.100).

47921938 07/02/2017

27.1 [27.100] / 16

Rear axle system - Powered rear axle

13. Place brake disc, (1), and stator, (2), onto axle shaft, (3).

20098409

20098777

20099010

14. Wrap a suitable chain, (1), or nylon strap around the final drive housing, (2). Carefully insert the final drive housing into the rear wheel drive housing, making sure the axle shaft and the brake discs are all properly aligned and inserted into the splined differential unit. 15. Start the M12 x 90 mm bolts through the final drive housing into the rear wheel drive housing, for alignment purposes. 16. Release the parking brake to allow the brake actuator to disengage. 17. Using a thin screw driver, hold the outer brake disc and stator into position. Work the final drive housing into the rear wheel drive housing, until fully seated. 18. Secure the final drive housing, (2), to the rear wheel drive housing using M12 x 45 mm retaining bolts, M12 nuts and flat washers. Torque all hardware to 85 NÂˇm (63 lb ft) NOTE: After securing the final drive housing, ensure that the axle hub moves freely. If axle hub does not move freely, remove the final drive housing and check for proper brake installation. 19. Reinstall rear remotes on the tractor, connect all hydraulic connections and control linkage.

47921938 07/02/2017

27.1 [27.100] / 17

Rear axle system - Powered rear axle

20. Reinstall rear wheels, (1), onto tractor. Torque bolts to 260 N·m (191.8 lb ft). 21. Jack up the rear of the tractor, and remove jack stands.

20093444

22. Reattach the Mechanical lift housing, (1), atop the rear wheel drive housing, using the M14 x ..50, (2), and the M14 nuts. Torque all hardware to 136 N·m (100 lb ft) 23. Reconnect the vent line, (3).

20098695

20098867

20098947

24. Reinstall left and right side fenders and ROPS onto tractor. Torque ROPS hardware, (1), to 157 – 193 N·m (116 – 142 lb ft).

25. Reinstall the left and right side platforms, (1), to the fender. Tighten all hardware. NOTE: Reconnect the throttle pedal to the right-hand platform.

47921938 07/02/2017

27.1 [27.100] / 18

Rear axle system - Powered rear axle

26. Reconnect the three point linkage, and check chains, (1), to the final drive housing.

20098688

20093437

20098948

27. Reattach the electrical connectors, (1), between the left and right side fenders. 28. Reattach the electrical connector to the brake switch below the right side platform.

29. Reconnect the rear electrical connection, (1), under the console. 30. Reconnect the negative (-) battery to the negative (-) battery post.

47921938 07/02/2017

27.1 [27.100] / 19

Rear axle system - Powered rear axle

Powered rear axle - Troubleshooting TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Problem Possible Cause Noisy rear axle when the Pinion and/or crown wheel bearing poorly tractor is moving and adjusted also when transmission in neutral (not originating from final drives) Excess differential side gears to half - shaft spline backlash Excess bevel pinion to crown wheel backNoisy rear axle with lash tractor under load and upon release Fault or defective inner components

Correction Remove the rear axle housing and adjust the pinion and ring gear bearings correctly.

Remove the rear axle housing and replace the damaged parts. Remove the rear axle housing and adjust the bevel pinion and ring gear bearings correctly. Remove the rear axle housing, replace the worn parts and adjust the differential gear play correctly. Noisy rear axle with over - Insufficient pinion and/or crown wheel Remove the rear axle housing and adjust the bevel pinion and ring gear bearings corheating bearing backlash rectly. Insufficient bevel pinion to crown wheel Remove the rear axle housing and adjust the ring gear bearings correctly. tooth backlash

47921938 07/02/2017

27.1 [27.100] / 20

Index Rear axle system - 27 Powered rear axle - 100 Powered rear axle - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered rear axle - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered rear axle - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered rear axle - Sealing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered rear axle - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered rear axle - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear axle housing - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear axle housing - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear axle housing - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

27.1 [27.100] / 21

47921938 07/02/2017

27.1 [27.100] / 22

Rear axle system - 27 Rear bevel gear set and differential - 106

47921938 07/02/2017

27.2 [27.106] / 1

Contents Rear axle system - 27 Rear bevel gear set and differential - 106

FUNCTIONAL DATA Bevel gear Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Differential Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Differential lock Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Bevel gear Preload (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Backlash (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Differential Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassemble Pinion shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Inspect Pinion shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Assemble Pinion shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Backlash (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Adjust Ring gear bearings (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

(*) See content for specific models 47921938 07/02/2017

27.2 [27.106] / 2

CONSUMABLES INDEX Consumable Loctite® 270 Loctite® 242®

Reference Differential - Assemble Differential - Adjust Ring gear bearings

47921938 07/02/2017

27.2 [27.106] / 3

PAGE 27.2 / 22 27.2 / 32

Rear axle system - Rear bevel gear set and differential

Bevel gear - Sectional view TT3840F TT3840 TT3880F TT4030

LA LA LA LA

BRAG12TRLUE0359

Outside the tractor. Two-wheel drive tractors

BRAG12TRLUE0360

Outside the tractor. Four wheel drive tractors.

47921938 07/02/2017

27.2 [27.106] / 4

Rear axle system - Rear bevel gear set and differential

BRAG12TRLUE0361

Inside the tractor. C. H1. and H2. C. D. 1. 2. 3. 4. 5.

Cross sectional view of special tool 380002737 inside differential housing Distance to measure using depth guage Locknut Adjustment tool 380002737 Bearing inner ring Spacer Bearing inner ring Front axle driven gear Transmission housing

47921938 07/02/2017

27.2 [27.106] / 5

Rear axle system - Rear bevel gear set and differential

Differential - Sectional view TT3840F TT3840 TT3880F TT4030

LA LA LA LA

20098880

1. 2. 3. 4. 5. 6. 7. 8. 9.

Cap screw Ring gear Differential pinion shaft Spring Differential lock shift fork Differential lock sliding sleeve Bevel pinion Taper roller bearing Taper roller bearing

10. 11. 12. 13. 14. 15. 16. 17. 18.

Differential support Taper roller bearing Thrust washer Differential pinion Thrust washer Side gear Differential housing Taper roller bearing Differential support

47921938 07/02/2017

27.2 [27.106] / 6

Rear axle system - Rear bevel gear set and differential

Differential lock - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

In normal conditions, owing to the effect of the differential , the two driving wheels of the tractor are stressed by two driving torques of the same intensity. In practice, the wheels may have different adhesion conditions and different loads. Then if equal torque is applied, the wheel in worse condition of adhesion slips (or slips more than the other), thereby reducing intensity of the tractive effort and its overall efficiency. To overcome this situation, it is necessary to lock the differential. For this tractors incorporate a differential lock on the rear wheel. The device pedal controlled, locks the axle shafts of the driving wheels together through the displacement of the sleeve.

47921938 07/02/2017

27.2 [27.106] / 7

Rear axle system - Rear bevel gear set and differential

Bevel gear - Preload TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Adjustment and setting Pinion Shaft Pre-loading Calculation of clearance adjustment shims for pinion shaft bearings: 1. Fit special tool No. 293101 into a vise and insert the pinion bearings (1) and the spacer (2). 2. Tighten the nut (1) by hand and measure dimension H1 using a depth gauge.

LAIL11TT0108A0A

LAIL11TT0109A0A

LAIL11TT0110A0A

3. Remove the spacer (1) from the tool and fit the tool in the rear axle housing with only the bearings. 4. Tighten the nut again by hand and measure the H2 dimensions using depth gauge.

5. The shim thickness Sp for clearance adjustment can be calculated by the following formula: Sp = H2 - H1 + 0.05 where 0.05 is the increase required to compensate for the preloading of the bearings. 6. You should add the calculated thickness shim (1) to the pinion shaft at the location shown in the figure 9.

47921938 07/02/2017

27.2 [27.106] / 8

Rear axle system - Rear bevel gear set and differential

Adjusting the pinion position 1. Without disturbing special tool No. 293101, already fitted into the housing, slot special tool No. 293400 into the rear wheel drive housing. 2. Measure dimension H5 (distance between the pinion bearing cone and the ring gear center locking tool).

LAIL11TT0111A0A

LAIL11TT0188A0A

3. Establish the correct nominal dimension H6 using formula H6 = H + C where H = 128 mm (standard) C = compensation dimension stamped on the piston. 4. Calculate the thickness of clearance adjustment shim â&#x20AC;&#x2DC;Sâ&#x20AC;&#x2122; using the formula S = H5 - H6. 5. Shims of the calculated thickness (1) should be added to the pinion shaft at the location shown in Figure 11.

47921938 07/02/2017

27.2 [27.106] / 9

Rear axle system - Rear bevel gear set and differential

Bevel gear - Adjust TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Adjustment of the preload of the tapered drive axle bearing See the references for the calls in Bevel gear - Sectional view (27.106). NOTE: Tool 380002737 sets the preload with an internal spring, but the rolling torque should be 0.8 N·m (7 lb in). Continue to adjust the bevel pinion bearing and calculate the shim thickness using tool 380002737. Image 1: procedure for the outside of the tractor. Twowheel drive tractors. Image 2. Procedure for the outside of the tractor. Fourwheel drive tractors. Image 3. Procedure for inside the tractor. 1. Attach bearing inner rings (1) and (3) to tool 380002737 (D). 2. Fit the spacer (2) on two-wheel drive tractors. Fit the drive gear (4) for four-wheel drive tractors ( (B)).

BRAG12TRLUE0359

BRAG12TRLUE0360

BRAG12TRLUE0361

3. Tighten the locknut (H1) on the tool and take the reading (C) using a depth gauge 4. Disassemble, lubricate the bearings and fit the tool in the housing. With the tool fitted on the tractor: • Tighten the lock nut ( (C)) again, turning the tool at the same time to settle the bearings.

• Take the reading (H2). Shim thickness (Sp) will be given by: Sp = H2 – H1 + 0.05 mm (0.002 in) where: 0.05 mm (0.002 in)= correcting required to compensate increased preload on bearings caused by tightening pinion shaft locknut. If necessary, round off Sp upwards to nearest 0.05 mm (0.002 in). NOTE: On completion of adjustment, do not remove tool from housing before performing bevel pinion position adjustment.

47921938 07/02/2017

27.2 [27.106] / 10

Rear axle system - Rear bevel gear set and differential

NOTE: This procedure is to calculate the amount of shims, (1), needed to properly set the bevel pinion bearings. Shim sizes are as follows:

20098907

1.0 - 1.05 - 1.1 - 1.15 - 1.2 - 1.4 - 1.5 - 1.7 - 1.75 - 1.85 - 1.9 - 1.95 mm (0.039 - 0.041 - 0.043 - 0.045 - 0.047 0.055 - 0.059- 0.067 - 0.069 - 0.073 - 0.075 - 0.078 in)

Shim sizes for bevel pinion preload adjustment

Adjustment of the shaft depth of the bevel pinion (shim thickness) 1. Install the tool, (A), on the differential supports as shown. 2. Tighten or loosen the two centering cones, (1), to bring the micrometer, (2), up to the bevel pinion shaft bearing inner race, (3). NOTE: Use tool mandrel marked 125 – 150 mm (5 – 6 in). 3. Turn the centering cones by hand and tighten the tool slightly against bearing cups to eliminate tool end play. 4. Lock micrometer gauge, (4), with the screw, (5). 5. Bring micrometer feeler in contact with bearing inner race and take reading (H1). 6. Establish correct nominal distance (H2) between ring gear centerline and back of pinion: H2 = H +/– C, where: H = 132 mm (5.2 in) nominal distance between ring gear centerline and back of pinion. C = correction factor stamped on pinion head, expressed inmmpreceded by + or – sign (if other than 0) to be summed with or subtracted from the nominal value (H) depending on the sign indicated. The shim thickness (S) will be given by: S = H1 – H2, where: H1 = distance measured by micrometer gauge. H2 = corrected nominal distance between ring gear centerline and back of pinion. Example: Micrometer reading H1 = 135.5 mm. Nominal distance between ring gear centerline and back of pinion H = 132.0 mm. Correction factor (C) = – 0.2 mm Corrected nominal distance (H2) = 132.0 mm – 0.2 mm = 131.8 mm Shim thickness = S = 135.5 mm – 131.8 mm= 3.7 mm Figure 5. Illustration of how to adjust the shaft depth of the bevel pinion using the universal tool (A) and the specific tool (B)

47921938 07/02/2017

27.2 [27.106] / 11

20098908

Rear axle system - Rear bevel gear set and differential

A. B. 1. 2. 3. 4. 5. 6. 7.

Universal tool 38000249 Specific tool 38000249 Centering cones Micrometer mandrel Differential bearing inner race Micrometer gauge Micrometer screw Threaded rod Bevel pinion shaft bearing inner race

NOTE: This procedure is to calculate the amount of shims, (1), needed to properly set the bevel pinion shaft depth. Shim sizes are as follows:

20098907

Shim Sizes for Bevel Pinion Shaft Depth Adjustment

3.8 - 3.9 - 4.0 - 4.1 - 4.2 - 4.3 - 4.4 - 4.5 - 4.6 - 4.7 4.8 mm (0.149 - 0.153 - 0.157 - 0.161 - 0.165 - 0.169 0.173 - 0.177 - 0.181 - 0.185 - 0.188 in)

Assembling the Bevel and Pinion Shaft 1. Tap the new bearings into place using a suitable punch or heat up the inboard races of the bearings in oil at 80 – 90 °C (176 – 194 °F). 2. Assemble the pinion shaft and tighten nut to 300 N·m (221 lb ft) using deep well socket tool no. 380002763, then lock the nut down.

20098909

47921938 07/02/2017

27.2 [27.106] / 12

Rear axle system - Rear bevel gear set and differential

Bevel gear - Backlash TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Differential Bearing Adjustment and Bevel Drive Backlash Check NOTE: To install lock rings, use tool no. 380002738 -- part of rear differential tool kit 380040203. 1. With bevel pinion installed, install the differential assembly, with bevel ring gear. 2. Fit the left-hand lock ring, (2), and tighten to ensure a minimum clearance of approximately 1.0 mm (0.04 in) between the sides of the bevel gear teeth. 3. As per Figure 1, fit the left-hand lock ring for adjustment of the crown gear/differential support bearing. (1). Adjustment tool No. 380002738 (2). Left-hand lock ring. (3). Left-hand support.

20098910

20098911

4. Fit the right-hand bearing, (2), and tighten to obtain a pinion ring gear assembly rolling torque of 9.8 – 14.7 N·m (7.2 – 10.8 lb ft). This torque is measured using a spring balance and cord wrapped around the pinion shaft, and corresponds to a spring balance pull of 98 – 147 N (22 – 33 lb). 5. Check the bevel drive play using a dial gauge. Record the measurements at three equidistant points and compare the average of the three readings with the expected play value — 0.10 – 0.23 mm (0.007 – 0.009 in), with an average of 0.21 mm (0.008 in). To compensate for excessive or insufficient backlash, note that the average ratio of normal backlash to equivalent ring gear displacement is 1 to 1.4. Ring gear end play will therefore be: Z = (G – 0.21 mm) x 1.4 where: G = bevel gear backlash as measured previously. 6. As per Figure 2, fit the right-hand lock ring (2) for adjustment of the crown gear/differential support bearing. (1). Adjustment tool No. 380002738 (2). Right-hand lock ring (3). Right-hand support

47921938 07/02/2017

27.2 [27.106] / 13

Rear axle system - Rear bevel gear set and differential

7. Adjust the rings, first unscrewing one on the right-hand side and then screwing in one on the left-hand side to the same degree, until you obtain the specified clearance — 0.18 – 0.23 mm (0.007 – 0.009 in), with an average of 0.21 mm (0.008 in). NOTE: One complete turn of the lock ring corresponds to 2.00 mm (0.079 in) ring gear axial displacement. Consequently, a 60° turn of the lock ring, equivalent to one side of the lock ring hexagon, corresponds to 0.33 mm (0.013 in) axial displacement. 8. Figure 3 shows the adjustment crown bearings. 60° rotation of the lock ring (1) is equivalent to 0,33 mm of movement.

20098897

20098898

Fit the lock washer, (1), on the lock rings so that the washer tab is aligned with a notch on the differential support.

47921938 07/02/2017

27.2 [27.106] / 14

Rear axle system - Rear bevel gear set and differential

Differential - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Remove mechanical rear wheel drive housing from tractor by following the procedure described in Rear axle housing - Remove (27.100) . 2. Remove the brake pedal, the brake assembly and the linkages, as per the procedures described in Brake control pedals and shafts - Remove Brake pedals and external linkages (33.120).

20098871

20098864

20098879

3. Loosen the bolt, (1), and remove differential lock pedal, (2).

4. Using a suitable punch, remove metal plug, (1), from left side of the rear wheel drive housing.

47921938 07/02/2017

27.2 [27.106] / 15

Rear axle system - Rear bevel gear set and differential

5. Remove shaft, (1), using a long punch and mallet, if necessary, from the left hand side of the transmission housing after having removed the plug.

20098865

20098866

20098874

20098868

6. Collect the differential spring, (1), and the shift fork, (2), from the housing.

7. Loosen the bolts and remove the differential bearing supports, (1), from both the sides by gently hammering.

8. Remove the differential assembly, (1), along with ring gear, (2), from the rear axle housing, (3).

47921938 07/02/2017

27.2 [27.106] / 16

Rear axle system - Rear bevel gear set and differential

9. Loosen the ring gear retaining bolts, (1).

20093425

20093426

10. Detach the ring gear, (1), from the differential housing. NOTE: Differential assembly can also be disassembled without removing ring gear.

11. Using a 4mm allen wrench, remove set screw, (1), from the differential housing.

20098881

20098878

12. Remove dowel pin from the differential housing by using suitable tool.

47921938 07/02/2017

27.2 [27.106] / 17

Rear axle system - Rear bevel gear set and differential

13. Remove the differential pinion shaft, (1), by pushing it out gently.

20098863

20098877

20098862

20098869

14. Withdraw the differential gears and thrust washers, (1) and (2).

15. Withdraw the side gears, (1), and thrust washers, (2).

16. Use suitable extractors to remove the bearings from both the sides. 17. Remove the differential lock clutch from the housing.

47921938 07/02/2017

27.2 [27.106] / 18

Rear axle system - Rear bevel gear set and differential

Differential - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Clean all parts in a suitable solvent and allow to air dry. 2. Rotate bearings by hand to check for roughness or binding. Check the bearings for excessive wear or damage, and replace as necessary. 3. Inspect side gear teeth for excessive wear or damage. 4. Measure the thickness of all the differential thrust washers. Replace the washers that measure less than the minimum thickness. 5. Inspect the differential pinion gears and shafts for excessive wear or damage. 6. Inspect the differential gear case for cracks, or any other damage.

47921938 07/02/2017

27.2 [27.106] / 19

Rear axle system - Rear bevel gear set and differential

Differential - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Differential - Inspect (27.106) 1. Reinsert the differential lock clutch, (1), into the housing, (2).

20098869

20098872

20098862

2. Press bearings, (1), onto both sides of the housing, (2).

3. Reinsert the two side gears, (1), along with thrust washers, (2), into the differential housing. NOTE: Make sure the side gear with holes in the back side, is placed inside the housing with the holes facing towards the differential lock clutch.

47921938 07/02/2017

27.2 [27.106] / 20

Rear axle system - Rear bevel gear set and differential

4. While rotating the two side gears, insert the two differential pinion gears, (1), along with thrust washers into the differential housing, (2), until the holes, (3), in the pinion gears and housing are all aligned.

20098877

20098863

20098878

20098881

5. Carefully drive the differential pinion shaft, (1), into the housing, (2), and through the differential pinion gears.

6. Reinstall the dowel pin, securing the pinion shaft within the differential housing.

7. Using a 4 mm allen wrench, reinstall set screw, (1), into the differential housing.

47921938 07/02/2017

27.2 [27.106] / 21

Rear axle system - Rear bevel gear set and differential

8. Apply LOCTITE® 270 to self locking ring gear bolts. Reattach the ring gear, (1), to the differential housing using the eight M12 x 37 mm self locking nuts and bolts, (2). Torque the bolts 85 N·m (63 lb ft).

20098861

20098875

9. Place spring compressor of special tool 380002739, (1), in a vise and screw the two halves together to compress the differential lock spring, (2). Place spring, (2), inside holder, (3), and release compression tool.

10. While holding the spring and shift fork into position, gently drive the spindle, (1), in through the housing, (2), spring, (3), and shift fork, (4). Remove holder, (3), (figure 58) Special tool 380002739 from inside of housing.

20098870

20098864

11. Reattach the differential lock pedal, (1), using a M12 x 25 mm bolt and lock washer. Torque each bolt to 75 N·m (55 lb ft).

47921938 07/02/2017

27.2 [27.106] / 22

Rear axle system - Rear bevel gear set and differential

12. Reinstall a new metal plug, (1), on the left side of the rear wheel drive housing, replacing the one removed, during disassembly.

20098879

20098868

20098874

13. Place the differential assembly, (1), into the rear wheel drive housing, (2).

14. Reattach the left-hand differential bearing supports, (1), to the rear wheel drive housing, (2). Secure the bearing holder using six M10 x 30 mm bolts. Torque the bolts 60 N·m (44 lb ft). NOTE: When installing the differential bearing holders, make sure the smallest of the three tabs, (3), face the rear of the housing. Three o’clock for the left-hand side, and nine o’clock on the right-hand side. 15. Repeat step (14) for right-hand side. 16. Set the ring and pinion backlash and total preload settings. See Bevel gear - Adjust (27.106) and Bevel gear - Backlash (27.106). Next operation: Rear axle housing - Install (27.100).

47921938 07/02/2017

27.2 [27.106] / 23

Rear axle system - Rear bevel gear set and differential

Differential - Disassemble Pinion shaft TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. To remove pinion shaft, first differential assembly, (1), has to be removed from the rear axle housing, (2). Refer to the procedures in Differential - Disassemble (27.106) for the differential assembly removal procedure.

20098868

20098888

20098883

2. Remove the locking nut, (1), from the pinion shaft, using special tool no. 380002763.

3. Remove the pinion shaft, (1), from the housing, (2), by hammering it out gently using suitable mandrill.

47921938 07/02/2017

27.2 [27.106] / 24

Rear axle system - Rear bevel gear set and differential

4. Retrieve spacer, (1), and shims, (2), from the pinion shaft. NOTE: The spacer (1) is replaced by a fixed gear on frontwheel drive models.

20098884

20098896

20098885

20098889

5. Remove outer race, (1), of the bearings from the case using suitable puller.

6. On front-wheel drive models, remove the gear (1) from within the housing.

7. Remove the bevel roller bearings from the pinion using a suitable extractor.

Next operation: To inspect the pinion shaft, see the procedures in Differential - Disassemble Pinion shaft (27.106). 47921938 07/02/2017

27.2 [27.106] / 25

Rear axle system - Rear bevel gear set and differential

Differential - Inspect Pinion shaft TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Clean all parts in a suitable solvent and allow to air dry. 2. Rotate bearings by hand to check for roughness or binding. Check the bearings for excessive wear or damage, and replace as necessary. 3. Inspect the drive pinion shaft for excessive wear, nicks, chips or other damage. Replace as necessary. 4. On FWD Models: Inspect the fixed gear, (1), for excessive wear or damage. Replace as necessary.

20098890

47921938 07/02/2017

27.2 [27.106] / 26

Rear axle system - Rear bevel gear set and differential

Differential - Assemble Pinion shaft TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Adjust the preload settings of the bevel roller bearing and ring/pinion clearance. See Bevel gear - Adjust (27.106) and Bevel gear - Backlash (27.106). 2. After installation of the proper pinion positioning shims, (1), press the bevel pinion bearing, (2), onto the pinion shaft, (3). 3. Place spacer, (4), and proper pinion bearing shims, (5), onto the pinion shaft.

20098884

20098885

20098896

4. On FWD Models: Reinstall the fixed gear, (1), into the housing as shown.

5. Using a suitable drift, insert both inner bearing races, (1), into the differential housing.

47921938 07/02/2017

27.2 [27.106] / 27

Rear axle system - Rear bevel gear set and differential

6. Reinstall the pinion shaft, (1), in through the rear of the housing and inner bearing races. 7. Place tapered bearing, (2), onto the pinion shaft.

20098891

20098888

20098868

8. Reinstall pinion shaft locking nut, (1). Torque the nut to 300 NÂˇm (221 lb ft) using Special tool No.380002763 and then, stake the nut.

9. Reinstall the differential assembly, (1), into the rear wheel drive housing, (2). See Differential - Assemble (27.106) for this procedure.

47921938 07/02/2017

27.2 [27.106] / 28

Rear axle system - Rear bevel gear set and differential

Differential - Backlash TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Differential pinion and side gear clearance adjustment Refer to the sectional view of the assembly and the reference for calls in Differential - Sectional view (27.106). 1. Fit the side gears, (15), in the differential carrier without the thrust washers, (12). 2. Install differential pinions, (13), complete with thrust washer, (14), and differential pinion shaft, (3), and insert dowel pin to prevent differential pinion shaft from working out. 3. Bring left-hand side gear into full contact with differential pinion. 4. Using a depth gauge measure dimension (H1) at two diametrically opposed points and average the two readings.

20097948

20097949

5. Then push side gear into contact with differential carrier and measure dimension (H2). 6. Repeat the same operations on right-hand side gear. 7. End float of each side gear without the shim ring must be: Lg or Rg = H1 -H2 where: Lg = Left-hand side gear end float; Rg = Right-hand side gear end float; H1 and H2 = Dimensions measured on left-hand or right-hand side gears.

8. Normal differential pinion and side gear backlash is 0.15 mm (0.006 in). 9. Note that the average ratio normal backlash to the equivalent side gear end float is 1 to 1.7. 10. Side gear end float corresponding to normal backlash will be: 0.15 x 1.7 = 0.23 mm (0.009 in)

47921938 07/02/2017

27.2 [27.106] / 29

Rear axle system - Rear bevel gear set and differential

11. Consequently the shim thickness required in the differential carrier is given by: Ss = Lg - 0.25 (for left-hand side gear) Sd = Rg - 0.25 (for right-hand side gear) The thickness of the thrust washer can vary 1 â&#x20AC;&#x201C; 2 mm at 0.1 mm intervals. For example, 1.0 mm, 1.1 mm 1.2 mm

20098899

47921938 07/02/2017

27.2 [27.106] / 30

Rear axle system - Rear bevel gear set and differential

Differential - Adjust Ring gear bearings TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. With pinion shaft and differential assembly with ring gear bearing supports installed. 2. Remove the two Allen screws, (1), and lock plates from both the sides.

20098900

20098901

20098902

3. Tighten left-hand ring nut, (1), using Special Tool No. 380002738 until minimum back lash between the bevel teeth is 1 mm.

4. â&#x20AC;˘ Measure the backlash using dial gauge and magnetic stand as shown in the figure.

47921938 07/02/2017

27.2 [27.106] / 31

Rear axle system - Rear bevel gear set and differential

5. Tighten right-hand ring nut until achieving rolling torque of the pinion bevel wheel 98 – 147 N (22 – 33 lb). 6. This torque can be measured using a spring balance and a chord wound around the differential housing and pull the spring balance. The value at which differential housing starts rotate is the rolling torque.

20098903

20098900

7. Reinstall the right-hand and left-hand lock plates, (1), back on the bearing supports. Apply thread lock sealant LOCTITE® 242® to the Allen screws, (2).

47921938 07/02/2017

27.2 [27.106] / 32

Index Rear axle system - 27 Rear bevel gear set and differential - 106 Bevel gear - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bevel gear - Backlash (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bevel gear - Preload (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bevel gear - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Adjust Ring gear bearings (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Assemble Pinion shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Backlash (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Disassemble Pinion shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Inspect Pinion shaft (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential lock - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

27.2 [27.106] / 33

47921938 07/02/2017

27.2 [27.106] / 34

Rear axle system - 27 Planetary and final drives - 120

47921938 07/02/2017

27.3 [27.120] / 1

Contents Rear axle system - 27 Planetary and final drives - 120

TECHNICAL DATA Planetary and final drives General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sealing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Planetary and final drives Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Planetary and final drives Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

(*) See content for specific models 47921938 07/02/2017

27.3 [27.120] / 2

CONSUMABLES INDEX Consumable Loctite® 518™

Reference Planetary and final drives - Sealing

47921938 07/02/2017

27.3 [27.120] / 3

PAGE 27.3 / 6

Rear axle system - Planetary and final drives

Planetary and final drives - General specification TT3840F TT3840 TT3880F TT4030

Component Type Gears Reduction ratio Clearance Final drive spline fits Interference Clearance

LA LA LA LA

TT3840

TT3840F TT3880F Planetary, single reduction Sprocket wheel 11/68 = 01:06.18 0.15 – 0.25 mm (0.006 – 0.0098 in)

TT4030

0.050 mm (0.0020 in) 0.048 mm (0.0019 in)

Planetary and final drives - Torque TT3840F TT3840 TT3880F TT4030

Description Bolts, final drive cover, (1) Bolts securing final drive housing to transmission housing, (2) Bolts securing Wheel Disc to Wheel shaft, (3) Lock-nut securing final drive driven gear to disc spindle, (4)

LA LA LA LA

Thread Size M10x1.25

Torque 60 N·m (44 lb ft)

M12 x 1.5

85 N·m (63 lb ft)

M16x1.5

260 N·m (192 lb ft)

M55 x 1.5

900 N·m (664 lb ft)

47921938 07/02/2017

27.3 [27.120] / 4

Rear axle system - Planetary and final drives

20099005

Planetary and final drives - Special tools TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Special tools Tool description Installer, trumpet housing seal 1 Installer, trumpet housing seal 2 Extractor, transmission gear remover Transmission gear spanner Remover, final drive bearing Installer, final drive cover seal - TT3880F/TT4030 Installer, final drive cover seal - TT3840/TT3840F

47921938 07/02/2017

27.3 [27.120] / 5

No. of the tool 9971350 9971351 292904 9971360 292927 9971362 9971380

Rear axle system - Planetary and final drives

Planetary and final drives - Sealing TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Operation Description Final drive housing to rear wheel drive housing, (1)

Sealant Specification LOCTITE® 518™

20099006

47921938 07/02/2017

27.3 [27.120] / 6

Rear axle system - Planetary and final drives

Planetary and final drives - Sectional view TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Longitudinal section through final drive

BRAG12TRLUE0357

TT3880F/TT4030

47921938 07/02/2017

27.3 [27.120] / 7

Rear axle system - Planetary and final drives

BRAG12TRLUE0358

TT3840F/TT3880 1. 2. 3. 4. 5. 6. 7.

Wheel shaft Cover Ball bearing Ball bearing Ball bearing. Ball bearing. Final drive driven gear (transmission gear)

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

Rear axle shaft Rear axle housing (Final drive) Disc brakes Seal Seal Driven gear retaining nut

47921938 07/02/2017

27.3 [27.120] / 8

Rear axle system - Planetary and final drives

Planetary and final drives - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Description and operation The outboard final reduction gear set is controlled by the bevel pinion and crown wheel output half - shaft, which also controls the brakes. Outboard reduction helps in improving traction and increasing brakes' life. It also gives more ground clearance and is sealed against water and dust. In this cascade arrangement bull pinion is integral part of the axle shaft. The wheel shaft can withstand bending and twisting loads due to its small length. The final drive housing can be located in various positions relative to the axle sleeves, which makes it possible to change in a stepwise fashion the wheel base and clearance of the tractor. These three clearance adjustments are possible: basic (average height), high and low. The tractor can be made to have low clearance setting by turning the final drive housings either fully backward or fully forward, provided the fenders is removed and the track width of the rear wheels is set at its minimum. In this case, one should bear in mind that turning the final drive housing forward improves the manoeuvrability of the tractor but impairs its stability, and vice-versa; turning them backward improves the stability of the tractor but impairs its manoeuvrability.

47921938 07/02/2017

27.3 [27.120] / 9

Rear axle system - Planetary and final drives

Planetary and final drives - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Remove the final drive assembly from the tractor as described in Rear axle housing - Remove (27.100) .

20098777

20099016

2. Loosen M10 x 45mm cap screws, (1), and remove final drive cover, (2), with bull gear.

47921938 07/02/2017

27.3 [27.120] / 10

Rear axle system - Planetary and final drives

3. Use a suitable puller to remove roller bearing internal ring, (1), from wheel shaft. 4. Use a chisel to bend tab down on washer, (2), to allow for removal of nut, (3).

20099017

20099018

20099019

20099887

5. Tighten two M16 x 1.5 bolts, (1), in to two of the wheel disc holes on the hub, and clamp the wheel shaft in a vice. 6. Remove M55 x 1.5 nut and locking plate, securing driven gear onto the wheel shaft.

7. Remove driven gear, (1), from wheel shaft using a suitable puller.

8. Remove spacer, (1).

47921938 07/02/2017

27.3 [27.120] / 11

Rear axle system - Planetary and final drives

9. Knock out wheel shaft (1), using a brass drift and hammer.

20099021

20099022

20099023

10. Remove seal protector and seal, (1), using suitable tool.

11. Use a suitable extractor to remove the roller bearing, (1), from the cover.

12. Remove retaining ring, (1), then remove bearing, (2), and thrust washer (not shown) from the cover.

20099024

Next operation: 47921938 07/02/2017

27.3 [27.120] / 12

Rear axle system - Planetary and final drives

To inspect the planetary and final drive components, see the procedures in Planetary and final drives - Assemble (27.120).

47921938 07/02/2017

27.3 [27.120] / 13

Rear axle system - Planetary and final drives

Planetary and final drives - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To remove the final drive housing, see the procedures in Planetary and final drives - Disassemble (27.120). 1. Check and replace damaged and worn parts 2. Check the seals of lips (1) and (2). Replace them if necessary.

BRAG12TRLUE0259

Next operation: To fit the final drive housing, see the procedures in Planetary and final drives - Assemble (27.120).

47921938 07/02/2017

27.3 [27.120] / 14

Rear axle system - Planetary and final drives

Planetary and final drives - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To inspect the final drive housing, see the procedures in Planetary and final drives - Inspect (27.120). Reassemble final drive assembly observing the following: 1. Reassembly follows the disassembly procedure in reverse, from step 14 back to step 1. 2. Place the roller bearing (1) in its seat in the final drive cover with the maker's logo faces outside.

BRAG12TRLUE0253

BRAG12TRLUE0254

3. Install other bearings, using appropriate installers. 4. Fit cover seal for final drive using Special Installation Tool No. 9971362 for the TT3880F/TT4030 models and 9971380 for the TT3840/TT3840F models.

47921938 07/02/2017

27.3 [27.120] / 15

Rear axle system - Planetary and final drives

5. Fit the rear axle housing seal using Special Installation Tool Nos. 9971350 and 9971351.

BRAG12TRLUE0255

BRAG12TRLUE0256

BRAG12TRLUE0257

BRAG12TRLUE0258

6. Fit the rear axle shaft (1) and the wheel shaft (2), taking care not to damage the seals.

7. Fit the internal ring for the roller bearing onto the axle shaft having heated it in oil to 80 – 90 °C. 8. Tighten the retaining nut for the bull gear to 900 N·m using Special Tool 9971360. .

9. Clean and grease the surfaces in contact between the housing and the cover and insert a new gasket (1).

47921938 07/02/2017

27.3 [27.120] / 16

Index Rear axle system - 27 Planetary and final drives - 120 Planetary and final drives - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary and final drives - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary and final drives - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary and final drives - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary and final drives - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary and final drives - Sealing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary and final drives - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary and final drives - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary and final drives - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

27.3 [27.120] / 17

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

47921938 07/02/2017 EN

SERVICE MANUAL Power Take-Off (PTO) TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017

Contents Power Take-Off (PTO) - 31

[31.101] Rear mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 [31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2

47921938 07/02/2017

CONSUMABLES INDEX Consumable Permatex #2 Form-A-Gasket Sealer Loctite® 518 Loctite® 242®

Reference

PAGE

Rear mechanical control - Sealing

31.1 / 5

Rear mechanical control - Sealing Engage and release control tie rod - Assemble Cross shafts

31.1 / 5 31.1 / 15

47921938 07/02/2017

Power Take-Off (PTO) - 31 Rear mechanical control - 101

47921938 07/02/2017

31.1 [31.101] / 1

Contents Power Take-Off (PTO) - 31 Rear mechanical control - 101

TECHNICAL DATA Rear mechanical control General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sealing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Rear mechanical control Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Engage and release control tie rod Remove PTO Clutch lever (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Assemble Cross shafts (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

(*) See content for specific models 47921938 07/02/2017

31.1 [31.101] / 2

CONSUMABLES INDEX Consumable Permatex #2 Form-A-Gasket Sealer Loctite® 518 Loctite® 242®

Reference

PAGE

Rear mechanical control - Sealing

31.1 / 5

Rear mechanical control - Sealing Engage and release control tie rod - Assemble Cross shafts

31.1 / 5 31.1 / 15

47921938 07/02/2017

31.1 [31.101] / 3

Power Take-Off (PTO) - Rear mechanical control

Rear mechanical control - General specification TT3840F TT3840 TT3880F TT4030

Component Type Clutch control Output Shaft Engagement Rotation (looking from Tractor Rear End) Engine speed at 540 RPM(standard PTO speed) PTO speed at engine Max. power rating Output Shaft Number of splines Shaft Diameter PTO Clutch Shaft Shaft Diameter Bushing Fitted Internal Diameter PTO Shaft Clearance in Bushing Bushing Interference Fit with Drive Shaft

LA LA LA LA

TT3840

TT3840F TT3880F TT4030 Independent Hand lever By lever situated on Transmission Housing Cover 1967 RPM 686 RPM 6 34.925 mm (1.375 in) 24.964 – 24.994 mm (0.983 – 0.984 in) 25.04 – 25.092 mm (0.986 – 0.988 in) 0.055 – 0.128 mm (0.0022 – 0.0050 in) 0.037 – 0.091 mm (0.0015 – 0.0036 in)

Rear mechanical control - Torque TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Tightening torques Name Bolts securing rear cover on transmission housing (C₁₁) Bolts securing rear cover on transmission housing (C₂₂) Bolts securing PTO lever cover (C₃₃) Nuts securing PTO shaft-driven gear (C₄₄)

47921938 07/02/2017

31.1 [31.101] / 4

Thread size M12 x 1.5 M16 x 1.5 M8 X 1.5 M22 x 1.5

Torque 100 N·m 230 N·m 26 N·m 260 N·m

Power Take-Off (PTO) - Rear mechanical control

LAIL11TT0381A0A

Rear mechanical control - Sealing TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Operation Description Transmission rear covers, (S1) Transmission top cover, (S2)

Sealant Specification PERMATEX #2 FORM-A-GASKET SEALER LOCTITEÂ® 518

47921938 07/02/2017

31.1 [31.101] / 5

Power Take-Off (PTO) - Rear mechanical control

20098755

47921938 07/02/2017

31.1 [31.101] / 6

Power Take-Off (PTO) - Rear mechanical control

Rear mechanical control - Sectional view TT3840F TT3840 TT3880F TT4030

LA LA LA LA

20098756

1. 2. 3. 4. 5. 6.

