New Holland TT4.80 TT4.90 Tractor Service Manual (47866580) New Holland TT4.80 TT4.90 - PDF Download by www.heydownloads.com

SERVICE MANUAL TT4.80 / TT4.90 Tractor

Part number 47866580 1st edition English December 2015

SERVICE MANUAL TT4.80 TT4.90

47866580 11/12/2015 EN

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 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 [10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

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

Transmission.............................................................................. 21 [21.114] Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.110] Master clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 [21.134] Power shuttle transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 [21.154] Power shuttle transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5 47866580 11/12/2015

[21.120] Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6 [21.126] Gearbox external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.7 [21.145] Gearbox internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.8 [21.160] Creeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.9 [21.200] Dropbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.10

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

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 [31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1

Brakes and controls .................................................................... 33 [33.120] Mechanical service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.100] Main lift system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

Steering..................................................................................... 41 [41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2

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[41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

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

Electrical systems ....................................................................... 55 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8

Platform, cab, bodywork, and decals ............................................. 90 [90.118] Protections and footboards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.114] Operator protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4 [90.116] Fenders and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5

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INTRODUCTION

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Contents INTRODUCTION Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Foreword Important notice All maintenance and repair operations described in this manual should be carried out exclusively by NEW HOLLAND authorised workshops. All instructions should be carefully observed and special equipment where indicated should be used. Anyone who carries out service operations described without carefully observing these prescriptions will be directly responsible for any damage caused.

Notes for equipment Equipment which NEW HOLLAND proposes and shows in this manual is: - Studied and designed expressly for use on NEW HOLLAND tractors. - Necessary to make reliable repair. - Accurately built and strictly tested to offer efficient and long-lasting working life.

Notice The words “front”, “rear”, “right-hand side” and “left-hand side” refer to the different parts as seen from the operator’s seat oriented to the normal direction of movement of the tractor.

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Safety rules This warning symbol points out important messages involving personal safety. Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and safeguarded your safety. In this manual you will find this symbol together with the following keywords. WARNING: It gives warning about improper repair operations and potential consequences affecting the service technicianâ&#x20AC;&#x2122;s personal safety. DANGER: It gives specific warning about potential dangers for personal safety of the operator or other persons directly or indirectly involved in the operation.

To prevent accidents Most accidents and personal injuries taking place in workshops are due from non-observance of some essential rules and safety precautions. The possibility that an accident might occur with any type of machines should not be disregarded, no matter how well the machine in question was designed and built. A wise and careful service technician is the best precautions against accidents. Careful observance of this only basic precaution would be enough to avoid many severe accidents.

DANGER Never carry out any cleaning, lubrication or maintenance operations when the engine is running.

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Safety rules Generalities Carefully follow specified repair and maintenance procedures. • Do not wear rings, wrist watches, jewels, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open jackets or shirts with open zips which could get caught in moving parts. Use approved safety clothing such as anti-slipping footwear, gloves, safety goggles, helmets, etc. • Wear safety glasses with side guards when cleaning parts using compressed air. • Damaged or frayed wires and chains are unreliable. Do not use them for lifting or towing. • Wear suitable protection such as approved eye protection, helmets, special clothing, gloves and footwear whenever welding. All persons standing in vicinity of the welding process should wear approved eye protection. Never look at the welding arc if your eyes are not suitably protected. • Never carry out any repair on the machine if someone is sitting on the operator’s seat, except they are qualified operators assisting in the operation to be carried out. • Never operate the machine or use attachments from a place other than sitting at the operator’s seat or at the side of the machine when operating the fender switches. • Never carry out any operation on the machine when the engine is running, except when specifically indicated. Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves, etc. • All repair and maintenance operations should be carried out with greatest care and attention. • Disconnect the batteries and label all controls to warn that the tractor is being serviced. Block the machine and all equipment which should be raised. • Never check or fill fuel tanks or batteries, nor use starting liquid if you are smoking or near open flames as such fluids are flammable. • The fuel filling gun should always remain in contact with filler neck. Maintain this contact until the fuel stops flowing into the tank to avoid possible sparks due to static electricity build-up. • To transfer a failed tractor, use a trailer of a low loading platform trolley if available. • To load and unload the machine from the transportation means, select a flat area providing a firm support to the trailer or truck wheels. Firmly tie the machine to the truck or the trailer platform and block wheels as required by the transporter. • Always use lifting equipment of appropriate capacity to lift or move heavy components. • Chains should always be safely fastened. Ensure that fastening device is strong enough to hold the load foreseen. No persons should stand near the fastening point. • The working area should be always kept clean and dry. Immediately clean any spillage of water or oil. • Never use gasoline, diesel oil or other flammable liquids as cleaning agents. Use non-flammable non-toxic proprietary solvents. • Do not pile up grease or oil soaked rags, as they constitute a great fire hazard. Always place them into a metal container.

Start up • Never run the engine in confined spaces which are not equipped with adequate ventilation for exhaust gas extraction. • Never bring your body, arms, legs, feet, hands, fingers near fans or rotating belts.

Engine • Always loosen the radiator cap very slowly before removing it to allow pressure in the system to dissipate. Coolant should be topped up only when the engine is stopped. • Do not fill up fuel tank when the engine is running. • Never adjust the fuel injection pump when the tractor is moving. Never lubricate the tractor when the engine is running. 47866580 11/12/2015

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Electrical systems • If it is necessary to use auxiliary batteries, cables must be connected at both sides as follows. (+) to (+) and (-) to (-). Avoid short-circuiting the terminals. Gas released from batteries is highly flammable. During charging, leave the battery compartment uncovered to improve ventilation. Avoid sparks or flames near the battery area. Do not smoke. • Do not charge batteries in confined spaces. • Always disconnect the batteries before performing any type of service on the electrical system.

Hydraulic systems • Some fluid coming out from a very small port can be almost invisible and be strong enough to penetrate skin. For this reason, Never use your hands to check for leaks, but use a piece of cardboard or a piece of wood for this purpose. If any fluid is injected into the skin, seek medical aid immediately. Lack of immediate medical attention may result in serious infections or dermatitis. • Always take system pressure readings using the appropriate gauges.

Wheels and tires • Check that the tires are correctly inflated at the pressure specified by the manufacturer. Periodically check for possible damage to the rims and tires. • Stay a the tire side when inflating. • Check the pressure only when the tractor is unloaded and tires are cold to avoid wrong reading due to over- pressure. • Never cut, nor weld a rim with the inflated tire assembled. • To remove the wheels, block both front and rear tractor wheels. Raise the tractor and install safe and stable supports under the tractor in accordance with the regulations in force. • Deflate the tire before removing any object caught into the tire tread. • Never inflate tires using flammable gases as they may originate explosions and cause injuries to bystanders.

Removal and installation • Lift and handle all heavy components using lifting equipment of adequate capacity. Ensure that parts are supported by appropriate slings and hooks. Use lifting eyes provided to this purpose. Take care of the persons near the loads to be lifted.

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

Acid and alkalis See battery acids, e.g. caustic soda, sulfuric acid. Used in batteries and cleaning materials.

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

Adhesives and sealers See fire highly flammable, flammable, combustible. Generally should be stored in “No smoking” areas, cleanliness and tidiness in use should be observed. E.g. disposable paper covering benches should be dispensed from applicators where possible containers including secondary containers, should be labelled.

Solvent based adhesive / sealers See solvents. Follow manufacturer’s instructions.

Water base adhesive / sealers Those based on polymer emulsions and rubber lattices may contain small amounts of volatile toxic and harmful chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use. Follow manufacturers instructions.

Resin based adhesives / sealers E.g. Epoxide and formaldehyde resin based. Mixing should only be carried out in well ventilated areas as harmful or toxic volatile chemicals may be released. Skin contact with uncured resins and hardeners can result in irritation, dermatitis and absorption of toxic of harmful chemicals through the skin. Splashes can damage the eyes. Provide adequate ventilation and avoid skin and eye contact. Follow manufacturers’ instructions.

Anaerobic, cyanoacrylate and other acrylic adhesives Many are irritant, sensitizing or harmful to the skin. Some are eye irritants. Skin and eye contact should be avoided and the manufacturers’ instructions followed. Cyanaocrylate adhesives (super-glues) must not contact the skin or eyes. If skin or eye tissue is bonded cover with a clean moist pad and get medical attention. Do not attempt to pull tissue apart. Use in well ventilated areas as vapors can cause irritation of the nose and eyes. For two-pack systems see resin based adhesives / sealers.

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

Antifreeze See fire, solvents e.g. isopropanol, ethylene glycol, menthol. Highly flammable, flammable, combustible. Used in vehicle cooling systems, brake air pressure systems, screen wash solutions. vapors given off from coolant antifreeze (glycol) arise only when heated. Antifreeze may be absorbed through skin in toxic or harmful quantities. Antifreeze if swallowed is fatal and medical attention must be found immediately.

Arc welding See welding.

Battery acids See acids and alkalis. Gases released during charging are explosive. Never use naked flames or allow sparks near charging or recently charged batteries.

Brake and clutch fluids (polyalkylene glycols) See fire combustible. Splashes to the skin and eyes are slightly irritating. Avoid skin and eye contact as far as possible. Inhalation of vapor hazards do not arise at ambient temperatures because of the very low vapor pressure.

Brazing See welding.

Chemical materials - general See legal aspects. Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids, antifreeze, brake fluids, oils and grease should always be used with caution and stored and handled with care. They may be toxic, harmful, corrosive irritant or highly inflammable and give rise to hazardous fumes and dusts. The effects of excessive exposure to chemicals may be immediate or delayed, briefly experienced or permanent, cumulative, superficial, life threatening or may reduce life expectancy.

Doâ&#x20AC;&#x2122;s Do remove chemical materials from the skin and clothing as soon as practicable after soiling. Change heavily soiled clothing and have it cleaned. Do carefully read and observe hazard and precaution warning given on material containers (labels) and in any accompanying leaflets, poster or other instructions. Material health and safety data sheets can be obtained from manufacturersâ&#x20AC;&#x2122;.

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Do organise work practices and protective clothing to avoid soling of the skin and eyes, breathing vapors / aerosols / dusts / fumes, inadequate container labelling; fire and explosion hazards. Do wash before job breaks, before eating, smoking, drinking or using toilet facilities when handling chemical materials. Do keep work areas clean, uncluttered and free of spills. Do store according to national and local regulations. Do keep chemical materials out of reach of children.

Do not’s Do not mix chemical materials except under the manufacturers’ instructions. Some chemicals can form other toxic or harmful chemicals give off toxic or harmful fumes be explosive when mixed together. Do not spray chemical materials, particular those based on solvents, in confined spaces. E.g. When people are inside a vehicle. Do not apply heat or flame to chemical materials except under the manufacturers’ instructions. Some are highly inflammable and some may release toxic or harmful fumes. Do not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations. Some fumes are heavier than air and will accumulate in confined areas, pits etc. Do not transfer chemical materials to unlabeled containers. Do not clean hands or clothing with chemical materials. Chemicals, particularly solvents and fuels will dry the skin and may cause irritation with dermatitis. Some can be absorbed through the skin in toxic or harmful quantities. Do not use emptied containers for other materials, except when they have been cleaned under supervised conditions. Do not sniff or smell chemical materials. Brief exposure to high concentrations of fumes can be toxic or harmful.

Clutch fluids See brake and clutch fluids.

Clutch linings and pads See brake and clutch linings and pads.

Corrosion protection materials See solvents, fire. Highly flammable, flammable. These materials are varied and the manufactures’ instructions should be followed. They may contain solvents, resins, petroleum products etc. skin and eye contact should be avoided. They should only be sprayed in conditions of adequate ventilation and not in confined spaces.

Cutting See welding.

De-waxing See solvents and fuels (kerosene).

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

Electric shocks Electric shocks can result from the use of the faulty electrical equipment or from the misuse of equipment even in good condition. Ensure that electrical equipment is maintained in good condition and frequently tested. Ensure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise damaged. Ensure that electric equipment is protected by the correct rated fuse. Never misuse electrical equipment and never use equipment which is in anyway faulty. The results could be fatal. Use reduced voltage equipment where possible in preference to electrical equipment. In cases of electrocution: • Switch off electricity before approaching victim • If this is not possible, push or drag victim from source of electricity using dry non-conductive material • Commence resuscitation if trained to do so • Summon medical assistance

Exhaust fumes These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides, nitrogen oxides, aldehydes, lead and aromatic hydrocarbons. Engines should only be run under conditions of adequate extraction or general ventilator and not in confined spaces.

Gasoline (petrol) engine There may not be adequate warning properties of odour or irritation before immediate and delayed toxic or harmful effects arise.

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

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

Fire See welding, foams, legal aspects. Many of the materials found on or associated with the repair of vehicles are highly inflammable. Some give off toxic or harmful fumes if burnt.

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Observe strict fire safety when storing and handling flammable materials or solvents, particularly near electrical equipment or welding processes. Ensure before using electrical or welding equipment but that there is no fire hazard present. Have suitable fire extinguisher available when using welding or heating equipment.

First aid Apart from meeting any legal requirements its i desirable for someone in the workshop to be trained in first aid procedures. Splashes in the eye should be flushed with clean water for at least 10 min. Soiled skin should be washed with soap and water. Inhalation affected individuals should be removed to fresh air immediately. If swallowed or if effects persist consult a doctor with information (label) on material used. Do not induce vomiting (unless indicated by manufacturer).

Foams See fire. Used in sound and noise insulation. Cured foams used in seat and trim cushioning. Follow manufacturersâ&#x20AC;&#x2122; instructions. Un reacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles. Individuals with chronic respiratory diseases, asthma, bronchial medical problems or histories of allergic diseases should not work with or near uncured materials. The components, vapors, spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmful. vapors and spray mists must not be breathed. These materials must be applied with adequate ventilation and respiratory protection. Do not remove respirator immediately after spraying, wait until vapor / mists have cleared. Burning of the uncured components and the cured foams can generate toxic and harmful fumes. Smoking, open flames or the use of electrical equipment during foaming operations and until vapors/mists have cleared should not be allowed. Any heat cutting of cured foams or partially cured foams should be conducted with extraction ventilation.

Fuels See fire, legal aspects, chemicals - general, solvents. Used as fuels and cleaning agents.

Gasoline (petrol) Highly flammable. Swallowing can result in mouth and throat irritation and absorption from the stomach can result in drowsiness and unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs, e.g. through vomiting, is a very serious hazard. Gasoline dries the skin and can cause irritation and dermatitis on prolonged or repeated contact. Liquid in the eye causes severe smarting. Motor gasoline may contain appreciable quantities of benzene, which is toxic upon inhalation and the concentrations of gasoline vapors must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache, depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of consciousness. 47866580 11/12/2015

INTRODUCTION

Ensure there is adequate ventilation when handling and using gasoline. Great care must be taken to avoid the serious consequences of inhalation in the event of vapor build up arising from spillages in confined spaces. Special precautions apply to cleaning and maintenance operations on gasoline storage tanks. Gasoline should not be used as a cleaning agent. It must not be siphoned by mouth.

Kerosene (paraffin) Used also as heating fuel, solvent and cleaning agent. Flammable. Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises if liquid aspiration into the lungs occurs. Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be slightly irritating. In normal circumstances the low volatility does not give rise to harmful vapors. Exposure to mists and vapors from kerosene at elevated temperatures should be avoided (mists may arise in de-waxing). Avoid skin and eye contact and ensure there is adequate ventilation.

Gas-oil (diesel fuel) See fuels (kerosene). Combustible. Gross or prolonged skin contact with high boiling gas oils may also cause serious skin disorders including skin cancer.

Gas cylinders See fire. Gases such as oxygen, acetylene, carbon dioxide, argon and propane are normally stored in cylinders at pressures of up to 2000 Ib/sq. in. (13,790 kn/m2) and great care should be taken in handling these cylinders to avoid mechanical damage to them or to the valve gear attached. The contents of each cylinder should be clearly identified by appropriate markings. Cylinders should be stored in well ventilated enclosures, and protected from ice and snow, or direct sunlight. Fuel gases (e.g. acetylene and propane) should not be stored in close proximity to oxygen cylinders. Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid sources of ignition. Only trained personnel should undertake work involving gas cylinders.

Gases See gas cylinders.

Gas shielded welding See welding.

Gas welding See welding.

General workshop tools and equipment It is essential that all tools and equipment are maintained in good condition and the correct safety equipment used where required. Never use tools or equipment for any purpose other than that for which they were designed. Never overload equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always immediately apparent andmay result in a fatal failurethe next time that the equipment is used.

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Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A damaged grinding wheel can disintegrate without warning and cause serious injury. Wear suitable eye protection when using grinding, chiselling or sand blasting equipment. Wear a suitable breathing mask when using sand blasting equipment, working with asbestos based materials or using spraying equipment.

Glues See adhesives and sealers.

High pressure air, lubrication and oil test equipment See lubricants and greases. Always keep high pressure equipment in good condition and regularly maintained, particularly at joints and unions. Never direct a high pressure nozzle at the skin as the fluid may penetrate to the underlying tissue etc. and cause serious injury.

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

Lubricants and greases Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated during service (e.g. routine service change sump oils) are more irritating and more likely to cause serious effects including skin cancer in the event of gross and prolonged skin contact. Wash skin thoroughly after work involving oil. Proprietary hand cleaners may be of value provided they can be removed from the skin with water. Do not use petrol, paraffin or other solvents to remove oil from the skin. Lubricants and greases may be slightly irritating to the eyes. Repeated or prolonged skin contact should be avoided by wearing protective clothing if necessary. Particular care should be taken with used oils and greases containing lead. Do not allow work clothing to be contaminated with oil. Dry clean or launder such clothing at regular intervals. Discard oil soaked shoes. Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur. Used oils may only be disposed of in accordance with local regulations. There are publications describing the problems and advising on precautionary measures.

Noise insulation materials See foams, fibre insulation.

Paints See solvents and chemical materials - general. Highly flammable, flammable.

One pack Can contain harmful or toxic pigments, driers and other components as well as solvents. Spraying should only be carried out with adequate ventilation.

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INTRODUCTION

Two pack Can also contain harmful and toxic unreacted resins and resin hardening agents. The manufacturers instructions should be followed and the on resin based adhesives, isocyanate containing adhesives and foams should be consulted. Spraying should preferably be carried out in exhausted ventilated booths removing vapor and spray mists from the breathing zone. Individuals working in booths should wear respiratory protection. Those doing small scale repair work in the open shop should wear supplied air respirators.

Paint thinners See solvents.

Petrol See fuels (gasoline).

Pressurised equipment See high pressure air, lubrication and oil test equipment.

Resistance welding See welding.

Sealers See adhesives and sealers.

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

Solvents See chemical materials- general fuels (kerosene), fire. E.g. Acetone, white spirit, toluene, xylene, trichlorethane. Used in cleaning materials, de-waxing, paints, plastics, resins, thinners etc. Highly Inflammable, flammable. Skin contact will decrease the skin and may result in.irritation and dematitis following repeated or prolonged contact. Some can be absorbed through the skin in toxic or harmful quantities. Splashes in the eye may cause severe irritation and could lead to loss of vision. 47866580 11/12/2015

INTRODUCTION

Brief exposure to high concentrations of vapors or mists will cause eye and throat irritation, drowsiness, dizziness, headaches and in the worst circumstances, unconsciousness. Repeated or prolonged exposures to excessive but lower concentrations of vapors or mists, for which theremight not be adequatewarning indications, can cause more serious toxic or harmful effects. Aspiration into the lungs (e.g. through vomiting) is the most serious consequence of swallowing. Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary. Ensure good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers tightly sealed. Do not use in confined spaces. When the spraying material contains solvents, e.g. paints, adhesives, coatings, use extraction ventilation or personal respiratory protection in the absence of adequate general ventilation. Do not apply heat or flame except under specific and detailed manufacturers instructions.

Sound insulation See fibre insulation, foams.

Spot welding See welding.

Suspended loads There is always a danger when loads are lifted or suspended. Never work under an unsupported suspended or raised load, e.g. jacked up vehicle, suspended engine, etc. Always ensure that lifting equipment such as jacks, hoists, axle stands, slings, etc. are adequate and suitable for the job, in good condition and regularly maintained. Never improvise lifting tackle.

Underseal See corrosion protection.

Welding See fire, electric shock, gas cylinders. Welding processes include resistance welding (spot welding), arc welding and gas welding.

Resistance welding This process may cause particles of molten metal to be emitted at high velocity and the eyes and skin must be protected.

Arc welding This process emits a high level of ultraviolet radiation which may cause eye and skin burns to the welder and to other persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal protection must be worn, and screens used to shield other people. Metal spatter will also occur and appropriate eye and skin protection is necessary. The heat of the welding arc will produce fumes and gases from the metals being welded and from any applied coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation should always be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary,

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INTRODUCTION

particularly in cases where the general ventilation is poor, or where considerable welding work is anticipated. In extreme cases where adequate ventilation cannot be provided, supplied air respirators may be necessary.

Gas welding Oxy-acetylene torches may be used for welding and cutting and special care must be taken to prevent leakage of these gases, with consequent risk of fire and explosion. The process will produce metal spatter and eye and skin protection is necessary. The flame is bright and eye protection should be used, but the ultra-violet emission is much less than that from arc welding, and lighter filters may be used. The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work, particularly during cutting away of damaged body parts and inhalation of the fumes should be avoided. In brazing, toxic fumes may be evolved from the metals in the brazing rod, and a severe hazard may arise if brazing rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert advice may be required. Special precautions must be taken before any welding or cutting takes place on vessels which have contained combustible materials, e.g. boiling or steaming out of fuel tanks.

White spirit See solvents.

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SERVICE MANUAL Engine TT4.80 TT4.90

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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 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 [10.310] Aftercooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

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Engine - 10 Engine and crankcase - 001

TT4.80 TT4.90

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Contents Engine - 10 Engine and crankcase - 001

TECHNICAL DATA Engine General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Crankcase General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Engine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Engine Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

DIAGNOSTIC Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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Engine - Engine and crankcase

Engine - General specification General specifications Make Type Power Number of cylinders Bore Stroke Cubic capacity Compression ratio Firing order Idle speed Maximum no load speed Rated speed

TT4.80

TT4.90

IVECO 4 stroke, diesel, naturally aspirated, direct injection, water cooled 80 Hp 88 Hp 4 104.000 mm (4.094 in) 115.000 mm (4.528 in) 3908 cm³ (238 in³) 18:1 1-3-4-2 650 RPM +/- 50 2550 RPM +/- 50 2300 RPM

Engine block Cylinder liner seat diameter in engine block Cylinder sleeve O.D Interference between liners and seats in block Liner O.D oversize Cylinder liner inner diameter Maximum ovality and taper due to wear Liner inner diameter oversize

106.850 – 106.900 mm (4.207 – 4.209 in) 107.020 – 107.050 mm (4.213 – 4.215 in) 0.120 – 0.200 mm (0.005 – 0.008 in) 0.200 mm (0.008 in) 104.00 – 104.024 mm (4.09 – 4.095 in) 0.120 mm (0.005 in) 0.400 – 0.800 mm (0.016 – 0.031 in)

Camshaft bush seat diameters 54.780 – 54.805 mm (2.157 – 2.158 in) 54.280 – 54.305 mm (2.137 – 2.138 in) 53.780 – 53.805 mm (2.117 – 2.118 in) 15.000 – 15.018 mm (0.591 – 0.591 in) 0.100 mm (0.004 in) – 0.200 mm (0.008 in) – 0.300 mm (0.012 in) 84.200 – 84.230 mm (3.315 – 3.316 in)

• Front • Intermediate • Rear Tappet seat bore diameter Tappet oversize Main bearing seat bore diameter

Cylinder head Valve guide seat bore diameter in head Valve guide oversize Valve stand-in • Maximum stand-in permitted Injector standout • Maximum stand-out permitted Original cylinder head height Maximum head dressing allowed

13.950 – 13.983 mm (0.549 – 0.551 in) 0.200 mm (0.008 in) 0.700 – 1.000 mm (0.028 – 0.039 in) 1.300 mm (0.051 in) 0.050 – 0.700 mm (0.002 – 0.028 in) 1.000 mm (0.039 in) 92 mm (4 in) 0.500 mm (0.020 in)

Exhaust valves 37.500 – 37.750 mm (1.476 – 1.486 in) 7.985 – 8.000 mm (0.314 – 0.315 in) 45° 30’±7’ 0.300 mm (0.012 in) 5.677 mm (0.224 in) 10.060 mm (0.396 in)

Valve head diameter Valve stem diameter Face angle Stem to guide clearance (worm or cold) Cam lift Valve lift

Intake valves 43.300 – 45.500 mm (1.705 – 1.791 in) 7.985 – 8.000 mm (0.314 – 0.315 in)

Valve head diameter Valve stem diameter 47866580 11/12/2015

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Engine - Engine and crankcase

Face angle Stem to guide clearance (worm or cold) Cam lift Valve lift

60° 30’±7’ 0.300 mm (0.012 in) 5.250 mm (0.207 in) 9.310 mm (0.367 in)

Valve springs Number per valve Free length Length loaded at 26.1 – 28.9 kg (57.5 – 63.7 lb) Length loaded at 51.2 – 56.5 kg (112.9 – 124.6 lb)

1 44.600 mm (1.756 in) 34.000 mm (1.339 in) 23.800 mm (0.937 in)

Valve timing Intake opening (before top dead centre) Intake closing (after bottom dead centre) Exhaust opening (before bottom dead centre) Exhaust closing (after top dead centre)

12° 31° 50° 16°

Valve inserts Valve guide O.D Valve guide oversize Valve guide interference fit in housing cylinder head Valve guide fitted I.D after reaming Valve stem clearance in guide Maximum wear clearance Maximum valve stem eccentricity over one revolution with stylus on sealing face

13.933 – 14.016 mm (0.549 – 0.552 in) 0.200 mm (0.008 in) 0.0050 – 0.0500 mm (0.0002 – 0.0020 in) 8.023 – 8.043 mm (0.316 – 0.317 in) 0.0230 – 0.0580 mm (0.0009 – 0.0023 in) 0.130 mm (0.005 in) 0.030 mm (0.001 in)

Engine - Special tools Sr .No

Special Tool Description Engine stand with support Nozzel tester Sling hook engine Adopter for slide hammer Tappet adjusting screw driver Angular torquing gauge Remover, filters Eng. oil pressure gauge with adapter Remover, FI pump nut Wrench to remove solenoid switch Compression gauge Dummy injector (Turbo Engine)

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Special Tool Number 380000301 380000215 380000216 380000541 380000232 380000304 380200593 380200591 380200594 380200595 380200596 380200334

Engine - Engine and crankcase

Crankcase - General specification Crank gear Crankshaft - bearings Main journal diameter Main journal undersize Main bearing wall thickness Main bearing undersize Main journal clearance in bearings • Maximum wear clearance Crankpin diameter Crankpin undersize Big end bearing wall thickness Big end bearing undersize Crankpin clearance in big end bearing • Maximum wear clearance Crankshaft thrust washer thickness Thrust washer oversize Width of main bearing housing over thrust washers Length of corresponding main journal Crankshaft end float • Maximum wear clearance Maximum main journal and crankpin ovality or taper after grinding Maximum main journal and crankpin ovality or taper due to wear Maximum main journal misalignment crankshaft resting on end journals Maximum misalignment of crankpins relative to main journals (in either direction) Tolerance from outer crankpin edge to crankshaft center line Maximum crankshaft flange run-out with gauge stylu, over 108.000 mm (4.252 in) diameter (total gauge reading) Maximum flywheel seat eccentricity relative to main journals (total gauge reading)

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79.791 – 79.810 mm (3.141 – 3.142 in) 0.254 mm (0.010 in) – 0.508 mm (0.020 in) – 0.762 mm (0.030 in) – 1.016 mm (0.040 in) 2.168 – 2.178 mm (0.085 – 0.086 in) 0.254 mm (0.010 in) – 0.508 mm (0.020 in) – 0.762 mm (0.030 in) – 1.016 mm (0.040 in) 0.034 – 0.103 mm (0.001 – 0.004 in) 0.180 mm (0.007 in) 63.725 – 63.744 mm (2.509 – 2.510 in) 0.254 mm (0.010 in) – 0.508 mm (0.020 in) – 0.762 mm (0.030 in) – 1.016 mm (0.040 in) 1.805 – 1.815 mm (0.071 – 0.071 in) 0.254 mm (0.010 in) – 0.508 mm (0.020 in) – 0.762 mm (0.030 in) – 1.016 mm (0.040 in) 0.033 – 0.087 mm (0.001 – 0.003 in) 0.180 mm (0.007 in) 3.378 – 3.429 mm (0.133 – 0.135 in) 0.127 mm (0.005 in) – 0.254 mm (0.508 in) – 0.508 mm (0.020 in) 31.766 – 31.918 mm (1.251 – 1.257 in) 32.000 – 32.100 mm (1.260 – 1.264 in) 0.082 – 0.334 mm (0.003 – 0.013 in) 0.400 mm (0.016 in) 0.0100 mm (0.0004 in) 0.0500 mm (0.0020 in) 0.0100 mm (0.00039 in) 0.2500 mm (0.00984 in) ± 0.1000 mm (0.0039 in) 0.0250 mm (0.0010 in) 0.0400 mm (0.0016 in)

Engine - Engine and crankcase

Connecting rods Small end bore diameter Small end bushing outer diameter Bushing interference fit in small end Small end bushing fitted ID Big end bore diameter Maximum connecting rod axis misalignment at 125.000 mm (4.921 in) Maximum connecting rod weight difference over a complete set from the same engine

41.846 – 41.884 mm (1.647 – 1.649 in) 41.979 – 42.017 mm (1.647 – 1.649 in) 0.0950 – 0.1710 mm (0.0037 – 0.0067 in) 38.004 – 38.014 mm (1.496 – 1.497 in) 67.407 – 67.422 mm (2.654 – 2.654 in) ± 0.0700 mm (0.0028 in) 25.00 g (0.88 oz)

Pistons Piston diameter (Measured at 57.000 mm (2.244 in) from base of skirt and right angles to pin) Piston clearance in liner • Maximum wear clearance Piston oversize range Piston stand-out with respect to head at TDC Piston pin diameter Piston pin seat bore in piston Piston pin clearance in piston Piston pin clearance in small end bushing • Maximum wear clearance Maximum weight difference between pistons on same engine Piston ring clearance in groove • Top • 2nd • 3rd Maximum wear clearance • Top • 2nd and 3rd Piston ring gap • Top • 2nd • 3rd Maximum wear gap

103.852 – 103.870 mm (4.089 – 4.089 in) 0.174 – 0.212 mm (0.007 – 0.008 in) 0.300 mm (0.012 in) 0.400 – 0.800 mm (0.016 – 0.031 in) 0.430 – 0.840 mm (0.017 – 0.033 in) 37.983 – 37.990 mm (1.495 – 1.496 in) 38.000 – 38.006 mm (1.496 – 1.496 in) 0.0100 – 0.0230 mm (0.0004 – 0.0009 in) 0.0140 – 0.0310 mm (0.0006 – 0.0012 in) 0.060 mm (0.002 in) 20.00 g (0.71 oz) 0.0900 – 0.1220 mm (0.0035 – 0.0048 in) 0.0600 – 0.0850 mm (0.0024 – 0.0033 in) 0.0400 – 0.0750 mm (0.0016 – 0.0030 in) 0.500 mm (0.020 in) 0.200 mm (0.008 in) 0.400 – 0.650 mm (0.016 – 0.026 in) 0.300 – 0.550 mm (0.012 – 0.022 in) 0.300 – 0.600 mm (0.012 – 0.024 in) 1.200 mm (0.047 in)

Dynamic balancer Idler gear jack shaft clearance in gear bushing * Flyweight gear shaft clearance in front bushing * Drive pinion clearance in bushings * Connecting sleeve spine, Power Take-Off (PTO) gear connection and flyweight drive gear backlash Flyweight gear shaft clearance in rear bushing ** Pivot clearance in flyweight bushings Flyweight bushing interference fit in housing Idler gear jack shaft clearance in bushing **

0.050 – 0.100 mm (0.002 – 0.004 in) 0.050 – 0.100 mm (0.002 – 0.004 in) 0.050 – 0.100 mm (0.002 – 0.004 in) 0.038 – 0.106 mm (0.001 – 0.004 in) 0.013 – 0.061 mm (0.001 – 0.002 in) 0.020 – 0.073 mm (0.001 – 0.003 in) 0.040 – 0.100 mm (0.002 – 0.004 in) 0.013 – 0.061 mm (0.001 – 0.002 in)

* Bushing interference fit in housing: 0.063 – 0.140 mm (0.002 – 0.006 in) ** Bushing interference fit in housing: 0.037 – 0.101 mm (0.001 – 0.004 in)

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Engine - Overview The engines are with 4 cylinders with turbo charger. Both engines feature cross flow cylinder heads, with the inlet and exhaust manifolds on opposite sides of the cylinder head. The fuel and air combustion process, takes place in the specially designed bowel in the crown of the pistons.

Cylinder head assembly The cylinder head incorporates valves and springs, with the valve rocker arm shaft assembly bolted to the cylinder block through the cylinder head. Cylinder head retaining bolts are evenly spaced with a six- point pattern around each cylinder, this ensures an even clamping load across the cylinder head. The intake and exhaust manifolds are bolted to the head. The intake manifold is mounted on the right-hand side of the engine, with the diesel injectors mounted outside the rocker cover. The exhaust manifold is mounted on the left side of the engine. Water outlet connections and thermostat being attached to the front of the cylinder block directly behind the radiator. Valve guides are inserted into the cylinder head, and replaceable. Special replaceable cast alloy valve seats are pressed into each valve port during manufacturing. No over size valve seats on guides are available. All valves are fitted with positive value rotators, valve clearance is maintained by adjustment of the self locking adjusting screw, mounted in each of the rocker arms.

Camshaft assembly The camshaft runs in 3 replaceable bushes. The camshaft drive gear is in mesh with and driven by the camshaft idler gear which is driven by the crankshaft timing gear. Camshaft end thrust is controlled by a thrust plate bolted to the block, and located between the camshaft gear and the front camshaft journal. A helical gear is integral on rear of cam shaft, and drives the engine oil lubrication pump mounted forward of the flywheel.

Cylinder block assembly The cylinder block is an alloy cast iron with deep cylinder skirts and water jackets for cooling the cylinders. The cylinder bores are machined integral with the cylinder block, during the manufacturing process. Cylinders are in line and vertical and numbered from 1 to 4 from front of the engine to the rear. The oil sump, which is attached to the bottom of the cylinder block, is the reservoir for the engine oil lubrication system. A cast iron engine front cover and front plate is attached to the front of the engine and covers all of the timing gear assembly.

Crankshaft assembly The crankshaft is supported in the cylinder block by 5 main bearings. The crankshaft is manufactured from steel with machined finished crank webs. End thrust is controlled by a thrust bearing incorporated in the second main bearing from flywheel side in engine. A dynamic balancer is fitted and driven by crankshaft to ensure smooth running operation. Front and rear crankshaft oil sealing is effected by one piece seals that are designed for long and durable service life.

Connecting rods Connecting rods â&#x20AC;&#x153;Wedgeâ&#x20AC;? shaped at the small end has 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.

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Engine - Engine and crankcase

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.

Pistons Pistons are constructed of an aluminium silicon alloy with notch type combustion chamber being recessed in to the piston crowns. Each piston has two compression rings and one oil control ring, to reduce the friction and increase positive seating. All rings are located above the piston pin.

Manifolds The cross flow design aluminium intake, and cast iron exhaust manifolds are on opposite sides of the cylinder head. This is designed to maintain balanced heat distribution within the cylinder head. The configuration of the manifolds also ensures minimum heat transfer to the intake manifold. The intake manifold is connected through hose to air cleaner.

GNIL15TR01500FA

Timing gears The crankshaft timing gear is heated and press fitted on to the front of the crankshaft, to a high degree of accuracy during manufacturing. This enables precise timing being maintained during the life of the engine. The crankshaft gear 47866580 11/12/2015

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Engine - Engine and crankcase

drives the idler gear, which is attached to the front of cylinder block. The idler gear then drives the camshaft and the injection pump via meshing helical gears. The camshaft gear is bolted to the front of the shaft and is keyed to maintain position of the gear on the camshaft.

Lubrication system Lubrication of the engine 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 viewing 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. This is located vertically above number 3 camshaft bearing and aligns to a hole in the cylinder head. The rotation of the camshaft allows a controlled intermediate flow of lubrication.

NDIL14TR00210FB

F. P. C. Vf. L.

Filter Pump Turbocharger Filter relief valve Dipstick

G. S. T. B.

Oil pressure sensor Suction filter Oil filter cap Breather cap

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Cooling system 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 correct engine temperature, and performance, during vehicle operation. The pump is driven by a â&#x20AC;&#x2DC;Vâ&#x20AC;&#x2122; belt from the crankshaft pulley, when the engine is running. The cooling system for the new generation of engines, is of recirculating by-pass type with full length water-jackets for the bottom tank of the radiator by the water pump, which passes 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 in the top of the water pump body, and controls the flow of the water as required by temperature changes. NOTE: A faulty thermostat may cause the engine to operate at too high (hot) or low (cold) on operating 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 an 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.

GNIL15TR01501FA

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Engine - Service instruction In the following procedures and illustrations the engine in the main is shown removed from the tractor. However there are certain operations that can performed with the engine still in the tractor, or separated at the connection to the front axle support, or separated from the transmission housing. The engine overhaul procedure initially describes the assembly process for rebuilding an engine using all new components. Following this section are defined headings, which describe detailed repair specifications and procedures, where components are suitable for re-use. Where overhaul of components is required without engine being removed from the tractor refer to the following headings, and the relevant paragraphs, in the main overhaul procedure. Operations or repairs that can be performed with the engine still in the tractor. 1.

Cylinder head and associated inlet and exhaust components.

Fuel injection pump and related parts.

Water pump, thermostat, and associated components.

Front timing cover/timing gear removal.

Front pulley.

Operations or repair that are performed with the engine separated from the front axle. • Oil pan removal for access to oil pan gasket, crankshaft, bearing shells, piston removal and oil pump. Operations or repairs that are performed with the engine separated from the transmission housing, and with oil pan removed. • Crankshaft rear oil seal and carrier removal. Dismantle the engine by referring to the following removal procedure. Refer to the specification section as necessary. NOTE: All gaskets, seals and O-rings must be replaced while reassembling. Where new sealant is to be applied refer to “Engine Specifications”.

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Engine - Engine and crankcase

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

1. If installed, remove the ballast. 2. Remove the battery. (55.302).

See the Battery - Remove

3. Remove the front hood. See the Hood - Remove â&#x20AC;&#x201C; Front hood (90.100). 4. Remove the side covers. See the Hood - Remove (90.100). 5. Disconnect the electrical harness. 6. Remove the water separator. See the Fuel-water separator filter - Remove (10.206). 7. Disconnect the Fuel Injection Pump (FIP) lines. See the Injection pump - Remove (10.218). 8. Disconnect the steering control hoses. See the Steering control - Disconnect (41.101). 9. Disconnect the hydraulic hoses. See the Pump - Remove (35.104). 10. Remove the exhaust muffler. See the Exhaust muffler - Remove (10.254). 11. Use wedge (1) between the axle and front axle support to prevent articulation. 12. Support front axle with a movable jack and rail and immovable screw jack below engine frame.

NDIL14TR00033AB

GNIL15TR00491AB

13. Remove the buckle up bolts (1) between engine and master clutch housing. Pull the engine away using moving rail jack.

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

1. Disconnect the radiator and turbocharger inlet and outlet hoses. See the Radiator - Remove (10.400). 2. Connect the engine to a suitable hoist.

GNIL15TR00777AB

GNIL15TR00778AB

NDIL14TR00042AA

3. Remove the buckle up bolts (1) coupling engine and front axle support. Separate it from the front axle.

4. Remove the engine from front axle carefully. Mount it on engine stand 380000301.

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Engine - Install 1. Insert and tighten the buckle up bolts (1) between engine and master clutch housing.

GNIL15TR00491AB

NDIL14TR00033AB

2. Support front axle with a movable jack and rail and immovable screw jack below engine frame. 3. Use wedge (1) between the axle and front axle support to prevent articulation.

4. Install the exhaust muffler. See the Exhaust muffler Install (10.254). 5. Connect the hydraulic hoses. See the Pump - Install (35.104). 6. Connect the steering control hoses. See the Steering control - Connect (41.101). 7. Connect the Fuel Injection Pump (FIP) lines. See the Injection pump - Install (10.218) 8. Install the water separator. See the Fuel-water separator filter - Install (10.206). 9. Connect the electrical harnesses. 10. Install the side covers. (90.100).

See the Hood - Install

11. Connect the battery negative cable. See the Battery - Install (55.302).

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Engine - Engine and crankcase

Reinstall the engine on tractor by observing the following: 1.

Apply thread sealant at the required places.

Before coupling engine and transmission housing, clean and decrease the mating surfaces thoroughly and apply a strip of sealing compound of about 2.00 mm (0.08 in) diameter as shown in the figure.

Due care should be taken in aligning input shaft with clutch plates and pilot bearing as to avoid damage to input shaft and hearing.

Apply the torque setting listed in tightening torque table.

Before starting all the fluid levels should be correct. Start and run the engine until oil and coolant temperature reaches to operating temperature and check for leaks and rectify if required and recheck fluid levels.

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GNIL15TR00780AB

Engine - Engine and crankcase

Engine - Disassemble NOTE: In case, replacement of parts is not required make and identification mark to keep the parts in a numbered rack to assemble parts back in the original order. 1. Remove the turbocharger. See the Turbocharger Remove (10.250). 2. Remove the exhaust manifold. See the Exhaust manifold - Remove (10.254) 3. Remove the alternator. See the Alternator - Remove (55.301). 4. Remove the oil cooler. See the Engine cooling system - Remove â&#x20AC;&#x201C; Oil cooler (10.400). 5. Remove the fuse box. See the Fuse and relay box Remove (55.100). 6. Remove the fuel filter. See the Fuel filters - Remove (10.206).

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Engine - Assemble 1. Install the fuel filter. (10.206).

See the Fuel filters - Install

2. Install the fuse box. See the Fuse and relay box Install (55.100) 3. Install the oil cooler. See the Engine cooling system - Install â&#x20AC;&#x201C; Oil cooler (10.400). 4. Install the alternator. (55.301).

See the Alternator - Install

5. Install the exhaust manifold. See the Exhaust manifold - Install (10.254) 6. Install the turbocharger. See the Turbocharger - Install (10.250).

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Engine - Troubleshooting Problem Possible Cause Engine does not develop Clogged air cleaner full power Fuel line obstructed Faulty injectors Incorrect valve clearance adjustment Burnt, worn or sticking valves Blown head gasket Incorrect fuel delivery Low cylinder compression Oil pressure warning light Bulb burnt out fails to operate Warning Light pressure switch faulty Warning light circuit faulty Excessive exhaust smoke Exhaust leak on exhaust manifold Air cleaner dirty or restricted Excessive fuel delivery Engine Knocks Diluted or thin oil

Engine overheats

Correction Clean or renew element Clean Clean and reset Check and reset Replace valves with new or oversize, and/or machine the valve guide bores Check head flatness and fit new gasket Check injectors and pump Renew piston rings or bore/ re‐sleeve as necessary Renew bulb

Renew pressure switch Check and renew wiring Fit new gasket Clean Overall injection pump and injectors Check crankshaft bearings for damage, change as required. Drain and refill with specified oil and renew filter Insufficient oil supply Check oil level and top up as necessary. Overhaul or renew pump as necessary. Check oil filter is not clogged Low oil pressure Overhaul pump or relief valve as necessary. Install new thrust bearing liner Excessive crankshaft end play Flywheel or ring gear excessive run—out. Skim flywheel or fit new ring gear Bent or twisted connecting rods Renew connecting rods Excessive piston‐to‐ cylinder Re‐bore/re‐sleeve block and fit i bore clearance new pistons Excessive piston ring clearance Fit new pistons and rings Broken rings Fit new rings, check bore and pistons for damage Excessive piston pin clearance Fit new piston or pin Piston pin retainer loose or missing Install new retainer, and check bore/pistons for damage Install new thrust plate Excessive camshaft play Renew timing gear Imperfections on timing gear teeth Excessive timing gear backlash Check and adjust backlash / renew timing gear Hose connection leaking or collapsed Tighten hose connection, renew hose if damaged Renew radiator cap Radiator cap defective or not sealing Radiator leakage. Repair/renew radiator Improper fan belt adjustment Re‐adjust fan belt Radiator fins restricted Clean with compressed air Faulty thermostat Renew thermostat Internal engine leakage Check for source of leakage, renew gasket or defective parts Water pump faulty Overhaul water pump Exhaust gas leakage into cooling Renew cylinder head gasket Tighten all connections and check coolant Coolant aeration level is correct. Ensure cylinder head gasket has not blown Cylinder head gasket improperly installed Renew cylinder head gasket installed Hot spot due to rust and scale or clogged Reverse flush entire clogged water water jackets 47866580 11/12/2015

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Engine - Engine and crankcase

Problem

Possible Cause Obstruction to radiator air flow Extended engine idling Oil cooler tube blocked Radiator core tubes blocked Water temperature gauge Faulty temperature sender fails to reach normal operating temperature Incorrect or faulty thermostat Faulty water temperature gauge Low oil pressure Engine oil level low Wrong grade of oil Blocked oil pump sump screen Oil pressure relief valve faulty Oil pump worn Excessive oil pump rotor and shaft assembly clearance Excessive main or connecting

Excessive oil consumption

Engine oil level too high External oil leaks Worn valves, valve guides or bores Cylinder head gasket leaking Oil loss past the pistons and rings

Oil cooler leak Engine tends to keep Air cleaner dirty or choked. firing after fuel is shut off Excessive exhaust smoke Exhaust leak in exhaust manifold Air cleaner dirty or choked Excessive fuel delivery

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Correction Remove the obstruction Do not allow engine to idle for long periods Clean Check free flow Renew sender switch

Renew thermostat Renew temperature gauge Top up, as necessary Drain and refill with correct grade of oil Clean pump screen Fit new relief valve Renew oil pump Overhaul pump Install new bearings inserts and bearing clearance or reâ&#x20AC;?grind crankshaft if necessary Reduce oil level Renew gaskets and seals, where necessary. Check mating surfaces for damage or distortion Renew Renew gasket. Check head for damage or distortion Renew rings and/or re-bore/ reâ&#x20AC;?sleeve block as necessary Repair/renew oil cooler assembly Clean or renew element Fit new gasket Clean Overall injection pump and injectors

Index Engine - 10 Engine and crankcase - 001 Crankcase - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Pan and covers - 102

TT4.80 TT4.90

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Contents Engine - 10 Pan and covers - 102

SERVICE Engine oil pan Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Engine block cover Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Timing gear housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Engine - Pan and covers

Engine oil pan - Remove WARNING Due to the weight of the oil sump, it is recommended that a hydraulic jack is used to support and lower the oil sump to the ground. NOTE: It is necessary to move the front support forward a couple of inches to allow removal of the oil sump. Refer to engine removal at beginning of this section. 1. Drain engine oil through oil sump plug and remove oil level indicator. 2. Remove oil sump bolts including those through the timing cover and lower to ground.

NDIL14TR00117AA

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Engine oil pan - Inspect Clean gasket material from sump face, clean sump in a suitable solvent, inspect sump for cracks damaged threads or sump face.

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Engine - Pan and covers

Engine oil pan - Install 1. Install the oil sump bolts including those through the timing cover and lower to ground. 2. Ensure block face is clear and free of gasket material. 3. Install a new gasket to the oil sump. 4. Position the oil sump and install a bolt at each corner finger tight to hold in position, install remaining bolts and tighten to specified torque.

NDIL14TR00117AA

5. Ensure block face is clear and free of gasket material. Install a new gasket to the oil sump. 6. Position the oil sump and install a bolt at each corner finger tight to hold in position, install remaining bolts and tighten to specified torque.

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Engine - Pan and covers

Engine block cover - Overhaul 1. Remove the cylinder head and timing cover with gears from the engine. (See the Cylinder heads - Remove (10.101) ). 2. Dismantle the engine block. (See the Engine - Disassemble (10.001) ).

NDIL14TR00135AA

NDIL14TR00136AA

NDIL14TR00137AB

3. Repair and inspection of cylinder bore :• 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. • Check the seating surface of the cylinder head for unevenness by means of a calibrated ruler and a feeler gauge. Surface-grind the sealing surface by means of a grinding machine, removing as little material as possible after determination of the unevenness. NOTE: Pull out the center ring pin, only if sealing surface must be surface ground. • Check the cylinder bore for scuffing or rings around the ring frame area. Irregularities can be felt by running a finger over the surface. To check out-ofroundness, wear, or taper, use a telescopic gauge or dial bore gauge.

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• After removal of the old sleeves, the parent bore must be thoroughly cleaned both in the top recess off the sleeve flange and in the parent bore itself. • A check must be made to ensure that the whole areas of contact with the sleeves in the cylinder block are free from burrs, corrosion or damage. Remove any burrs present. • Check engine block bore ovality and if necessary restore to 106.850 – 106.900 mm (4.207 – 4.209 in). • Check if cylinder liner outer diameter is 107.020 – 107.050 mm (4.213 – 4.215 in). NOTE: The cylinder liners are delivered as spare parts with an over dimension outer diameter of 0.2 mm. 4. Ensure that the sleeve is thoroughly clean before fitting. If cleaning fluid is used to wash the sleeve, it is important that the sleeve be thoroughly dried and well oiled before fitting. 5. Throughout the whole operation, extreme cleanliness is essential as the entry of the smallest particle or other foreign matter is sufficient to cause local distortion of the sleeve bore. Lubricate the outside diameter of the sleeves with clean oil using spray. The use of brush is not recommended. 6. Inspect the dynamic balancer (Please refer the engine disassembly section). 7. Repair and inspection of connecting rods, bearings, pistons and rings. 8. Clean the piston, and connecting rod assembly, in a suitable solvent and inspect for damage to ring lands, skirts, or pin bosses. 9. Check connecting rod components for damage, and place in the test mandrel to check for distortion, and ensure that any distortion, is within specifications.

Removal of sleeves NOTE: Engines are supplied with initially no sleeves. However for engine overhauling, new sleeves have to be fitted. Press or draw the sleeves out through the top of the cylinder block ensuring no damage is done to the parent bores (cast iron production sleeves are an interference fit and it should be removed with a heavy duty press). NOTICE: For sleeve removal and Installation, do not heat sleeves, use a press.

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NDIL14TR00138AB

Engine - Pan and covers

Installation of new sleeves 1. Preparation for fitting new sleeves: • After removal of the old sleeves, the parent bore must be thoroughly cleaned both in the top recess off the sleeve flange and in the parent bore itself. • A check must be made to ensure that the whole areas of contact with the sleeves in the cylinder block are free from burrs, corrosion or damage. Remove any burrs present. • Check engine block bore ovality and if necessary restore to 106.850 – 106.900 mm (4.207 – 4.209 in). • Check if cylinder liner outer diameter is 107.020 – 107.050 mm (4.213 – 4.215 in). NOTE: The cylinder liners are delivered as spare parts with an over dimension outer diameter of 0.200 mm (0.008 in). • Ensure that the sleeve is thoroughly clean before fitting. If cleaning fluid is used to wash the sleeve, it is important that the sleeve be thoroughly dried and well oiled before fitting. • Throughout the whole operation, extreme cleanliness is essential as the entry of the smallest particle or other foreign matter is sufficient to cause local distortion of the sleeve bore. 2. Lubricate the outside diameter of the sleeves with clean oil using spray. The use of brush is not recommended. 3. Press a new sleeve ( 0.200 mm (0.008 in) oversize if necessary) from the top of the block as below. • Set the liner on the crankcase and start force fitting. After force fitting 70.000 – 90.000 mm (2.756 – 3.543 in). Check that the load is higher than 5000 N (1124 lb) and lower than 23000 N (5171 lb). Continue force fitting stop for 5 min with a setting load of above 50000 N (11240 lb). • Ensure contact between edge and crank case with a settling blow. After inserting, the liners must be bored and surface-ground. 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. Skim the block face, and top of sleeves to achieve required flatness. 5. A chamfer in the internal diameter at the top of sleeve to 30 °, 0.500 mm (0.020 in) should be maintained, to prevent piston damage on re-assembly.

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Engine - Pan and covers

Timing gear housing - Remove Engine front cover and timing gear removal NOTE: Timing cover and gears can only be serviced after removing the radiator. 1. Remove the aftercooler. See the Aftercooler - Remove - Mechanical version (10.310). 2. Remove the power shuttle aftercooler. See the Aftercooler - Remove - Power shuttle version (10.310). 3. Remove the radiator. See the Radiator - Remove (10.400). 4. Loosen the fan mounting bolts (2) and remove the fan (1). 5. Remove the fan pulley by gently hammering with mallet or plastic hammer.

GNIL15TR01042AB

NDIL14TR00090AA

NDIL14TR00091AB

6. Loosen the dog nut and remove pulley using special tool number 380200597.

7. Loosen all the bolts (1) securing front cover and bolts (2) on oil sump. NOTE: In power steering model, connect hydraulic connections to power steering pump and remove pump before removing timing cover 8. Remove the front cover, taking care of front oil seal and oil sump gasket

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Engine - Pan and covers

Timing gear removal NOTE: The crankshaft timing gear cannot be removed without removing crankshaft from the engine. For crankshaft removal procedure 1. Before removing the timing gear use a dial indicator on feeler gauge to measure the backlash between each set of gears. 2. Rotate the gears and check the backlash at four equal points on the gears. Renew if the backlash exceeds 0.160 mm (0.006 in).

NDIL14TR00092AA

NDIL14TR00093AB

NDIL14TR00094AB

Idler gear removal 1. Remove the circlip (1) and spacer and idler gear (2) from the hub.

2. Remove the bolts (1) and remove hub from the rear cover.

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Engine - Pan and covers

Feed pump drive gear 1. Remove the nuts (1) and remove the feed pump along with supporting bracket (2) from the rear side of timing gear case.

NDIL14TR00095AB

NDIL14TR00096AB

NDIL14TR00098AA

2. Remove the circlip (1) from the feed pump drive shaft.

3. Pull out the feed pump drive shaft along with the feed pump drive gear. NOTE: Drive gear can be removed from shaft by loosening bolts.

4. Remove the bush housing from rear cover

NDIL14TR00099AA

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Engine - Pan and covers

Fuel injection pump drive gear 1. Remove the bolt (A) securing gear to Fuel injection Pump (FIP) drive shaft.

NDIL14TR00111AB

NDIL14TR00100AA

NDIL14TR00101AB

2. Remove the gear from the shaft using special tool number 380200597.

Camshaft drive gear 1. Pull out the bolts (1) retaining thrust washers (2) with rear cover. 2. Pull out the drive gear along with camshaft

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Engine - Pan and covers

Hydraulic and power steering pump drive gear removal 1. Loosen the bolts and remove the bracket (1) 2. Take-off the hydraulic pump drive gear from the rear timing gear case

NDIL14TR00102AB

NDIL14TR00103AB

Inspection and repair of gears 1. Wash the gears using a suitable solvent and examine gear teeth for wear, burrs or scratches. Minor marks can be removed using a fine abrasive, thoroughly clean before reassembly. 2. Ensure the idler gear adapter is free from obstruction and bushing is not damaged. Camshaft key and keyway should be checked for damage and repaired as required. 3. Clean the oil galleries on idler gear hub and feed pump drive gear bush housings and in rear cover using suitable solvent and pressurized air.

Camshaft Inspection and repair 1. The surfaces of the bearing journals of the shaft and cams must be completely smooth. If they have scoring and furrows, the shaft and the corresponding bushes must be replaced. 2. Clamp the camshaft (1) between centers and check cam lift by means of a dial gauge (2) for cams. Cam lifts â&#x20AC;˘ Inlet cam - 5.889 mm (0.232 in) â&#x20AC;˘ Exhaust cam - 6.127 mm (0.241 in) 3. The above value changes with tines and lobes dimensions as mentioned in engine specification sheet 4. Check the alignment of bearing journals by means of dial gauge. The offset must not exceed 0.020 mm (0.001 in).

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Engine - Pan and covers

5. Straighten the camshaft with press for distortion up to 0.200 mm (0.008 in). If distortion exceeds 0.200 mm (0.008 in), replace camshaft.

Camshaft drive gear 6. Check for the excessive wear or damage in the camshaft drive gear teeth, replace gear if necessary. 7. In order to mount the new drive gear it must be heated to 180 Â°C (356 Â°F) in the furnace for about 10 min and must be fitted in the shaft with the plate and the conical washer.

NDIL14TR00104AA

NDIL14TR00105AB

Camshaft mounting clearance 8. In order to check the mounting clearance, measure inner diameter of bushes and diameter of camshaft journals. The difference represents the actual clearance If clearance exceeds 0.160 mm (0.006 in) replace bushes and if necessary also the camshaft.

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Engine - Pan and covers

Timing gear housing - Install 1. If the rear cover was removed thoroughly clean the mating surfaces between the cover and engine block. Use a suitable solvent cleaner and apply a thin coat of grease to the engine block. Assemble the cover to the engine and tighten the retaining bolts to the specified torque. 2. Rotate the flywheel to PMS1 position before assembling timing gears.

NDIL14TR00112AB

NDIL14TR00112AA

NDIL14TR00112AB

3. Assemble the camshaft, thrust washer, flange and camshaft gear and tighten the two bolts to specified torque.

4. Install the Feed Pump Drive Gear by following the removal procedure in reverse. 5. Install the idler gear to the block. Align the timing marks 1-1, 2-2 and 3-3 to the crankshaft gear, camshaft drive gear and feed pump drive gear respectively. NOTE: Ensure that the flywheel is positioned at PMS1 mark while aligning the timing marks. 6. Install the Fuel Injection Pump (FIP) drive gear. Align mark 4-4 to the feed pump drive gear when idler gear is aligned with other gears. 7. Tighten the FIP drive gear bolt to the specified torque. 8. Install the hydraulic and power steering drive gear. Follow the removal procedure in reverse. 9. Replace new gaskets between timing cover and hydraulic and power steering pump flange before installing pump.

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Index Engine - 10 Pan and covers - 102 Engine block cover - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pan - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Valve drive and gears - 106

TT4.80 TT4.90

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Contents Engine - 10 Valve drive and gears - 106

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

SERVICE Rocker shaft Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Camshaft Adjust â&#x20AC;&#x201C; Tappets and pushrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Camshaft bushings Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - Valve drive and gears

Valve drive and gears - General specification Valve gear Valve timing gears Timing gear backlash Idler gear jack shaft diameter Idler gear bushing fitted I.D. after reaming Jack shaft journal clearance in bushing • Max wear clearance Bushing interference fit in idler gear Lift and power steering pump drive gear shaft diameter Bushing fitted I.D. after reaming Shaft clearance in bushing Bushing interference fit in housing Pump drive gear thrust washer thickness

0.160 mm (0.006 in) 36.975 – 37.000 mm (1.456 – 1.457 in) 37.050 – 37.075 mm (1.459 – 1.460 in) 0.050 – 0.100 mm (0.002 – 0.004 in) 0.150 mm (0.006 in) 0.063 – 0.140 mm (0.002 – 0.006 in) 36.975 – 37.000 mm (1.456 – 1.457 in) 37.050 – 37.075 mm (1.459 – 1.460 in) 0.050 – 0.100 mm (0.002 – 0.004 in) 0.063 – 0.140 mm (0.002 – 0.006 in) 1.450 – 1.500 mm (0.057 – 0.059 in)

Camshaft Camshaft bushing O.D. • Front • Intermediate • Rear Bushing interference fit in housing Camshaft bushing fitted I.D. after reaming • Front • Intermediate • Rear Camshaft journal diameter • Front • Intermediate • Rear Camshaft journal clearance in bushing Maximum wear clearance Camshaft end float (thrust plate to associated seat in camshaft)

54.875 – 54.930 mm (2.160 – 2.163 in) 54.375 – 54.430 mm (2.141 – 2.143 in) 53.875 – 53.930 mm (2.121 – 2.123 in) 0.070 – 0.150 mm (0.003 – 0.006 in) 51.080 – 51.130 mm (0.003 – 0.006 in) 50.580 – 50.630 mm (1.991 – 1.993 in) 50.080 – 50.130 mm (1.972 – 1.974 in) 50.970 – 51.000 mm (2.007 – 2.008 in) 50.470 – 50.500 mm (1.987 – 1.988 in) 49.970 – 50.000 mm (1.967 – 1.969 in) 0.080 – 0.160 mm (0.003 – 0.006 in) 0.200 mm (0.008 in) 0.070 – 0.220 mm (0.003 – 0.009 in)

Tappets 14.950 – 14.970 mm (0.589 – 0.589 in) 0.030 – 0.068 mm (0.001 – 0.003 in) 0.150 mm (0.006 in) 0.1000 mm (0.0039 in) 0.2000 mm (0.0079 in) 0.3000 mm (0.0118 in)

Tappet O.D. Tappet clearance in housing on engine block Maximum wear clearance Tappet oversize

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Engine - Valve drive and gears

Rockers Rocker bushing O.D. Rocker bore diameter Bushing interference fit in rocker Rocker bracket bore diameter Rocker shaft diameter Rocker shaft clearance in bracket Maximum wear clearance Rocker spacer spring length • Free • Under load ( 4.7 – 5.3 kg (10.4 – 11.7 lb))

21.006 – 21.031 mm (0.827 – 0.828 in) 20.939 – 20.972 mm (0.824 – 0.826 in) 0.034 – 0.092 mm (0.001 – 0.004 in) 18.016 – 18.034 mm (0.709 – 0.710 in) 17.982 – 18.000 mm (0.708 – 0.709 in) 0.016 – 0.052 mm (0.001 – 0.002 in) 0.150 mm (0.006 in) 59.500 mm (2.343 in) 44.00 mm (1.732 in)

Valves, guides and springs • Valve head diameter inlet • Valve head diameter exhaust • Valve stem diameter Valve face angle • Inlet • Exhaust Timing check Valve clearance: • Valve clearance inlet (warm or cold) • Valve clearance exhaust (warm or cold) Cam lift inlet Cam lift exhaust Valve lift Inlet Valve lift exhaust Valve guide O.D. Valve guide oversize Valve guide interference fit in housing on cylinder head Valve guide fitted I.D. after reaming Valve stem clearance in guide • Maximum wear clearance Maximum valve stem eccentricity over one revolution with stylus on sealing face Inlet and exhaust valve spring length • Free • With load of 26.1 – 28.9 kg (57.5 – 63.7 lb) • With load of 51.2 – 56.5 kg (112.9 – 124.6 lb)

45.300 – 45.500 mm (1.783 – 1.791 in) 37.500 – 37.750 mm (1.476 – 1.486 in) 7.985 – 8.000 mm (0.314 – 0.315 in) 60° 30’ ± 7’ 45° 30’ ± 7’ 0.450 mm (0.018 in) 0.300 mm (0.012 in) 0.300 mm (0.012 in) 5.2500 mm (0.2067 in) 5.6770 mm (0.2235 in) 9.3100 mm (0.3665 in) 10.0600 mm (0.3961 in) 13.933 – 14.016 mm (0.549 – 0.552 in) 0.2000 mm (0.0079 in) 0.0050 – 0.0500 mm (0.0002 – 0.0020 in) 8.023 – 8.043 mm (0.316 – 0.317 in) 0.023 – 0.058 mm (0.001 – 0.002 in) 0.1300 mm (0.0051 in)

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0.0300 mm (0.0012 in) 44.600 mm (1.756 in) 34.000 mm (1.339 in) 23.800 mm (0.937 in)

Engine - Valve drive and gears

Rocker shaft - Inspect 1. Inspect rocker arm adjusting screws and push rod ends of the rocker arm, including the ball end of the screws for nicks, damage or excessive wear. 1.

Also inspect the inside diameter of rocker arm for damage or wear. If any of these characteristics are not to specification replace with new parts.

Check the rocker shaft for signs of wear or damage on diameter. If not to specification replace with new. If re-used, before assembly clean thoroughly in solvent making sure all oil passages are clear. NOTE: When dressing of the rockers and screw working surfaces becomes necessary, remove as little material as possible.

Length of rocker spacer spring length should be checked on both free length and load length.

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NDIL14TR00078AA

Engine - Valve drive and gears

Camshaft - Adjust â&#x20AC;&#x201C; Tappets and pushrods 1. Ensure that the tappets slide smoothly in their housing without excessive clearance. 1.

If excessive tappet clearance is detected, replace with oversize tappets and open out the associated housing bores. See figure for standard dimension.

Oversize tappets are available in steps of 0.1000 mm (0.0039 in), 0.2000 mm (0.0079 in) and 0.3000 mm (0.0118 in).

The push rods should be perfectly straight and the rocker screw seat should not show signs of pick-up or undue wear.

NOTE: Do not attempt to straighten bent push rods, replace with new.

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NDIL14TR00077AB

Engine - Valve drive and gears

Camshaft bushings - Inspect Measurement and replacement of camshaft bushes 1. Check the camshaft to bush clearance if found excess or with deep scoring replace bush. Use a suitable mandrel in order to dismount and mount the bushes. NOTICE: During mounting bushes, pay attention to the alignment of oil holes (1) which must be aligned to the crankcase oil holes for the supply of the lubricating oil.

NDIL14TR00107AB

NDIL14TR00108AA

NDIL14TR00109AB

2. After mounting grind all the bushes using mandrel, milling cutter along with grind bushes to obtain the prescribed diameter.

3. Mount cover (1) completely with sealing ring (2) and fix it together with the corresponding plate in rear side of engine.

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Engine - Valve drive and gears

Idler gear bush inspection and repair Check the contact surface of the bush (1). They must not have furrows or score grooves otherwise that bush must be replaced by means of suitable diving mandrel. After mounting the bush into idler gear. It must be bored in order to obtain the diameter as shown in figure.

NDIL14TR00110AB

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Index Engine - 10 Valve drive and gears - 106 Camshaft - Adjust â&#x20AC;&#x201C; Tappets and pushrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Camshaft bushings - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rocker shaft - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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Engine - 10 Cylinder heads - 101

TT4.80 TT4.90

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Contents Engine - 10 Cylinder heads - 101

SERVICE Cylinder heads Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Valves Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Valve guide Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Engine - Cylinder heads

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

1. Loosen the bolts securing injector and remove injectors from cylinder head using special tool 380000549.

NDIL14TR00053AA

NDIL14TR00054AB

NDIL14TR00055AB

2. For easy access to cylinder head, remove intake and exhaust manifolds and retrieve packing seals from the housing. NOTE: Cylinder head can also be removed from the engine without removing intake and exhaust manifolds. 3. Loosen bolts (1) and remove tappet cover (2).

4. Loosen rocker shaft mounting bolts (1) and nuts (2) and remove rocker shaft assembly.

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Engine - Cylinder heads

5. Take out all the push rods (1) from the cylinder head.

NDIL14TR00056AB

NDIL14TR00057AA

6. Loosen the cylinder head bolts (1) and lift off the cylinder head from cylinder block. Retrieve gasket from the cylinder block.

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Engine - Cylinder heads

Cylinder heads - Disassemble NOTICE: In case of replacement of parts is not required make and identification mark to keep the parts in a numbered rack to assemble parts back in original location. 1. Remove the circlip on each side of the rocker shaft and withdraw the rocker arm (1), adjusting shims (2), rocker bracket (3), spring (4) from the rocker shaft (5).

NDIL14TR00058AB

NDIL14TR00059AB

GN1L14TR0001 AA

NOTE: Prior to disassembling rockershaft, take-off the screw (1) securing support (2) to shaft.

Valves and spring assembly removal 1. Remove the upper boot of valve. 2. Detach the retainer locks by using special tool 380000302. 3. Slowly release the special tool and withdraw springs, seal and take out the valves.

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Engine - Cylinder heads

Cylinder heads - Inspect 1. Clean the cylinder head and remove the carbon deposits around the valve heads. 2. Cylinder head core plugs if discolored (rusting) or leaking require changing. Before fitting new plugs. Remove all old sealer from the cylinder head. Apply sealant to the new plug mating faces and drive the new plugs into location.

NDIL14TR00061AA

NDIL14TR00062AB

3. Scrape all gasket surfaces clean and wash cylinder head in a suitable solvent, also cleaning valve guide bores. NOTE: Ensure injector washers have been removed prior to cleaning. 4. Inspect cylinder head for nicks and burrs on mating face. Remove using a suitable abrasive and ensure faces are clean after repair. 5. Using a straight edge (1) and feeler gauges (2), check the flatness of the cylinder head in all directions. The cylinder head face may be skimmed if necessary, removing not more than 0.500 mm (0.020 in).

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Engine - Cylinder heads

Cylinder heads - Assemble Cylinder head re-assembly 1. Insert the valves into the guides from which they were removed and lap with a suitable paste. Ensure that all traces and paste are removed after lapping. A. Exhaust B. Inlet

NDIL14TR00079AB

GN1L14TR0001 AA

NDIL14TR00081AB

2. Lubricate all components with clean engine oil on re-assembly. Use a spring compressor (special tool number 380000302) to re-assemble the valves, valve springs and retainers, and collects. 3. Coat all tappets with clean engine oil prior to assembly and insert tappet into its original position. 4. Reassemble the rocker shaft assembly following the same order in reverse of disassembly.

NOTE: Ensure that screw (1) securing second retainer (from side of the engine) and shaft is fitted. This ensures oil grooves and holes face downwards. 5. Ensure each ball end of rocker arm screws are seated in its push rod before tightening rocker assembly fully.

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Engine - Cylinder heads

Cylinder heads - Install 1. Install new gasket on the cylinder block. 2. Install the cylinder hear with the cylinder head blots (1) on the cylinder block.

NDIL14TR00057AA

NDIL14TR00056AB

NDIL14TR00055AB

NDIL14TR00054AB

3. Install all the push rods (1) on the cylinder head.

4. Install the rocker shaft assembly with mounting bolt (1) and nuts (2).

5. Install the tapper cover (2) with the bolts (1). NOTE: Cylinder head can also be installed to the engine without removing intake and exhaust manifolds. 6. For easy access to cylinder head, install intake and exhaust manifolds and retrieve packing seals from the housing. 7. Install intake and exhaust manifolds with new packing seal on the housing.

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Engine - Cylinder heads

8. Install the injectors with the bolts on the cylinder head using the special tool 380000549 .

NDIL14TR00053AA

GNIL15TR01043AB

NDIL14TR00083AB

9. Thoroughly clean the mating surfaces and re-position the head gasket with the mark “ALTO” facing towards the cylinder head. 10. Replace the cylinder head and tighten the retaining bolts in sequence and progressively in four stages as shown in figure. 11. Install new cylinder head, intake and exhaust manifold gaskets. NOTE: Lightly lubricate the bolts prior to assembly and tighten to the torque specification, with the engine cold. Stage 1 • Initial tightening torque: 40 N·m (354 lb in) Stage 2 • Initial tightening torque check: 40 N·m (354 lb in) Stage 3 • Tightening angle: 130 ° Stage 4 • Tightening angle: 140 ° NOTE: Before re-using the bolts, check that the diameter “d” measured as shown above zone “a”) exceeds 11.5 mm (0.5 in), if not replace bolt.

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12. Adjust valve clearance setting with each piston in turn at top dead centre and rockers free to move. â&#x20AC;˘ Intake valve clearance: 0.30 mm (0.01 in) (warm or cold) â&#x20AC;˘ Exhaust valve clearance: 0.30 mm (0.01 in) (warm or cold)

NDIL14TR00085AA

NDIL14TR00086AA

13. Install the injectors with new seat washers, cork seals. 14. Install the high pressure fuel lines between injectors and fuel injection pump. 15. Install the leak off line with new washers. 16. Tighten all bolts and nuts to correct torques.

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Engine - Cylinder heads

Valves - Inspect Valve settings 1. Check that valve seating stand-in from cylinder head plane does not exceed 0.7000 â&#x20AC;&#x201C; 1.0000 mm (0.0276 â&#x20AC;&#x201C; 0.0394 in) (max permissible stand-in: 1.30 mm (0.05 in)).

To recruit valve seats, use suitable fixture and universal hand lathe.

Maintain the valve seat and guide dimensions as shown in figure.

NDIL14TR00069AA

NDIL14TR00070AB

NDIL14TR00071AB

Valves 1. To eliminate slight seating defects, grind valves together with seats using air grinder. With greater defects, re-cut the valve seats and grind the valves. 1.

During grinding maintain the dimensions of the valves as in figure.

After grinding, check that the minimum stand-in is not less than 0.500 mm (0.020 in).

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Engine - Cylinder heads

Valve guide - Inspect 1. To remove and install the valve guides, use special tool number 291046 together with 293231.

NDIL14TR00072AA

NDIL14TR00073AB

NDIL14TR00074AA

Valve guides should be a drive fit in their housing. If loose, they should be replaced using oversize guides. See figure Valves - Inspect (10.101) for valve guide dimensions (B).

2. After installation, each valve guides should be reamed using suitable reaming tool. Also refer general specifications.

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Index Engine - 10 Cylinder heads - 101 Cylinder heads - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder heads - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder heads - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder heads - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder heads - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve guide - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Connecting rods and pistons - 105

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Contents Engine - 10 Connecting rods and pistons - 105

SERVICE Connecting rods and pistons Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - Connecting rods and pistons

Connecting rods and pistons - Remove NOTE: Connecting rods and pistons can be removed with the engine installed on tractor after removing of the cylinder head and oil pan. 1. With cylinder head removed clean off any ridge from the top of the cylinder bore to enable removal of the pistons, this is essential if old pistons are to be re-used and failure to do so could result in ring damage when removing. 2. With the piston at the bottom of the stroke remove the end cap bolts, cap, and sleeve using the handle end of a hammer push the piston assembly out through the top of the block, and remove the bearing sleeve from the connecting rod. NOTE: Bearing caps and sleeves must be kept with their respective connecting rods. NDIL14TR00125AA

NDIL14TR00126AA

NDIL14TR00127AA

3. Turn the crankshaft again and repeat the process for the remaining pistons. 4. Using expander remove the piston rings.

5. Remove piston pin snap rings from each side of piston using a suitable tool and remove pin. 6. Ensure each piston and rod assembly, remains matched together for re-assembly into the cylinder block.

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Connecting rods and pistons - Inspect Connecting rod alignment Large and small end bores must be square and parallel to each other within the limits of 0.070 mm (0.003 in) measured at a distance of 125 mm (5 in) from the longitudinal axis of connecting rod. NOTICE: Replacement rods should be stamped with the reference numbers of the cylinder to which they belong. Also ensure that the weight difference between rods of the same engine does not exceed 25.00 g (0.88 oz).

NDIL14TR00128AA

NDIL14TR00129AA

NDIL14TR00130AA

NOTICE: Ensure that the connecting rod lubricating ports (L and M ) are unobstructed. NOTE: Connecting rod nuts should be replaced whenever the big ends are disturbed. 1. Check connecting rod small end bush and piston pin for wear. • Connecting rod bush fitted internal diameter: 38.004 – 38.014 mm (1.496 – 1.497 in).

If new bush to be replaced, proceed as follows: • The small end bushes are press fitted in the connecting rods. • Press out the old bushes using a suitable press. • Remove any sharp edges around the connecting rod small end parent bores. • Press in the new bushes using a suitable dolly at the same time ensuring that the oil holes in the bushes coincide with the holes in the top of the connecting rods. • After installation grind the side faces of the new bush to match the side faces of the connecting rod. Ensure all sharp edges are removed, and loose clippings are cleaned from the connecting rod before re-assembly into the engine. • Ream out the new bushes to suit their respective piston pins, and check parallelism and twist.

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2. Wash the piston assembly in a suitable solvent and dry with a clean lint free cloth or compressed air. 3. Inspect the piston ring lands, skirts and pin boses for damage. 4. Clean the ring grooves and using a new ring and feeler gauge check the piston ring land for wear. (Gap between the ring and the groove.) • Top compression ring – 0.0900 – 0.1220 mm (0.0035 – 0.0048 in) • 2nd compression ring – 0.0600 – 0.0920 mm (0.0024 – 0.0036 in) • Oil control ring – 0.0400 – 0.0750 mm (0.0016 – 0.0030 in)

NDIL14TR00131AA

NDIL14TR00132AA

NDIL14TR00133AA

Maximum groove wear clearance: • Top compression ring – 0.0500 mm (0.0020 in) • 2nd compression ring and oil control ring – 0.0200 mm (0.0008 in) 5. Place a new ring into the cylinder bore and check the piston ring gap width at top middle and bottom of the bore. • Top ring – 0.4000 – 0.6500 mm (0.0157 – 0.0256 in) • Second ring – 0.3000 – 0.5500 mm (0.0118 – 0.0217 in) • Third ring – 0.3000 – 0.6000 mm (0.0118 – 0.0236 in) • Maximum wear gap – 1.2000 mm (0.0472 in) NOTE: In a worn cylinder, ring gap should be checked at the bottom of cylinder. 6. Measure of piston diameter by means of micrometer in order to determine the mounting clearance. NOTE: The diameter must be measured at a distance of 12.000 mm (0.472 in) from the piston head. The pistons are delivered as spare parts with standard dimension or over size dimension of 0.400 – 0.800 mm (0.016 – 0.031 in).

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Engine - Connecting rods and pistons

7. The clearance between piston and cylinder liner can also be checked by means of a feeler gauge as shown in the Fig. 7.

NDIL14TR00134AA

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Engine - Connecting rods and pistons

Connecting rods and pistons - Assemble NOTE: Pistons that are replaced must be of the same type that were removed and have the same identification letters, and numbers, as embossed on the piston. 1. Upon re-assembly with the piston at top dead centre, ensure that piston stand out from engine block is 0.355 – 0.761 mm (0.014 – 0.030 in). NOTE: With most new pistons, a machining allowance is provided on the crown of the piston and the necessary amount must be removed in a lathe to give clearance quoted above. Some pistons may be available that do not require topping. • Measure the piston stand out and depending on the piston projection value choose the below mentioned gasket of desired thickness. 0.72 mm (0.03 in) A type ( 1.35 mm (0.05 in)) 0.72 – 0.90 mm (0.03 – 0.04 in) B type ( 1.55 mm (0.06 in)). Ensure words ALTO on top.

NDIL14TR00139AA

NDIL14TR00140AA

NDIL14TR00141AB

2. Lubricate all the components with engine oil and assemble the connecting rod and piston, piston pin and retainers. When fitting pistons to connecting rods, ensure that the side of the connecting rod which is stamped with the number is placed opposite to the lettering “Tappet side” stamped on the piston.

3. Ensure the correct expander tool is used to remove or install rings. The rings must be mounted with the lettering “Top” to the top. 4. Install the piston rings, but note the following. NOTE: Before installing new pistons and rings into a used cylinder bore, remove the high polish from the cylinder walls by honing. 5. Ensure the ring gaps are staggered a minimum of 120 ° from each other on the diameter and with no gap on the thrust side of the piston.

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Engine - Connecting rods and pistons

Connecting rods and pistons - Install 1. Select the correct bearing sleeves as in the following crankshaft section, and install in the rod and cap, ensure the liner tang locates in the slots of the rod and cap. NOTE: The sleeves are pre-finished and needs no reworking. 2. Turn the crankshaft to position number 1 crankpin at the bottom of the stroke, and lubricate all parts with new engine oil. Using ring compressor and a soft drive slide pistons into bores.

NDIL14TR00142AA

NDIL14TR00143AA

NDIL14TR00144AA

NDIL14TR00145AB

3. See figure 2 for correct fitment of piston and connecting rods in cylinder block. The arrow indicates the direction of rotation of the engine looked from the front of engine.

4. Ensure the connecting rod bearing liner, seats on the crankpin with the bearing cap fitted, to the connecting rod as a matched assembly. Fit bolts lubricated with oil, and tighten to a torque value as detailed below: • By means of a torque wrench tighten to 40 N·m (30 lb ft). • Using angular torque wrench tighten further by 60 °.

NOTICE: The connecting rod screws can be used as long as the thread diameter measured at a distance of between 19.00 – 35.00 mm (0.75 – 1.38 in) from the screw head is not smaller than 10.50 mm (0.41 in).

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5. Using feeler gauges, check the side clearance of each connecting rod to crankshaft, which should be within 0.060 â&#x20AC;&#x201C; 0.100 mm (0.002 â&#x20AC;&#x201C; 0.004 in). 6. Refit the oil pump tube/screen and oil sump as described in the relevant section, refill engine oil and coolant and run the engine checking for leaks.

NDIL14TR00146AA

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Index Engine - 10 Connecting rods and pistons - 105 Connecting rods and pistons - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting rods and pistons - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting rods and pistons - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting rods and pistons - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Crankshaft and flywheel - 103

TT4.80 TT4.90

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Contents Engine - 10 Crankshaft and flywheel - 103

SERVICE Crankshaft and flywheel Service instruction â&#x20AC;&#x201C; Main bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Engine flywheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Crankshaft oil seal Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Main bearings Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Engine - Crankshaft and flywheel

Crankshaft and flywheel - Service instruction â&#x20AC;&#x201C; Main bearing To remove the flywheel, the engine requires to be split from the transmission housing. See the Engine - Remove (10.001). The crankshaft itself can only be serviced after removal from the engine for which engine has to be separated from the tractor totally. NOTE: Replaceable bearings are installed in production. Ensure correct crankshaft journal to bearing clearance is maintained in service. To renew main bearings, crankshaft has to be removed.

NDIL14TR00147AB

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Engine - Crankshaft and flywheel

Engine flywheel - Remove 1. To gain access to the flywheel separate the engine to transmission. See the Crankshaft and flywheel - Service instruction (10.103). 2. Remove clutch assembly from the flywheel. Clutch - Remove (18.110).

See

3. Prior to removal and using a dial indicator, rotate the flywheel, figure 1 and measure the flywheel run-out and eccentricity relative to flywheel housing. If not to specification, check crankshaft to flywheel seating.

NDIL14TR00149AA

NDIL14TR00150AB

4. Loosen flywheel mounting bolts (1) and carefully remove flywheel from engine using suitable hoist.

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Engine - Crankshaft and flywheel

Engine flywheel - Inspect 1. Inspect the flywheel ring gear and if damaged renew in the following manner, cut old ring gear free from the flywheel. Clean the mating surfaces of the new ring gear and flywheel. 2. Use an oxy-acetylene torch with a tip size of number 2 (maximum) and direct the flame against the internal face of the gear. 3. Quickly place the hot gear on the flywheel, with flat face against the shoulder on the flywheel. The gear to flywheel run out should be checked using a dial indicator and should not exceed the specified limit.

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Engine - Crankshaft and flywheel

Engine flywheel - Install 1. Clean the crankshaft rear flange and mating surface of the flywheel and install the flywheel, torque the bolts to 40 N·m (30 lb ft) followed by angular torque of 60 °.

NDIL14TR00151AA

NDIL14TR00152AB

2. Before reusing flywheel bolts. Check that diameter ‘d’ (measured as shown at zone ‘a’) exceeds 11.500 mm (0.453 in). If not replaces the bolts.

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Engine - Crankshaft and flywheel

Crankshaft oil seal - Remove Front oil seal NOTE: Front oil seal can also be removed and installed with front cover mounted on the engine. 1. The front oil seal should be replaced every time the front cover is removed. Drive out the old seal using punch taking care, not to damage the front cover. 2. Thoroughly clean the mating surface between the rear cover and front cover using a suitable solvent. Apply a thin coat of grease on the mating surface and paste the timing cover gasket. Assemble the timing cover to the rear cover and tighten the retaining bolts. 3. Lubricate the new seal (1) and install the seal using special tool number 293329 with tip of the seal towards the engine side. 4. Ensure that the new seal does not sit on the seat/mark already made by old seal on crankshaft journal.

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NDIL14TR00114AB

Engine - Crankshaft and flywheel

Main bearings - Disassemble 1. Remove the engine from tractor and install on stand (special tool number 293860) by following the procedure.

NDIL14TR00153AA

NDIL14TR00154AA

NDIL14TR00155AB

GNIL15TR01044AB

2. Remove clutch assembly and flywheel from the engine as described earlier.

3. Remove oil sump as described earlier to gain access to the crankshaft. 4. Remove oil pump (1) by loosening the securing bolts (2).

5. Loosen two bolts (1) and remove rear oil seal housing (2).

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Engine - Crankshaft and flywheel

6. Remove front timing gear cover. 7. Remove engine head.

NDIL14TR00157AA

NDIL14TR00158AA

NDIL14TR00159AA

NDIL14TR00160AA

8. Loosen the crankshaft big end bearing bolts and remove connecting rod piston assembly from the engine.

NOTE: It is possible to remove crankshaft without removing connecting rod and piston assembly from cylinder block. However it is advisable to remove the assembly from cylinder block for easy removal and installation. 9. Loosen the main bearing bolts and remove main bearing caps.

10. Lift the crankshaft from the cylinder block carefully and place it on a clean flat surface.

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Engine - Crankshaft and flywheel

11. Retrieve main bearing shells (1) and thrust washer from the cylinder block.

NDIL14TR00161AB

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Engine - Crankshaft and flywheel

Main bearings - Inspect Carefully inspect the crankshaft, even the slightest crack makes replacement necessary. 1. Measure crankshaft main journals (1) by means of a micrometer caliper. If necessary, grind to the next undersize bearing. Refer to Crankcase - General specification (10.001) for undersize specifications. NOTICE: All main and connecting rod bearings journals are always ground to the same smaller dimension in order to avoid out of balance of the shaft.

NDIL14TR00162AB

NDIL14TR00163AA

NDIL14TR00164AB

NDIL14TR00165AA

2. Measure connecting rod journals by means of a micrometer caliper. If necessary, grind to the next undersize.

3. Check that the plugs (1) of the lubricating circuit are not leaking for an inner pressure of 15 bar (218 psi), otherwise replace plugs by means of a suitable drift.

4. The crankshaft clamped between centres, alignment should be checked using dial gauge. Max. tolerance Âą 0.100 mm (0.004 in). NOTICE: Alignment check must be carried out after regrinding crankshaft.

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Engine - Crankshaft and flywheel

5. Connecting rod bearing. 6. Connecting rod bearing journal alignment referred to main bearing journals the axis of each connecting rod bearing journal pair and the axis of the main bearing journals must be at one plain. Maximum permissible tolerance perpendicular to this plain Âą 0.250 mm (0.010 in).

NDIL14TR00166AB

NDIL14TR00167AB

7. Check the tooth of the gear (1) or damage or wear. If any damage or wear is noticed the gears should be replaced. Pull of gear by means of special tool number 292911. In order to move the new gear, heat the gear in an oven to 180 Â° for 10 min.

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Engine - Crankshaft and flywheel

Main bearings - Assemble 1. Place bearing shell (1) in the main bearings. NOTE: The bearing shells are all pre-finished and requires no re-work. NOTE: The main bearings are delivered as spare parts with the following under sizes 0.254 mm (0.010 in) and 0.508 mm (0.020 in).

NDIL14TR00161AB

NDIL14TR00160AA

NDIL14TR00171AB

NDIL14TR00172AA

2. Lubricate bearing shells. Lift and mount crankshaft in the crank case. NOTE: The bearings caps with attached thin shell bearing are numbered for correct installation. The cap identification number should tally with that stamped on the engine block.

3. The clearance between the shaft journal and the corresponding bearings are checked by means of a plastic gauge (1) as follows: • Clean parts carefully and remove oil, place a piece of correct size plastic gauge (1) across the full width of the bearing cap, approximately 6.000 mm (0.236 in) of centre. • Mount bearing cover fastening screws and tighten them by means of a torque. Wrench to the prescribed tightening torque ( 80 N·m (59 lb ft) + 90 ° angular torque). NOTE: The screws must be previously lubricated with oil. • Remove the cap and use the scale to check the width of the flattened plastic gauge. • Widest point, of gauge establishes the minimum clearance. The difference between the two readings is the taper. NOTE: Normally main bearings journals wear evenly and will not be out of round, but if a bearing which is to specification is fitted to an out of round journal, ensure liner suits maximum diameter of journal. • If these combinations of bearings do not produce specified clearance, refinish crankshaft and fit approximate size service bearings.

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Engine - Crankshaft and flywheel

4. Position the bearings and caps in the block and coat with oil. If the crankshaft has been refinished, fit approximate size service bearings. 5. Place thrust washer (1) at the 2nd bearing from flywheel side with surface covered with anti-friction metal, facing the crankshaft.

NDIL14TR00173AB

NDIL14TR00174AB

NDIL14TR00175AB

NDIL14TR00176AB

NOTE: The mounting clearance is in general 0.032 – 0.334 mm (0.001 – 0.013 in). For a longer clearance the thrust washer must be replaced by new ones with standard dimension or with over dimensions. NOTE: Over dimensions of the thrust washer available 0.127 mm (0.005 in), 0.254 mm (0.010 in), 0.508 mm (0.020 in). 6. Mount the bearing cap together with bearing shells. Lubricate the bolt and tighten them by means of a torque wrench to 80 N·m (59 lb ft) followed by angular torque of 90 °. NOTE: Before re-using main bearing cap bolts, check that diameter ‘d’ (measured at zone ‘a’ shown in the figure 7) exceeds 13.5 mm (0.5 in). If not replace bolt.

7. Place dial gauge (1) with magnetic base check end play of the crank shaft.

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Engine - Crankshaft and flywheel

8. Mount real oil seal cover (1) together with oil seal in the crankcase. NOTE: In service, the rear oil seal (1) has left a groove on the crank shaft, the location of the crankshaft. Oil seal has to be moved inside by removing the spacer ring (2) provided on the inside.

NDIL14TR00177AB

9. Install flywheel, connecting and piston assembly, front timing cover, cylinder head and oil pan as described earlier. 10. Install the engine on tractor and test the engine for compression check as described earlier.

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Index Engine - 10 Crankshaft and flywheel - 103 Crankshaft and flywheel - Service instruction â&#x20AC;&#x201C; Main bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft oil seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine flywheel - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main bearings - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main bearings - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main bearings - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Balancer and damper - 110

TT4.80 TT4.90

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Contents Engine - 10 Balancer and damper - 110

SERVICE Balancer Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - Balancer and damper

Balancer - Remove To remove balancer assembly with engine fitted on tractor, proceed as follows: 1. Drain completely oil in engine sump and remove oil sump cover.

NDIL14TR00119AA

NDIL14TR00120AA

NDIL14TR00121AB

2. Remove oil pump strainer support screw. 3. Remove oil pump along with the strainer.

4. Loosen balancer assembly retaining bolts and slide the assembly towards flywheel side until shaft (1) cleans stiff coupling (2). 5. Remove balancer assembly from the engine.

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Engine - Balancer and damper

Balancer - Disassemble 1. Withdraw split pins (1) and disassemble weight shaft by punch blows. 2. Disassemble drive gear (2) by removing circlip (3) and bolts (4) securing housing. 3. Disassemble idler gear (5) removing circlip (6).

NDIL14TR00122AB

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Engine - Balancer and damper

Balancer - Inspect Check wear of parts, replacing damaged ones and dress inside of bushes replaced using expanding blade dressers. Weight bushes must be fitted in their housing after heating weights in oil at 140 째C (284 째F) - 160 째C (320 째F).

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Engine - Balancer and damper

Balancer - Assemble 1. When reassembling part, gear (5), and weights (8) must be positioned so as to observe matching of marks shown by arrows. 2. Refer to figures and note that: • Weight drive idler gear (5) must have longer part of hub facing case wall. • Holes for the pins made on the shaft must be aligned with corresponding holes on case. 3. When refitting contra-rotating mass unit, timing is undertaken as follows: • Position piston number 1 at T.D.C.

NDIL14TR00123AB

• Secure power drive (9), matching reference marks as shown in figure.

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Index Engine - 10 Balancer and damper - 110 Balancer - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Balancer - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Balancer - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Balancer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Fuel tanks - 216

TT4.80 TT4.90

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Contents Engine - 10 Fuel tanks - 216

SERVICE Fuel tank Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - Fuel tanks

Fuel tank - Remove 1. Disconnect the battery negative cable. See the Battery - Remove (55.302) 2. Remove the mounting bolts (1) from the foot steps (2).

GNIL15TR00492AB

GNIL15TR00892AB

GNIL15TR00497AB

GNIL15TR00498AB

3. Remove the bolts (1) and washers from the fuel tank plate (2). 4. Remove the fuel tank plate (2) from the fuel tank (3). NOTE: Place a suitable container below the fuel tank. Remove the drain plug and drain the fuel from the fuel tank.

5. Place a suitable jack below the fuel tank (1). 6. Loosen and remove the screws (3) and the retaining straps (2) partially withdraw the fuel tank.

7. Disconnect the fuel gauge connector (2). 8. Disconnect the fuel suction and return pipes (1). 9. Remove the fuel tank from the vehicle.

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Engine - Fuel tanks

10. Remove the bolt (1) and fuel tank clamp (2). 11. Remove the bolt (4) and fuel tank bracket (3).

GNIL15TR01045AB

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Engine - Fuel tanks

Fuel tank - Install 1. Install the fuel tank bracket (3) with the bolt (4). 2. Install the fuel tank clamp (2) with the bolt (1).

GNIL15TR01045AB

GNIL15TR00498AB

GNIL15TR00497AB

GNIL15TR00892AB

3. Position the fuel tank on the vehicle. 4. Connect the fuel suction and return pipes (1). 5. Connect the fuel gauge connector (2).

6. Place the fuel tank (1) on the fuel tank bracket. 7. Tighten the screws (3) on the retaining straps (2).

8. Install the fuel tank plate (2) on the fuel tank (3) with the bolts (1) and washers.

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Engine - Fuel tanks

9. Install the foot steps (2) with the bolts (1).

GNIL15TR00492AB

10. Connect the battery negative cable. See the Battery - Install (55.302)

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Index Engine - 10 Fuel tanks - 216 Fuel tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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Engine - 10 Fuel filters - 206

TT4.80 TT4.90

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Contents Engine - 10 Fuel filters - 206

SERVICE Fuel filters Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Fuel-water separator filter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - Fuel filters

Fuel filters - Remove 1. Remove the battery. (55.302).