Drive shaft Driven shaft Oil seal Driven gear - 51 teeth Spacer Transmission rear cover

7. 8. 9. 10. 11.

Plain roller bearing Plain roller bearing Ball bearing Drive gear PTO shaft - 14 teeth PTO brake

47921938 07/02/2017

31.1 [31.101] / 7

Power Take-Off (PTO) - Rear mechanical control

Rear mechanical control - Static description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

The power take-off (PTO) transfers engine power directly to mounted or trailed equipment through a splined shaft, (1), at the rear of the tractor. The PTO system is independent, that is, the PTO may be engaged or disengaged whether the tractor is moving or stationary. Rotation of the PTO shaft is not affected by the main clutch and tractor speed but is related directly to the speed of the engine. The PTO system utilizes the standard 6-spline shaft designed to operate at 540 RPM, with a clockwise rotation, as viewed from the rear of the tractor. The standard speed of 540 RPM is obtained at engine 1967 RPM. 20098748

20098746

The PTO is engaged or disengaged by means of lever, (1).

DANGER To avoid inadvertent movement of the implement, disengage the PTO after each use. Failure to comply could result in death or serious injury. B014

WARNING Whenever operating PTO equipment, observe the following precautions: - Check that you are using the correct PTO speed for the implement. Follow the operatorâ&#x20AC;&#x2122;s instructions in the Operatorâ&#x20AC;&#x2122;s Manual. - Make sure that the PTO guard is installed when using PTO driven equipment - DO NOT wear loose clothing when operating PTO driven equipment. - Firmly apply the parking brake, place all control levers in the neutral position and block all four wheels before operating any stationary PTO equipment. - DO NOT approach, clean or adjust PTO driven equipment while the engine is still running. Stop the engine and remove the key, wait until the PTO and the equipment stop turning before leaving the machine or before working on the PTO, or the equipment. - With the engine stopped and key removed, the PTO brake is released and the shaft may be turned by hand to assist in the installation or removal of the implement shaft. Failure to comply could result in death or serious injury. M1422

47921938 07/02/2017

31.1 [31.101] / 8

Power Take-Off (PTO) - Rear mechanical control

Engage and release control tie rod - Remove PTO Clutch lever TT3840F TT3840 TT3880F TT4030

LA LA LA LA

To remove the PTO clutch lever, (1), proceed as follows

20098368

20098365

20098369

1. Remove pin, (1), by releasing lock plate and disconnect linkage between PTO clutch lever and PTO clutch cross shaft.

2. Remove the split pin lock, (1), take out the pin and remove hand lever from the mounting bracket. 3. Remove bolt, (2), from the housing to take out the levers with the bracket.

47921938 07/02/2017

31.1 [31.101] / 9

Power Take-Off (PTO) - Rear mechanical control

Engage and release control tie rod - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

PTO lever and internal linkages 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 bolts of the transmission cover plate (1) and open the cover.

LAIL11TT0112A0A

LAIL11TT0180A0A

LAIL11TT0181A0A

2. Push out the positioning pin (1) from the internal lever.

3. Pull out the lever assembly and remove the lock pin (1) and spring (2) from the lever cage.

47921938 07/02/2017

31.1 [31.101] / 10

Power Take-Off (PTO) - Rear mechanical control

4. The PTO engagement sliding sleeve (1) can only be removed after removing the PTO shaft assembly. See the procedure for removing the PTO shaft in Front drive shaft - Remove PTO Shaft Assembly (31.114).

LAIL11TT0113A0A

47921938 07/02/2017

31.1 [31.101] / 11

Power Take-Off (PTO) - Rear mechanical control

Engage and release control tie rod - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Installation Installation is the reverse operation of the removal procedure. â&#x20AC;˘ Before securing the transmission top cover, thoroughly clean and degrease the mating surfaces and apply a 2 mm bead of sealant following the pattern shown in Fig. 1.

LAIL11TT0001A0A

47921938 07/02/2017

31.1 [31.101] / 12

Power Take-Off (PTO) - Rear mechanical control

Engage and release control tie rod - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. To remove cross shafts, clutch housing has to be split between engine flywheel housing and transmission housing. Refer to Engine - Remove (10.001).

20098370

20098371

20098372

2. Remove clips, (1), from both the forks locking forks and release bearing.

3. Loosen the PTO clutch fork lock screw, (1).

47921938 07/02/2017

31.1 [31.101] / 13

Power Take-Off (PTO) - Rear mechanical control

4. Pull out the PTO clutch cross shaft, (1), from right-hand side of the transmission housing and retrieve fork from housing.

20098374

20098373

20097515

5. Loosen the transmission clutch fork lock screw. 6. Pull out the transmission cross shaft, (1), from left-hand side of the transmission housing and retrieve fork from the housing.

7. Slide out both transmission and PTO clutch release bearings, (1), and (2), from the shaft.

Next operation: To fit the transverse axis, see the procedures in Engage and release control tie rod - Assemble Cross shafts (31.101).

47921938 07/02/2017

31.1 [31.101] / 14

Power Take-Off (PTO) - Rear mechanical control

Engage and release control tie rod - Assemble Cross shafts TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To disassemble the cross shafts, see the procedures in Engage and release control tie rod - Disassemble (31.101). Reassemble the clutch mechanical release control, taking care of the following. 1. Ensure that lock clips, (1), are properly seated on clutch release forks. 2. Check whether the tightening torques are correct as shown in Rear mechanical control - Torque (31.101). 3. Apply LOCTITEÂŽ 242ÂŽ sealant to clutch release fork lock-screw and left-hand brake pedal lock-screw before tightening. 4. Before securing the transmission and engine, thoroughly clean and degrease mating surfaces and apply a bead of liquid gasket of approximately 2 mm (0.079 in) of diameter following pattern shown in . 20098371

47921938 07/02/2017

31.1 [31.101] / 15

Index Power Take-Off (PTO) - 31 Rear mechanical control - 101 Engage and release control tie rod - Assemble Cross shafts (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engage and release control tie rod - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engage and release control tie rod - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engage and release control tie rod - Remove PTO Clutch lever (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear mechanical control - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear mechanical control - Sealing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear mechanical control - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear mechanical control - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear mechanical control - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

31.1 [31.101] / 16

Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114

47921938 07/02/2017

31.2 [31.114] / 1

Contents Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114

SERVICE Front drive shaft Remove PTO Shaft Assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassemble PTO assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assemble PTO Assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install PTO Shaft Assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

(*) See content for specific models 47921938 07/02/2017

31.2 [31.114] / 2

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Front drive shaft - Remove PTO Shaft Assembly TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Drain oil from the transmission and rear wheel drive housing by opening drain plugs, (1), and, (2).

20098382

20098383

20098384

2. Open transmission top cover plate, (1).

3. Remove PTO cover bolts, (1). 4. Pull out the PTO shaft assembly along with PTO cover.

Next operation: 47921938 07/02/2017

31.2 [31.114] / 3

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

To remove the PTO assembly, see the procedures in Front drive shaft - Disassemble PTO assembly (31.114).

47921938 07/02/2017

31.2 [31.114] / 4

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Front drive shaft - Disassemble PTO assembly TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: When removing the PTO assembly, see the procedures in Front drive shaft - Remove PTO Shaft Assembly (31.114). 1. For correct disassembly install PTO assembly on rotary stand or bench. 2. Loosen nut, (1), and pull out gear, (2), from PTO shaft. NOTE: Nut, (1), is locked by punching at the end of the nut. Unlock the nut using suitable tool before removing.

20098759

20098764

20098763

3. Remove the PTO shaft, (1), out of the cover plate by hammering with a mallet on the threaded end of the shaft.

4. Remove front seal, (1), from housing.

47921938 07/02/2017

31.2 [31.114] / 5

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

5. Remove the retaining ring, (1), in the front and rear of the housing. 6. Remove the bearings, (2), and spacer, (3), from the housing.

20098760

20098761

20098392

20098762

7. Unscrew the bolts, (1), securing PTO input shaft cover, (2), on PTO assembly cover plate.

8. Remove snap ring, (1), and spacer. 9. Remove the input shaft from the bearing.

10. Inspect the bearings, shafts and gears for wear out, damage, scouring and pitting. Replace parts as necessary. 11. Remove the bearing, (1), from coverplate using suitable puller and drifts.

47921938 07/02/2017

31.2 [31.114] / 6

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

12. Remove snap ring, (1), and remove the bearing, (2), from the shaft. 13. Remove the inner snap ring, (3), from the shaft as required.

20098393

Next operation: When fitting the PTO assembly, see the procedures in Front drive shaft - Assemble PTO Assembly (31.114).

47921938 07/02/2017

31.2 [31.114] / 7

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Front drive shaft - Assemble PTO Assembly TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Install retaining ring, (1) onto the PTO shaft, followed by the bearing, (2), and secure with another retaining ring, (3).

20098393

20098395

20098761

2. Install bearing, (1), into housing using a suitable bearing installer. 3. Install shaft, (2), into bearing and secure with bearing spacer, (3), and retaining ring, (4).

4. Install cover, (1), with a new gasket. Secure the cover with flat washers, lock washers, and M14 X 1.50 X 40 mm retaining bolts, (2). 5. Torque the hardware to 89 NÂˇm (66 lb ft).

47921938 07/02/2017

31.2 [31.114] / 8

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

6. Install the bearings, (1), and spacer, (2), into the housing. 7. Install the retaining rings, (3), in the front and rear of the housing.

20098760

20098763

20098764

20098759

8. Install front seal, (1), into housing.

9. Install the PTO shaft, (1), through the bearings and spacer from the front side of the cover.

10. Install PTO drive gear, (1), onto PTO shaft and secure with a M22 X 1.50 mm nut, (2). 11. Secure the nut to 260 NÂˇm (192 lb ft). 12. Lock the nut by depressing the tabs of the nut into the grooves of the shaft.

47921938 07/02/2017

31.2 [31.114] / 9

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Front drive shaft - Install PTO Shaft Assembly TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Reassemble and install PTO assembly on rear housing observing the following. • Refer to figure for correct orientation of the gears, bearings, oil seals and sleeve. • Install new oil seals. • Replace the engagement coupler and circlip on input shaft before inserting pullers. • Before reassembling PTO cover, thoroughly clean and degrease mating surfaces and apply a 2 mm (0.08 in) head of silicone sealant following the pattern shown in the Figure 1. • Replace the input shaft cover gasket. • The clamping components should be tightened to the torques specified in Rear mechanical control - Torque (31.101).

20098757

47921938 07/02/2017

31.2 [31.114] / 10

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

1. Install PTO sleeve, (1), as shown.

20098758

20098386

20098383

20098382

2. Install new gasket, (1), onto dowel pins located on housing surface, (2). 3. Install the PTO shaft assembly along with PTO cover, (3). 4. Secure M12 X 1.50 mm PTO bolts, (4), to 100 N·m (74 lb ft). 5. Secure the M16 X 1.50 mm PTO bolts, (5), to 230 N·m (170 lb ft).

6. Install top cover, (1), and secure the hardware to 25 N·m (18 lb ft).

7. Install transmission drain plug, (1), and rear wheel drive housing drain plug, (2). 8. Fill both housing to level with the appropriate fluids. Refer to Operator’s Manual for correct fluid requirements.

47921938 07/02/2017

31.2 [31.114] / 11

Index Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114 Front drive shaft - Assemble PTO Assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front drive shaft - Disassemble PTO assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front drive shaft - Install PTO Shaft Assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front drive shaft - Remove PTO Shaft Assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

31.2 [31.114] / 12

47921938 07/02/2017

31.2 [31.114] / 13

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

47921938 07/02/2017 EN

SERVICE MANUAL Brakes and controls TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017

Contents Brakes and controls - 33

[33.120] Mechanical service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

47921938 07/02/2017

CONSUMABLES INDEX Consumable Tutela Transaxle fluid SAE 20W-40 Loctite® 518 Loctite® 518 Loctite® 242 Loctite® 518™

Reference

PAGE

Mechanical service brakes - General specification

33.1 / 4

Brake Brake Brake Brake

33.1 / 6 33.1 / 6 33.1 / 6 33.1 / 22

control pedals and shafts - Sealing control pedals and shafts - Sealing control pedals and shafts - Sealing drums - Assemble

47921938 07/02/2017

Brakes and controls - 33 Mechanical service brakes - 120

47921938 07/02/2017

33.1 [33.120] / 1

Contents Brakes and controls - 33 Mechanical service brakes - 120

TECHNICAL DATA Mechanical service brakes General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Brake control pedals and shafts Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Brake control pedals and shafts - Sealing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Mechanical service brakes Sectional view Brake control assembly (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Brake control pedals and shafts Remove Brake pedals and external linkages (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Adjust Free play (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Brake drums Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

DIAGNOSTIC Mechanical service brakes Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

(*) See content for specific models 47921938 07/02/2017

33.1 [33.120] / 2

CONSUMABLES INDEX Consumable Tutela Transaxle fluid SAE 20W-40 Loctite® 518 Loctite® 518 Loctite® 242 Loctite® 518™

Reference

PAGE

Mechanical service brakes - General specification

33.1 / 4

Brake Brake Brake Brake

33.1 / 6 33.1 / 6 33.1 / 6 33.1 / 22

control pedals and shafts - Sealing control pedals and shafts - Sealing control pedals and shafts - Sealing drums - Assemble

47921938 07/02/2017

33.1 [33.120] / 3

Brakes and controls - Mechanical service brakes

Mechanical service brakes - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Component

TT3840

Type - Service brake. - Parking brake. Control

TT3840F

TT3880F

TT4030

Wet disc acting on differential axle shafts Wet disc acting on differential axle shafts Controlled by mechanical pedals that are independent (or interlocked for joint operation) Mechanical release, with manual lever and ratchet (sector located on the right-hand side of the transmission housing)

- Service brake. - Parking brake. No. disks per side - TT3880F/TT4030 - TT3840/TT3840F Brake oil specification (Common for Transmission and Brakes) Service Brake/ Parking brake Disc Material Nominal brake disk thickness Discard thickness of the service/parking brake disks. Brake pedal play Suporte do pedal do freio Right-hand pedal internal diameter Bushing thickness Right-hand pedal internal diameter with bushing (without bore hole) Right-hand pedal bushing/housing clearance Right-hand pedal bushing/housing interference Left-hand pedal shaft diameter Clearance between the left-hand pedal shaft and the right-hand pedal bushing Left-hand pedal internal diameter Clearance between the left-hand pedal shaft and housing Internal diameter of left-hand pedal shaft with bushing (without bore hole) Left-hand brake with bushing Bushing thickness Left-hand pedal bushing/housing clearance Left-hand pedal bushing/housing interference Handbrake shaft diameter Left-hand brake bushing Diameter of bushing housing in transmission housing Internal diameter of the left-hand brake shaft on the transmission housing (without bore hole) Bushing thickness Clearance between the bushings and transmission casing Interference between the bushings and transmission casing

4 3 API GL-4 TUTELA TRANSAXLE FLUID SAE 20W-40 Organic Compound 4.65 – 4.8 mm

47921938 07/02/2017

33.1 [33.120] / 4

4.30 mm 50 – 55 mm 40.000 – 40.025 mm 1.968 – 1.932 mm 36.064 – 36.161 mm 0.097 mm max. 0.097 mm max. 36.000 – 35.961 mm

0.103 – 0.161 mm 36.025 – 36.087 mm 0.064 – 0.087 mm 22.052 – 22.137 mm 25.000 – 25.021 mm 1.442 – 1.474 mm 0.064 mm max. 0.085 mm max. 21.967 – 22.000 mm 0.052 – 0.170 mm 40.000 – 40.025 mm

36.064 – 36.161 mm 1.932 – 1.968 mm 0.097 mm max. 0.103 – 0.161 mm

Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Torque TT3840F TT3840 TT3880F TT4030

Description Rear axle Housing to Differential Housing Bolts, (C1) ROPS bolts, (C2) Bottom cover plate bolts, (C3) Screw, (C4)

LA LA LA LA

Bolt Size

Torque

M12 x 45

100 N路m (74 lb ft)

M15 x 200 M 8 x 22 M16 x 32

200 N路m (148 lb ft) 26 N路m (19 lb ft) 167 N路m (123 lb ft)

20098842

47921938 07/02/2017

33.1 [33.120] / 5

Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Sealing TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Operation Description Buckle up of Rear Axle Housing to Differential Housing, (S1) Bottom cover plate sealing, (S2) Thread lock for locking screw, (S3)

20098774

Sealant Specification LOCTITE® 518 LOCTITE® 518 LOCTITE® 242

47921938 07/02/2017

33.1 [33.120] / 6

Brakes and controls - Mechanical service brakes

Mechanical service brakes - Sectional view Brake control assembly TT3840F TT3840 TT3880F TT4030

LA LA LA LA

20098839

1. 2. 3. 4.

Rear wheel drive housing Brake Actuating linkage Actuating disc Axle shaft

5. 6. 7.

Brake disc Stator Final drive housing

47921938 07/02/2017

33.1 [33.120] / 7

Brakes and controls - Mechanical service brakes

Mechanical service brakes - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Oil immersed brakes have externally lined brake discs, (1), and are driven by spline on final drive pinion shaft passing through the housing bolted to the tractor rear drive housing. An actuating assembly, (2), is mounted between the brake discs, (1), which consists of two discs, (3), separated by steel balls, (4), but connected by short springs, (5). Lugs on the discs are attached to a yoke, (6), on the operating rod. Between 1st and 2nd and 3rd and 4th brake discs stator discs, (7), are fitted.

20098775

When the tractor is moving, the brake discs rotate with the final drive pinion shaft If brake pedal is depressed, its associated brake links cause the actuating discs to turn in opposite directions. As the pressure plates turn, the balls, (4), clamped between the actuating discs roll over the inclined surfaces of their sockets, (8). In the plates, thus causing the actuating discs to move axially outwards to contact the rotating brake discs which in turn contact the inner faces of the final drive housing, (9), differential support, (10), and stator discs. This movement increases the axial force on the housing support, stator and actuation and produce brake torque. This action causes the final drive pinion, hence 47921938 07/02/2017

33.1 [33.120] / 8

Brakes and controls - Mechanical service brakes

the associated driving wheel of the tractor, to slow down and then stop rotating completely. On release of the brake, retracting springs, (5), return the plates to their original positions. The force exerted by the driver is transmitted to the brake assembly by a system of levers and rods. The actuating system not only connects the pedal with the brake but also increases the relatively small force available at the pedal to the much larger force required to brake the vehicle. It can also permit the braking effort to be divided between the axles in the required proportion. Left wheel brake pedal can be retained in the applied position by means of latch controlled by a hand lever fitted at right hand side, below operatorâ&#x20AC;&#x2122;s seat used as a parking brake.

47921938 07/02/2017

33.1 [33.120] / 9

Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Remove Brake pedals and external linkages TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Remove brake pedal spring, (1). 2. Remove split pin, (2), and disconnect linkage, (3). 3. Remove circlip, (4), and pull out right-hand brake pedal.

20098375

20098376

20098377

4. Loosen Lock screw, (1), and remove left-hand brake pedal, (2).

5. Remove spring, (1), split pin and disconnect left-hand brake linkage, (2), at left-hand side of the tractor.

47921938 07/02/2017

33.1 [33.120] / 10

Brakes and controls - Mechanical service brakes

6. Remove clutch pedal spring, (1).

20098378

20098379

20098380

7. Remove split pin, (1), and disconnect linkage, (2), from clutch cross shaft.

8. Pull out clutch/brake pedal support rod, (1), from the rear axle housing. 9. Remove clutch pedal, (2), from the support shaft.

Inspection Clean the brake pedal assembly thoroughly and check for bushing and support rod wear, replace as necessary.

47921938 07/02/2017

33.1 [33.120] / 11

Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Insert clutch/brake pedal support rod, (1), through clutch pedal, (2), and into rear axle housing.

20098380

20098379

20098378

2. Reconnect the linkage, (1), to the clutch cross shaft and secure with split pin, (2).

3. Reattach the clutch pedal spring, (1).

47921938 07/02/2017

33.1 [33.120] / 12

Brakes and controls - Mechanical service brakes

4. Reconnect the left-hand side brake linkage, (1), and secure with spit pin. 5. Reconnect brake linkage return spring, (2),

20098377

20098376

20098375

6. Reinstall the left-hand brake pedal, (1), onto the cross shaft and secure with locking screw, (2).

7. Reinstall the right-hand brake pedal onto the cross shaft and secure with circlip, (1). 8. Reconnect the right-hand side brake linkage, (2), and secure with spit pin, (3). 9. Reconnect brake linkage return spring, (4).

47921938 07/02/2017

33.1 [33.120] / 13

Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Adjust Free play TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Measure free play of the brake pedals which should be 35 – 45 mm (1.38 – 1.77 in). With the brake pedals locked together, the tractor should stop in a straight line when brakes are applied.

20098410

20098375

Adjustment is made to the brake pull rods beneath the tractor. Block the wheels, front and rear, unlock the brake pedals and release the parking brake lever. Unlock nut, (1), and rotate screw, (2), to adjust play.

• Screw in to reduce the play • Screw out to increase the play Repeat the same procedure for the left brake pull rod. Lock the brake pedals together and road test to ensure that the brakes are balanced and will stop the tractor in a straight line. Any further adjustment necessary to balance the brakes should be carried out on the right brake.

47921938 07/02/2017

33.1 [33.120] / 14

Brakes and controls - Mechanical service brakes

Brake drums - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

NOTE: To remove brake assembly, final drive assembly has to be removed from the rear wheel drive assembly. 1. Remove final drive assembly, (1), from rear axle housing. Consult the procedures in Rear axle housing Remove (27.100).

20098777

20098778

2. Remove outer brake discs and stator from the brake assembly. Repeat this procedure on the other side.

47921938 07/02/2017

33.1 [33.120] / 15

Brakes and controls - Mechanical service brakes

3. Remove split pin, (1), and spring, (2), disconnect brake linkage, (3). Repeat this procedure on the other side.

20098375

20098403

20098404

20098405

4. Loosen two bolts and remove cover, (1). (Left side cover already removed).

5. Loosen and remove locking screws, (1).

6. Remove actuating shaft, (1), from the housing. Repeat this procedure on the other side.

47921938 07/02/2017

33.1 [33.120] / 16

Brakes and controls - Mechanical service brakes

7. Remove the brake actuating assembly, along with inner brake discs and stator from housing. Repeat this procedure on the other side.

20098406

Next operation: To inspect the brake drums, see the procedures in Brake drums - Inspect (33.120).

47921938 07/02/2017

33.1 [33.120] / 17

Brakes and controls - Mechanical service brakes

Brake drums - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To remove the brake drums, see the procedures in Brake drums - Disassemble (33.120). 1. Inspect the actuating plate faces for wear and damage, replace if necessary. 2. Inspect the brake discs, if badly scored, worn or cracked, replace. 3. Check O-ring on actuating shaft for any damage and replace if necessary. NOTICE: Brake discsâ&#x20AC;&#x2122; thickness should be minimum 4.30 mm (0.169 in). Next operation: To fit the brake drums, see the procedures in Brake drums - Assemble (33.120).

47921938 07/02/2017

33.1 [33.120] / 18

Brakes and controls - Mechanical service brakes

Brake drums - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To inspect the brake drums, see the procedures in Brake drums - Inspect (33.120). 1. Insert the inner two brake discs, (1), with a stator, (2), between them into the rear wheel drive housing. Secure the assembly by placing the notch in the stator on the ear of the differential bearing support, (3). Repeat this step for the other side.

20098411

20098406

2. Insert the brake actuating assembly, (1), into the rear wheel drive housing, (2). Repeat this step for the other side.

47921938 07/02/2017

33.1 [33.120] / 19

Brakes and controls - Mechanical service brakes

3. Insert the actuating shaft, (1), in through the rear wheel drive housing and linkage of the brake actuating assembly. Repeat this step for the other side.

20098405

20098404

20098403

20098375

4. Insert M16 x 32 tapered locating bolts, (1), securing the actuating shafts into the rear wheel drive housing. Torque bolts to 167 NÂˇm (123 lb ft).

5. Install both cover plates, (1), using M8 x 22 bolts, (2). Torque bolts to 26 NÂˇm (19 lb ft).

6. Attach the brake linkage, (1), to the actuating shaft, (2), using pin, washers, and split pin, (3). 7. Reconnect the return spring, (4). Repeat steps (5) through (8) for other side.

47921938 07/02/2017

33.1 [33.120] / 20

Brakes and controls - Mechanical service brakes

8. Insert a single brake disc, (1), allowing it to rest on the ears of the differential bearing support, (2).

20098778

20098408

20097446

9. Insert brake disc alignment arbor, (1), (Special Tool No.380002743) through brake discs and stators, (2), into the differential unit splines.

10. Press brake pedals to engage actuator plates, and set the parking brake, (1). 11. Remove brake disc alignment arbor (Special Tool No.380002743), from within the rear wheel drive housing.

47921938 07/02/2017

33.1 [33.120] / 21

Brakes and controls - Mechanical service brakes

NOTICE: Before reinstalling the rear axle housing, thoroughly clean and degrease mating surfaces. 12. Apply a bead of LOCTITEÂŽ 518â&#x201E;˘ Sealant, approximately 2 mm (0.079 in) in width following the pattern shown.

20098840

20098409

13. Place the brake disc, (1), and the stator, (2), onto the axle shaft, (3).

47921938 07/02/2017

33.1 [33.120] / 22

Brakes and controls - Mechanical service brakes

14. Wrap a suitable chain, (1), or nylon strap around the final drive housing, (2). Carefully insert the final drive housing into the rear wheel drive housing, making sure the axle shaft and the brake discs are all properly aligned and inserted into the splined differential unit. 15. Start the M12 x 90 mm bolts through the final drive housing into the rear wheel drive housing, for alignment purposes. NOTICE: The M12 x 90 mm bolts are for the sole purpose of alignment only. DO NOT try to draw the final drive and rear wheel drive housings together. Failure to follow this warning could cause severe damage to internal components and or drive housings of the tractor. 16. Release the parking brake to allow the brake actuator to disengage. 17. Using a thin screw driver, hold the outer brake disc and stator into position. Work the final drive housing into the rear wheel drive housing, until fully seated. 18. Secure the final drive housing, (2), to the rear wheel drive housing using the M12 x 45 mm retaining bolts, M12 nuts, and flat washers. Torque all hardware to 101 NÂˇm (74 lb ft) NOTE: After final drive housing has been secured, check axle hubs for free movement. If axle hub does not move freely, remove final drive housing and check for proper brake installation.

47921938 07/02/2017

33.1 [33.120] / 23

20098777

Brakes and controls - Mechanical service brakes

Mechanical service brakes - Troubleshooting TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Problem Possible Cause The brake only activates Incorrect pedal adjustment when the pedal is fully depressed. The tractor pulls to one The brakes are not equally adjusted side when the brakes are applied Wrong tire pressure Wrong liners on one side Brakes noisy Oil contamination Wrong brake disc Brakes remain applied Seized brake actuating linkages when pedals are released Pedals are hard to operate Seized brake actuating linkages

47921938 07/02/2017

33.1 [33.120] / 24

Correction Check and adjust

Adjust

Inflate tires to correct pressure Replace discs Check and change with recommended oil Replace brake discs. Clean and lubricate linkages Clean and lubricate linkages

Index Brakes and controls - 33 Mechanical service brakes - 120 Brake control pedals and shafts - Sealing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake control pedals and shafts - Adjust Free play (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake control pedals and shafts - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake control pedals and shafts - Remove Brake pedals and external linkages (*) . . . . . . . . . . . . . .

Brake control pedals and shafts - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake drums - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake drums - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake drums - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - Sectional view Brake control assembly (*) . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

33.1 [33.120] / 25

47921938 07/02/2017

33.1 [33.120] / 26

Brakes and controls - 33 Parking brake or parking lock - 110

47921938 07/02/2017

33.2 [33.110] / 1

Contents Brakes and controls - 33 Parking brake or parking lock - 110

SERVICE Parking brake external control Remove Parking brake (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install Parking brake (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(*) See content for specific models 47921938 07/02/2017

33.2 [33.110] / 2

Brakes and controls - Parking brake or parking lock

Parking brake external control - Remove Parking brake TT3880F

1. Remove split pin from hand brake linkage 2. Pull out hand brake lever, (1), along with linkage rod from the linkage assembly.

20097446

20097447

3. Remove bolt, (1), and hand brake pawl, (2).

Inspection Clean the brake pedal assembly thoroughly and check for bushing and support rod wear, replace as necessary.

47921938 07/02/2017

33.2 [33.110] / 3

Brakes and controls - Parking brake or parking lock

Parking brake external control - Install Parking brake TT3880F

1. Reinstall hand brake pawl, (1), and secure with bolt, (2).

20097447

20097446

2. Insert hand brake lever, (1), along with linkage rod downward through the operators platform. 3. Reinstall split pin, securing hand brake linkage to brake pawl, (1), Refer Brake control pedals and shafts Assemble (33.120) .

47921938 07/02/2017

33.2 [33.110] / 4

Index Brakes and controls - 33 Parking brake or parking lock - 110 Parking brake external control - Install Parking brake (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake external control - Remove Parking brake (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

33.2 [33.110] / 5

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

47921938 07/02/2017 EN

SERVICE MANUAL Hydraulic systems TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017

Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.100] Main lift system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.116] Three-point hitch cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.114] Three-point hitch control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7

47921938 07/02/2017

Hydraulic systems - 35 Hydraulic systems - 000

47921938 07/02/2017

35.1 [35.000] / 1

Contents Hydraulic systems - 35 Hydraulic systems - 000

FUNCTIONAL DATA Hydraulic systems Component identification Introduction and circuit identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic schema Open center hydraulic circuit and mechanical lift (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(*) See content for specific models 47921938 07/02/2017

35.1 [35.000] / 2

Hydraulic systems - Hydraulic systems

Hydraulic systems - Component identification Introduction and circuit identification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

The hydraulic system on the TT tractor is for mechanical lift assembly to raise and lower the lift arms in turn three point linkages and for remote control valves. The high pressure hydraulic circuit is of open center load sensing type. In this system, hydraulic lift and remote control valve are connected in series and pump flow is continuously circulating through the hydraulic system even when the circuit are not being operated. The priority of operation is given to the order of components in the circuit, that is remote valves and hydraulic lift. This means for example when fully operating a remote valve the lift will not operate at the same time. The open center high pressure hydraulic circuit with mechanically controlled hydraulic lift is shown in Hydraulic systems - Hydraulic schema Open center hydraulic circuit and mechanical lift (35.000) and includes the components shown below.

Pump Open center hydraulic pump assembly is a high pressure gear pump, (1). See the pump details in Variable displacement pump - General specification (35.106) for more details on the pump.

20098412

20098413

Filter Full-flow spin on type filter, (1), directly mounted on suction side of the pump.

47921938 07/02/2017

35.1 [35.000] / 3

Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema Open center hydraulic circuit and mechanical lift TT3840F TT3840 TT3880F TT4030

LA LA LA LA

See figure 1 and figure 2. High pressure pump is directly connected on rear side of engine timing gear. Oil is drawn from transmission housing through filter. The pump supplies constant oil flow according to engine speed through remote control valve. Oil after passing through remote, enters the distributor oil located at the front of the lift assembly, which controls the raising and lowering of the lift. All excess oil flow produced by the hydraulic pump is returned direct to the rear axle through the control valve spool located in the hydraulic lift distributor. Also located within the distributor is the lift cylinder safety valve, which protects the lift cylinder and seals from excessive peaks of pressure during operation. For further details on operating the mechanical hydraulic lift assembly, see the specifications in Rear three-point hitch - General specification (37.110) and the subsequent information.

20098850

1. 2. 3. 4.

Suction line drawing from Transmission housing Delivery line to control valve Lift arm Control Valve

5. 6. 7.

Oil filter Hydraulic pump Relief valve

47921938 07/02/2017

35.1 [35.000] / 4

Hydraulic systems - Hydraulic systems

Hydraulic circuit diagram

20098853

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

Filter Hydraulic pump Relief valve (installed on lift body or on remote control valve) Spool Spool return spring Control valve plunger Plunger Spring Control valve position seat

47921938 07/02/2017

35.1 [35.000] / 5

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

Control valve position Sensitivity control valve Ball Cylinder saftey valve Arm response adjacent valve Check valve Adjusting pipe lever Arm response adjusting pin knob

Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Component identification Introduction and circuit identification (*) . . . . . . . . . . .

Hydraulic systems - Hydraulic schema Open center hydraulic circuit and mechanical lift (*) . . . . . .

(*) See content for specific models 47921938 07/02/2017

35.1 [35.000] / 6

Hydraulic systems - 35 Variable displacement pump - 106

47921938 07/02/2017

35.2 [35.106] / 1

Contents Hydraulic systems - 35 Variable displacement pump - 106

TECHNICAL DATA Variable displacement pump General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Variable displacement pump Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Variable displacement pump Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

(*) See content for specific models 47921938 07/02/2017

35.2 [35.106] / 2

Hydraulic systems - Variable displacement pump

Variable displacement pump - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Component

TT3840

TT3840F

TT3880F

TT4030

Filter Type Position

Paper cartridge On Pump Body, Suction Side

Pump Type Position Model Make Transmission Rotation (seen from drive end) Engine/Pump Drive Ratio Max. rated speed (engine at governed speed) Max rated Output Output at 1450 RPM and 16603 kPa (2408 psi) New or Reconditioned Used Test Oil Temperature Test Oil Grade Pump Gear Journal Diameter Journal Housing Bore Diameter in Bearing Journal Clearance in Bearing Max. Wear Clearance Gear in Pump Body Max Pump Body wear on Suction Side Gear Flank Width Bearing Width Pump Body Width Gear and Bearing End Float (Applicable to New and Reconditioned Pumps)

Gear, drawing from rear Transmission housing Behind timing cover A31 Hema Valve timing gear driven Counterclockwise (CCW) 1:0.931 2328 RPM 41.0 l/min (10.8 US gpm) 19 l/min (5.02 US gpm) 13.3 l/min (3.51 US gpm) 55 – 65 °C (131 – 149 °F) SAE 20W 30/API-GL4 17.4 – 17.418 mm (0.6850 – 0.6857 in) 17.45 – 17.470 mm (0.6870 – 0.6878 in) 0.032 – 0.070 mm (0.00126 – 0.00276 in) 0.1 mm (0.0039 in) 0.020 – 0.064 mm (0.00079 – 0.00252 in) 0.1 mm (0.0039 in) 24.000 – 24.015 mm (0.9449 – 0.9455 in) 24.490 – 24.510 mm (0.9642 – 0.9650 in) 73.15 – 73.16 mm (2.8799 – 2.8803 in) 0.100 – 0.180 mm (0.0039 – 0.0071 in)

Variable displacement pump - Torque TT3840F TT3840 TT3880F TT4030

LA LA LA LA

47921938 07/02/2017

35.2 [35.106] / 3

Hydraulic systems - Variable displacement pump

20098843

Description Nut, pump drive gear, (C1) Nut, pump mounting on timing case, (C2) Bolt, pump cover, (C3) Bolt, delivery pipe to pump, (C4)

Thread size 7/16 - 20

Torque 47.5 N路m (35.0 lb ft)

M6 x 1

8 N路m (5.9 lb ft)

M10 x 1.25 M6 x 1

58 N路m (42.8 lb ft) 10 N路m (7.4 lb ft)

47921938 07/02/2017

35.2 [35.106] / 4

Hydraulic systems - Variable displacement pump

Variable displacement pump - Static description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Hydraulic pumps are spur gear type with fixed displacement according to rpm. Pump is mounted on the engine timing gear case. It is driven by engine timing gears. Oil is drawn by pump from the transmission housing by pump via oil filter. The bushing gears is housed in the body and consists of a pair of meshing gears with integral journals supported in two matched pairs of composite bushings. One of the drive gear journals extends through the mounting flange to form the pump drive shaft, and an oil seal located in housing surrounding the shaft prevents oil leakage. The pump is flange mounted and the drive coupling is keyed to the tapped shaft by a woodruff key and secured by a nut and tap washer to the threaded shaft end. Inlet is cast on the body to identify the inlet port. The bushing/gear assembly is pressure loaded against the end cover and the bushings and the pressure balanced to prevent tilt. These features ensure that internal leakage is kept to a minimum, enabling the pump to operate at high efficiency. The condition of the bushing faces adjacent to the gears is an important factor in maintaining this efficiency and during any dismantling on assembly operations, the bushings must be handled carefully to prevent damage. It is essential that the pump is operated only in a clean system. Any foreign matter in the oil will score the bushing faces, and this will lead to shortened service life and eventual failure.

20098422

1. 2. 3. 4. 5. 6. 7. 8. 9.

Coupling gear nut Tab washer Shaft oil seal Bolt Mounting flange Body seal O-ring Backing washer Backing washer Lobe seal

10. 11. 12. 13. 14. 15. 16. 17. 18.

Composite bushing Composite bushing Woodruff key Drive shaft and gear -- Taper Driven gear Body End cover Lockwasher Snap Ring

47921938 07/02/2017

35.2 [35.106] / 5

Hydraulic systems - Variable displacement pump

Variable displacement pump - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

WARNING Handle all parts carefully. Do not put your hands or fingers between parts. Always wear suitable safety items such as fitted clothing, safety goggles, gloves, shoes, etc. Failure to comply could result in death or serious injury. M954A

1. Loosen clamp screws, (1), and disconnect supply pipe, (2), from filter bracket.

20098423

2. Loosen bolts, (1), and disconnect delivery pipe from pump. 3. Remove filter, (2), and filter bracket, (3), from the pump.

4. Loosen four pump mounting bolts, (1). 5. Remove pump from the tractor. Retrieve seal from the timing case.

47921938 07/02/2017

35.2 [35.106] / 6

Hydraulic systems - Variable displacement pump

Next operation: Variable displacement pump - Disassemble (35.106)

47921938 07/02/2017

35.2 [35.106] / 7

Hydraulic systems - Variable displacement pump

Variable displacement pump - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Variable displacement pump - Remove (35.106) 1. Place hydraulic pump into vise. Bend back the ears of the locking tab washer, (1), and remove nut, (2).

20098424

20098425

20098856

2. Using a suitable puller, (1), remove hub, (2), and retaining ring. Retain keyway, (3), shown in Figure 1, pump shaft.

3. Lightly mark the end cover flange, (1), body flange, (2), and mounting flange, (3), to ensure reassembly in the correct position and take note of the direction of rotation of the pump. 4. Remove the bolts, (4), and lock washers, (5).

47921938 07/02/2017

35.2 [35.106] / 8

Hydraulic systems - Variable displacement pump

5. Remove the end cover, (1), and carefully lift out the cover seal, (2), the bushing lobe seal, (3) and the backing washers, (4). 6. Lightly tap the mounting flange clear of the hollow dowels in the pump body and slide it squarely to the shaft. NOTICE: Make sure there are no burrs on the keyway in the shaft

20098856

7. Carefully lift out body seal, (1), the backing washers, (2), and the lobe seal, (3).

8. Hold the pump body vertically with the mounting flange end downwards and with one hand underneath to prevent the bushings from dropping out. 9. Tap the side of the body, (1), with a rubber hammer to dislodge the lower bushings, (2). Carefully slide these out of the body. NOTE: Keep the bushings as a pair and place them on the mounting flange.

10. Invert the body and lift out the drive gear, (1) and driven gear, (2). 11. Remove the remaining pair of bushings as already described and place on the end cover. 12. Remove snap ring, (3), and oil seal, (4), from the mounting flange.

Next operation: Variable displacement pump - Inspect (35.106) 47921938 07/02/2017

35.2 [35.106] / 9

Hydraulic systems - Variable displacement pump

Variable displacement pump - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Variable displacement pump - Disassemble (35.106) NOTE: It is likely that wear of the internal parts will be uniform and it may be more economical to obtain a service replacement unit than to fit several new parts. Wash all metal parts thoroughly in a proprietary cleaning fluids, such as Belco cleaning solvent. Inspect in the order set out below, for wear and damage.

Body To obtain high efficiency the design allows for the tips of the gear teeth to wipe the walls of the body bores when the pump is running. Pressure will force the gears against the inlet side of the bores and a witness mark will be visible in this area. If excessive wear of the bushing inserts or gear journals occurs this witness mark will deepen to form a wear track, causing a step in the bore. Examine the body bores and if a pronounced step is felt the body must be rejected. It is inadvisable to fit worn bushings in a new body. Check the security of the two dowels.

Composite Bushings Examine the bearing inserts for signs of wear and bushing faces adjacent to the gears for scoring or pitting. Ensure that the holes and slots in the bushings are unobstructed. Light scoring on the bushing faces can be polished out on a lapping plate. NOTICE: If new bushings are to be fitted into an old body; check for the presence of a burr at the edges of the wear track. If present, this burr must be polished out otherwise it will hold the bushing faces away from the gears and increase the internal leakage.

Gears Examine the gears for discolouration, indicating, overheating. Check the journals for scoring. Ensure that the contract marks on the teeth are evenly distributed across each tooth surface and ensure that none of the teeth are chipped. If the pump has suffered overheating this may have been caused by a fault in the hydraulic system, such as a defective relief valve, and this must be investigated. NOTE: Bushings and gears are mated for width within 0.005 mm (0.0002 in) and can be renewed only in pairs.

End Cover Ensure that the flat, inner surface of the cover is free from scoring or pitting.

Mounting Flange Examine for damage and check the condition of the drive shaft oil seal.

47921938 07/02/2017

35.2 [35.106] / 10

Hydraulic systems - Variable displacement pump

Measure gear to pump body end float. Dimension, (1), must be smaller than dimension, (2), by 0.090 â&#x20AC;&#x201C; 0.160 mm (0.0035 â&#x20AC;&#x201C; 0.0063 in). If necessary remove minimum qualities of material from flat faces of bearing assemblies to obtain specified end float.

20098426

Next operation: Variable displacement pump - Assemble (35.106)

47921938 07/02/2017

35.2 [35.106] / 11

Hydraulic systems - Variable displacement pump

Variable displacement pump - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Variable displacement pump - Inspect (35.106) 1. Install oil seal, (1) and snap ring, (2), into the mounting flange, (3). 2. Install the pair of bushings from removal. 3. Invert the body and install the drive gear, (4), and driven gear, (5).

20098856

4. Carefully slide the bushings, (1), into the body, (2).

5. Carefully install the lobe seal, (1), the two backing washers, (2) and the body seal, (3).

47921938 07/02/2017

35.2 [35.106] / 12

Hydraulic systems - Variable displacement pump

6. Lightly tap the mounting flange, (1), onto the two hollow dowels in the pump body, (2), and slide it squarely to the shaft. 7. Install the bushings, (3), and carefully install the bushing lobe seal, (4), two backing washers, (5), cover seal, (6), and the end cover, (7).

20098856

20098424

8. Reassemble the end cover flange, (1), body flange, (2) and mounting flange, (3), in the correct position. 9. Install lock washer, (4), and bolt, (5). Torque bolt to 56 NÂˇm (41 lb ft).

10. Install the Woodruff key, (1). Install hub, (2), locking tab washer, (3) and nut, (4). Torque nut to 47.5 NÂˇm (35.0 lb ft). Bend the ears of the tab washer to secure nut.

Next operation: Variable displacement pump - Install (35.106)

47921938 07/02/2017

35.2 [35.106] / 13

Hydraulic systems - Variable displacement pump

Variable displacement pump - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Variable displacement pump - Assemble (35.106) NOTE: Clean and degrease the mating surfaces thoroughly. Replace the packing seal if necessary. 1. Install pump, (1), onto tractor with a new gasket. 2. Secure pump with four M6 lock washers and four M6 x 30 mm bolts, (2). Tighten to 12 N·m (106 lb in).

20098423

3. Install filter bracket, (1), onto pump with a new O-ring (not shown). Torque the below mentioned Allen screws to 15 N·m (11 lb ft). (2X) M8 X 1.25 X 45 MM ALLEN SCREW (1X) M8 X 1.25 X 30 MM ALLEN SCREW 4. Install a new filter, (2). 5. Install delivery pipe, (3), with a new O-ring and new ring (not shown). 6. Secure the pipe to the pump with two lock washers and two M6 x 30 mm hex head bolts. Torque to 12 N·m (106 lb in).

7. Install supply pipe, (1), onto filter bracket connection. Secure clamps, (2).

47921938 07/02/2017

35.2 [35.106] / 14

Hydraulic systems - Variable displacement pump

NOTE: Repair to the pump is limited to replacement of the seals only. All other components are serviced as a pump replacement only. NOTICE: Oil pump should always be repaired in very clean conditions to prevent contamination from foreign matter which could damage the pump.

47921938 07/02/2017

35.2 [35.106] / 15

Hydraulic systems - Variable displacement pump

Variable displacement pump - Test TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: Variable displacement pump - Install (35.106)

WARNING Pressurized hydraulic fluid can penetrate the skin and cause severe injuries. Tighten all of the connections before starting the engine. If hydraulic fluid has penetrated the skin, seek medical assistance immediately. Failure to comply could result in death or serious injury. M950A

NOTE: Inlet restriction test cannot be performed at the rear remote couplers, because of a reduced pressure reading. 1. Start the engine and operate the hydraulic system to warm the hydraulic fluid to normal operating temperature. 2. Open the restrictor valve, (1), to allow full flow through the flow meter. 3. Run the engine at 1375 RPM and record the flow meter reading. 4. Run the engine at full throttle ( 2750 RPM) and read the flow meter. The reading should indicate that the flow has doubled. If the meter reading is low, check the hydraulic lines, and filter for damage, clogs, or air leaks. If there are no problems with the hydraulic lines or the hydraulic filter, the hydraulic pump may require replacement. Use the Pump Efficiency Test described below to further inspect the hydraulic pump.

20098857

47921938 07/02/2017

35.2 [35.106] / 16

Hydraulic systems - Variable displacement pump

NOTE: Pump efficiency test cannot be performed at the rear remote couplers, because of a reduced pressure reading. 1. Start the engine and operate the hydraulic system to warm the hydraulic fluid to normal operating temperature. 2. Operate the tractor engine at full rpm. Observe the flow meter reading. See chart below for the no load pressure readings. 3. Tighten the flow restrictor valve, (1), on the flow meter until the system pressure is 15995 kPa (2320 psi). 4. Observe the flow meter reading, the results should be approximately 80% of the no-load flow. Minimum flow rating is 32.8 l/min (8.66 US gpm). If testing shows the hydraulic pump output is low, the pump requires replacement. NOTICE: Do not exceed 15995 kPa (2320 psi).

20098857

Pump Capacity rpm @ half throttle pump flow @ half throttle rpm @ full throttle pump flow @ full throttle

41.0 l/min (10.8 US gpm) 1375 RPM 20.4 l/min (5.4 US gpm) 2750 RPM 41.0 l/min (10.8 US gpm)

47921938 07/02/2017

35.2 [35.106] / 17

Index Hydraulic systems - 35 Variable displacement pump - 106 Variable displacement pump - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Variable displacement pump - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Variable displacement pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Variable displacement pump - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Variable displacement pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Variable displacement pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Variable displacement pump - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Variable displacement pump - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Variable displacement pump - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

35.2 [35.106] / 18

Hydraulic systems - 35 Remote control valves - 204

47921938 07/02/2017

35.3 [35.204] / 1

Contents Hydraulic systems - 35 Remote control valves - 204

TECHNICAL DATA Remote control valves General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Remote control valves Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(*) See content for specific models 47921938 07/02/2017

35.3 [35.204] / 2

Hydraulic systems - Remote control valves

Remote control valves - General specification TT3840F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016

LA LA LA

TT3840F

TT3880F 45 L 185.0 – 195.0 bar (2682.5 – 2827.5 psi) 315.0 bar (4567.5 psi)

Maximum flow rate Opening pressure Operating pressure

Remote control valves - Torque TT3840F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016

LA LA LA

TT3840F Bolts to secure the pump bypass tube onto the remote control valve Bolts to secure the pump bypass tube onto the hydraulic reservoir Bolts to secure the pump hydraulic tube onto the remote control valve Bolts to secure the remote control valve onto the Rollover Protective Structure (ROPS)

TT3880F

65.0 – 75.0 N·m (47.9 – 55.3 lb ft) 65.0 – 75.0 N·m (47.9 – 55.3 lb ft) 65.0 – 75.0 N·m (47.9 – 55.3 lb ft) 22.0 – 29.0 N·m (16.2 – 21.4 lb ft)

47921938 07/02/2017

35.3 [35.204] / 3

Hydraulic systems - Remote control valves

Remote control valves - Remove TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

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. Remove the bolt (3). Remove the hydraulic pressure tube (4). 2. Remove the bolt (2). Remove the hydraulic tube (1).

CUIL16TR00908AA

CUIL16TR00904AA

CUIL16TR00905AA

3. Remove the bolt (1). Remove the hydraulic tube (2).

4. Remove the pins (1) and (4). Remove the control levers (2) and (3).

47921938 07/02/2017

35.3 [35.204] / 4

Hydraulic systems - Remote control valves

5. Remove the four bolts (1) that secure the valve onto the Rollover Protective Structure (ROPS). 6. Remove the valve assembly (2) from the machine.

CUIL16TR00906AA

47921938 07/02/2017

35.3 [35.204] / 5

Index Hydraulic systems - 35 Remote control valves - 204 Remote control valves - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valves - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valves - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

35.3 [35.204] / 6

Hydraulic systems - 35 Main lift system - 100

47921938 07/02/2017

35.4 [35.100] / 1

Contents Hydraulic systems - 35 Main lift system - 100

FUNCTIONAL DATA Main lift system Dynamic description Internal linkage system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47921938 07/02/2017

35.4 [35.100] / 2

Hydraulic systems - Main lift system

Main lift system - Dynamic description Internal linkage system TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Functioning of : 1. Position control 2. Float Control 3. Draft control 4. Combined Draft and Position Control

Position control When the traction control lever, (1), is fully lowered, the traction control inner lever, (2), moves away from roller, (3). In this way the draft linkages/levers will not in any way interfere with position control. When the lever, (4), is moved back, the cam on the end of the shaft, (5), moves the lever, (6), located between the roller, (7), and the cam, (8), upwards. As the cam, (8), is stationary on the arm cross-shaft at the beginning of the operation, the lever, (6), reacts against it and pushes the roller, (7), forward. This moves link, (9), and lever, (10), in the direction indicated by the solid arrows to set control valve, (11), in the arm lift position. Arms rise until cam, (8), turns far enough to permit lever, (10), link, (9), and lever, (6), to move under the action of spool return spring, (1), refer Rear three-point hitch - Hydraulic schema (37.110) , in the direction indicated by the clear arrows. The control valve, (11), therefore returns to neutral and the arms stop in the neutral position. Maximum arm upward travel is limited by rod, (12). When rod, (12), contacts piston, (13), the control valve is returned to neutral through adjusting screw, (14), before the piston reaches mechanical travel limit stop. The same movements occur in reverse when lever, (4), is moved forward to lower arms.

Float Control â&#x20AC;˘ With position control lever, (4), and draft control lever, (1), fully forward: â&#x20AC;˘ Lever, (6), link, (9), and lever, (10), are moved in the direction opposite to that indicated by the solid arrows, and control valve is held in lowered position, refer Rear three-point hitch - Hydraulic schema (37.110) , thereby letting arms swing freely and associated implement float on the surface of the soil.

47921938 07/02/2017

35.4 [35.100] / 3

Hydraulic systems - Main lift system

20098693

47921938 07/02/2017

35.4 [35.100] / 4

Hydraulic systems - Main lift system

Draft control Move position control lever, (1), fully forward. When the implement has been set to the desired working depth by means of lever, (2), and if the implement then hits a stretch of harder or more compact soil, the draft force on the lower links will increase. This will then cause a greater top link thrust against the spring, (3), which, compressing, transmits motion in the direction of the solid arrows, to the lever, (4), the lever, (5), the link, (6), the lever, (7), the link, (8), and the lever, (9), thereby setting the control valve in the arm lifting position. The arms will rise until the resulting reduction in draft force reduces the compression of spring, (3), and causes lever, (4), to rotate in the opposite direction, allowing lever, (9), to move backwards, pulled by the control valve spool spring. Control valve returns to neutral and arms stop lifting. Once the hard stretch has been left behind, the draft control spring, (3), returns completely to its original position and lever, (9), moves further back. The control valve returns to the discharge position refer Rear three-point hitch - Hydraulic schema (37.110) so that the arms lower the implement to its original working position. The control lever, (2), is positioned further back on the quadrant (draft reduction), the hollow shaft, (10), pushes the lever, (7), roller, (11), linkage, (8), and lever, (9), to act against the control valve spool, setting the valve to the delivery position. If the lever, (2), is moved forward (increased draft), operation is the same but in the opposite direction.

47921938 07/02/2017

35.4 [35.100] / 5

Hydraulic systems - Main lift system

20098694

47921938 07/02/2017

35.4 [35.100] / 6

Hydraulic systems - Main lift system

Combined Draft and Position Control With position control lever, (1), fully forward, and moving the draft control lever, (2), forward from the fully back position, the working depth is established as described above. When lever, (1), is then shifted backwards, lever, (3), link, (4), and lever, (5), move in the direction indicated by the solid arrows in the position control diagram, placing the control valve in the delivery position and causing a slight upward movement of the lift arms. This condition permits lift to operate in draft control mode when patches of hard or compact soil are encountered. Combined draft and position control therefore limits the changes in working depth which can occur when draft control alone is used.

20098693

47921938 07/02/2017

35.4 [35.100] / 7

Index Hydraulic systems - 35 Main lift system - 100 Main lift system - Dynamic description Internal linkage system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

35.4 [35.100] / 8

Hydraulic systems - 35 Three-point hitch cylinder - 116

47921938 07/02/2017

35.5 [35.116] / 1

Contents Hydraulic systems - 35 Three-point hitch cylinder - 116

TECHNICAL DATA Three-point hitch cylinder Three-point hitch cylinder - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Three-point hitch cylinder Three-point hitch cylinder - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Three-point hitch cylinder Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

(*) See content for specific models 47921938 07/02/2017

35.5 [35.116] / 2

Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Specifications Component Type Make Localisation Command Relief valve setting Valve plunger clearance in body. Relief valve spring length: free below 294 N + 53 N ( 30 kg + 5.4 kg or 66.2 lb + 11.9 lb) Valve plunger return spring length Check valve spring length

TT3840

TT3840F TT3880F Spool (automatic return to neutral) Hema On RH final drive Hand levers 186 bar â&#x20AC;&#x201C; 11 bar 0.003 mm â&#x20AC;&#x201C; 0.006 mm 39.4 mm 38.2 mm 42.8 mm 15.9 mm

Three-point hitch cylinder - Special tools TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Special tools Tool description Hydraulic Pressure Test Kit

No. of the tool 292870

47921938 07/02/2017

35.5 [35.116] / 3

TT4030

Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Description and operation The auxiliary cylinders are used to control external hydraulic implements connected to the tractor. The tractor is equipped with 2 auxiliary cylinders, which are secured by the upper right-hand side of the rear axle housing. The auxiliary cylinders are operated by means of a control lever located on the right-hand side of the operations area behind the hydraulic lift control levers. The auxiliary cylinder control lever has three positions.

LAIL11TT0438F0A

Single acting cylinder control

47921938 07/02/2017

35.5 [35.116] / 4

Hydraulic systems - Three-point hitch cylinder

LAIL11TT0439F0A

Double acting cylinder control

A - Raise Pulling the lever forward will extend the cylinder and raise the implement.

B - Neutral When released, the spring automatically returns the lever to the neutral position, disabling the connected cylinder.

C â&#x20AC;&#x201C; Lower Pushing the lever backward will retreat the cylinder and lower the implement. NOTE: Shuffling the cylinder connection to the auxiliary cylinder will reverse the lever function. i.e. forward movement will lower the implement; backward movement will raise the implement. NOTE: The auxiliary cylinder uses the same hydraulic fluid as the hydraulic lift, but is operated independently with the hand lever (c). It is not possible, however, to operate the auxiliary cylinder and the hydraulic lift unit simultaneously.

47921938 07/02/2017

35.5 [35.116] / 5

Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

WARNING Pinch point! Lift arm assembly pivots create pinch points. Keep fingers, hands, and feet away from pivot points. Failure to comply could result in death or serious injury. W0357A

1. Loosen the bolts (1) and disconnect the hydraulic delivery pipe. 2. Loosen the banjo bolt (2) and disconnect the hydraulic line from the lift housing.

LAIL11TT0465A0A

LAIL11TT0466A0A

3. Disconnect the hydraulic line (1) between the auxiliary cylinder and the cylinder.

47921938 07/02/2017

35.5 [35.116] / 6

Hydraulic systems - Three-point hitch cylinder

4. Loosen bolts (1) and (2), which hold the auxiliary cylinder bracket on the rear axle housing and remove the tractorâ&#x20AC;&#x2122;s auxiliary cylinder assembly.

LAIL11TT0467A0A

Next operation: To remove the auxiliary cylinder, see the procedures in Three-point hitch cylinder - Disassemble (35.116).

47921938 07/02/2017

35.5 [35.116] / 7

Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

WARNING Pinch point! Lift arm assembly pivots create pinch points. Keep fingers, hands, and feet away from pivot points. Failure to comply could result in death or serious injury. W0357A

Prior operation: To remove the auxiliary cylinder, see the procedures in Three-point hitch cylinder - Remove (35.116). 1. Remove the auxiliary cylinder from the tractor as described above. 2. Loosen the bolt (1) and remove the retaining clamp for the auxiliary cylinder. 3. Loosen the banjo bolts (2) and remove the auxiliary cylinders from the housing. 4. Loosen two bolts (3) and remove the auxiliary cylinder bracket.

LAIL11TT0042A0A

LAIL11TT0043A0A

5. Loosen the jam nut (1) and remove the hand lever (2).

47921938 07/02/2017

35.5 [35.116] / 8

Hydraulic systems - Three-point hitch cylinder

6. Remove the return spring for the hand lever (1) from the housing.

LAIL11TT0044A0A

LAIL11TT0045A0A

LAIL11TT0046A0A

LAIL11TT0047A0A

7. Loosen three bolts and remove the plate and spool housing (1) from the base plate.

8. Pull out the spool shaft (1) from the spool housing.

9. Loosen and remove the pressure relief valve (1) from the spool housing. 10. Retrieve relief valve spring from the spool housing.

Next operation: To inspect the auxiliary cylinder components, see the procedures in Three-point hitch cylinder - Inspect (35.116).

47921938 07/02/2017

35.5 [35.116] / 9

Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To remove the auxiliary cylinder, see the procedures in Three-point hitch cylinder - Disassemble (35.116).

Inspection Inspect ‘O’ rings and seals and replace if necessary. Next operation: To fit the auxiliary cylinder, see the procedures in Three-point hitch cylinder - Assemble (35.116).

47921938 07/02/2017

35.5 [35.116] / 10

Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

WARNING Pinch point! Lift arm assembly pivots create pinch points. Keep fingers, hands, and feet away from pivot points. Failure to comply could result in death or serious injury. W0357A

Prior operation: To inspect the auxiliary cylinder parts, see the procedures in Three-point hitch cylinder - Inspect (35.116).

Fitting the auxiliary cylinder Re-assembly follows the disassembly procedure in reverse. See the procedures in Three-point hitch cylinder - Disassemble (35.116). â&#x20AC;˘ Check the pressure relief valve setting, as described in Relief valve - Pressure test (35.114). Next operation: To fit the auxiliary cylinder, see the procedures in Three-point hitch cylinder - Install (35.116).

47921938 07/02/2017

35.5 [35.116] / 11

Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

WARNING Pinch point! Lift arm assembly pivots create pinch points. Keep fingers, hands, and feet away from pivot points. Failure to comply could result in death or serious injury. W0357A

Prior operation: To fit the auxiliary cylinder, see the procedures in Three-point hitch cylinder - Assemble (35.116). Installing the auxiliary cylinder is the reverse of the removal procedure. Just be careful about the following point: â&#x20AC;˘ Replace all the sealing washers on hydraulic connections.

47921938 07/02/2017

35.5 [35.116] / 12

Index Hydraulic systems - 35 Three-point hitch cylinder - 116 Three-point hitch cylinder - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch cylinder - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch cylinder - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch cylinder - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch cylinder - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch cylinder - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch cylinder - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

35.5 [35.116] / 13

47921938 07/02/2017

35.5 [35.116] / 14

Hydraulic systems - 35 Three-point hitch control valve - 114

47921938 07/02/2017

35.6 [35.114] / 1

Contents Hydraulic systems - 35 Three-point hitch control valve - 114

FUNCTIONAL DATA Three-point hitch control valve Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Detailed view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Three-point hitch control valve Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Relief valve Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

(*) See content for specific models 47921938 07/02/2017

35.6 [35.114] / 2

Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - Sectional view TT3840F TT3840 TT3880F TT4030

LA LA LA LA

20098916

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Valve spool Valve spool seat plug Cover Valve spool return spring Valve plunger Plunger Spring Plug Piston seat Valve piston Spring cup Draft sensitivity adjusting valve spring (if applicable)

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

Ball Response control adjusting pin Delivery connection Check valve spring Check valve Retention valve seat Descent ball Adjusting pin lever Sector Plug Adjusting pin

47921938 07/02/2017

35.6 [35.114] / 3

Hydraulic systems - Three-point hitch control valve

12. 13. 14. 15. 16. 17.

Draft sensitivity adjusting valve (if applicable) Plug Spool seat ring Cylinder saftey valve Response control adjusting valve spring Response control adjusting valve

29. 30. 31. 32. 33.

Response control adjustment knob Retaining ring Roll Pin Thrust ring O-Ring

47921938 07/02/2017

35.6 [35.114] / 4

Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - Detailed view TT3840F TT3840 TT3880F TT4030

LA LA LA LA

BRAG12TRLUE0362

1. 2. 5. 8. 9. 13. 15.

Valve spool Seat Plunger Seat Piston Plug Safety valve

17. 19. 20. 22. 25. 28. 29.

Response control valve Pin Fitting Check valve Sensitivity control adjustment Draft control valve Handle

47921938 07/02/2017

35.6 [35.114] / 5

Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Disconnect hydraulic line (1) between the distributor and the remote control valve.

20098737

20098705

20098706

2. Loosen the Allen screw, (1), and remove valve assembly, (2).

3. Remove pipe, (1), and O-rings.

47921938 07/02/2017

35.6 [35.114] / 6

Hydraulic systems - Three-point hitch control valve

4. Remove the bolts, (1), and distributor, (2), from the lift housing.

20098707

For the following procedures, see the references in Three-point hitch control valve - Detailed view (35.114). 5. Remove the cylinder safety valve (15), response control valve (17) and pin (19), after removing the handle (29). 6. Remove the fitting (20), the check valve (22) and the seat (23). 7. Remove the plug (3), the valve spool (1), seat (2), spring (4) and ring (14). 8. Remove the control valve plug for the draft sensitivity (13), the plug (7), the plunger (5), the spring (6), the piston (9) and the seat (8). 9. Remove the retaining ring (30), the spring cup (10), the spring (11) and the control valve for the draft sensitivity. 10. Remove the plug (27), the roll pin (31), and the valve pin for the draft control (28). Next operation: To inspect the control valve components, see the procedures in Three-point hitch control valve - Inspect (35.114).

47921938 07/02/2017

35.6 [35.114] / 7

Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To remove the control valve, see procedures in Three-point hitch control valve - Disassemble (35.114). 1. Thoroughly check the seals, replacing them if necessary. 2. Check valves for wear and clearance in associated seats. 3. If replacement is required, note that replacement valve spools ( (1), Three-point hitch control valve - Sectional view (35.114)) are supplied together with matching seats (2) and that the valve plunger (5) is supplied together with the control valve body. Check that the spool (1) works using the procedures described in Three-point hitch control valve - Adjust (35.114). 4. Check the adjustment of the cylinderâ&#x20AC;&#x2122;s safety and relief valves using the procedures described in Relief valve Pressure test (35.114). The valve can be incorporated into the auxiliary cylinders or fitted on the front cover. Next operation: To fit the control valve, see the procedures in Rear hitch external controls - Assemble (37.110).

47921938 07/02/2017

35.6 [35.114] / 8

Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To inspect the control valve, see the procedures in Three-point hitch control valve - Inspect (35.114) . 1. Fit the control valve by following steps 10 to 1 described in Three-point hitch control valve - Disassemble (35.114). 2. Fit the front cover only after making the adjustments described in Three-point hitch control valve - Adjust (35.114).

47921938 07/02/2017

35.6 [35.114] / 9

Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - Adjust TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To fit the control valve, see the procedures in Three-point hitch control valve - Assemble (35.114). In case of complete disassembly of the lift, it is necessary to make the following checks, adjustments and settings : 1. To check that the spool works, see the procedures in Three-point hitch control valve - Pressure test (35.114). 2. To adjust the position control, see the procedures in Rear three-point hitch - Adjust of the position control (37.110). 3. To bench adjust the maximum displacement of the lift arm, see the procedures in Rear three-point hitch Travel adjust maximum of the lift arm (37.110). 4. To tractor adjust the maximum displacement of the lift arm, see the procedures in Rear three-point hitch Travel adjust maximum of the lift arm (37.110). 5. To adjust the draft control spring, refer to the procedures in Rear three-point hitch - Travel adjust the draft control spring (37.110). 6. To bench adjust the draft control linkage, see the procedures in Rear three-point hitch - Adjust the draft control linkage (37.110). 7. To adjust the Lift-O-Matic device, see the procedures in Rear hitch external controls - Adjust (37.110).

47921938 07/02/2017

35.6 [35.114] / 10

LAIL11TT0345A0A

Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - Pressure test TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Effectiveness test for the control valve spool 1. Attach the seat (2) with the O–ring, and spool (1) to fitting 293982, checking that seals at the bottom of the seat prevent leakage through the fitting itself and connect the latter to the hand pump.

LAIL11TT0346A0A

2. Push the spool (1) into contact with the seat (2) and lock the spool (1) with the screw lock tool. 3. Use the pump to bring the system oil pressure up to 250 Kg/cm² and check the pressure gauge to see that pressure takes more than six seconds to drop from 200 Kg/cm² to 100 Kg/cm². 4. If necessary, replace spool. Note that spare spools are provided together with matching seats.

47921938 07/02/2017

35.6 [35.114] / 11

Hydraulic systems - Three-point hitch control valve

Relief valve - Pressure test TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Bench-testing the cylinder relief valve and the cylinder safety valve The relief valve (installed on the remote control valve in the TT3880F/TT4030 and on a support on the righthand side of the lift housing in the TT3840/TT3840F) can be tested either on a workbench or on the tractor. The setting test for the cylinder safety valve can only be carried out on a workbench. 1. To bench test the cylinder safety valve and the relief valve incorporated into the auxiliary cylinder, use hand pump 290284 (A) with fittings 290828 (C) and 290824 (B). The relief valve must be open to 190 – 195 Kg/cm² and the safety valve to a pressure of 215 – 220 Kg/cm². LAIL11TT0189A0A

LAIL11TT0190A0A

NOTE: If the valve setting is not as specified, discard and replace the valves. If necessary, valves may be adjusted through threaded plugs after raising the peened area, and using wrenches 291862 and 291863 for the cylinder safety valve and the relief valve, respectively.

ATTENTION: When travelling on the road with mounted implements, completely unscrew knob (1) to lock the implements in transport position.

47921938 07/02/2017

35.6 [35.114] / 12

Index Hydraulic systems - 35 Three-point hitch control valve - 114 Relief valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Detailed view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

35.6 [35.114] / 13

47921938 07/02/2017

35.6 [35.114] / 14

Hydraulic systems - 35 Fixed displacement pump - 104

47921938 07/02/2017

35.7 [35.104] / 1

Contents Hydraulic systems - 35 Fixed displacement pump - 104

TECHNICAL DATA Pump Gear pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Gear pump - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Pump Gear pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Gear pump - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Gear pump - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Gear pump - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Gear pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Gear pump - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

(*) See content for specific models 47921938 07/02/2017

35.7 [35.104] / 2

Hydraulic systems - Fixed displacement pump

Pump Gear pump - General specification TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016

LA LA LA LA LA LA

TT3840F

TT3880F

TT3880 45 L/min 18.2 cm³/rev 207.0 bar (3001.5 psi) Counter-clockwise 3000 RPM 0.7 – 2.0 bar (10.1 – 29.0 psi)

Flow Pump displacement Maximum pressure Shaft rotation direction Maximum rotation Oil suction pressure

TT4030

Pump Gear pump - Torque TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016

LA LA LA LA LA LA

TT3840F Bolts to secure the hydraulic tube onto the pump

TT3880F

TT3880

8.9 – 11.6 N·m (78.8 – 102.7 lb in)

47921938 07/02/2017

35.7 [35.104] / 3

TT4030

Hydraulic systems - Fixed displacement pump

Pump Gear pump - Remove TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

1. Remove the clamps (1) and (2). 2. Remove the oil supply line (3).

CUIL16TR00986AA

CUIL16TR00309AA

3. Remove the filter (5) and the respective cradle. 4. Remove the bolts (1) and (2). Remove the oil outlet tube (5). 5. Remove the bolts (3) and (4), along with the rear bolts. Remove the pump from its cradle.

Next operation: Pump Gear pump - Disassemble (35.104).

47921938 07/02/2017

35.7 [35.104] / 4

Hydraulic systems - Fixed displacement pump

Pump Gear pump - Disassemble TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

Prior operation: Pump Gear pump - Remove (35.104).. 1. Position the pump in the vise. 2. Bend back the tabs of the locking tab washers (1). 3. Remove the tight nut (2).

20098424

20098425

4. Use the extractor (1) to remove the hub and (2) and the retaining ring.

47921938 07/02/2017

35.7 [35.104] / 5

Hydraulic systems - Fixed displacement pump

5. Remove the keyway (3).

20098424

20098856

6. Mark the flange (1) of the end cap, the flange of the body (2), and the mounting flange (3). NOTE: Make sure that the flanges are correctly positioned in relation to the rotation of the pump. 7. Remove the two bolts (4) and the lock washers (5).

8. Remove the end cap (1). Carefully lift out the cap seal (2), the bushing lobe seal (3), and the backing washers (4). 9. Lightly tap the mounting flange to separate the mounting flange from the guide pins in the pump body. Slide the mounting flange directly to the shaft. NOTICE: Make sure that there are no burrs on the keyway in the shaft.

10. Carefully lift out the body seal (1), the backing washers (2), and the lobe seal (3).

47921938 07/02/2017

35.7 [35.104] / 6

Hydraulic systems - Fixed displacement pump

11. Hold the pump body vertically with the mounting flange end downwards and with one hand underneath to prevent the bushings from dropping out. 12. Tap the side of the body (1) with a rubber hammer to dislodge the lower bushings. (2).. Carefully slide these out of the body. NOTE: Keep the bushings as a pair and place them on the mounting flange.

20098856

13. Invert the body. Lift out the drive gear (1) and the driven gear (2). 14. Remove the remaining pair of bushings as already described and place on the end cover. 15. Remove the snap ring (3) and the oil seal (4) from the mounting flange.

Next operation: Pump Gear pump - Inspect (35.104)..

47921938 07/02/2017

35.7 [35.104] / 7

Hydraulic systems - Fixed displacement pump

Pump Gear pump - Inspect TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

Prior operation: Pump Gear pump - Disassemble (35.104). NOTE: It is likely that wear of the internal parts will be uniform and it may be more economical to obtain a service replacement unit than to fit several new parts. Wash all metal parts thoroughly in a proprietary cleaning fluids, such as Belco cleaning solvent. Inspect in the order set out below, for wear and damage.

Body To obtain high efficiency the design allows for the tips of the gear teeth to wipe the walls of the body bores when the pump is running. Pressure will force the gears against the inlet side of the bores and a witness mark will be visible in this area. If excessive wear of the bushing inserts or gear journals occurs this witness mark will deepen to form a wear track, causing a step in the bore. Examine the body bores and if a pronounced step is felt the body must be rejected. It is not advisable to install worn bushings into a new body. Check the security of the two dowels.

Gears Examine the gears for discolouration, indicating, overheating. Check the journals for scratches. Ensure that the contract marks on the teeth are evenly distributed across each tooth surface and ensure that none of the teeth are chipped. If the pump has suffered overheating this may have been caused by a fault in the hydraulic system, such as a defective relief valve, and this must be investigated. NOTE: Bushings and gears are mated for width within 0.005 mm (0.0002 in) and can be renewed only in pairs.

End Cover Ensure that the flat, inner surface of the cover is free from scoring or pitting.

Mounting flange Examine for damage and check the condition of the drive shaft oil seal. 47921938 07/02/2017

35.7 [35.104] / 8

Hydraulic systems - Fixed displacement pump

Seals and Tie Bolts Inspect all seals and renew if necessary. Check the condition of tie bolt threads. NOTE: Once the internal condition of the pump has been assessed it may be considered more feasible to renew the complete unit than to fit several new parts. Measure gear to pump body end float. Dimension, (1), must be smaller than dimension, (2), by 0.090 â&#x20AC;&#x201C; 0.160 mm (0.0035 â&#x20AC;&#x201C; 0.0063 in). If necessary remove minimum qualities of material from flat faces of bearing assemblies to obtain specified end float.

20098426

Next operation: Pump Gear pump - Assemble (35.104).

47921938 07/02/2017

35.7 [35.104] / 9

Hydraulic systems - Fixed displacement pump

Pump Gear pump - Assemble TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

Prior operation: Pump Gear pump - Inspect (35.104). 1. Install the oil seal (1) and the snap ring (2) into the mounting flange (3). 2. Install the pair of bushings. 3. Invert the body. Install the drive gear (4) and the driven gear (5).