See the Battery - Remove

2. Remove the side covers. See the Hood - Remove (90.100). 3. Turn off fuel supply by rotating fuel cock (1) to OFF position.

GNIL15TR00759AB

GNIL15TR00878AB

GNIL15TR00890AB

4. Loosen and remove the bolt and remove the fuel pipe (1) connecting primary fuel filter (2) to suction pump. 5. Loosen and remove the bolt and remove the fuel pipe (4) connecting secondary fuel filter (3) to FIP.

6. Remove the primary fuel filter assembly (2). 7. Remove the secondary fuel filter assembly (3). 8. Loosen and remove the bolts (1) and remove the fuel filter mounting head.

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Engine - Fuel filters

Fuel filters - Install 1. Install the fuel filter mounting head with the bolts (1). 2. Install the secondary fuel filter assembly (3). 3. Install the primary fuel filter assembly (2) . 4. Connect the fuel pipe (4) connecting secondary fuel filter (3) to FIP.

GNIL15TR00890AB

GNIL15TR00878AB

GNIL15TR00759AB

5. Connect the fuel pipe (1) connecting primary fuel filter (2) to suction pump.

6. Rotate the fuel cock (1) to ON position. 7. Install the side covers. See the Hood - Install (90.100). 8. Install the battery. See the Battery - Install (55.302).

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Engine - Fuel filters

Fuel-water separator filter - Remove 1. Remove the battery. (55.302).

See the Battery - Remove

2. Remove the side covers. See the Hood - Remove (90.100). 3. Loosen the worm drive clamp of fuel suction flexible pipe (1) and disconnect the flexible pipe, connecting pre-filter to water separator (2).

GNIL15TR00759AB

GNIL15TR00496AB

GNIL15TR00793AB

4. Loosen the worm drive clamp of fuel suction flexible pipe (1) and disconnect the hose (2) connecting water separator to feed pump.

5. Loosen and remove the bolt (1) and water separator (2).

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Engine - Fuel filters

Fuel-water separator filter - Install 1. Connect the outlet pipe (1)to the power shuttle oil filter with the banjo bolts (2). 2. Install the fuel tank. (10.216).

See the Fuel tank - Install

GNIL15TR01506AB

GNIL15TR01516AB

GNIL15TR00764AB

GNIL15TR01515AB

3. Connect the other end of the outlet pipe (1) to the steering motor.

4. Connect the power steering delivery pipe to power steering pump (2) with the bolts (1).

5. Connect the other end of the pipe (1) to the steering motor.

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Engine - Fuel filters

6. Secure the power steering pipes with the pipe clamp (1)and bolt (2).

GNIL15TR00762AB

GNIL15TR00763AB

GNIL15TR01505AB

GNIL15TR01514AB

7. Secure the power steering pipes with the pipe clamp (1) and bolt (2).

8. Install the bracket (3) securing the power steering pipes (1) and (2). 9. Connect the pipe (2) to the steering motor and righthand side front steering cylinder.

10. Connect the pipe (1) to the steering motor to left-hand side front steering cylinder.

11. Install the battery. See the Battery - Install (55.302).

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Index Engine - 10 Fuel filters - 206 Fuel filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel filters - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel-water separator filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel-water separator filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Fuel injection system - 218

TT4.80 TT4.90

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Contents Engine - 10 Fuel injection system - 218

TECHNICAL DATA Fuel injection system General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Fuel injection system Remove – Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overhaul – Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inspect – Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Assemble – Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Injection pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Fuel injectors Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Engine - Fuel injection system

Fuel injection system - General specification Double diaphragm Engine driven 100 L/hour (26 US gal/hour) 3.0000 mm (0.1181 in)

Fuel pump Operation Minimum fuel flow at 1600 RPM shaft speed Drive shaft eccentricity

Fuel pump drive Shaft journal diameter Bushing fitted I.D. after reaming Shaft clearance in bushing Bushing interference fit in housing Inner washer thickness Outer washer thickness

31.9750 – 32.0000 mm (1.2589 – 1.2598 in) 32.0500 – 32.0750 mm (1.2618 – 1.2628 in) 0.0500 – 0.1000 mm (0.0020 – 0.0039 in) 0.0630 – 0.1400 mm (0.0025 – 0.0055 in) 1.4500 – 1.5000 mm (0.0571 – 0.0591 in) 2.9300 – 3.0000 mm (0.1154 – 0.1181 in) Distributor, integral governor and advance device

Injection pump BOSCH

VE 4/12 F1150 LV16750-04 (B460816750-04) VE 4/12 F1150LV16750-04 (B460816751-02) Anti-clockwise 1-3-4-2

TT4.80 TT4.90 Rotation direction Firing order

Injectors Make

BOSCH F002C70567 (KBAL86P163) F002C40738 (DSLA 145 P5544) 6 0.1930 mm (0.0076 in) 260 – 268 Kg/cm² (3698 – 3812 psi)

Nozzle holder Nozzle Number of spray orifices Spray orifice diameter Pressure setting

Delivery pipes Pipe dimensions Pump timing, cylinder number 1 in compression stroke (delivery connection of cylinder number 1 marked with letter “A”

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6 x 1.6 x 530 0.5 ± 0.05 @ 0° T.D.C.

Engine - Fuel injection system

Fuel injection system - Remove â&#x20AC;&#x201C; Feed pump NOTE: Ensure that the pump and the areas around the feed pump are clean. 1. Close fuel cock (1) by rotating knob to OFF position. 2. Disconnect fuel intake and return lines from the feed pump. 3. Loosen the two nuts (1) securing feed pump to the mounting bracket. Remove the feed pump. Retrieve gasket between the feed pump and the mounting bracket.

NDIL14TR00200AB

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Engine - Fuel injection system

Fuel injection system - Overhaul – Feed pump 1. Screw out butterfly nut open strainer cap (1) and remove strainer (2).

NDIL14TR00201AB

NDIL14TR00202AB

NDIL14TR00203AB

NDIL14TR00204AB

2. Loosen screws and remove feed pump head (1).

3. Remove nyloc cup (1) using suitable tool.

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

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Engine - Fuel injection system

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

NDIL14TR00205AB

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Engine - Fuel injection system

Fuel injection system - Inspect â&#x20AC;&#x201C; Feed pump 1. Check diaphragm for damage cut or cracks. Replace diaphragm assembly if necessary. 2. Check rubber valves and O-ring in nyloc cup and head for damage. If necessary, replace nyloc cup and O-ring.

NDIL14TR00206AA

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Engine - Fuel injection system

Fuel injection system - Assemble â&#x20AC;&#x201C; Feed pump NOTE: Ensure that the pump and the areas around the feed pump are clean. 1. Install the gasket between the feed pump and the mounting bracket. 2. Install the feed pump with the two nuts (1) securing the feed pump on the mounting bracket. 3. Install the fuel intake and return lines on the feed pump. 4. Rotate the fuel cock (1) knob to ON position.

NDIL14TR00200AB

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Engine - Fuel injection system

Injection pump - Remove 1. Remove the battery. (55.302).

See the Battery - Remove

2. Remove the side covers. See the Hood - Remove (90.100). NOTE: Ensure that the fuel injection pump and the areas around the fuel pump are clean. 3. Close fuel cock (1) by rotating knob to OFF position.

GNIL15TR00759AB

GNIL15TR00757AB

GNIL15TR00875AB

4. Loosen the hose clamp and disconnect the hose connecting the Fuel Injection Pump (FIP) to fuel tank (1).

5. Connection to the KSB (2).

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Engine - Fuel injection system

6. Remove the split pin (1) and disconnect accelerator rod from FIP lever (2).

GNIL15TR00758AB

GNIL15TR00875AB

GNIL15TR00795AB

GNIL15TR00876AB

7. Loosen the nut (1), and disconnect the fuel high pressure line from Fuel Injection Pump (FIP).

8. Loosen the nuts (1) and disconnect the high pressure line.

9. Loosen and remove the bolt and disconnect turbo boost pipe (1) from intake manifold.

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Engine - Fuel injection system

10. Unscrew pump retaining nut securing pump shaft to drive gear and remove injection pump. 11. Loosen dog nut and remove pulley using special tool number 380200597.

NDIL14TR00190AB

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Engine - Fuel injection system

Injection pump - Inspect The pump should not be tampered in any way. If the pump operation is suspicious, it should be taken to an approved BOSCH service centre for testing and repair.

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Engine - Fuel injection system

Injection pump - Install 1. Place the flat gasket between the pump flange and the spacer. 2. Fit shaft to drive gear locking by means of provided nut and insert pump retaining nuts (2), figure 1 without tightening. 3. Turn the pump body to align reference marks (1) on the pump and spacer.

NDIL14TR00194AB

NDIL14TR00193AA

NDIL14TR00194AB

4. Tighten the pump retaining nuts reconnect the various fuel lines, solenoid switch electric connection and throttle linkage. 5. Finally vent the circuit. 6. If there are no reference marks (1), figure 1, or if they are not reliable, timing must be carried out as follows: • Bring cylinder number 1 piston in compression stage to T.D.C. (valves closed), turn the flywheel anticlockwise (as seen from fan side) until the reference mark is aligned with the inscription PMS1. • With the pump reinstalled, remove the plug, fit the tool 380200424 complete with gauge 9971094 and with feeler preloaded by about 2.500 mm (0.098 in). • Turn again slowly backwards until the pumping element to B.D.C. in start of delivery position (the gauge will stop dropping). • Set gauge to zero and turn flywheel clockwise until reference marks is aligned with the inscription PMS1. • Check the gauge to ensure that the pumping element stroke is 1.000 mm (0.039 in). If not, slacken the pump retaining nuts (2). • If the stroke is too short, turn the pump clockwise (as seen from drive side). If it is too long, turn anticlockwise. • Check that a pumping element stroke of 1.000 mm (0.039 in) has been obtained, and repeat above operations as required. • Tighten the pump retaining nuts and cut reference. • Marks into the pump flange and spacer. • Remove gauge, tool and fit plug, tightening to 8 – 10 N·m (6 – 7 lb ft). • Reconnect the fuel lines, the fuel pump and filters. • Vent the circuit.

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Engine - Fuel injection system

Injection pump - Timing check BOSCH injection pump timing 1. Using an external cable, supply 12 V to the thermometric circuit breaker cutting out starting advance according to temperature (KSB) (1) attaching the positive terminal to the connection and earth to the pump housing.

NDIL14TR00236AB

NDIL14TR00237AB

NDIL14TR00238AB

GNIL15TR01049AB

2. Make sure that the KSB fork (1) is free to move.

3. Unscrew the unions of the supply lines (1), detaching them from the injection pump. If necessary, disconnect the injection pump supply and return lines (2) and (3) and the LDA / intake manifold connecting pipe.

4. Remove the flywheel inspection window cover (1) and the tappet cover. Rotate the crankshaft to bring cylinder number 1 at PMS1 (T.D.C.) and make sure the valves are closed (compression stroke).

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Engine - Fuel injection system

5. Check through the inspection window that the pointer is aligned with reference marks PMS1.

NDIL14TR00240AA

NDIL14TR00241AB

NDIL14TR00242AB

6. With the injection pump in its seat, remove the plug (1) on the pump cover.

7. Fit dial gauge 380200424 (1) and the adopter 9971500 (2), pre-loading the shaft by approximately 2.500 mm (0.098 in).

8. Turn the flywheel slowly anti-clockwise, so as to bring the plunger to B.D.C. at the start of the delivery stroke (the point at which the dial gauge needle stops falling). 9. Zero-set the dial gauge and slowly turn the flywheel clockwise (as viewed from the fan end of the engine) until the pointer lines up with PMS1. 10. Check on the dial gauge that the plunger has completed a stroke of 1.000 mm (0.039 in) up to this point, if not, slacken off the pump mounting bolts. 11. Turn the pump upwards if the plunger has completed a shorter stroke and downwards if the stroke is longer, repeating the test until the correct stroke is obtained. 12. Having obtained the correct plunger stroke, fix the pump in position by tightening the mounting nuts to the torque specified.

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Engine - Fuel injection system

13. Remove the dial gauge 9971094 (1) and adopter 380200424 (2) and replace the plug and tighten to a torque of 8 – 10 N·m (71 – 89 lb in). 14. Disconnect the KSB external power supply unit. 15. Install the pulley using the special tool number 82834300. Install the injection pump.

NDIL14TR00190AB

GNIL15TR00876AB

16. Connect turbo boost pipe (1) to the intake manifold with the bolt.

17. Connect the fuel high pressure line (1) with the nuts.

GNIL15TR00795AB

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Engine - Fuel injection system

18. Connect the fuel high pressure to the Fuel Injection Pump (FIP) with the nut (1).

GNIL15TR00875AB

GNIL15TR00758AB

GNIL15TR00757AB

GNIL15TR00759AB

19. Install the accelerator rod on the FIP lever (2) with the split pin (1).

20. Install the KSB (2) connections. 21. Connect the hose connecting the Fuel Injection Pump (FIP) to fuel tank. Install the hose clamp on the hose (1).

22. Rotate the fuel cock (1) to ON position.

23. Remove the side covers. See the Hood - Install (90.100). 47866580 11/12/2015

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Engine - Fuel injection system

24. Remove the battery. (55.302).

See the Battery - Install

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Engine - Fuel injection system

Fuel injectors - Inspect Injector sleeves 1. If the cylinder head has been skimmed, check that fuel injector projection is shown in figure. • Injector stand-out: 0.028 in).

0.050 – 0.700 mm (0.002 –

• Maximum permissible (0.039 in).

stand-out:

1.000 mm

NDIL14TR00063AA

NDIL14TR00064AB

NDIL14TR00065AB

NDIL14TR00066AB

2. If projection is more than 1.000 mm (0.039 in), replace injector sleeve as follows: 1.

Secure sleeve puller special tool number 293784 (1) to cylinder head screwing nuts (2) on injector retaining studs.

Turn nut (3) so as to pull sleeve (4) from cylinder head.

3. Install O-rings (2) on sleeve, insert sleeve in housing using special tool number 380000834 and ensure that lower part contacts seat in cylinder head.

4. Position bushing (1), special tool number 380000830 in new sleeve. Secure bushing in seat by tightening nut (2) anti-clockwise, insert dresser (3) (special tool number 293747) in bushing (1) and buts bottom of sleeve.

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Engine - Fuel injection system

5. Remove tool 293747 and fit cutter (special tool number 293790) (1). Using cutter, remove material until seat is perfectly smooth and free from burrs or tool marks.

NDIL14TR00067AB

NDIL14TR00068AA

6. When dressing is completed, insert injector in sleeve and check that stand-out is 0.050 â&#x20AC;&#x201C; 0.700 mm (0.002 â&#x20AC;&#x201C; 0.028 in).

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Engine - Fuel injection system

Fuel injectors - Remove 1. Ensure the areas around the injectors and fuel pump are clean prior to disassembly. 2. Remove the injector high pressure lines (1) loosen leak off pipe banjo bolts (2) and carefully pull the leak off tubes from the injectors.

NDIL14TR00195AB

NDIL14TR00196AA

3. Remove the retaining nuts of each injector and withdraw the injectors from the cylinder head.

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Engine - Fuel injection system

Fuel injectors - Overhaul WARNING The spray from a fuel injector tester can pierce human skin with fatal results. When an injector is spraying, the nozzle holder should be turned away from the operator and any other persons. During the nozzle opening pressure and spray pattern tests, collect the spray in a container partly filled with rags to absorb the spray. When conducting the nozzle seat leakage test, release the injector tester pump pressure before touching the nozzle tip with a sheet of blotting paper.

NDIL14TR00197AA

WARNING The spray is flammable make sure no open flames are in the area of the tester and do not generate excessive vapor. 1. Fill the injector tester, tool number 380000215 , with a calibrating type fuel oil and leave the filler cap loose to prevent a vacuum forming during testing. 2. Prime the tester until oil is emitted from the tester line, then connect the injector. 3. Make sure the knob on the right-hand side of the tester is screwed into prevent the gauge being over-pressurised, if the injector nozzle is blocked. 4. Pump the tester and check the nozzle is free to open. Open the pressure gauge valve and begin injector testing. 5. Nozzle opening pressure setting - slowly pump the injector tester and observe the pressure at which the needle valve lifts and fuel is injected from the nozzle tip. The minimum acceptable opening pressure is 260 bar (3770 psi). If the opening pressure is below 260 bar (3770 psi) reset to 260 â&#x20AC;&#x201C; 272 bar (3770 â&#x20AC;&#x201C; 3944 psi). 6. Spray pattern - pump the tester rapidly (80 - 90 strokes per/min) and observe the spray pattern from the holes. An atomized spray free from distortion and irregular streaks of fuel should be observed. The tester is not regarded as providing a suitable test for atomization under working conditions, but gives an indication of the working of the nozzle. 7. Nozzle seat leakage - wipe the nozzle tip dry and apply a pressure 10 bar (145 psi) below the opening pressure. The nozzle tip and bottom face must remain essentially dry and there must be no tendency for blobs of fuel to collect or drip. A slight dampness can be ignored. If there is any leakage from the nozzle seat, the nozzle assembly must be cleaned or replaced.

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Engine - Fuel injection system

8. Nozzle back leakage - apply a pressure 10 bar (145 psi) below the opening pressure, then release the handle and time the pressure drop. The pressure should drop 100 – 150 bar (1450 – 2175 psi) in 5 – 45 s below 5 s, the nozzle assembly must be replaced. If above 45 s, check for carbon on the value and /or blocked back leak drillings. NOTE: If the injectors meet the tests carried out then re-fit the injectors to the engine. If not take it to approved BOSCH service centre for further testing and repair.

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Index Engine - 10 Fuel injection system - 218 Fuel injection system - Assemble – Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel injection system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel injection system - Inspect – Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel injection system - Overhaul – Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel injection system - Remove – Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel injectors - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel injectors - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel injectors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injection pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injection pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injection pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injection pump - Timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Air cleaners and lines - 202

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Contents Engine - 10 Air cleaners and lines - 202

SERVICE Air pre-cleaner Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Air cleaner Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Engine - Air cleaners and lines

Air pre-cleaner - Remove 1. Disconnect the battery. See the Battery - Remove (55.302). 2. Loosen and remove the bolts (1) and remove the prefilter cover assembly (2).

GNIL15TR00841AB

GNIL15TR00842AB

3. Remove the pre-cleaner body (2) and the pre-cleaner sleeve assembly (1).

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Air pre-cleaner - Install 1. Positionthe pre-cleaner body (2) and the pre-cleaner sleeve assembly (1).

GNIL15TR00842AB

GNIL15TR00841AB

2. Install the prefilter cover assembly on the pre-cleaner body (2) with the bolts (1).

3. Connect the battery. See the Battery - Install (55.302).

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Air cleaner - Remove 1. Remove the Air pre-cleaner. See the Air pre-cleaner - Remove (10.202). 2. Loosen and remove the hose clamps (1). Disconnect the connecting air cleaner to turbocharger inlet (2). 3. Loosen and remove the air cleaner mounting clamp bolt (3) and remove the air filter assembly (4).

GNIL15TR00844AB

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Air cleaner - Inspect 1. Check for damage of rubber gaskets. Replace if necessary. 2. Clean the wire mesh with the help of diesel and allow it to dry. 3. Release the locking clips (1) and remove the air cleaner cover (2).

GNIL15TR00844AB

GNIL15TR00846AB

GNIL15TR00847AB

4. Remove the primary filter (1).

5. Remove the safety filter (Inner element) (1). 6. Clean the outer element using either method (A) or (B), depending on the elements condition. NOTE: An outer element may be dry cleaned (methods A or B). Every 300 h or when warning bulb glows (whichever is earlier). Outer element to be replaced after 3 times of cleaning by method B or maximum 900 h. Inner element should be replaced after three outer element replacements or every 2700 h whichever is earlier.

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Air cleaner - Cleaning WARNING Chemical hazard! Stop the fan before you open the lid. Avoid exposure to airborne chemicals. Dust and fumes will be exhausted if you open the tank lid while the tank is pressurized. Chemicals may cause eye, skin, or breathing problems. Wear a face mask, gloves, and goggles. Failure to comply could result in death or serious injury. W1307A

NOTE: Clean the air filters in a well ventilated room with a provision to artificially throw out the dusty air. If it is not available, it is advised to do the cleaning outdoors, but never in an unventilated room.

Method A 1. Lightly tap the element against the palm. Continue till the accumulated dust does not come out completely. NOTE: Do not tap the element against a hard surface. This will damage the element.

GNIL15TR00848AA

GNIL15TR00816AA

Method B 1. Using compressed air, not exceeding 1.3 bar (19 psi), insert the air nozzle inside the element. NOTE: Hold the nozzle at a safe distance from the element. Blow the dust from the inside, through the element, to the outside. Never blow air from outside to inside.

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Air cleaner - Inspect 1. Examine the element for damage by placing a light inside the element.. Discard the element if pin pricks of light can be seen or there are areas where paper appears thin. 2. Check the element material for bunching, metal casing for distortion and rubber gasket for damage. Discard the filter element if damaged. 3. Clean the inside of the air cleaner housing using a damp, lint free cloth on a probe. Do not damage the inner filter element. Ensure that the inner end of the housing is clean and smooth. This ensures good seating of the rubber seal on the element. GNIL15TR00850AA

4. Install the cleaned outer element or new outer element. Gently push it inside the housing in clockwise direction. 5. While fitting back the cover, make sure that the dust cup/ejector (2) is facing downward. 6. Check all the air intake hoses for damage and replace as necessary. Check clamps for tightness.

Replacement of inner element 1. The inner element to be removed only at the time of replacement. It should never be cleaned. The inner element should be replaced after three outer element replacements or 2700 h whichever is earlier. 2. Follow the similar instructions of removing and fitting outer element from casting to replace inner element.

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Air cleaner - Install 1. Loosen and remove the hose clamps (1). Disconnect the connecting air cleaner to turbocharger Inlet (2). 2. Loosen and remove the air cleaner mounting clamp bolt (3) and remove the air filter assembly (4). 3. Install the air filter assembly (4) with the air cleaner mounting clamp bolt (3). 4. Connect the hose connecting air cleaner to turbocharger inlet (2). 5. Secure the hose with the clamps (1). GNIL15TR00844AB

6. Install the air pre-cleaner. See the Air pre-cleaner Install (10.202).

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Index Engine - 10 Air cleaners and lines - 202 Air cleaner - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air cleaner - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air cleaner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air cleaner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air pre-cleaner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air pre-cleaner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Turbocharger and lines - 250

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Contents Engine - 10 Turbocharger and lines - 250

FUNCTIONAL DATA Turbocharger Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Turbocharger Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Turbocharger - Overview The turbocharger uses the exhaust flow from the engine to spin a turbine, which in turn spins air pump. The turbine in the turbo charger spins at very high speeds. The turbocharger is bolted to the exhaust manifold of the engine. The exhaust from the cylinders spins the turbine. The turbine is connected by shaft to the compressor, which is located between the air filter and the intake manifold. The compressor pressurizes the air going into the pistons. The exhaust from the cylinders passes through the turbine blades, causing the turbine to spin. The more exhaust that goes through the blades, the faster they spin.

GNIL15TR01050FB

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Turbocharger - Remove 1. Remove the battery. (55.302).

See the Battery - Remove

2. Remove the side covers. See the Hood - Remove (90.100). 3. Loosen and remove the nuts (1) between the silencer muffler and turbo charger.

GNIL15TR00818AB

GNIL15TR00819AB

GNIL15TR00820AB

4. Remove the silencer muffler assembly (1) with metal packing (2).

5. Loosen and remove the hose clamp (1), and disconnect the air Intake hose (2), connecting air cleaner to turbocharger.

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6. Loosen and remove the hose clamps (1) and remove the air Intake pipe connecting turbo charger with after cooler inlet hose (2).

GNIL15TR00821AB

GNIL15TR00822AB

GNIL15TR00823AB

GNIL15TR00824AB

7. Loosen and remove the worm drive clamps, (1) and disconnect the air intake hose (2) connecting turbo charger to after cooler.

8. Loosen and remove the bolts (1) and remove the baffle plate (2) mounted on cylinder head.

9. Loosen the hollow nut and disconnect the turbocharger oil feed pipe (1) from turbocharger end.

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Engine - Turbocharger and lines

10. Loosen the hollow nut (1) and remove the turbocharger oil feed pipe.

GNIL15TR00825AB

GNIL15TR00826AB

11. Loosen the nut (1) and disconnect the return line pipe (2) from turbocharger by pulling it from other end.

12. Loosen and remove the nuts (1) and remove the turbo charger assembly (2).

GNIL15TR00827AB

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Engine - Turbocharger and lines

Turbocharger - Install 1. Install the turbo charger assembly (2) with the nuts (1).

GNIL15TR00827AB

GNIL15TR00826AB

GNIL15TR00825AB

GNIL15TR00824AB

2. Connect the return line pipe (2) on turbocharger with the nut (1).

3. Connect the turbocharger oil feed pipe with the hollow nut (1).

4. Connect the oil feed pipe (1) to turbocharger with the hollow nut.

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Engine - Turbocharger and lines

5. Install the baffle plate (2) on cylinder head with the bolts (1).

GNIL15TR00823AB

GNIL15TR00822AB

GNIL15TR00821AB

GNIL15TR00820AB

6. Connect the air intake hose (2) connecting the turbo charger and after cooler with the worm drive clamps (1).

7. Connect the air intake pipe connecting turbo charger and after cooler inlet hose (2) with the hose clamps (1).

8. Connect the air intake hose (2) connecting the air cleaner and turbocharger with the hose clamp (1).

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Engine - Turbocharger and lines

9. Install the silencer muffler assembly (1) with the metal packing (2).

GNIL15TR00819AB

10. Install the nuts (1) between the silencer muffler and turbo charger.

GNIL15TR00818AB

11. Install the side covers. (90.100).

See the Hood - Install

12. Install the battery. See the Battery - Install (55.302).

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Index Engine - 10 Turbocharger and lines - 250 Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharger - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Intake and exhaust manifolds and muffler - 254

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

SERVICE Exhaust manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Exhaust muffler Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Remove 1. Remove the battery. (55.302).

See the Battery - Remove

2. Remove the exhaust muffler. See the Exhaust muffler - Remove (10.254). 3. Remove the turbocharger. See the Turbocharger Remove (10.250). 4. Loosen and remove the bolts (1) and separate the exhaust manifold (2).

GNIL15TR00782AB

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Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Install 1. Install the exhaust manifold (2) with the bolts (1). 2. Install the turbocharger. See the Turbocharger - Install (10.250). 3. Install the exhaust muffler. See the Exhaust muffler Install (10.254). 4. Install the battery. See the Battery - Install (55.302).

GNIL15TR00782AB

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Exhaust muffler - Remove 1. Remove the battery. (55.302).

See the Battery - Remove

2. Remove the side covers. See the Hood - Remove (90.100). 3. Loosen and remove the bolts (1) and remove muffler pipe (2).

GNIL15TR00769AB

GNIL15TR00493AB

GNIL15TR00771AB

4. Loosen and remove the bolts (2). Remove the heat shield (1).

5. Loosen and remove the clamp bolts (1) and remove the clamp from muffler U-pipe (3). 6. Loosen and remove the U-clamp bolts (2). Remove the muffler U-pipe (3).

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Engine - Intake and exhaust manifolds and muffler

7. Remove the muffler pipe support bracket (2) by removing the bolts (1).

GNIL15TR00781AB

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Engine - Intake and exhaust manifolds and muffler

Exhaust muffler - Install 1. Install the muffler pipe support bracket (2) with the bolts (1).

GNIL15TR00781AB

GNIL15TR00771AB

GNIL15TR00493AB

GNIL15TR00769AB

2. Install the muffler U-pipe (3) with the U-clamp bolts (2).

3. Install the clamp on the muffler U-pipe (3) with the clamp bolts (1). 4. Install the heat shield (1) with the bolts (2).

5. Install the muffler pipe (2) with the bolts (1).

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Engine - Intake and exhaust manifolds and muffler

6. Install the side covers. See the Hood - Install (90.100). 7. Install the battery. See the Battery - Install (55.302).

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

Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust muffler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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Engine - 10 Engine cooling system - 400

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Contents Engine - 10 Engine cooling system - 400

TECHNICAL DATA Engine cooling system General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine cooling system Remove – Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install – Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Radiator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Water pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Test – Water temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Coolant thermostat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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Engine - Engine cooling system

Engine cooling system - General specification Water pump Water pump drive ratio Shaft interference fit in impeller Shaft interference fit in fan hub Face sealing bushing interference fit in impeller

Centrifugal, vane 1.16/1.03 :1 0.0170 – 0.0590 mm (0.0007 – 0.0023 in) 0.0240 – 0.0580 mm (0.0009 – 0.0023 in) 0.0120 – 0.0580 mm (0.0005 – 0.0023 in)

Thermostat Type Opening temperature Close off temperature Valve travel when fully open

Radiator Fan Water temperature gauge

Wax 77 – 81 °C (171 – 178 °F) 94 °C (201 °F) 7.5000 mm (0.2953 in) Vertical tube and copper fins Suction, steel, 4 blades Three colored sectors

Temperature range for each sector • White sector • Green sector • Red sector

0 – 40 °C (32 – 104 °F) 40 – 112 °C (104 – 234 °F) 112 – 120 °C (234 – 248 °F)

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Engine - Engine cooling system

Engine cooling system - Remove â&#x20AC;&#x201C; Oil cooler 1. Disconnect the battery negative terminal. See the Battery - Remove (55.302). 2. Disconnect the oil cooler outlet hose from the radiator bottom hose (1).

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3. Disconnect the oil cooler inlet and outlet hoses (2) and (3). 4. Remove the oil filter (1).

5. Loosen and remove the adapter nut (1) and remove the oil cooler (2).

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Engine - Engine cooling system

Engine cooling system - Install â&#x20AC;&#x201C; Oil cooler 1. Install the oil cooler (2) with the adapter nut (1).

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2. Install the oil filter (1) on the oil cooler (2) using the special tool. 3. Connect the oil cooler inlet and outlet hoses (2) and (3).

4. Connect the oil cooler outlet hose to the radiator bottom hose (1).

5. Connect the battery negative terminal. See Battery Install (55.302).

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Engine - Engine cooling system

Radiator - Remove CAUTION Burn hazard! Wait for all components to cool before performing any operation. Failure to comply could result in minor or moderate injury. C0053A

Prior operation: See the Battery - Remove (55.302) for battery removal process. Prior operation: Remove the side covers. See the Hood - Remove (90.100). 1. Loosen and remove the hose clamps and remove the bottom hose (1) from radiator to drain the coolant.

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2. Loosen and remove the hose clamp (1) and disconnect the radiator upper hose (2).

3. Loosen and remove the hose clamps (1) and disconnect hose (2) from air cleaner to turbocharger, turbocharger to after-cooler (3) and intercooler to air intake (4).

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Engine - Engine cooling system

4. Loosen and remove both left-hand side and right-hand side (1) radiator mounting bolts.

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5. Remove the radiator assembly (1).

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Engine - Engine cooling system

Radiator - Disassemble CAUTION Burn hazard! Wait for all components to cool before performing any operation. Failure to comply could result in minor or moderate injury. C0053A

Prior operation: Remove the battery. See the Battery - Remove (55.302) process. Prior operation: Remove the air pre-cleaner assembly. See the Air pre-cleaner - Remove (10.202) process. Prior operation: Remove the air cleaner assembly. See the Air cleaner - Remove (10.202) process. Prior operation: Remove the Aftercooler assembly. See the Aftercooler - Remove (10.310) process. Prior operation: If installed, remove the power shuttle oil cooler assembly. See the Aftercooler - Remove (10.310) process. Prior operation: Remove the radiator assembly from the vehicle. See the Radiator - Remove (10.400) radiator removal process. 1. Remove the clamp (1) and disconnect the over flow pipe (2) from the recovery bottle.

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2. Remove the clamp (1) and disconnect the over flow pipe (2) from the radiator adapter.

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Engine - Engine cooling system

3. Remove the clamp (1) and disconnect the other side of over flow pipe (2) to the recovery bottle.

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4. Remove the recovery bottle mounting bolts (1) and washers. 5. Remove the recovery bottle (2) from the radiator assembly.

6. Remove the clamps (1) from the radiator outlet pipe (2). 7. Remove the radiator outlet pipe (2) from the radiator (3).

8. Remove the clamps (1) from the radiator inlet pipe (2). 9. Remove the radiator inlet pipe (2) from the radiator (3).

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Engine - Engine cooling system

10. Remove the bolts (1) and the cover plate sealing (2) from the radiator.

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11. Remove the foam (1) from the radiator (2).

12. Remove the bolts (1) and the bottom sealing bracket (2) from the radiator (3).

13. Remove the rubber seals (1) from the air deflector (2).

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Engine - Engine cooling system

14. Remove the air deflector mounting bolts (1) from the radiator (3). 15. Remove the air deflector (2) from the radiator (3).

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16. Remove the bolts (1) from the left-hand and right-hand side bracket seals (2). 17. Remove the left-hand and right-hand side bracket seals from the radiator.

18. Remove the flange bolts (1) from the caul (2). 19. Remove the caul (2) from the radiator (3). 20. If installed with scavenging, remove the caul (2) with the scavenging.

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Engine - Engine cooling system

NOTE: If installed with scavenging follow the below mentioned steps. 1. Remove the bolts (1), washers (2) and nuts (3) from the scavenging. 2. Remove the scavenging from the caul (5).

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3. Remove the spacers (1) from the caul (2).

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Engine - Engine cooling system

Radiator - Assemble CAUTION Burn hazard! Wait for all components to cool before performing any operation. Failure to comply could result in minor or moderate injury. C0053A

NOTE: If installed with scavenging follow the below mentioned steps. 1. Install the spacers (1) on the caul (2).

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2. Install the scavenging with the bolts (1), washers (2) and nuts (3) on the caul.

3. Install the caul (2) with the flange bolts (1) on the radiator (3).

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Engine - Engine cooling system

4. Install the left-hand and right-hand side bracket seals (2) with the bolts (1) on the radiator.

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5. Install the air deflector (2) with the mounting bolts (1) on the radiator.

6. Install the rubber seals (1) on the air deflector (2).

7. Install the bolts (1) and the bottom sealing bracket (2) on the radiator (3).

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Engine - Engine cooling system

8. Install the foam (1) on the radiator (2).

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9. Install the bolts (1) and the cover plate sealing (2) on the radiator.

10. Install the radiator inlet pipe (2) with the clamps (1) on the radiator (3).

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11. Install the radiator inlet pipe (2) with the clamps (1) on the radiator (3).

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Engine - Engine cooling system

12. Install the recovery bottle (2) with the mounting bolts (1) and washers on the radiator assembly.

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13. Install the clamp (1) and the other side of the over flow pipe (2) on the recovery bottle.

14. Install the clamp (1) and connect the over flow pipe (2) on the radiator adapter.

15. Install the clamp (1) and connect the over flow pipe (2) on the recovery bottle.

16. Install the air pre-cleaner assembly. See the Air precleaner - Install (10.202). 47866580 11/12/2015

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Engine - Engine cooling system

17. Install the air cleaner assembly. See the Air cleaner - Install (10.202). 18. Install the aftercooler assembly. See the Aftercooler - Install - Mechanical version (10.310) and Aftercooler - Install - Power shuttle version (10.310). 19. Install the battery. See the Battery - Install (55.302).

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Engine - Engine cooling system

Radiator - Inspect The radiator cap incorporates two valves. Pressure relief valve (1) set at 0.9 Kg/cm² (12.8 psi) and a vacuum relief valve. Periodically check that valves operate correctly. On overhaul, eliminate scales in radiator as follows:• Prepare a solution of warm water and sodium bicarbonate ( 30 g/L) in quantity using a measuring jar. • Pour solution into radiator, drain and rinse with abundant water. To check for radiator leakage, submerge radiator in a tank of water at 30 °C +/- ±10 and apply air at 1 Kg/cm² (14.2 psi) 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. Operate tractor for about 1 h before draining solution with the tractor off.

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Engine - Engine cooling system

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

1. Lift the radiator (1) with the suitable device on the housing. NOTE: Do not let the cooling assembly come into contact with the fan blades.

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2. Install the radiator mounting bolts (1) on both the sides.

3. Connect the hoses intercooler to air intake (4), turbocharger to after-cooler (3) and air cleaner to turbocharger (2) with the hose clamps (1).

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Engine - Engine cooling system

4. Install the radiator upper hose (2) with the hose clamp (1).

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5. Install the bottom hose (1) with the clamp on the radiator and fill the coolant.

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Engine - Engine cooling system

Water pump - Remove 1. Remove the coolant fan. See the Timing gear housing - Remove (10.102). 2. Remove the hoses and remove the bolts securing water pump.

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Engine - Engine cooling system

Water pump - Disassemble Water Pump Disassembly To overhaul the water pump, proceed as follows: • Remove cover (8) and retaining screw (3) form shaft bearing (2). • Tap end of shaft lightly to break oxide film between shaft and impeller and remove impeller using puller 380000223 (1). • Using a suitable puller, withdraw shaft complete with bearing and fun hub. Remove seal (5) only if replacement is necessary, i.e. when graphitized surface in contact with impeller bushing is no longer sufficiently smooth to prevent leakage. Reassemble bearing in mind the following:

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• The bearing (2) requires no lubrication. • The impeller (7) must be fitted flush with end of drive shaft.

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Engine - Engine cooling system

Water pump - Assemble Re-assembly follows the removal procedure in reverse, bearing in mind the following:â&#x20AC;˘ The bearing (2) requires no lubrication. â&#x20AC;˘ The impeller (7) must be fitted flush with end of drive shaft.

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Engine - Engine cooling system

Water pump - Install 1. Install the water pump with the bolts. 2. Connect the hoses with the clamps and bolts. 3. Install the coolant fan. 4. Install the radiator. See the Radiator - Install (10.400).

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5. After the installation of radiator, refill the cooling system and run the engine for checking leaks.

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Engine - Engine cooling system

Water pump - Test – Water temperature gauge The water temperature gauge is divided into two colored zones corresponding to the following temperature ranges:• Green zone 1 – 40 – 90 °C (104 – 194 °F) • Green zone 2 – 90 – 109 °C (194 – 228 °F) • Red zone – 109 – 120 °C (228 – 248 °F) In normal conditions, pointer should be in green zone. In case of doubt, test instrument by immersing bulb in water and check scale with reference thermometer 291979. Repeat the test several times.

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Engine - Engine cooling system

Coolant thermostat - Remove 1. Remove the bolts (1) and bracket (2).

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2. Loosen the bolts and remove top flange (1). 3. Withdraw the thermostat (2) from the housing, along with the gasket.

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Engine - Engine cooling system

Coolant thermostat - Test 1. Place the thermostat in a container of water, and raise the temperature to 100 Â°C (212 Â°F). If the thermostat fails to open when hot, or close properly when cooled, it must be replaced.

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Engine - Engine cooling system

Coolant thermostat - Install 1. Coat new gasket with sealer and position the recess on the thermostat housing, prior to installing the thermostat. 2. Coat the edge of the thermostat with grease and install. 3. Refit the thermostat housing.

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Index Engine - 10 Engine cooling system - 400 Coolant thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant thermostat - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine cooling system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine cooling system - Install – Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine cooling system - Remove – Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water pump - Test – Water temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Fan and drive - 414

TT4.80 TT4.90

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Contents Engine - 10 Fan and drive - 414

SERVICE Belt Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - Fan and drive

Belt - Check 1. Apply a load of 8 – 10 kg (18 – 22 lb) at the mid-point of the belt span (1) between the alternator and water pump pulley, as shown in the figure. 2. If the belt deflects by about 10.00 – 11.00 mm (0.40 – 0.43 in), then the tension is correct. If not do the belt tension adjustment, as given in the next section.

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Engine - Fan and drive

Belt - Tension adjust 1. Loosen the nut (2) securing alternator to belt tensioner. 2. Move alternator on tensioner bracket to obtain desired tension, then tighten nut (1).

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Index Engine - 10 Fan and drive - 414 Belt - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Belt - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Aftercooler - 310

TT4.80 TT4.90

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Contents Engine - 10 Aftercooler - 310

FUNCTIONAL DATA Aftercooler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Aftercooler Remove - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Engine - Aftercooler

Aftercooler - Overview Function of an after-cooler is to keep intake air temperature as low as possible and controls NOx. Aftercooling enables an engine to meet emissions regulations with better fuel economy and lower installation costs. Ensure that there is no leakage from the inlet and the outlet hoses of the after cooler. This can lead to serious engine damage. Keep the after cooler fins clean and check them periodically (based on the type of operation) for cleanliness. Also check that the gap between after cooler and radiator is maintained. Avoid accumulation any dirty particles between them.

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Engine - Aftercooler

Aftercooler - Remove - Mechanical version CAUTION Burn hazard! Wait for all components to cool before performing any operation. Failure to comply could result in minor or moderate injury. C0053A

Prior operation: Remove the battery. See the Battery - Remove (55.302) process. Prior operation: Remove the side covers. See the Hood - Remove (90.100). Prior operation: Remove the air pre-cleaner assembly. See the Air pre-cleaner - Remove (10.202) process. Prior operation: Remove the air cleaner assembly. See the Air cleaner - Remove (10.202) process. 1. Loosen and remove the screws (1) from the inlet and the outlet hose clamps (2). 2. Remove the inlet and the outlet hoses, (3) and (4) of the after cooler.

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GNIL15TR00872AB

GNIL15TR00946AB

3. Loosen and remove the mounting bolts (1) and remove the intercooler (3) along with mounting bracket (2).

4. Remove the bolts (1) from the intercooler (2). 5. Remove the intercooler (2) from the intercooler bracket (3).

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6. Loosen and remove the bolts (2), washer (3) from the intercooler bracket (1). 7. Remove the air cleaner bracket (4) from the intercooler bracket (1).

GNIL15TR00947AB

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Aftercooler - Remove - Power shuttle version CAUTION Burn hazard! Wait for all components to cool before performing any operation. Failure to comply could result in minor or moderate injury. C0053A

GNIL15TR00871AB

GNIL15TR00949AB

GNIL15TR00950AB

3. Loosen and remove the screw (1) from the inlet and outlet hose clamp (2). 4. Disconnect the inlet hose (3) and outlet hose (4).

5. Remove the bolts (1) and washer (2) from the oil cooler (3). 6. Remove the oil cooler (3) from the oil cooler mounting bracket.

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7. Loosen and remove the oil cooler bracket mounting bolts (1) and washer (2). 8. Remove the oil cooler bracket (3) from the intercooler bracket (4) .

GNIL15TR00948AB

GNIL15TR00946AB

GNIL15TR00947AB

9. Remove the bolts (1) from the intercooler (2). 10. Remove the intercooler (2) from the intercooler bracket (3).

11. Loosen and remove the bolts (2), washer (3) from the intercooler bracket (1). 12. Remove the air cleaner bracket (4) from the intercooler bracket (1).

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Aftercooler - Install - Power shuttle version 1. Install the air cleaner bracket (4) with the bolts (2) and washer (3) on the intercooler bracket (1).

GNIL15TR00947AB

GNIL15TR00946AB

GNIL15TR00948AB

GNIL15TR00950AB

2. Install the intercooler (2) with the bolts (1) on the intercooler bracket (3).

3. Install the oil cooler bracket (3) with the mounting bolts (1) and the washer (2) on the intercooler bracket (4).

4. Install the oil cooler (3) with the bolts (1) and the washer (2) on the oil cooler (3).

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5. Install the inlet hose (3) and outlet hose (4) with the screw (1) and the hose clamp (2).

GNIL15TR00949AB

GNIL15TR00871AB

6. Install the inlet hose (3) and the outlet hose (4) with the screws (1) and hose clamps (2) on the after cooler.

7. Install the air cleaner assembly. See the Air cleaner Install (10.202). 8. Install the air pre-cleaner assembly. See the Air precleaner - Install (10.202). 9. Install the battery. See the Battery - Install (55.302).

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Aftercooler - Install - Mechanical version 1. Install the air cleaner bracket (4) with the bolt (2), washer (3) on the intercooler bracket (1).

GNIL15TR00947AB

GNIL15TR00946AB

GNIL15TR00872AB

GNIL15TR00871AB

2. Install the intercooler (2) with the bolts (1) on the intercooler bracket (3).

3. Install the intercooler (3) and the mounting bracket (2), with the mounting bolts (1).

4. Install the inlet hose (3) and the outlet hose (4) with the hose calms (2) and the screws (1).

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6. Install the air pre-cleaner assembly. See the Air precleaner - Install (10.202). 7. Install the battery. See the Battery - Install (55.302).

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Index Engine - 10 Aftercooler - 310 Aftercooler - Install - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Aftercooler - Install - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Aftercooler - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Aftercooler - Remove - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Aftercooler - Remove - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Engine lubrication system - 304

TT4.80 TT4.90

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Contents Engine - 10 Engine lubrication system - 304

TECHNICAL DATA Engine lubrication system General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine lubrication system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Engine lubrication system Test â&#x20AC;&#x201C; Oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Engine oil pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Piston cooling Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Engine lubrication system - General specification Oil pump Oil pump drive ratio Oil pressure, warm at governed speed Relief valve crack-off setting Shaft clearance in bushing Shaft clearance in driven gear Gear backlash Gear clearance in pump body Drive and driven gear width Gear housing depth in pump body Drive and driven gear end float Relief valve spring length • Free • Loaded, 9 – 9.6 kg (20 – 21 lb) Oil filter

Gear, camshaft driven 2: 1 3.0 – 4.0 Kg/cm² (42.7 – 56.9 psi) 3.6 Kg/cm² (51.2 psi) 0.0160 – 0.0550 mm (0.0006 – 0.0022 in) 0.0330 – 0.0660 mm (0.0013 – 0.0026 in) 0.1000 mm (0.0039 in) 0.0600 – 0.1700 mm (0.0024 – 0.0067 in) 40.961 – 41.000 mm (1.613 – 1.614 in) 41.025 – 41.087 mm (1.615 – 1.618 in) 0.0250 – 0.1260 mm (0.0010 – 0.0050 in) 45.000 mm (1.772 in) 30.500 mm (1.201 in) Mesh on suction and cartridge on delivery

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Engine lubrication system - Overview Lubrication of the engine, fig. 1 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 viewing 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 spray jets fitted in the cylinder block and oil supply is via a internal drilled passage through the 2nd bearing in the cylinder block. Big end are without a hole for small end bush as lubrication is through 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. This is located vertically above No. 3 camshaft bearing and aligns to a hole in the cylinder head. The rotation of the camshaft allows a controlled intermediate flow of lubrication.

NDIL14TR00210FB

F. P. C. Vf. L.

Filter Pump Turbocharger Filter relief valve Dipstick

G. S. T. B.

Oil pressure sensor Suction filter Oil filter cap Breather cap

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Engine lubrication system - Test â&#x20AC;&#x201C; Oil consumption NEW HOLLAND service procedure for determining engine oil consumption. Before any repairs are carried out on a tractor that is suspected of engine oil consumption the following procedures must be followed, to diagnose if oil consumption is present. No consumption test should be carried out on an engine until it has completed at least 350 h. NOTE: The NEW HOLLAND definition of high oil consumption is when an engine consumes lubricating oil in excess of 0.4 % of the total fuel used over the same period, i.e. 0.4 L (0.1 US gal) of a liter of engine oil to 100 L (26 US gal) of fuel. Oil consumption can occur in three main areas: 1.