20098856

4. Carefully slide the bushings (1) into the body (2).

5. Install the lobe seal ring (1). 6. Install the two backing washers (2). 7. Install the seal ring (3).

47921938 07/02/2017

35.7 [35.104] / 10

Hydraulic systems - Fixed displacement pump

8. Lightly tap the mounting flange (1) into the two guide pins in the pump body (2). Slide the mounting flange directly to the shaft. 9. Install the bushings (3). 10. Install the bushing lobe seal ring (4). 11. Install the two washers (5). 12. Install the sealing ring (6). 13. Install the cover (7).

20098856

20098424

14. Install the end cap flange (1). 15. Install the body flange (2). 16. Install the mounting flange (3). 17. Install the lock washer (4) and the bolt (5). Torque the screw to 56 NÂˇm (41 lb ft).

18. Install the key (1). 19. Install the hub (2). 20. Install the washer (3) and the nut (4). 47.5 NÂˇm (35.0 lb ft).

Torque to

21. Bend the tabs of the tab washer to secure the nut.

Next operation: Pump Gear pump - Install (35.104).

47921938 07/02/2017

35.7 [35.104] / 11

Hydraulic systems - Fixed displacement pump

Pump Gear pump - Install TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

Prior operation: Pump Gear pump - Assemble (35.104). 1. Insert the pump into its cradle with a new gasket. 2. Install the bolts (3) and (4), along with the rear bolts. 3. Install the tube (6). Install the bolts (1) and (2). Torque to 8.9 – 11.6 N·m (6.6 – 8.6 lb ft). 4. Add oil as per the specification on the filter. 5. Install the filter (5) in its cradle.

CUIL16TR00309AA

CUIL16TR00986AA

6. Install the tube (3). Tighten the clamps (1) and (2).

Next operation: Pump Gear pump - Install (35.104).

47921938 07/02/2017

35.7 [35.104] / 12

Hydraulic systems - Fixed displacement pump

Pump Gear pump - Test TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

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

Prior operation: Pump Gear pump - Install (35.104).

Inlet Restriction Test Perform the inlet restriction test to check for the hydraulic lines and filter for damage, obstructions, or air leaks. A hydraulic flowmeter is required to perform the inlet restriction test. NOTE: Inlet restriction test cannot be performed at the rear remote couplers, because of a reduced pressure reading. 1. Start the engine and operate the hydraulic system to warm the hydraulic fluid to normal operating temperature. 2. Open the restrictor valve (1) to allow the full flow rate through the flowmeter. 3. Run the engine at a speed of 1375 RPM. Record the flowmeter reading. 4. Increase the engine speed to 2750 RPM. Read the flowmeter. 5. The reading should indicate that the flow rate has doubled. If the meter reading is low, check the hydraulic lines, and filter for damage, clogs, or air leaks. 6. If there are no problems with the hydraulic lines or the hydraulic filter, the hydraulic pump may require replacement. Use the Pump Efficiency Test described below to further inspect the hydraulic pump.

20098857

47921938 07/02/2017

35.7 [35.104] / 13

Hydraulic systems - Fixed displacement pump

Pump Efficiency Test The pump efficiency test measures the hydraulic pump output to determine if the pump is excessively worn or damaged. Perform the pump efficiency test only after the inlet restriction test has been completed. A hydraulic flowmeter is required to perform the pump efficiency test. NOTE: Pump efficiency test cannot be performed at the rear remote couplers, because of a reduced pressure reading. 1. Start the engine and operate the hydraulic system to warm the hydraulic fluid to normal operating temperature. 2. Adjust the engine speed to its maximum speed. 3. Observe the flowmeter reading. See chart below for the no load pressure readings. 3. Tighten the flow restrictor valve (1) on the flowmeter until the system pressure is 15995 kPa (2320 psi). 4. Observe the flowmeter reading. The results should be approximately 80% of the no-load flow. The nominal minimum flow rate is 32.8 l/min (8.66 US gpm). If testing shows the hydraulic pump output is low, the pump requires replacement. NOTICE: Do not exceed 15995 kPa (2320 psi).

20098857

Pump Capacity Half speed Pump flow rate at half speed Full speed Pump flow rate at full speed

45.0 L/min (11.9 US gpm) 1375 RPM 20.4 l/min (5.4 US gpm) 2750 RPM 45.0 L/min (11.9 US gpm)

47921938 07/02/2017

35.7 [35.104] / 14

Index Hydraulic systems - 35 Fixed displacement pump - 104 Pump Gear pump - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Gear pump - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Gear pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Gear pump - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Gear pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Gear pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Gear pump - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Gear pump - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

35.7 [35.104] / 15

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

47921938 07/02/2017 EN

SERVICE MANUAL Hitches, drawbars, and implement couplings TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017

Contents Hitches, drawbars, and implement couplings - 37

[37.110] Rear three-point hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.1

47921938 07/02/2017

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

515™ 515™ 515™ 515™ 515™ 515™

Reference Rear Rear Rear Rear Rear Rear

hitch housing - Sealing hitch housing - Sealing hitch housing - Sealing hitch housing - Install hitch internal controls - Assemble hitch internal controls - Assemble

47921938 07/02/2017

PAGE 37.1 / 8 37.1 / 8 37.1 / 8 37.1 / 31 37.1 / 42 37.1 / 43

47921938 07/02/2017

Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110

47921938 07/02/2017

37.1 [37.110] / 1

Contents Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110

TECHNICAL DATA Rear three-point hitch General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Rear hitch housing Sealing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FUNCTIONAL DATA Rear three-point hitch Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Rear hitch external controls Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Dynamic description of the Lift-O-Matic (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SERVICE Rear three-point hitch Adjust of the position control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Travel adjust maximum of the lift arm (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Travel adjust maximum of the lift arm (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Travel adjust the draft control spring (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Adjust the draft control linkage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Rear hitch housing Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Rear hitch internal controls Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Rear hitch external controls Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

(*) See content for specific models 47921938 07/02/2017

37.1 [37.110] / 2

Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Rockshaft Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

DIAGNOSTIC Rear three-point hitch Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

(*) See content for specific models 47921938 07/02/2017

37.1 [37.110] / 3

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

515™ 515™ 515™ 515™ 515™ 515™

Reference Rear Rear Rear Rear Rear Rear

hitch housing - Sealing hitch housing - Sealing hitch housing - Sealing hitch housing - Install hitch internal controls - Assemble hitch internal controls - Assemble

47921938 07/02/2017

37.1 [37.110] / 4

PAGE 37.1 / 8 37.1 / 8 37.1 / 8 37.1 / 31 37.1 / 42 37.1 / 43

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Specifications Component Type Command Lift Sensitivity adjustment LIFT-O-MATIC

TT3840 TT3840F TT3880F TT4030 Position control, traction control and combined position Traction control Two independent levers External four–position lever on control valve. Permits rapid lift arm up/down movement by push button without operating the traction or position control levers Knob on control valve

Response adjustment Single-acting cylinder: – Internal diameter x stroke – Displacement Opening pressure of relief valve Cylinder safety valve opening pressure Lift piston diameter Lift cylinder internal diameter Piston working clearance

90 mm x 110 mm 700 cm³ 186 – 191 bar (2697 – 2770 psi) 210 – 215 bar (3045 – 3118 psi) 89.980 – 90.000 mm 90.036 – 90.071 mm 0.036 – 0.091 mm

Lift Component Cross shaft journal diameter – Right – Left Adjusted internal diameter of bushing inside lift (no bore hole) – Right – Left Cross shaft working clearance in bushings: – Right – Left Adjustment of the right-hand bushing interference in the housing Adjustment of the left-hand bushing interference in the housing Cross shaft end float with lift arms in position External diameter of the draft control shaft Internal diameter of the axle housing inside the lift body Shaft clearance in body Diameter of position control shaft Internal diameter of the axle housing inside the draft control shaft Shaft clearance in body Diameter of the draft control lever pin and of the hinge pin on the inner lever for the draft control on the needle roller bearings Internal diameter of the link arm of the control valve and the inner lever for the draft control on the needle roller bearings Valve spool clearance in body

TT3840

47921938 07/02/2017

37.1 [37.110] / 5

TT3840F

TT3880F

47.975 – 48.000 mm 54.970 – 55.000 mm

48.100 – 48.184 mm 55.100 – 55.184 mm 0.100 – 0.209 mm 0.100 – 0.214 mm 0.065 – 0.161 mm 0.065 – 0.161 mm 0.200 – 1.400 mm 21.967 – 22.000 mm 22.020 – 22.072 mm 0.020 – 0.105 mm 13.973 – 14.000 mm 14.016 – 14.059 mm 0.016 – 0.086 mm 13.973 – 14.000 mm

19.985 – 20.006 mm 0.008 – 0.012 mm

TT4030

Hitches, drawbars, and implement couplings - Rear three-point hitch

0.008 – 0.012 mm

Lift valve clearance in control valve body Valve spool return spring length: – Free – Under load of 31.7 – 35 N (7.1 – 7.9 lb) Control valve return spring length: – Free – Under load of 103 – 114.7 N (23.2 – 25.8 lb) Response adjustment valve spring length: – Free – Under load of 1.7 – 2.3 N (0.4 – 0.5 lb) Sensitivity adjustment valve spring length: – Free – Under load of 15.8 – 17.6 N (3.6 – 4.0 lb) Check valve return spring length: – Free – Under load of 35.3 – 39.2 N (7.9 – 8.8 lb) Sensitivity adjustment pin lever outer spring length: – Free – Under load of 61.8 – 67.7 N (13.9 – 15.2 lb)

50.5 mm 34 mm 44 mm 29 mm 13 mm 9.8 mm 14.5 mm 11 mm 23.5 mm 18 mm 20.5 mm 13.8 mm

Implement attachment Component

TT3840

Type Category (TT3880F/TT4030) Draft control Maximum lift capacity with lower links in the horizontal position

TT3840F TT3880F 3-point linkage I and II Top link sensing

1750 kg

TT4030 II

1620 kg

Rear three-point hitch - Torque TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Tightening torques Description Mounting bolt, lift to rear transmission housing (C₁₁) Mounting bolt, control valve body to lift (C₂₂) Mounting bolt, lift arm (C₃₃) Plug, maximum lift adjustment (C₄₄) Nut, position control shafts (C₆₆) Nut, lever bracket studs (C₇₇) Mounting bolt, spring to top link support (C₈₈) Mounting bolt, spring to lift body (C₉₉) ₁₀) Mounting bolt, shaft to top link support (C₁₀ ₁₀ ₁₁) Mounting bolt, suction connection (C₁₁ ₁₁ ₁₂) Mounting bolt, delivery connection on lift control valve (C₁₂ ₁₂ ₁₃) Mounting bolt, pump (C₁₃ ₁₃ ₁₄) Nut, pump cover (C₁₄ ₁₄ ₁₅) Nut, check chain bracket (C₁₅ ₁₅ ₁₆) Nut, check chain to lower link arms (C₁₆ ₁₆ ₁₇) Top mounting bolt, drawbar cross link (TT3880F/TT4030 models) (C₁₇ ₁₇ ₁₈) Bottom retaining nut, drawbar cross link (TT3880F/TT4030 models) (C₁₈ ₁₈ ₁₉) Mounting bolt, rear cover and drawbar support (TT3880F/TT4030 models) (C₁₉ ₁₉ 47921938 07/02/2017

37.1 [37.110] / 6

Thread size M14 x 1.5 M8 X 1.25 M14 x 1.5 M12 x 1.25 M10 X 1.25 M8 X 1.25 M14 x 1.5 M14 x 1.5 M16 x 1.5 M12 x 1.25 M10 X 1.25 M6 x 1 M10 X 1.25 M14 x 1.5 M18 x 1.5 M20 x 1.5 M20 x 1.5 M16 x 1.5

Torque 150 N·m 27 N·m 150 N·m 105 N·m 15 N·m 26 N·m 22 N·m 22 N·m 20 N·m 10 N·m 6 N·m 8 N·m 42 N·m 15 N·m 320 N·m 48 N·m 40 N·m 22.5 N·m

Hitches, drawbars, and implement couplings - Rear three-point hitch

Description ₂₀) Mounting bolt, front tow hitch mount to axle support (TT3880F/TT4030 models) (C₂₀ ₂₀ ₂₁) Nut, mounting bolts for control valve (C₂₁ ₂₁ ₂₂) Connection, oil outlet to lift (C₂₂ ₂₂ ₂₃) Plug, relief valve spring (C₂₃ ₂₃ ₂₄) Mounting bolt, control lever support (C₂₄ ₂₄ ₂₅) Plug, valve Single/double action switch (TT3880F/TT4030) (C₂₅ ₂₅

Thread size M16 x 1.5 — — — — —

Rear three-point hitch - Special tools TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Special tools Tool description Installer, lift shaft housing seal Installer, lift piston with seal Adjuster, position/draft control Main spool leakage testing tool Adopter, over pressure relief valve Adopter, cylinder safety valve Cylinder safety valve pressure adjusting tool Wrench, lift arm maximum height adjustment Installer, lever needle bearing Installer, needle bearing main spool lever ‘C’ spring tensioning lever Hydraulic ‘C’ spring travel gauge Installer, hydraulic housing ‘C’ spring bushing Remover, lift–o–matic spring Hydraulic Pressure Test Kit Rapid clutch male connector Adapter Coupling Adopter (banjo bolt steering) Pressure gauge ( 250 bar) Pipe (high pressure) Adopter (oil pressure) Installer / remover, hydraulic housing shaft bush L. H Installer / remover, hydraulic housing shaft bush R. H Installer, response pin seal

47921938 07/02/2017

37.1 [37.110] / 7

No. of the tool 292535 292547 293846 293982 290824 290828 291862 293870 380000261 293839 290819 9971359 9971352 291215 292870 293449 292060 293168 291318 293247 292246 291328 9971353 9971355 293858

Torque 22.5 N·m 20 N·m 20 N·m 20 N·m 6 N·m 20 N·m

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear hitch housing - Sealing TT3840F TT3840 TT3880F

LA LA LA

20098914

Operation Description Lift Housing to Rear Axle Housing, (S1) Front Cover to Lift Housing, (S2) Distributor Assembly to Front cover, (S3)

Sealant Specification LOCTITE® 515™ LOCTITE® 515™ LOCTITE® 515™

47921938 07/02/2017

37.1 [37.110] / 8

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Hydraulic schema TT3840F TT3840 TT3880F TT4030

LA LA LA LA

The Distributor is Pre-set to perform three phases: 1. Neutral phase 2. Lifting Phase 3. Lowering Phase

Neutral phase In this phase the control valve keeps pressure on the oil coming from the pump to flow freely to the tank. In this phase the control spool, (1), is in such a position, oil is delivered through sensitivity control valve, (2), to piston, (3), which overcomes spring, (4), and moves plunger, (5), to the right, thus opening discharge port and returns oil to transmission housing rather than to cylinder. NOTE: When travelling on the road with implements attached, fully unscrew knob, (6), to block implement in desired positions; oil contained in cylinder remains trapped by check valve, (7), and Response Control valve, (8). Arms therefore remain blocked, even if operator accidentally moves lift Control levers. Cylinder safety valve, (9), protects lift cylinder pressure circuit while relief valve, (10), protects pump circuit.

20098420

47921938 07/02/2017

37.1 [37.110] / 9

Hitches, drawbars, and implement couplings - Rear three-point hitch

Lifting Phase During this phase, the control valve supplies the oil under pressure to the cylinder and it consequently lifts the arms. The control spool, (1), is in such a position, oil flows to piston, (2), is cut off and plunger, (3), is forced to the left by spring, (4), thus closing discharge port. Oil under pressure opens check valve, (5), and operates piston, (6), to raise arms. NOTE: Draft sensitivity may be adjusted throughout lever, (7), which controls the position of valve seat, (8). When seat, (8), is moved to the right, piston, (2), covers ports, (9), and (10), and oil in valve may be discharged through port, (11). Since discharge thereby takes longer, lift reaction time increases with a consequent decrease in sensitivity. When seat, (8), is moved to the left, ports, are free and oil may be discharged quickly through all three ports, (9), (10), and, (11), with consequent short reaction time resulting in increased sensitivity.

20098691

47921938 07/02/2017

37.1 [37.110] / 10

Hitches, drawbars, and implement couplings - Rear three-point hitch

Lowering Phase During this phase, the control valve supplies at the same time the oil coming from the pump and the oil contained in the cylinder to the discharge causing the lowering of the arms. When return spring, (1), moves spool, (2), to the right, cylinder is discharged under piston pressure, (3), through response control valve, (4), and the port uncovered by spool. Through spool port, (5), and Draft sensitivity valve, (6), oil flows to piston, (7), which holds plunger, (8), in the open position, thus allowing oil from pump to be discharge past plunger, (8). NOTE: Response (rate of drop) is adjusted by knob, (9). Loosening this knob restricts exhaust passage between valve, (4), and control valve body, thus increasing the time taken to lower the implement (slow response). Tightening knob, (9), increases effective area of discharge port and the implement drops more quickly (fast response).

20098692

47921938 07/02/2017

37.1 [37.110] / 11

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Sectional view TT3840F TT3840 TT3880F TT4030

LA LA LA LA

20098915

A. B. B1. B2. C. C1. D= 1. 2. 3. 4.

Draft control spring (if applicable) Control Valve Lift sensitivity adjustment lever Response control knob Lift retaining screw Thrust plate retaining screw 0.2 â&#x20AC;&#x201C; 1.4 mm (0.008 â&#x20AC;&#x201C; 0.055 in), shaft end float Inner arm Arm Lift Arms Arm thrust plates

8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Left-hand bushings Thrust washers Top link support Piston rod pin Travel limit adjusting screw Travel limit adjusting screw locknut Travel limit control rod Control valve link pin Draft Control inner lever pivot (if applicable) Setscrew Front cover

47921938 07/02/2017

37.1 [37.110] / 12

Hitches, drawbars, and implement couplings - Rear three-point hitch

5. 6. 7.

Right-hand seal Left-hand seal Right-hand bushings

19. 20.

Screw retaining spring to top link support Screw retaining spring to lift body

47921938 07/02/2017

37.1 [37.110] / 13

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear hitch external controls - Dynamic description TT3840F TT3840 TT3880F

LA LA LA

Hydraulic System This is a live hydraulic system, where a gear type hydraulic pump is mounted directly to the timing case. Transmission lubrication oil is used also as hydraulic oil. This system described here mechanically senses changes in the draft loading via the top link of the three point linkage. The system allows the operator to select position control, draft control (if applicable), combined position and draft control and float. The system is operated by draft control lever (if applicable), (1), position control lever, (2), response control, (3), and sensitivity control, (4).

Preâ&#x20AC;&#x201C;operation checks NOTICE: Some mounted or semi-mounted equipment may interfere with and cause damage to tractor sheet metal. To avoid damage check for clearance between tractor and implements.

47921938 07/02/2017

37.1 [37.110] / 14

20098737

20098435

Hitches, drawbars, and implement couplings - Rear three-point hitch

Position Control Operation Position control provides accurate control of implements such as sprayers, rakes, rotary tillers etc. that operate above the ground. Once set, position control will maintain the selected implement height. NOTICE: Always set the system to position control at any time when not actually operating in draft control, such as when attaching or transporting equipment or when no equipment is attached. Move the draft control lever, (1), fully forward in the quadrant. Set the required implement height/depth using the position control lever, (2). Pull the lever back to raise the implement, push forward to lower. Implement height/ depth is relative to the position of the lever in quadrant. An adjustable stop, (3), is provided to enable the lever to be returned to the required working position.

20098684

20098685

Draft Control Operation (if applicable) Draft control is most suitable for mounted or semimounted implements operating in the ground. Changes in the working depth or changes in soil resistance will cause draft loading on the implement to increase or decrease. When starting work, move the position control lever, (1), fully forward. Lower the implement in to the work using draft control lever, (2). Push the lever forward to increase the draft loading. Pull rearwards to reduce the draft loading. Forward movement of the draft control lever will increase the implement depth and rearward movement will reduce the depth. Once set, the tractor hydraulic system will automatically adjust the implement depth to maintain an even pull on the tractor and minimize wheel slip.

47921938 07/02/2017

37.1 [37.110] / 15

Hitches, drawbars, and implement couplings - Rear three-point hitch

Combined Position and Draft Control Operation On very light soil or varying soil types in the same field, it may be necessary to use the draft control and position control in combination. When starting work, lower the implement to the required depth by means of the draft control lever, (1), as previously described. When the implement reaches the required depth, raise the Position control lever, (2), back until the lift arms tends to rise. The lift linkage is now operating in draft control but the implement is prevented, by the position control function, from sinking too far when draft reduces.

20098686

20098685

20098435

Float Operation Move the position control lever, (1), and the draft control lever, (2), fully forward. The 3-point linkage will now be free to 'float' or follow the ground contour, a feature useful for scraper blades etc.

Sensitivity Control To adjust the sensitivity of hydraulic system when working in draft control, lever, (1), needs to be adjusted. Lever UP - Reduces sensitivity Lever DOWN - Increases sensitivity

47921938 07/02/2017

37.1 [37.110] / 16

Hitches, drawbars, and implement couplings - Rear three-point hitch

Response Control The response control knob, (1), varies the speed of drop of the lower links. CLOCKWISE rotation - Increases speed of drop COUNTERCLOCKWISE rotation - Decreases speed of drop NOTICE: To lock implements in transport position when driving on road, fully raise Position control lever, (2), and screw in (rotate clockwise) knob, (1).

47921938 07/02/2017

37.1 [37.110] / 17

20098435

20098690

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear hitch external controls - Dynamic description of the Lift-O-Matic TT3840F TT3840 TT3880F

LA LA LA

The Lift–O–Matic is used for automatic repositioning of implement after turn. It helps in saving the time and adds comfort to the operator. Further it maintains uniform depth and prepares a better seedbed. To raise the implement at the end of each pass, or whenever required, move the latch (1) rearward to release the fast raise button (2). The 3–point linkage (and implement) will raise to the full height without need to move either the Position or Draft control lever.

LAIL11TT0213A0A

LAIL11TT0214A0A

LAIL11TT0215A0A

To lower the implement, simply press the fast raise button (1) fully in and the implement will lower to the preset depth, set by the position control lever or traction control lever.

Sensitivity Control To adjust the sensitivity of the hydraulic system when working in traction control, the lever (1) needs to be adjusted. Lever UP - Reduces sensitivity Lever DOWN - Increases sensitivity

47921938 07/02/2017

37.1 [37.110] / 18

Hitches, drawbars, and implement couplings - Rear three-point hitch

Response Control The response control knob (1) varies the speed of drop of the lower links. CLOCKWISE rotation â&#x20AC;&#x201C; Increases speed of drop. COUNTER CLOCKWISE rotation â&#x20AC;&#x201C; Decreases speed of drop. NOTICE: To lock implements in the transportation position when driving on the road, pull the position control lever (2), Figure 5, all the way up and twist the knob (1) clockwise, Figure 4. 4

LAIL11TT0216A0A

Using the bypass valve and external supply port The bypass valve (2), Figure 4, is used to divert oil, normally flowing to the left cylinder of the 3-point linkage, to the external supply port. A single acting cylinder can be connected to this external port and be operated by the Draft control lever.

20098737

47921938 07/02/2017

37.1 [37.110] / 19

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Adjust of the position control TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To remove the lift housing, see the procedures in Rear hitch housing - Remove (37.110).

Position control adjustment With lift unit removed from tractor 1. Remove distributor assembly from lift housing 2. Raise the lift arms to the fully raised position, so that the inner arm (1) comes into contact with the lift housing.

LAIL11TT0347A0A

LAIL11TT0348A0A

LAIL11TT0349A0A

3. Carefully mark the position on the arm “S2” and on the housing “S1”.

4. Loosen the lock nut (10) and unscrew the adjustment bolt for maximum lifter height (6) using Special Tool No. 293870 until it is no longer in contact with the control valve lever (7).

47921938 07/02/2017

37.1 [37.110] / 20

Hitches, drawbars, and implement couplings - Rear three-point hitch

5. Attach Special Tool 293846 (A) to the lift housing.

LAIL11TT0350A0A

LAIL11TT0351A0A

LAIL11TT0352A0A

LAIL11TT0353A0A

6. Using two wrenches, remove the jam nut ( (8), Fig. 6) and tighten or loosen the adjustable link rod ( (9), Fig. 3) until the plunger (P1) is aligned with the outer scale (R1) of Special Tool No. 293846. ATTENTION: This condition corresponds to a clearance (L1) of 82.0 – 82.1 mm between the lever end (7) and the front face of the lift housing when a force (F1) of 4 – 4.5 kg is applied to the end of the lever.

7. Tighten the counter nut (8).

8. Pull the position control lever (P) all the way forward. 9. Rotate the arm shaft to bring the piston all the way forward and check that the moving rod (P1) of tool 293846 is no more than 1.3 – 1.7 mm back from the inner register (R2) of the tool.

47921938 07/02/2017

37.1 [37.110] / 21

Hitches, drawbars, and implement couplings - Rear three-point hitch

ATTENTION: This condition corresponds to a clearance (4) of 86.3 â&#x20AC;&#x201C; 86.7 mm between the lever end (7) and the front face of the lift housing when a force (F1) of 4 â&#x20AC;&#x201C; 4.5 kg is applied to the end of the lever.

LAIL11TT0354A0A

47921938 07/02/2017

37.1 [37.110] / 22

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Travel adjust maximum of the lift arm TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To remove the lift housing, see the procedures in Rear hitch housing - Remove (37.110). This procedure describes how to bench adjust the lifter housing. Proceed as follows: 1. Attach Special Tool 293846 (A) to the lift body.

LAIL11TT0355A0A

LAIL11TT0356A0A

LAIL11TT0357A0A

2. Move the position control lever (P) all the way forward. 3. Raise the lift arms to the fully raised position, so that the inner arm (1) comes into contact with the lift housing. 4. Push the piston into cylinder so that piston moves through full lift stroke and hold the piston in that position.

5. Loosen the jam nut (10).

47921938 07/02/2017

37.1 [37.110] / 23

Hitches, drawbars, and implement couplings - Rear three-point hitch

6. Use Special Tool No 293870 to tighten bolt (6) until the indentation between the plunger (P1) and the internal record (R2) of the tool 293846 is 1.3 â&#x20AC;&#x201C; 1.7 mm or less. 7. Tighten the counter nut (10). ATTENTION: This condition corresponds to a clearance (L1) of 86.3 â&#x20AC;&#x201C; 86.7 mm between the end of the lever and the front of the top cover.

LAIL11TT0351A0A

47921938 07/02/2017

37.1 [37.110] / 24

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Travel adjust maximum of the lift arm TT3840F TT3840 TT3880F TT4030

LA LA LA LA

This procedure describes how to tractor adjust the movement of the lift housing. 1. Raise the hydraulic lift arms by hand to maximum height position. Make two corresponding marks, one on the lift body (S1) and one on the lift arm (S2). 2. Move the position and draft control levers (P) and (F) all the way forward. 3. Operate the lift with the LIFT–O–MATIC. After a few lifting operations, check that distance "d" between notches (S1) and (S2) is 2 – 4 mm. 4. If LIFT–O–MATIC is not fitted, move the position control lever and the draft control lever all the way forward (maximum lift position) and check the distance between (S1) and (S2). 5. If the distance "d" is not 2 – 4 mm, adjust as follows: 6. Remove the plug (19), loosen the jam nut (10) and turn the adjusting screw (6) using Special Tool No. 293870 until you obtain the distances specified above. 7. Tighten the counter nut (10). 8. Re-install plug (19).

47921938 07/02/2017

37.1 [37.110] / 25

LAIL11TT0358A0A

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Travel adjust the draft control spring TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Disengage the stop block (1) and, with the draft control spring (2) free, check that the distance (L2) between the plate (3) and the spring (2) is 12.7 â&#x20AC;&#x201C; 13 mm. If necessary, adjust the thickness of the shims (H1), reducing them if the distance is less and increasing them if it is greater.

LAIL11TT0359A0A

LAIL11TT0360A0A

2. Place the spring fully under draft using a suitable rod at the base of the link support. Check that the distance (L3) between the plate (16) and the spring (94) is in the 19.2 â&#x20AC;&#x201C; 19.7 mm range. If it is smaller, reduce the shims (H2) between the spring and the fork link support. If it is greater, increase the shims.

47921938 07/02/2017

37.1 [37.110] / 26

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Adjust the draft control linkage TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Adjusting the draft control linkage These procedures describe how to bench adjust the lift housing linkage. 1. Having carried out the position control, maximum lift arm displacement and traction control spring adjustments, adjust the traction control as follows: 2. Remove the control valve assembly following the procedures described in Three-point hitch control valve - Disassemble (35.114) and attach special tool No. 293846. 3. Attach the draft control arm (1).

LAIL11TT0361A0A

LAIL11TT0362A0A

LAIL11TT0363A0A

4. Move the position control lever (P) all the way forward and pull back the draft control lever (F) until there is a distance of 184 – 186 mm (L2) between the beginning of the slot and the edge of the lever (F). 5. Adjust the arm (22) to 70 – 70.5 mm (L3).

6. Adjust the outer draft control arm ( (1), Fig. 1) so that the end (P1) of tool 293846 (A) is on a level with the outer register (R1). ATTENTION: This condition corresponds to a clearance (L1) of 82 – 82.1 mm between the end of the lever (7) and the front edge of the lift housing when a force of 4 – 4.5 N is applied to the end of the lever.

47921938 07/02/2017

37.1 [37.110] / 27

Hitches, drawbars, and implement couplings - Rear three-point hitch

7. Tighten the counter nut (1). 8. To fit the control valve, follow the procedures in Threepoint hitch control valve - Assemble (35.114).

LAIL11TT0364A0A

47921938 07/02/2017

37.1 [37.110] / 28

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear hitch housing - Remove TT3840F TT3840 TT3880F

LA LA LA

Remove the hydraulic lift from the rear axle housing as follows: 1. Remove operatorâ&#x20AC;&#x2122;s seat, (1).

20098687

20098688

20098435

2. Remove three-point linkages, (1), (top link and lift arms).

3. Disconnect oil supply line at, (1), between remote control valve and distributor.

47921938 07/02/2017

37.1 [37.110] / 29

Hitches, drawbars, and implement couplings - Rear three-point hitch

4. Disconnect rear remote control valve return line at hydraulic lift housing, (1).

20098689

20098695

20098696

5. Loosen and remove the hydraulic lift housing retaining bolts, (1).

6. Lift the housing using suitable hoist and place it on a clean flat surfaced table or secure it on stand. NOTICE: Never lift the housing by holding distributor knobs and delicate parts.

Next operation: When fitting the rear hitch housing, see the procedures in Rear hitch housing - Install (37.110).

47921938 07/02/2017

37.1 [37.110] / 30

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear hitch housing - Install TT3840F TT3840 TT3880F

LA LA LA

Prior operation: When removing the rear hitch housing, see the procedures in Rear hitch housing - Remove (37.110). Install the hydraulic lift on the transmission housing as follows. • Before installing the hydraulic lift in the rear transmission casing, clean and degrease the mating surfaces thoroughly and apply a strip of sealing compound LOCTITE® 515™ of about 2 mm (0.08 in) diameter as shown.

20098926

1. Install the hydraulic lift housing, (1), and secure retaining bolts, (2). Torque the bolts 132 N·m (97 lb ft).

20098695

47921938 07/02/2017

37.1 [37.110] / 31

Hitches, drawbars, and implement couplings - Rear three-point hitch

2. Connect the rear remote control valve return line, (1), at the hydraulic lift housing.

20098689

20098435

20098688

3. Connect oil supply line, (1), to the remote control valve and distributor.

4. Install the three point linkage, (1), (top link and lift arms), as shown.

47921938 07/02/2017

37.1 [37.110] / 32

Hitches, drawbars, and implement couplings - Rear three-point hitch

5. Install operatorâ&#x20AC;&#x2122;s seat, (1).

20098687

47921938 07/02/2017

37.1 [37.110] / 33

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear hitch internal controls - Disassemble TT3840F TT3840 TT3880F

LA LA LA

1. Remove external control levers as described in Rear hitch external controls - Remove (37.110).

20098696

20098705

20098706

2. Loosen the Allen screws, (1), and remove valve block assembly, (2).

3. Remove pipe, (1), and O-rings.

47921938 07/02/2017

37.1 [37.110] / 34

Hitches, drawbars, and implement couplings - Rear three-point hitch

4. Loosen the bolts, (1), and remove distributor (control valve) assembly, (2).

20098707

20098708

20098709

5. Loosen the bolts, (1), and remove lift housing front cover.

6. Remove piston, (1), and cylinder from the housing. NOTE: To remove piston, lower the lift arm by hand to push out the piston out of lift housing. NOTE: To remove cylinder, gently hammer out the cylinder using plastic hammer or aluminium rod.

47921938 07/02/2017

37.1 [37.110] / 35

Hitches, drawbars, and implement couplings - Rear three-point hitch

7. Remove pin, (1), by screwing out bolt, (2).

20098710

20098711

20098712

8. Remove the roll pin, (1), from shaft inside the housing.

9. Remove linkages, (1), from the housing.

47921938 07/02/2017

37.1 [37.110] / 36

Hitches, drawbars, and implement couplings - Rear three-point hitch

10. Remove sector plate, (1).

20098713

20098714

20098715

11. Remove draft control plate, (1), if applicable.

12. Remove position control lever/draft control lever shaft, (1), from the housing.

47921938 07/02/2017

37.1 [37.110] / 37

Hitches, drawbars, and implement couplings - Rear three-point hitch

13. Disconnect draft sensing linkage, (1), by removing circlip, (2), and loosening bolt, (3).

20098716

20098717

20098718

20098719

14. Remove bolt, (1), that secures lever, (2), to the shaft, (3).

15. Pull out draft sensing shaft, (1), from the housing.

16. Remove draft sensing linkages, (1), from the housing.

47921938 07/02/2017

37.1 [37.110] / 38

Hitches, drawbars, and implement couplings - Rear three-point hitch

17. Loosen Allen screws, (1), and remove stopper assembly, (2). NOTE: Piston connecting rod can be removed only after removing cross shaft from the housing. Consult the removal procedures in Rockshaft - Disassemble (37.110).

20098710

47921938 07/02/2017

37.1 [37.110] / 39

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear hitch internal controls - Assemble TT3840F TT3840 TT3880F

LA LA LA

NOTE: Check O-rings and needle bearing for wear and damage. 1. Install shaft, (1), through housing. 2. Insert lever, (2), onto shaft coming through housing and secure the lever to the shaft with coned shaped bolt, (3).

20098717

20098721

20098722

3. Install lever shaft, (1), through housing at location shown. NOTE: It is necessary for the cylinder sleeve to be forward in order to install the shaft. 4. Install position control lever, (2) and secure with safety clip, (3).

5. Install fitting, (1), with washer, (2), if fitting was removed. 6. Install a new O-ring, (3), onto shaft. 7. Install snap ring, (4), onto shaft.

47921938 07/02/2017

37.1 [37.110] / 40

Hitches, drawbars, and implement couplings - Rear three-point hitch

8. Before installing lever, (1), pre-fit roll pin, (2), into lever and insert shaft, (3), through housing as shown. 9. Install the roll pin, (2), through the shaft until flush.

20098711

20098723

20098710

10. Install pin, (1), through housing at location shown. 11. Engage pin through the needle bearings of the lever, (2). Secure lever to the pin with one washer, (3), and snap ring, (4).

12. Insert pin, (1), in the housing and secure with bolt, (2).

47921938 07/02/2017

37.1 [37.110] / 41

Hitches, drawbars, and implement couplings - Rear three-point hitch

13. Install and secure the stroke rod assembly, (1), with M8 x 1.25 Allen head screws, (2). Torque the two Allen screws to 19 N·m (14 lb ft).

20098724

20098725

20098708

14. Install cylinder sleeve (not shown) into housing, if it was removed. 15. Install piston, (1) into sleeve. 16. Apply a light coat of hydraulic oil to O-ring and install at location shown, (2). Insert cylinder seal, (3), on O-ring.

17. Clean the surface of the housing and cover. Apply a 2 mm (0.08 in) bead of LOCTITE® 515™ sealer to housing. 18. Install the lift body front cover, (1), and secure with four M14 x 1.50 x 45mmbolts, (2). Torque the bolts 132 N·m (97 lb ft).

47921938 07/02/2017

37.1 [37.110] / 42

Hitches, drawbars, and implement couplings - Rear three-point hitch

19. Clean the surface of the lift body front cover and distributor. Apply a 2 mm (0.08 in) bead of LOCTITE® 515™ sealer to the distributor. 20. Install distributor control valve assembly, (1), and secure with four M8 x 1.25 x 55 mm cap screws. (2), torque the bolts to 19 N·m (14 lb ft).

20098707

20098706

20098705

21. Insert pipe (with O-rings), (1), into housing as shown.

22. Secure delivery piping to control valve, (1), with M10 x 1.25 x 45 mm Allen screw, (2), and M10 x 1.25 x 85 mm Allen screw, (3). Torque the two Allen screws to 56 N·m (41 lb ft). 23. Install the hydraulic lift assembly onto the tractor.

47921938 07/02/2017

37.1 [37.110] / 43

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear hitch external controls - Remove TT3840F TT3840 TT3880F

LA LA LA

With hydraulic lift assembly on tractor. Proceed as follows: 1. Remove nuts (1) and Lift–O–Matic button (2).

LAIL11TT0437A0A

LAIL11TT0432A0A

LAIL11TT0433A0A

2. Loosen nuts (1) and remove support plate (2).

NOTE: To remove the plate (2), the Lift–O–Matic lever shaft nut (1) should be loosened.

47921938 07/02/2017

37.1 [37.110] / 44

Hitches, drawbars, and implement couplings - Rear three-point hitch

3. Retrieve springs (1) and clutch plate and remove lock–nut (2).

LAIL11TT0434A0A

LAIL11TT0435A0A

LAIL11TT0436A0A

4. Remove position control lever, clutch plates draft control lever and spacer.

5. Retrieve position and draft control lever keys. 6. Remove quadrant plate (1). NOTE: To remove the Lift–O–Matic lever (1), the lift housing must be removed from the tractor. See the procedure for removing internal controls in Rear hitch internal controls - Disassemble (37.110).

47921938 07/02/2017

37.1 [37.110] / 45

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear hitch external controls - Assemble TT3840F TT3840 TT3880F

LA LA LA

Reassembly Assembly is the reverse of the disassembly procedure, see steps 6 to 1 described in Rear hitch external controls - Remove (37.110). See all the various adjustments of the control valve in Relief valve - Pressure test (35.114).

47921938 07/02/2017

37.1 [37.110] / 46

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear hitch external controls - Adjust TT3840F TT3840 TT3880F

LA LA LA

Lift–O–Matic adjustment 1. Apply a 50 kg load to the lift arm pivot bearings. 2. Run the engine at an average of 1.200 – 1.500 RPM. 3. Move the position and draft control levers (P) and (F) all the way forward. 4. Adjust the position of the support together with the LIFT– O–MATIC control levers on lift control support. Secure the support with a bolt (1) so that, when button (Q) is pressed, the arm starts descending with a movement clearance (L5) of 9 – 12 mm at the end of the button. LAIL11TT0365A0A

LAIL11TT0366A0A

LAIL11TT0367A0A

Start–to–lift check 1. Push the position control lever ((P), Fig. 2) all the way forward. 2. Put the Lift–O–Matic lever (1) in the position shown in the Figure.

3. Use the draft control lever (F) to check that the lift starts with the lever at a distance of 184 – 186 mm from the end of its slot. 4. Otherwise, adjust the arm (1) to obtain the specified length and tighten the jam nut (2).

47921938 07/02/2017

37.1 [37.110] / 47

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rockshaft - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Remove bolt, (1), and thrust plate, (2), from both sides of the lift arm.

20098726

20098727

20098728

NOTICE: Before removing the lift arms, use a hammer with a chisel and mark a line on the shaft, (1), and the lift arm, (2), as shown.

2. Remove lift arms, (1), from shaft using suitable puller or by hammering gently.

47921938 07/02/2017

37.1 [37.110] / 48

Hitches, drawbars, and implement couplings - Rear three-point hitch

3. Remove lift arm shaft, (1), by tapping on the right-hand end of the shaft with mallet. NOTE: In some instances, the seals will need to be removed in order to remove the shaft from the housing.

20098729

20098720

20098730

4. Remove piston rod, (1), and cam sleeve from the housing.

5. Remove left-hand and right-hand shaft bushings from the housing using a suitable bushing driver. Left-hand Bushing Dimensions: • OD - 60.111 – 60.161 mm (2.367 – 2.369 in) • ID - 55.100 – 55.184 mm (2.169 – 2.173 in) Right-hand Bushing Dimensions: • OD - 53.111 – 53.161 mm (2.091 – 2.093 in) • ID - 48.100 – 48.184 mm (1.894 – 1.897 in)

Next operation: To fit the rockshaft, see the procedures in Rockshaft - Assemble (37.110).

47921938 07/02/2017

37.1 [37.110] / 49

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rockshaft - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

WARNING Pinch point! Lift arm assembly pivots create pinch points. Keep fingers, hands, and feet away from pivot points. Failure to comply could result in death or serious injury. W0357A

Prior operation: To remove the rockshaft, see the procedures in Rockshaft - Disassemble (37.110). 1. Install the left-hand and right-hand shaft bushings into the housing using a suitable bushing driver. Left-hand Bushing Dimensions: • OD - 60.111 – 60.161 mm (2.367 – 2.369 in) • ID - 55.100 – 55.184 mm (2.169 – 2.173 in) Right-hand Bushing Dimensions: • OD - 53.111 – 53.161 mm (2.091 – 2.093 in) • ID - 48.100 – 48.184 mm (1.894 – 1.897 in)

20098730

20098731

20098732

2. Ensure that dimensions (A), (B) and (C) are as shown in figure. Bushings do not require reaming after installation. 3. On completing assembly, check cross shaft end float is 0.2 – 1.4 mm (0.0079 – 0.0551 in). • A = 55 mm (2.17 in) • B = 65 mm (2.56 in) • C = 15 mm (0.59 in)

4. Install the piston rod assembly, (1) and cross shaft sleeve, (2), into housing.

47921938 07/02/2017

37.1 [37.110] / 50

Hitches, drawbars, and implement couplings - Rear three-point hitch

5. Install the cross shaft, (1), into housing with the smaller side of the shaft going through the left-hand side of the housing. NOTE: Make sure not to damage the shaft while inserting shaft through the rod and sleeve.

20098733

20098734

20098735

6. Install new seals, (1), on both sides of the shaft using a suitable seal installer. Seal Dimensions • OD - 65 mm (2.56 in) • Ideal Tool Diameter - 59 mm (2.32 in)

7. Install spacer, (1), followed by lift arm, (2) and secure with washer, (3), lock washer and bolt, (4). 8. Torque the M14 x 1.50 x 30 mm bolt to 132 N·m (97 lb ft). NOTICE: When installing lift arms onto shaft, verify that mark on shaft lines up with mark on lift arm.

47921938 07/02/2017

37.1 [37.110] / 51

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Troubleshooting TT3840F TT3840 TT3880F TT4030

Problem Erratic upward lift movement.

Relief valve blows with lift arms in max. raised position. Lift fails to operate

LA LA LA LA

Possible Cause Clogged oil filter.

Correction Inspect filter and replace cartridge if necessary. Air entering the suction line. Check for faulty connections or faulty seals. Replace seals. Oil leakage through the spool seals. Leakage through the spool. Remove, check for leakage, clean and replace damaged parts. Check valve leakage. Inspect filter. Remove, inspect, and clean. Leak through the lift piston. Replace seals. Replace seals. . Bushing seal or lift cylinder seal. Safety valve leakage or incorrect setting of Replace valve. safety valve. Adjust travel. Travel adjustment error on lift arm.

Governor locked open.

Inefficient pump. Insufficient or inaccurate Incorrect relief valve setting. lifting Incorrect safety setting. Poor pump performance.

47921938 07/02/2017

37.1 [37.110] / 52

Remove foreign particles from drain holes and inspect filter. Disassemble and inspect. Replace or adjust. Replace valve. Check pump and overhaul or replace.

Index Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110 Rear hitch external controls - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear hitch external controls - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear hitch external controls - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear hitch external controls - Dynamic description of the Lift-O-Matic (*) . . . . . . . . . . . . . . . . . . . . . .

Rear hitch external controls - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear hitch housing - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear hitch housing - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear hitch housing - Sealing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear hitch internal controls - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear hitch internal controls - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Adjust of the position control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Adjust the draft control linkage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Hydraulic schema (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Travel adjust maximum of the lift arm (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Travel adjust the draft control spring (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rockshaft - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rockshaft - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

37.1 [37.110] / 53

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

47921938 07/02/2017 EN

SERVICE MANUAL Steering TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017

Contents Steering - 41

[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

47921938 07/02/2017

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

Reference

PAGE

Steering control - General specification

41.1 / 4

47921938 07/02/2017

Steering - 41 Steering control - 101

47921938 07/02/2017

41.1 [41.101] / 1

Contents Steering - 41 Steering control - 101

TECHNICAL DATA Steering control General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Steering control Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Steering control Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

DIAGNOSTIC Steering control Steering control - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

(*) See content for specific models 47921938 07/02/2017

41.1 [41.101] / 2

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

Reference

PAGE

Steering control - General specification

41.1 / 4

47921938 07/02/2017

41.1 [41.101] / 3

Steering - Steering control

Steering control - General specification TT3840F TT3840 TT3880F TT4030

Component Type Reduction ratio Steering column angle Number of balls Ball diameter Inner column bearings Oil capacity (approximate) The type of oil Steering column bearing preload Total torque after assembly of the steering axle

LA LA LA LA

All models Hydrostatics 35.0 constant 61° 81 93/32 Angular contact bearings 2 l (0.5 US gal) NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL 4 – 7 Kg/cm² 6 – 9 Kg/cm²

Steering control - Torque TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Tightening torques Name Outer column bolts (C₁₁) Cover plate bolts (C₂₂) Adjustable bolt jam nut (C₃₃) Drop arm nut (C₄₄) Steering wheel nut (C₅₅) Mounting bolts for the steering assembly (C₆₆)

Thread size M12 x 1.25 M8 X 1.25 M14 x 1.5 M30 x 1.5 M18 x 1.25 M16 x 1.5

47921938 07/02/2017

41.1 [41.101] / 4

Torque 50 N·m 20 N·m 30 N·m 350 N·m 70 N·m 145 N·m

Steering - Steering control

LAIL11TT0191F0A

Steering control - Special tools TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Special tools Tool description Steering Wheel Puller Steering Wheel Puller Sleeve Hand Accelerator Dowel Remover Steering Arm Puller

No. of the tool 82834312 9971375 9971378 9971363

47921938 07/02/2017

41.1 [41.101] / 5

Steering - Steering control

Steering control - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Description and operation This is an anti-friction, re-circulating ball, constant ratio sector steering gear. A hardened and precision ground single star worm shaft which forms lower part of the inner column is supported in the steering gear housing by angular contact bearings assembly at each end. The upper part of the inner column is supported by bearing bush. Adjustment of the bearing preload on these bearings is achieved by shims between the outer column and steering housing. The inner column is provided with spline and taper construction for fitting the steering wheel. As the steering wheel is turned the inner column rotates and moves the main nut in the axial direction on the inner column. The main nut employs two independent ball circuits. The transfer tubes guide the ball at the end of the circuit to bring them back to the beginning of the relevant helical path. They are positioned so that the balls leave and re-enter on a line that is at a tangent to the pitch circle. The transfer tubes re-clamped in place by the retainer. The rack on one side of the main nut meshes with the taper tooth gear of the sector shaft. This makes the sector shaft rotate during axial movement of the main nut. The sector shaft teeth are conical and are designed specially to provide true rack and sector action when main nut is positioned at a slight angle. This construction permits backlash adjustments by shifting sector shaft slightly along its axis by means of a adjuster screw. The sector shaft is supported on its longer side by two bushes fitted in the housing. There is a taper spline at the shaft end to which drop arm is fitted and is retained in position by nut and tab washer.

47921938 07/02/2017

41.1 [41.101] / 6

Steering - Steering control

Steering control - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

How to remove the steering assembly 1. Disconnect the negative cable (1) from the battery and insulate the cable.

LAIL11TT0026A0A

LAIL11TT0027A0A

LAIL11TT0028A0A

2. Remove the nut (1).

3. Remove the steering wheel with special tools Nos. 82834312 and 9971375.

47921938 07/02/2017

41.1 [41.101] / 7

Steering - Steering control

4. Remove the electrical couplers (1) for the tail lights, flasher unit, fuse box, etc.

LAIL11TT0029A0A

LAIL11TT0030A0A

LAIL11TT0031A0A

LAIL11TT0032A0A

5. Disconnect electric connections to the fenders below the rear hood.

6. Disconnect the RPM meter cable connection (1) on the instrument cluster by opening the instrument cluster through the rear hood.

7. Loosen the rear hood retaining bolts (1) on both sides and (2) on the steering column, and carefully remove the rear hood from the tractor (keeping it parallel to the steering column).

47921938 07/02/2017

41.1 [41.101] / 8

Steering - Steering control

8. Disconnect the pipe from the diesel overflow hose (1) and the fuel distributor electrical connections (2). 9. Remove the nut (3) and loosen the fuel tank strap from the steering column journal. 10. Remove the hand accelerator cable.

LAIL11TT0033A0A

LAIL11TT0034A0A

11. Close the diesel cap (1) and disconnect the hose (2) between the diesel tank and supply pump. 12. Remove the tractor fuel reservoir tank. NOTE: It is advisable to drain the diesel from the fuel reservoir tank if the tank is more than half full.

13. Remove the drop arm nut (1).

LAIL11TT0035A0A

LAIL11TT0036A0A

14. Remove the drop arm from the steering roller shaft using special tool No. 9971363. NOTE: Before removing the drop arm from steering roller shaft, note the position of the drop arm relative to the shaft. This is normally shown by the marking line on the arm and on the rear end of the steering roller shaft. If this mark is not provided, make a mark on the drop arm and end face of the shaft before removing. This is required to remount the drop arm in its original position relative to the shaft.

47921938 07/02/2017

41.1 [41.101] / 9

Steering - Steering control

15. Remove the bolts (1) that hold the steering assembly on the clutch housing. 16. Remove the steering assembly from the clutch housing.

LAIL11TT0037A0A

47921938 07/02/2017

41.1 [41.101] / 10

Steering - Steering control

Steering control - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Steering assembly 1. Remove the steering assembly from the tractor as described earlier. 2. Remove the oil drain plug (1) and drain the oil by tilting the steering assembly.

LAIL11TT0468A0A

LAIL11TT0369A0A

LAIL11TT0370A0A

3. Rotate the inner column and keep the gear in mid-gear position. 4. Loosen the jam nut on the adjuster screw (1) and remove the four bolts (2) that hold the side cover.

5. Remove the cover plate and the rockshaft by gently tapping the end of the shaft with a mallet.

47921938 07/02/2017

41.1 [41.101] / 11

Steering - Steering control

6. Further loosen the adjusting jam nut and remove the areaâ&#x20AC;&#x2122;s cover plate.

LAIL11TT0371A0A

LAIL11TT0372A0A

LAIL11TT0373A0A

LAIL11TT0374A0A

7. Remove the four bolts (1) that hold the outer column into its housing.

8. Remove the outer column assembly (1), along with the top bearing cage assembly, and remove the shims (2).

9. Take out the bottom bearing cage from the housing.

47921938 07/02/2017

41.1 [41.101] / 12

Steering - Steering control

10. Remove the inner column assembly (1) from the steering housing.

LAIL11TT0375A0A

LAIL11TT0376A0A

11. Remove the bearing races (1) from the inner column with a suitable extractor.

12. Unscrew and remove the clamp screws for the transfer tube retainer from the main nut.

LAIL11TT0377A0A

LAIL11TT0378A0A

13. Remove the transfer tubes (1) from the main unit.

47921938 07/02/2017

41.1 [41.101] / 13

Steering - Steering control

14. Dislodge main nut ball by twisting the main nut (1) in either direction. Collect the main nut balls (81 in number). 15. After dislodging all the main nut balls, remove the main nut from the inner column.

LAIL11TT0379A0A

LAIL11TT0380A0A

16. Remove the oil seal (1) from the housing by carefully levering it at diametrically opposite points.

47921938 07/02/2017

41.1 [41.101] / 14

Steering - Steering control

Steering control - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. To maintain safety and reliability, all steering gear components should be in good condition. If any damage is noted, the components should replaced, not repaired. 2. Wash all parts prior to inspection. Inspection, repair and assembly of steering parts must not be attempted in dirty surroundings. Parts must be kept absolutely clean. 3. Examine the steel balls and the bearing tracks of the main nut and the inside column to look for undue wear or erosion. If any of these components are damaged, showing erosion, or splitting, the inside column and the main nut assembly should be completely replaced. 4. Check for wear on the rack teeth portion of the main nut. 5. Check for damages on the serration and threads of the inner column. If any damage is observed, check serration of the corresponding mating serration of the steering wheel also for damages. 6. Check sector shaft for wear and damages at gear teeth, spline and threads. 7. Check adjuster screw visually for any bend and threads for damage and replace if necessary. 8. Check for axial play of the adjuster screw in the sector shaft "T" slot. In case of excess play replace the spacer. 9. Examine the bearing and races for wear, pitting, cracked, deformed cages. If evidence of the above are found the bearing must be renewed. It is advisable to replace both worm bearing together when renewal is required. 10. Check fit of the sector shaft in the housing bush. If a slack fit is apparent, replace both the bushes in the housing. 11. Check fit of inner column upper bearing area in the outer column bush. If a slack fit is apparent the rubber sleeve in the outer column assembly should be driven out and the bush to be replaced. 12. Check the transfer tube for any damages or wear especially at the tip and ball entry points.

47921938 07/02/2017

41.1 [41.101] / 15

Steering - Steering control

Steering control - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Fitting the steering cylinder 1. Clean all components before assembly. Care to be taken to clean the shimming face of the housing and outer column and cover plate seating area. 2. Insert the main nut into the inner column and align the nut and auger shafts. Ensure that the ball circuit with shorter pitch towards top. 3. Fit the top and bottom inner race on the inner column. 4. Count the Nos. If steel balls 9/32 in in diameter, insert 23 Nos. into the shorter circuit and 38 Nos. into the longer circuit. The 20 remaining Nos. should be placed in two transfer tube assemblies (10 Nos. per assembly), with enough grease to keep them in position. 5. Ensure that the balls are assembled properly in the right track. The track from the end of the top circuit to the beginning of bottom circuit is called as ĂŹ no ball zoneĂŽ and are should be taken to see that the balls does not slips in to this zone. Any balls present in this zone will damage the transfer tube leading to failure of the steering mechanism. 6. Insert the transfer tubes in the correct position in the primary nut. Keep the transfer tube retainer in position over the transfer tubes and secure it with bolts and washers. Check for free movement of the main nut on the worm shaft. 7. Press the bottom bearing outer race in to positon in the housing and place bearing cage over it. 8. Press the top bearing outer race in to positon in the outer column. 9. Insert the inner column assembly in to the box and place the top cage over the inner race. 10. Fit the outer column in to the housing without shims and tighten the bolts to finger tight. Ensure proper seating of the bearings and faces in position. 11. Measure the clearance between the housing face and outer column with a feeler gauge to determine the shim pack thickness. Deduct 0.002 in from the thickness found. 12. Remove the outer column bolts and take out the outer column assembly. 13. Apply a uniform bead of Anabond 666 to the housing and outer column face. 14. Assemble the outer column assembly in to the housing by placing shims between the housing face and outer column. Tighten the outer column bolts to 50 NÂˇm after applying a thin coating of Holdtite on the bolts. 47921938 07/02/2017

41.1 [41.101] / 16

Steering - Steering control

15. Ensure smooth rotation of the inner column with out axial movement. Adjust the shims if necessary to get smooth rotation. 16. Insert the spacer in to the adjuster and fit to the T-slot of the sector shaft. Check for axial play of the adjuster screw. If there is still play, replace the spacer with a thicker one. Adjuster screw should not be jammed and should be free to rotate by hand. 17. Set the steering in the mid gear position. 18. Insert the spacer in the correct position, so that center teeth of the sector shaft engages with the middle portion of the main nut rack. 19. Apply a uniform coat of Anabond 666 on the housing and fit the cover plate into the housing by engaging the adjustment bolt provided in the cover plate. 20. Draw out the sector shaft adjuster screw fully. 21. Provide a thin coating of Holdtite on the bolts and tighten the cover plate to 20 N·m. 22. Drive in the adjustment bolt until the required pre–load of 60 – 90 Kg/cm² is achieved and tighten the adjustment bolt lock nut. Ensure that the adjustment is done in the mid gear position only. 23. Drive new seals in position in to the sector shaft side of the housing. 24. Fit the dust sleeve and fix the drop arm by matching the mark already made. 25. Place the tab washer, tighten the lock nut to 350 N·m and fold the tab washer. 26. Fill the steering gear assembly with specified grade of oil and check for smooth operation.

47921938 07/02/2017

41.1 [41.101] / 17

Steering - Steering control

Steering control - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Installation of the steering assembly Installation of the steering assembly is the reverse of the removal procedure, but observe the following: 1. The drop arm should be fitted on the steering roller shaft so that each marking line matches up with the other. 2. The splined section and the thread on the shaft should be well lubricated with lubricating oil before pushing the arm onto the splines. 3. If the position of the drop arm is not marked, you should use the following method: The steering gears should be turned exactly to the middle position. The front wheels should also be brought as close as possible to the straight-ahead position. The drop arm can then be placed in the required position on the steering roller shaft. You must take the utmost care at this time not to change the position of the steering or the front wheels. Small discrepancies can be balanced out by adjusting the length of the track rod. 4. Finally, you should also check whether the assembly fully locks when turned to the right and to the left. The stop occurs on the backstop of the relevant axle ( (1), Fig. 1). Under no circumstances can the stop occur on the steering gear because this can cause serious mechanical damage.

47921938 07/02/2017

41.1 [41.101] / 18

LAIL11TT0461A0A

Steering - Steering control

Steering control - Adjust TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Setups Provision is made in the design for adjustments, so that there is no backlash in the straightâ&#x20AC;&#x201C;ahead position (SAP). However, there may be backlash when moving out of SAP, which will increase toward the point where the steering locks. If there is excessive play in the steering wheel at SAP, check and adjust the backlash as per the procedure given below. 1. Rock the steering wheel and look for visual lift in the ball joints. If there is excessive lift, the ball joint requires replacement. 2. Keep the vehicle in the SAP. This detail is extremely important, since the sector shaft is machined to give more play at the extremity of each lock. Therefore, if the backlash is adjusted at any position other than at SAP, a serious lock-up could occur at SAP. 3. Disconnect the drag link from the drop arm. 4. Check the smaller end of the drop arm for any backlash by rocking in the direction of movement. 5. Loosen the locking nut on the adjuster screw and screw in the adjuster screw until there is no more play in the drop arm. 6. Tighten the lock nut on the adjuster screw. 7. Pull the drag link.

47921938 07/02/2017

41.1 [41.101] / 19

Steering - Steering control

Steering control - Troubleshooting TT3840F TT3840 TT3880F TT4030

Problem Pulling laterally

Hard steering

Oscillation

LA LA LA LA

Possible Cause Low tire pressure

Correction Check the tire pressure and inflate accordingly. Worn knuckle joint Replace knuckle joint Wrong wheel alignment Check and correct the toe-in Spindle bushing tight Check and replace bushing Play between arm and spindle Replace the worn parts Wheel bearing play Check and adjust the preload of the bearings One of the tires is more worn than the oth- Replace the worn tire ers Worn rim Replace rim Replace bearings Broken / damaged / tight axle bearing Oil level or quality Check and replace or top-up Tire pressure Check and inflate to correct pressure. Clean and grease Lack of grease Check toe-in setting Wheel alignment Replace the bushing or repair the spindle. Recondition or replace the tire Replace thrust washers Spindle seize in bush Tire too worn Thrust washers damaged Check and adjust Wrong play setting in steering assembly Worn knuckle joint pin Replace knuckle joint Renew bushes King pin / spindle bush wear off Adjust the play by adding or removing Steering play shims on the auger shaft flange Wrong wheel alignment Check and correct the toe-in Adjust the play Steering roller shaft loose / play

47921938 07/02/2017

41.1 [41.101] / 20

Index Steering - 41 Steering control - 101 Steering control - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

41.1 [41.101] / 21

47921938 07/02/2017

41.1 [41.101] / 22

Steering - 41 Hydraulic control components - 200

47921938 07/02/2017

41.2 [41.200] / 1

Contents Steering - 41 Hydraulic control components - 200

TECHNICAL DATA Hydraulic control components General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic control components - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Hydraulic control components Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Hydraulic control components Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Power steering control valve Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Steering circuit relief valve Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

(*) See content for specific models 47921938 07/02/2017

41.2 [41.200] / 2

Steering - Hydraulic control components

Hydraulic control components - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Specifications Component Type Make Hydraulic circuit Oil Tank Oil filter Hydraulic pump Type Drive Rotation Drive ratio Flow at rated speed - 2328 RPM: Flow on workbench at 1.450 RPM ( 70102 Kg/cm²): - New or reconditioned pump - Used pump - Test oil temperature - Test oil viscosity Diameter of drive/driven gear journal Internal diameter of bearing Gear journal play in bearing Maximum wear clearance. Gear clearance in pump body Maximum wear clearance Bearing Width Gear width Pump Body Width Bearing and gear end clearance in pump body Control Valve Type Outfit code: Relief valve setting Adjusting the cylinder overload valve Front axle hydraulic cylinder Type Make Cylinder bore Piston rod diameter Maximum piston stroke with cylinder make

TT3840

TT3840F TT3880F TT4030 Hydrostat Danfoss Independent pump Located on the right-hand side of the engine Located inside the oil reservoir Gears From engine valve gear Clockwise 1 to 0.931 26.4 l/min

15.3 l/min 10.7 l/min 55 – 65 °C SAE 20 W 17400 – 17418 mm 17450 – 17470 mm 0.032 – 0.070 mm 0.1 mm 0.020 – 0.064 mm 0.1 mm 19.812 mm 18.348 mm 58072 – 58122 mm 0.1 – 0.2 mm Danfoss Operated by the steering column 100 bar 200 bar Dual action Ognibene 48 mm 22 mm 214 mm

Hydraulic control components - Torque TT3840F TT3840 TT3880F TT4030

LA LA LA LA

47921938 07/02/2017

41.2 [41.200] / 3

Steering - Hydraulic control components

Tightening torques Name Capscrew, control valve support (C1) Capscrew, control valve to tractor (C2) Capscrew, cover to control valve (C3) Nut, power cylinder pivot pin (C4) Nut, power cylinder piston rod to steering arm (C5) Nut, piston to rod (C6) Capscrew, steering pump to engine (C7) Nut, cover to pump body (C5) Nut, drive sleeve to pump drive shaft (C5)

Thread size M16 x 1.5 0.375 in-16 UNC M8 x 1 M18 x 1.5 M16 x 1.5 M16 x 1.5 M12 x 1.25 M6 x 1 0.4375 in -20 UNF -2B

Hydraulic control components - Special tools TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Special tools Tool description Steering wheel extractor Adapter, pressure check for power steering (included in hydraulic pressure kit 292870) Installer, rotor spring for power steering

47921938 07/02/2017

41.2 [41.200] / 4

No. of the tool 82834312 291318 292927

Torque Nm 150 N·m 45 N·m 35 N·m 300 N·m 210 N·m 100 N·m 8 N·m 50 N·m 28 N·m

Steering - Hydraulic control components

Hydraulic control components - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Description and operation

LAIL11TT0040F0A

D1. E. H. M.

Control Valve Filter cartridge Power cylinder Pump output line

P. S. T. V.

Hydraulic pump Return to the reservoir Reservoir Steering wheel

47921938 07/02/2017

41.2 [41.200] / 5

Steering - Hydraulic control components

Hydraulic control components - Test TT3840F TT3840 TT3880F TT4030

LA LA LA LA

System testing When the hydrostatic steering system is in operation, the pressure of oil supplied by the steering pump to the steering motor can rise toward the maximum setting of the steering motor relief valve, which is 120 bar, depending on the tractor model.

Steering pump There is no relief valve in the steering/low pressure pump. The following practical test will determine if steering pump output is sufficient to allow satisfactory operation of the steering system.

Steering test 1. Run the engine at 1000 RPM. 2. Turn steering quickly from lock to lock. If steering is operating correctly the reaction of the steering should be immediate with no time delay between turning the steering wheel and movement of the wheels. At full lock the relief valve in the steering motor should be heard to blow and the engine speed should drop to approximately 970 RPM.

LAIL11TT0038A0A

47921938 07/02/2017

41.2 [41.200] / 6

Steering - Hydraulic control components

Steering relief valve pressure test NOTICE: There is no relief valve in the steering pump and the following pressure test must only be performed as specified below. Failure to observe this precaution may result in severe damage to the hydraulic pump. 1. Turn steering onto full left hand lock. 2. Disconnect left hand turn feed hose at steering cylinder. 3. Install the pressure checking kit for the power steering (Special Tool No. 292870 with adapter 271318). As shown in Figure 4. Start the tractor and increase the throttle to 1450 RPM. Turn the steering wheel to the left with a force of approximately 22 N (5 lb) and check the pressure reading. NOTE: The use of a force greater than 2.25 kgf at the rim of the steering wheel may lead to slightly inaccurate readings due to the pumping action of the hydrostatic steering motor. If the steering test was satisfactory but pressure readings were outside the specification, the relief valve in the steering motor must be adjusted. The pressure measured should be 110 â&#x20AC;&#x201C; 125 bar. 5. If the system pressure is not to specification proceed to Relief Valve Adjustment.

47921938 07/02/2017

41.2 [41.200] / 7

LAIL11TT0039A0A

Steering - Hydraulic control components

Power steering control valve - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Position the tractor on a hard level surface and apply the parking brake. 2. To gain access to the Steering motor: • Remove tractor rear hood. • Remove the fuel tank. 3. Disconnect the supply/return tubes and ‘O’ ring seals from the steering motor and cap the ends of the tubes and steering motor to prevent entry of foreign particles. • To the tank, (1) • From Pump, (2). • Left Port, (3). • Right Port, (4).

20096327

20098800

4. Remove the bolts, (1), at the base of the steering column and slide out the steering motor from the steering column.

Next operation: To remove the control valve for the hydraulic power steering, refer to the procedures in Power steering control valve - Disassemble (41.200).

47921938 07/02/2017

41.2 [41.200] / 8

Steering - Hydraulic control components

Power steering control valve - Disassemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To remove the control valve for the power steering, refer to the procedures in Power steering control valve - Remove (41.200). 1. Hold the steering motor securely in a vice. 2. Remove the end cover bolts, (1). (6 plus one special screw).

20096246

20096247

20096248

3. Remove the end cover, (1), sideways.

4. Lift the gear wheel set, (1), (with spacer fitted) off the unit. Take out the O-rings.

47921938 07/02/2017

41.2 [41.200] / 9

Steering - Hydraulic control components

5. Remove cardan shaft, (1).

20096249

20096250

20096251

20096252

6. Remove distributor plate, (1).

7. Screw out the threaded bushing, (1), over the check valve.

8. Remove O-ring, (1).

47921938 07/02/2017

41.2 [41.200] / 10

Steering - Hydraulic control components

9. Shake out the check valve ball and suction valve pins and balls. NOTE: Replace pins prior to the reassembly.

20096253

20096254

10. Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool. Press the spool inwards and the sleeve, ring, bearing races and needle bearing will be pushed out of the housing together.

11. Take ring, (1), bearing races, (2), and needle bearing, (3), from sleeve and spool. The outer (thin) bearing race can sometimes "stick" in the housing, therefore check that it has come out.

20096283

20096284

12. Press out the cross pin, (1). Use the special screw, (2), from the end cover.

47921938 07/02/2017

41.2 [41.200] / 11

Steering - Hydraulic control components

NOTE: A small mark has been made with pumice stone on both spool and sleeve close to one of the slots for the neutral position springs, Figure 12. If the mark is not visible, remember to leave a mark of your own on sleeve and spool before the neutral position springs are dismantled.

20096285

20096286

20096287

20096288

13. Carefully press the spool, (1), out of the sleeve, (2).

14. Press the neutral position springs, (1), out of their slots in the spool.

15. Remove dust seal and O-ring/kin-ring/Roto Glyd ring.

47921938 07/02/2017

41.2 [41.200] / 12

Steering - Hydraulic control components

16. The steering unit OSPB is now completely dismantled.

20096289

Next operation: To inspect the control valve for the power steering, see the procedures in Power steering control valve - Inspect (41.200).

47921938 07/02/2017

41.2 [41.200] / 13

Steering - Hydraulic control components

Power steering control valve - Inspect TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: When removing the power steering control valve, refer to the procedures in Power steering control valve - Disassemble (41.200) .

Cleaning and inspection 1. Clean all parts carefully in Shellsoi K or the like. 2. Replace all seals and washers. Check all parts carefully and make any replacements necessary. 3. Before assembling, lubricate all parts with hydraulic oil. Next operation: When fitting the power steering control valve, refer to the procedures in Power steering control valve - Assemble (41.200).

47921938 07/02/2017

41.2 [41.200] / 14

Steering - Hydraulic control components

Power steering control valve - Assemble TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Prior operation: To inspect the power steering control valve, see the procedures in Power steering control valve - Inspect (41.200). 1. Place the flat neutral position springs in the slot. Place the curved springs between the flat ones and press them into place.

20096290

20096291

20096292

2. Line up the spring set.

3. Guide the spool, (1), into the sleeve, (2). Make sure that spool and sleeve are placed correctly in relation to each other.

47921938 07/02/2017

41.2 [41.200] / 15

Steering - Hydraulic control components

4. Assemble spool and sleeve.

20096293

20096294

20096295

20096296

NOTE: When assembling spool and sleeve, only two possible ways of positioning the spring slots are correct. There are three slots in the spool and three holes in the sleeve in the end of the spool/sleeve opposite to the end with spring slots. Place the slots and holes opposite each other so that parts of the holes in the sleeve are visible through the slots in the spool.

5. Press the springs together and push the neutral position springs into place in the sleeve.

6. Line up the springs and center them.

47921938 07/02/2017

41.2 [41.200] / 16

Steering - Hydraulic control components

7. Guide the ring, (1), down over the sleeve. NOTE: The ring should be able to move-free of springs.

20096297

20096298

8. Install the cross pin, (1), into the spool/sleeve, (2).

9. Install bearing races and needle bearing as shown in 11.

86071903

47921938 07/02/2017

41.2 [41.200] / 17

Steering - Hydraulic control components

Assembly Pattern for Standard Bearing

20096299

1. 2. 3.

4. 5.

Outer bearing race Needle bearing Inner bearing race

Spool Coupling

NOTE: The inside chamfer on the inner bearing race must face the inner spool.

Installation of O-ring/king ring/roto Glyd ring 1. Turn the steering unit until the bore is horizontal in position. Guide the outer part of the assembly tool into the hole for the spool/sleeve.

20096300

47921938 07/02/2017

41.2 [41.200] / 18

Steering - Hydraulic control components

2. Grease O-ring and king ring/ roto Glyd ring with hydraulic oil and place them on the tool.

20096301

20096302

20096303

20096304

3. Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to the bottom.

4. Press and turn the O - ring/kin - ring into position in the housing.

5. Draw the inner and outer parts of the assembly tool out of the steering unit bore, leaving the guide from the inner part in the bore.

47921938 07/02/2017

41.2 [41.200] / 19

Steering - Hydraulic control components

Installation of Lip Seal 1. Lubricate the lip seal with hydraulic oil and place it on the assembly tool.

20096305

20096306

20096307

2. Guide the assembly tool right to the bottom.

3. Press and turn the lip seal into place in the housing.

47921938 07/02/2017

41.2 [41.200] / 20

Steering - Hydraulic control components

4. With a light turning movement, guide the spool and sleeve into the hole. NOTE: Install the spool set holding the cross pin horizontal.

20096308

20096309

20096310

20096251

5. The spool set will push out the assembly tool guide. The O - ring and kin/roto Glyd are now in position.

6. Turn the steering unit until the bore is vertical again. Put the check valve ball, (1), into the hole indicated by the arrow.

7. Screw the threaded bushing, (1), lightly into the check valve bore. The top of the bush must lie just below the surface of the housing.

47921938 07/02/2017

41.2 [41.200] / 21

Steering - Hydraulic control components

8. Place a ball in the holes, (1).

20096311

20096312

20096313

20096314

9. Place the new pins in the same holes.

10. Grease the O-ring with mineral oil.

11. Place the distributor plate so that the channel holes match the holes in the housing.

47921938 07/02/2017

41.2 [41.200] / 22

Steering - Hydraulic control components

12. Guide the cardan shaft down into the bore so that the slot is parallel with the connection flange.

20096315

20096316

20096317

20096318

13. Place the cardan shaft as shown - so that it is held in position by mounting fork.

14. Grease the O-rings with mineral oil and place them in the two grooves in the gear rim. Install the gearwheel and rim on the cardan shaft.

NOTICE: Install the gearwheel (rotor) and cardon shaft so that a tooth base in the rotor is positioned in relation to the shaft slot as shown. Turn the gear rim so that the through holes match the holes in the housing.

47921938 07/02/2017

41.2 [41.200] / 23

Steering - Hydraulic control components

15. Install the spacer if applicable.

20096319

20096320

20096321

20096246

16. Place the end cover in position.

17. Install the special screw with washer and place it in the hole, (1).

18. Fit the bolts with washers and insert them. Torque all the bolts and the roll pin to 3.0 – 3.6 N·m (27 – 32 lb in). The steering motor can now be function tested.

47921938 07/02/2017

41.2 [41.200] / 24

Steering - Hydraulic control components

19. Install the dust seal in the housing using suitable tool and a plastic hammer.

20096322

20096323

20. Press the plastic plugs into the connection ports. NOTE: Do not use a hammer.

47921938 07/02/2017

41.2 [41.200] / 25

Steering - Hydraulic control components

Steering circuit relief valve - Adjust TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Relief valve adjustment â&#x20AC;&#x201C; all models With reference to Fig. 1 NOTE: To adjust the steering system relief valve it is necessary to remove the steering motor from the steering bracket, to gain access to the hexagon headed adjusting screw. 1. Release the steering motor from the steering bracket using the procedures described in Power steering control valve - Remove (41.200) . 2. Fabricate suitable test hose to connect pump pipeline to steering motor. Connect locally procured â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; joint between test hose and steering motor and Install pressure gauge as shown in the Figure. 3. Block the plug connections to steering cylinder with suitable blanking cap. 4. Connect the return hose normally. If required connect with extra hose and suitable adopter. 5. Start the engine and idle it between 1.450 RPM and 1.500 RPM. Keep the engine running until the transmission oil reaches normal operating temperature. 6. With the engine running, turn the steering motor shaft to obtain full lock. The pressure gauge should read 120 bar. 7. If the pressure readings are not correct, zero the adjuster (11) using a 8 mm hexagonal wrench.

47921938 07/02/2017

41.2 [41.200] / 26

Steering - Hydraulic control components

LAIL11TT0462A0A

1. 2. 3. 4. 5. 6.

Plug. Steering axle. Relief valve. Fabricated steering motor output hose. Tractor tubing to steering cylinder. Fabricated hose for pump supply to steering motor.