External oil leaks.

Oil lost past the pistons and rings.

3. Oil lost past the valves and guides. Items to check before an oil consumption test is carried out. 1. Check the pre cleaner / exhaust manifold, air intake hoses, gaskets for signs of air or fuel leaks where applicable. 2. Oil bath air cleaner. The filter element must be clean and in good condition. The filter bowl must be free from accumulated dirt, clean and refill the bowl if necessary with the correct grade of oil to the level indicated on the bowl if necessary with the correct grade of oil to the level indicated on the bowl (see operatorâ&#x20AC;&#x2122;s manual for correct grade of oil). 3. Check the condition and tightness of fan belt / check and adjust, if necessary. 4. Check the pressure of the radiator cap and condition of its seal and replace if necessary. 5. Check the type, condition and level of the radiator coolant and replace if necessary. 6. Visually check for engine oil leaks, with particular attention to the gaskets joints of the valve rocker cover, cylinder head and engine mounted auxiliary pump mountings, front timing cover, the engine oil sump and the front and rear crankshaft seals. 7. Check the filter of engine breather for contamination by oil or sludge and replace if necessary. After checking the above items and carrying out repairs as necessary. The following test can be carried out to establish the level of oil consumption of the engine.

Oil consumption test procedure 1. The tractor details, i.e. serial number, model, hours, date codes etc. and the observations as indicated should be recorded on a copy of the reference check sheet.

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2. Place the tractor on level ground and mark its position. Manually turn the engine and bring number 1 piston to top dead center on the compression stroke. With the engine cold measure the engine oil level and adjust to the full level, do not over fill. 3. Completely fill the tractor fuel tank with diesel. NOTE: Oil and filters should have been changed recently prior to carrying out any test to determine excessive oil consumption. 4. Drain engine oil (using clean drain cans) for 30 min. 5. Weigh the drained oil and record the weight in kilograms (kg). 6. Pour the weighed oil back into the engine. The tractor should now be operated for a minimum of 50 h, record the type of work being performed, implements used, terrain and type of soil being worked. 7. Measure the quantity of fuel used by using containers of a known capacity, or a pump with an accurate gauge to fill the diesel tank. Maintain a record of the quantity of fuel used over this period (on the sheet provided) as this will be required when calculating the oil consumption rate. During this period check but do not top up the oil level. If the oil level drops below the minimum, it will be necessary to carry out the calculation (shown below) before re-establishing the correct oil level. 8. After operating for a minimum of 50 h, carry out steps c,d,e and f ensuring the tractor is placed back in the same position as when the oil was initially drained and weighed. 9. Carry out a second test repeating procedures as described, preferably operating in different conditions and when the engine has carried out a further 200 h operation.

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Oil consumption calculation To determine the oil consumption rate use the following formula : (A) = The difference in weight of the oil (in kg) at the end of the test from that at the beginning. (B) = Total oil consumption in liters during test period. B = A ÷ 0.88 (0.88 is the conversion factor from kg. to liters). (C) = Total oil consumption in liters during test period. (D) = Oil consumption to fuel consumption ratio. D = B ÷ C x 100 = Percentage oil consumption. Example: (A) = 2.5 kg (5.5 lb) (B) = 2.5 ÷ 0.88 = 2.840909 liters. (C) = 500 liters of fuel used. (D) = 2.840909500 ÷ 500 = 0.0056818 x 100 = 0.56818. Oil to fuel consumption ratio = 0.56818 % (oil consumption percentage). Once the actual oil consumption figure has been calculated a decision can be made on what course of action to take, if the figure is above 0.4 % it will be necessary to do a compression test to determine where the oil consumption is occurring either in the valves / cylinder head or at the piston rings and bores.

Engine compression test A. Test procedure 1.

Check and confirm that the battery condition is good and as per specifications.

Run the engine for a minimum of half an hour at 1200 RPM to warm the engine.

Stop the engine and remove the injector and seat washer from No. 1 cylinder.

Clean the injector bore and crank the engine for a few ( 3 – 4 s) to blow out any loose carbon particles.

Fit dummy injector into the injector bore, using a new seat washer and injector mounting bolts.

Connect the hose of a Engine Compression Test Gauge to the adapter of the dummy injector.

Crank the engine with the electric fuel shut off to prevent engine start up.

Observe the gauge reading and repeat the compression test, steps 5 - 7 for each cylinder.

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Test readings and conclusion All cylinder compressions values should be uniform or difference between them should be within permitted value given below. Permitted difference in cylinder compression between the cylinders - 1.7 bar (25 psi). 1.

A reading of more than the 1.7 bar (25 psi) below the other cylinders indicates leakage at the cylinder head gasket, piston rings or valves.

A reading of more than 1.7 bar (25 psi) above the other cylinders indicates excessive carbon deposits on the piston and cylinder head.

A low compression pressure in two adjacent cylinders indicates a cylinder head gasket leak. Hence check the cylinder head gasket condition before proceeding to replace piston rings or valves.

If the compression pressure fails to increase steadily or remains constant during the first two successive strokes, but suddenly increases during later strokes, then there might be a sticking valve.

NOTE: In some cases due to a sticky valve the compression pressure may never increase during the entire test

B. Further investigation In cylinders where the compression pressure is below the specified value, further test have to be carried out to determine the faulty component. The following procedure will help identify a faulty piston rings or a faulty valve. 1.

Pour a small amount (equivalent of a table spoon) of heavy oil into the combustion chamber.

Repeat the compression test.

NOTE: Allow the engine to crank for sometime before taking the readings this will allow the oil to be distributed.

Findings and conclusion 1.

Approximately same reading is obtained: The piston rings are in fairly good condition; hence the leakage is due to faulty valves. This can be further confirmed by removing the exhaust manifold and visually inspecting oil leakage from the valve stems.

The compression pressure reading has increased. The oil poured during the test has temporarily sealed the leakage past the piston rings, which has resulted in increased reading. In this case the rings are faulty and need to be replaced.

Re-work Instructions:After the above tests have been carried out and an oil consumption figure has been calculated, a decision can be made on what course of action to take.

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Oil consumption values Permitted engine oil consumption value - 0.4 % See the lubrication chapter for details. If the oil consumption is below the permitted value then no service repair action should be taken. If the oil consumption is more than the permitted value then engine should be repaired.

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Oil consumption test form

NDIL14TR00039HA

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Engine diagnostic sheet 2

NDIL14TR00695HA

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Engine diagnostic sheet 3

NDIL14TR00697HA

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Engine diagnostic sheet 4

NDIL14TR00696HA

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Engine oil pump - Remove NOTE: This operation has to be carried out after the sump has been removed. 1. Remove bolts (1) to remove lubricating pipe (2).

NDIL14TR00226AB

NDIL14TR00227AB

NDIL14TR00228AB

NDIL14TR00229AB

2. Remove bolts (1), (2) and (3) as shown.

3. Remove pump pipe (1) as shown.

4. Remove lubricating oil pump (1). Push it with the help of screw driver.

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Engine oil pump - Overhaul 1. Fix the pump in bench vice and loosen bolts (1).

NDIL14TR00232AB

NDIL14TR00233AB

NDIL14TR00234AB

2. Separate the oil pump cover.

3. To remove the relief valve, remove circuit lock (1) and bolt (2).

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Engine oil pump - Install 1. Install the lubricating oil pump (1).

NDIL14TR00229AB

NDIL14TR00228AB

NDIL14TR00227AB

NDIL14TR00226AB

2. Install the pump pipe (1) as shown.

3. Install the bolts (1), (2) and (3) as shown.

4. Install the lubricating pipe (2) with the bolts (1).

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5. Check tension, spring, relief valve and replace if necessary.

NDIL14TR00235AB

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Piston cooling - Remove 1. Rotate the engine on a stand by 90 Â°. Loosen the big end bearing cap bolts (1). Remove the big end caps (2) with half shell bearings.

NDIL14TR00230AB

NDIL14TR00231AB

2. Remove the spray jets (1) as shown and clean them before refitting.

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Piston cooling - Install 1. Install the spray jets (1) as shown and clean them before refitting.

NDIL14TR00231AB

NDIL14TR00230AB

2. Install the half shell bearing and big end caps (2) with the bolts (1). 3. Rotate the engine on a stand by 90 Â°.

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Index Engine - 10 Engine lubrication system - 304 Engine lubrication system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine lubrication system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine lubrication system - Test â&#x20AC;&#x201C; Oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pump - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston cooling - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston cooling - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India 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.

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SERVICE MANUAL Clutch TT4.80 TT4.90

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Contents Clutch - 18

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

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Clutch - 18 Clutch and components - 110

TT4.80 TT4.90

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Contents Clutch - 18 Clutch and components - 110

TECHNICAL DATA Clutch Technical Data - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Technical Data - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Clutch Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Clutch and components Remove - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Remove - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Adjust - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Remove - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Install - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Remove - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Install - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Remove - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Install - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Clutch Remove - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Install - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Overhaul - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Inspect – Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Assemble – Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Adjust – Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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Replace - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Remove - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Install - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Overhaul - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Adjust - Power shuttler version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

DIAGNOSTIC Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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Clutch - Clutch and components

Clutch - Technical Data - Mechanical version Pedal type Type Control

Suspended pedals Double, dry plate, NEC, (11” X 11”), torsion spring Mechanical pedal for transmission hand lever for Power Take-Off (PTO) Finger type Suspended pedals Power Take-Off (PTO) disc ‐ organic compound Main disc ‐ cerametallic

Release mechanism Pedal type Plate material

Plate thickness

10.10 – 10.90 mm (0.40 – 0.43 in) 7.30 – 7.90 mm (0.29 – 0.31 in) Main disc ‐ 18 max Power Take-Off (PTO) disc ‐ 7 max Tangential springs 0.160 – 0.280 mm (0.006 – 0.011 in)

Transmission Power Take-Off (PTO) Wear limit travel Plate with pressure springs Transmission clutch control sleeve working clearance. with bearing cover Power Take-Off (PTO) clutch control sleeve working clearance Power Take-Off (PTO) clutch lever free play adjustment Transmission clutch pedal free play adjustment

0.060 – 0.180 mm (0.002 – 0.007 in) 2.500 – 5.000 mm (0.098 – 0.197 in) 40 – 50 mm (1.575 – 1.969 in)

Transmission pedal requirements

27.959 – 27.980 mm (1.101 – 1.102 in) 22.052 – 22.137 mm (0.868 – 0.872 in) 0.025 – 0.101 mm (0.001 – 0.004 in) 32.045 – 32.085 mm (1.101 – 1.102 in) 32.045 – 32.085 mm (1.101 – 1.102 in) 0.085 mm (0.003 in) max

Pedal shaft diameter Supporting bush internal diameter (fitted, non‐dressed) Pin/bush play Diameter of bushing housing in steering column casing Bush outer diameter Pedal /bush interference fit

Clutch - Technical Data - Power shuttle version Type No. of Clutches Number of plates Material Method of operation

Wet 02 Forward, Reverse) Steel disc 6, Friction disc 6 Paper Hydraulic

Clutch - Torque Description Master clutch housing to fly-wheel housing buckle up bolts (C1) Clutch assembly mounting bolts (C2) Release fork bolts (C3)

Thread size M12 x 1.25

Torque 100 N·m (74 lb ft)

M8 x 1.25 M16 x 1.5

26 N·m (19 lb ft) 160 N·m (118 lb ft)

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Clutch - Clutch and components

GNIL15TR00201GB

Mechanical version

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Clutch - Clutch and components

GNIL15TR01508GB

Power shuttle version

Clutch - Special tools Tool description Clutch centralizer and finger height setting gauge Clutch finger height adjusting gauge NDC clutch setting gauge and NDC clutch alignment setting too

Tool number 380000612 380000256 380200583

Clutch - Sealing Operation description Engine to master clutch housing (S1) Release fork bolts (S2)

Sealants specification LOCTITE® 518™ LOCTITE® 243™

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Clutch - Clutch and components

GNIL15TR00202FB

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Clutch - Clutch and components

Clutch - Overview 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 Power Take-Off (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 Power Take-Off (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 Power Take-Off (PTO) clutch pressure plate pushes the Power Take-Off (PTO) clutch disc against engine flywheel and transmission pressure 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 Power Take-Off (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 presses 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 Power Take-Off (PTO) clutch is engaged and disengaged independent of transmission clutch by operating Power Take-Off (PTO) clutch control lever. Antifreeze may be absorbed through skin in toxic or harmful quantities. Antifreeze if swallowed is fatal and medical attention must be found immediately.

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Clutch - Clutch and components

Clutch - Sectional view

GNIL15TR00203GB

1. 2. 3. 4. 5. 6. 7. 8. 9.

Power Take-Off (PTO) clutch release finger Transmission clutch plate Fly-wheel bearing Power Take-Off (PTO) clutch plate Disc spring Release control sleeves with thrust bearings Release control sleeves with thrust bearings Power Take-Off (PTO) clutch release fork Transmission clutch release fork

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Clutch - Clutch and components

GNIL15TR00204GB

Mechanical version 1. 2. 3. 4. 5. 6. 7.

Clutch facing Facing rivet Segment rivet Hub Segment Idle damper spring Main damper spring

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Clutch - Clutch and components

GNIL15TR01510FB

Power shuttle version 1. 2. 3. 4. 5.

Main damper spring Idle damper spring Hub Facing rivet Clutch facing

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Clutch - Clutch and components

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

Clutch pedal removal NOTE: Remove the brake pedal. See the Brake control pedals and shafts - Remove - Mechanical version (33.120) 1. Remove the clutch pedal spring (1).

GNIL15TR00210AB

GNIL15TR00211AB

GNIL15TR00212AB

2. Remove the split pin (1) and remove the pivot pin (2) to disconnect the clutch pedal at the bottom.

3. Pull out shaft assembly (brake pedal and clutch pedal) (1) and separate clutch pedal (2) by sliding it out from the shaft.

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Clutch - Clutch and components

Power Take-Off (PTO) clutch hand lever removal 1. Disconnect the spring (1) at the base of the lever.

GNIL15TR00213AB

GNIL15TR00214AB

2. Remove split pin (1) and pull out the pin (2) and remove the Power Take-Off (PTO) lever.

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Clutch - Clutch and components

Clutch and components - Install - Mechanical version Power Take-Off (PTO) clutch hand lever installation 1. Install the Power Take-Off (PTO) lever with the pin (2) and split pin (1) to the Power Take-Off (PTO) lever.

GNIL15TR00214AB

GNIL15TR00213AB

GNIL15TR00212AB

2. Install the spring (1) to the base of the lever.

Clutch pedal installation 1. Install the clutch pedal (2) by sliding it in to the shaft and install the shaft assembly (1).

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Clutch - Clutch and components

2. Install the clutch pedal to the bottom link assembly with the pivot pin (2) and split pin (1).

GNIL15TR00211AB

GNIL15TR00210AB

3. Install the clutch pedal spring (1).

4. Install the brake pedal. See the Brake control pedals and shafts - Install (33.120).

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Clutch - Clutch and components

Clutch and components - Remove - Mechanical version Cross shafts removal 1. Remove the fuel tank. See the Fuel tank - Remove (10.216). 2. Separate the transmission housing from engine. See the Engine - Remove (10.001). 3. Remove the clips (1) from both the forks and release the bearing (2). 4. Separate collar sleeve and release bearing from Power Take-Off (PTO) clutch sleeve using mallet. 5. Separate collar sleeve and release bearing from main clutch sleeve using mallet. 6. Disconnect the Power Take-Off (PTO) clutch lever shaft from Power Take-Off (PTO) cable by removing cotter pin and pivot. GNIL15TR00218AB

GNIL15TR00219AB

GNIL15TR00220AB

7. Loosen the Power Take-Off (PTO) clutch fork lock bolt (1).

8. Pull out the Power Take-Off (PTO) clutch cross shaft (1) from left-hand side by transmission housing.

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Clutch - Clutch and components

9. Remove the fork from housing (1).

GNIL15TR00221AB

GNIL15TR00222AB

GNIL15TR00223AB

GNIL15TR00224AB

10. Remove the pin (1) and disconnect the main clutch lever shaft (2) from the clutch pedal linkage. 11. Remove the pin (3) and disconnect the shuttle lever cable (4) from the main clutch lever shaft.

12. Remove the split pins (1) from the pivot pins (2) and disconnect the left-hand brake linkage (3) from brake pedal.

13. Loosen the main clutch fork screw (1).

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Clutch - Clutch and components

14. Pull out the main cross shaft from the left-hand side of the transmission housing.

GNIL15TR00225AB

GNIL15TR00226AB

15. Remove fork (1) from the housing.

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Clutch - Clutch and components

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

Cross shafts installation 1. Install the fork (1) to the housing. NOTE: Make sure that lock lips are properly seated on clutch release forks.

GNIL15TR00226AB

GNIL15TR00225AB

GNIL15TR00224AB

2. Insert the main cross shaft (1) to the left-hand side of the transmission housing.

3. Tighten the main clutch fork screw (1) with the torque value of 160 N·m (118 lb ft). NOTE: Apply LOCTITE® 243™ sealant before tightening.

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Clutch - Clutch and components

4. Connect the left-hand brake linkage (3) to brake pedal. 5. Install the pivot pins (2) and split pins (1) on the brake pedal.

GNIL15TR00223AB

GNIL15TR00222AB

GNIL15TR00221AB

GNIL15TR00220AB

6. Connect the shuttle lever cable (4) to the main clutch lever shaft and install the pin (3) on the shuttle lever cable (4). 7. Connect the main clutch lever shaft (2) to the clutch pedal linkage and install the pin (1)on the main clutch lever shaft (2).

8. Install the fork to the housing (1).

9. Insert the Power Take-Off (PTO) clutch cross shaft (1) to the left-hand side by transmission housing.

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Clutch - Clutch and components

10. Tighten the Power Take-Off (PTO) clutch fork lock bolt (1) to the torque of 160 N·m (118 lb ft). NOTE: Apply LOCTITE® 243™ sealant before tightening.

GNIL15TR00219AB

11. Connect the Power Take-Off (PTO) clutch lever shaft to the Power Take-Off (PTO) cable by installing the cotter pin and pivot. 12. Join the collar sleeve and release bearing to the main clutch sleeve using mallet. 13. Install the collar sleeve and release bearing to the Power Take-Off (PTO) clutch sleeve using mallet. 14. Install the bearing (2) and install the clips (1) to both the forks. 15. Install the transmission housing (with rear axle) to the engine (with front axle). See the Engine - Remove (10.001). NOTE: Before assembling the transmission and engine, thoroughly clean and degrease the mating surfaces apply a bead of liquid gasket of approximately 2.000 mm (0.079 in) of diameter. 16. Install the fuel tank. (10.216).

See the Fuel tank - Install

17. Ensure that lock lips are properly seated on clutch release forks. 18. Use tightening torque table for tightening nuts and bolts. 19. Apply LOCTITE® 243™ sealant to clutch release fork lock screw and left-hand brake pedal lock screw before tightening.

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Clutch - Clutch and components

Clutch and components - Adjust - Mechanical version Clutch pedal settings 1. Clutch pedal free play should be 30.00 – 35.00 mm (1.18 – 1.38 in) measured at the clutch pedal. To adjust the free play proceed as follows: 2. Loosen the locknut (1). 3. Turn the buckle (2) to tighten or shorten the operating rod as required. 4. After the desired free play is attained tighten the locknut (1). NOTE: Increasing the length of the operating rod will increase the free play and vice versa. GNIL15TR00215AB

GNIL15TR00216AB

GNIL15TR00217AB

Power Take-Off (PTO) clutch lever free play 1. Move the Power Take-Off (PTO) clutch lever to engaged position (fully raised). 2. Loosen the locknut (1) and remove the snap ring to pull out the pin (2). 3. Turn the sleeve to completely tighten the cable. 4. Loosen the sleeve (3) by 4 turns approximately 4.50 mm (0.18 in) to increase the cable length. 5. Insert the pin (2), lock it with snap ring to reconnect the sleeve. 6. Check the free play at the lever, it should be 30.00 – 35.00 mm (1.18 – 1.38 in).

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Clutch - Clutch and components

Clutch and components - Remove - Power shuttle version Prior operation: See the Brake pedal control valve - Remove (33.202) for the removal of the brake pedal. Prior operation: Remove the rear hood. See the Hood - Remove â&#x20AC;&#x201C; Rear hood (90.100). 1. Remove the clutch pedal spring (1).

GNIL15TR00988AB

GNIL15TR00973AB

GNIL15TR00974AB

2. Remove the split pin (1) and pivot pin (2) from the clutch linkage (3). 3. Disconnect the linkage (3) from the clutch pedal (4) as shown.

4. Pull out the clutch and brake pedal support-rod (1) from the steering column housing. 5. Retrieve the clutch pedal (2) from the clutch and brake pedal support-rod (1).

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Clutch - Clutch and components

Clutch and components - Install - Power shuttle version Clutch pedal installation 1. Install the clutch pedal (2) on the clutch and brake pedal support-rod (1). 2. Install the clutch and brake pedal support-rod (1) on the steering column housing.

GNIL15TR00974AB

GNIL15TR00973AB

3. Connect the linkage (3) to the clutch pedal (4) as shown in the figure. 4. Install the pivot pin (2) and split pin (1) on the clutch linkage (3).

5. Install the clutch pedal spring (1). 6. Install the brake pedal. See the Brake pedal control valve - Install (33.202). 7. Install the rear hood. See the Hood - Install â&#x20AC;&#x201C; Rear hood (90.100).

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Clutch - Clutch and components

Clutch and components - Remove - Power shuttle version Prior operation: Separate the transmission housing with rear axle from the engine with front axle. See Engine - Remove (10.001). 1. Remove the clips (1) from the forks. 2. Slide out the Power Take-Off (PTO) clutch release bearings (2) from the shaft (3).

GNIL15TR00984AB

GNIL15TR00987AB

GNIL15TR00986AB

3. Loosen and remove the Power Take-Off (PTO) clutch fork lock bolt (1).

4. Pull out the Power Take-Off (PTO) clutch cross shaft (1) from left hand-side of the transmission housing and retrieve fork from the housing. 5. Remove the fork (2) from housing.

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Clutch - Clutch and components

Clutch and components - Install - Power shuttle version Cross shafts installation 1. Insert the Power Take-Off (PTO) clutch cross shaft (1) to the left hand-side of the transmission housing. 2. Install the Power Take-Off (PTO) clutch cross shaft (1) fork (2) to the housing.

GNIL15TR00986AB

GNIL15TR00987AB

GNIL15TR00984AB

3. Install and tighten the Power Take-Off (PTO) clutch fork lock bolt (1). Tighten to the bolts (1) to the torque of 160 NÂˇm (118 lb ft).

4. Install the Power Take-Off (PTO) clutch release bearings (2) on the shaft (3). 5. Install the clips (1) from the forks. NOTE: Make sure that lock lips are properly seated on clutch release forks.

6. Install the transmission housing with rear axle from the engine with front axle. See the Engine - Install (10.001).

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Clutch - Clutch and components

Clutch and components - Remove - Power shuttle version Prior operation: See the Fuel tank - Remove (10.216) for the fuel tank removal. 1. Remove the split pin (1). 2. Disconnect the linkage (2) from the clutch cross shaft (3).

GNIL15TR00985AB

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Clutch - Clutch and components

Clutch and components - Install - Power shuttle version 1. Connect the linkage (2) to the clutch cross shaft (3). 2. Install the split pin (1).

GNIL15TR00985AB

3. See the Fuel tank - Install (10.216) for the fuel tank installation. 4. Install for the left-hand side platform installation. See the Protections and footboards - Install (90.118).

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Clutch - Clutch and components

Clutch - Remove - Mechanical version 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 fuel tank. See the Fuel tank - Remove (10.216). 2. Separate the transmission housing with rear axle from engine with front axle.

GNIL15TR00227AB

GNIL15TR00228AB

3. Insert centralizing pin special tool number 271184 (1) in clutch plate shaft seats, remove 13 size cap screws (2) which retains the clutch assembly to the engine fly wheel and remove assembly completely. Retrieve the Power Take-Off (PTO) clutch disc.

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Clutch - Clutch and components

Clutch - Install - Mechanical version Install the clutch assembly back on flywheel taking care of the following: • Check condition of ball bearing (1) pressed in flywheel. Replace in the event of excessive noise or binding. • Refit old /new bearing packing the seat with grease. • Use centralizing pin while installing clutch assembly with Power Take-Off (PTO) clutch disc on flywheel. • Tighten cap screws as specified in tightening torque table. NDIL14TR00297AB

GNIL15TR00229AB

• Before buckling up the transmission housing and engine, thoroughly clean and degrease mating surfaces and apply a bead of liquid gasket of approximate 2.00 mm (0.08 in) of diameter. • Install the fuel tank. See the Fuel tank - Install (10.216).

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Clutch - Clutch and components

Clutch - Overhaul - Mechanical version 1. Remove clutch assembly from tractor as described earlier in this section. 2. Loosen the Power Take-Off (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.

NDIL14TR00299AB

NDIL14TR00300AB

NDIL14TR00301AB

NDIL14TR00302AB

3. Remove the Power Take-Off (PTO) pressure plate (1).

4. Remove disk ring (1) and lock ring (2).

5. Loosen lock nut (1).

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Clutch - Clutch and components

6. Remove transmission clutch pressure plate (1).

NDIL14TR00303AB

NDIL14TR00304AB

NDIL14TR00305AB

NDIL14TR00306AB

7. Remove transmission clutch disc (1) from the housing.

Release fingers disassembly 1. Pull-out dowel pin (1).

2. Pull out pin (1) from the housing and retrieve spring (2).

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Clutch - Clutch and components

3. Remove release fingers (1) from the housing.

NDIL14TR00307AA

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Clutch - Clutch and components

Clutch - Inspect – Mechanical version 1. Check clutch driven discs for wear and replace. 2. If rivets (2), are near or flush with top facing. 3. Discs are also to be replaced if the organic facings are found to be soaked with oil. 4. 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’ = 2.00 mm (0.08 in) • Power Take-Off (PTO) clutch pressure plate (2) thickness - ‘B’ = 22.00 mm (0.87 in) • Transmission clutch pressure plate (3) thickness ‘C’ = 24.00 mm (0.94 in)

GNIL15TR00230AB

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Clutch - Clutch and components

Clutch - Assemble – Mechanical version Re-assembly follows disassembly procedure in reverse. • See figure for correct orientation of clutch discs.

GNIL15TR00231BB

NDIL14TR00310AB

• Position disk springs correctly and lock-ring (2) on transmission pressure plates (1) as shown in the figure. • Using special tool number 380000612, centralize clutch discs. • Install the clutch assembly on flywheel and do release finger adjustments as described under clutch release finger settings.

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Clutch - Clutch and components

Clutch - Adjust â&#x20AC;&#x201C; Mechanical version For correct function of clutch release mechanism (1), the release fingers must be set at the distances D 96.00 mm (3.78 in) adm D1 - 121.00 mm (4.76 in) relative to flywheel face (2) from release fingers of transmission clutch and Power Take-Off (PTO) clutch respectively. Follow the below described procedure to obtain these settings. 1. Install the clutch assembly (1) on engine flywheel (2).

GNIL15TR00232AB

NDIL14TR00312AA

NDIL14TR00313AB

2. Insert centralizer pin special tool number 380000612 along with fingers height setting gauge, drive shaft seats, ensuring that the end is in contact with flywheel housing. 3. First set Power Take-Off (PTO) release fingers by using clutch assignment setting gauge 380200583 (1) as shown in Figure. Gap between gauge and finger should be between 0.300 mm (0.012 in). Use feeler gauge to check the gap. 4. Set the gap by rotating locknut using special tool number 9971365. 5. Similarly set the height setting gauge to set transmission clutch release fingers. The gap between fingers and gauge should be 0.300 mm (0.012 in). 6. Adjust the gap by loosening locknut and rotating screw using special tool number 9971365.

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Clutch - Clutch and components

Clutch - Replace - Mechanical version 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

Important points to be taken into account while replacing clutch: 1. Check the condition of spigot bearing, replace if necessary. 2. Check the condition of the oil seals on the engine and transmission sides for leaks and replace if necessary. 3. Check the flywheel face is free from scores and cracks. When machining the surface, follow specified tolerances. NOTICE: Machine the bolting surface to the same amount of the running surface, to maintain original clamp loads.

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

4. Ensure correct alignment of the clutch cover to the flywheel. Use Special Tool No. 380000612 for alignment. 5. Ensure the clutch cover is secured to the flywheel evenly and sequentially. Use new spring washers. 6. After an initial running-in period, any variation lever height will correct itself. 7. Before fitting, check the clutch plate for lateral run out. 8. Ensure the clutch plate is fitted the correct way. Observe the direction as indicated on the driven plate. 9. Check the gearbox input shaft for damage. Only nonmetallic based high melting point grease should be used to lubricate the splines and release bearing guide sleeve. 10. Check the release bearing guide sleeve for wear and replace if necessary. 11. After applying the grease to the gearbox input shaft, guide the clutch driven plate on to the shaft and remove the surplus grease. 12. Ensure correct alignment between the engine and transmission/clutch housing, ensure that the locating dowels are fitted and are secure.

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Clutch - Clutch and components

13. Carefully guide the input shaft into the clutch hub splines, taking care not to allow the weight of the transmission to hang on the hub of the driven plate, this will prevent irreparable damage to the segments and associated cushion springs. 14. Ensure the correct adjustment of clutch pedal free play.

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Clutch - Clutch and components

Clutch - Remove - Power shuttle version Prior operation: Separate the transmission housing with rear axle from the engine with front axle. See Engine - Remove (10.001). 1. Insert the centralizing pin special tool (1) in clutch plate shaft seats.

GNIL15TR00980AB

GNIL15TR00978AB

2. Remove the bolts (1) which retains the clutch assembly to the engine fly wheel. 3. Remove the Power Take-Off (PTO) clutch disc from the vehicle.

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Clutch - Clutch and components

Clutch - Install - Power shuttle version 1. Install the Power Take-Off (PTO) clutch disc to the vehicle. 2. Install the bolts (1) which retains the clutch assembly to the engine fly wheel.

GNIL15TR00978AB

GNIL15TR00980AB

3. Insert the centralizing pin special tool (1) in clutch plate for installation of shaft seats.

4. Install the transmission housing with rear axle to the engine with front axle. See the Engine - Install (10.001).

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Clutch - Clutch and components

Clutch - Overhaul - Power shuttle version 1. Loosen the Power Take-Off (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.

GNIL15TR00981AB

GNIL15TR00982AB

GNIL15TR00983AB

GNIL15TR00976AB

2. Remove Power Take-Off (PTO) pressure plate (1) .

3. Remove the spring (1) from clutch finger assembly.

Release fingers disassembly 4. Remove the lock (1) using the special tool.

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Clutch - Clutch and components

5. Pull out the pin (1) from the housing. 6. Retrieve the spring (2).

GNIL15TR00975AB

GNIL15TR00977AB

7. Remove the release fingers (1) from the housing.

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Clutch - Clutch and components

Clutch - Adjust - Power shuttler version For correct function of clutch release mechanism, the release fingers must be set at the distances D 96.00 mm (3.78 in) adm D1 - 121.00 mm (4.76 in) relative to flywheel face from release fingers of transmission clutch and Power Take-Off (PTO) clutch respectively. Follow the below described procedure to obtain these settings. 1. Install the clutch assembly on engine flywheel with the bolts (1).

GNIL15TR00978AB

GNIL15TR00980AB

2. Insert centralizer pin special tool number along with fingers height setting gauge, drive shaft seats, ensuring that the end is in contact with flywheel housing. 3. First set Power Take-Off (PTO) release fingers by using height setting gauge (1) as shown in figure. Gap between gauge and finger should be between 0.300 mm (0.012 in). Use feeler gauge to check the gap. 4. Set the gap by rotating locknut using special tool number. 5. Similarly set the height setting gauge to set transmission clutch release fingers. The gap between fingers and gauge should be 0.300 mm (0.012 in). 6. Adjust the gap by loosening locknut and rotating screw using special tool number 9971365.

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Clutch - Clutch and components

Clutch - Troubleshooting Problem Clutch slips

Clutch grabs

Clutch noise at engagement and /or disengagement

Clutch control pedal hardness

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

Correction Replace clutch disc; replace clutch if necessary and grind the flywheel Replace finger assembly Replace clutch disc; repair leak of lubricant in to clutch housing; thoroughly clean friction surfaces Stiff external control linkage Check and lubricate linkage pivot points Warped clutch disc Replace clutch disc Clutch disc with damaged damper springs Replace clutch disc or loose hub Oil or grease on friction material Replace clutch disc; repair leak of lubricant in to clutch housing; thoroughly clean friction surfaces Finger springs broken Replace finger springs Warped clutch disc Replace clutch disc

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 bearing Hard pedal Check and lubricate linkage.

Broken or disconnected clutch return Replace or hook up clutch return spring. spring. Replace clutch disc Clutch fails to disconnect Warped clutch disc and drags Damaged clutch release bearing Replace clutch release bearing Damaged finger spring Replace finger springs

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Index Clutch - 18 Clutch and components - 110 Clutch - Adjust - Power shuttler version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Adjust – Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Assemble – Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Inspect – Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Install - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Install - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Overhaul - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Overhaul - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Remove - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Remove - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Replace - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Clutch - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Technical Data - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Technical Data - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Clutch and components - Adjust - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch and components - Install - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch and components - Install - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch and components - Remove - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch and components - Remove - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch and components - Remove - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch and components - Remove - Power shuttle version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

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SERVICE MANUAL Transmission TT4.80 TT4.90

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Contents Transmission - 21

[21.114] Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.110] Master clutch housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 [21.134] Power shuttle transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 [21.154] Power shuttle transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5 [21.120] Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6 [21.126] Gearbox external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.7 [21.145] Gearbox internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.8 [21.160] Creeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.9 [21.200] Dropbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.10

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TT4.80 TT4.90

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Contents Transmission - 21 Mechanical transmission - 114

TECHNICAL DATA Mechanical transmission General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Mechanical transmission Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Mechanical transmission Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DIAGNOSTIC Mechanical transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Transmission - Mechanical transmission

Mechanical transmission - General specification Transmission type Speeds Shuttle type Speed gears Range gears Transmission controls Reverse gear drive Internal diameter (with bush) Shaft OD under reverse gear 2nd gear driven Internal diameter (with bush) Shaft OD under 2nd gear Power Take-Off (PTO) clutch shaft diameter Bushing fitted int. diameter PTO shaft clearance in bushing Bushing interference fit with drive shaft Shim thickness for adjusting float of synchro shuttle

Syncromesh /constant mesh 12F/12R Mechanical synchro shuttle Helical gears Spur gears Side shift arrangement 45.125 mm (1.777 in +/- 0.02) 45.0 ± 0.02/ + 0.015 mm 45.125 mm (1.777 in +/- 0.02) 45.0 ± 0.02/ + 0.015 mm 24.957 – 24.975 mm (0.983 – 0.983 in) 24.040 – 24.092 mm (0.946 – 0.949 in) 0.065 – 0.135 mm (0.003 – 0.005 in) 0.037 – 0.091 mm (0.001 – 0.004 in) 1.00 mm (0.04 in), 1.50 mm (0.06 in), 2.00 mm (0.08 in), 2.50 mm (0.04 in)

Selector lever ball spring length: • free • loaded ( 6.11 – 6.35 kg (13.47 – 14.00 lb)) Speed and range detent spring length • free • loaded ( 11.70 – 12.90 kg (25.8 – 28.44 lb))

18.00 mm (0.71 in) 13.00 mm (0.51 in) 35.50 mm (1.40 in) 31.40 mm (1.24 in)

Mechanical transmission - Sealing Operation description Master clutch housing to axle casing (S1) Master clutch housing to engine (S2) Main shaft bearing cover (sleeve) (S3) Axle casing top cover (S4) Bearing cover screws (S5) Seal (S6)

Sealants specification LOCTITE® 518™ LOCTITE® 518™ LOCTITE® 518™ LOCTITE® 518™ LOCTITE® 243™ LOCTITE® 270

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Transmission - Mechanical transmission

GNIL15TR00635FB

Mechanical transmission - Special tools Tool description Sling hook, gear box Gear box stand Roll pin remover

Tool number 291517 290086 Standard

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Transmission - Mechanical transmission

Mechanical transmission - Overview NOTE: Transmission has twelve forward and twelve reverse gears as standard fitment.

WARNING Loss of control hazard! To prevent inadvertent machine movement, take care to avoid accidental contact with the gearshift levers. Always stop the engine, firmly apply the parking brake, and place all gearshift levers in neutral before leaving the machine. Failure to comply could result in death or serious injury. W0130A GNIL15TR00636AB

GNIL15TR00637AB

GNIL15TR00638AB

Shuttle lever is used to engage the transmission into forward or reverse mode. To change the mode press the clutch pedal and move the lever to the desired mode. The main gear shift lever (1) figure 3 is used to select any one of the four gears. The selector lever (2) is used to select the high (H), medium (M) or low (L) range which gives three times the number of available gears. To change the gear in the selected range press the clutch pedal and move the lever to the desired gear.

NOTE: A safety switch prevents operation of the starter motor unless the shuttle lever is in neutral position (N). See the figure 1. If it is necessary to tow the tractor both the selector and main gear shift lever must be in neutral. 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 synchronizing the speeds of mating gears before they engage. This is possible by adding an extra device, called a â&#x20AC;&#x153;Synchronizerâ&#x20AC;? to equalise the speed of the mating points before they engage. It permits gear shifting while the tractor is moving.

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Transmission - Mechanical transmission

Mechanical transmission - Service instruction NOTICE: Please read this carefully before starting assembly or disassembly operations.

Precaution at flange and tool ends While hammering at flange and tool ends during removal or installation, attention must be paid to the various phases. Functioning and integrity of tool as well as various components must not be endangered.

Reassembling methods Adequate holding equipment should be used for reassembling group. Lifting system will be necessary for reconnecting, disassembling and reassembling the ring gear or for holding the gear box. Use cross section drawings to ease assembly and disassembly operations.

Recommendations regarding lubrication It is very important to use proper lubricants and to maintain a constant level of correct lubrication. Right operational temperature is to be maintained.

Shaft seals Respect the following recommendations during seal and gasket assembly: • Clean shaft very carefully and ensure that the part in contact with the rings is not damaged, cut or out of roundness. • Assemble the seals so that the lips is fitted towards the oil side. • Lubricate seal lips (use oil ) and fill 3/4 of seal cavity with grease. • Use appropriate driver. Do not use a hammer directly on the seals. • Do not damage the seals while assembling the shaft.

O-ring Lubricate adequately before inserting them at the right place so as to avoid rolling while assembling shaft.

Adjusting shims Use appropriate adjusting shims and measure each one separately. Complete group measurement or stamping on the shim is not always reliable check.

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Transmission - Mechanical transmission

Bearings Use correct pullers for bearings removal. Clean, lubricate and inspect well before reassembling the bearings. The spiral elastic pins do not need such adjustment.

Sealing Use sealants as specified. ensure that parts to be sealed are clean, dry and grease free.

Oil drain Before disassembly oil should be drained out from the group. WARNING Disposal of used oil must be done according to the laws.

Cleaning 1. All parts in motion (gears, bearings, etc) are to be washed accurately with parts cleaning solution. 2. Petrol and watery alkaline solutions are to be avoided. 3. Do not wash with stream or hot water as it will be very difficult to eliminate surface humidity. 4. Dry all parts with a rag or air jet to avoid scratching from abrasive residuals. 5. All surfaces should be covered with lubricant so as to protect it from future oxidation.

Inspections 1. Examine accurately that all bearings, external rings which may be still stuck in their position pivot pins on which rolls rotate and replace those which are worn out or damaged. 2. Gears should not be damaged and toothing should not be excessively worn. Teeth smoothing should not be deteriorated. 3. Control all grooves assure that they are not worn out or damaged. 4. Replace damaged parts with original spare parts. 5. Replace seals on rotating shaft, after disassembly.

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Transmission - Mechanical transmission

Mechanical transmission - Overhaul 1. Loosen and remove the upper right-hand side bolt (1) on the intermediate plate and remove transmission lubrication pipe (2).

GNIL15TR00639AB

GNIL15TR00640AB

GNIL15TR00641AB

GNIL15TR00642AB

2. Remove the circlip (1) and spacer (2) from the output shaft.

3. Remove the bolts (1) and remove the shuttle gear housing (2).

4. Remove the dog teeth synchronizer ring (1) of the shuttle synchronizer.

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Transmission - Mechanical transmission

5. Remove the needle bearing (1).

GNIL15TR00643AB

GNIL15TR00644AB

GNIL15TR00645AB

GNIL15TR00646AB

6. Remove the circlip (1) at the other end of the intermediate plate.

7. Then tap the intermediate plate (1) with mallet to separate it out from the shuttle rail. NOTE: Ensure that ball and spring meant for neutral position shuttle are collected properly.

8. Remove the circlip (1) of synchronizer shuttle gear and then remove synchronizer assembly (2) from input shaft.

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Transmission - Mechanical transmission

9. Remove the circlip (1) from input shaft, and remove synchronizer dog teeth (2) of synchronizer assembly.

GNIL15TR00647AB

10. Remove the circlip (1) from rear side of input shaft, remove spacer (2) and the gear (3) (Reverse gear on input shaft).

GNIL15TR00648AB

GNIL15TR00649AB

11. On intermediate plate, remove lock screw (1) holding the reverse idler. Once removed, take out the pin (2).

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Transmission - Mechanical transmission

12. Remove the washer (1), gear (2), needle bearing (3) and spacer (4). See the figure 12 and 13.

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GNIL15TR00650AB

GNIL15TR00651AB

Transmission - Mechanical transmission

Mechanical transmission - Troubleshooting Problem Possible Cause Correction 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 Failed or defective inner components and replace faulty parts Internal component seizure due to poor lu- Overhaul transmission and top up oil up to brication correct level Faulty clutch plate springs Replace clutch plates Noisy operation with tractor stationery, idling engine and transmission in neutral External linkage and levers misadjusted Adjust correctly Self disengagement of speed, range gears Failed control rail retaining springs Replace springs Partial engagement travel Correct reasons for problem and restore full travel External levers wrongly adjusted Adjust correctly Difficult engagement of speed and range gears External levers stiff or seized Check pivot points and correct Internal control items (rails, forks and Overhaul control items sleeves) slide with difficulty

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Index Transmission - 21 Mechanical transmission - 114 Mechanical transmission - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Transmission - 21 Power shuttle transmission - 112

TT4.80 TT4.90

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Contents Transmission - 21 Power shuttle transmission - 112

TECHNICAL DATA Power shuttle transmission Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Power shuttle transmission Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Transmission - Power shuttle transmission

Power shuttle transmission - Special tools Sr. No 1

Tool description Power shuttle valve pressure checking gauge (40 380200582 bar), adapter and pipe

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Tool number

Transmission - Power shuttle transmission

Power shuttle transmission - Remove Prior operation: Remove the battery connection. See the battery removal process Battery - Remove (55.302). Prior operation: Transmission separation from flywheel and gear box. See Master clutch housing - Remove (21.110) for transmission. Prior operation: Remove the fuel tank. See the fuel tank removal process Fuel tank - Remove (10.216). Prior operation: Remove the clutch. See the clutch removal process Clutch - Remove (18.110). Prior operation: Disconnect the power shuttle inlet and outlet pipes. See the Power shuttle transmission external controls - Remove (21.134). Prior operation: Disconnect the power shuttle external controls. See the Power shuttle transmission external controls - Remove (21.134). 1. Remove the switch (1) along with washer from the power shuttle valve (2).

GNIL15TR00989AB

GNIL15TR00990AB

GNIL15TR00991AB

2. Remove the circlip (1) and take out the connecting rod (2).

3. Remove the circlips (1) and washers (2) from the forward and reverse lever (3) and clutch control lever (4).

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Transmission - Power shuttle transmission

4. Remove the nut (1) and washer (2) from the power shuttle valve (3).

GNIL15TR00992AB

GNIL15TR00993AB

GNIL15TR00994AB

GNIL15TR00995AB

5. Remove the screws (1) and nuts (2) from the power shuttle valve (3). 6. Remove the gasket (4) from the power shuttle valve (3).

7. Remove the studs (1) and (2) from the transmission housing. 8. Remove the plug (3) and bolts (4), (5) from the transmission housing.

9. Remove the bolts (1) and take out the sleeve (2).

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Transmission - Power shuttle transmission

10. Remove the bolts (1) fixing the front bearing support to the gearbox.

ANIL12TR00177AB

ANIL12TR00178AB

11. Remove the union (1) for reverse clutch oil inlet.

12. Pull out and remove the forward drive clutch unit (1) carefully.

ANIL12TR00179AB

GNIL15TR00996AB

13. Remove the circlip (1) from the drive gear (2).

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Transmission - Power shuttle transmission

14. Remove bolts (1) fixing the rear bearing support to the gearbox.

ANIL12TR00180AB

GNIL15TR00998AB

GNIL15TR00999AB

GNIL15TR01000AB

15. Remove the reverse drive clutch pin (1) from the transmission housing.

16. Remove the shaft (1) and washer (2) from the reverse idler (3). 17. Remove the reverse idler (3) along with the needle bearing (4) and washer (5) from the transmission.

18. Remove the creeper drive gears (1) from the input shaft.

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Transmission - Power shuttle transmission

19. Pull out and remove the reverse drive clutch unit (1) carefully.

ANIL12TR00181AB

GNIL15TR01001AB

GNIL15TR00997AB

20. Remove the circlip lock (1) from creeper driven gear shaft (2). 21. Pull out the creeper driven gear shaft (2) with the gear carefully.

22. Remove the circlip (1) and take out the delivery pipe (2).

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Transmission - Power shuttle transmission

Power shuttle transmission - Install 1. Install the delivery pipe (2) with the circlip (1).