47921938 07/02/2017

41.2 [41.200] / 27

7. 8. 9. 10. 11.

Pressure Gauge â&#x20AC;&#x201C; 0 â&#x20AC;&#x201C; 5.000 lbf. Swivel running Tee. Blanking cap. Spring. Adjuster.

Index Steering - 41 Hydraulic control components - 200 Hydraulic control components - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic control components - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic control components - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic control components - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic control components - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering control valve - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering control valve - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering control valve - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering control valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering circuit relief valve - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

41.2 [41.200] / 28

Steering - 41 Cylinders - 216

47921938 07/02/2017

41.3 [41.216] / 1

Contents Steering - 41 Cylinders - 216

FUNCTIONAL DATA Cylinders Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Steering cylinder Detailed view (Non-powered front axle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Exploded view (Non-powered front axle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Cylinders Disassemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Steering cylinder Remove (Non-powered front axle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble (Non-powered front axle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble (Non-powered front axle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install (Non-powered front axle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

(*) See content for specific models 47921938 07/02/2017

41.3 [41.216] / 2

Steering - Cylinders

Cylinders - Exploded view TT3840F TT3880F TT4030

LA LA LA

Steering cylinder group

LAIL11TT0165F0A

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Nut Swivel Housing Tie rod Nut Constant velocity joint Fixing bolt Steering cylinder Constant velocity joint Nut Tie rod Nut Housing Seal

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Seal Cylinder Head O-ring O-ring Liner Rod O-ring O-ring O-ring Cylinder Head Seal Seal

47921938 07/02/2017

41.3 [41.216] / 3

Steering - Cylinders

Steering cylinder - Detailed view (Non-powered front axle) TT3840 TT4030

LA LA

Steering cylinder

LAIL11TT0229F0A

1. 2. 3. 4.

Nut Washer Nut Washer

5. 6. 7.

Cylinder mounting bracket Spacer Bolt

47921938 07/02/2017

41.3 [41.216] / 4

Steering - Cylinders

Steering cylinder - Exploded view (Non-powered front axle) TT3840 TT4030

LA LA

Steering cylinder assembly

LAIL11TT0168F0A

1. 2. 3. 4.

Cylinder Wiper Seal Retaining ring Gland Nut

5. 6. 7. 8.

Cylinder Rod Gland and Seal Assembly Piston Nut

47921938 07/02/2017

41.3 [41.216] / 5

Steering - Cylinders

Cylinders - Disassemble (Narrow shaft) TT3840F TT3880F TT4030

LA LA LA

Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. See the exploded view of the assembly in Cylinders - Exploded view (41.216). 1. Loosen the nut (3) with enough turns until it is protruding over the threaded pin end of the tie rod (1). Tap the nut (3) with an appropriate hammer in order to separate the tie rod (1) from the swivel housing (2). NOTICE: Do not beat on the threaded pin end of the tie rod (3). NOTE: This may damage the nut (1). Repeat the whole sequence at the other side.

LAIL11TT0503A0A

LAIL11TT0504A0A

LAIL11TT0505A0A

2. Remove the tie rods (3) and (9) by loosening the nuts (4) and (10) with a suitable wrench, then check their condition. Unscrew the fastening bolts (6), remove the two cylinder heads (15) and (23) and the steering cylinder (7) out of its housing, if necessary use a rubber hammer. 3. Remove only parts that need to be overhauled and/or replaced.

4. Remove the rod (19) and liner (18). 5. Remove all the seals and O-rings ( (13), (14), (16), (17), (20), (21), (22), (24) and (25)) from the cylinder heads (15) and (23), and the rod (19).

47921938 07/02/2017

41.3 [41.216] / 6

Steering - Cylinders

Cylinders - Assemble TT3840F TT3880F

LA LA

Prior operation: For removing the power steering cylinder from the narrow shaft, see the procedures in Cylinders - Disassemble (Narrow shaft) (41.216) .

Mounting Some of the following pictures may not show your axle exactly, but the indicated operations are correct anyway. See the exploded view of the system in Cylinders - Exploded view (41.216). 1. Fit the new seals and O-rings (13), (14), (16), (17), (20), (21), (22), (24) and (25) on the cylinder heads (15) and (23) on the rod piston (19).

LAIL11TT0387A0A

LAIL11TT0388A0A

LAIL11TT0528A0A

2. Slide the rod (9) inside the liner (18). 3. Slide the pre-assembled cylinder (7) onto its seat on the axle beam.

4. Slide the two cylinder heads (15) and (23) onto the rod (19).

47921938 07/02/2017

41.3 [41.216] / 7

Steering - Cylinders

5. Fit connecting rods (3) and (10), constant velocity joints (5) and (8), nuts (4) and (9) to the rod ends (19), then tighten to the torque specified in Powered front axle Torque (Narrow shaft) (25.100).

LAIL11TT0389A0A

LAIL11TT0390A0A

LAIL11TT0495A0A

LAIL11TT0525A0A

Position the two cylinder heads (15) and (23) as shown in the picture.

6. Fit the bolts (6) and tighten them to the torque given in Powered front axle - Torque (Narrow shaft) (25.100).

7. Align the housing (12) with the axle. Screw the connecting rod (10) so that its constant velocity joint can be inserted into the housing arm (12). NOTE: It is important to unscrew the auto-lock nut (9) to carry out this operation. 8. Repeat the whole sequence of the mentioned operations to the other side.

47921938 07/02/2017

41.3 [41.216] / 8

Steering - Cylinders

9. Insert the end of the connecting rod (3) into the housing (2). 10. Fit the auto-lock nut (1) and tighten it to the torque specified in Powered front axle - Torque (Narrow shaft) (25.100). 11. Repeat the whole sequence of the mentioned operations to the other side.

LAIL11TT0526A0A

LAIL11TT0527A0A

12. Only tighten auto-lock nuts (4) and (9) of connecting rods (3) and (10) when you have adjusted the toe-in. Consult the procedures in Powered front axle - Toe in adjust (Narrow shaft) (25.100).

47921938 07/02/2017

41.3 [41.216] / 9

Steering - Cylinders

Steering cylinder - Remove (Non-powered front axle) TT3840 TT4030

LA LA

Removal 1. Stand the tractor on a hard level surface and position the front wheel in the straight ahead position. 2. Disconnect flexible pipes, cap the open pipe ends and remove hose clamps. NOTICE: Position of flexible pipes and orientation of connectors must be the same upon reâ&#x20AC;&#x201C;assembly. 3. Remove the nut securing the cylinder rod ball joint to the steering arm and separate the joint, Steering cylinder - Detailed view (Non-powered front axle) (41.216). 4. Remove the nut (3) securing the steering cylinder on the front axle beam. 5. Remove the steering cylinder from the tractor and remove the washer (4), spacer (6) and bolt (pivot pin) (7). Next operation: When removing the power steering cylinder, see the procedures in Steering cylinder - Disassemble (Non-powered front axle) (41.216).

47921938 07/02/2017

41.3 [41.216] / 10

Steering - Cylinders

Steering cylinder - Disassemble (Non-powered front axle) TT3840 TT4030

LA LA

Prior operation: To remove the power steering cylinder from the narrow shaft, see the procedures in Steering cylinder - Remove (Non-powered front axle) (41.216). 1. Using an appropriate â&#x20AC;&#x2DC;Câ&#x20AC;&#x2122; spanner, unscrew and remove the bushing nut (4). 2. Using a punch, push the steering cylinder bushing into the cylinder and remove the wire locking ring (3). 3. Pull out the rod (5) and bushing assembly (6) from the cylinder. 4. Remove the nut from the cylinder rod and disassemble to replace seals. 5. Inspect the bore of the cylinder and replace if scored. LAIL11TT0115A0A

Next operation: To fit the steering cylinder, see the procedures in Steering cylinder - Assemble (Non-powered front axle) (41.216).

47921938 07/02/2017

41.3 [41.216] / 11

Steering - Cylinders

Steering cylinder - Assemble (Non-powered front axle) TT3840 TT4030

LA LA

Prior operation: When removing the power steering cylinder, see the procedures in Steering cylinder - Disassemble (Non-powered front axle) (41.216). 1. Reassemble the cylinder in the reverse to diassembly, lubricating all components as assembled. Replace all seals supplied in the service seal kit. NOTICE: The seal located in the centre of the gland is replaceable.

LAIL11TT0116A0A

Next operation: When fitting the power steering cylinder on the axle, see the procedures in Steering cylinder - Install (Non-powered front axle) (41.216).

47921938 07/02/2017

41.3 [41.216] / 12

Steering - Cylinders

Steering cylinder - Install (Non-powered front axle) TT3840 TT4030

LA LA

Prior operation: When fitting the power steering cylinder, see the procedures in Steering cylinder - Assemble (Non-powered front axle) (41.216). 1. Installation is the reversal of the removal procedure. Reverse the procedure described in Steering cylinder - Remove (Non-powered front axle) (41.216).

47921938 07/02/2017

41.3 [41.216] / 13

Index Steering - 41 Cylinders - 216 Cylinders - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinders - Disassemble (Narrow shaft) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinders - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Assemble (Non-powered front axle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Detailed view (Non-powered front axle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Disassemble (Non-powered front axle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Exploded view (Non-powered front axle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Install (Non-powered front axle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Remove (Non-powered front axle) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

41.3 [41.216] / 14

47921938 07/02/2017

41.3 [41.216] / 15

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

47921938 07/02/2017 EN

SERVICE MANUAL Wheels TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017

Contents Wheels - 44

[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1

47921938 07/02/2017

Wheels - 44 Front wheels - 511

47921938 07/02/2017

44.1 [44.511] / 1

Contents Wheels - 44 Front wheels - 511

TECHNICAL DATA Front wheels Tires - Compatibility table (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47921938 07/02/2017

44.1 [44.511] / 2

Wheels - Front wheels

Tires - Compatibility table TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

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: The compatibility tables are continually reviewed by NEW HOLLAND. New combinations that may be more suitable to your activity are often released. See your NEW HOLLAND dealer when you change your machine’s tires. Table of Acronyms Acronym GY BF T TR MI FI PI S-ARZ S-ARZ TD8 SSG TD8 TFR STR SAT FWD CF-151 CGG CSG II S-LM TRC-CA

Meaning Goodyear Bfgoodrich Titan Trelleborg Michelin Firestone Pirelli Super Rice Tire Super Rice Tire TD8 Special Sure Grip TD8 Traction Field & Road ST Radial Super All Traction FWD Champion F-151 Champion G.G. Champion Space Grid II. Super Mud Tire Cultivator Tractor

Acronym ALLT DYT II DYT III MXB AGB 125A6 RDT 23 SAT 23 T 414 PWT PWG R1 R2 GZ CAP F.T. R.T. MANUF

47921938 07/02/2017

44.1 [44.511] / 3

Meaning All Traction Dyna Torque II Dyna Torque III Maxibib Agribib Power Grip 125 A6 Radial DT 23° Super All Traction 23° Twin 414 Power Torque Power Gripper Normal grip High Grip Guizhou Load capacity Front Tires Rear Tires Manufacturer

CAP

6 PR

8 PR

Measure

13.6x38 R1

16.9x28 R1

14.9x28 R1

R.T. DYT II TC PWT TM 64/R TM 93 TM 75 SAT FWD TM 95 PWT R-1 PWT

Check the acronyms in the table below

Measure CAP F.T. MANUF FI GY PI PI PI PI GY FI FI PI GY X X X

SAT 23 FI

9.5x24 R1 6 PR R-1 GZ

TT3840: Compatibility table for front and rear tires. Transmission ratio: 1.4100 Table code: 87679544P

TM 95 PI

DYT II GY X X X X X

12.4x24 R1 6 PR TM 95 PI X R-1 GZ X X X X X X

8.3x24 R1 6PR CGG FI

Wheels - Front wheels

47921938 07/02/2017

44.1 [44.511] / 4

CAP

6 PR

8 PR

Measure

14.9X24 R1

12.4x24 R1

Check the acronyms in the table below R.T. TM95 CGG SAT 23 BF 125 A6 DYT II

Measure CAP F.T. MANUF PI FI FI MI GY

TT3840F and TT3880F: Compatibility table for front and rear tires. Transmission ratio: 1.4974 Table code: 87679544P 8.0 x 18 R1 12 PR Front 2 Maggion X X X X X

8.0 x 16 R1 8PR DYT III GY

Wheels - Front wheels

47921938 07/02/2017

44.1 [44.511] / 5

CAP

8 PR

10 PR

8 PR

Measure

16.9x30 R1

18.4x30 R1

14.9x28 R1

R.T. DYT II TM 93 DYT II TM 95 R-1 PWT

Check the acronyms in the table below

Measure CAP F.T. MANUF GY PI GY PI GZ GY

11.2x24 R1 6 PR DYT II FI X X

TT4030: Compatibility table for front and rear tires. Transmission ratio: 1.3800 Table code: 87679544P

DYT II GY

X X

12.4x24 R1 6 PR TM 95 PI

R-1 GZ

8.3X24 R1 6 PR CGG FI

Wheels - Front wheels

47921938 07/02/2017

44.1 [44.511] / 6

Index Wheels - 44 Front wheels - 511 Tires - Compatibility table (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

44.1 [44.511] / 7

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

47921938 07/02/2017 EN

SERVICE MANUAL Electrical systems TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017

Contents Electrical systems - 55

[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5

47921938 07/02/2017

Electrical systems - 55 Engine starting system - 201

47921938 07/02/2017

55.1 [55.201] / 1

Contents Electrical systems - 55 Engine starting system - 201

TECHNICAL DATA Engine starting system General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Engine starter Engine starter - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Engine starter Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Engine starter Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

(*) See content for specific models 47921938 07/02/2017

55.1 [55.201] / 2

Electrical systems - Engine starting system

Engine starting system - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Specifications Component Nominal voltage Nominal output Rotation (view from the operator seat) No. of teeth on the pinion No. of poles Stator winding Control Operation Pinion stroke Solenoid details Winding resistance at 20 °C Pull-in winding Hold-in winding Current draw of 12 V Pull-in + hold-in – instant (max.) Hold-in – continuous (max.)

TT3840

TT3840F

TT3880F TT4030 12 V 2.7 kW Clockwise 10 4 Electrical stimulation Vehicle start switch Pre-activated solenoid for direct drive 18 mm

0.24 Ω 1.05 Ω 60 A 12 A

47921938 07/02/2017

55.1 [55.201] / 3

Electrical systems - Engine starting system

Engine starter - Torque TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Tightening torque Name Starter motor mounting bolts

Thread size M12 x 1.5

47921938 07/02/2017

55.1 [55.201] / 4

Torque 74 NÂˇm

Electrical systems - Engine starting system

Engine starter - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Description and operation The tractor has a 12 V starter driven by a pre-action solenoid. When you put the key in the start position, it establishes an electrical circuit from the key switch to the starter solenoid, passing through the safe start switch mounted in the switch box. The electricity in this circuit powers the solenoid coils and the solenoid plunger is magnetically attracted to the solenoid core. This movement, transmitted by a mechanical coupling, pulls the drive pinion to engage with the flywheel ring gear. When the pinion is completely engaged with the ring gear, the solenoid plunger reaches the end of its stroke and makes contact with a switch that connects the battery directly to the starter. This switch takes power directly from the battery to the starter. It makes the engine rotate, which drives the engine and causes it to start. When the key switch is released, battery power to the solenoid is disconnected. The solenoid plunger returns to its rest position (aided by the plunger spring) and the starter pinion disengages from the flywheel ring gear. This also breaks the connection with the battery. Installation of a free wheel between the starter and the pinion protects the starter from excessive rotation.

LAIL11TT0230F0A

Ignition and starter switch or drive switch

Solenoid switch

Return spring

Excitation coil series coil

Hitch lever

Roller-type overrunning clutch

Pinion

47921938 07/02/2017

55.1 [55.201] / 5

Electrical systems - Engine starting system

Battery

Armature

1. Idle position No current goes into the starter and the pinion is not engaged. 2. Favorable gear position Power goes to the pull-in coil and the hold-in coil. A pinion tooth catches between the teeth of the ring gear and the pinion immediately engages. The diagram shows the position of the starter shortly before the main current is switched on. 3. Unfavorable gear position A pinion tooth meets a ring gear tooth. The coupling lever in its final position, the gear spring compressed, and no power to the pull-in coil. The main current flows and the armature rotates. The pinion attempts to engage with the ring gear. 4. Final position The coupling lever in its final position with no power to the pull-in coil. The main current flows and the pinion fully engages. The engine starts.

47921938 07/02/2017

55.1 [55.201] / 6

Electrical systems - Engine starting system

Engine starter - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Disconnect the battery from the electrical circuit. 2. Disconnect connectors (1), (2) and (3). 3. Loosen the mounting bolts and remove the tractorâ&#x20AC;&#x2122;s starter. NOTICE: Only an authorized MICO dealer should repair the starter. Fitting a starter is the reverse of the removal procedure.

LAIL11TT0427A0A

Next operation: Perform the procedures for testing the starter in Engine starter - Test (55.201).

47921938 07/02/2017

55.1 [55.201] / 7

Electrical systems - Engine starting system

Engine starter - Test TT3840F TT3840 TT3880F TT4030

LA LA LA LA

System testing NOTICE: Before performing any test on the starting system, check that the battery is fully charged and in good condition.

Test for voltage supply to the starter solenoid 1. Connect the voltmeter between the battery terminal for the starter solenoid and the chassis ground. 2. If the voltmeter reads below the battery voltage, check the battery connections with the solenoid and with the chassis ground.

LAIL11TT0428A0A

LAIL11TT0430A0A

Test for voltage supply "with loadâ&#x20AC;? on the solenoid 1. Connect the voltmeter between the battery terminal for the starter solenoid and the chassis ground. 2. Start the engine with the fuse of the fuel injection pump removed, to prevent start-up. 3. If the voltmeter indicates less than 9.6 V during startup, check the battery. If the battery is in good condition, check for incorrect connections between the battery and the starter or a fault with the starter. 4. If the voltage is greater than 11 V and the starting speed is low, check for faults with the starter.

47921938 07/02/2017

55.1 [55.201] / 8

Electrical systems - Engine starting system

Safety start-up circuit test 1. Connect the voltmeter between the start-up circuit for the solenoid safety and the chassis ground. 2. Start the engine. 3. If the reading is less than 8.5 V, check the ignition key, the safety start-up switch and the connections.

LAIL11TT0430A0A

47921938 07/02/2017

55.1 [55.201] / 9

Index Electrical systems - 55 Engine starting system - 201 Engine starter - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starter - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Engine starter - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

(*) See content for specific models 47921938 07/02/2017

55.1 [55.201] / 10

Electrical systems - 55 Alternator - 301

47921938 07/02/2017

55.2 [55.301] / 1

Contents Electrical systems - 55 Alternator - 301

TECHNICAL DATA Alternator General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Alternator Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Alternator Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Alternator Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Test Alternator Amp Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Test Full Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Test - Amperage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Tension adjust - Belt (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Test - Ignition Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

(*) See content for specific models 47921938 07/02/2017

55.2 [55.301] / 2

Electrical systems - Alternator

Alternator - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Specifications TT3840

Component Nominal voltage Rotation (seen from the pulley end) Circuit speed at 12 V and 25 °C Outlet at 14 V by the battery after warm-up Rotor coil resistance between the manifold rings - 20 °C Rotation of the tractor alternator - 2328 RPM Drive ratio Alternator pulley torque Voltage Regulator Type Alternator test RPM Adjust tension

TT3840F TT3880F 14 V Clock Wise 1050 – 1150 RPM 23 A 3.4 – 3.8 Ω 6000 RPM 1:1992 41 N·m

TT4030

Integrated to the alternator 4000 RPM 13.6 – 14 V

Alternator - General specification TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

TT3840

Component Nominal voltage Rotation (seen from the front of the pulley) Alternator current at 1100 RPM Alternator current at 1500 RPM Alternator current at 6000 RPM Voltage regulator

TT3840F

TT3880F 14 V Clockwise 0A 28 A 90 A Integrated to the alternator

TT4030

TT3840F TT3880F 80.0 – 90.0 N·m (59.0 – 66.4 lb ft)

TT4030

Alternator - Torque TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

Component Torque for the bolt that secures the pulley on the alternator

TT3840

47921938 07/02/2017

55.2 [55.301] / 3

Electrical systems - Alternator

Alternator - Exploded view TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

CUIL16TR00910GA

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

Description Pulley Fan Flange Bearing Protection Rotor

47921938 07/02/2017

55.2 [55.301] / 4

Reference (7) (8) (9) (10) (11)

Description Stator Rectifier Shield assembly Protector Regulator

Electrical systems - Alternator

Alternator - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

The Alternator is fitted on the right side of the engine and driven by the fan belt. The two electrical cables ( (1) and (2)) connects the alternator to the electrical system. The small wire (1) is connected from the key start switch through the battery warning light. The other larger wire (2) is connected to the battery.

ALTERNATOR FUNCTION When the key switch is turned on, a 12 V electrical circuit is made through a 1.4 W bulb, used as the battery warning light, to the alternator. This circuit illuminates the bulb and supplies a small electrical current, which partially magnetizes the rotor of the alternator. 20098421

When the engine starts and begins to drive the alternator, electricity will be produced. Once the Voltage produced rises above battery voltage, the circuit through the battery-warning bulb is disconnected and light extinguished. As the alternator voltage is now above battery voltage, electricity starts to flow through the large wire connected directly to the battery. An inbuilt regulator is used to limit the maximum voltage to 14 V.

47921938 07/02/2017

55.2 [55.301] / 5

Electrical systems - Alternator

Alternator - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Disconnect battery from electric circuit. 2. Disconnect connections, (1) and (2). 3. Loosen bolts and remove belt guard (3).

20098421

4. Slacken and remove the nut and bolt, (1) fastening the alternator to the belt stretcher, (2). 5. Move the alternator to reduce belt tension and remove it from the alternator pulley. 6. Screw out the alternator mounting bolts and remove the alternator. NOTE: Alternator should be serviced as a complete assembly.

47921938 07/02/2017

55.2 [55.301] / 6

Electrical systems - Alternator

Alternator - Test Alternator Amp Test TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Remove lead from Alternator terminal, connect an Ammeter (minimum 30 A capacity) between B+ terminal and B+ lead . Crank engine on starter (with fuel shut-off). Start engine, switch on all electrical loads. Ammeter should show 40 â&#x20AC;&#x201C; 45 A initially, gradually reducing as battery is charged. If Alternator output is low, ensure connections between battery and alternator are good. If connections are good, but Alternator output is low, repair or replace Alternator as required.

47921938 07/02/2017

55.2 [55.301] / 7

20099878

Electrical systems - Alternator

Alternator - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

1. Secure the alternator with alternator mounting bolts. 2. Place the belt in the alternator pulley and move the alternator to increase the belt tension. 3. Assemble the nut and bolt, (1) fastening the alternator to the belt stretcher, (2).

20098421

20098780

20098421

4. Tighten the belt, (1), to 10 â&#x20AC;&#x201C; 13 mm (0.4 â&#x20AC;&#x201C; 0.5 in) deflection when moderate finger pressure is applied to the longest run of the belt.

5. Install the bolts securing belt guard, (1). 6. Reconnect connections, (2) and (3). 7. Reconnect battery to the electric circuit.

47921938 07/02/2017

55.2 [55.301] / 8

Electrical systems - Alternator

Alternator - Test TT3840F TT3840 TT3880F TT4030

LA LA LA LA

NOTE: Ensure that the battery is at least 75% charged before commencing alternator test.

Alternator Quick Test 1. Battery warning light should illuminate when the key switch is turned to position 2.

20098421

1. 2.

D - Terminal B+ - Terminal

If the warning light does not fully illuminate when the key switch is turned on, check the fuse and bulb. If the fuse or bulb was not the cause, check the wiring connections to the alternator. To do this, disconnect the lead from the Alternator ‘D’ terminal. Touch the lead to a good/clean chassis ground with the ignition switch in position 2. Result Bulb illuminates Bulb does not illuminate

Possible cause Alternator faulty Faulty circuit

Remedy Repair or Replace Alternator Check fuse, bulb and wiring from key switch to alternator

2. If result from test shows that wiring is satisfactory, but alternator performance is still doubtful, check alternator output. 3. To do this, connect a voltmeter between Alternator ‘B+’ terminal and chassis ground, leaving all connections intact. Result 12.5 V(or battery voltage) Less than battery voltage

Possible cause System good Faulty circuit

4. If Battery voltage is shown, start the engine.

47921938 07/02/2017

55.2 [55.301] / 9

Remedy None Check fusible link at Starter Check wiring between battery and alternator

Electrical systems - Alternator

Result 13.6 â&#x20AC;&#x201C; 14 V Battery warning light extinguished. Less/more than 13.6 â&#x20AC;&#x201C; 14 V. Battery warning light illuminated

Possible cause System good Engine RPM low. Alternator faulty. Faulty circuit

47921938 07/02/2017

55.2 [55.301] / 10

Remedy None Increase engine RPM. Repair or replace alternator. Check fusible link and wiring to battery.

Electrical systems - Alternator

Alternator - Test Full Test TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Check battery condition and Alternator belt as described in Alternator - Test (55.301).

Ignition Circuit Test 1. Battery warning light should illuminate when the key switch is turned on. If the warning light is not fully illuminated, check the bulb and fuse. If the bulb or fuse is not the cause, check the wiring connections to the alternator. • Disconnect lead from Alternator ‘D’ terminal, connect voltmeter between ‘D’ lead and chassis ground. With ignition switch on voltmeter should show 12 V. If there is a fault with the ignition or warning light circuit. • If meter shows 12 V, test the alternator connection. 20099879

20099880

20099881

With D lead connected to alternator terminal, connect voltmeter between ‘D’ terminal and chassis ground. With key switch on voltmeter should show between 1 – 15 V. If less there may be a height resistance fault in the key switch / warning light circuit or a fault with the alternator. If considerably more than 1.5 V, fault is with the alternator. Repair or replace as required.

Alternator Output Test Alternator should supply DC current at 13.6 – 14 V in order to charge the battery and power accessories. • To test. connect voltmeter between alternator ‘B+’ terminal and chassis ground, leaving wiring intact. With the engine off, voltmeter should show battery voltage. If less. there is a fault with the charging circuit.

Start the engine with connections as above, increase engine speed until battery warning light extinguishes. Voltmeter should show 13.6 – 14 V.

47921938 07/02/2017

55.2 [55.301] / 11

Electrical systems - Alternator

If less, then Alternator is faulty. If considerably more, then regulator is faulty.

47921938 07/02/2017

55.2 [55.301] / 12

Electrical systems - Alternator

Alternator - Remove TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

1. Disconnect battery from electric circuit. 2. Remove the connections (1) and (2).

20098421

CUIL16TR00335AA

3. Remove the nuts and the bolts (1) and (2). 4. Move the alternator to reduce the belt tension. Remove the belt from the alternator pulley. 5. Remove the lower bolt (3). Remove the alternator.

47921938 07/02/2017

55.2 [55.301] / 13

Electrical systems - Alternator

Alternator - Install TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

1. Install the alternator with the lower bolt (3). 2. Place the belt in the alternator pulley and move the alternator to increase the belt tension. 3. Assemble the nuts of the bolts (1) and (2) that secure the alternator to the belt tensioner. See the procedures for adjustment of the belt tension at Alternator - Tension adjust - Belt (55.301).

CUIL16TR00335AA

20098421

4. Reconnect the connections (2) and (3). 5. Reconnect the battery to the electric circuit.

47921938 07/02/2017

55.2 [55.301] / 14

Electrical systems - Alternator

Alternator - Test - Amperage TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

1. Remove lead from Alternator terminal, connect an Ammeter (minimum 30 A capacity) between B+ terminal and B+ lead . 2. Crank engine on starter (with fuel shut-off). Start engine, switch on all electrical loads. 3. Ammeter should show 40 â&#x20AC;&#x201C; 45 A initially, gradually reducing as battery is charged. 4. If Alternator output is low, ensure connections between battery and alternator are good. 5. If connections are good, but Alternator output is low, repair or replace Alternator as required. 20099878

47921938 07/02/2017

55.2 [55.301] / 15

Electrical systems - Alternator

Alternator - Tension adjust - Belt TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

WARNING Entanglement hazard! Always stop the engine and engage the parking brake, unless otherwise instructed in this manual, before checking and/or adjusting any drive belt or chain. Failure to comply could result in death or serious injury. W0097A

1. Open the engine hood. 2. Remove the bolts (1). Remove the guard (2).

CUIL16TR00302AA

CUIL16TR00217AA

CUIL16TR00337AA

3. Unscrew the bolt (1). 4. Loosen the lower bolt that secures the alternator to the engine block. 5. Remove the drive belt

6. Install a new drive belt as shown in the adjacent image. NOTE: Ensure the correct direction of rotation of the belt.

47921938 07/02/2017

55.2 [55.301] / 16

Electrical systems - Alternator

7. Press the ball (1) of the tool 380001325 so that the lower rods fit into the belt. NOTE: To obtain a uniform tension, do not position the tool under the seam of the belt. NOTE: Purchase the tool on the local market or from your dealer.

CUIS15TR00246AA

CUIS15TR00247AA

CUIL16TR00335AA

8. Keep the tool flush on the edge of the belt. Release the ball (1) in one single movement.

9. Perform the reading on the gauge (2). The correct specification for the belt should be 30.6 â&#x20AC;&#x201C; 40.8 kg ( 300 â&#x20AC;&#x201C; 400 N) 10. If the value is not correct, adjust the alternator to the correct specification. Remove the belt tool.

11. Tighten bolts (1), (2), and (3). 12. Install the belt guard.

47921938 07/02/2017

55.2 [55.301] / 17

Electrical systems - Alternator

Alternator - Test TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

Alternator Quick Test 1. Ensure that the battery is at least 75% charged before commencing alternator test. 2. Turn the ignition key to position 2. The battery warning lamp should come on. (1): Terminal D. (2): Terminal B+ 3. If the warning light does not fully illuminate when the key switch is turned on, check the fuse and bulb. If the fuse or bulb was not the cause, check the wiring connections to the alternator. 4. Disconnect the cable from the terminal (D) (1) of the alternator. Touch the lead to a good/clean chassis ground with the ignition switch in position 2. Result Bulb illuminates

Possible Cause Alternator faulty

Bulb does not illuminate

Faulty circuit

20098421

Resolve Repair or Replace Alternator Check fuse, bulb and wiring from key switch to alternator

5. If result from test shows that wiring is satisfactory, but alternator performance is still doubtful, check alternator output. 6. To do this, connect a voltmeter between terminal (B+) (2) of the alternator and chassis ground, leaving all connections intact. Result 12.5 V(or battery voltage)

Possible Cause System good

Less than battery voltage

Faulty circuit

Resolve None Check fusible link at Starter Check wiring between battery and alternator

7. If Battery voltage is shown, start the engine. Result 13.6 â&#x20AC;&#x201C; 14 V: The battery warning light is off. Less/more than 13.6 â&#x20AC;&#x201C; 14 V: The battery warning light is on

Possible Cause

Resolve

System good

None

Low engine speed. Faulty alternator.

Increase the engine rpm Repair or replace alternator. Check fusible link and wiring to battery.

Faulty circuit

47921938 07/02/2017

55.2 [55.301] / 18

Electrical systems - Alternator

Alternator - Test - Ignition Circuit TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

Prior operation: Alternator - Test (55.301).. Identification of terminals: (1): Terminal D. (2): Terminal B+

20098421

20099879

1. The battery warning light should illuminate when the key switch is turned on. 2. If the warning light is not fully illuminated, check the bulb and fuse. If the bulb or fuse is not the cause, check the wiring connections to the alternator. 3. Disconnect the lead from terminal D (1) of the alternator. Connect the voltmeter between the â&#x20AC;&#x153;Dâ&#x20AC;? lead and the chassis ground. With the ignition switch on, the voltmeter should show 12 V. 4. If the meter shows 12 V, test the alternator connection.

47921938 07/02/2017

55.2 [55.301] / 19

Electrical systems - Alternator

5. With the D lead connected to the alternator terminal, connect the voltmeter between the D terminal and the chassis ground. With the key switch on, the voltmeter should show between 1 â&#x20AC;&#x201C; 15 V. 6. If the reading is lower, there may be a height resistance fault in the key switch or warning light circuit, or a fault with the alternator. 7. If the reading is considerably more than 15 V, the fault is with the alternator. 8. Repair or replace as necessary. 20099880

20099881

Alternator Output Test 1. The alternator should supply DC at 13.6 â&#x20AC;&#x201C; 14 V in order to charge the battery and power accessories. 2. To test. Connect the voltmeter between terminal B+ of the alternator and the chassis ground. Leave the wiring intact. With the engine off, the voltmeter should show the battery voltage. 3. If the voltage is down, there is a fault with the charge circuit. 4. Start the engine with the connections as above. Increase the engine rpm until the battery warning light goes off. 5. The voltmeter should read 13.6 â&#x20AC;&#x201C; 14 V. 6. If the reading is lower, then the alternator is faulty. If the reading is considerably higher, then the regulator is faulty.