GNIL15TR00997AB

GNIL15TR01001AB

ANIL12TR00181AB

GNIL15TR01000AB

2. Place the creeper driven gear assembly (2) on the transmission. 3. Install the circlip (1) on the creeper gear.

4. Install the reverse gear (1).

5. Install the creeper gears (1) on the input shaft.

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Transmission - Power shuttle transmission

6. Install the reverse idler (3) with needle bearing (4), washer (5), shaft (1) and washer (2) on the transmission.

GNIL15TR00999AB

GNIL15TR00998AB

ANIL12TR00180AB

GNIL15TR00996AB

7. Install the reverse drive clutch pin (1) on the transmission housing.

8. Install the bolts (1) fixing the rear bearing support to the gear box.

9. Install the circlip (1) on the drive gear (2).

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Transmission - Power shuttle transmission

10. Install the forward drive clutch unit (1).

ANIL12TR00179AB

11. Install union (1) on the reverse clutch oil inlet.

ANIL12TR00178AB

ANIL12TR00177AB

GNIL15TR00995AB

12. Install bolts (1) fixing the front bearing support to the gear box.

13. Install the sleeve (2) with three bolts (1).

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Transmission - Power shuttle transmission

14. Install the studs (1) and (2) with the plug (3) and the bolts (4) and (5) on the transmission housing.

GNIL15TR00994AB

GNIL15TR00993AB

GNIL15TR00992AB

GNIL15TR00991AB

15. Install the screws (1) and nuts (2) with the gasket (4) on the power shuttle valve (3).

16. Install the nut (1) and washer (2) on the power shuttle valve (3).

17. Install the circlips (1) and washers (2) to the forward and reverse lever (3) and clutch control lever (4).

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Transmission - Power shuttle transmission

18. Install the connecting rod (2) with circlip (1).

GNIL15TR00990AB

19. Install the switch (1) along with washer on the power shuttle valve (2).

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Index Transmission - 21 Power shuttle transmission - 112 Power shuttle transmission - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power shuttle transmission - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power shuttle transmission - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Transmission - 21 Master clutch housing - 110

TT4.80 TT4.90

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Contents Transmission - 21 Master clutch housing - 110

SERVICE Master clutch housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Transmission - Master clutch housing

Master clutch housing - Remove 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

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

1. To remove the transmission, separate engine (with front axle) from transmission housing and rear axle housing. 2. Drain the fuel tank by removing pipe connecting fuel tank to fuel strainer. 3. Remove the rear hood, see the Hood - Remove â&#x20AC;&#x201C; Rear hood (90.100).

GNIL15TR00652AA

GNIL15TR00654AB

GNIL15TR00657AB

4. Loosen and remove the bolt using an open end spanner (1) behind the mounting bracket (2) and remove the fuel strainer assembly (3).

5. Loosen and disconnect the steering pipes (1) connecting steering motor to cylinder and also remove the bracket (2) holding both pipes so that removal of individual pipe can be done.

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Transmission - Master clutch housing

6. Disconnect the pipe joint (1) of return line for transmission lubrication.

GNIL15TR00658AB

GNIL15TR00659AB

GNIL15TR00660AB

GNIL15TR00661AB

7. Push the handle throttle cable (1) from bottom end. NOTE: Take care not to have sharp bends and ensure proper routing during assembly.

8. Remove the R-pin (1) used for locking on top at HT lever.

9. Use a hammer and a pin to remove the roll pin (1) from shuttle lever rod at the bottom.

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Transmission - Master clutch housing

10. Loosen and remove the four mounting bolts (two on either sides) (1). Remove the steering housing (2).

GNIL15TR00662AB

GNIL15TR00663AB

11. Remove the roll pin (1), and remove the handle (2) of 4WD control lever.

12. Remove the roll pin (1), of foot throttle pedal, and remove the outer pedal (2).

GNIL15TR00664AB

GNIL15TR00665AB

13. Remove the plastic locks (1) using a screw driver, and remove mats (2) of tractor from both left-hand and right-hand side.

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Transmission - Master clutch housing

14. Remove footboard right-hand side by removing: • Two bolts (1) from top joining front platform with rear one.

GNIL15TR00666AB

GNIL15TR00667AB

GNIL15TR00668AB

GNIL15TR00669AB

• Three bolts (1) below footboard (two slotted and one normal).

• Two bolts (1) clamping footboard with fenders. NOTE: Use the bubble sheet or some cloth with magnets to avoid any scratch on fenders.

15. Remove the brake linkage pin of right-hand side from rear end, (1) and open the front pivot of linkages (2) and remove the linkage (3). 16. Similarly remove the left-hand side brake linkage.

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Transmission - Master clutch housing

17. Remove the neutral start switch (1).

GNIL15TR00670AB

GNIL15TR00671AB

GNIL15TR00672AB

GNIL15TR00673AB

18. Loosen and remove the parking brake cable (1).

19. Loosen front drain plug (1), and drain the oil (common for transmission, hydraulics and steering).

20. Similarly drain the oil from the rear drain plug (1).

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Transmission - Master clutch housing

21. Remove suction pipe by removing the hose clamp (1) and suction pipe rear mounting bolts (2). NOTE: Place tray for oil spill at rear end below suction pipe joint.

GNIL15TR00674AB

GNIL15TR00675AB

GNIL15TR00676AB

GNIL15TR00677AB

22. Loosen and remove the steering return union joint (1) on transmission housing.

23. Loosen and remove the hydraulic delivery pipe union joint (1) below hydraulic housing.

24. Loosen the nut (1) and remove the shuttle interlock cable (2). 25. Remove the clutch release bearing.

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Transmission - Master clutch housing

26. Remove the sleeve (2) from the transmission housing by loosening the bolts (1) (seal inside sleeve and bearing in housing).

GNIL15TR00678AB

GNIL15TR00679AB

GNIL15TR00680AB

GNIL15TR00681AB

27. Remove the seal (1) from the sleeve (2).

28. Loosen and remove the bolts (1), and remove the top cover (2).

29. Remove the buckle up bolts (1).

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Transmission - Master clutch housing

30. Pull the shuttle cam lever (1) upwards, and then push transmission housing over splitting trolley to separate the transmission housing from master clutch housing (2).

GNIL15TR00682AB

GNIL15TR00683AB

31. Remove the bearing (1) from housing.

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Transmission - Master clutch housing

Master clutch housing - Install 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. Install the bearing (1) to housing.

GNIL15TR00683AB

GNIL15TR01700AB

GNIL15TR00681AB

2. Install transmission housing on master clutch housing (2). 3. Install the shuttle can lever (1) from upwards.

4. Install the buckle up bolts (1).

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Transmission - Master clutch housing

5. Install the top cover (2) with the bolts (1).

GNIL15TR00680AB

GNIL15TR00679AB

GNIL15TR00678AB

GNIL15TR00677AB

6. Install the seal (1) on the sleeve (2).

7. Install the sleeve (2) on the transmission housing with the bolts (1).

8. Install the clutch release bearing. 9. Install the shuttle interlock cable (2) with the nut (1).

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Transmission - Master clutch housing

10. Install the hydraulic delivery pipe union joint (1) below hydraulic housing.

GNIL15TR00676AB

GNIL15TR00675AB

11. Install the steering return union joint (1) on transmission housing.

12. Install the suction pipe with the hose clamp (1) and bolts (2).

GNIL15TR00674AB

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Transmission - Master clutch housing

13. Install the front and rear drain plug (1).

GNIL15TR00672AB

GNIL15TR00673AB

GNIL15TR00671AB

GNIL15TR00670AB

14. Insert the parking brake cable (1).

15. Install the neutral start switch (1).

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Transmission - Master clutch housing

16. Install the linkage (3) with the front pivot linkages (2) and linkage pin (1). 17. Similarly install the left-hand side brake linkage.

GNIL15TR01701AB

GNIL15TR00668AB

GNIL15TR00667AB

GNIL15TR00666AB

18. Install footboard right-hand side by installing: Two bolts (1) clamping footboard with fenders. NOTE: Use the bubble sheet or some cloth with magnets to avoid any scratch on fenders.

Three bolts (1) below footboard (two slotted and one normal).

Two bolts (1) from top joining front platform with rear one.

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Transmission - Master clutch housing

19. Install mats (2) with the plastic locks (1) using a screw driver on both left-hand and right-hand side.

GNIL15TR00665AB

GNIL15TR00664AB

GNIL15TR00663AB

GNIL15TR00662AB

20. Install the outer pedal (2) and insert the roll pin (1) of foot throttle pedal.

21. Install the handle (2) of 4WD control lever and install roll pin (1).

22. Install the steering housing (2) with four mounting bolts (two on either sides) (1).

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Transmission - Master clutch housing

23. Install the roll pin (1) on the shuttle lever rod at the bottom.

GNIL15TR00661AB

GNIL15TR00660AB

GNIL15TR00659AB

GNIL15TR00658AB

24. Install the R-pin (1) used for locking on top at HT lever.

25. Install the handle throttle cable (1) from bottom end. NOTE: Take care not to have sharp bends and ensure proper routing.

26. Install the pipe joint (1) on return line for transmission lubrication.

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Transmission - Master clutch housing

27. Install the steering pipes (1) connecting steering motor to the cylinder. 28. Install the bracket (2) holding both the pipes.

GNIL15TR00657AB

GNIL15TR01702AB

GNIL15TR00652AA

29. Install the strainer assembly (3) with the mounting bracket (2) and the bolts.

30. Install the rear hood, see the Hood - Install â&#x20AC;&#x201C; Rear hood (90.100). 31. Install the pipe between fuel tank and fuel strainer. 32. Install the transmission, with the engine (with front axle) between transmission housing and rear axle housing.

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Index Transmission - 21 Master clutch housing - 110 Master clutch housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Master clutch housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Transmission - 21 Power shuttle transmission external controls - 134

TT4.80 TT4.90

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Contents Transmission - 21 Power shuttle transmission external controls - 134

SERVICE Power shuttle transmission external controls Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Transmission - Power shuttle transmission external controls

Power shuttle transmission external controls - Remove 1. Place a suitable container below the power shuttle valve (2) and disconnect the pressure pipe (1) from the power shuttle valve (2). 2. Wait till the oil drains completely.

GNIL15TR01519AB

GNIL15TR01507AB

GNIL15TR01520AB

GNIL15TR01521AB

3. Remove the banjo bolt (2) and disconnect the other end of the pressure pipe (1) connecting the hydraulic filter (3).

4. Disconnect the power shuttle inlet pipe (1) connecting power shuttle to the oil cooler. 5. Remove the allen screw (3) and disconnect the power shuttle outlet pipe (2) connecting power shuttle to the oil cooler.

6. Remove the securing brackets (1) and (2) from the power shuttle inlet pipe and outlet pipe.

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Transmission - Power shuttle transmission external controls

7. Loosen and remove the screw (1) from the inlet and outlet pipe clamp (2). 8. Disconnect the other end of power shuttle inlet pipe (3) and power shuttle outlet pipe (4).

GNIL15TR00949AB

GNIL15TR01522AB

GNIL15TR00897AB

9. Disconnect the force lubrication pipe (1) from the power shuttle valve (2).

10. Disconnect the other end of force lubrication pipe (1) with the O-ring from the transmission inlet plug (2).

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Transmission - Power shuttle transmission external controls

Power shuttle transmission external controls - Remove 1. Remove the pins (1) and disconnect the forward reverse clutch cable (2) and clutch control cable (3). 2. Loosen the nuts (4) and remove the forward reverse clutch cable (2) and clutch control cable (3) from the mounting bracket.

GNIL15TR01021AB

GNIL15TR01022AB

GNIL15TR01040AB

3. Remove the bolts (1), washers (2) and take out the forward and reverse cable mounting bracket (3).

4. Remove the pin (1) and disconnect the clutch control cable (2) from the clutch pedal. 5. Loosen the nut (3) and remove the clutch control cable (2).

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Transmission - Power shuttle transmission external controls

6. See the Clutch and components - Remove - Power shuttle version (18.110) for clutch pedal removal. 7. Remove the cotter pin (1) from the clutch cable (2). 8. Loosen the nut (3) and disconnect the clutch cable (2) from the cable mounting bracket (4).

GNIL15TR01524AB

GNIL15TR01525AB

GNIL15TR01526AB

GNIL15TR01527AB

9. Remove the pin (1) and cotter pin from the shaft rooler (2). 10. Lossen and remove the screw (3) from the shaft rooler (2). 11. Loosen and remove the nut (4) from the bracket (5).

12. Pull and remove the lever assembly (1) from the bracket (2).

13. Loosen the bolts (1) and remove the brackets (2) and (3) from the steering support.

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Transmission - Power shuttle transmission external controls

Power shuttle transmission external controls - Install 1. Install the force lubrication pipe (1) with the O-ring from the transmission inlet plug (2).

GNIL15TR00897AB

GNIL15TR01522AB

GNIL15TR00949AB

GNIL15TR01521AB

2. Install the other end of force lubrication pipe (1) with the power shuttle valve (2).

3. Install the power shuttle inlet pipe (3) and the power shuttle outlet pipe (4). 4. Install inlet and outlet pipe clamp (2) with the screw (1).

5. Insert the securing brackets (1) and (2) on the power shuttle inlet pipe and outlet pipe.

6. Install the power shuttle outlet pipe (2) connecting power shuttle to the oil cooler with the allen screw (3). 47866580 11/12/2015

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Transmission - Power shuttle transmission external controls

7. Install the power shuttle inlet pipe (1) connecting power shuttle to the oil cooler.

GNIL15TR01520AB

GNIL15TR01507AB

GNIL15TR01519AB

8. Install the pressure pipe (1) connecting the hydraulic filter (3) with the banjo bolt (2).

9. Install the pressure pipe (1) with the power shuttle valve (2).

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Transmission - Power shuttle transmission external controls

Power shuttle transmission external controls - Adjust Disengaged position 1. Cable must be assembled at disengaged position (1) of spool and bracket. 2. Spool must be extreme outside position as its comes from store. 3. Cable must be fully closed conditions.

GNIL15TR01024AB

GNIL15TR01026AB

GNIL15TR01025AB

Clutch pedal 1. Keep the pedal at full press conditions. 2. Lock the pedal with clutch stopper lock (2). 3. Assemble and adjust the cable (1) wherever cable mounting holes are coming. 4. Unlock the pedals (3).

Engaged position 1. As we unlock the pedal after assembling cable, the spool and bracket itself moves to engaged position (1). 2. Use adjustable side of the cable for adjustment, if required.

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Transmission - Power shuttle transmission external controls

Power shuttle control lever 3. Loosen the locknut (1). 4. Adjust the clutch cable (2) and tighten or shorten it as required. 5. After the desired free play is attained tighten the locknut (1).

GNIL15TR01523AB

GNIL15TR01528AB

6. Loosen the locknut (1). 7. Adjust the clutch cable (2) and tighten or shorten it as required. 8. After the desired free play is attained tighten the locknut (1).

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Index Transmission - 21 Power shuttle transmission external controls - 134 Power shuttle transmission external controls - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power shuttle transmission external controls - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power shuttle transmission external controls - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Transmission - 21 Power shuttle transmission internal components - 154

TT4.80 TT4.90

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Contents Transmission - 21 Power shuttle transmission internal components - 154

TECHNICAL DATA Clutch Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Clutch Remove - Forward shuttle clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install - Forward shuttle clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remove - Reverse shuttle clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Transmission - Power shuttle transmission internal components

Clutch - Special tools Sr. No 1 2 3 4

Tool description Power shuttle clutch lifting tackle Belleville washer pressing tool Piston pressing tool Piston guide tool

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Tool number 380200585 380200584 380200586 380200587

Transmission - Power shuttle transmission internal components

Clutch - Remove - Forward shuttle clutch 1. Remove the circlip (1) and remove the front bearing support (2).

ANIL12TR00182AB

ANIL12TR00183AB

ANIL12TR00184AB

ANIL12TR00185AB

2. Remove the circlip (1) and remove the shaft (2).

3. Remove the circlip (1) that secures the clutch disk assembly.

4. Extract the gear (1) and recover the clutch disk assembly (2) and the relative clips (3).

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Transmission - Power shuttle transmission internal components

5. Using an extractor (1) and tool 380200584 (2) compress the belleville washers (3), remove the stop ring (4) and recover the washers and piston.

ANIL12TR00781AB

ANIL12TR00782AB

6. Remove the stop ring (1) and extract the clutch body (2).

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Transmission - Power shuttle transmission internal components

Clutch - Install - Forward shuttle clutch 1. Install the stop ring (1) on the clutch body (2).

ANIL12TR00782AB

ANIL12TR00781AB

ANIL12TR00185AB

ANIL12TR00184AB

2. Using an extractor (1) and special tool 380200584 (2) compress the belevelle washers (3), install the stop ring (4) with the washers and piston.

3. Install the clutch disk assembly (2) with the relative clips (3) and install gear (1).

4. Install the circlip (1) that secures the clutch disk assembly.

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Transmission - Power shuttle transmission internal components

5. Install the shaft (2) with the circlip (1)

ANIL12TR00183AB

ANIL12TR00182AB

6. Install the front bearing support (2) and the circlip (1) .

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Transmission - Power shuttle transmission internal components

Clutch - Remove - Reverse shuttle clutch 1. Remove the circlip (1) and take out the bearing (2) with drive shaft.

GNIL15TR01002AB

GNIL15TR01003AB

GNIL15TR01004AB

GNIL15TR01005AB

2. Using an extractor (1) and tool 380200584 (2) compress the belleville washers (3), remove the stop ring and recover the washers and piston.

3. Retrieve the washer (1) from the reverse clutch housing.

4. Remove the snap ring (1) from reverse shuttle clutch housing.

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Transmission - Power shuttle transmission internal components

Clutch - Install 1. Install the snap ring (1) on reverse shuttle clutch housing.

GNIL15TR01005AB

GNIL15TR01003AB

GNIL15TR01002AB

2. Install the washer (1) to the reverse clutch housing.

3. Using an extractor (1) and tool (2) compress the belleville washers (3), install the stop ring with the washers and piston.

4. Install the bearing (2) and drive shaft with the circlip (1).

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Index Transmission - 21 Power shuttle transmission internal components - 154 Clutch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Install - Forward shuttle clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Remove - Forward shuttle clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Remove - Reverse shuttle clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Transmission - 21 Gearbox - 120

TT4.80 TT4.90

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Contents Transmission - 21 Gearbox - 120

SERVICE Gearbox Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Transmission - Gearbox

Gearbox - Disassemble Prior operation: Remove the fuel tank. See the Fuel tank - Remove (10.216) for fuel tank removal process . Prior operation: Separation of the engine and transmission. See the Engine - Remove (10.001) for engine removal process. Prior operation: Remove the creeper assembly. See the Creeper - Remove (21.160) for creeper assembly. 1. Remove the snap ring (1) from the input shaft. 2. Remove the circlips (2) and (3) from the output shaft. 3. Remove the bolts (4) and washers from the intermediate plate (5). 4. Remove the intermediate plate (5) along with the input and output shaft bearings from the housing. 5. Remove the circlip (3) and take out the input and output shaft bearings from the intermediate plate (5).

GNIL15TR00894AB

GNIL15TR00895AB

GNIL15TR00896AB

6. Remove the first gear (1) and the circlip (2) and from the input shaft.

7. Remove the cluster gear (1) along with the needle roller bearing (2), main spacer (3), and shims (4) from the output shaft.

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Transmission - Gearbox

8. Remove the roll pin (1) on the 2nd and 3rd gear fork. 9. Remove the circlip (2) on output shaft and pull out the 1st and 2nd gear fork (3) with the synchronizer shift assembly.

GNIL15TR00687AB

GNIL15TR00688AB

GNIL15TR00689AB

GNIL15TR00898AB

10. Remove the 2nd gear (1) and spacer (2) from the output shaft.

11. Remove the 3rd gear (1) from the output shaft.

12. Loosen and remove the bolts (1) from the shifter housing cover (2). 13. Pull out and remove the dipstick from the shifter housing assembly (2). 14. Loosen and remove the filler plug (3), washer from the shifter housing assembly (2). 15. Lift and remove the shifter housing cover (2).

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Transmission - Gearbox

16. Remove the roll pin from the creeper selector fork (1). 17. Remove the creeper selector fork (1) from the gear box.

GNIL15TR00899AB

GNIL15TR00900AB

18. Remove the circlip (1) and (2) from the input shaft (3).

19. Remove the 2nd gear (1) and 3rd gear (2) from the input shaft (3).

GNIL15TR00901AB

GNIL15TR00902AB

20. Remove the synchronizer shift assembly (1) from the input shaft (2).

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Transmission - Gearbox

21. Remove the roll pin (1) from the 3rd and 4th gear fork (3). 22. Remove the 3rd and 4th gear fork (3) from the input shaft (2).

GNIL15TR00903AB

GNIL15TR00904AB

GNIL15TR00905AB

GNIL15TR00906AB

23. Remove the circlip (1) from the output shaft (3). 24. Remove the 4th gear (2) and spacer from the output shaft (3).

25. Remove the circlip (1) from the input shaft (2) and remove the shaft along with the bearing.

26. Remove the circlip (1) from the output shaft (2).

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Transmission - Gearbox

27. Remove the circlip (1) from the range gear shaft. 28. Pull out and remove the range gear shaft from the gear box.

GNIL15TR00907AB

GNIL15TR00908AB

GNIL15TR00912AB

GNIL15TR00913AB

29. Remove the transmission inlet plug (1) with washer (2) and spacer (3) from the force lubrication inlet valve (4).

30. Remove the 4th gear (1) from the gearbox. 31. Pull out and remove the output shaft (2) with bearing, needle bearing and driven gear.

32. Remove the driven gear (1) and needle bearing (2) from the output shaft (3). 33. Remove the circlip (4) from the output shaft (3).

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Transmission - Gearbox

34. Using the bearing puller, remove the bearing (1) from the output shaft (2).

GNIL15TR00914AB

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Transmission - Gearbox

Gearbox - Disassemble Range gear removal 1. Remove the force lubrication inlet valve (1) and the circlip (2) from the gearbox.

GNIL15TR00909AB

GNIL15TR00910AB

GNIL15TR00911AB

GNIL15TR00922AB

2. Remove the low range drive gear (1), washer from the gearbox.

3. Remove the high range drive gear (1) with needle bearing (2) from the gearbox.

4. Remove the circlip (1) from the drive low gear (2).

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Transmission - Gearbox

5. Remove the drive low gear (1) from the gearbox.

GNIL15TR00923AB

GNIL15TR00924AB

GNIL15TR00925AB

GNIL15TR00926AB

6. Remove the bolt (1) from the transmission oil pipe pinion shaft (2). 7. Remove the transmission oil pipe pinion shaft (2) connecting the pinion shaft (3).

8. Remove the circlips (1) and (2) from the range gear output shaft (3).

9. Remove the sleeve shifter (1) and hub gear (2) from the range gear output shaft (3).

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Transmission - Gearbox

10. Release the lock washer and loosen the nut (1) from the range gear output shaft (2).

GNIL15TR00927AB

11. Pull out and remove the pinion shaft (1) from the gearbox.

GNIL15TR00928AB

GNIL15TR00929AB

GNIL15TR00930AB

12. Remove the nut (1) and range driven gear (2) from the gearbox. 13. Remove the range driven gear (3) and taper roller inner bearing from the gearbox.

14. Remove the transmission oil pipe pinion shaft (1) from the gearbox.

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Transmission - Gearbox

Gearbox - Install 1. Install the output shaft (2) bearing (1) by using tool.

GNIL15TR01703AB

GNIL15TR00913AB

GNIL15TR00912AB

2. Install the driven gear (1) and needle bearing (2) with the circlip (4) on the output shaft (3).

3. Install the output shaft assembly (2) with the 4th gear (1) on the gearbox.

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Transmission - Gearbox

4. Install the transmission inlet plug (1) with washer (2) and spacer (3) to the force lubrication inlet valve (4).

GNIL15TR00908AB

GNIL15TR00907AB

GNIL15TR00906AB

GNIL15TR00905AB

5. Install the range gear shaft with the circlip (1) on the gear box.

6. Install the circlip (1) to the output shaft (2).

7. Install the input shaft (2) and bearing with the circlip (1).

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Transmission - Gearbox

8. Install the output shaft (3) and the 4th gear (2) with the circlip (1).

GNIL15TR00904AB

GNIL15TR00903AB

9. Install the input shaft (2) and the 3rd and 4th gear fork (3) with the roll pin (1).

10. Install the 2nd gear (1) and 3rd gear (2) on the input shaft (3).

GNIL15TR00901AB

GNIL15TR00900AB

11. Install the circlip (1) and (2) on the input shaft (3).

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Transmission - Gearbox

12. Install the creeper selector fork (1) and the roll pin on the gear box.

GNIL15TR00899AB

GNIL15TR00898AB

GNIL15TR00680AB

GNIL15TR00688AB

13. Install the shifter housing cover (2) with the filler plug (3) and washer.

14. Install the dipstick and bolts (1) on the shifter housing cover (2).

15. Install the 2nd gear (1) and spacer (2) on the output shaft.

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Transmission - Gearbox

16. Install the 1st and 2nd gear fork (3) and the synchronizer shift assembly with the circlip (2) and roll pin (1).

GNIL15TR00687AB

GNIL15TR00896AB

GNIL15TR00895AB

GNIL15TR00894AB

17. Install the cluster gear (1) with needle roller bearing (2), main spacer (3), and shims (4) on the output shaft.

18. Install the circlip (2) and the first gear (1) on the input shaft.

19. Install the intermediate plate (5) with bolts (4) and washers on the housing. 20. Install the input and output shaft bearing with circlip (3) on the intermediate plate (5). 21. Install the circlip (2) and (3) on the output shaft. 22. Install the snap ring (1) on the input shaft.

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Index Transmission - 21 Gearbox - 120 Gearbox - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Transmission - 21 Gearbox external controls - 126

TT4.80 TT4.90

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Contents Transmission - 21 Gearbox external controls - 126

SERVICE Gearbox external controls Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Transmission - Gearbox external controls

Gearbox external controls - Remove 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

Range and speed selection lever removal NOTE: The removal process for range selection lever and speed selection lever is same. 1. Remove the gear lever boots. 2. Loosen and remove the split pins (1) and the pins (2) of both the pivots.

GNIL15TR00707AB

GNIL15TR00708AB

3. Remove the lever (1).

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Transmission - Gearbox external controls

Gearbox external controls - Inspect 1. Inspect the rubber boot (1) for cracks or damage and replace if necessary.

GNIL15TR00709AB

GNIL15TR00710AB

2. Before fixing cover plate, thoroughly clean and degrease mating surface and apply a 2.000 mm (0.079 in) bead of sealant (1). 3. Tighten to correct torque as specified in tightening torque table.

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Transmission - Gearbox external controls

Gearbox external controls - Install ATTENTION: 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.

Range and speed selection lever Install 1. Install the lever (1).

GNIL15TR00708AB

GNIL15TR00707AB

2. Install the split pins (1) and the pins (2) of both the pivots. 3. Install the gear lever boots.

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Index Transmission - 21 Gearbox external controls - 126 Gearbox external controls - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox external controls - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox external controls - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Transmission - 21 Gearbox internal components - 145

TT4.80 TT4.90

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Contents Transmission - 21 Gearbox internal components - 145

SERVICE Internal controls Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Transmission - Gearbox internal components

Internal controls - Remove Gear / range rail removal 1. Remove the roll pins (1), (2), (3) from the selector fork and range gear shifter link.

GNIL15TR00915AB

GNIL15TR00917AB

GNIL15TR00918AB

GNIL15TR00919AB

2. Remove the roll pin (1) from the gear speed shifter link.

3. Loosen and remove the interlocking screws (1) of range and speed gears with Allen key.

4. Remove the spring (1) and ball (2) using a special tool. NOTE: Remove spring and ball on speed gears rails whereas spring, spacer and ball on the range gear rails.

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Transmission - Gearbox internal components

5. Pull out and remove the speed selector linkage (1) and range selector linkage (2) from the gear housing. 6. Remove the range gear shifter link and gear speed shifter link from the gearbox.

GNIL15TR00920AB

GNIL15TR00921AB

7. Slide and remove the 1st and 2nd gear selection rail (1), (2) and 3rd and 4th gear selection rail (3), (4) from the gearbox.

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Transmission - Gearbox internal components

Internal controls - Inspect • Check synchromesh assembly, spring, ball and cage for damage and wear. If necessary, replace. • Check the bearings and bushes, 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.

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Transmission - Gearbox internal components

Internal controls - Install 1. Install the 1st and 2nd gear selection rail (1), (2) and 3rd and 4th gear selection rail (3), (4) on the gearbox.

GNIL15TR00921AB

GNIL15TR00920AB

GNIL15TR00919AB

GNIL15TR00918AB

2. Install the range gear shifter link and gear speed shifter link on the gearbox. 3. Install the speed selector linkage (1) and range selector linkage (2) on the gear housing.

4. Install the spring (1) and ball (2) using a special tool.

5. Install the interlocking screws (1) on the range and speed gears with Allen key.

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Transmission - Gearbox internal components

6. Install the roll pin (1) on the gear speed shifter link.

GNIL15TR00917AB

GNIL15TR00915AB

7. Install the roll pins (1), (2), (3) on the selector fork and range gear shifter link.

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Index Transmission - 21 Gearbox internal components - 145 Internal controls - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Internal controls - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Internal controls - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Transmission - 21 Creeper - 160

TT4.80 TT4.90

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Contents Transmission - 21 Creeper - 160

SERVICE Creeper Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Splitter gears, shafts, and bearings Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Transmission - Creeper

Creeper - Remove Prior operation: Remove the fuel tank. See the Fuel tank - Remove (10.216) for fuel tank removal process . Prior operation: Separation of the engine and transmission. See the Engine - Remove (10.001) for engine removal process. 1. Remove the roll pin (1) from the gear shifter fork sub assembly (2). 2. Remove the snap ring (3) and the fork sub assembly (2) along with the splitter sleeve (4) from the input shaft. 3. Remove the splitter hub (5) from the input shaft. 4. Remove the circlip (6) from the input shaft. 5. Remove the gear assembly (7) and the spacer (8) from the input shaft.

GNIL15TR00893AB

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Transmission - Creeper

Creeper - Install 1. Install the gear assembly (7) and the spacer (8) on the input shaft. 2. Install the circlip (6) on the input shaft. 3. Install the splitter hub (5) on the input shaft. 4. Install the snap ring (3) and the fork sub assembly (2) with the splitter sleeve (4)on the input shaft. 5. Install the roll pin (1) on the gear shifter fork sub assembly (2).

GNIL15TR00893AB

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Transmission - Creeper

Splitter gears, shafts, and bearings - Remove Prior operation: Remove the fuel tank. See the Fuel tank - Remove (10.216) for engine removal process. Prior operation: Separation of the engine and transmission. See the Engine - Remove (10.001) 1. Remove the circlip (1) from the splitter shaft (2). 2. Pull out and remove the splitter drive gear (3), driven gear (4) and reverse driven (5) from the splitter shaft (2).

GNIL15TR01517AB

GNIL15TR01518AB

3. Remove the circlip (1) from the groove. 4. Pullout and remove the splitter shaft (2) along with the bearing. 5. Remove the circlip (3) from the groove.

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Index Transmission - 21 Creeper - 160 Creeper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Creeper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Splitter gears, shafts, and bearings - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Transmission - 21 Dropbox - 200

TT4.80 TT4.90

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Contents Transmission - 21 Dropbox - 200

TECHNICAL DATA Dropbox General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Dropbox Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Dropbox Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Dropbox drive shaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Transmission - Dropbox

Dropbox - General specification 44/26/42 44/26/43 34.925 – 34.950 mm (1.375 – 1.376 in) 35.000 – 35.025 mm (1.378 – 1.379 in) 25.020 – 25.041 mm (0.985 – 0.986 in) 24.987 – 25.000 mm (0.984 – 0.984 in)

Reduction ratio Gear shaft outer diameter Gear inner diameter Idler pivot bore diameter in casing Pivot pin outer diameter Idler gear Inner diameter Lever spring length Under load

130.00 mm (5.12 in) 138.00 mm (5.43 in)

Dropbox - Torque

GNIL15TR00725FB

Description Transmission shaft central support retaining bolt (C12) Drive gear housing (drop box) retaining bolt (C13)

Thread size M16 x 1.5 M10 x 1.25

Torque 190 N·m (140 lb ft) 60 N·m (44 lb ft)

Dropbox - Sealing Operation description Drive gear housing (Drop box) retaining bolt (S1)

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Sealant specification LOCTITE® 518™

Transmission - Dropbox

Dropbox - Sectional view

GNIL15TR00726GB

C12 1. 2. 3. 4. 5. 6.

Drive shaft centre bearing cap-screw Intermediate gear Driven gear Roll pin Four - wheel drive engagement sleeve Ball bearing Splined driven shaft

7. 8. 9. 10. 11. 12.

Dust excluder Seal Intermediate shaft Driven shaft Centre bearing Drive shaft guard

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Transmission - Dropbox

Dropbox - Remove 1. Remove the propeller shaft and its shield. See the Dropbox drive shaft - Remove (21.200). 2. Loosen and remove the bolts (1) and remove the 4WD gear box assembly from the transmission housing.

GNIL15TR00727AB

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Transmission - Dropbox

Dropbox - Disassemble 1. Remove the tension spring (1).

GNIL15TR00728AB

GNIL15TR00729AB

GNIL15TR00730AB

GNIL15TR00731AB

2. Remove circlip (1), metal washer (2) and then remove the 4WD gear shifter lever (3) from the shaft.

3. Loosen and remove the spring retainer pin (1).

4. Remove out dowel pin (1) and remove spring retainer fork (2) from shaft.

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Transmission - Dropbox

5. Loosen and remove the lock screw (1).

GNIL15TR00732AB

GNIL15TR00733AB

GNIL15TR00734AB

GNIL15TR00735AB

6. Remove the drive gear shaft (1).

7. Remove the gear (1) and spacers (2) on both sides.

8. Remove the dust cover (1), oil seal (2).

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Transmission - Dropbox

9. Remove the circlip (1) from output shaft (2).

GNIL15TR00736AB

10. Remove output shaft (1).

GNIL15TR00737AB

GNIL15TR00738AB

GNIL15TR00739AB

11. Remove out the gear coupler (1).

12. Remove the output shaft gear (1) with spacer.

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Transmission - Dropbox

13. Remove the shifter fork (1) with spring (2) from gear box housing.

GNIL15TR00740AB

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Transmission - Dropbox

Dropbox - Install Follow the reverse order of removal for fitment.

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Transmission - Dropbox

Dropbox drive shaft - Remove Transmission shaft and guards 1. Drain the transmission oil. 2. Loosen and remove the front, rear and center bolts and remove propeller shaft shield (For 4WD).

GNIL15TR00741AB

GNIL15TR00742AB

GNIL15TR00743AB

3. Loosen and remove the bolts (1) and remove the centre mounting brackets (2).

4. Remove the circlip (1), spacers (2) from both the ends of the propeller shaft and disengage the coupler (3) to remove the shaft (4).

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Index Transmission - 21 Dropbox - 200 Dropbox - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dropbox - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dropbox - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dropbox - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dropbox - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dropbox - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dropbox - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dropbox drive shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47866580 11/12/2015 EN

SERVICE MANUAL Front axle system TT4.80 TT4.90

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Contents Front axle system - 25

[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 [25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3

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TT4.80 TT4.90

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Contents Front axle system - 25 Powered front axle - 100

TECHNICAL DATA Four-Wheel Drive (4WD) axle General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Four-Wheel Drive (4WD) axle Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Four-Wheel Drive (4WD) axle Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - General specification Type

Steering, load bearing structure, pivoting at centre

Bevel gear pair - differential Pinion-crown gear ratio: 30 km/h (19 mph) Backlash between bevel gear pair Ratio between front wheel revs and rear wheel revs 9.50 x 24-16.9 x 28 11.2 x 24-16.9 x 30 11.2 x 24-18.4 x 30

9/29=1:3.22 0.150 – 0.200 mm (0.006 – 0.008 in) 1.36 1.35 1.41

Bevel drive and differential 2.500 mm (0.098 in +/- 0.020) - 2.550 mm (0.100 in +/- 0.020) - 2.600 mm (0.102 in +/- 0.020) - 2.650 mm (0.104 in +/0.020) - 2.700 mm (0.106 in +/- 0.020) - 2.750 mm (0.108 in +/- 0.020) - 2.800 mm (0.110 in +/- 0.020) - 2.850 mm (0.112 in +/- 0.020) - 2.900 mm (0.114 in +/- 0.020) 2.950 mm (0.116 in +/- 0.020) - 3.000 mm (0.118 in +/- 0.020) - 3.050 mm (0.120 in +/- 0.020) - 3.100 mm (0.122 in +/0.020) - 3.150 mm (0.124 in +/- 0.020) - 3.200 mm (0.126 in +/- 0.020) - 3.300 mm (0.130 in +/- 0.020) - 3.400 mm (0.134 in +/- 0.020) - 3.450 mm (0.136 in +/- 0.020) 3.500 mm (0.138 in +/- 0.020) - 3.550 mm (0.140 in +/- 0.020) - 3.600 mm (0.142 in +/- 0.020) - 3.650 mm (0.144 in +/0.020) - 3.700 mm (0.146 in +/- 0.020) 2.500 mm (0.098 in) - 2.600 mm (0.102 in) - 2.700 mm (0.106 in) - 2.800 mm (0.110 in) - 2.900 mm (0.114 in) 3.000 mm (0.118 in) - 3.100 mm (0.122 in) - 3.200 mm (0.126 in) - 3.300 mm (0.130 in) - 3.400 mm (0.134 in) 3.500 mm (0.138 in) - 3.600 mm (0.142 in) - 3.700 mm (0.146 in)

Thickness of pinion bearing adjustment spacer

Thickness of crown wheel position adjustment spacer

Clearance between sides of planet and side pinion teeth Thickness of planet pinion thrust washers Thickness of side gear thrust washers Diameter of cross pin for planet pinions Side diameter cross pin bore diameter Clearance between cross pin and bores Diameter of outer axle shafts and corresponding bushes Inside diameter of installed bushes Clearance between axle shafts and bushes

0.1500 mm (0.0059 in) 1.470 – 1.530 mm (0.058 – 0.060 in) 1.500 – 1.600 mm (0.059 – 0.063 in +/- 0.030) 21.939 – 21.960 mm (0.864 – 0.865 in) 22.012 – 21.991 mm (0.867 – 0.866 in) 0.080 – 0.122 mm (0.003 – 0.005 in) 35.011 – 34.950 mm (1.378 – 1.376 in) 35.100 – 35.050 mm (1.382 – 1.380 in) 0.039 – 0.150 mm (0.002 – 0.006 in)

Axle shafts and steering knuckles Diameter of outer axle shafts and corresponding bushes Inside diameter of installed front bush Clearance between pin and bush Interference fit between bushes and respective bores Thickness of steering knuckle bearing adjuster plates

44.975 – 45.000 mm (1.771 – 1.772 in) 45.100 – 45.175 mm (1.776 – 1.779 in) 0.100 – 0.200 mm (0.004 – 0.008 in) 0.059 – 0.129 mm (0.002 – 0.005 in) 0.100 mm (0.004 in) - 0.150 mm (0.006 in) - 0.200 mm (0.008 in) - 0.250 mm (0.010 in) - 0.300 mm (0.012 in)

Planetary final drives Reduction ratio Driven gear thrust washer thickness Number of teeth in gear shaft Number of teeth in ring shaft

1:(60/12+1) = 1:6 0.770 – 0.830 mm (0.030 – 0.033 in) 12 60

Axle pivot Pivotting angle (on either side ) Centre pivot and support end float

11 ° 0.30 – 1.10 mm (0.01 – 0.04 in) 47866580 11/12/2015

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Front axle system - Powered front axle

Max. wear clearance Centre pivot diameter Centre pivot front bushing fitted Centre pivot working clearance in bushing Rear bevel pinion carrier spigot Rear bushing fitted Spigot fitted clearance in bushing Axle front and rear thrust washer thickness

2.00 mm (0.08 in) 52.652 – 52.671 mm (2.073 – 2.074 in) 52.720 – 52.790 mm (2.076 – 2.078 in) 0.052 – 0.101 mm (0.002 – 0.004 in) 90.037 – 90.072 mm (3.545 – 3.546 in) 90.035 – 90.000 mm (3.545 – 3.543 in) 0.0720 – 0.0200 mm (0.003 – 0.001 in) 4.95 – 5.00 mm (0.19 – 0.20 in)

Four-Wheel Drive (4WD) axle - Torque Part Lock ring, bevel pinion (C1) Bolt, differential case to axle casing (C2) Bolt, ring gear to differential case (C3) Bolt, king pin (C4) Bolt, ring gear support (C5) Bolt, planetary final drive housing (C6) Bolt, wheel disc to hub (C7) Nut for rim to disc securing bolt (C8) Front axle front and rear pivot support bolt (C9) Differential cage support cap bolt (C10) Front axle support to engine retaining bolt (C11)

Thread M35 x 1.5 M12 x 1.25 M12 x 1.25 M10x 1.25 M10x 1.25 M10 x 1.25 M16 x 1.5 M16x 1.5 M18 x 1.5 M12 x 1.25 M18 x 1.5

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Tightening torque 380 – 420 N·m (280 – 310 lb ft) 120 N·m (89 lb ft) 120 N·m (89 lb ft) 70 N·m (52 lb ft) 65 N·m (48 lb ft) 75 N·m (55 lb ft) 220 N·m (162 lb ft) 250 N·m (184 lb ft) 320 N·m (236 lb ft) 120 N·m (89 lb ft) 320 N·m (236 lb ft)

Front axle system - Powered front axle

GNIL15TR00546GB

Four-Wheel Drive (4WD) axle - Special tools Tool description Knuckle Seal Installer (Big)-(N4WD) Pinion O Ring Installer (N4WD Knuckle Bush Installer (N4WD) Knuckle Oil seal Installer (Small) - (N4WD) Bearing puller Magnet stand Filler gauge Spring balance Tool used for 4WD hub tightening Pinion Bearing preloading and pinion Nut tightening/removal tool 4WD

Tool number 380200599 380200601 380200602 380200600 Standard Standard Standard Standard 380200604 380200605

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Sectional view

GNIL15TR00547FB

Front axle differential X S1 S2 C1 C2 C3 Gd, Gs 1.

0.500 â&#x20AC;&#x201C; 1.000 mm (0.020 â&#x20AC;&#x201C; 0.039 in) Bevel pinion bearing shim Bevel pinion position shim Bevel pinion bearing locking Differential carrier bolt Ring gear bolt Right-hand side and left-hand side differential bearing lock ring Pinion shaft

2. 3. 4. 5. 6. 7.

Seal Bevel pinion bearing spacer Ring gear Axle shaft with universal joint Side gear Side gear

Differential pinion

Differential pinion journal

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Front axle system - Powered front axle

GNIL15TR00549FB

Front axle steering knuckle and hub 1. 2. 3. 4. 5.

Wheel hub cap Hub cap bolt Ring gear retaining bolt Hub Taper roller bearing

6. 7. 8. 9. 10.

Ring gear King pin bolt Universal joint Lock pin Front axle shaft

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Front axle system - Powered front axle

GNIL14TR02333FA

Front axle pivot 1. 2. 3. 4. 5.

Axle pivot support bolt Differential bearing bolt Ring gear Shim Roller bearing

6. 7. 8. 9. 10.

Bolt, ring gear support Spacer, bevel pinion bearing Seal Pinion shaft Roller bearing

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Overview This tractor has a centrally pivoting front axle with the pivot and the drive shaft coaxial with the longitudinal axis of the tractor. The drive shaft has no universal joints. The differential has two planet pinions; drive is transmitted to lateral epicyclic final drive units (installed on the wheel hubs) through universal joints which require no maintenance.

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Remove Prior operation: Disconnect the battery terminals. See the Battery - Remove (55.302) process. Prior operation: Remove the engine from the transmission. See the Engine - Remove (10.001) process. 1. Disconnect the steering hoses. See the Steering control - Disconnect (41.101). 2. Place the screw jack (1) below the engine sump (2).

GNIL15TR00551AB

GNIL15TR00552AB

GNIL15TR00553AB

3. Loosen and remove the drain plug (1), and drain the oil from the front axle.

4. Loosen and remove the wheel nuts (1), and remove both the tires (3).

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Front axle system - Powered front axle

5. Place an overhaul table (1) below the front axle (hoist or screw jacks can also be used). Place suitable wedges (2) to avoid any articulation across the pivot.

GNIL15TR00554AB

GNIL15TR00555AB

6. Loosen and remove the bolts (1) (two in front and two in rear of axle) of the brackets. 7. Move the overhaul table forward to separate the font axle from the vehicle.

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Overhaul 1. Remove the wheel hub (1) from the front axle on both sides.

GNIL15TR00557AB

GNIL15TR00558AB

GNIL15TR00559AB

2. Remove the axle shaft (1) on both sides.

3. Loosen and remove the bolts and remove the differential assembly support (1) with crown wheel pinion.

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Install 1. Place an overhaul table (1) below the front axle (hoist or screw jacks can also be used). Place suitable wedges (2) to avoid any articulation across the pivot.

GNIL15TR00554AB

GNIL15TR00555AB

GNIL15TR00553AB

GNIL15TR00552AB

2. Install the front axle to the vehicle with the brackets and bolts (1) (Two in front and two in rear of axle).

3. Install the both tires (3) and with the nuts (2).

4. Install the drain plug (1).

5. Connect the steering hoses. See the Steering control - Install (41.101). 47866580 11/12/2015

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Front axle system - Powered front axle

6. Connect the battery terminals. See the Battery - Install (55.302). 7. Insert the engine to the transmission. See the Engine - Install (10.001).

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Index Front axle system - 25 Powered front axle - 100 Four-Wheel Drive (4WD) axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) axle - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) axle - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) axle - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Front axle system - 25 Front bevel gear set and differential - 102

TT4.80 TT4.90

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Contents Front axle system - 25 Front bevel gear set and differential - 102

SERVICE Front bevel gear set and differential Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Differential Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Axle pinion Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Adjust Bevel drive adjustments 1. Place differential support on the test bench after fitting pinion shaft bearing cups into the support. 2. Fit the dummy shaft (9971264) provided with pinion (head side) bearing cone and fit the gauge (9971259) into bearing seats of the differential casing.

GNIL15TR00572AB

GNIL15TR00573AB

3. Through a feeler gauge/slip gauge determine the clearance L1 between the dummy shaft and the gauge. The position adjusting shim (1), see the figure 2 of the pinion shaft shall be: • SP = L1 + C if C has negative sign • SP = L1 – C if C has positive sign The resulting value has always to be rounded off in excess. Shims differ one from the other by a thickness of 0.100 mm (0.004 in +/- 0.02)

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Front axle system - Front bevel gear set and differential

Backlash setting 1. Assemble into the differential gearing support the differential assembly provided with ring bevel gear and its bearing cones. 2. Insert the bearing cups into the differential support after lubrication. Assemble differential support keeps, tighten their M12 x 1.25 screws to the torque of 60 N·m (44 lb ft), loosen and tighten them again to the torque of 20 N·m (15 lb ft). 3. Assemble the right adjusting ring nut M95 x 2 and tighten it up to approximate in excess the intentional backlash referred on the drawing between pinion shaft and ring gear. NDIL14TR00427AB

4. Tighten the left ring nut M95 x 2 rotating the ring gear at the same time up to the torque of 40 – 60 N·m (30 – 44 lb ft). 5. Through a centesimal gauge positioned perpendicularly to the outer extremity of the ring gear teeth, check the backlash gn between tooth side of the bevel pinion and the ring gear. Perform the measure in three points at 120 ° intervals and average the three values. It must result within the range of 0.150 – 0.200 mm (0.006 – 0.008 in). 6. In case the measured backlash gn is not included within the above tolerance range, act properly on the two ring nuts so as to get the fixed backlash: loosen one of the ring nuts and, at the same time, tighten the other one of the same amount and, in any case, up to the torque of 40 – 60 N·m (30 – 44 lb ft).

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Front axle system - Front bevel gear set and differential

Differential - Disassemble 1. Place the differential assembly on a suitable fixture. 2. Straighten the lock plates (1) from both ends of differential assembly using a chisel and hammer.