47921938 07/02/2017

55.2 [55.301] / 20

Index Electrical systems - 55 Alternator - 301 Alternator - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Tension adjust - Belt (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Test - Amperage (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Test - Ignition Circuit (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Test Alternator Amp Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Test Full Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

55.2 [55.301] / 21

47921938 07/02/2017

55.2 [55.301] / 22

Electrical systems - 55 Harnesses and connectors - 100

47921938 07/02/2017

55.3 [55.100] / 1

Contents Electrical systems - 55 Harnesses and connectors - 100

FUNCTIONAL DATA Wiring harnesses Electrical schematic sheet 02 SH02-ENGINE (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrical schematic sheet 03 SH03-HOOD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electrical schematic sheet 04 SH04-REAR HOOD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Electrical schematic sheet 05 SH05-INSTRUMENT CLUSTER (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Electrical schematic sheet 06 SH06-FUSE BOX (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Electrical schematic sheet 07 SH07-TRANSMISSION/FENDERS/SIDELIGHTS (*) . . . . . . . . . . . . . . . . 14 Electrical schematic sheet 08 SH08-LICENSE PLATE (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Wire connectors Component diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Component diagram 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Component diagram 02 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Component diagram 03 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Component diagram 04 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Component diagram 10 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Electrical components ECU description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Sensor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Lamp description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Voltage source description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Speaker description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Motor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Resistor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Switch description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Solenoid description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

(*) See content for specific models 47921938 07/02/2017

55.3 [55.100] / 2

47921938 07/02/2017

55.3 [55.100] / 3

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 02 SH02-ENGINE TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

Type ECU ECU Sensor Voltage source Voltage source Motor Resistor Switch Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Solenoid

Component A-001 A-004 B-001 G-001 G-002 M-001 R-001 S-001 S-002 X-001 X-002 X-003F X-003M X-004 X-005 X-006 X-007 X-008 X-009 X-010 X-011 X-012 X-013 X-014 X-015 X-016 X-024 X-041F X-041M X-042 X-043 X-044 X-045 Y-001

LA LA LA LA LA LA

Connector / Link X-016 X-044 X-043 X-008 X-013 X-012 X-002 X-001 X-011 X-009 X-004 X-005 X-007 X-001 X-002 X-003F X-003M X-004 X-005 X-006 X-007 X-008 X-009 X-010 X-011 X-012 X-013 X-014 X-015 X-016 X-024 X-041F X-041M X-042 X-043 X-044 X-045 X-006

Description FLASHER UNIT FUSE ENGINE TEMPERATURE SENDER BATTERY ALTERNATOR STARTER MOTOR THERMOSTART AIR RESTRICTION SWITCH ENGINE OIL PRESSURE SWITCH ALTERNATOR B+ ALTERNATOR D/W ENGINE / MAIN HARNESS ENGINE/MAIN HARNESS AIR RESTRICTION SWITCH AIR RESTRICTION SWITCH FUEL SHUT-OFF ENGINE OIL PRESSURE SWITCH ENGINE TEMPERATURE SENDER THERMOSTART STARTER MOTOR STARTER MOTOR BATTERY BATTERY STARTER B+ GROUND FLASHER UNIT HAZARD SWITCH ENGINE / MAIN HARNESS STARTER B+ (CAB) FUSE FUSE BATTERY FUEL SHUT-OFF SOLENOID

47921938 07/02/2017

55.3 [55.100] / 4

Electrical systems - Harnesses and connectors

M-001 STARTER MOTOR G-001 BATTERY 1

BA-002 BK 50.0 X-012

X-045

2 NEG

BA-001 RD 50.0

POS

X-013

X-010

1 1

X-014

PWR GND M

X-042 1

X-011

EN-0150 WH 4.0

ENGINE / MAIN HARNESS

EN-01 RD 16.0

X-041F R-001 THERMOSTART N

EN-1022 OR 2.5

X-009

A-004

CB-1022 OR 2.5

SH4: C-5

SH2: C-6

EN-1005 GN 1.0

CB-1005 GN 1.0

SH5: B-5

SH2: B-5

EN-2015 YE 1.0

CB-2015 YE 1.0

SH5: C-5

CB-2003 WH 2.5

SH7: C-2

CB-1030 YE 1.5

SH4: C-3

CB-0155 RD 4.0

SH4: D-4

CB-057B BK 1.5

SH7: C-1

FUSE 1

30.0 A

X-044

1 X-043

EN-2003 RD 2.5

S-001 AIR RESTRICTION SWITCH 1 SH2: C-2

EN-1005 GN 1.0

SH3: B-1

EN-1030 YE 1.5

X-004

EN-0155 RD 4.0

Y-001

FUEL SHUT-OFF SOLENOID N

SH2: A-6

EN-057B BK 1.5

X-006

S-002 ENGINE OIL PRESSURE SWITCH P IN

OUT

X-041M X-007 ENGINE / MAIN HARNESS X-003F B-001 ENGINE TEMPERATURE SENDER

EN-1003 RD 1.0

CB-1003D GN 0.5

SH6: C-2

CB-2041 PK 1.0

SH6: C-2

CB-031 BR 1.0

SH5: B-5

CB-039 BL 1.0

SH5: C-5

T P

X-008

EN-2041 PK 1.0

G-002 ALTERNATOR

D+

EN-031 BR 1.0

CHARGE INDICATOR

A B+

X-001

W PHASE

A-001

1 SH2: C-2

EN-2015 YE 1.0

FLASHER UNIT

EN-039 BL 1.0

X-002

87A

1 6

EN-1027 GN 1.5

CB-1027 GN 1.5

SH4: B-3

SH3: B-1

EN-0376 WH 1.0

CB-0376 WH 1.0

SH4: B-2

EN-1006 BR 1.0

CB-1006 BR 1.0

SH5: C-5

CB-3000 GN 1.5

SH6: B-2

CB-1033 PK 1.0

SH5: B-5

CB-044 GY 1.5

SH4: B-6

86 85

X-016

SH2: C-2

SH3: B-1

EN-3000 GN 1.5

EN-057B BK 1.5 EN-1033 PK 1.0

A X-015

EN-057A BK 1.5

EN-044 GY 1.5

EN-057 BK 1.5

SP-057A X-003M

GROUND SH3: B-1

EN-057C BK 1.5

3 SHT_2

47921938 07/02/2017

55.3 [55.100] / 5

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 03 SH03-HOOD TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

Type Lamp Lamp Speaker Connector Connector Connector Connector Connector Connector

47921938 07/02/2017

55.3 [55.100] / 6

Component E-001 E-002 H-001 X-017 X-018 X-019 X-020 X-021F X-021M

Connector / Link X-019 X-020 X-017 X-018 X-017 X-018 X-019 X-020 X-021F X-021M

LA LA LA LA LA LA

Description HEADLAMP R.H. HEADLAMP L.H. HORN HORN HORN HEADLAMP R.H. HEADLAMP L.H. CONNECTOR HEADLAMP HARNESS CONNECTOR HEADLAMP HARNESS W/H

Electrical systems - Harnesses and connectors

E-001 HEADLAMP R.H. 1

HO-1030A YE 1.5 DIP BEAM

2 GND

HO-057A BK 1.5 X-019

HO-1027A GN 1.5 MAIN BEAM X-019

E-002 HEADLAMP L.H. 1

SP- 057A

HO-057B BK 1.5

CONNECTOR HEADLAMP HARNESS

SP-1030

HO-1030B YE 1.5

DIP BEAM

X-021F

GND X-020

HO-1030 YE 1.5

EN-1030 YE 1.5

SH2: C-2

HO-1027 GN 1.5

EN-1027 GN 1.5

SH2: B-3

HO-057 BK 1.5

EN-057C BK 1.5

SH2: A-4

EN-0376 WH 1.0

SH2: A-3

3 SP-1027

HO-1027B GN 1.5

MAIN BEAM X-020

HO-057C BK 1.5 SP-057

B X-021M

H-001 HORN X-017 1

HO-0376 WH 1.0

P 1

HO-057D BK 1.5

N X-018

3 SHT_3

47921938 07/02/2017

55.3 [55.100] / 7

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 04 SH04-REAR HOOD TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

Type Sensor Switch Switch Switch Switch Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector

47921938 07/02/2017

55.3 [55.100] / 8

Component B-002 S-003 S-004 S-005 S-006 S-007 X-023F X-023M X-024 X-025F X-025M X-026 X-027F X-027M X-028 X-029 X-030 X-031

Connector / Link X-028 X-024 X-026 X-023F X-023M X-024 X-025F X-025M X-026 X-027F X-027M X-028 X-029 X-030 X-031

LA LA LA LA LA LA

Description FUEL LEVEL SENDER STARTER SWITCH HAZARD SWITCH TURN SWITCH HORN SWITCH HEADLAMP SWITCH STARTER SWITCH STARTER SWITCH HAZARD SWITCH TURN SWITCH TURN SWITCH HORN SWITCH HEADLAMP SWITCH HEADLAMP SWITCH FUEL LEVEL SENDER INSTRUMENT CLUSTER ACC SUPPLY ACC SUPPLY

Electrical systems - Harnesses and connectors

D STARTER SWITCH

X-023M

TURN SWITCH

1 2 IN

X-025M

S-005

S-003

CB-071 WH 2.5

SH6: C-5

CB-1001 WH 2.0

SH7: C-2

CB-010A RD 4.0

CB-1022 OR 2.5

CB-044A GY 1.0

SH4: B-6

CB-049 GN 1.0

SH4: A-3

CB-050 GN 1.0

SH4: A-3

CB-010 RD 4.0 SP-010

SH2: C-1

CB-0155 RD 4.0

SH2: D-1

X-023F

CB-010D RD 1.0

SH6: B-5

CB-010B RD 0.5

SH5: C-5

CB-010C RD 1.5

SH4: B-4

X-025F

C SH5: B-5

B-002 FUEL LEVEL SENDER 1

CB-1013A RD 0.5

SH7: D-4

CB-1013B RD 0.5

SH7: C-4

CB-1013C RD 0.5

X-027F

CB-057C BK 0.75

SH7: C-1

SP-1013A X-028

SH7: D-2

X-028

CB-1013 RD 1.0

SH2: C-1

CB-1030 YE 1.5

SH6: C-2

CB-015 BL 1.5

SH2: B-1

CB-1027 GN 1.5

SH5: B-5

CB-1027A GN 1.5

CB-1013D RD 0.75

S-007 HEADLAMP SWITCH

CB-029 GN 0.5

SH5: C-5

1 2 IN

3 4

X-027M

S-004 HAZARD SWITCH 6 SH6: B-5

4 SH2: A-1 SH4: D-1

CB-3000A GN 1.5

SH6: C-5

CB-010C RD 1.5

SH4: C-4

PIN15

CB-044 GY 1.5

CB-071A WH 1.5

S-006 SP-049

HORN SWITCH

CB-049A GN 1.0

CB-049B GN 1.0

SH7: D-4

CB-049C GN 1.0

SH7: D-2

SH2: A-1

CB-044A GY 1.0 PIN18

PIN16

. 5

X-024

CB-049D GN 0.5

SH5: A-5

CB-049 GN 1.0

SH4: D-1

SH6: C-2

CB-1004 GN 1.0 X-026

X-026

CB-0376 WH 1.0

SP-050

CB-050A GN 1.0

CB-050B GN 1.0

SH7: C-4

CB-050C GN 1.0

SH7: D-2

CB-050D GN 0.5

SH5: B-5

CB-050 GN 1.0

SH4: D-1

ACC SUPPLY

CB-057H BK 1.5

SH7: C-1

CB-1050 GN 1.5

SH6: B-2

X-030

X-031

3 SHT_4

47921938 07/02/2017

55.3 [55.100] / 9

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 05 SH05-INSTRUMENT CLUSTER TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

Type ECU Connector Connector

47921938 07/02/2017

55.3 [55.100] / 10

Component A-003 X-028 X-029

Connector / Link X-029 X-028 X-029

LA LA LA LA LA LA

Description INSTRUMENT CLUSTER FUEL LEVEL SENDER INSTRUMENT CLUSTER

Electrical systems - Harnesses and connectors

D A-003 INSTRUMENT CLUSTER

1 SH6: C-2

CB-1003B GN 0.5

SH2: A-1

CB-1006 BR 1.0

SH2: B-1

CB-039 BL 1.0

SH7: C-1

CB-057G BK 0.5

SH4: B-5

CB-029 GN 0.5

SH6: C-2

CB-1003A GN 0.5

SH2: C-1

CB-2015 YE 1.0

SH4: C-4

CB-010B RD 0.5

SH4: C-4

CB-1013A RD 0.5

SH2: B-1

CB-031 BR 1.0

SH4: B-3

CB-1027A GN 1.5

SH2: C-1

CB-1005 GN 1.0

+12 V (STARTER SWITCH)

ALTERNATOR WARNING LAMP

ENGINE TEMPERATURE SENDER

GROUND

FUEL LEVEL SENDER

C 6

+12 V ( STARTER SWITCH)

7 TACHOMETER SENSOR SIGNAL

8 + 12 V (BATTERY)

9 BACKLIGHTING

10 ENGINE OIL PRESSURE

11 HIGH BEAM INDICATOR

12 AIR RESTRICTION WARNING LAMP

B 13

14 SH2: A-1

CB-1033 PK 1.0

SH4: A-3

CB-050D GN 0.5

SH4: A-3

CB-049D GN 0.5

TURN SIGNAL WARNING LAMP

15 LEFT HAND TURN SIGNAL

16 RIGHT HAND TURN SIGNAL

X-029

3 SHT_5

47921938 07/02/2017

55.3 [55.100] / 11

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 06 SH06-FUSE BOX TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

Type ECU Connector Connector

47921938 07/02/2017

55.3 [55.100] / 12

Component A-002 X-022 X-024

LA LA LA LA LA LA

Description

Connector / Link X-022 X-022 X-024

FUSE BOX FUSE BOX HAZARD SWITCH

Electrical systems - Harnesses and connectors

A-002

CB-1003D GN 0.5

SH2: B-1

CB-1003A GN 0.5

SH5: C-5

CB-1003B GN 0.5

SH5: D-5

CB-1003C GN 0.5

SH7: C-2

CB-015 BL 1.5

SH4: B-3

CB-2041 PK 1.0

SH2: B-1

CB-1004 GN 1.0

SH4: B-1

CB-3000 GN 1.5

SH2: A-1

CB-0997 GN 0.75

SH7: C-2

CB-1050 GN 1.5

SH4: A-1

FUSE BOX SH4: B-4

CB-071A WH 1.5

1A SH4: D-5

1B 10.0 A

CB-071 WH 2.5

CB-1003 GN 0.75

15.0 A

SP-1003

10.0 A

4A SH4: B-6

CB-3000A GN 1.5

SH4: D-4

CB-010D RD 1.0

4A 10.0 A

15.0 A

X-022

3 SHT_6

47921938 07/02/2017

55.3 [55.100] / 13

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 07 SH07-TRANSMISSION/ FENDERS/SIDELIGHTS TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

Type Lamp Lamp Lamp Lamp Lamp Switch Switch Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector

47921938 07/02/2017

55.3 [55.100] / 14

Component E-003 E-004 E-005 E-006 E-007 S-008 S-009 S-010 X-022 X-032 X-033 X-034 X-035 X-036 X-037 X-038 X-039 X-040F X-040M

Connector / Link X-035 X-036 X-037 X-038 X-039 X-032 X-033 X-034 X-022 X-032 X-033 X-034 X-035 X-036 X-037 X-038 X-039 X-040F X-040M

LA LA LA LA LA LA

Description FENDER REAR LAMP R.H. FENDER REAR LAMP L.H. REAR WORKLAMP SIDE LAMP R.H. SIDE LAMP L.H. STOPLAMP SWITCH HANDBRAKE SWITCH SAFETY START FUSE BOX STOPLAMP SWITCH/ HANDBRAKE SWITCH STOPLAMP SWITCH/ HANDBRAKE SWITCH SAFETY START FENDER REAR LAMP R.H. FENDER REAR LAMP L.H. REAR WORKLAMP SIDE LAMP R.H. SIDE LAMP L.H. MAIN / TRANSMISSION HARNESS MAIN / TRANSMISSION HARNESS

Electrical systems - Harnesses and connectors

E-006 SIDE LAMP R.H. MAIN / TRANSMISSION HARNESS 1 TURN

4 SH7: C-1

GND

CB-057E BK 1.0

X-040M

SH4: B-3

CB-049B GN 1.0

3 X-038

SH4: C-4

CB-1013B RD 0.5

SIDE X-038

E-007 SIDE LAMP L.H.

SH7: B-5

TR-1013D RD 0.75

CB-1013D RD 0.75

SH4: C-4

SH7: B-6

TR-049C GN 1.0

CB-049C GN 1.0

SH4: A-3

SH7: A-6

TR-050C GN 1.0

CB-050C GN 1.0

SH4: A-3

SH7: B-3

TR-0997 GN 0.75

CB-0997 GN 0.75

SH6: B-2

SH7: C-4

TR-1003C GN 0.5

CB-1003C GN 0.5

SH6: C-2

2 SH4: C-4

CB-1013C RD 0.5 SIDE

4 SH7: C-1

GND

CB-057F BK 1.0

X-039

1 SH7: A-3

TR-057D BK 1.5

CB-057D BK 1.5

X-039

SH7: A-1

TR-1001 WH 2.0

S-009

X-032

SH4: C-5

CB-057E BK 1.0

SH7: D-6

CB-057F BK 1.0

SH7: C-6

CB-057G BK 0.5

SH5: C-5

CB-057H BK 1.5

SH4: A-1

SP-057C 9

S-008

SH2: C-1

SH4: A-3

CB-050B GN 1.0 TURN

STOPLAMP SWITCH

CB-057B BK 1.5 CB-057C BK 0.75

CB-1001 WH 2.0

SH4: D-5

CB-2003 WH 2.5

SH2: C-1

HANDBRAKE SWITCH 1

TR-1003D GN 0.5 X-033

TR-1003C GN 0.5

SH7: C-3

SH7: A-2

TR-2003 WH 2.0

X-033

TR-0810 GN 0.5

X-032

X-040F

E-003 FENDER REAR LAMP R.H. SP-0810

STOP

TAIL

TR-0810A GN 0.5

GND

TR-1013E RD 0.5

TR-057L BK 1.0 X-035 2

SH7: D-3

TURN

E-005

TR-049C GN 1.0

REAR WORKLAMP X-035 SH7: C-3

TR-0997 GN 0.75

SP-1013D SH7: D-3

TR-1013D RD 0.75

SP-057L

TR-057N BK 0.75 X-037

TR-057D BK 1.5

SH7: C-3

E-004 FENDER REAR LAMP L.H. X-036 SH7: D-3

TR-050C GN 1.0

TURN X-036 S-010

TR-1013F RD 0.5

TAIL

GND

SAFETY START

TR-057M BK 1.0 4

2 SH7: C-3

TR-0810B GN 0.5

TR-2003 WH 2.0 X-034

1 SH7: C-3

TR-1001 WH 2.0 X-034

STOP

3 SHT_7

47921938 07/02/2017

55.3 [55.100] / 15

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 08 SH08-LICENSE PLATE TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

Type Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector

47921938 07/02/2017

55.3 [55.100] / 16

Component X-100 X-101 X-102 X-103 X-104 X-105 X-106 X-107 X-108 X-109 X-110 X-111 X-112 X-113

Connector / Link X-100 X-101 X-102 X-103 X-104 X-105 X-106 X-107 X-108 X-109 X-110 X-111 X-112 X-113

LA LA LA LA LA LA

Description TO TRANSMISSION HARNESS TO FENDER HARNESS LICENSE PLATE LH FRONT TURN LAMP LH FRONT SIDE LAMP LH FRONT LAMP - GROUND LH REAR TURN LAMP LH REAR SIDE LAMP LH REAR LAMP - GROUND LH REAR STOP LAMP TO MAIN HARNESS WORKLAMP WORKLAMP LICENSE PLATE

Electrical systems - Harnesses and connectors

NARROW LICENSE PLATE ADAPTER

LICENSE PLATE LAMP 1

LP-1013B RD 1.0

X-102

LP-057B BK 1.0

X-100

X-101

TO TRANSMISSION HARNESS

TO FENDER HARNESS SP-057B

LP-057 BK 1.0

LP-057A BK 1.0

LP-810 GN 1.0 SP-1013B

LP-1013 RD 1.0

LP-1013A RD 1.0

LP-050 GN 1.0

LICENSE PLATE 1

STD LICENSE PLATE ADAPTER

1014B GN 1.0

N 2

X-113

57A BK 1.0

LH REAR LAMP

LH FRONT LAMP

X-104 LH FRONT SIDE LAMP

X-107 LH REAR SIDE LAMP SP-1014

1014C RD 1.0

1014A RD 1.0

X-103 LH FRONT TURN LAMP

X-106 LH REAR TURN LAMP

SP-50A

50B GN 1.0

50A GN 1.0

X-105 LH FRONT LAMP - GND

X-108 LH REAR LAMP - GND

SP-057D

57D BK 1.0

57B BK 1.0 X-109 LH REAR STOP LAMP 1

WORKLAMP X-112 WORKLAMP

X-110 TO MAIN HARNESS

57C BK 1.0

57 BK 1.0 X-111 WORKLAMP

810 GN 1.0

997 BR 1.0 4

1014 RD 1.0

50 GN 1.0

3 SHT_8

47921938 07/02/2017

55.3 [55.100] / 17

Electrical systems - Harnesses and connectors

47921938 07/02/2017

55.3 [55.100] / 18

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 00 TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

X-001 - ALTERNATOR B+ [ G-002] (84399576) (Plug)

84399576

84399576 Pin 1

From Wire X-014 (Plug) pin 1 STARTER EN-01 B+

Description Color-Size ALTERNATOR / STARTER RD - 16.0 MOTOR

Frame SHEET 02

X-002 - ALTERNATOR D/W [ G-002] (84015523) (Receptacle)

84015523

84015523 Pin 1 2

From Wire X-041F pin 3 ENGINE / MAIN EN-2015 HARNESS X-003F pin 7 ENGINE / MAIN EN-1006 HARNESS

Description EN-2015

Color-Size YE - 1.0

EN-1006

BR - 1.0

47921938 07/02/2017

55.3 [55.100] / 19

Frame SHEET 02

Electrical systems - Harnesses and connectors

X-003F - ENGINE / MAIN HARNESS [ SH2: A-3] (47921520) (Receptacle)

47921520

47921520 X-003M - ENGINE / MAIN HARNESS (Receptacle)

47921520

X-004 - AIR RESTRICTION SWITCH [ S-001] (87705140) (Receptacle)

87705140

87705140 Pin 1

From Wire X-003F pin 8 ENGINE / MAIN EN-1003 HARNESS

Description EN-1003

47921938 07/02/2017

55.3 [55.100] / 20

Color-Size RD - 1.0

Frame SHEET 02

Electrical systems - Harnesses and connectors

X-005 - AIR RESTRICTION SWITCH [ S-001] (87705140) (Receptacle)

87705140

87705140 Pin 1

From Wire X-041F pin 4 ENGINE / MAIN EN-1005 HARNESS

Description EN-1005

Frame

Color-Size GN - 1.0

SHEET 02

Color-Size PK - 1.0

SHEET 02

X-006 - FUEL SHUT-OFF [ Y-001] (87675193) (Receptacle)

87675193

87675193 Pin 1

From Wire X-003F pin 9 ENGINE / MAIN EN-2041 HARNESS

Description FUEL SHUT-OFF

Frame

X-007 - ENGINE OIL PRESSURE SWITCH [ S-002] (82944111) (Receptacle)

82944111

82944111 Pin 1

From Wire X-003F pin 1 ENGINE / MAIN EN-031 HARNESS

Description Color-Size ENGINE OIL PRESSURE BR - 1.0 SWITCH

47921938 07/02/2017

55.3 [55.100] / 21

Frame SHEET 02

Electrical systems - Harnesses and connectors

X-008 - ENGINE TEMPERATURE SENDER [ B-001] (87675193) (Receptacle)

87675193

87675193 Pin 1

From Wire X-003F pin 2 ENGINE / MAIN EN-039 HARNESS

Description EN-039

Frame

Color-Size BL - 1.0

SHEET 02

Color-Size OR - 2.5

SHEET 02

X-009 - THERMOSTART [ R-001] (87747155) (Receptacle)

87747155

87747155 Pin 1

From Wire X-041F pin 5 ENGINE / MAIN EN-1022 HARNESS

Description THERMOSTART

47921938 07/02/2017

55.3 [55.100] / 22

Frame

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 01 TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

X-010 - STARTER MOTOR (84401295) (Plug)

84401295

84401295 Pin 1

From X-013 (Plug) pin 2 BATTERY

Wire BA-001

Description BATTERY

Frame

Color-Size RD - 50.0

SHEET 02

Description EN-2003

Color-Size RD - 2.5

SHEET 02

Description BATTERY

Color-Size BK - 50.0

SHEET 02

Description BATTERY

Color-Size RD - 50.0

SHEET 02

X-011 - STARTER MOTOR [ M-001] (87675193) (Receptacle)

87675193

87675193 Pin 1

From Wire X-041F pin 2 ENGINE / MAIN EN-2003 HARNESS

Frame

X-012 - BATTERY [ G-001] (Plug) Pin 1

From X-045 (Plug) pin 1 BATTERY

Wire BA-002

Frame

X-013 - BATTERY [ G-001] (Plug) Pin 2

From Wire X-010 (Plug) pin 1 STARTER BA-001 MOTOR

47921938 07/02/2017

55.3 [55.100] / 23

Frame

Electrical systems - Harnesses and connectors

X-014 - STARTER B+ (84401295) (Plug)

84401295

84401295 Pin 1

From X-001 (Plug) pin 1 ALTERNATOR B+

Wire EN-01

Description Color-Size ALTERNATOR / STARTER RD - 16.0 MOTOR

Frame SHEET 02

X-015 - GROUND (84426125) (Plug)

84426125

84426125 Pin 1

From SP-057A-P-X

Wire EN-057

Description EN-057

X-016 - FLASHER UNIT [ A-001] (82944112) (Receptacle)

82944112

47921938 07/02/2017

55.3 [55.100] / 24

Color-Size BK - 1.5

Frame SHEET 02

Electrical systems - Harnesses and connectors

Pin 30 85 87 87A

From X-003F pin 3 ENGINE / MAIN HARNESS SP-057A-P-X X-003F pin 10 ENGINE / MAIN HARNESS X-003F pin 5 ENGINE / MAIN HARNESS

Wire EN-044

Description FLASHER UNIT

Color-Size GY - 1.5

Frame

EN-057A EN-1033

FLASHER UNIT FLASHER UNIT

BK - 1.5 PK - 1.0

EN-3000

FLASHER UNIT

GN - 1.5

Wire HO-0376

HORN

Color-Size WH - 1.0

SHEET 03

Wire HO-057D

Description EARTH

Color-Size BK - 1.5

SHEET 03

SHEET 02

X-017 - HORN [ H-001] (Plug) Pin 1

From X-021F (Receptacle) pin 4 CONNECTOR HEADLAMP HARNESS

Description

Frame

X-018 - HORN [ H-001] (Plug) Pin 1

From SP-057-P-X

Frame

X-019 - HEADLAMP - RIGHT HAND SIDE [ E-001] (Plug) Pin 1 2 3

From SP-1030-P-X SP- 057A-P-X SP-1027-P-X

Wire HO-1030A HO-057A HO-1027A

Description DIP BEAM EARTH MAIN BEAM

47921938 07/02/2017

55.3 [55.100] / 25

Color-Size YE - 1.5 BK - 1.5 GN - 1.5

Frame SHEET 03

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 02 TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

X-020 - HEADLAMP - LEFT HAND SIDE [ E-002] (Plug) Pin 1 2 3

From SP-1030-P-X SP- 057A-P-X SP-1027-P-X

Wire HO-1030B HO-057B HO-1027B

Description DIP BEAM EARTH MAIN BEAM

Color-Size YE - 1.5 BK - 1.5 GN - 1.5

Frame SHEET 03

X-021F - CONNECTOR HEADLAMP HARNESS (Receptacle) 1

From SP-1030-P-X

Wire HO-1030

2 3 4

SP-1027-P-X SP-057-P-X X-017 (Plug) pin 1 HORN

HO-1027 HO-057 HO-0376

Description HEADLAMP - RIGHT HAND SIDE MAIN BEAM EARTH HORN

Color-Size YE - 1.5

Frame SHEET 03

GN - 1.5 BK - 1.5 WH - 1.0

X-021M - CONNECTOR HEADLAMP HARNESS [ SH2: A-4] (47921522) (Plug)

47921522

47921522 X-022 - FUSE BOX [ A-002] (Plug) Pin 1A 2A 3A 4A 5A 6A 1B 2B 3B 3B 4B 5B 6B

From SP24-P-X SP23-P-X SP22-P-X X-024 (Plug) pin 6 HAZARD SWITCH SP-010-P-X SP22-P-X SP-1003-P-X X-027F (Receptacle) pin 2 HEADLAMP SWITCH X-003M (Plug) pin 9 ENGINE / MAIN HARNESS X-026 (Plug) pin 1 HORN SWITCH X-003M (Plug) pin 5 ENGINE / MAIN HARNESS X-040F (Plug) pin 6 MAIN / TRANSMISSION HARNESS X-031 (Plug) pin PIN1 ACC SUPPLY

Wire WIRE177 WIRE174 WIRE172 CB-3000A

Description WIRE177 WIRE174 WIRE172 HAZARD SWITCH

CB-010D WIRE171 CB-1003 CB-015

FUSE BOX WIRE171 FUSE BOX HEADLAMP SWITCH

RD - 1.0

CB-2041

FUSE BOX

PK - 1.0

CB-1004

HORN SWITCH

GN - 1.0

CB-3000

FUSE BOX

GN - 1.5

CB-0997

REAR WORKLAMP

GN - 0.75

SHEET 06

CB-1050

ACC SUPPLY

GN - 1.5

SHEET 04

47921938 07/02/2017

55.3 [55.100] / 26

Frame

Color-Size SHEET 06

GN - 1.5

GN - 0.75 BL - 1.5 SHEET 02

Electrical systems - Harnesses and connectors

X-023F - STARTER SWITCH [ SH2: D-1] (Receptacle) X-023M - STARTER SWITCH (Receptacle) Pin 1 2 3 4

From S-003-P-4 S-003-P-IN S-003-P-3 S-003-P-2

Wire WIRE88 WIRE89 WIRE87 WIRE86

Description WIRE88 WIRE89 WIRE87 WIRE86

Frame

Color-Size SHEET 04

X-024 - HAZARD SWITCH [ SH4: B-4] (Plug) Pin 2 3 4 4 5 6 8

From SP-010-P-X SP-049-P-X X-003M (Plug) pin 3 ENGINE / MAIN HARNESS X-025F (Plug) pin 1 TURN SWITCH SP-050-P-X X-022 (Plug) pin 4A FUSE BOX SP24-P-X

Wire CB-010C CB-049A CB-044

Description HAZARD SWITCH HAZARD SWITCH HAZARD SWITCH

Color-Size RD - 1.5 GN - 1.0 GY - 1.5

CB-044A

HAZARD SWITCH

GY - 1.0

CB-050A CB-3000A

HAZARD SWITCH HAZARD SWITCH

GN - 1.0 GN - 1.5

CB-071A

HAZARD SWITCH

WH - 1.5

Frame SHEET 02

X-025F - TURN SWITCH [ SH4: B-6] (Receptacle) X-025M - TURN SWITCH (Receptacle) Pin 1 2 3

From S-005-P-IN S-005-P-1 S-005-P-2

Wire WIRE196 WIRE194 WIRE195

Description WIRE196 WIRE194 WIRE195

Color-Size

Frame

Description HORN SWITCH

Color-Size GN - 1.0

SHEET 04

HORN SWITCH

WH - 1.0

SHEET 02

Color-Size GN - 1.5

SHEET 02

SHEET 04

X-026 - HORN SWITCH [ SH4: B-2] (Plug) Pin 1 2

From Wire X-022 (Plug) pin 3B FUSE CB-1004 BOX X-003M (Plug) pin 6 ENGINE CB-0376 / MAIN HARNESS

Frame

X-027F - HEADLAMP SWITCH [ SH4: C-3] (Receptacle) Pin 1 1 2 3 4

From X-003M (Plug) pin 4 ENGINE / MAIN HARNESS X-029 (Plug) pin 11 INSTRUMENT CLUSTER X-022 (Plug) pin 2B FUSE BOX X-041M (Plug) pin 1 SP-1013A-P-X

Wire CB-1027

Description HEADLAMP SWITCH

Frame

CB-1027A

INSTRUMENT CLUSTER GN - 1.5

CB-015

HEADLAMP SWITCH

BL - 1.5

SHEET 04

CB-1030 CB-1013

HEADLAMP SWITCH HEADLAMP SWITCH

YE - 1.5 RD - 1.0

SHEET 02 SHEET 04

SHEET 04

X-027M - HEADLAMP SWITCH (Receptacle) X-028 - FUEL LEVEL SENDER [ SH4: B-5] (Plug) Pin 1 2

From X-029 (Plug) pin 5 INSTRUMENT CLUSTER SP-057C-P-X

Wire CB-029

Description FUEL LEVEL SENDER

Color-Size GN - 0.5

CB-057C

FUEL LEVEL SENDER

BK - 0.75

Frame

X-029 - INSTRUMENT CLUSTER [ SH5: C-5] (Plug) Pin 1 2 3

From Wire SP-1003-P-X CB-1003B X-003M (Plug) pin 7 ENGINE CB-1006 / MAIN HARNESS X-003M (Plug) pin 2 ENGINE CB-039 / MAIN HARNESS

Description Color-Size INSTRUMENT CLUSTER GN - 0.5 INSTRUMENT CLUSTER BR - 1.0 INSTRUMENT CLUSTER BL - 1.0

47921938 07/02/2017

55.3 [55.100] / 27

Frame SHEET 04 SHEET 02

Electrical systems - Harnesses and connectors

Pin 4 5 6 7 8 9 10 11 12 14 15 16

From SP-057C-P-X X-028 (Plug) pin 1 FUEL LEVEL SENDER SP-1003-P-X X-041M (Plug) pin 3 SP-010-P-X SP-1013A-P-X X-003M (Plug) pin 1 ENGINE / MAIN HARNESS X-027F (Receptacle) pin 1 HEADLAMP SWITCH X-041M (Plug) pin 4 X-003M (Plug) pin 10 ENGINE / MAIN HARNESS SP-050-P-X SP-049-P-X

Wire CB-057G CB-029

Description GROUND FUEL LEVEL SENDER

Color-Size BK - 0.5 GN - 0.5

CB-1003A CB-2015 CB-010B CB-1013A CB-031

INSTRUMENT CLUSTER INSTRUMENT CLUSTER INSTRUMENT CLUSTER HEADLAMP SWITCH INSTRUMENT CLUSTER

GN - 0.5 YE - 1.0 RD - 0.5 RD - 0.5 BR - 1.0

CB-1027A

INSTRUMENT CLUSTER GN - 1.5

SHEET 04

CB-1005 CB-1033

INSTRUMENT CLUSTER GN - 1.0 INSTRUMENT CLUSTER PK - 1.0

SHEET 02

CB-050D CB-049D

HAZARD SWITCH HAZARD SWITCH

SHEET 04

47921938 07/02/2017

55.3 [55.100] / 28

GN - 0.5 GN - 0.5

Frame SHEET 04

SHEET 02 SHEET 04 SHEET 02

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 03 TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

X-030 - ACC SUPPLY (Plug) Pin PIN1

From SP-057C-P-X

Wire CB-057H

Description ACC SUPPLY

Color-Size BK - 1.5

SHEET 04

Frame

Wire CB-1050

Description ACC SUPPLY

Color-Size GN - 1.5

SHEET 04

X-031 - ACC SUPPLY (Plug) Pin PIN1

From X-022 (Plug) pin 6B FUSE BOX

Frame

X-032 - STOPLAMP SWITCH / HANDBRAKE SWITCH [ S-008] (Plug) Pin 2 3

From SP-0810-P-X X-033 (Plug) pin 1 STOPLAMP SWITCH/ HANDBRAKE SWITCH

Wire TR-0810 TR-1003D

Description STOPLAMP SWITCH STOPLAMP/ HANDBRAKE

Color-Size GN - 0.5 GN - 0.5

Frame SHEET 07

X-033 - STOPLAMP SWITCH/ HANDBRAKE SWITCH [ S-009] (Plug) Pin 1

From X-032 (Plug) pin 3 STOPLAMP SWITCH/ HANDBRAKE SWITCH X-040M (Receptacle) pin 7 MAIN / TRANSMISSION HARNESS

Wire TR-1003D

Description STOPLAMP/ HANDBRAKE

Color-Size GN - 0.5

TR-1003C

HANDBRAKE SWITCH

GN - 0.5

Frame SHEET 07

X-034 - SAFETY START [ SH7: C-3] (Plug) Pin 1

From X-040M (Receptacle) pin 11 MAIN / TRANSMISSION HARNESS X-040M (Receptacle) pin 13 MAIN / TRANSMISSION HARNESS

Wire TR-1001

Description Color-Size SAFETY START SWITCH WH - 2.0

TR-2003

SAFETY START SWITCH WH - 2.0

Frame SHEET 07

X-035 - FENDER REAR LAMP - RIGHT HAND SIDE [ E-003] (Plug) Pin

From SP-1013D-P-X

Wire TR-1013E TR-049C

X-040M (Receptacle) pin 4 MAIN / TRANSMISSION HARNESS SP-0810-P-X

TR-0810A

SP-057L-P-X

TR-057L

1 2

Description FENDER REAR LAMP RIGHT HAND SIDE FENDER REAR LAMP

Color-Size RD - 0.5

FENDER REAR LAMP RIGHT HAND SIDE FENDER REAR LAMP RIGHT HAND SIDE

GN - 0.5

Frame SHEET 07

GN - 1.0

BK - 1.0

X-036 - FENDER REAR LAMP - LEFT HAND SIDE [ E-004] (Plug) Pin 1 2

3 4

From SP-1013D-P-X

Wire TR-1013F

X-040M (Receptacle) pin 5 MAIN / TRANSMISSION HARNESS SP-0810-P-X SP-057L-P-X

TR-050C

TR-0810B TR-057M

Description FENDER REAR LAMP LEFT HAND SIDE FENDER REAR LAMP

FENDER REAR LAMP FENDER REAR LAMP LEFT HAND SIDE

47921938 07/02/2017

55.3 [55.100] / 29

Color-Size RD - 0.5 GN - 1.0

GN - 0.5 BK - 1.0

Frame SHEET 07

Electrical systems - Harnesses and connectors

X-037 - REAR WORKLAMP [ E-005] (Plug) Pin 1

From X-040M (Receptacle) pin 6 MAIN / TRANSMISSION HARNESS SP-057L-P-X

Wire TR-0997

Description REAR WORKLAMP

Color-Size GN - 0.75

TR-057N

REAR WORKLAMP

BK - 0.75

Frame SHEET 07

X-038 - SIDE LAMP - RIGHT HAND SIDE [ SH4: B-3] (Plug) Pin 1 2 4

From SP-049-P-X SP-1013A-P-X SP-057C-P-X

Wire CB-049B CB-1013B CB-057E

Description HAZARD SWITCH HEADLAMP SWITCH GROUND

Color-Size GN - 1.0 RD - 0.5 BK - 1.0

Frame SHEET 04 SHEET 07

X-039 - SIDE LAMP - LEFT HAND SIDE [ E-007] (Plug) Pin 1 2 4

From SP-050-P-X SP-1013A-P-X SP-057C-P-X

Wire CB-050B CB-1013C CB-057F

Description HAZARD SWITCH HEADLAMP SWITCH GROUND

47921938 07/02/2017

55.3 [55.100] / 30

Color-Size GN - 1.0 RD - 0.5 BK - 1.0

Frame SHEET 07 SHEET 04 SHEET 07

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 04 TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

X-040F - MAIN / TRANSMISSION HARNESS [ SH7: C-2] (Receptacle) X-040M - MAIN / TRANSMISSION HARNESS [ SH7: B-6] (Receptacle) Pin 3 4

6 7

8 11 13

From SP-1013D-P-X X-035 (Plug) pin 2 FENDER REAR LAMP - RIGHT HAND SIDE X-036 (Plug) pin 2 FENDER REAR LAMP - LEFT HAND SIDE X-037 (Plug) pin 1 REAR WORKLAMP X-033 (Plug) pin 4 STOPLAMP SWITCH/ HANDBRAKE SWITC SP-057L-P-X X-034 (Plug) pin 1 SAFETY START X-034 (Plug) pin 2 SAFETY START

Wire TR-1013D TR-049C

Description FENDER REAR LAMP FENDER REAR LAMP

Color-Size RD - 0.75 GN - 1.0

TR-050C

FENDER REAR LAMP

GN - 1.0

TR-0997

REAR WORKLAMP

GN - 0.75

TR-1003C

HANDBRAKE SWITCH

GN - 0.5

TR-057D TR-1001

BK - 1.5 GROUND SAFETY START SWITCH WH - 2.0

TR-2003

SAFETY START SWITCH WH - 2.0

X-041F - ENGINE / MAIN HARNESS [ SH3: B-1] (47921521) (Plug)

47921521

47921938 07/02/2017

55.3 [55.100] / 31

Frame SHEET 07

Electrical systems - Harnesses and connectors

X-041M - (Receptacle) X-042 - STARTER B+ (CAB) (84140737) (Plug)

84140737

84140737 Pin 1

From X-043 (Plug) pin 1 FUSE

Wire EN-0150

Description FUSE

Frame

Color-Size WH - 4.0

SHEET 02

Color-Size WH - 4.0

SHEET 02

X-043 - FUSE [ A-004] (84128192) (Plug)

84128192

84128192 Pin 1

From Wire X-042 (Plug) pin 1 STARTER EN-0150 B+ (CAB)

Description FUSE

X-044 - FUSE [ A-004] (84128192) (Plug)

84128192

47921938 07/02/2017

55.3 [55.100] / 32

Frame

Electrical systems - Harnesses and connectors

Pin 1

From Wire X-041F pin 10 ENGINE / MAIN EN-0155 HARNESS

Description

Frame

FUSE

Color-Size RD - 4.0

SHEET 02

Description BATTERY

Color-Size BK - 50.0

SHEET 02

X-045 - BATTERY (Plug) Pin 1

From X-012 (Plug) pin 1 BATTERY

Wire BA-002

47921938 07/02/2017

55.3 [55.100] / 33

Frame

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 10 TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