GNIL15TR00575AB

GNIL14TR02363AA

GNIL15TR00577AB

GNIL15TR00578AB

3. Remove the retainer nut lock bolts on both sides using special tool (1).

4. Use the special tool (1) (part number 9971263) to open the retaining nut of differential from both ends.

5. Loosen and remove the bolts (1) and remove the differential cap (2).

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Front axle system - Front bevel gear set and differential

6. Separate the differential assembly (1).

GNIL15TR00579AB

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Front axle system - Front bevel gear set and differential

Differential - Assemble 1. Position the differential assembly (1).

GNIL15TR00579AB

GNIL15TR00578AB

GNIL14TR02363AA

GNIL15TR00577AB

2. Install the differential cap (2) on the differential assembly with bolts (1).

3. Use the special tool (1) and install the retaining nut of differential from both ends.

4. Install the bolts of the retainer nut locks on both sides. 5. Install the lock plates (1) from both ends of differential assembly using a chisel and hammer.

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Front axle system - Front bevel gear set and differential

Differential - Adjust NOTICE: When overhauling the differential assembly it is necessary to adjust the backlash between the teeth of the planet pinions and the side gears. 1. Thoroughly clean the components of the differential to remove any traces of oil which would otherwise prevent accurate backlash measurement. 2. Install the side gears without thrust washers. 3. Fit the planet pinions complete with thrust washers and pins and screw the pin retaining bolts in by a few turns sufficient to hold the pins in place. 4. Position a dial gauge on the differential housing, as shown in figure 1. 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 float (Gs) on the dial gauge.

NDIL14TR00432AA

NDIL14TR00431AA

6. Repeat the above operations to measure the End float on the right-hand side gear (Gd). The end float should be 0.25 mm (0.0098 in). Therefore the shims to be inserted in the differential housing are given by: Ss = Gs - 0.25 mm (0.0098 in) for the left-hand side gear; Sd = Gd - 0.25 mm (0.0098 in) for the right-hand side gear. 7. Install shims as near as possible to the calculated value and, using a dial gauge and following the procedure described above; check that the end float of the left and right -- hand side gears is approximately 0.25 mm (0.0098 in).

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Front axle system - Front bevel gear set and differential

Differential - Install 1. Position the differential assembly (1).

GNIL15TR00579AB

GNIL15TR00578AB

GNIL15TR00577AB

GNIL14TR02363AA

2. Install the differential cap (2) on the differential assembly with bolts (1).

3. Use the special tool (1) and install the retaining nut of differential from both ends.

4. Install the bolts (2) of the retainer nut locks on both sides.

5. Install the lock plates (1) from both ends of differential assembly using a chisel and hammer. 47866580 11/12/2015

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Front axle system - Front bevel gear set and differential

Axle pinion - Remove 1. Flip the axle assembly upside down on fixture and remove pinion outboard circlip (1).

GNIL15TR00582AB

GNIL15TR00583AB

GNIL15TR00584AB

GNIL15TR00585AB

2. Unlock the check nut (1) using a chisel/screw driver.

3. Using the special tool (1), figure 3 (part number 9971263) and remove the check nut.

4. Hammer the pinion using a mallet from the splined end and remove pinion (1) from assembly. NOTE: Take caution to remove the ball in the assembly, used to lock bush with the pinion shaft.

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5. Remove the dust cover (1), and seal (2) from housing by tapping inner race of the outboard bearing.

GNIL15TR00586AB

GNIL15TR00587AB

6. Remove the inner bearing (1).

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Axle pinion - Adjust Calculation of pinion shaft bearing adjusting shim NOTE: Use the bearing heater in order to install the bearing onto the shaft with interference. By trying out, determine the pinion shaft bearing adjusting shim SR so as to determine the correct pinion rolling torque as follows: 1. Fit onto the pinion shaft the shim SP, its bearing (head side) cone together with taper rollers. 2. Assemble the pinion shaft into the differential support provided with bearing cups, fit the spacer, the trial shim SR, (standard is 4.500 mm (0.177 in)) the pinion shaft rear bearing cone, the seal ring, the anti-rotational ball and the ring nut M35 x 1.5. 3. Tighten the ring nut rotating the pinion shaft at the same time in order to bed the taper rollers in their seats. The ring nut tightening torque should be 380 – 420 N·m (280 – 310 lb ft) for M35 x 1.5 ring nut. 4. Without the pinion shaft seal installed, measure the bevel pinion rolling torque which must be included in the following range: • RP = 0.80 – 1.30 N·m (7.08 – 11.51 lb in) In case RP is lower than the required value the correct shim shall be reduced and vice versa in case it is higher. Shims will be available in sizes varying from 4.30 – 4.80 mm (0.17 – 0.19 in) with a difference of 0.050 mm (0.002 in). 5. The final adjusting shim SRf should be increased by 0.050 mm (0.002 in) with respect to the trial one SR. • SRf = SR + 0.05 6. Once the adjusting shim SR (1), figure 1 has been fixed. 7. Fit the shaft seal onto the pinion shaft. 8. Tighten the ring nut rotating the pinion shaft at the same time in order to bed the taper rollers in their seats. The ring nut tightening torque should be 380 – 420 N·m (280 – 310 lb ft) for M35 x 1.5 ring nut. 9. With the pinion shaft seal installed, measure the bevel pinion rolling torque which must be included in the following range: RP = 0.60 – 1.50 N·m (5.31 – 13.28 lb in). NOTE: Rolling torque can also be measured with a spring balance with string tied to it in case rolling torque meter is not available.

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GNIL15TR00588AB

Front axle system - Front bevel gear set and differential

Axle pinion - Install 1. Install the inner bearing (1).

GNIL15TR00587AB

GNIL15TR00586AB

GNIL15TR00585AB

GNIL15TR00584AB

2. Install the dust cover (1), and seal (2) from the inner bearing.

3. Install the pinion (1) using hammer. NOTE: Make sure to install the ball in the assembly, used to lock bush with the pinion shaft.

4. Install the check nut by using special tool (1).

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Front axle system - Front bevel gear set and differential

5. Lock the check nut (1) using a chisel/screw driver.

GNIL15TR00583AB

GNIL15TR00582AB

6. Install the pinion outboard circlip (1) and lock it.

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Index Front axle system - 25 Front bevel gear set and differential - 102 Axle pinion - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle pinion - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle pinion - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front bevel gear set and differential - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

TT4.80 TT4.90

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Contents Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

SERVICE Steering knuckle and king pin Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Wheel hub Remove – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Overhaul – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Front axle system - Final drive hub, steering knuckles, and shafts

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

NOTE: Install the front axle on stand 293460 and proceed as follows. 1. Smear grease on king pin and bearing area. Tighten the upper kingpin bolts using the special tool (1) and torque them at 70 N·m (52 lb ft).

NDIL14TR00412AB

NDIL14TR00413AB

NDIL14TR00414AB

2. Smear grease on king pin and bearing area. Tighten the lower kingpin bolts until a rolling torque of 20 – 30 N·m (15 – 22 lb ft) is maintained in the knuckle.

3. Measure the gap (H) created between the lower cover and the casing adjacent to each of the three bolts. 4. Partially unscrew the bolts (1) of the upper cover, insert the selected shims equal to dimension "H" already measured.

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Front axle system - Final drive hub, steering knuckles, and shafts

5. After having rotated the casing a few times to allow the components to bed down, check that the torque necessary to rotate the casing (ignoring the initial torque) is 70 – 110 N·m (52 – 81 lb ft). 6. If the torque value measured is greater than the prescribed value, increase the thickness of the shims (S3). If the measured value is less than the prescribed value, reduce the thickness of the shims. 7. Fit the grease nipples in the upper and lower covers and grease the assembly.

NDIL14TR00415AB

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Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Remove â&#x20AC;&#x201C; 4WD Prior operation: Remove the front axle from the vehicle. (See the Four-Wheel Drive (4WD) axle - Remove (25.100) for front axle removal). 1. Place the axle on a suitable support. 2. Loosen the drain plug (1) and drain oil from wheel hubs from both sides. Place the axle on a suitable support.

GNIL15TR01032AB

GNIL15TR01028AB

GNIL15TR01029AB

3. Loosen and remove the tie rod end nut (1) from both the ends and remove the tie-rod (2).

4. Disconnect the steering pipe connections and remove the steering cylinder (1).

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Front axle system - Final drive hub, steering knuckles, and shafts

5. Loosen and remove the hub bolts (1) and remove the planetary gear cover plate (2).

GNIL15TR01030AB

GNIL15TR01031AB

GNIL15TR01033AB

6. Remove the planetary gear assembly (1) from the front axle.

7. Loosen and remove the drive bushing (1) and remove the ring hub (2).

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Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Overhaul â&#x20AC;&#x201C; 4WD Right-hand side wheel hub removal 1. Remove the seal (1) from the steering knuckle housing (2).

GNIL15TR01034AB

GNIL15TR00604AB

GNIL15TR00605AB

GNIL15TR01035AB

2. Using a suitable puller (1) remove the inner hub taper roller bearing (2).

3. Loosen and remove the three king pin bolts (1) from top and bottom from both the sides and remove the kingpins (2). NOTE: Ensure shims are present from both the ends and the seals are in good condition.

4. Remove the steering knuckle housing (1).

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Front axle system - Final drive hub, steering knuckles, and shafts

5. Loosen the lock pin (1) to free the shaft from the axle housing (2).

GNIL15TR01038AB

GNIL15TR01039AB

GNIL15TR01036AB

GNIL15TR01037AB

6. Remove the axle shaft (1) from the axle housing (2).

7. Remove circlip (1) from axle shaft (2) and remove bearing assembly with bushing (3).

8. Remove the circlip (1) from the bearing assembly and then remove ball bearing (2).

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Front axle system - Final drive hub, steering knuckles, and shafts

Left-hand side wheel hub removal Repeat the step 1 to 8 for the left-hand side wheel hub removal process.

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Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Install 1. Install the ring hub (2) with the drive bushing (1).

GNIL15TR01033AB

GNIL15TR01031AB

GNIL15TR01030AB

GNIL15TR01031AB

2. Install the planetary gear assembly (1) to the front axle.

3. Install the planetary gear cover plate (2) and tighten the hub bolts (1).

4. Install the planetary gear assembly (1) with the front axle.

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Front axle system - Final drive hub, steering knuckles, and shafts

5. Install the planetary gear cover plate (2) with the hub bolts (1).

GNIL15TR01030AB

GNIL15TR01029AB

GNIL15TR01028AB

GNIL15TR01032AB

6. Install the steering cylinder (1) and connect the steering pipe connections.

7. Install the tie-rod (2) with the tie rod end nut (1) on both the ends.

8. Install the drain plug (1).

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Index Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108 Steering knuckle and king pin - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel hub - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel hub - Overhaul – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel hub - Remove – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47866580 11/12/2015 EN

SERVICE MANUAL Rear axle system TT4.80 TT4.90

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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

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TT4.80 TT4.90

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Contents Rear axle system - 27 Powered rear axle - 100

SERVICE Rear axle housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Rear axle system - Powered rear axle

Rear axle housing - Remove Final drive housing (left or right hand side) 1. Remove the final drive housing. See Final drive housing - Remove (27.120). 2. Remove the mechanical lift assembly. See Hydraulic systems - Overview (35.000). 3. Remove the canopy. See Operator protections - Remove (90.114). 4. Remove the fenders. See Fender - Remove (90.116) 5. Remove the three point linkage. See Final drive housing - Remove (27.120) 6. Remove the drawbars and the Power Take-Off (PTO) assembly. See Two-speed rear Power Take-Off (PTO) - Remove (31.114).

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Rear axle system - Powered rear axle

Rear axle housing - Install Final drive housing (left or right hand side) Re-install the rear axle housing on the transmission housing by following the instructions: • Install the final drive housing. See the Final drive housing - Install (27.120) • Install the mechanical lift assembly. See the Hydraulic systems - Overview (35.000). • Install the canopy. See the Operator protections Install (90.114). • Install the fenders. (90.116).

See the Fender - Install

• Install the three point linkage. See the Final drive housing - Install (27.120). • Install the Power Take-Off (PTO). See the Two-speed rear Power Take-Off (PTO) - Install (31.114). 1. Before reassembling housings, supports and covers, thoroughly clean and degrease mating surfaces and apply a bead of liquid gasket of approximately 2.000 mm (0.079 in) of diameter following the patterns shown in the figure below. 2. Renew the two gaskets between transmission and rear axle housing. 3. Tighten to correct torques as detailed in tightening torque table. See the Rear bevel gear set and differential - Torque (27.106).

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Rear axle system - Powered rear axle

GNIL15TR00394GB

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Index Rear axle system - 27 Powered rear axle - 100 Rear axle housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear axle housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Rear axle system - 27 Rear bevel gear set and differential - 106

TT4.80 TT4.90

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Contents Rear axle system - 27 Rear bevel gear set and differential - 106

TECHNICAL DATA Rear bevel gear set and differential General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Rear bevel gear set and differential Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Rear bevel gear set and differential Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Bevel pinion Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Differential Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

DIAGNOSTIC Rear bevel gear set and differential Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Rear axle system - Rear bevel gear set and differential

Rear bevel gear set and differential - General specification Bevel drive and differential Bevel drive ratio Bevel drive backlash Differential Differential lock Differential pinion bore diameter Differential pinion journal diameter Differential pinion running clearance on journal Side gear boss housing diameter in differential case Side gear boss diameter Side gear boss clearance in case Bevel pinion bearing shim thickness availability Side gear and differential pinion backlash Side gear thrust washer thickness availability Differential pinion thrust washer thickness Side gear end float adjustment Differential lock fork spring length • Free • Loaded 28.50 – 31.50 kg (62.83 – 69.45 lb)

9/38 = 1 : 4.22 0.150 – 0.300 mm (0.006 – 0.012 in) Four pinion Pedal-controlled 24.040 – 24.061 mm (0.946 – 0.947 in) 23.939 – 23.960 mm (0.942 – 0.943 in) 0.080 – 0.122 mm (0.003 – 0.005 in) 44.080 – 44.119 mm (1.735 – 1.737 in) 43.961 – 44.000 mm (1.731 – 1.732 in) 0.080 – 0.158 mm (0.003 – 0.006 in) (1.15,1.2,1.25,1.3,1.35,1.4,1.45,1.5 1.55,1.6,1.65,1.70) mm 0.150 mm (0.006 in) 1.500 – 1.600 mm (0.061 – 0.065 in) 1.500 mm (0.061 in)

106.00 mm (4.17 in) 94.00 mm (3.70 in)

Rear bevel gear set and differential - Torque Description Self-locking nuts for bolts securing ring gear (C1)

Nut locking bevel pinion shaft (C2) Bolts securing differential lock pedal bracket (C3) Bolts securing final drive housing to axle casing (C4) Bolts securing mechanical lift housing on axle casing (C5) Differential assembly on axle casing (retainer ring) (C6) Retainer ring lock screw (C7) Power Take-Off (PTO) drive shaft cover (C8) PTO output shaft cover (C9) Intermediate plate buckle up (C10) Drain plug (C11)

Thread size

Torque

M12 x 1.25

M45

125 N·m (92 lb ft) 50 – 70 N·m (37 – 52 lb ft) as required to achieve preload of 10 – 20 kgf (22 – 44 lbf).

M10 x 1.25

60 N·m (44 lb ft)

M14 x 1.5

210 N·m (155 lb ft)

M12 x 2

140 N·m (103 lb ft)

M8 x 1.25 M8 x 1.25 M8 x 1.25 M8 x1 .25 M12 x 1.5 M22 x 1.5

100 N·m (74 lb ft) 26 N·m (19 lb ft) 26 N·m (19 lb ft) 26 N·m (19 lb ft) 100 N·m (74 lb ft) 65 N·m (48 lb ft)

Rear bevel gear set and differential - Special tools Tool description Sling hook, gear box Pinion bearing inner race pressing Pinion nut tightening tool Gauge for checking differential assembly roll pin length Differential retaining nut tightening tool Open ended spanner for locking gearbox Dummy pinion gauge for checking position shim (with slip gauges)

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Tool number 291517 380200329 380200327 380200325 380200324 380200326 380200323

Rear axle system - Rear bevel gear set and differential

Tool description Table for holding gears during pinion assembly Installer for Power Take-Off (PTO) seal in hollow shaft Stake for pressing outer race in differential nut- right-hand side Stake for pressing outer race in differential nut- left-hand side

Tool number 380200321 380200422 380200319 380200320

Rear bevel gear set and differential - Sealing Operation description Final drive housing to axle casing (S1) Power Take-Off (PTO) drive shaft cover (S2) PTO output shaft cover (S3) Mechanical lift housing to axle casing (S4) Axle casing top cover (S5) Retainer ring lock screw

Sealant specification LOCTITE® 518™ LOCTITE® 518™ LOCTITE® 518™ LOCTITE® 518™ LOCTITE® 518™ LOCTITE® 243™

GNIL15TR00341FB

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Rear bevel gear set and differential - Sectional view

GNIL15TR00342FB

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

Bolt Ring gear Differential journal Differential lock shift fork Differential lock sliding sleeve Bearing cone Bearing cone

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

Bevel pinion Thrust washer Differential pinion Thrust washer Side gear Differential housing Taper roller bearing

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Rear bevel gear set and differential - Overview Rear wheel drive assembly transfers drive from the transmission to the outboard final drive through a bevel pinion and crown wheel coupling. The bevel gears are spiral type and one supported by tappet roller bearings. The differential is fitted with two planetary and two side gears and mechanical lock. The differential lock is dog clutch type and 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 wheel slip consequent to the different wheel speeds.

Differential lock 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 is worse conditions 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 cut of 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.

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Rear axle system - Rear bevel gear set and differential

Rear bevel gear set and differential - Disassemble 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. Loosen and remove the bolt (1) and the differential lock outer lever (2).

GNIL15TR00343AB

GNIL15TR00419AB

GNIL15TR00344AB

2. Remove the oil collector (1).

3. Remove the roll pin (1), and pull out the cross shaft (2).

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Rear axle system - Rear bevel gear set and differential

4. Remove the spring (1), spacer (2), and fork (3).

GNIL15TR00345AB

GNIL15TR00346AB

GNIL15TR00347AB

GNIL15TR00348AB

5. Remove the allen screw (1) used to lock the retainer nut.

6. Loosen and remove the differential retainer (2) from both the sides (left-hand side and right-hand side) by using special tool number 380200324 (1). NOTE: Lock the pinion before measuring backlash.

7. Lift the crown wheel with differential assembly (1).

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8. Loosen and remove the bolts (1), and remove the differential unit (2). NOTE: Differential assembly can also be disassembled without removing crown wheel.

GNIL15TR00349AB

GNIL15TR00350AB

9. Remove the dowel pin from the differential housing by using suitable tool.

NDIL14TR00466AA

NDIL14TR00467AB

10. Remove the differential journal (1) by pushing it out gently.

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Rear axle system - Rear bevel gear set and differential

11. Withdraw the differential gears and thrust washers.

NDIL14TR00468AA

NDIL14TR00469AA

NDIL14TR00470AA

NDIL14TR00471AA

12. Withdraw the side gears and thrust washers.

13. Using suitable pullers, remove the bearings from both the sides.

14. Remove the differential lock clutch from the housing.

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Rear axle system - Rear bevel gear set and differential

Rear bevel gear set and differential - Inspect 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: Check if all parts are in good condition. Replace if any parts are found defective.

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Rear axle system - Rear bevel gear set and differential

Rear bevel gear set and differential - Assemble 1. Install the differential lock clutch on the housing.

NDIL14TR00471AA

NDIL14TR00470AA

NDIL14TR00469AA

NDIL14TR00468AA

2. Install the bearings on both the sides.

3. Install the side gears and thrust washers.

4. Install the differential gears and thrust washers.

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Rear axle system - Rear bevel gear set and differential

5. Install the differential journal (1).

NDIL14TR00467AB

NDIL14TR00466AA

GNIL15TR00350AB

GNIL15TR00349AB

6. Install the dowel pin on the differential housing by using suitable tool.

7. Install the differential unit (2) with the bolts (1)

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Rear axle system - Rear bevel gear set and differential

8. Position the crown wheel with differential assembly (1).

GNIL15TR00348AB

9. Install the differential retainer (2) on both the sides (lefthand side and right-hand side) by using special tool.

GNIL15TR00347AB

GNIL15TR00346AB

GNIL15TR00345AB

10. Install the allen screw (1).

11. Install the spring (1), spacer (2), and fork (3).

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12. Install the cross shaft (2) and place the roll pin (1).

GNIL15TR00344AB

GNIL15TR00419AB

GNIL15TR00343AB

13. Install the oil collector (1).

14. Install the differential lock outer lever (2) with the bolts (1).

15. Install the Power Take-Off (PTO) assembly. See the Two-speed rear Power Take-Off (PTO) - Assemble (31.114). 16. Install the brake pedal and brake assembly. See the Brake control pedals and shafts - Install (33.120).

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Rear axle system - Rear bevel gear set and differential

17. Install mechanical rear wheel drive housing to tractor. See the Final drive housing - Install (27.120).

NDIL14TR00455AA

18. Set crown/pinion backlash and total preload setting. 19. Use suitable tools to fit bearings. 20. Tighten to correct torques as detailed earlier. 21. Use thread sealant ( LOCTITEÂŽ 270) on crown wheel bolts.

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Rear axle system - Rear bevel gear set and differential

Rear bevel gear set and differential - Adjust Adjustment of bevel wheels Bearings 1. Loosen and remove the allen screw (1) and loosen differential retainer from both the sides.

GNIL15TR00351AB

GNIL15TR00352AB

GNIL15TR00353AB

2. Tighten right-hand side retainer nut using 380200324 (1) until back lash between the bevel teeth is 0.15-0.25. NOTE: Lock the pinion before measuring backlash.

3. Place the tip of the dial gauge (1) on the crown gear and measure the backlash.

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Rear axle system - Rear bevel gear set and differential

4. Tighten right-hand side ring nut until achieving rolling torque of the pinion bevel wheel 2 – 4 N·m (18 – 35 lb in). 5. This torque can be measured using a angular torque wrench along with dial gauge. The value at which differential housing starts rotate is the rolling torque. • Rolling torque = 1 – 2 N·m (9 – 18 lb in). • Rolling torque after CWP and differential fitment = 2 – 4 N·m (18 – 35 lb in).

GNIL15TR00354AA

GNIL15TR00355AB

6. Fit the Allen screw (1) meant to lock the retainer ring (2). Apply thread lock sealant Loctite 274 to the Allen screws.

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Rear axle system - Rear bevel gear set and differential

Bevel pinion - Disassemble 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 differential assembly with crown wheel (1).

GNIL15TR00348AB

GNIL15TR00357AB

GNIL15TR00358AB

2. Unlock the lock (1) meant to lock the pinion lock nut.

3. Lock the pinion lock nut using special tool number 3031700 (1) and loosen using the special tool number 30316000 (2).

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Rear axle system - Rear bevel gear set and differential

4. Remove the outer taper roller bearing (1) from the pinion shaft.

GNIL15TR00359AB

GNIL15TR00360AB

GNIL15TR00361AB

5. Hammer the shaft gently with a mallet and remove the pinion shaft (1) from the housing.

6. Remove outer race (1) of the bearings from the case using a suitable puller.

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Rear axle system - Rear bevel gear set and differential

7. Remove the tapper roller bearing (1) from the pinion shaft using special tool number 292911.

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GNIL15TR00362AB

GNIL15TR00363AA

Rear axle system - Rear bevel gear set and differential

Bevel pinion - Assemble 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. Install the tapper roller bearing (1) on the pinion shaft using special tool number 292911.

GNIL15TR00363AA

GNIL15TR00362AB

GNIL15TR00361AB

2. Install the outer race (1) of the bearings on the case using a suitable tool.

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Rear axle system - Rear bevel gear set and differential

3. Install the pinion shaft (1) on the housing.

GNIL15TR00360AB

GNIL15TR00359AB

GNIL15TR00358AB

GNIL15TR00348AB

4. Install the outer taper roller bearing (1) on the pinion shaft.

5. Install the pinion lock nut using special tool (1) and tighten using the special tool (2).

6. Install the differential assembly with crown wheel (1).

7. Install the differential housing. 8. Set tapper roller bearing pre-load and crown/pinion backlash settings. 47866580 11/12/2015

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Rear axle system - Rear bevel gear set and differential

9. Use suitable tools to fit the bearings.

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Rear axle system - Rear bevel gear set and differential

Bevel pinion - Adjust Adjustment of pinion position 1. Install the special tool number 30353000 (1) along with pinion bearings and crown centralizer. 2. Measure the gap between pinion bearing cone and the crown center locking tool using a slip gauge (2).

GNIL15TR00364AB

GNIL15TR00365AB

Calculate the shim (1) required following the procedure given below:1.

Suppose the gap measure with slip gauge = x

Look at the pinion face for the pinion correction value.

• If correction value= 0.00, then shim size= x+0=50 • If correction value is positive say +0.yy then shim size= x - 0.yy • If the correction value is negative say -0.zz then shim size = x + 0.zz

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Rear axle system - Rear bevel gear set and differential

Differential - Adjust Differential pinion and side gear backlash adjustment 1. Fit the two side gears in the differential carrier without the shims. 2. Install differential pinions complete with thrust washer and journal and tighten bolts a few turns to prevent journal work out. 3. Bring left-hand side gear into full contact with differential pinion. 4. Using a depth gauge measure dimension at two diametrically opposed points and average the two readings. GNIL14TR04269AB

GNIL14TR04270AB

5. Then push side gear into contact with differential carrier and measure dimension. 6. Repeat the same operations on right-hand side gear. End float of each side gear without the baulk ring must be: Gs or Gd = H1 - H2 where: Gs = Left-hand side gear end float. Gd = Right-hand side gear end float. H1 and H2 = Dimensions measured on left-hand side or right-hand side gears. Normal differential pinion and side gear backlash is 0.15 mm (0.01 in). Note that the average ratio normal backlash to the equivalent side gear end float is 1 to 1.7. Side gear end float corresponding to normal backlash will be: 0.15 x 1.8 = 0.250 mm (0.010 in). Consequently the shim thickness required in the differential carrier is given by: Ss = Gs - 0.25 (for left-hand side gear) Sd = Gd - 0.25 (for right-hand side gear) Available shims are 1.200 â&#x20AC;&#x201C; 2.000 mm (0.047 â&#x20AC;&#x201C; 0.079 in). Install closest to calculated thickness.

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Rear axle system - Rear bevel gear set and differential

Rear bevel gear set and differential - Troubleshooting Problem Possible Cause Noisy rear axle when the Pinion and/or crown wheel bearing miss tractor is moving and adjustment 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 rear axle housing and adjust pinion and crown wheel bearings correctly

Remove rear axle housing and replace damaged parts Remove rear axle housing and adjust bevel pinion and crown wheel bearings correctly

Remove rear axle housing, replace worn parts and adjust differential gear backlash correctly Noisy rear axle with over - Insufficient pinion and/or crown wheel Remove rear axle housing and adjust bevel pinion and crown wheel bearings correctly heating bearing backlash Insufficient bevel pinion to crown wheel Remove rear axle housing and adjust crown wheel bearings correctly tooth backlash

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Index Rear axle system - 27 Rear bevel gear set and differential - 106 Bevel pinion - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bevel pinion - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bevel pinion - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear bevel gear set and differential - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear bevel gear set and differential - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear bevel gear set and differential - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear bevel gear set and differential - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear bevel gear set and differential - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear bevel gear set and differential - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear bevel gear set and differential - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear bevel gear set and differential - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear bevel gear set and differential - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear bevel gear set and differential - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear bevel gear set and differential - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Rear axle system - 27 Planetary and final drives - 120

TT4.80 TT4.90

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Contents Rear axle system - 27 Planetary and final drives - 120

TECHNICAL DATA Planetary and final drives General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Planetary and final drives Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Planetary and final drives Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Final drive housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Rear axle system - Planetary and final drives

Planetary and final drives - General specification Type Gears Reduction ratio Backlash between sun shaft and planetary gear Backlash between planetary gear and ring gear End float in the axle Final drive spline fits Interference Clearance

Planetary, single reduction Spur 12/60 = 1:6 0.150 – 0.250 mm (0.006 – 0.010 in) 0.250 – 0.350 mm (0.010 – 0.014 in) 0.200 mm (0.008 in) 0.050 mm (0.002 in) 0.048 mm (0.002 in)

Planetary and final drives - Torque Description Bolt securing planet carrier assembly (C1) Bolts securing final drive housing to axle casing (C2) Bolts securing wheel disc to wheel shaft (C3) Screw securing planetary gears on planet carrier (C4) Bolts securing dust cover to final drive housing (C5)

Thread size M11 x 1.5 M14 x 1.5

Torque 160 N·m (118 lb ft) 210 N·m (155 lb ft)

M18 M10 x 2.5

320 N·m (236 lb ft) 25 N·m (18 lb ft)

M8 x 1.25

26 N·m (19 lb ft)

GNIL15TR00366FB

Planetary and final drives - Special tools Tool description Seal installer - wheel side - heavy duty trumpets Seal installer - wheel side - normal trumpets 47866580 11/12/2015

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Tool No. 380200441 380200442

Rear axle system - Planetary and final drives

Tool description Seal installer - inner side - heavy duty trumpet Bearing puller Installer, rubber boot in outer brake linkage groove Installer, brake boot in final drive housing

Tool No. 380200421 standard 84261391 84261390

Planetary and final drives - Sealing Operation description Final drive housing to axle casing (S1) Brake boot to final drive housing

GNIL15TR00367FB

Sealant specification LOCTITE® 518™ LOCTITE® 638™

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Rear axle system - Planetary and final drives

Planetary and final drives - Sectional view

GNIL15TR00368GB

Longitudinal section through final drive 1. 2. 3. 4. 5.

Rear axle casing Ring gear Final drive housing Disc brakes Ball bearing

6. 7. 8. 9.

Seal Rear axle shaft Ball bearing Seal

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Rear axle system - Planetary and final drives

Planetary and final drives - Disassemble 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 final drive (1).

GNIL15TR00393AB

GNIL15TR00370AB

GNIL15TR00371AB

2. Loosen and remove the turn buckle, and lock nut (1), and remove the brake linkage.

3. Remove the outer brake disc (1) and the half axle (2).

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Rear axle system - Planetary and final drives

4. Remove actuator assembly (1), and inner brake disc.

GNIL15TR00372AB

GNIL15TR00373AB

GNIL15TR00374AB

GNIL15TR00375AB

5. Remove the brake support (1).

6. Loosen and remove the Allen screws of planetary pinions (1).

7. Lift the pinions along with the top and bottom washer (1). NOTE: Note Make sure that the whole assembly along with top and bottom washer is held together while lifting it so that needles remain intact and do not fall off.

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Rear axle system - Planetary and final drives

8. Remove lock of the pinion carrier (1).

GNIL15TR00376AB

GNIL15TR00377AB

9. Loosen and remove the pinion career bolt (1).

10. Remove the washer (1) and shim (2) carefully.

GNIL15TR00378AB

GNIL15TR00379AB

11. Remove the planet pinion carrier (1).

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Rear axle system - Planetary and final drives

12. Tilt the final drive assembly housing by 180 Â°. 13. Loosen and remove 3 bolts (1), and remove the dust cover (2).

GNIL15TR00380AB

GNIL15TR00381AB

GNIL15TR00382AB

GNIL15TR00383AB

14. Lift the axle (1).

15. Remove the outer oil seal (1).

16. Remove the outer bearing (1).

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Rear axle system - Planetary and final drives

17. Remove the inner bearing (1).

GNIL15TR00384AB

GNIL15TR00385AB

18. Remove the inner oil seal (1).

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Rear axle system - Planetary and final drives

Planetary and final drives - Assemble 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. Insert the inner oil seal (1).

GNIL15TR00385AB

GNIL15TR00384AB

GNIL15TR00383AB

2. Insert the inner bearing (1).

3. Insert the outer bearing (1).

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Rear axle system - Planetary and final drives

4. Insert the outer oil seal (1).

GNIL15TR00382AB

GNIL15TR00381AB

GNIL15TR00380AB

GNIL15TR00379AB

5. Position the axle (1).

6. Insert the dust cover (2) with the 3 bolts (1).

7. Install the planet pinion carrier (1).

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Rear axle system - Planetary and final drives

8. Insert the washer (1) and shim (2).

GNIL15TR00378AB

GNIL15TR00377AB

9. Insert the pinion career bolt (1).

10. Insert the lock of the pinion carrier (1).

GNIL15TR00376AB

GNIL15TR00375AB

11. Install the pinions along with the top and bottom washer (1).

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Rear axle system - Planetary and final drives

12. Insertl the allen screws of planetary pinions (1).

GNIL15TR00374AB

GNIL15TR00373AB

GNIL15TR00372AB

GNIL15TR00371AB

13. Install the brake support (1).

14. Install actuator assembly (1) and inner brake disc.

15. Install the outer brake disc (1) and the half axle (2).

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Rear axle system - Planetary and final drives

16. Install the brake linkage, turn buckle, and lock nut (1).

GNIL15TR00370AB

GNIL15TR00393AB

GNIL15TR00386AB

17. Install the final drive (1).

18. Install the oil seals using installers. 19. A float of 0.14 should be maintained between the planetary pinion carrier and axle shaft, using shims. 20. Using magnetic stand check float (1) and accordingly insert/remove shim. If either no play is found or if it found to be less, add shim, and if the play is more, then remove the shims.

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Rear axle system - Planetary and final drives

Final drive housing - Remove Prior operation: To remove the canopy. See the Operator protections - Remove (90.114). Prior operation: To remove the fenders. See the Fender - Remove (90.116). Prior operation: To remove the Power Take-Off (PTO). See the Two-speed rear Power Take-Off (PTO) - Remove (31.114) 1. Remove guard and detach rear electric connections (1) under rear hood.

NDIL14TR00443AB

NDIL14TR00444AB

GNIL15TR00388AA

2. Detach the electric connections (1) for left-hand side fender. 3. Detach electric connections for brake switch below right-hand side foot rest. 4. Remove the electric cables from the transmission and rear wheel drive housing. 5. Place the chokes at front and back on both sides of the front tyres.

6. Loosen the bolts (1) and remove operator seat.

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Rear axle system - Planetary and final drives

7. Remove three point linkages (1) from the tractor.

GNIL15TR00389AB

GNIL15TR00390AA

GNIL15TR00391AB

NDIL14TR00501AB

8. Refer relevant section and remove the following A. See the Hand brake lever - Remove (33.110). B. See the Two-speed rear Power Take-Off (PTO) Remove (31.114) . C. Remove HLB cover. See the Main lift system Remove (35.100). D. See the Protections and footboards - Remove (90.118). E. See the Roll Over Protective Structure (ROPS) frame - Remove (90.114). F.

Left-hand side and right-hand side fenders (1). See the 5.

9. Loosen mechanical lift housing securing bolts (1) and remove housing using a hoist.

10. Jack up rear tractor and place two suitable stands (1) under the transmission housing to raise the wheels off the ground. 11. Position splitting trolley (special tool number 292320) under the tractor supporting transmission housing and rear wheel drive housing.

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Rear axle system - Planetary and final drives

12. Remove both left and right side wheels. 13. Drain oil from the transmission housing. Refer the transmission section.

GNIL15TR01047AB

GNIL15TR00392AB

14. Remove the suction pipe by removing the hose clamp (1) and bolts (2) mounting the suction pipe at the rear.

15. Remove the brake linkages. See the Brake control pedals and shafts - Remove (33.120). 16. Wrap suitable chain or nylon rope on the final drive housing and connect it to a hoist. Loosen attaching bolts and remove the entire final drive (1). 17. Repeat for the final drive housing on the other side.

GNIL15TR00393AB

NDIL14TR00455AA

18. Connect the rear wheel drive housing to a suitable hoist using chain with hook (special tool number 291517). 19. 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. 20. Remove the PTO assembly from the housing as detailed in PTO section.

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Rear axle system - Planetary and final drives

Final drive housing - Install 1. Install the PTO assembly to the housing. See the Twospeed rear Power Take-Off (PTO) - Install (31.114). 2. Install the transmission housing and tighten the nut and bolts.

NDIL14TR00455AA

GNIL15TR00393AB

GNIL15TR00392AB

GNIL15TR01047AB

3. Wrap suitable chain or nylon rope on the final drive housing and connect it to a hoist. Install the entire final drive (1) and attaching bolts. 4. Insert the brake linkages.

5. Connect the suction pipe with the hose clamp (1) and bolts (2).

6. Install both left and right side wheels.

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Rear axle system - Planetary and final drives

7. Install the housing with bolts (1).

GNIL15TR00391AB

GNIL15TR00390AA

GNIL15TR00389AB

GNIL15TR00388AA

8. Install the following sections: A. Hand brake lever and cable. See the Hand brake lever - Install (33.110). B. PTO clutch lever and cable. See the Two-speed rear Power Take-Off (PTO) - Install (31.114). C. HLB cover. See the Main lift system - Install (35.100). D. Rear platform. See the Roll Over Protective Structure (ROPS) frame - Install (90.114). E. ROPS. See Roll Over Protective Structure (ROPS) frame - Install (90.114). F.

Hydraulic lines. See the Main lift system - Install (35.100).

G. Left-hand side and right-hand side fenders. 9. Install three point linkages (1) to the tractor.

10. Install the operator seat with the bolts (1).

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Rear axle system - Planetary and final drives

11. Install the electric cables to the transmission and rear wheel drive housing. 12. Connect electric connections for brake switch below right-hand side foot rest. 13. Connect the electric connections (1) for left-hand side fender.

NDIL14TR00444AB

14. Connect rear electric connections (1) under rear hood.

NDIL14TR00443AB

15. Replace the brake discs before inserting rear axial shaft into rear wheel drive housing. 16. Before reassembling housings, supports and covers, thoroughly clean and degrease mating surfaces and apply a 2.000 mm (0.079 in) bead of sealant following the patterns shown in 11. 17. Tighten to correct torques as detailed in tightening torque table. Refer the Planetary and final drives - Torque (27.120).

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Rear axle system - Planetary and final drives

GNIL15TR00395FB

Pattern for application of sealant during installation, final drive housing.

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Index Rear axle system - 27 Planetary and final drives - 120 Final drive housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary and final drives - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary and final drives - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary and final drives - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary and final drives - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary and final drives - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary and final drives - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary and final drives - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47866580 11/12/2015 EN

SERVICE MANUAL Power Take-Off (PTO) TT4.80 TT4.90

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Contents Power Take-Off (PTO) - 31

[31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1

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Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114

TT4.80 TT4.90

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Contents Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114

TECHNICAL DATA Two-speed rear Power Take-Off (PTO) General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Two-speed rear Power Take-Off (PTO) Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Two-speed rear Power Take-Off (PTO) Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - General specification Type Control Output shaft engagement Rotation (looking from tractor rear end)

Independent Hand lever By lever situated on transmission housing Clock wise

Standard: 2198 RPM

Engine speed at 540 RPM (standard) Power Take-Off (PTO) speed Power Take-Off (PTO) speed at engine maximum power rating

565 RPM

100 RPM 2125 RPM 1080 RPM

Engine speed at 1000 RPM Power Take-Off (PTO) speed Power Take-Off (PTO) speed at engine rated RPM

540E Power Take-Off (PTO) 1715 RPM 724 RPM

Engine speed at 540 E Power Take-Off (PTO) speed Power Take-Off (PTO) speed at engine rated RPM

Output shaft 6 or 21 11/8 in ( 6 splines )

Number of splines Shaft diameter

Power Take-Off (PTO) clutch shaft Shaft diameter Bushing fitted internal diameter Power Take-Off (PTO) shaft clearance in bushing Bushing interference fit with drive shaft

24.957 – 24.975 mm (0.983 – 0.983 in) 25.040 – 25.092 mm (0.986 – 0.988 in) 0.065 – 0.135 mm (0.003 – 0.005 in) 0.037 – 0.091 mm (0.001 – 0.004 in)

Two-speed rear Power Take-Off (PTO) - Torque Description Bolt securing Power Take-Off (PTO) driven shaft coupler (C1) Bolt securing Power Take-Off (PTO) driven shaft coupler (C2) Ring nut securing Power Take-Off (PTO) shaft and driven gear (C3)

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Thread size M14 x 1.5 x 35 M8 x 1.25 M32 x 1.5

Torque 140 N·m (103 lb ft) 26 N·m (19 lb ft) 260 N·m (192 lb ft)

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

GNIL15TR00411GB

Two-speed rear Power Take-Off (PTO) - Sealing Operation description Power Take-Off (PTO) drive shaft cover (S1) Power Take-Off (PTO) output shaft cover (S2) Hydraulic lift housing to axle casing (S3)

Sealants specification LOCTITE® 518™ LOCTITE® 518™ LOCTITE® 518™

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

GNIL15TR00412GB

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Sectional view

GNIL15TR00413GB

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

Power Take-Off (PTO) lever Power Take-Off (PTO) input shaft intermediate Power Take-Off (PTO) shifting fork Coupler Power Take-Off (PTO) input rear shaft Power Take-Off (PTO) shaft 540/540E Ball bearing

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

Nut Coupling, Splined Gear, Power Take-Off (PTO) with dog teeth Gear, Power Take-Off (PTO) economy Thrust washer Power Take-Off (PTO) output shaft Cover, Power Take-Off (PTO) shaft

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Overview The Power Take-Off (PTO) transfers engine power directly to mounted, semi-mounted or trailed equipment via a splined shaft at the rear of the tractor. The system utilizes the standard 6 - splines shaft designed to operator at 540 RPM, the speed at which most PTO driven equipment is designed to run. The PTO input shaft front end can be connected and disconnected to the transmission input shaft by means of a lever (1) on the side of the transmission unit. The rear end of the PTO input shaft is connected to the PTO output shaft through reduction gears (2). Standard speed of 540PTO can be obtained at 1967 engine rpm. GNIL15TR00414AB

DANGER Entanglement hazard! Disengage the Power Take-Off (PTO), turn off the engine, and remove the key. Wait for all movement to stop before leaving the operator's position. Never adjust, lubricate, clean, or unplug machine with the engine running. Failure to comply will result in death or serious injury. D0097A

WARNING Entanglement hazard! Before operating stationary Power Take-Off (PTO) equipment, do the following: apply the parking brake, place all controls in the neutral position, and block all four wheels. Failure to comply could result in death or serious injury. W0336A

WARNING Entanglement hazard! Do not wear loose clothing when operating Power Take-Off (PTO) driven equipment. Failure to comply could result in death or serious injury. W0337A

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Overhaul 1. Loosen front drain plug (1), and drain the oil (common for transmission, hydraulics and steering).

GNIL15TR00415AB

GNIL15TR00416AB

GNIL15TR00417AB

GNIL15TR00418AB

2. Similarly drain the oil from the rear drain plug (1). 3. Remove the three point linkages, rear tow hook/swinging drawbar and the hydraulic lift body (HLB). Refer the hydraulic section. 4. Remove Power Take-Off (PTO) guard (dust cover).

5. Loosen and remove the four bolts (1), and remove PTO rear upper plate.

6. Loosen and remove the four bolts (1), and remove PTO rear lower plate (2).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

7. Remove the oil collector (1).

GNIL15TR00419AB

GNIL15TR00420AB

GNIL15TR00421AB

GNIL15TR00422AB

8. Remove the circlip (1) from the end of the upper PTO shaft.

9. Remove the upper shaft (1) by tapping it out with help of a mallet.

10. Remove the PTO intermediate shaft (1).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

11. Using the PTO shaft lock nut 380200328 (1) and PTO shaft rotating 380200330 (3) loosen the nut on the PTO shaft (3).

GNIL15TR00423AB

12. Remove the split pin and then remove the PTO multi speed selector lever (1).

GNIL15TR00424AB

GNIL15TR00425AB

GNIL15TR00426AB

13. Loosen and remove the outer nuts (1).

14. Remove the roll pin of the PTO fork (1) (for multi speed selection).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

15. Loosen and remove the interlocking bolt (1).

GNIL15TR00427AB

GNIL15TR00428AB

GNIL15TR00429AB

GNIL15TR00430AB

16. Using a magnet remove spring (1) and ball from PTO position rail.

17. Tap the rail (1) using a mallet and remove it.

18. Remove the shifter fork (1).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

19. Remove PTO shaft with bearing.

GNIL15TR00431AB

GNIL15TR00432AB

GNIL15TR00433AB

GNIL15TR00434AB

20. Now remove the PTO gear (1), spacer and washer.

21. Remove the shifter sleeve (2) and gear (3).

22. Remove PTO shaft bearing / smaller bearing (1). 23. Remove the bearing of the PTO shaft.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Remove Power Take-Off (PTO) seal replacement 1. Remove the PTO shaft cover (1)

GNIL15TR00435AB-01

GNIL15TR00418AB

GNIL15TR00437AB-01

2. Loosen and remove the four bolts (1), and remove PTO rear lower plate (2).

3. Remove the PTO seal (1) from the cover (2). 4. Place the new seal and tap it evenly so that it fits properly.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Install Power Take-Off (PTO) seal replacement 1. Install the PTO seal (1) on the cover.

GNIL15TR00437AB-01

GNIL15TR00418AB

GNIL15TR00435AB-01

2. Install the PTO rear lever lower plate (2) with the four bolts (1).

3. Install the PTO shaft cover (1).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Remove Power Take-Off (PTO) lever and linkages 1. Remove the hydraulic lift body (HLB), Refer the hydraulic section. 2. Remove roll pin (1) of the PTO engagement lever (from outside) and remove the PTO lever (2).

GNIL15TR00438AB

GNIL15TR00439AB

GNIL15TR00440AB

GNIL15TR00441AB

3. Remove the circlip of the PTO engagement rod and fork assembly (1).

4. Remove the PTO shifting fork (1) and coupler (2).

5. Tap the lever assembly rod (1), (2) from outside so that complete assembly can be removed.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

6. Remove the low gear end circlip (1) with GS PTO coupler and the bearing (2).

GNIL15TR00442AB

GNIL15TR00443AB

7. Tap from rear to push out the low gear with GS PTO assembly (1).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Install Power Take-Off (PTO) lever and linkages 1. Install the low gear on the GS PTO assembly (1).

GNIL15TR00443AB

GNIL15TR00442AB

GNIL15TR00441AB

GNIL15TR00440AB

2. Install the bearing (2) and the low gear end circlip (1) on the GS PTO coupler.

3. Tap the lever assembly rod (1), (2) so that complete assembly can be installed.

4. Install the coupler (2) and the PTO shifting fork (1).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

5. Install the circlip of the PTO engagement rod and fork assembly (1).

GNIL15TR00439AB

GNIL15TR00438AB

6. Install the PTO leaver (2) and the roll pin (1) on the PTO engagement lever. 7. Install the hydraulic lift body (HLB), See the Main lift system - Install (35.100).

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Index Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114 Two-speed rear Power Take-Off (PTO) - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-speed rear Power Take-Off (PTO) - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-speed rear Power Take-Off (PTO) - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-speed rear Power Take-Off (PTO) - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-speed rear Power Take-Off (PTO) - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-speed rear Power Take-Off (PTO) - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-speed rear Power Take-Off (PTO) - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-speed rear Power Take-Off (PTO) - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47866580 11/12/2015 EN

SERVICE MANUAL Brakes and controls TT4.80 TT4.90

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Contents Brakes and controls - 33

[33.120] Mechanical service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3

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Contents Brakes and controls - 33 Mechanical service brakes - 120

TECHNICAL DATA Mechanical service brakes General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Mechanical service brakes Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Brake control pedals and shafts Remove - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Brake actuators Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

DIAGNOSTIC Mechanical service brakes Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Brakes and controls - Mechanical service brakes

Mechanical service brakes - General specification Type Service brake Parking brake Control Service brake

Wet disc acting on differential axle shafts Wet disc acting on differential axle shafts Suspended type mechanical, independent pedal control (or latched for joint operation) Mechanical, hand lever, cable operated with pawl release (Sector fitted on left side of transmission housing)

Parking brake No. of discs per side

2 3 API GL4 20W/30 Organic compound Organic compound 4.750 – 4.900 mm (0.187 – 0.193 in) 4.300 mm (0.169 in) 0 mm (0 in)

Brake oil specification Service brake/ parking brake disc material Nominal Brake disc thickness. Nominal Brake disc thickness Service/Parking brakes disc discard thickness Hand Brake free play at 1st teeth of ratchet

Brake Pedal Support Right-hand side pedal I.D Bushing thickness Right-hand side pedal bushing fitted I.D Right-hand side pedal bushing/housing interference Left-hand side pedal shaft diameter Clearance between left-hand side pedal shaft and right-hand side pedal bushing Left-hand side pedal I.D Clearance between left-hand side pedal shaft and housing Bushing thickness Left-hand side pedal bushing/housing interference Handbrake shaft diameter Left-hand side brake bushings Diameter of bushing housing in steering column casing I.D. of left-hand side brake shaft support bushing in transmission casing Bushing thickness Clearance between bushings and transmission casing Interference between bushings and transmission casing

32.000 – 32.030 mm (1.260 – 1.261 in) 1.970 – 2.010 mm (0.078 – 0.079 in) 28.005 – 28.060 mm (1.103 – 1.105 in) 0.085 mm (0.003 in) 26.300 – 28.060 mm (1.035 – 1.105 in) 1.405 – 1.760 mm (0.055 – 0.069 in) 28.000 – 28.052 mm (1.102 – 1.104 in) 0.064 – 0.087 mm (0.003 – 0.003 in) 1.442 – 1.474 mm (0.057 – 0.058 in) 0.085 mm (0.003 in) 21.967 – 22.000 mm (0.865 – 0.866 in) 0.052 – 0.170 mm (0.002 – 0.007 in) 32.045 – 32.085 mm (1.262 – 1.263 in)

1.920 – 2.010 mm (0.076 – 0.079 in) 0.097 mm (0.004 in) 0.020 – 0.085 mm (0.001 – 0.003 in)

Mechanical service brakes - Torque Description Final drive housing to axle casing bolts (C1) Fender bolts (C2)

Thread size M14 x 1.5 M16 x 1.5

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Torque 200 N·m (148 lb ft) 210 N·m (148 lb ft)

Brakes and controls - Mechanical service brakes

GNIL15TR00446GB

Mechanical service brakes - Sealing Operation description Final drive housing to axle casing (S1)

Sealants specification LOCTITE® 518™ GASKET ELIMINATOR ®

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GNIL15TR00447FB

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Brakes and controls - Mechanical service brakes

Mechanical service brakes - Overview Oil immersed brakes used, has externally lined brake discs (1) 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, 3rd and 4th brake discs back-up discs (7) are fitted.

GNIL15TR00448FB

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 back-up discs. This movement increases the axial force on the housing support, back-up and actuation and produce brake torque. This action causes the final drive pinion, hence 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.

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Brakes and controls - Mechanical service brakes

Mechanical service brakes - Sectional view

GNIL15TR00449GB

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

Brake actuator assembly Final drive housing Brake disc Retaining spring Ball Actuating disc

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Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Remove - Mechanical version Brake pedal removal NOTE: Remove the steering wheel and rear hood. 1. Remove the split pin (1) and disconnect the left-hand side brake link near the clutch pedal on the left-hand side.

GNIL15TR00450AB

GNIL15TR00451AB

GNIL15TR00452AB

2. Remove the right-hand side brake pedal spring (1).

3. Remove circlip (1) and spacer (2) from the right-hand side brake pedal.

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Brakes and controls - Mechanical service brakes

4. Remove the split pin (1). 5. Remove the pin (2) and disconnect the right-hand side brake link (3). 6. Remove the right-hand side brake pedal.

GNIL15TR00453AB

GNIL15TR00454AB

7. Loosen and remove the lock bolt (1) and remove the left-hand side brake pedal (2).

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Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Remove Brake pedal linkages removal 1. Remove the split pin (1) from the pivot pin (2) and disconnect the left-hand side brake linkage (3).

GNIL15TR00455AB

GNIL15TR00456AB

2. Remove the split pin (1) and the pivot pin (2) and remove the rear left-hand side linkage of brake (3). 3. Similarly remove the right-hand side linkages.

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Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Install Installation 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

Brake pedal installation 1. Install the left-hand side brake pedal (2) and tighten the lock bolt (1).

GNIL15TR00454AB

GNIL15TR00453AB

GNIL15TR00452AB

2. Install the rightâ&#x20AC;?hand side brake pedal on the pedal shaft. 3. Connect the rightâ&#x20AC;?hand side brake link (3) to the righthand side brake pedal with the pin (2) and the split pin (1).

4. Install the spacer (2) and circlip (1) to the right-hand side brake pedal.

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Brakes and controls - Mechanical service brakes

5. Install the right-hand side brake pedal spring (1).

GNIL15TR00451AB

GNIL15TR00450AB

GNIL15TR00456AB

GNIL15TR00455AB

6. Connect the left-hand side brake link with the split pin (1).

Brake pedal linkages install 1. Install the rear left-hand side brake linkage (3) with the pivot pin (2) and split pin (1).

2. Connect the left-hand side brake linkage (3) with the pivot pin (2) and split pin (1).

3. Similarly install the right-hand side linkages.

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Brakes and controls - Mechanical service brakes

Reinstall the brake assembly and rear axle housing to the differential housing taking the following into consideration: • See the image 8 to orient the different parts. • Before reinstalling the rear axle housing, thoroughly clean and degrease the mating surface and apply a bead of liquid gasket of approximately 2.000 mm (0.079 in) of diameter, following patterns shown in the figure 8. • Check seals for wear and damage and replace if necessary. • Tighten to correct torques as detailed in tightening torque table. After brake assembly fitted in differential housing, check brake pedals for free movement between brake discs.

GNIL15TR00458FB

GNIL15TR00457AA

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Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Adjust 1. Park the tractor on level ground and place chokes on the wheels. 2. Unlock the pedals from each other. Adjust the right- brake pedals as follows: A. Loosen the locknut (1) on the right-hand side brake pull rod (2) and turn the adjuster nut till the free play in the right-hand side brake pedal is 50.00 – 55.00 mm (1.97 – 2.17 in). B. Tighten the locknut (1). While adjusting: • Screw in to reduce the play. • Screw out to increase the play. NOTE: Repeat the same procedure for the left brake pull rod. To adjust the hand brake, refer hand brake adjustment section.

Road test 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.

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GNIL15TR00459AB

Brakes and controls - Mechanical service brakes

Brake actuators - Disassemble 1. Remove the final drive from the rear axle. 2. Remove the outer brake disc (1) and the half axle (2).

GNIL15TR00460AB

GNIL15TR00461AB

GNIL15TR00462AB

GNIL15TR00463AB

3. Loosen and remove the turn buckle and lock nut (1), the nuts (1), the spring (2) and the plate (3).

4. Remove actuator assembly (1) and inner brake disc (2).

5. Remove the four springs (1) and separate the actuator plates.

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Brakes and controls - Mechanical service brakes

6. Remove the six balls (1) in the groove.

GNIL15TR00464AB

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Brakes and controls - Mechanical service brakes

Brake actuators - Assemble 1. Install the six balls (1) in the groove.

GNIL15TR00464AB

GNIL15TR00463AB

GNIL15TR00462AB

GNIL15TR00461AB

2. Install the actuator plates with the four springs (1).

3. Install the actuator assembly (1) and the inner brake disc (2).

4. Install the plate (3), spring (2) and lock nut (1) and turn buckle.

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Brakes and controls - Mechanical service brakes

5. Install the outer brake disc (1) and the half axle (2). 6. Install the final drive on the rear axle. See the Final drive housing - Install (27.120).

GNIL15TR00460AB

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Brakes and controls - Mechanical service brakes

Brake actuators - Inspect • Check the rubber boot for wear and damages. • Inspect the brake flange friction face for wear and damage, replace if necessary. • Inspect the brake discs, if badly scored, worn or cracked, replace. • Inspect the balls and the pate and replace if any defect is found. • Check O-ring on actuating shaft for any damage and replace if necessary. NOTE: Brake disc’s thickness should be minimum 4.30 mm (0.17 in)

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Brakes and controls - Mechanical service brakes

Brake actuators - Overhaul Prior operation: See Rear axle housing - Remove (27.100) for final drive removal process. 1. Remove the nut (1) from the cylinder caliper.

GNIL15TR01007AB

GNIL15TR01009AB

GNIL15TR00460AB

2. Using the special tool 380200581 remove the wheel cylinder push rod nut (1). 3. Remove the Allen key (2) from the cylinder caliper (3). 4. Remove the cylinder caliper (3) from the final drive.

5. Remove the outer brake disc (1) and the half axle (2).

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Brakes and controls - Mechanical service brakes

6. Remove actuator assembly (1) and inner brake disc.

GNIL15TR00462AB

GNIL15TR00463AB

GNIL15TR00464AB

7. Remove the four springs (1) and separate the actuator plates.

8. Remove the six balls (1) in the groove.

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Brakes and controls - Mechanical service brakes

Mechanical service brakes - Troubleshooting Problem Possible Cause Brake actuate only when Incorrect pedal adjustment pedal is depressed fully Tractor pulls to one side Brakes not equally adjusted when brakes 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

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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 actuators - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake actuators - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake actuators - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake actuators - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake control pedals and shafts - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake control pedals and shafts - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake control pedals and shafts - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake control pedals and shafts - Remove - Mechanical version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Brakes and controls - 33 Hydraulic service brakes - 202

TT4.80 TT4.90

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Contents Brakes and controls - 33 Hydraulic service brakes - 202

SERVICE Brake pedal control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Brakes and controls - Hydraulic service brakes

Brake pedal control valve - Remove 1. Remove the brake pedal springs (1) from the brake pedal (2) .

GNIL15TR01020AB

GNIL15TR01006AB

GNIL15TR01011AB

GNIL15TR01012AB

2. Remove the brake pedal circlip lock (1) from the brake pedal (2).

3. Remove the split pins (1) and take out the pins from the brake master cylinder (2).

4. Remove the brake pedal latch (1) from the brake pedal (2).

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Brakes and controls - Hydraulic service brakes

5. Remove the right-hand side brake pedal (1).

GNIL15TR01010AB

GNIL15TR01008AB

GNIL15TR01015AB

GNIL15TR01016AB

6. Place a suitable container below the master cylinder. 7. Disconnect the reservoir to master cylinder inlet pipe (3). 8. Drain the brake oil from the master cylinder inlet pipe (3). 9. Remove the banjo bolts (1) and washers from the master cylinder outlet pipes (2).

10. Remove the mounting bolts (2)and washers (3). 11. Remove the master cylinder assembly (1).

12. Remove the bolt (1) from the brake pedal shaft (2). 13. Remove the left-hand side cylinder brake pedal (3).

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Brakes and controls - Hydraulic service brakes

14. Remove the banjo bolt (1), washer and left-hand side brake pipe (2) from the cylinder caliper (3). 15. Repeat the step 14 for the removal of right-hand side brake pipe (4).

GNIL15TR01017AB

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Brakes and controls - Hydraulic service brakes

Brake pedal control valve - Install 1. Install left-hand side brake pipe (2) with washer and the banjo bolt (1) on the cylinder caliper (3). 2. Repeat the step 1 for the installation of right-hand side brake pipe (4).

GNIL15TR01017AB

GNIL15TR01016AB

GNIL15TR01015AB

GNIL15TR01008AB

3. Install the left-hand side cylinder brake pedal (3) with the bolt (1) on the brake pedal shaft (2).

4. Install the master cylinder assembly (1) with the mounting bolts (2) and the washers (3).

5. Install washers and the banjo bolts (1) on the master cylinder outlet pipes (2). 6. Fill the brake oil on the master cylinder inlet pipe (3). 7. Connect the reservoir to master cylinder inlet pipe (3) and connect the reservoir.

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Brakes and controls - Hydraulic service brakes

8. Install the right-hand side brake pedal (1).

GNIL15TR01010AB

GNIL15TR01012AB

GNIL15TR01011AB

GNIL15TR01006AB

9. Install the brake pedal latch (1) on the brake pedal (2).

10. Install the brake master cylinder (2) with the split pins (1).

11. Install the brake pedal circlip lock (1) on the brake pedal (2).

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Brakes and controls - Hydraulic service brakes

12. Install the brake pedal springs (1) on the brake pedal (2).

GNIL15TR01020AB

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Index Brakes and controls - 33 Hydraulic service brakes - 202 Brake pedal control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake pedal control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Brakes and controls - 33 Parking brake or parking lock - 110

TT4.80 TT4.90

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Contents Brakes and controls - 33 Parking brake or parking lock - 110

SERVICE Hand brake lever Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Parking brake external control Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Brakes and controls - Parking brake or parking lock

Hand brake lever - Remove 1. Remove the split pin (1) and the pivot pin (2) and remove the cable of hand brake (3) from both the sides.

GNIL15TR00465AB

GNIL15TR00466AB

GNIL15TR00467AB

GNIL15TR00468AB

2. Loosen and remove the six bolts (1) and the boot (2). 3. Remove the two split pins (3), pivot pin (2) and remove the cables of the hand brake.

4. Remove the split pin (1), pivot pin (2) and disconnect the hand brake linkage (3).

5. Loosen and remove mounting bolt (1) and remove spring (2) and remove hand brake switch (3).

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6. Loosen and remove the three bolts (1) and 4 upper bolts (2) and remove the left-hand side footboard extension assembly (3).

GNIL15TR00469AB

GNIL15TR00470AB

7. Loosen and remove the two bolts (1) and remove the complete hand brake assembly along with the bracket.

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Brakes and controls - Parking brake or parking lock

Hand brake lever - Install 1. Install the complete hand brake assembly and the bracket with the two bolts (1).

GNIL15TR00470AB

GNIL15TR00469AB

GNIL15TR00468AB

GNIL15TR00467AB

2. Install the left-hand side footboard extension assembly (3) with the three bolts (1)) and 4 upper bolts (2).

3. Install the hand brake switch (3) and spring (2) with the mounting bolt (1).

4. Connect the hand brake linkage with the pivot pin (2) and split pin (1) on the hand brake linkage.

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Brakes and controls - Parking brake or parking lock

5. Install the cables of the hand brake with the two pivot pins (3) and the two split pins (4) on the hand brake. 6. Install the boot (2) with the six bolts (1) on the hand brake.

GNIL15TR00466AB

GNIL15TR00465AB

7. Install the hand brake cable (3) on both the sides with the pivot pin (2) and split pin (1) on the hand brake.

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Parking brake external control - Adjust 1. Adjust the service brake, see the brake pedal adjustment. 2. Keep the hand brake lever in the first teeth and loosen the nut (1).

GNIL15TR00471AB

GNIL15TR01048AA

3. Adjust the nut (2) such that the hand brake cable is neither too tight nor too loose. 4. Tighten the nut (1).

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Index Brakes and controls - 33 Parking brake or parking lock - 110 Hand brake lever - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand brake lever - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake external control - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47866580 11/12/2015 EN

SERVICE MANUAL Hydraulic systems TT4.80 TT4.90

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Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.100] Main lift system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

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Contents Hydraulic systems - 35 Hydraulic systems - 000

FUNCTIONAL DATA Hydraulic systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Overview The hydraulic system on these tractors is for remote control valves and mechanical lift assembly to raise and lower the lift arms. Thus in turn the three point linkages. The high pressure hydraulic circuit is of open centre load sensing type. In this system, hydraulic lift and remote control valve are connected in series. The pump flow is continuously circulating through the hydraulic system, even when the circuit is not being operated. The priority of operation is given to the order of components in the circuit, that is the 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 centre high pressure hydraulic circuit with mechanically controlled hydraulic lift includes the components shown on the following pages.

Pump Open centre hydraulic pump assembly is of high pressure gear pump (1).

NDIL14TR00574AB

NDIL14TR00575AB

GNIL15TR00233AB

Filter Full flow spin on type filter (1) directly mounted on suction side of the pump.

Mechanical hydraulic lift assembly It is mounted on top of transmission housing. It comprises of the following components: • Position control lever (1) • Draft control lever (2) • Lift-O-Matic button (3)

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Hydraulic systems - Hydraulic systems

• Response control valve (4) • Sensitivity control valve (5) • Diverter valve (6)

GNIL15TR00234AB

GNIL15TR00235AB

GNIL15TR00253BB

• Lift arms (8) • Internal linkages and cylinder assembly Internal mechanical linkages, relief valves and hydraulic cylinder assembly are mounted inside the hydraulic lift housing. This must be removed to obtain access.

Remote control valves Remote control valves (1) is mounted behind operator seat. It comprises of the following components.

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Hydraulic systems - Hydraulic systems

Couplers for remote cylinder hoses

GNIL15TR00874AB

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Overview Open center hydraulic circuit and mechanical lift 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 control valve, 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 protect the lift cylinder and seals from excessive peaks of pressure during operation.

GNIL15TR00237GB

1. 2.

Suction line drawing from transmission housing Delivery line to control valve

F. P.

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Oil filter Hydraulic pump

Hydraulic systems - Hydraulic systems

B. D.

Lift arm Control valve

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Relief valve

Hydraulic systems - Hydraulic systems

GNIL15TR00238GB

Hydraulic circuit diagram F. P. T. 22. 8

Filter Hydraulic pump Lift arm piston Check valve Piston seat

V. 1. 5. 6. 9

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Relief valve Spool valve Plunger Plunger spring Piston

Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Fixed displacement pump - 104

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TECHNICAL DATA Pump General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Pump - General specification Filter Type Location

Paper cartridge On pump body, suction side

Pump Type Location Model Make Drive Rotation (seen from drive end) Engine / pump drive ratio Maximum rated speed (engine at governed speed) Maximum rated output Output at 1500 RPM and 207 bar (3002 psi) • New or reconditioned • Test oil temperature • Test oil grade

Gear, drawing from rear transmission housing Behind timing cover IP3060 A0008 Dynamatics Valve timing gear driven Anti clockwise 1:1.08 2300 RPM 45.2 L/min (11.9 US gpm) 27.3 L/min (7.2 US gpm) 50 °C VG-68

Pump - Torque Description Nut, pump drive gear (C1) Nut, pump mounting on timing case (C2) Bolt, pump cover (C3) Screw, delivery pipe adopter to pump (C4)

Thread size M12 M6 M8 x 1.25 M8

GNIL15TR00239FB

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Torque 30 N·m (266 lb in) 12 N·m (106 lb in) 25 N·m (221 lb in) 10 N·m (89 lb in)

Hydraulic systems - Fixed displacement pump

Pump - Special tools Tool description Hydraulic pump flow and pressure checking Nut Tightening Tool for Coil Spring Preload

Tool number. 380200592 380200440

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Pump - Overview Hydraulic pumps are spur gear type with fixed displacement according to engine 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 via oil filter. Pump comprises of four main components. The end cover, the body, the bush/gear assembly and the mounting flange. Whole of them being held together by four tie bolts. The bush gears are housed in the body and consists of a pair of meshing gears with integral journals supported in two matched pairs of composite bushes. 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 wood ruff 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 bush/gear assembly is pressure loaded against the end cover and the bushes 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 bush faces adjacent to the gears is an important factor in maintaining this efficiency and during any dismantling on assembly operations; the bushes 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 bush faces, and this will lead to shortened service life and eventual failure.

NDIL14TR00586FB

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Hydraulic systems - Fixed displacement pump

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 bush Composite bush Woodruff key Drive shaft and gear - taper Driven gear Body End cover Spring washer Nut

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Hydraulic systems - Fixed displacement pump

Pump - Remove 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. Loosen clamp screws (1) and disconnect suction pipe (2) from filter bracket.

GNIL15TR00240AB

GNIL15TR00241AB

GNIL15TR00242AB

2. Loosen screws (1) and disconnect delivery pipe from pump. 3. Remove filter (2) and filter bracket (3) from the pump.

4. Loosen four pump mounting screws (1). 5. Remove pump from the tractor. Retrieve seal from the timing case.

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Pump - Install 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. Install the pump on the tractor with the seal and screws (1).

GNIL15TR00242AB

GNIL15TR00241AB

GNIL15TR00240AB

2. Install the filter (2) on the pump with the filter bracket (3). 3. Connect delivery pipe to the pump with the screws (1).

4. Connect suction pipe (2) to filter bracket with the clamp (1).

5. Clean and degrease the mating surfaces thoroughly. 6. Replace the packing seal if necessary. 7. Tighten all fasteners to correct torque as detailed on tightening torque table. Refer the Pump - Torque (35.104).

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Pump - Disassemble 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

NDIL14TR00586FB

NOTICE: Oil pump should always repaired in very clean conditions, to prevent contamination from foreign matter which could damage the pump.

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Hydraulic systems - Fixed displacement pump

1. Bend back the ears of the tap washer (2) and screw back the nut (1) until its outer face is one turn beyond the end of the shaft thread. 2. Attach the puller tool to that it bears against the face of the nut. Withdraw the gear (3) as far as the nut will allow. 3. Remove the tool, nut, tap washer and gear. Retain the woodruff key (12). NOTE: Do not attempt to remove the coupling by hammering on levering, as this will damage pump internally. 4. Lightly mark the end cover, body and mounting flange (5), (15) and (16) to ensure reassembly in the correct relationship and take note of the direction of rotation of the pump. 5. Remove the nuts (18) and spring washer (17). 6. Remove the end cover (10) and carefully lift out the cover seal (11), the bush lobe seal (12) and anti-extrusion ring (13). 7. Make sure there are no burrs on the keyway in the shaft. Lightly tap the mounting flange clean of the two hollow dowels in the pump body and slide it squarely to the shaft. 8. Carefully lift out the body seal (6), the two backing washers (7) and (8) and the lobe seal (9). 9. Hold the pump body vertically with the mounting flange end downwards and with one hand underneath to prevent the bushes dropping out. Tap the side of the body with a hide-faced hammer to dislodge the lower bushes (10) and (11), and slide these carefully out of the body. NOTE: Keep the bushes as a pair and place them on the mounting flange. 10. Invert the body and lift out the driver and driven gears (14) and (15). 11. Remove the remaining pair of bushes as already described and place on the end cover. 12. Remove circlip (16) and oil seal (17) from the front cover.

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Hydraulic systems - Fixed displacement pump

Pump - Inspect NOTICE: 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 bush 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 bushes in a new body. Check the security of the two dowels.

Composite bushes Examine the bearing inserts for signs of wear and bush faces adjacent to the gears for scoring or pitting. Ensure that the holes and slots in the bushes are unobstructed. Light scoring on the bush faces can be polished out on a lapping plate. NOTE: If new bushes 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 bush 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: Bushes are gears are mated for width to within 0.0050 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.

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Seals and tie bolts Inspect all seals and renew if necessary. Check the condition of tie bolt threads. NOTICE: 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 (2) must be smaller than dimension (1) by 0.090 â&#x20AC;&#x201C; 0.160 mm (0.004 â&#x20AC;&#x201C; 0.006 in). If necessary remove minimum qualities of material from flat faces of bearing assemblies to obtain specified end float.

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Pump - Assemble 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

NOTE: Oil pump should always repaired in very clean conditions, to prevent contamination from foreign matter which could damage the pump. 1. Insert circlip (16) and oil seal (17) to the front cover. 2. Install the remaining pair of bushes as already described and place on the end cover. 3. Insert the body and keep it the driver and driven gears (14) and (15). 4. Hold the pump body vertically with the mounting flange end upwards and with one hand underneath to prevent the bushes dropping out. Tap the side of the body with a hide-faced hammer to locate the lower bushes (10) and (11). NOTE: Keep the bushes as a pair and place them on the mounting flange. 5. Insert the body seal (6), the two backing washers (7) and (8) and the lobe seal (9). 6. Make sure there are no burrs on the keyway in the shaft. Lightly tap the mounting flange clean of the two hollow dowels in the pump body and slide it squarely to the shaft. 7. Insert the end cover (10) and carefully lift down the cover seal (11), the bush lobe seal (12) and anti-extrusion ring (13). 8. Insert the nuts (18) and spring washer (17). 9. Place the marked end cover, body and mounting flange (5), (15) and (16). NOTE: Do not attempt to remove the coupling by hammering on levering, as this will damage pump internally. 10. Insert the tool, nut, tap washer and gear. Retain the woodruff key (12). 11. To insert the gear (3) by using special tool. 12. To insert the tap washer (2) and screw back the nut (1).

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Reassemble the pump referring to figure 1 and observe the following: 13. Always work in very clean conditions, to prevent contamination from foreign matter which could damage the pump. 14. Match the components (5) , (6) and (7) Referring to the previously marked figure. Reassemble them in their original position. 15. Assemble the gear composite bushes into the pump body. Ensure the bushes are installed the correct way round and the seal grooves are facing the end plates. NDIL14TR00591AB

16. Install seals in their locations. 17. Assemble seal (17) on front end cover.

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Pump - Test Hydraulic pump may be tested to ensure full pressure and flow. NOTICE: Before performing any pressure or flow testing, operate the tractor until the oil in the transmission is at normal operating temperature of 75 °C (167 °F). 1. Remove connection (1) between hydraulic pressure line and distributor assembly. 2. Install special tool number 380000240 at hydraulic pressure line as shown in figure 2. 3. Insert outlet hose of the tool into transmission oil filter port. 4. Ensure flow control tap is fully open.

GNIL15TR00243AB

NDIL14TR00593AA

5. Start and set engine speed to 1000 RPM. 6. Close flow control tap slowly until pressure gauge shows 166 bar (2407 psi). 7. Moving quickly, transfer the tester outlet hose to a 10 L (21 US pt) measuring jar. Simultaneously starting a stop watch. 8. Note the time to fill 10 L (21 US pt) measuring jar. Repeat the same procedure 4 to 5 times and calculate the average time. 9. At 1000 RPM, a new or reconditioned pump delivers, 18.000 – 19.000 L/min (0.636 – 0.671 cfm) at 166 bar (2407 psi). • The minimum acceptable deliveries of a used pump is 11 L/min (2.9 US gpm) at 166 bar (2407 psi). • If more than 30 s is required, or if the required pressure of 166 bar (2407 psi) cannot be achieved, then a fault exists in the hydraulic pump, hydraulic filter or oil lines. NOTE: Check oil lines and filter before investigating pump. The same procedure can also be performed using remote valves (if fitted), by making suitable changes to the adapter. Operate the remote valve lever, and then measure the flow and the pressure.

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Index Hydraulic systems - 35 Fixed displacement pump - 104 Pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Remote control valves - 204

TT4.80 TT4.90

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Contents Hydraulic systems - 35 Remote control valves - 204

TECHNICAL DATA Remote control valves General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Remote control valve Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Remote control valves Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Hydraulic systems - Remote control valves

Remote control valves - General specification Type Make Location Control Relief valve setting Cracking pressure Sustain pressure

Spool (automatic return to neutral) Walvoil On final drive Hand levers 185 – 195 bar (2682 – 2828 psi) 205 – 215 bar (2972 – 3118 psi)

Remote control valves - Special tools Tool description Hydraulic pressure testing kit

Tool number 380000240

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Hydraulic systems - Remote control valves

Remote control valve - Overview The remote control valves serve to control hydraulic loads external to the tractor and may be mounted at the rear of the centre housing. The remote control valves are operated by hand levers located to the right of the driving position. Each control lever will have three or four positions depending on the type of control valve it operates. 1. Lifting Pull lever back to lift the implement. 2. Lowering Push the lever forward to lower the implement. 3. Neutral When the lever is released from the lifting and lowering positions it will automatically return to neutral position. 4. Float Push the lever forward beyond the “lowering” position to select “float position”. In this position the only force exerted on the implement will be that created by its own weight, thus allowing the implement to follow the profile of the terrain. Operating stages of remote control valve for operation of a double-acting cylinder with automatic detent release and float position.

GNIL15TR00244FB

2. 23. 24. 25.

Spool Internal plunger Spring Cover

26. 27. 28. 32.

Detent balls Spool return spring Spring cup Float mode selection groove

NOTE: Some parts related with automatic detent release are not shown in this view. Automatic detent release working principle of valve shown in Fig. 1 is same as the valve shown at Fig. 9 & amp; Fig. 10 .

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Hydraulic systems - Remote control valves

Float control operation To select float control operation, push the control lever (located in the cab) fully forward. The control valve spool (2) will move and detent balls (26) will engage in the grooves (32) where they will be held in position by the support and the spring (24). In this position the spool directs the oil at (A) and (B) ports to exhaust lines (T). No pressure applied to both ports. In this condition, the only force acting on the attached implement is that created by its own weight and the hydraulic lift may be operated. Automatic detent release does not occur during float control as there is no pressure inside the remote control valve. Operating stages of remote control valve for operation a double acting cylinder automatic detent release and float position

GNIL15TR00245FB

Lifting When the spool (2) moves to left, the detent balls (26) engage the groove (33), where they are held in place by the support (28) and spring (24). The movement of the spool (2) connects, the pressure line (P) with the line (B), and also the upper cylinder chamber with the exhaust line (T) by way of line (A), intercepting the supply of oil to the hydraulic lift control valve.

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Hydraulic systems - Remote control valves

GNIL15TR00246FB

Lowering When the spool (2) moves to right, the detent balls engage in the groove (34) where they are held in position by the support (28) and the spring (24). In this condition the oil contained in the lower chamber of the cylinder can flow to the exhaust (T) by way of line (B), while the upper chamber is connected with the pressure line (P) by way of line (A). On completion of the lowering operation, the detent will be automatically released.

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Hydraulic systems - Remote control valves

Operating stages of remote control valve for operation of a double-acting cylinder (Fig. 4 and Fig. 5) and single-acting cylinder (Fig. 6 and amp, 7) Lifting

GNIL15TR00247FB

On pulling back the control lever, (located in the cab) the control valve spool (2) moves to connect: pressure line (P) with the lower chamber of the cylinder by way of line (A), and also exhaust line (T) by way of line (B), intercepting the supply of oil to the lift control valve. Keep the lever pulled back, to extend the cylinder to its full stroke. On releasing the lever it will automatically return to neutral position, under the action of the return spring, and the entire flow from the pump will be conveyed to the lift control valve by way of line (P).

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Hydraulic systems - Remote control valves

Lowering

GNIL15TR00248FB

To lower the implement, push the control lever (located in the cab) forward. The control valve spool (2) will move to the position indicated in Fig. 5, thus allowing the oil in the lower cylinder chamber to flow to the exhaust (T) through line (A), while the upper chamber is connected to the pressure line (P) through line (B).

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Hydraulic systems - Remote control valves

Lifting

GNIL15TR00247FB

On pulling the control lever back, the control valve spool (2), Fig. 6 moves to connect the cylinder with the pressure line (P) by way of line (A). Line (C), for the control of single-acting cylinders, is used in this stage as it is permanently connected to the exhaust (T) by the open position of the switching valve (1).

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Hydraulic systems - Remote control valves

Lowering

GNIL15TR00250FB

On pushing the control lever forward, the spool (2) will move to the position indicated in Fig. 7. The oil contained in the cylinder, pressurised by the weight of the lifted implement, will flow to the exhaust (T) by way of line (A), while the entire flow from the pump is also conveyed to the exhaust (T) through the line (B). NOTE: To operate a double-acting cylinder, tighten screw (1) fully home. To operate a single-acting cylinder, fully undo screw (1).

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Hydraulic systems - Remote control valves

Operating stages of remote control valve operating a double-acting cylinder with automatic detent release Lifting

GNIL15TR00251FB

On pulling back the control lever, the spool (2) moves and the detent balls (26) engage the groove, where they are held in place by the support (28) and spring (24). The movement of the spool (2) connects: the pressure line (P) with the line (B), and also the upper cylinder chamber with the exhaust line (T) by way of line (A), intercepting the supply of oil to the hydraulic lift control valve. On completion of the lifting movement, the oil pressure increases to 170 â&#x20AC;&#x201C; 175 bar. Acting through port (V), it overcomes the resistance of the spring of the needle valve (23). Inside chamber (D) , the oil pressure increases and, acting on the detent ball support (28), it overcomes the resistance of the spring, thus moving the support (28). In this condition the two detent balls (26) drop onto the support, releasing the spool (2) which, under the action of spring (6) returns to neutral position. Consequently the entire flow from the pump is conveyed to the lift control valve through lines (P).

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Hydraulic systems - Remote control valves

Lowering

GNIL15TR00252FB

To lower the implement, push the control lever forward. The control valve spool (2) moves and the detent balls engage in the central groove where they are held in position by the support (28) and the spring (24). In this condition the oil contained in the lower chamber of the cylinder can flow to the exhaust (T) by way of line (B), while the upper chamber is connected with the pressure line (P) by way of line (A). On completion of the lowering operation, the detent will be automatically released.

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Hydraulic systems - Remote control valves

Remote control valves - Remove 1. Loosen and remove the plastic (1) of remote valve operating lever.

GNIL15TR00253AB

GNIL15TR00254AB

GNIL15TR00255AB

GNIL15TR00256AB

2. Remove bolts (1) and then remove guide plate (2) by sliding through the lever.

3. Remove the operating lever (1) from remote valve assembly by unscrewing bolt (2).

4. Loosen and remove the banjo bolt (1) and disconnect one end of the return pipe from remote valve assembly. 5. Loosen and remove the banjo bolt (2) and disconnect the other end from the lift housing body.

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Hydraulic systems - Remote control valves

6. Loosen and remove the banjo bolt (1) and disconnect the inlet pipe from remote valve assembly.

GNIL15TR00257AB

GNIL15TR00258AB

GNIL15TR00259AB

GNIL15TR00260AB

7. Loosen and remove the banjo bolt (1) and disconnect one end of delivery pipe from remote valve assembly.

8. Hold the adaptor (1) and loosen the nut. 9. Disconnect the other end of delivery pipe from distributor assembly.

10. Remove the inlet delivery pipes (1) from the remote valve.

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Hydraulic systems - Remote control valves

Remote control valve option 11. Loosen and remove the mounting bolts (1). 12. Remove the remote valve assembly (2) from its mounting bracket.

GNIL15TR00261AB

Two remote control valves option 13. Loosen and remove the mounting bolts of remote control valve. 14. Remove the remote valve assembly (1) from its mounting bracket.

GNIL15TR00971AB

GNIL15TR00972AB

Three remote control valves option 15. Loosen and remove the mounting bolts of remote control valve. 16. Remove the remote valve assembly (1) from its mounting bracket.

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Hydraulic systems - Remote control valves

17. Loosen and remove the mounting bolts (1). 18. Remove the remote valve mounting bracket.

GNIL15TR00262AB

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Hydraulic systems - Remote control valves

Remote control valves - Install 1. Install the remote valve mounting bracket with the mounting bolts (1).

GNIL15TR00262AB

GNIL15TR00972AB

GNIL15TR00971AB

Three remote control valves option 2. Install the remote valve assembly (1) on the mounting bracket.

Two remote control valves option 3. Install the remote valve assembly (1) on the mounting bracket with the bolts.

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Hydraulic systems - Remote control valves

Remote control valve option 4. Install the remote valve assembly (2) on the mounting bracket with the bolts (1).

GNIL15TR00261AB

GNIL15TR00260AB

GNIL15TR00259AB

GNIL15TR00258AB

5. Insert the inlet delivery pipes (1) to the remote valve.

6. Connect the other end of delivery pipe to the distributor assembly. 7. Hold the adaptor (1) and tighten the nut.

8. Connect the end of delivery pipe to the remote valve assembly with the banjo bolt (1).

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Hydraulic systems - Remote control valves

9. Connect the inlet pipe to the remote valve assembly with the banjo bolt (1).

GNIL15TR00257AB

GNIL15TR00256AB

10. Connect the return pipe to remote valve assembly with the banjo bolt (1). 11. Connect the other end of the return pipe to the lift housing body with the banjo bolt (2).

12. Install the operating lever (1) on the remote valve assembly with the bolt (2).

GNIL15TR00255AB

GNIL15TR00254AB

13. Slide and insert the guide plate (2) on the lever. 14. Install the guide plate (2) with the bolts (1).

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Hydraulic systems - Remote control valves

15. Install the plastic (1) on remote valve operating lever.

GNIL15TR00253AB

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Index Hydraulic systems - 35 Remote control valves - 204 Remote control valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valves - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valves - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valves - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valves - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Main lift system - 100

TT4.80 TT4.90

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Contents Hydraulic systems - 35 Main lift system - 100

TECHNICAL DATA Main lift system General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Main lift system Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Main lift system Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

DIAGNOSTIC Main lift system Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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Hydraulic systems - Main lift system

Main lift system - General specification Type Control Lift sensitivity adjustment Lift-o-matc Response adjustment Single-acting cylinder: Bore x Stroke Displacement Relief valve opening pressure Cylinder safety valve opening pressure Lift piston diameter Lift cylinder bore diameter Piston working Cross shaft journal diameter Right-hand side Left-hand side Bushing fitted I.D. in lift body: (not reamed) Right-hand side Left-hand side Cross shaft working clearance in bushings Right-hand side Left-hand side Bushing interference fit in housing Right-hand side Left-hand side Cross shaft end float with lift arms in position Draft control shaft OD Shaft housing bore diameter. in lift body Shaft clearance in body Position control shaft diameter Shaft housing bore diameter on draft control shaft Shaft clearance in body Draft control lever pin and draft control inner lever hinge pin diameter. at needle roller bearings Control valve link arm and draft control inner lever ID. at needle roller bearings Valve spool clearance in body Lift valve clearance in control valve body Valve spool return spring length: Free Under 31.5 – 35.0 N (7.1 – 7.9 lb) Control valve return spring length: Free Under 103 – 114.7 N (23.2 – 25.8 lb) Response adjustment valve spring length: Free Under 1.7 – 2.3 N (0.4 – 0.5 lb) Sensitivity adjustment valve spring length: Free Under Check valve return spring length: Free

Position control, draft control and combined position and draft control Two independent levers External four-position lever on control Permits rapid lift arm up/down movement by push button without operating position or draft control levers. Knob on control valve 100.0 mm (3.9 in) x 110.0 mm (4.3 in) 863 cm (340 in) 186 – 191 bar (2697 – 2770 psi) 210 – 215 bar (3045 – 3118 psi) 99.980 – 100.000 mm (3.936 – 3.937 in) 100.036 – 100.071 mm (3.938 – 3.940 in) 0.036 – 0.091 mm (0.001 – 0.004 in) 54.970 – 55.000 mm (2.164 – 2.165 in) 62.670 – 62.700 mm (2.467 – 2.469 in) 55.100 – 55.184 mm (2.169 – 2.173 in) 62.800 – 62.884 mm (2.472 – 2.476 in) 0.100 – 0.214 mm (0.004 – 0.008 in) 0.100 – 0.214 mm (0.004 – 0.008 in) 0.065 – 0.161 mm (0.003 – 0.006 in) 0.065 – 0.161 mm (0.003 – 0.006 in) 0.200 – 1.400 mm (0.008 – 0.055 in) 21.967 – 22.000 mm (0.865 – 0.866 in) 22.020 – 22.072 mm (0.867 – 0.869 in) 0.020 – 0.105 mm (0.001 – 0.004 in) 13.973 – 14.00 mm (0.550 – 0.551 in) 14.016 – 14.059 mm (0.552 – 0.554 in) 0.016 – 0.086 mm (0.001 – 0.003 in) 13.973 – 14 mm (0.550 – 0.551 in) 19.985 – 20.006 mm (0.787 – 0.788 in) 0.0080 – 0.0120 mm (0.0003 – 0.0005 in) 0.0080 – 0.0120 mm (0.0003 – 0.0005 in)

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50.5 mm (2.0 in) 34.0 mm (1.3 in) 44.0 mm (1.7 in) 29.0 mm (1.1 in) 44.0 mm (1.7 in) 9.8 mm (0.4 in) 14.5 mm (0.6 in) 11.0 mm (0.4 in) 23.5 mm (0.9 in)

Hydraulic systems - Main lift system

Under Sensitivity adjustment pin lever outer spring length: Free Under

18.0 mm (0.7 in) 20.5 mm (0.8 in) 13.8 mm (0.5 in)

Implement attachment Type Category Draft control Maximum lift capacity Without assist ram With assist ram

3 point linkage II Top link sensing 2000 kg (5512 lb) 2500 kg (5512 lb)

Main lift system - Torque Description Bolt, hydraulic lift body to axle casing Bolt, control valve body to hydraulic lift body Bolt, lift arm Plug, max. rise adjustment Nut, position control shafts Quadrant mounting screws Hydraulic cylinder mounting bolts - top Hydraulic cylinder mounting bolts - front Retainer plate - draft springs Draft feedback mechanismspacer Control lever cover Draft feedback mechanism bolt Lift-o-matic limiter bracket bolts Lift-o-matic button mounting bracket Tap off adopter Tap off mounting screw - long Tap off mounting screw - short Banjo bolt assist ram pipe from tap off Bracket remote valve lever (bolt)

Thread size M14x1.5

Torque 140 N·m (103 lb ft)

M8x1.25

26 N·m (19 lb ft)

M14x1.5 M12 x 1.25 M8 M6 x 1 M16x1.5

150 N·m (111 lb ft) 105 N·m (77 lb ft) 20 N·m (15 lb ft) 11 N·m (8 lb ft) 260 N·m (192 lb ft)

M14x1.5

140 N·m (103 lb ft)

M12 x 1.25 M12

86 N·m (63 lb ft) 70 N·m (52 lb ft)

M8x1.25 M12 x 1.25

25 N·m (18 lb ft) 80 N·m (59 lb ft)

M6 x 1 M8x1.25

11 N·m (8 lb ft) 25 N·m (18 lb ft)

M18 x 1.5 M8x1.25 M10 x 1.25 M14 M8x1.25

70 N·m (52 lb 40 N·m (30 lb 65 N·m (48 lb 50 N·m (37 lb

ft) ft) ft) ft)

25 N·m (18 lb ft)

Main lift system - Sealing Operating descriptions Hydraulic lift housing to axle casing (S1) Distributor assembly to hydraulic lift housing (S2)

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Sealant specification LOCTITE® 518™ LOCTITE® 518™

Hydraulic systems - Main lift system

GNIL15TR00263GB

Main lift system - Special tools Tool description Installer, lift shaft housing 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 Remover, lift-o-matic spring Hydraulic pressure testing kit Rapid clutch male connector Adopter Coupling Adopter (banjo bolt steering) Pressure gauge ( 250 bar (3625 psi)) Pipe (high pressure) Adopter (oil pressure) Installer, response pin seal

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Part number 380000262 380200439 380000274 380000217 380000218 380000230 380000267 380000260 380000261 380001769 380000240 293439 292060 293168 380000613 293247 380000545 380000614 380000266

Hydraulic systems - Main lift system

Main lift system - Sectional view

GNIL15TR00264FB

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

Hydraulic lift cylinder Distributor Diverter valve Adaptor Sensitivity control valve Travel limit control rod

7. 8. 9. 10. 11. 12.

Piston rod pin Thrust plate retaining screw Spacer Lifting arm Rock shaft Draft control spring

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GNIL15TR00265GB

Lift hydraulic control valve 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Spool valve Spool valve seat Plug Spool return spring Valve plunger Plunger spring Plug Piston seat Piston Spring cup Draft sensitivity adjustment valve spring Draft sensitivity adjustment valve Plug Ring

15. 16. 17. 18. 19. 20. 21. 22. 23. 30. 31. 32. 33.

Cylinder safety valve Response control valve Arm lowering speed control valve Ball Response control valve adjustment pin Delivery connection Check valve spring Check valve Check valve seat Retaining ring Roll Pin Back-up ring O-ring

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Main lift system - Overview This is a live hydraulic system, where gear type hydraulic pump is mounted directly to timing gears case. Transmission lubrication oil is also used as hydraulic oil. The 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, combined position, draft control and float. NOTICE: Hydraulic filter is to be changed at regular intervals as recommended. Hydraulic and transmission parts may get damaged if the filter is choked. Always use genuine NEW HOLLAND filters.

Pre-operation checks The system is operated by draft control lever (1), position control lever (2), lift-o-matic buttons (3), response control (4), sensitivity control (5) and diverter valve (6). NOTICE: Before starting the engine, always ensure that the lIft-o-matic fast rise button is pushed in, to prevent inadvertent rising of the three point linkage. 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.

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GNIL15TR00233AB

GNIL15TR00234AB

Hydraulic systems - Main lift system

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 point of time when not actually operating in draft control. Such as when attaching or transporting equipment or when no equipment is attached. Fully open the diverter valve (6), Fig. 2 and 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 the quadrant.

GNIL15TR00268AB

GNIL15TR00269AB

An adjustable stop (3) is provided to enable the lever to return to the required working position.

Draft control operation Draft control is most suitable for mounted or semimounted implements operating in the ground. Changes in the working depth or changes in the soil resistance will increase or decrease the draft loading on the implements. When starting work, fully open the diverter valve and move the position control lever (2) fully forward. Lower the implements into the work using draft control lever (1). Push the lever forward to increase the draft loading. Forward movement of the draft control lever will increase the implement depth and rearward movement will reduce the depth. Once set, tractor hydraulic system will automatically adjust the implement depth to maintain an even pull on the tractor. This will minimize the wheel slip.

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 implements to the required depth by means of draft control lever (1), as described previously. 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.

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Float operation Move the position control lever (2) and the draft control lever (1) fully forward. The three point linkage will now be free to ’float’ or follow the ground contour, a feature useful for scraper blades etc.

GNIL15TR00269AB

NDIL14TR00603AB

NDIL14TR00604AB

GNIL15TR00272AB

Lift-o-matic The Lift-o-matic is used for automatic repositioning of implements after turn. It helps in saving the time and adds comfort to the operator. Further it maintains a uniform depth and prepares a better seeded. To raise the implement at the end of each pass, or whenever required, move the latch (1) rearward to release the fast release the fast release button (2). The three point linkage and implement will raise to the full height without need to move either the position or draft control lever.

To lower the implement, simply press he fast raise button (1) fully in, and the implement will lower to the preset depth, set by the position control lever or draft. NOTICE: When transporting equipment on three point linkage, raise the implement using the position control lever. The hydraulic system will maintain the height set by the position control lever. This will prevent the equipment from lowering and getting damaged.