X-100 - TO TRANSMISSION HARNESS (87695376) (Plug)

87695376

87695376 Pin 1 2 3 4

From SP-057B-P-X X-101 (Receptacle) pin 2 TO FENDER HARNESS SP-1013B-P-X X-101 (Receptacle) pin 4 TO FENDER HARNESS

Wire LP-057 LP-810

Description LP-057 LP-810

Color-Size BK - 1.0 GN - 1.0

LP-1013 LP-050

RD - 1.0 GN - 1.0

Frame SHEET 08

X-101 - TO FENDER HARNESS (87695525) (Receptacle)

87695525

87695525 Pin 1 2 3 4

From SP-057B-P-X X-100 (Plug) pin 2 TO TRANSMISSION HARNESS SP-1013B-P-X X-100 (Plug) pin 4 TO TRANSMISSION HARNESS

Wire LP-057A LP-810

Description LP-057A LP-810

Color-Size BK - 1.0 GN - 1.0

LP-1013A LP-050

RD - 1.0 GN - 1.0

47921938 07/02/2017

55.3 [55.100] / 34

Frame SHEET 08

Electrical systems - Harnesses and connectors

X-102 - LICENSE PLATE (82012083) (Plug)

82012083

82012083 X-103 - FRONT TURN LAMP - LEFT HAND SIDE (87705127) (Receptacle)

87705127

87705127 Pin 1

From SP-50A-P-X

Wire 50B

Description 50B

Color-Size GN - 1.0

Frame SHEET 08

X-104 - FRONT SIDE LAMP - LEFT HAND SIDE (87705127) (Receptacle)

87705127

87705127 Pin 1

From SP-1014-P-X

Wire 1014C

Description 1014C

47921938 07/02/2017

55.3 [55.100] / 35

Color-Size RD - 1.0

Frame SHEET 08

Electrical systems - Harnesses and connectors

X-105 - FRONT LAMP - LEFT HAND SIDE - GROUND (87705127) (Receptacle)

87705127

87705127 Pin 1

From SP-057D-P-X

Wire 57D

Description 57D

Color-Size BK - 1.0

Frame SHEET 08

X-106 - REAR TURN LAMP - LEFT HAND SIDE (87705127) (Receptacle)

87705127

87705127 Pin 1

From SP-50A-P-X

Wire 50A

Description 50A

Color-Size GN - 1.0

Frame SHEET 08

X-107 - REAR SIDE LAMP - LEFT HAND SIDE (87705127) (Receptacle)

87705127

87705127 Pin 1

From SP-1014-P-X

Wire 1014A

Description 1014A

47921938 07/02/2017

55.3 [55.100] / 36

Color-Size RD - 1.0

Frame SHEET 08

Electrical systems - Harnesses and connectors

X-108 - REAR LAMP - LEFT HAND SIDE - GROUND (87705127) (Receptacle)

87705127

87705127 Pin 1

From SP-057D-P-X

Wire 57B

Description 57B

Color-Size BK - 1.0

Frame SHEET 08

X-109 - REAR STOP - LEFT HAND SIDE - LAMP (87705127) (Receptacle)

87705127

87705127 Pin 1

From X-110 (Receptacle) pin 2 TO MAIN HARNESS

Wire 810

Description 810

47921938 07/02/2017

55.3 [55.100] / 37

Color-Size GN - 1.0

Frame SHEET 08

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 11 TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

X-110 - TO MAIN HARNESS (82867472) (Receptacle)

82867472

82867472 Pin 1 2

3 5

From SP-057D-P-X X-109 (Receptacle) pin 1 REAR STOP LAMP - LEFT HAND SIDE X-111 (Receptacle) pin 1 WORKLAMP SP-50A-P-X

Wire

Description

57 810

Color-Size BK - 1.0 GN - 1.0

997

BR - 1.0

GN - 1.0

Frame SHEET 08

X-111 - WORKLAMP (84120007) (Receptacle)

84120007

84120007 Pin 1

From X-110 (Receptacle) pin 3 TO MAIN HARNESS

Wire 997

Description 997

47921938 07/02/2017

55.3 [55.100] / 38

Color-Size BR - 1.0

Frame SHEET 08

Electrical systems - Harnesses and connectors

X-112 - WORKLAMP (84120007) (Receptacle)

84120007

84120007 Pin 1

From SP-057D-P-X

Wire 57C

Description 57C

X-113 - LICENSE PLATE (82012083) (Plug)

82012083

47921938 07/02/2017

55.3 [55.100] / 39

Color-Size BK - 1.0

Frame SHEET 08

Electrical systems - Harnesses and connectors

Electrical components - ECU description TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

A-001 - FLASHER UNIT (ECU) Component Type Wiring frames Connectors

ECU SHEET 02 X-016 (Receptacle)

A-002 - FUSE BOX (ECU) Component Type Wiring frames Connectors

ECU SHEET 06 X-022 (Plug)

A-003 - INSTRUMENT CLUSTER (ECU) Component Type Wiring frames Connectors

ECU SHEET 05 X-029 (Plug)

A-004 - FUSE (ECU) Component Type Wiring frames Connectors

ECU SHEET 02 X-044 (Plug) X-043 (Plug)

47921938 07/02/2017

55.3 [55.100] / 40

Electrical systems - Harnesses and connectors

Electrical components - Sensor description TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

B-001 - ENGINE TEMPERATURE SENDER (Sensor) Component Type Wiring frames Connectors

Sensor SHEET 02 X-008 (Receptacle)

B-002 - FUEL LEVEL SENDER (Sensor) Component Type Wiring frames Connectors

Sensor SHEET 04 X-028 (Plug)

47921938 07/02/2017

55.3 [55.100] / 41

Electrical systems - Harnesses and connectors

Electrical components - Lamp description TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

E-001 - HEADLAMP R.H. (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 03 X-019 (Plug)

E-002 - HEADLAMP L.H. (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 03 X-020 (Plug)

E-003 - FENDER REAR LAMP R.H. (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 07 X-035 (Plug)

E-004 - FENDER REAR LAMP L.H. (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 07 X-036 (Plug)

E-005 - REAR WORKLAMP (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 07 X-037 (Plug)

E-006 - SIDE LAMP R.H. (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 07 X-038 (Plug)

E-007 - SIDE LAMP L.H. (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 07 X-039 (Plug)

47921938 07/02/2017

55.3 [55.100] / 42

Electrical systems - Harnesses and connectors

Electrical components - Voltage source description TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

G-001 - BATTERY (Voltage source) Component Type Wiring frames Connectors

Voltage source SHEET 02 X-013 (Plug) X-012 (Plug)

G-002 - ALTERNATOR (Voltage source) Component Type Wiring frames Connectors

Voltage source SHEET 02 X-002 (Receptacle) X-001 (Plug)

47921938 07/02/2017

55.3 [55.100] / 43

Electrical systems - Harnesses and connectors

Electrical components - Speaker description TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

H-001 - HORN (Speaker) Component Type Wiring frames Connectors

Speaker SHEET 03 X-017 (Plug) X-018 (Plug)

47921938 07/02/2017

55.3 [55.100] / 44

Electrical systems - Harnesses and connectors

Electrical components - Motor description TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

M-001 - STARTER MOTOR (Motor) Component Type Wiring frames Connectors

Motor SHEET 02 X-011 (Receptacle)

47921938 07/02/2017

55.3 [55.100] / 45

Electrical systems - Harnesses and connectors

Electrical components - Resistor description TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

R-001 - THERMOSTART (Resistor) Component Type Wiring frames Connectors

Resistor SHEET 02 X-009 (Receptacle)

47921938 07/02/2017

55.3 [55.100] / 46

Electrical systems - Harnesses and connectors

Electrical components - Switch description TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

S-001 - AIR RESTRICTION SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 02 X-004 (Receptacle) X-005 (Receptacle)

S-002 - ENGINE OIL PRESSURE SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 02 X-007 (Receptacle)

S-003 - STARTER SWITCH (Switch) Component Type Wiring frames

Switch SHEET 04

S-004 - HAZARD SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 04 X-024 (Plug)

S-005 - TURN SWITCH (Switch) Component Type Wiring frames

Switch SHEET 04

S-006 - HORN SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 04 X-026 (Plug)

S-007 - HEADLAMP SWITCH (Switch) Component Type Wiring frames

Switch SHEET 04

S-008 - STOPLAMP SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 07 X-032 (Plug)

S-009 - HANDBRAKE SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 07 X-033 (Plug)

47921938 07/02/2017

55.3 [55.100] / 47

Electrical systems - Harnesses and connectors

S-010 - SAFETY START (Switch) Component Type Wiring frames Connectors

Switch SHEET 07 X-034 (Plug)

47921938 07/02/2017

55.3 [55.100] / 48

Electrical systems - Harnesses and connectors

Electrical components - Solenoid description TT3840F Without cab, 8x2, Model Year 2016 TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016 TT3880F Without cab, 8x2, Model Year 2016 TT3880F Without cab, 12x3, Model Year 2016 TT4030 Without cab, 8x2, 2WD, Model Year 2016 TT4030 Without cab, 8x2, 4WD, Model Year 2016

LA LA LA LA LA LA

Y-001 - FUEL SHUT-OFF SOLENOID (Solenoid) Component Type Wiring frames Connectors

Solenoid SHEET 02 X-006 (Receptacle)

47921938 07/02/2017

55.3 [55.100] / 49

Index Electrical systems - 55 Harnesses and connectors - 100 Wiring harnesses - Electrical schematic sheet 03 SH03-HOOD (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 04 SH04-REAR HOOD (*) . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 05 SH05-INSTRUMENT CLUSTER (*) . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 06 SH06-FUSE BOX (*) . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 07 SH07-TRANSMISSION/FENDERS/SIDELIGHTS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 08 SH08-LICENSE PLATE (*) . . . . . . . . . . . . . . . . . .

Electrical components - ECU description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical components - Lamp description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical components - Motor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical components - Resistor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical components - Sensor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical components - Solenoid description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical components - Speaker description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical components - Switch description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical components - Voltage source description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire connectors - Component diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire connectors - Component diagram 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire connectors - Component diagram 02 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire connectors - Component diagram 03 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire connectors - Component diagram 04 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire connectors - Component diagram 10 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire connectors - Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 02 SH02-ENGINE (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

55.3 [55.100] / 50

Electrical systems - 55 Battery - 302

47921938 07/02/2017

55.4 [55.302] / 1

Contents Electrical systems - 55 Battery - 302

TECHNICAL DATA Battery General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Battery Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Battery Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

(*) See content for specific models 47921938 07/02/2017

55.4 [55.302] / 2

Electrical systems - Battery

Battery - General specification TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Specifications Component Voltage Capacity (in 20 h of operation) Localisation

TT3840

47921938 07/02/2017

55.4 [55.302] / 3

TT3840F

TT3880F 12 V 88 A·h / 100 A·h In front of the radiator

TT4030

Electrical systems - Battery

Battery - Static description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

The Class II tractors are equipped with a BCI group 31, 12 V battery with a minimum cold cranking ability of 800 A at -18 Â°C (0 Â°F)The battery is located under the hood in front of the radiator. The battery connections must be tight and free of corrosion. If necessary, wash the battery's outside surface and terminals with a solution of baking soda and water, making sure the solution does not get inside the battery. After cleaning, wash the battery with clean water, then apply a small amount of petroleum jelly to the terminals to prevent corrosion. A good battery charge must be maintained in freezing temperatures. If the battery is allowed to become discharged or run down, the electrolyte will become weak and possibly freeze. This can result in damage to the case. If water must be added, use distilled water. Add the water just before using the tractor. This ensures that the water will mix with the electrolyte during the charging process, preventing the water from freezing. Check the specific gravity of the electrolyte to determine battery charge.

47921938 07/02/2017

55.4 [55.302] / 4

20099894

Electrical systems - Battery

Battery - Remove TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Removal 1. Remove the air pre-filter (1).

LAIL11TT0460A0A

LAIL11TT0459A0A

LAIL11TT0458A0A

2. A gas strut (1) is provided inside the hood to keep the hood in the raised position.

3. Disconnect the battery terminals. NOTICE: Always disconnect the negative cable (1) first. 4. Loosen the retaining clamp (2) and remove the tractor battery.

47921938 07/02/2017

55.4 [55.302] / 5

Electrical systems - Battery

Battery - Install TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Battery installation To fit the battery, reverse the removal procedure, but observe the following: • Before fitting, clean the battery casing, terminals and retaining clamps using a solution of bicarbonate of soda and water. NOTICE: Cover the openings while you are cleaning. • Finally, connect the negative terminal. • Do not over-tighten the battery retaining clamp because that can damage the battery casing.

47921938 07/02/2017

55.4 [55.302] / 6

Electrical systems - Battery

Battery - Test TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Battery testing You can use the following different methods for checking the battery condition. 1. Test with hydrometer (specific gravity). 2. Voltmeter testing. 3. Load test (voltmeter during start-up). 4. Current drain test.

Hydrometer testing Testing with a hydrometer indicates the battery charge status by measuring the specific gravity of the electrolyte in the battery cells. Using a hydrometer, pull through enough electrolyte to raise the float in the container with the bulb fully expanded. NOTICE: Do not pull through too much electrolyte, because the float could make contact with the top of the container. Read and record the specific gravity of each cell. The average specific gravity of all the cells must be between 1.230 and 1.260. If the average value for all the cells is less than 1.230, recharge the battery. If the average specific gravity of all the cells is greater than 1.230, but the variation between cells is greater than 0.050, the battery may be defective. Check again after fully charging the battery.

47921938 07/02/2017

55.4 [55.302] / 7

Electrical systems - Battery

LAIL11TT0453F0A

Voltmeter testing Testing an open circuit with a voltmeter indicates the battery’s charge status by measuring the voltage stored in the battery. Connect a voltmeter between the battery terminals and read the voltage. NOTE: The battery must be disconnected from any charge for at least 10 h before the test, and the temperature must be 25 °C. Due to these restrictions, it is not common to measure battery condition in this way. The table below indicates the voltage with an open circuit and the specific gravity readings relating to the charge status. LAIL11TT0454A0A

Charge status 100% 75% 50% 25% 0%

Voltage with an open circuit ( 25 °C) 12.78 V 12.53 V 12.28 V 12.02 V 11.71 V

Test charge NOTICE: The battery must be fully charged before the charge test is performed.

47921938 07/02/2017

55.4 [55.302] / 8

Specific gravity 1.260 – 1.280 1.230 – 1.250 1.200 – 1.220 1.1700 – 1.190 1.100 – 1.130

Electrical systems - Battery

Never conduct this test on a battery that is less than 75% charged. Connect a voltmeter between the battery terminals. Read the battery voltage while you run the engine for 20 s. The voltmeter should not read less than 9.6 V during this 20 s period. If the battery does not hold 9.6 V for 20 s, fully charge the battery as described in the Charging the Battery section of Battery - Service instruction (55.302). Do another charge test, as indicated above. If the battery is again unable to hold 9.6 V, change it.

Current drain test The current drain test is used in cases in which the battery and charging system test are OK, but the battery still has a low charge. This can be caused by a circuit that draws battery current continuously. To identify this, disconnect the cable from the negative battery terminal. Connect the voltmeter between the negative battery terminal and the negative battery cable. With all electrical switches off, the voltmeter should read 0 V. If the reading shows battery voltage, the circuit is drawing power. Remove the fuses one by one until the voltage drops to 0 V and the faulty circuit is identified. If removing fuses does not make the voltmeter drop to zero, disconnect the wiring to electrical accessories (alternator, etc.) until the voltmeter reads 0 V.

47921938 07/02/2017

55.4 [55.302] / 9

LAIL11TT0455A0A

Electrical systems - Battery

Battery - Service instruction TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Charging the battery Requirements for charging the batteries: Slow charging is the only method for fully charging a battery. You can use a quick charger to increase a battery’s capacity quickly, but you must follow this procedure with a slow charge to fully charge the battery. Observe the following throughout the slow charging of the battery: • If the battery needs to remain in the tractor, disconnect the battery cables to prevent damage to the electrical system during charging. • Thoroughly clean the battery. • Ensure that the electrolyte level is correct. The battery will be fully charged when three specific gravity readings taken at 1 h intervals do not indicate any specific gravity increase.

Battery maintenance During the tractor’s scheduled services, you must also pay the battery careful attention. You will be able to prolong the battery’s useful life by regularly performing the following servicing procedure. • Loosen the clamps holding the battery terminal in place and disconnect the battery cables. Always disconnect the negative cable first and reconnect it last. • Use a solution of bicarbonate of soda and water to clean the battery casing and terminals, and the cable retaining clamps. NOTICE: Cover the openings while you are cleaning.

47921938 07/02/2017

55.4 [55.302] / 10

Electrical systems - Battery

• You can remove serious corrosion from the battery terminals and the cable retaining clamps with a wire brush. • Inspect the condition of the cables and their connectors. Carefully look at both ends of the cables. Remove all the corrosion and check that the contact is clean. Check the negative cables at the chassis and the positive cables at the starter. • Keep the electrolyte level halfway between the plates and the top cover. Add distilled water, as required. Do not use well water or tap water. Do not top up with acid. • You must use the battery retaining clamps so that the battery does not move. Do not over-tighten because that can damage the battery casing. • Ensure that the openings are closed and clean the battery. The battery must remain clean and dry. • Once more cover the terminals and the cable retaining clamps with petroleum jelly to prevent corrosion. Do not use grease. • Batteries should not be allowed to discharge completely. If you are going to store the tractor for a period of over 2 weeks, you should remove the battery from the tractor and store it in a dry place on a wooden platform. Trickle charge the battery every two or three weeks to keep it in good condition.

47921938 07/02/2017

55.4 [55.302] / 11

Index Electrical systems - 55 Battery - 302 Battery - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

55.4 [55.302] / 12

Electrical systems - 55 Warning indicators, alarms, and instruments - 408

47921938 07/02/2017

55.5 [55.408] / 1

Contents Electrical systems - 55 Warning indicators, alarms, and instruments - 408

FUNCTIONAL DATA Instrument cluster Analog instrument cluster - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47921938 07/02/2017

55.5 [55.408] / 2

Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster Analog instrument cluster - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Description and operation Instrument cluster

LAIL11TT0461F0A

Analog panel The instrument cluster comprises: 1. 2. 3. 4. 5.

Leftâ&#x20AC;?hand direction indicators Park lights High beam indicator light Engine oil pressure gauge Battery charge indicator

6. 7. 8. 9. 10.

Rightâ&#x20AC;?hand direction indicators Fuel level gauge Tachometer Hour meter Water thermometer

47921938 07/02/2017

55.5 [55.408] / 3

Electrical systems - Warning indicators, alarms, and instruments

LAIL11TT0462F0A

Digital Panel

Engine oil pressure gauge: A pressure sensor (1) is fitted on the left-hand side of the engine, inside the main oil gallery. Oil pressure changes can affect this sensorâ&#x20AC;&#x2122;s resistance. The gauge shows the current in the circuit on the gauge as the oil pressure. Below 0.5 bar, the sensorâ&#x20AC;&#x2122;s switch completely closes, and the indicator (4), Fig. 1 and 2 comes on.

LAIL11TT0463A0A

47921938 07/02/2017

55.5 [55.408] / 4

Electrical systems - Warning indicators, alarms, and instruments

Battery charge indicator Used to show whether the alternator is working properly. A 1.4 W lamp is connected to the key switch for the alternator circuit. The lamp will come on if the key switch is turned to position 2. The lamp should go out when you start the engine and the alternator starts to charge the battery.

Right-hand and left-hand direction indicators Turning right and left. 1.4 W lamps are fitted on the instrument cluster. They are connected to the circuit for the right-hand and left-hand direction indicators and they flash when you activate the direction indicators. Both the direction indicators flash when you use the hazard warning switch.

High beam indicator light A 1.4 W lamp is connected to the full beam circuit. When you select full beam, the lamp should come on.

Thermometer A temperature sensor (1) fitted on the poppet water liner outlet changes its resistance according to the water temperature. The gauge indicates the water temperature according to the electrical current that passes through the sensor.

LAIL11TT0464A0A

LAIL11TT0465A0A

Tachometer The cable (1) that comes out of the engine indicates the engine RPM and the number of operating hours.

47921938 07/02/2017

55.5 [55.408] / 5

Electrical systems - Warning indicators, alarms, and instruments

Fuel level gauge A sensor inside the fuel reservoir changes its resistance according to the fuel level. The gauge measures the resulting current and displays it as the fuel level on the gauge.

LAIL11TT0466A0A

47921938 07/02/2017

55.5 [55.408] / 6

Index Electrical systems - 55 Warning indicators, alarms, and instruments - 408 Instrument cluster Analog instrument cluster - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

55.5 [55.408] / 7

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

47921938 07/02/2017 EN

SERVICE MANUAL Platform, cab, bodywork, and decals TT3840 Without cab, 8x2, TIER 2, Upgrade, Model Year 2016, TT3840F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 8x2, Model Year 2016, TT3880F Without cab, 12x3, Model Year 2016, TT4030 Without cab, 8x2, 2WD, Model Year 2016, TT4030 Without cab, 8x2, 4WD, Model Year 2016

47921938 07/02/2017

Contents Platform, cab, bodywork, and decals - 90

[90.151] Cab interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1

47921938 07/02/2017

Platform, cab, bodywork, and decals - 90 Cab interior - 151

47921938 07/02/2017

90.1 [90.151] / 1

Contents Platform, cab, bodywork, and decals - 90 Cab interior - 151

FUNCTIONAL DATA Console Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47921938 07/02/2017

90.1 [90.151] / 2

Platform, cab, bodywork, and decals - Cab interior

Console - Dynamic description TT3840F TT3840 TT3880F TT4030

LA LA LA LA

Control switches

LAIL11TT0467F0A

1. 2. 3. 4. 5. 6.

Right-hand and left-hand direction indicator switch Klaxon Hand throttle lever Ignition/shut-down key switch Head light switch Hazard light switch

1. Right-hand and left-hand direction indicator switch

Used to activate the right- or left-hand direction indicator circuits. The switch has three positions. 1. 2. 3.

Righthand Center Left

Right turn Off Left turn

2. Hazard Light Switch Used on the right-hand and left-hand direction indicator circuits. Serves as a warning to other vehicles.

47921938 07/02/2017

90.1 [90.151] / 3

Platform, cab, bodywork, and decals - Cab interior

3. Start-up switch 2 A start-up switch with three positions is fitted. The ignition key switch positions are as follows: Position 1 Position 2

Position 3

Electrical equipment OFF Accessories on (headlights, instrument cluster, horn and gauges, brake lights, direction indicators) Starter activated

LAIL11TT0468A0A

LAIL11TT0469A0A

LAIL11TT0470A0A

LAIL11TT0471A0A

4. Horn Switch You use a switch to complete the horn signal circuit.

5. Light switch 3

You turn a key to activate the lighting circuits. The switch has four positions: Position 1 Position 2 Position 3 Position 4

OFF Parking lights and instrument cluster lights Low beam High beam

Start-up switch in neutral 4 A ballpoint plunger switch (1) with two positions fitted on the left-hand side of the transmission housing, activated with the range lever.

Brake light switch 5

The brake pedal switch (1) is located below the right-hand running board, near the brake pedal. It is activated when the brake is activated, and is indicated with a light on the fender.

47921938 07/02/2017

90.1 [90.151] / 4

Index Platform, cab, bodywork, and decals - 90 Cab interior - 151 Console - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) See content for specific models 47921938 07/02/2017

90.1 [90.151] / 5

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

47921938 07/02/2017 EN

SCHEMAS INDEX Reference Electrical components - ECU description Electrical components - Lamp description Electrical components - Motor description Electrical components - Resistor description Electrical components - Sensor description Electrical components - Solenoid description Electrical components - Speaker description Electrical components - Switch description Electrical components - Voltage source description Wire connectors - Component diagram 00 Wire connectors - Component diagram 01 Wire connectors - Component diagram 02 Wire connectors - Component diagram 03 Wire connectors - Component diagram 04 Wire connectors - Component diagram 10 Wire connectors - Component diagram 11 Wiring harnesses - Electrical schematic sheet 02 SH02-ENGINE Wiring harnesses - Electrical schematic sheet 03 SH03-HOOD Wiring harnesses - Electrical schematic sheet 04 SH04-REAR HOOD Wiring harnesses - Electrical schematic sheet 05 SH05-INSTRUMENT CLUSTER Wiring harnesses - Electrical schematic sheet 06 SH06-FUSE BOX Wiring harnesses - Electrical schematic sheet 07 SH07-TRANSMISSION/FENDERS/ SIDELIGHTS Wiring harnesses - Electrical schematic sheet 08 SH08-LICENSE PLATE

47921938 07/02/2017

PAGE 55.3 / 40 55.3 / 42 55.3 / 45 55.3 / 46 55.3 / 41 55.3 / 49 55.3 / 44 55.3 / 47 55.3 / 43 55.3 / 19 55.3 / 23 55.3 / 26 55.3 / 29 55.3 / 31 55.3 / 34 55.3 / 38 55.3 / 4 55.3 / 6 55.3 / 8 55.3 / 10 55.3 / 12 55.3 / 14 55.3 / 16

SPECIAL TOOL INDEX Genuine 380000569 [Tractor Separation Trolley] 290740 [Engine Lifting Hook] 380000301 [Rotating Engine Stand] 293240 [Turbocharger / Engines Check Kit] 293679 [Manoevre Wrench ] 296118 [Belt Tensione Test Device] 380000221 [Handle] 380000226 [Engine Hub Puller used on 4.5L & 6.7L NEF Engines ] 380000232 [Rocker Wrench - used for valve clearance adjustment on 4.5L & 6.7L NEF Engines] 291046 [Valve Guide Remover And Installer] 380000222 [Valve Guide Reamer] 294028 [Exhaust Gas Cylinder Head Valve Guide Reamer ] 380000242 [Cylinder Head Valve Guide Installer - used with 4.5L & 6.7L NEF Engines] 380000219 [Valve Guide Remover/installer] 380000223 [Water Pump Puller used on 4.5L & 6.7L NEF Engines] 380000549 [Slide Hammer] 380000228 [Dial Gauge (0 - 5 mm)] 380000322 [Injection Pump Drive Gear Puller] 380000829 [Thread Tap (M 12 X 1.75)] 380000830 [Guide Socket ] 380000833 [Cutter For Grinding Injector Holder Seat] 380000834 [Injection Holder Cap Rolling Beater] 380000322 [Injection Pump Drive Gear Puller] 86512999 [Front Crankshaft Seal Installer] 380000804 [Pinion Seal Installer] 380000301 [Rotating Engine Stand] 380000301 [Rotating Engine Stand] 380000804 [Pinion Seal Installer]

Reference

PAGE

Engine - Special tools

10.1 / 10

Engine - Special tools Engine - Special tools

10.1 / 10 10.1 / 10

Engine - Special tools

10.1 / 10

Engine - Special tools Engine - Special tools

10.1 / 10 10.1 / 10

Engine - Special tools Engine - Special tools

10.1 / 10 10.1 / 10

Engine - Special tools

10.1 / 10

Engine - Special tools

10.1 / 10

Engine - Special tools

10.1 / 10

Engine - Special tools

10.1 / 10

Engine - Special tools

10.1 / 10

Engine - Special tools

10.1 / 10

Engine - Special tools

10.1 / 10

Engine - Special tools Engine - Special tools

10.1 / 10 10.1 / 10

Engine - Special tools

10.1 / 10

Engine - Special tools

10.1 / 11

Engine - Special tools Engine - Special tools

10.1 / 11 10.1 / 11

Engine - Special tools

10.1 / 11

Engine - Special tools

10.1 / 11

Engine - Special tools

10.1 / 11

Engine - Disassemble

10.1 / 38

Engine - Disassemble

10.1 / 38

Engine - Disassemble

10.1 / 38

Engine - Disassemble

10.1 / 38

47921938 07/02/2017

Genuine 380000322 [Injection Pump Drive Gear Puller] 290740 [Engine Lifting Hook] 290740 [Engine Lifting Hook] 380000226 [Engine Hub Puller used on 4.5L & 6.7L NEF Engines ] 290740 [Engine Lifting Hook] 380000301 [Rotating Engine Stand] 290740 [Engine Lifting Hook] 380000804 [Pinion Seal Installer] 380000303 [Cylinder Liner Pressure Check Kit] 291883 [Valve Clearance Adjuster] 380000232 [Rocker Wrench - used for valve clearance adjustment on 4.5L & 6.7L NEF Engines] 380000222 [Valve Guide Reamer] 291046 [Valve Guide Remover And Installer] 291046 [Valve Guide Remover And Installer] 293231 [Cylinder Head Valve Guide Installer] 294028 [Exhaust Gas Cylinder Head Valve Guide Reamer ] 294028 [Exhaust Gas Cylinder Head Valve Guide Reamer ] 294028 [Exhaust Gas Cylinder Head Valve Guide Reamer ] 294028 [Exhaust Gas Cylinder Head Valve Guide Reamer ] 294006 [General Tool] 291160 [Pliers For Piston Rings Removal And Installation (65 -110 mm)] 291160 [Pliers For Piston Rings Removal And Installation (65 -110 mm)] 380000226 [Engine Hub Puller used on 4.5L & 6.7L NEF Engines ] 380000226 [Engine Hub Puller used on 4.5L & 6.7L NEF Engines ] 380000322 [Injection Pump Drive Gear Puller] 380000228 [Dial Gauge (0 - 5 mm)] 380000228 [Dial Gauge (0 - 5 mm)] 380001601 [Dial Indicator Extension Pin and Adapter] 380000228 [Dial Gauge (0 - 5 mm)]

Reference

PAGE

Engine - Disassemble

10.1 / 41

Engine - Disassemble Engine - Disassemble Engine - Disassemble

10.1 / 43 10.1 / 44 10.1 / 45

Engine - Disassemble Engine - Disassemble

10.1 / 48 10.1 / 49

Engine - Disassemble Engine - Disassemble

10.1 / 49 10.1 / 49

Engine - Compression test

10.1 / 55

Rocker arm - Adjust the clearance between the valves and rockers Valves - Adjust of the gap

10.3 / 5 10.4 / 11

Valve guide - Replace

10.4 / 12

Valve guide - Replace

10.4 / 12

Valve guide - Replace

10.4 / 12

Valve guide - Replace

10.4 / 12

Valve guide - Replace

10.4 / 13

Valve guide - Replace

10.4 / 13

Valve guide - Replace

10.4 / 13

Valve guide - Replace

10.4 / 13

Valve seat - Regrind Piston - Inspect

10.4 / 15 10.5 / 7

Piston - Assemble

10.5 / 10

Crankshaft oil seal Front seal - Remove

10.6 / 7

Crankshaft oil seal Front seal - Install

10.6 / 9

Rotary injection pump - Remove

10.10 / 9

Rotary injection pump - Timing adjust

10.10 / 13

Rotary injection pump - Timing adjust

10.10 / 13

Rotary injection pump - Timing adjust

10.10 / 16

Rotary injection pump - Timing adjust

10.10 / 16

47921938 07/02/2017

Genuine 293763 [Clutch Lever Adjusting Wrench Set] 380002740 [Double Clutch Alignment Arbor] 380002740 [Double Clutch Alignment Arbor] 380002740 [Double Clutch Alignment Arbor] 292909 [Special Tool] 293836 [Drive Shaft Seal Guard] 293836 [Drive Shaft Seal Guard] 293544 [Differential Slotted Nut Socket] 295030 [Wheel Hub Bearing Slotted Nut Socket] 293812 [M16x1,5 Wheel Pin Guide] 380000295 [Wheel Hub Bearing Slotted Nut Socket] 380000268 [Bevel Pinion Ring Nut Wrench] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 293952 [Torque Wrench] 293952 [Torque Wrench] CA715082 [Driver] CA715082 [Driver] 380000252 [Front Axle Ring Nut Wrench] 380000252 [Front Axle Ring Nut Wrench] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000265 [Swivel Housing Pin Pivot Puller] 380000234 [Swivel Pin Bearing Outer Race Puller] 380000235 [Swivel Housing Torque Check Adapter] 380000235 [Swivel Housing Torque Check Adapter] 292911 [Special Tool] 293101 [Bevel Pinion Bearings Adjuster] 293342 [Bevel Pinion Nut Wrench] 9971366 [Special Tool] 290870 [Differential Lock Fork Spring Installer] 293101 [Bevel Pinion Bearings Adjuster] 293101 [Bevel Pinion Bearings Adjuster] 380002737 [Rear Differential Pinion Gear Preload Tool] 380002737 [Rear Differential Pinion Gear Preload Tool]

Reference

PAGE

Clutch - Special tools

18.2 / 6

Clutch - Remove Clutch assy

18.2 / 10

Clutch - Assemble Clutch Assembly

18.2 / 18

Clutch - Install Clutch Assembly

18.2 / 19

Mechanical transmission - Special tools Gearbox - Special tools

21.1 / 5 23.1 / 4

Gearbox - Assemble

23.1 / 8

Powered front axle - Special tools

25.1 / 9

Powered front axle - Special tools

25.1 / 9

Powered front axle - Special tools

25.1 / 9

Powered front axle - Disassemble - 4WD

25.1 / 30

Powered front axle - Disassemble - 4WD

25.1 / 32

Powered front axle - Disassemble - 4WD

25.1 / 32

Differential - Preload Differential - Preload Differential Input shaft assembly - Assemble Differential Input shaft assembly - Assemble Differential - Gear tooth contact - 4WD Ring/pinion adjustment

25.2 25.2 25.2 25.2 25.2

Differential - Gear tooth contact - 4WD Ring/pinion adjustment

25.2 / 29

Differential - Gear tooth contact - 4WD Ring/pinion adjustment

25.2 / 29

Steering knuckle and king pin - Replace - 4WD Steering knuckle pins and bearings Steering knuckle and king pin - Replace - 4WD Steering knuckle pins and bearings Steering knuckle and king pin - Adjust

25.3 / 13

Steering knuckle and king pin - Adjust

25.3 / 14

Powered rear axle - Special tools Powered rear axle - Special tools

27.1 / 6 27.1 / 6

Powered rear axle - Special tools

27.1 / 6

Powered rear axle - Special tools Powered rear axle - Special tools

27.1 / 6 27.1 / 7

Bevel gear - Preload

27.2 / 8

Bevel gear - Preload

27.2 / 9

Bevel gear - Adjust

27.2 / 10

Bevel gear - Adjust

27.2 / 10

47921938 07/02/2017

/ / / / /

14 14 23 23 28

25.3 / 13 25.3 / 14

Genuine 380002737 [Rear Differential Pinion Gear Preload Tool] 380002738 [Rear Differential Ring Tightening Wrench] 380002738 [Rear Differential Ring Tightening Wrench] 380002738 [Rear Differential Ring Tightening Wrench] 380002763 [Pinion Nut Spanner Wrench (55mm)] 292904 [Set Of Adjustable Pullers] 292535 [Lift Arm Shaft Seal Installer] 292547 [Piston And Seal Install Guide] 293870 [Lift Arm Stroke Adjusting Wrench] 380000261 [Punch for Fitting Needle Bearings on Control Valve Block Control Lever Bushing] 293839 [Control Link Needle Bearing Installer] 290819 [Draft Control Spring Adjusting Lever] 291215 [Straight Reduction 22L-15L] 292060 [HYDRAULIC TEST ADAPTER] 293168 [Quick Coupling] 293247 [Pressure Gauge ] 293870 [Lift Arm Stroke Adjusting Wrench] 293870 [Lift Arm Stroke Adjusting Wrench] 293870 [Lift Arm Stroke Adjusting Wrench] 380001325 [Compressor Belt Tension Checking Tool]

Reference

27.2 / 10

Bevel gear - Backlash

27.2 / 13

Bevel gear - Backlash

27.2 / 13

Bevel gear - Backlash

27.2 / 13

Differential - Disassemble Pinion shaft

27.2 / 24

Planetary and final drives - Special tools

27.3 / 5

Rear three-point hitch - Special tools

37.1 / 7

Rear three-point hitch - Special tools

37.1 / 7

Rear three-point hitch - Special tools

37.1 / 7

Rear three-point hitch - Special tools

37.1 / 7

Rear three-point hitch - Special tools

37.1 / 7

Rear three-point hitch - Special tools

37.1 / 7

Rear three-point hitch - Special tools

37.1 / 7

Rear three-point hitch - Special tools

37.1 / 7

Rear three-point hitch - Special tools Rear three-point hitch - Special tools Rear three-point hitch - Adjust of the position control

37.1 / 7 37.1 / 7 37.1 / 20

Rear three-point hitch - Travel adjust maximum of the lift arm

37.1 / 24

Rear three-point hitch - Travel adjust maximum of the lift arm

37.1 / 25

Alternator - Tension adjust - Belt

55.2 / 17

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] 380000229 [Dial Gauge Holder Tool For Rotary Injection Pump Timing]

PAGE

Bevel gear - Adjust

Reference

PAGE

Engine - Special tools

10.1 / 10

Engine - Special tools

10.1 / 10

Engine - Special tools

10.1 / 10

Engine - Remove

10.1 / 30

Engine - Install

10.1 / 51

Rotary injection pump - Timing adjust

10.10 / 13

47921938 07/02/2017

Kit 380000229 [Dial Gauge Holder Tool For Rotary Injection Pump Timing] 380040203 [Rear Differential Kit]

Reference

PAGE

Rotary injection pump - Timing adjust

10.10 / 13

Bevel gear - Backlash

27.2 / 13

47921938 07/02/2017

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

47921938 07/02/2017 EN