Sensitivity control To adjust the sensitivity of the hydraulic system when working in draft control, lever (1) needs to be adjusted. Lever up– Reduces sensitivity Lever down – Increases sensitivity

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Hydraulic systems - Main lift system

Operation of distributor The distributor is pre-set to perform three phases:A. Neutral phase B. Lifting phase C. Lowering phase

Neutral phase (See the figure 10) In this phase the control valve keeps the 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 (12) to piston (9) which overcomes spring (6) and moves plunger (5) to the right. Thus opening discharge port and returns oil to transmission housing rather than to cylinder. NOTE: When travelling to the roads with the implements attached, fully unscrew knob (29) to block implement in desired positions; oil contained in cylinder remains trapped by check valve (22) and response control valve (17). Arms therefore remain blocked, even if operator accidentally moves lift control levers. Cylinder safety valve (15) protects lift cylinder pressure circuit while relief valve (v) protects pump circuit.

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Hydraulic systems - Main lift system

GNIL15TR00273GB

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Lifting phase (See the figure 11) 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 (9) is cut off and plunger (5) is forced to the left by spring (6), thus closing discharge port. Oil under pressure opens check valve (22) and operates piston (T) to raise arms. NOTE: Draft sensitivity may be adjusted throughout lever (25), which controls the position of valve seat (8). When seat (8) is moved to the right, piston (9) covers ports ( (T1) and (T2)) and oil in valve may be discharged through port (T3). Since discharge thereby takes longer, lift reaction time increases with a consequent decrease in sensitivity. When seat (8) is moved to the left , all the three ports are free and oil may be discharged quickly through all the three ports (T1), (T2) and (T3)with consequent short reaction time resulting in increased sensitivity.

GNIL15TR00274GB

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Hydraulic systems - Main lift system

Lowering phase (See the figure 12) 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 (4) pulls spool (1) to the right, cylinder is discharged under piston pressure (T) through response control valve (17) and the port uncovered by spool. Through spool port (F1) and draft sensitivity valve (12), oil flows to piston (9) which holds plunger (5) in the open position, thus allowing oil from pump to be discharge past plunger (5). NOTE: Response (rate of drop) is adjusted by knob (29). Slackening this knob restricts exhaust passage between valve (17) and control valve body, thus increasing the time taken to lower the implement (slow response). Tightening knob (29) increases effective area of discharge port and the implement drops more quickly (fast response).

GNIL15TR00275GB

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Hydraulic systems - Main lift system

Internal linkage system Functioning of internal linkage system A. Position control B. Float operation C. Draft control D. Combined position and draft control

Position control (See the figure 13) By lowering the draft control lever (F) fully down draft control inner lever (15) will be away from roller (13). In this way the draft linkages/levers will not in any way interfere with position control. When lever (P) is moved back, cam on end of shaft (27) moves lever (14), located between roller (12) and cam (28) on arm cross-shaft is stationary at the beginning of the operation, lever (14) reacts against it and pushes roller (12) forward. This moves link (9) and lever (6) in the direction indicated by the solid arrows to set control valve (1) in the lift arm position. Arms rise until cam (28) turns far enough to permit lever (6), link (9) and lever (14) to move under the action of spool return spring in the direction indicated by clear arrows. The control valve (1) therefore returns to neutral and the arms stop in the neutral position. Maximum arm upward travel is limited by rod (16). When rod (16) contacts piston (29), the control valve is returned to neural through adjusting screws (3) before the piston reaches mechanical travel limit stop. The same movement occur in reverse when lever (P) is moved froward to lower arms.

Float operation (See the figure 13) With position control lever (P) and draft control lever (F) fully forward. â&#x20AC;˘ The draft control linkage is not activated â&#x20AC;˘ Lever (14), link (9) and lever (6) are moved in the direction opposite to that indicated by solid arrows. The control valve is held in the raised position thereby letting arms swing freely and associated implement float on the soil.

NDIL14TR00610FB

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Draft control (See the figure 14) Move position control lever (P) fully forward. When the implement has been set to the desired working depth by means of lever (F), and if the implement then hits a stretch of harder or more compact soil, the draft forces on the lower links will increase. This will then cause a greater top link thrust against the spring (20) which, compressing, transmits motions in the directions of the solid arrows, to the lever (15), the link (9) and the lever (6), thereby setting the control valve in the arm lifting position. The arms will rise until the resulting reduction in draft forces reduces the compression of spring (22) to rotate in the opposite directions, allowing lever (6) to move backwards, pulled by the control valve spool spring. Control valve returns to neutral and the arms stop lifting. Once the hard stretch has been left behind, the draft control spring (20) returns completely to its original working position. If the control lever (F) is positioned further back on quadrant (draft reduction), the hollow shaft (26) pushes lever (15), roller (13), link (9) and lever (6) to act against the control valve spool, setting the valve in delivery position. If the lever (F) is moved forward (increased draft), operation is the same but in the opposite direction.

NDIL14TR00611FB

Combined draft and position control (See the figures 13 and 14) With position control lever (P) fully forward, and moving the draft control lever (F) forward from the fully back position, the working depth is established as described above. When lever (P) is then shifted backwards, lever (14), link (9) and lever (6) 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.

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Hydraulic systems - Main lift system

Main lift system - Remove 1. Remove the operatorâ&#x20AC;&#x2122;s seat. See the Operator seat Remove (90.120). 2. Remove the rear platform. See the Protections and footboards - Remove (90.118). 3. Loosen and remove the bolts and the trailer socket with top link holder (2). 4. Remove the three point linkage. 5. Disconnect all hydraulic lines attached to hydraulic lift body. 6. Remove the assist ram. See the Main lift system Remove (35.100).

GNIL15TR00276AB

GNIL15TR00277AB

7. Loosen and remove the bolts (1) and the hydraulic lift assembly (2).

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Hydraulic systems - Main lift system

Main lift system - Install 1. Install the hydraulic lift assembly (2) with the mounting bolts (1).

GNIL15TR00277AB

GNIL15TR00276AB

2. Install the assist ram. See the Main lift system - Install (35.100). 3. Connect all hydraulic lines attached to hydraulic lift body. 4. Install the three point linkage. See the Final drive housing - Install (27.120). 5. Install the trailer socket with top link holder (2) and tighten the bolts. 6. Install the rear platform. See the Protections and footboards - Install (90.118). 7. Install the operatorâ&#x20AC;&#x2122;s seat. See the Operator seat Install (90.120).

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Hydraulic systems - Main lift system

Main lift system - Remove Assist ram cylinder 1. Loosen the nut (1) on the assist ram cylinder end (2) and remove oil pipe (3) connecting assist ram cylinder.

GNIL15TR00278AB

GNIL15TR00279AB

GNIL15TR00280AB

2. Remove the circlip (1) and the washer (2) to remove the assist ram cylinder (3).

3. Loosen and remove the bolts (1) and remove the assist ram racket (2).

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Hydraulic systems - Main lift system

Main lift system - Install 1. Install the assist ram racket (2) with the bolts (1).

GNIL15TR00280AB

GNIL15TR00279AB

GNIL15TR00278AB

2. Install the assist ram cylinder (3) with the washer (2) and the circlip (1).

3. Connect the oil pipe (3) to the assist ram cylinder (2) and tighten the nut (1).

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Hydraulic systems - Main lift system

Main lift system - Remove External control 1. Lock the lift-o-matic button (2) and remove the lift-omatic button assembly (1) by loosening bolts (3).

GNIL15TR00281AB

GNIL15TR00282AB

GNIL15TR00283AB

GNIL15TR00284AB

2. Loosen the Allen screws (1) and circlip (2). Then remove the lift-o-matic mounting bracket (3).

3. Remove the pin (1), washer spacer circlip (2) and then remove the position control lever.

4. Remove pin (1), washer (2), and clip (3). Then remove the draft control lever (4).

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5. Loosen and remove bolts (1) and remove PC and DC mounting bracket (2).

GNIL15TR00285AB

GNIL15TR00286AB

GNIL15TR00287AB

GNIL15TR00288AB

6. Loosen the connectors (1) between PC and DC mounting brackets and lift housing body.

7. Loosen and remove the mounting bolts (1) and remove linkage (2) for height limiter assembly.

8. Loosen and remove the nuts (1) and then remove the spring cap (2).

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Hydraulic systems - Main lift system

9. Remove the spring (1).

GNIL15TR00289AB

10. Remove locking clips (1) and take out PC lever linkage.

GNIL15TR00290AB

GNIL15TR00291AB

GNIL15TR00292AB

11. Remove locking clips and take out DC lever linkage (1).

12. Remove circlip (1), metal washer (2) and plastic washer (3).

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Hydraulic systems - Main lift system

13. Remove PC crank lever (1) and Woodruff key (2).

GNIL15TR00293AB

GNIL15TR00294AB

GNIL15TR00295AB

GNIL15TR00296AB

14. Remove lock washer (1).

15. Remove out DC crank lever (1) with the Woodruff key (2).

16. Loosen and remove the bolt (1) from one side and circlip (2) from the other side and then remove draft feedback lever (3).

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Hydraulic systems - Main lift system

17. Loosen and remove the bolts (1).

GNIL15TR00297AB

GNIL15TR00298AB

GNIL15TR00299AB

GNIL15TR00300AB

18. Remove the roll pin (1) and then the pin assembly.

19. Remove the rocker bracket along with the sensing arrangement (1).

20. Loosen and remove locknut (1) by holding the Allen screws (2) from the bottom side.

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Hydraulic systems - Main lift system

21. Remove the spring assembly (1).

GNIL15TR00301AB

GNIL15TR00302AB

GNIL15TR00303AB

GNIL15TR00304AB

22. Remove the sensing coil springs (1).

23. Remove the retainer plate (1).

24. Loosen and remove the Allen screws (1) and then remove the height limiter (2).

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Hydraulic systems - Main lift system

25. Rotate height limiter knob (1) anti-clockwise to separate cam (2) and connector bolt (3).

GNIL15TR00305AB

GNIL15TR00307AB

GNIL15TR00308AB

26. Loosen and remove the bolt (1) and lift arm cover plate (2).

27. Remove left-hand side lift arm (1) and spacer (2).

28. Repeat the instructions 26 and 27 to remove righthand side.

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Hydraulic systems - Main lift system

Main lift system - Install 1. Position the left-hand side lift arm (1) and spacer (2).

GNIL15TR00308AB

GNIL15TR00307AB

GNIL15TR00305AB

GNIL15TR00304AB

2. Install the lift arm cover plate (2) on the lift arm with the bolt (1).

3. Rotate the height limiter knob (1) clockwise to install the cam (2) and connector bolt (3).

4. Install the height limiter (2) with the Allen screws (1).

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Hydraulic systems - Main lift system

5. Insertl the retainer plate (1).

GNIL15TR00303AB

GNIL15TR00302AB

GNIL15TR00301AB

GNIL15TR00300AB

6. Install the sensing coil springs (1).

7. Position the spring assembly (1).

8. Install the spring assembly with the locknut (1) and Allen screws (2).

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Hydraulic systems - Main lift system

9. Install the rocker bracket with the sensing arrangement (1).

GNIL15TR00299AB

10. Insert the pin assembly and install the roll pin (1).

GNIL15TR00298AB

GNIL15TR00297AB

GNIL15TR00296AB

11. Install the bolts (1).

12. Install the draft feedback lever (3) with the bolt (1) and circlip (2).

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Hydraulic systems - Main lift system

13. Install the DC crank lever (1) with the Woodruff key (2).

GNIL15TR00295AB

GNIL15TR00294AB

GNIL15TR00293AB

GNIL15TR00292AB

14. Install lock washer (1).

15. Install PC crank lever (1) with the woodruff key (2).

16. Install the plastic washer (3), metal washer (2) and circlip (1).

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Hydraulic systems - Main lift system

17. Connect the DC lever linkage (1) with the locking clips.

GNIL15TR00291AB

GNIL15TR00290AB

GNIL15TR00288AB

GNIL15TR00287AB

18. Connect the PC lever linkage (1) with the locking clips.

19. Install the spring cap (2) with the nuts (1).

20. Install the linkage (2) of height limiter assembly with the bolts (1).

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Hydraulic systems - Main lift system

21. Install the connectors (1) between PC and DC mounting brackets and lift housing body.

GNIL15TR00286AB

GNIL15TR00285AB

GNIL15TR00284AB

GNIL15TR00283AB

22. Install the PC and DC mounting bracket (2) with the bolts (1).

23. Install the draft control lever with the pin (1), washer (2), and clip (3).

24. Install the position control lever with the pin (1), washer, spacer, circlip (2).

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Hydraulic systems - Main lift system

25. Install lift-o-matic mounting bracket (3) with the Allen screws (1) and circlip (2).

GNIL15TR00282AB

GNIL15TR00281AB

26. Install the lift-o-matic button assembly (2) with the bolts (3).

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Hydraulic systems - Main lift system

Main lift system - Overhaul 1. Loosen and remove bolt (1) and disconnect draft feedback pin (2) sensing lever linkage (3).

GNIL15TR00309AB

GNIL15TR00310AB

GNIL15TR00311AB

GNIL15TR00312AB

2. Remove lock clip (1) by hand and take it out and then remove PC Cam and PC lever shaft.

3. Remove the lock clips (1) by hand and then remove DC Cam (2).

4. Loosen and remove the two bolts (1) and then remove the PC and DC shaft assembly (2) from lift housing body.

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Hydraulic systems - Main lift system

5. Remove out PC lever shaft (1) by hand from PC and DC tube (2).

GNIL15TR00313AB

GNIL15TR00315AB

GNIL15TR00316AB

GNIL15TR00317AB

6. Remove out roll pin (1) from lift-o-matic lever shaft, remove the lift-o-matic roller linkage (2).

7. Remove out lift-o-matic cam and lift-o-matic lever shaft (1).

8. Loosen and remove out the three lift cylinder mounting bolts (1) and (2).

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Hydraulic systems - Main lift system

9. Remove lift cylinder assembly (1) with control valve linkages.

GNIL15TR00318AB

10. Loosen and remove bolt (1) and take out control valve linkage assembly from cylinder body.

GNIL15TR00319AB

GNIL15TR00320AB

GNIL15TR00321AB

11. Pull pin (1) out to remove main spool activating linkage.

12. Remove piston (1) from lift cylinder using air pressure from behind.

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Hydraulic systems - Main lift system

13. Hammer the rock shaft (1) from right-hand side and take out the shaft from left-hand side.

GNIL15TR00322AB

GNIL15TR00323AB

GNIL15TR00324AB

GNIL15TR00325AB

14. Remove position control mango cam (1).

15. Loosen and remove the piston pin screw (1).

16. Remove out connecting rod (1), piston pin (2) and inside arm (3).

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Hydraulic systems - Main lift system

Main lift system - Remove Distributor removal 1. Hold the adaptor (1) and loosen the nut and disconnect the other end of the delivery pipe from distributor assembly.

GNIL15TR00326AB

GNIL15TR00327AB

GNIL15TR00328AB

GNIL15TR00329AB

2. Loosen and remove the banjo bolt (1) and disconnect the oil pipe connecting the assist ram cylinder.

3. Loosen and remove the two Allen screws (1), (2) and then remove the tap-off valve assembly (3).

4. Loosen and remove the bolts (1) and the distributor assembly (2).

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Hydraulic systems - Main lift system

Main lift system - Install Distributor Installation 1. Install the distributor assembly (2) and tighten bolts (1).

GNIL15TR00329AB

GNIL15TR00328AB

GNIL15TR00327AB

GNIL15TR00326AB

2. Install the tap-off valve assembly (3) with the Allen screws (1) and (2).

3. Connect the oil pipe to the main lift assembly with the banjo bolt (1).

4. Connect the delivery pipe to the distributor assembly with the adaptor (1).

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Hydraulic systems - Main lift system

Main lift system - Adjust In case of complete disassembly of the lift, it is necessary to make the following checks, adjustments and settings.

Control valve spool efficiency check 1. Install seat with O-ring, and spool in connection fitting special tool number 380000274 380000274 checking that seals at the bottom of the seat prevent leakage through the connection fitting itself. Then connect the latter to the hand pump. 2. Push spool into contact with seat and lock the spool with lock screw tool. 3. Operate the pump to bring oil pressure in system to 250 Kg/cm² (3556 psi) and check on pressure gauge that pressure takes more than 6 s to drop from 200 – 100 Kg/cm² (2845 – 1422 psi). 4. If necessary, replace spool. Note that spare spools are provided together with matching seats.

NDIL14TR00658AA

GNIL15TR00331AB

GNIL15TR00332AB

Position control adjustment With lift unit removed from tractor. 1. Remove the distributor assembly (1) from lift housing.

2. Raise lift arms to fully raised position, so that inner arm (1) comes into contact with lift housing.

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Hydraulic systems - Main lift system

3. Carefully mark the position on the arm (S2) and on the housing (S1).

NDIL14TR00661AA

NDIL14TR00662AB

GNIL14TR02667AA

GNIL15TR00333AB

4. Slacken lock-nut (10) and unscrew the maximum lift height adjuster screw (6) using special tool number 380000240, until it is no longer in contact with control valve lever (7).

5. Install special tool dummy distributor (Tool number 380260939) (A) on lift housing.

6. Using two wrenches, back off lock-nut (8), and tighten or slacken adjustable link rod (9), The plunger (P1) should align with outer scale (R1) of tool (special tool number 380260939). NOTE: The face of the plunger (P1) should be at the same level as the outer scale (R1). 7. Tighten the locknut (8).

Maximum lift arm travel adjustment (on bench) Proceed as follows :-

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1. Install special tool 380000264 (A) on lift body.

NDIL14TR00668AA

GNIL15TR00332AB

2. Put position control lever (P) fully back on quadrant. 3. Raise lift arms to fully raised position, so that inner arm (1) comes into contact with 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 lock-nut (10). 6. Using special tool number 380000240 (C), tighten screw (6). The plunger (P1) stand-in is not more than 1.300 – 1.700 mm (0.051 – 0.067 in) from the inner register ( (R2), of the tool 380000264. 7. Tighten the lock-nut (10). NOTE: This condition corresponds to a gap (L1) of 86.300 – 86.700 mm (3.398 – 3.413 in) between lever and top cover front face.

NDIL14TR00670AB

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Maximum lift arm travel adjustment (on tractor) 1. Raise the hydraulic lift arms by hand to maximum height. Make two corresponding marks, one on lift body and one on lift arm. 2. Set position and draft control levers and fully forward on quadrant. 3. Operate lift by means of lift-o-matic and after carrying out a few lift operations, check that distance between notches and is “d” 2.000 – 4.000 mm (0.079 – 0.157 in). 4. If lift-o-matic is not fitted, raise position and draft control levers fully back on quadrant (maximum lift position) and check distance. 5. If distance “d” is not between 2.000 – 4.000 mm (0.079 – 0.157 in), then adjust as follows. 6. Remove plug (19), unscrew lock-nut (10) and turn setting screw (6) using special tool number 380000267 to obtain distances specified above. 7. Tighten lock-nut (10). 8. Reinstall plug (19).

NDIL14TR00671AB

GNIL15TR00336AB

Draft control level setting The adjustment of the Draft control lever must be carried out to have a correct synchronisation between this lever and the stroke (positive and negative) of the top link bracket. Full use of the reaction spring has to be made. The adjustment must be carried out without implements or loads applied to the three point linkage (20) (i.e. in a neutral position). Position the two control levers (1) and (2) in the lowest position. With a motor running at minimum RPM slowly raise the draft control lever (2). The adjustment of the draft lever (2) is correct when the arms are completely raised if the lever is moved upward to the (6–8) sign on the sector. If the lever (2) raises the arms completely before arriving at the (6–8) sign on the sector, then the measurement (L) of the rod (T) must be shortened. If the lever (2) raises the arms completely after passing the (6–8) sign on the sector, then the measurement (L) of the rod (T) must be lengthened. NOTE: The position of the lever (1) establishes only the position of the arms. It does not influence the adjustment of the draft control lever (2).

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Hydraulic systems - Main lift system

Reaction spring setting For the correct functioning of the rockshaft and the top line bracket , when not working, must not have a positive or negative axial play. Carry out the correct assembly. The spring holder (2) must rest against the rockshaft housing (1). The spring holder cover (4) must rest against the flange (3). In this condition the spring (M) is preloaded by about 0.300 – 0.600 mm (0.012 – 0.024 in). Before assembling the complete reaction assembly to the rockshaft housing a pre-assembly of the spring (M) is needed in order to obtain a measurement of about 8.40 mm (0.33 in). After carrying out the reaction assembly a definitive adjustment is made :GNIL15TR00337AB

NDIL14TR00678AB

NDIL14TR00679AB

Keep the screw (V) fixed with an 8.00 mm (0.31 in) wrench and adjust the self locking nut (D) by tightening or loosening it gradually in order to eliminate the axial play completely.

Lift-o-matic adjustment 1. Apply a load of 50 kg (110 lb) to lifting arm swivel bearings. 2. Run engine at medium speed of 1200 – 1500 RPM. 3. Put position and draft control levers (P) and (F) fully forward on quadrant. 4. Adjust position of support together with lift-o-matic control levers on lift control support, securing it by screw (1) so that, when pressing button (Q), arm descent starts with free travel at the end of the button of 9.00 – 12.00 mm (0.35 – 0.47 in).

Start-to-lift check 1. Place position control lever (P) fully forward on quadrant. 2. Place lift-o-matic lever (1) in position. 3. Check by means of draft control lever (F) that lift starts with lever 184.00 – 186.00 mm (7.24 – 7.32 in) from end of slot in the quadrant.

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Hydraulic systems - Main lift system

4. Otherwise, adjust link (1) to obtain specified length and tighten locknut (2).

GNIL15TR00338AB

NDIL14TR00681AB

Valve check Relief and cylinder safety valve setting check on the bench Relief valve may be checked either on bench or on tractor. But, the cylinder safety valve setting check may only be carried out on bench. To bench test cylinder safety valve and relief valve incorporated in remote valve use hand pump 290284 (A), with fittings 380000218 and 380000217 (B). Relief valve should open at 190 – 195 Kg/cm² (2702 – 2774 psi) while safety valve opening pressure should be 215 – 220 Kg/cm² (3058 – 3129 psi). NOTE: If valve setting is not as specified, scrap and replace valves. If necessary, valves may be adjusted through threaded plugs after raising the penned area. Use Wrenches 380000230 and 291863 for cylinder safety valve and relief valve respectively. NOTICE: When travelling on the road with mounted implements, completely unscrew knob (1) to block implement transport position.

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Hydraulic systems - Main lift system

Main lift system - Troubleshooting Problem Lift fails to operate

Erratic upward lift movement.

Possible Cause Governor blocked open

Correction Remove foreign particles from drain holes and inspect filter. Disassemble and inspect. Inefficient pump Clogged oil filter Inspect filter and replace cartridge if necessary. Air entering suction line Check for faulty connections or seals. Replace seals. Oil leakage past spool seals Leakage past spool Remove, check for leakage, clean and replace damaged parts. Inspect filter. Remove, inspect and clean. Check valve leakage Leakage past lift piston Replace seals. Replace seals. Gland or lift cylinder seal Safety valve leakage or incorrect setting Replace valve.

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Index Hydraulic systems - 35 Main lift system - 100 Main lift system - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47866580 11/12/2015 EN

SERVICE MANUAL Steering TT4.80 TT4.90

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Contents Steering - 41

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

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TT4.80 TT4.90

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Contents Steering - 41 Steering control - 101

TECHNICAL DATA Steering control General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Steering control Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Steering control Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Remove - Fixed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove - Tiltable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Disassemble – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Cleaning – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Inspect – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Lubricate – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Assemble - Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

DIAGNOSTIC Steering control Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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Steering - Steering control

Steering control - General specification Type Make Hydraulic circuit Oil reservoir Oil filter Hydraulic pump Type Mode Make Drive Rotation (Seen from rear) Drive ratio Rated speed (at engine governed speed) Rated output at maximum rate On-bench output at 1450 RPM New or reconditioned pump Test oil temperature Test oil viscosity

Hydrostatic DANFOSS / Ognibene Independent, separate pump Common oil with transmission and hydraulic Common filter with hydraulic Gear C-25 Dynamatics / Rex From engine Clockwise 1 - 1.08 2300 RPM 28.5 L/min (7.5 US gpm) 17.3 L/min (4.6 US gpm) 50 °C SAE 20 DANFOSS / Ognibene with steering column operated rotary valve (permitting steering also in case of pump failure)

Control valve type Outfit code: DANFOSS (with valves in control valve) Relief valve setting Power cylinder overload valve setting Power cylinder Type Make Cylinder bore diameter Piston rod diameter Maximum piston stroke with cylinder make

OSPJ 1 00 0N 100 – 115 bar (1450 – 1668 psi) 200 bar (2900 psi) Double acting, located behind front axle OGNIBENE 48 mm 22 mm 214 mm

Steering control - Torque Description Bolt, steering motor mounting Bolt, steering column mounting Connectors on steering motor Banjo bolt on steering motor Ferrule nut to adopter on steering motor Hoses to steering cylinder Steering cylinder mounting bolt (pivot pin side) Steering cylinder mounting bolts (steering arm side) Steering pump suction side adopter Steering pump delivery side adopter

Thread size M10x1.5 M10x1.5 ¾ - 16UNF - 2A ¾ - 16UNF - 2A 1-1/16-16UN-2A M16x1.5 M18x1.5 M16x1.5 M8x1.25 M6x1.0

Torque 45 N·m (33 lb ft) 45 N·m (33 lb ft) 35 N·m (26 lb ft) 49 N·m (36 lb ft) 49 N·m (36 lb ft) 29 N·m (21 lb ft) 170 N·m (125 lb ft) 170 N·m (125 lb ft) 10 N·m (7 lb ft) 10 N·m (7 lb ft)

Steering control - Special tools Description Steering wheel puller Adopter, power steering pressure check (includes in the set of hydraulic pressure kit 380000240 ) Installer, power steering rotor spring

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Tool number 380200598 380000613 380000549

Steering - Steering control

Description Installer, power steering rotor O-ring Steering knuckle seal Installer big end Steering knuckle seal Installer small end Pinion "O"ring installer Knuckle Bush Installer

Tool number 380000305 380200599 380200600 380200601 380200602

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Steering - Steering control

Steering control - Overview

GNIL15TR00487FB

D1 M S V

Control valve filter cartridge Pump outlet line. Return to tank Steering wheel

H P T

Power cylinder Hydraulic pump Reservoir

Hydrostatic steering system is powered (when the engine is running) by steering pump mounted on the front side of the engine timing gear. Hydrostatic steering system incorporate a steering pump (1) pressurizes the steering column operated control valve (2). The pressurised oil from the control valve operates the axle mounted double acting steering cylinder (3). The control valve is bolted to a bracket mounted on transmission housing and connected to the steering column by a spindle shaft. The steering cylinder is fixed at one end to the front axle beam and at the other to an eye on the spindle arm. The pressure relief value for the system is contained within the steering control valve itself.

Operation Oil is common with transmission (T) so it is drawn into pump through a filter (3), pressurised by the rotation of the gears and expelled through the pump outlet port to the steering control valve. The pressurised oil when received at the control valve is directed to the steering actuating cylinder when the steering wheel is turned. The control valve incorporates a metering unit which regulates the volume of oil supplied to the cylinder so that it is proportional to the angular movement of the steering wheel. The metering unit in combination with the check value also allows the steering to be operated manually without pressurised oil being supplied from the pump. The system is fully hydrostatic and as such there is no mechanical connection between the steering column and the steering wheels.

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Steering - Steering control

GNIL14TR04488JB

(A) Operation in straight-ahead driving position (B) R.H. (Sd) and L.H. (Ss) steer (C) R.H. and L.H. emergency steer (Sed and Ses) (d) Operation diagram for straight-ahead driving

(V) Steering wheel

(7) Rotor drive shaft

(23) Check valve

(8) Rotor cam ring

(25) Washer

(26) Oil passage to L.H. power cylinder chamber (a) Section through control (13) and (14) . Oil ports (27) Oil passage to R.H. unit with valve (5) in neutral cylinder chamber, piston rod side (b) Sections through control (15) . Rotor inlet passages (29) Thrust bearing unit with valve (5) in R.H. (6) off steer position (for L.H. steer, valve rotation is symmetrical in opposite direction) (e), (f) Operation diagram (G1, G2) Gap between pin (16) . Connecting port (12) (31) Seals for two-stage R.H. steering (1) and rotary valve (5) off communicating with passages (15) and (17) alternatively (32) Dust excluder (17) Pressure passages (E) Filter cartridge (r1, r2) Sections through (6) off to power cylinder DANFOSS OSPC 100 communicating with the control valve rotor recesses and ports (18) and (20) (33) Cylinder safety valves (g) Steering system (1) Drive pin (18) R.H. power cylinder schematics chamber outlet or exhaust ports ( (6) pairs) (34) Make-up valves (H) Power cylinder (2) Sleeve return springs (19) Power cylinder exhaust passages (6 off) communicating with ports (18 and 20) (35) O-rings (M) Pump outlet line (3) Control valve body (20) L.H. power cylinder chamber outlet or exhaust ports (6) off

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Steering - Steering control

(P) Hydraulic pump

(4) Check valve

(S) Return to tank

(5) Rotary valve

(T) Reservoir

(6) Valve seat sleeve

(21) Oil passage from ports (36) Valve adjusting screw (16) to rotor recesses (22) Supply ports for (37) Plugs passages (15) (24) Relief valve (38) Valve adjusting screw

Straight - ahead driving ( A, a, d) With steering wheel (V) stationary, rotary valve (5) takes neutral position relative to sleeve (6). This position is maintained through the action of springs (2), (see figure 2 section A-A) and the following conditions exist: • Pin (1), (see figure 2 section B-B) is central in the valve (5) aperture. • Ports (13) and (14) are in alignment (see figure 2 section C-C) and the oil pressure from pump (P) is returned to tank. • Passages (15), (17) and (19) on the valve (see figure 2 sections D-D and E-E) are off register relative to ports (16), (18) and (20) on the sleeve (i.e. all ports in communication with the power cylinder remain closed).

Right-hand side steer ( B, Sd, b, e, f) Upon turning steering wheel (V) clockwise, springs (2), (see figure 2 section A-A) deflect allowing valve (5) to rotate relative to sleeve (6) until gap (G), (see figure 2 section B-B) is taken up. Thus: • Ports (13) and (14), (see figure 2 section C-C) go out of alignment to discontinue oil return. • Six passages (15), (see figure 2 section D-D) line up with an equal number of ports (16) connected instant by instant with the rotor recesses during the inlet phase. • Six pressure passages (17), (see figure 2 2 section E-E) line up with ports (18) communicating with the power cylinder. Moreover, the oil pressure passages communicate with the remaining ports (16), (see figure 2 section D-D) connected instant by instant with the rotor recesses during the actuation phase. • Six exhaust passages (19) line up with ports (20), (see figure 2 section E-E) communicating with the power cylinder. Once the gap (G) is eliminated valve (5) positively transmits steering wheel input to both sleeve (6) and rotor (9) through pin (1) and shaft (7). Diagrams (e and f) show the principle of operation at start of right-hand side steer and after a certain amount of wheel rotation. The flow of oil pressure from pump to rotor during inlet, and from rotor to power cylinder line during the power actuation phase, is provided instant by instant.

Left-hand side steer ( B, Ss) Upon turning the steering wheel anti-clockwise, a reversal of the above sequence is obtained and delivery passages (17), (see figure 2 section E-E) supply ports (20) to bring about left-hand side steering.

Emergency hydraulic steer ( C, Sed, Ses) Steering is possible even in cases of loss of hydraulic pressure. Upon turning the steering wheel, valve (5) takes up the normal operating position, whilst the rotor functions as a hand pump directing oil pressure to the power cylinder. Check valve (4) opens, thereby permitting the flow of oil from tank to rotor by-passing the pump. Valve (23) remains closed preventing leakage in connecting line between pump and control unit.

Power cylinder safety and make-up valves (N2) As of safety valves open (33), pressure created by piston (H) is exhausted in one cylinder chamber under the action of strong external stress on wheels. Simultaneously, vacuum in the opposite chamber is compensated by oil flow through the opening of the associated make up valve (34). Pressure in one cylinder chamber deriving from small external stress which are not sufficient to open cylinder safety valve, is exhausted through normal leakage past control valve (D), while vacuum in the opposite chamber is compensated through make-up (34), as shown in detail N2, for DANFOSS OSPC 100 control valve. 47866580 11/12/2015

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Steering - Steering control

Operation of the above valves eliminates continuous steering wheel correction and prevents front wheel shimmy, hydraulic circuit failure and damage to the steering linkage.

GNIL14TR04489FB

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Steering - Steering control

Steering control - Disconnect 1. Remove the battery. (55.302).

See the Battery - Remove

2. Disconnect the pipe (1) connecting steering motor to left-hand side front steering cylinder. 3. Disconnect the pipe (2) connecting steering motor to right-hand side front steering cylinder.

GNIL15TR01514AB

GNIL15TR01505AB

GNIL15TR00762AB

GNIL15TR00763AB

4. Remove the bracket (3) securing the power steering pipes (1) and (2).

5. Remove the bolt (2) and pipe clamp (1) holding the power steering pipes.

6. Remove the bolt (2) and pipe clamp (1) holding the power steering pipes.

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Steering - Steering control

7. Disconnect the pipe (1) connecting the steering motor to the pump.

GNIL15TR01515AB

GNIL15TR00764AB

GNIL15TR01516AB

GNIL15TR01506AB

8. Loosen and remove the bolts (1) and remove the power steering delivery pipe from power steering pump (2).

9. Disconnect the outlet pipe (1) connecting the steering motor to the power shuttle oil filter.

10. Remove the fuel tank. See the Fuel tank - Remove (10.216). 11. Remove the banjo bolt (2) and disconnect the other end of outlet pipe (1).

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Steering control - Connect 1. Connect the outlet pipe (1) to the power shuttle oil filter with the banjo bolts (2). 2. Install the fuel tank. (10.216).

See the Fuel tank - Install

GNIL15TR01506AB

GNIL15TR01516AB

GNIL15TR00764AB

GNIL15TR01515AB

3. Connect the other end of the outlet pipe (1) to the steering motor.

4. Connect the power steering delivery pipe to power steering pump (2) with the bolts (1).

5. Connect the other end of the pipe (1) to the steering motor.

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Steering - Steering control

6. Secure the power steering pipes with the pipe clamp (1) and bolt (2).

GNIL15TR00762AB

GNIL15TR00763AB

GNIL15TR01505AB

GNIL15TR01514AB

7. Secure the power steering pipes with the pipe clamp (1) and bolt (2).

8. Install the bracket (3) securing the power steering pipes (1) and (2). 9. Connect the pipe (2) to the steering motor and righthand side front steering cylinder.

10. Connect the pipe (1) to the steering motor to left-hand side front steering cylinder.

11. Install the battery. See the Battery - Install (55.302).

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Steering - Steering control

Steering control - Remove - Fixed Prior operation: Remove the instrument panel, see Instrument cluster - Remove (55.408) for instrument panel removal process. Prior operation: Remove the rear hood, see Hood - Remove (90.100) for rear hood removal process 1. Loosen and remove the two union joints (1) of delivery pipes to disconnect them from the steering motor.

GNIL15TR00404AB

GNIL15TR00405AB

GNIL15TR00406AB

2. Loosen and remove the banjo bolt (1) and disconnect the return line pipe from the steering motor.

3. Loosen and remove the inlet pipe union joint (1) and disconnect the Inlet pipe from the steering motor.

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Steering - Steering control

4. Loosen the shuttle lever shaft mounting bolts (1) and remove the lever shaft from the bracket. (2).

GNIL15TR00490AB

GNIL15TR00408AB

GNIL15TR00488AB

GNIL15TR00410AB

5. Loosen and remove the bolts (1) holding the steering column to the rear hood.

6. Loosen and remove the steering column mounting bolts (1) and remove the steering motor assembly (2) with steering column.

7. Loosen and remove the bolts (1) and separate the steering motor (2) from steering shaft.

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Steering - Steering control

Steering control - Install 1. Install the steering motor (2) with the bolts (1) on the steering shaft.

GNIL15TR00410AB

GNIL15TR00488AB

GNIL15TR00408AB

GNIL15TR00490AB

2. Install the steering column and the steering motor assembly (2) with the steering column mounting bolts (1).

3. Install and tighten the bolts (1) to hold the steering column on the rear hood.

4. Install the lever shaft with the mounting bolts (1) on the bracket (2).

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Steering - Steering control

5. Connect the inlet pipe to the steering motor and install the inlet pipe union joint (1).

GNIL15TR00406AB

GNIL15TR00405AB

GNIL15TR00404AB

6. Connect the return line pipe and install the banjo bolt (1) on the steering motor.

7. Install the delivery pipes with the union joints (1) on the steering motor.

8. Install the rear hood, see Hood - Install â&#x20AC;&#x201C; Rear hood (90.100). 9. Install the instrument panel, see Instrument cluster Install (55.408).

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Steering - Steering control

Steering control - Remove - Tiltable Prior operation: Remove the instrument panel, see Instrument cluster - Remove (55.408) for instrument panel removal process. Prior operation: Remove the rear hood, see Hood - Remove â&#x20AC;&#x201C; Rear hood (90.100) for rear hood removal process. 1. Remove the bracket mounting bolts (1) and washers. 2. Remove the bracket from steering tilting column.

GNIL15TR00964AB

GNIL15TR00965AB

GNIL15TR00966AA

3. Remove the split pins (1) from top and bottom link of gas stud.

4. Loosen the nut and remove the gas stud bottom link (1).

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Steering - Steering control

5. Remove the bolt (2) and nut from tilting pedal (1). 6. Remove the tilting pedal (1).

GNIL15TR00969AB

GNIL15TR01511AB

GNIL15TR01512AB

GNIL15TR01513AB

7. Remove the steering pivot pin (1) from the pivot support.

8. Disconnect the steering pump hoses. See the Steering control - Disconnect (41.101). 9. Loosen and remove the steering column mounting bolts (1) and remove the steering motor assembly (2) with steering column.

10. Loosen and remove the bolts (1) and separate the steering motor (2) from steering shaft.

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Steering - Steering control

Steering control - Install 1. Install the bracket from the steering tilting column with the washers and the bracket mounting bolts (1).

GNIL15TR00964AB

GNIL15TR00965AB

GNIL15TR00966AA

GNIL15TR00969AB

2. Install the split pins (1) on the top and bottom line of the gas stud.

3. Install the gas stud bottom link (1) with the nut.

4. Install the tilting pedal (1) with the bolt (2) and nut.

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Steering - Steering control

5. Install the steering pivot pin (1) on the pivot support.

GNIL15TR01511AB

GNIL15TR01512AB

GNIL15TR01513AB

6. Install the steering pump hoses. See the Steering control - Install (41.101). 7. Install the steering motor assembly (2) and steering column with steering column mounting bolts (1).

8. Install the steering motor (2) with the bolts (1) on steering shaft.

9. Install the instrument panel, see the Instrument cluster - Install (55.408). 10. Install the rear hood, see the Hood - Install â&#x20AC;&#x201C; Rear hood (90.100).

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Steering - Steering control

Steering control - Disassemble â&#x20AC;&#x201C; Steering motor 1. Hold the steering securely in a vice. 2. Remove the end cover bolts (6 plus one special screw).

GNIL14TR04492AA

GNIL14TR04493AA

GNIL14TR04494AA

GNIL14TR04495AA

3. Remove the end cover, sideways.

4. Lift the gear wheel set (with spacer fitted) off the unit. Take out the two O-rings.

5. Remove cardan shaft.

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Steering - Steering control

6. Remove distributor plate.

GNIL14TR04496AA

GNIL14TR04497AA

GNIL14TR04498AA

GNIL14TR04499AA

7. Screw out the threaded bush over the check valve.

8. Remove O-ring.

9. Shake out the check valve ball and suction valve pins and balls. NOTE: Replace pins prior to the reassembly.

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Steering - Steering control

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.

GNIL14TR04500AA

11. Take ring, bearing races and needle bearing from sleeve and spool. The outer (thin) bearing race can sometimes â&#x20AC;&#x153;stickâ&#x20AC;? in the housing, therefore check that it has come out.

GNIL14TR04501AA

GNIL14TR04502AA

GNIL14TR04503AA

12. Press out the cross pin. Use the special screw from the end cover.

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 (see figure). 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.

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Steering - Steering control

13. Carefully press the spool out of the sleeve.

GNIL14TR04504AA

GNIL14TR04505AA

GNIL14TR04506AA

GNIL14TR04507AA

14. Press the neutral position springs out of their slots in the spool.

15. Remove dust seal and O-ring/kin-ring/roto glyd.

16. The steering unit OSPB is now completely dismantled.

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Steering - Steering control

Steering control - Cleaning â&#x20AC;&#x201C; Steering motor Clean all parts carefully in Shellsoi K or the like

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Steering - Steering control

Steering control - Inspect â&#x20AC;&#x201C; Steering motor Replace all seals and washers. Check all parts carefully and make any replacements necessary.

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Steering control - Lubricate â&#x20AC;&#x201C; Steering motor Before assembly, lubricate all parts with hydraulic oil.

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

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

1. Place the two flat neutral position springs in the slot. Place the curved springs between the flat ones and press them into the place.

GNIL14TR04508AA

GNIL14TR04509AA

GNIL14TR04510AA

2. Line up the spring set.

3. Guide the spool into the sleeve. Make sure that spool and sleeve are placed correctly in relation to each other.

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4. Assemble spool and sleeve.

GNIL14TR04511AA

GNIL14TR04512AA

GNIL14TR04513AA

GNIL14TR04514AA

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 speing 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 centre them.

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7. Guide the ring down over the sleeve. NOTE: The ring should be able to move - free of the springs.

GNIL14TR04515AA

GNIL14TR04516AA

8. Fit the cross pin into the spool/sleeve.

9. Fit bearing races and needle bearing as shown on below drawing.

GNIL14TR04517AA

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Assembly pattern for standard bearing 1.

Outer bearing race

Needle bearing

Inner bearing race

Spool

Sleeve

GNIL14TR04518AB

GNIL14TR04519AA

*The inside chamfer on the inner bearing race must face the inner spool.

Installation of O-ring 1. Turn the steering unit until the bore is horizontal in position. Guide the outer part of the assembly tool into the bore for the spool/sleeve.

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2. Grease O-ring and king ring/roto glyd with hydraulic oil and place them on the tool.

GNIL14TR04520AA

GNIL14TR04521AA

GNIL14TR04522AA

GNIL14TR04523AA

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.

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Installation of lip seal 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. Lubricate the lip seal with hydraulic oil and place it on the assembly tool.

GNIL14TR04524AA

GNIL14TR04525AA

GNIL14TR04526AA

GNIL14TR04527AA

2. Guide the assembly tool right to the bottom.

3. Press and turn the lip seal into place in the housing.

4. With a light turning movement, guide the spool and sleeve into the bore. NOTE: Fit the spool set holding the cross pin horizontal.

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5. The spool set will push out the assembly tool guide. The O-ring and kin ring/roto glyd are now in position.

GNIL14TR04528AA

GNIL14TR04529AA

GNIL14TR04530AA

GNIL14TR04531AB

6. Turn the steering unit until the bore is vertical again. Put the check valve ball into the hole indicated by the arrow.

7. Screw the threaded bush lightly into the check valve bore. The top of the bush must lie just below the surface of the housing.

8. Place a ball in the two holes (1).

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9. Place a new pin in the same two holes.

GNIL14TR04538AA

GNIL14TR04532AA

GNIL14TR04533AA

GNIL14TR04534AA

10. Grease the O-ring with mineral oil approximately viscosity 500 mm2/s at 20 Â°C (68 Â°F).

11. Place the distributor plate so that the channel holes match the holes in the housing.

12. Guide the cardan shaft down into the bore so that the slot is parallel with the connection flange.

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13. Place the cardan shaft as shown - so that it is held in position by mounting fork.

GNIL14TR04535AA

GNIL14TR04536AA

GNIL14TR04537AA

GNIL14TR04539AA

14. Grease two O-rings with mineral oil approximately viscosity 500 mm2/s at 20 Â°C (68 Â°F) and place them in the two grooves in the gear rim. Fit the gearwheel and rim on the cardan shaft.

NOTE: Fit the gear wheel (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 seven through holes match the holes in the housing.

15. Fit the spacer, if any.

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16. Place the end cover in position.

GNIL14TR04540AA

GNIL14TR04541AB

GNIL14TR04542AA

GNIL14TR04543AA

17. Fit the special screw with washer and place it in the hole (1).

18. Fit the six screws with washers and insert them. Cross-tighten all the screws and the rolled pin with a torque of 3.0 Âą 0.6 daNm. The steering motor can now be function tested.

19. Fit the dust seal ring in the housing using suitable tool and a plastic hammer.

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20. Press the plastic plugs into the connection ports. NOTE: Do not use a hammer.

GNIL14TR04544AA

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Steering control - Test NOTE: 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. 1. Set engine speed to 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.

GNIL14TR04484AA

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Steering control - Troubleshooting Problem Regular adjustments of the steering wheel are necessary (“Snake-like driving”)

“Motoring” effect. The steering wheel can turn on its own

Backlash

“Shiny” ‐ effect. The steered Wheels vibrate. (Rough tread on tyres gives vibrations)

Neutral position of steering wheel cannot be obtained, i.e. there is a tendency towards “Motoring”

Steering wheel can be turned the whole time without the steered wheels moving

Steering wheel can be turned slowly in one or both directions without the steered wheels turning

Possible Cause Correction Leaf spring without spring force or broken Replace leaf springs

Spring in double shock valve broken Gear wheel set worn Cylinder seized or piston seals worn Leaf springs are stuck or broken and have therefore reduced spring force

Replace Replace Replace Replace

shock valve gear wheel set defective parts leaf springs

Inner and outer spools pinch, possible due to dirt Return pressure in connection with the reaction between differential cylinder and steering unit too high Cardan shaft fork worn or broken. Leaf springs without spring force or broken. Worn splines on the steering column. Air in the steering cylinder.

Clean steering unit or contact your authorised NEW HOLLAND dealer Reduce return pressure, change cylinder type or use a non - reaction control unit. Replace cardan shaft Replace leaf springs. Replace steering column. Bleed cylinder. Find and remove the reason for air collection.

Mechanical connections or wheel bearings Replace worn parts. worn. Steering Column and steering unit out of Align the steering column with steering unit line

Too little or no play between steering col- Adjust the play and, if necessary, shorten umn and steering unit input shaft the splines journal Pinching between inner and outer spools Contact your authorised NEW HOLLAND dealer Fill with clean oil and bleed the system Oil is needed in the tank

Steering cylinder worn Gear wheel set worn Spacer across cardan shaft forgotten One or both anti—cavitation valves are leaky or are missing in OSPC or OVP/OVR

Replace or repair cylinder Replace gear wheel set Install spacer Clean or replace defect or missing valves

One or both shock valves are leaky or are Clean or replace defective or missing missing in OS PC or OVP/OV valves. “Kick‐‐back” in steering Fault in the system Contact your authorised NEW HOLLAND wheel from system. Kicks dealer or Danfoss from wheels. Heavy kick‐‐back in Wrong setting of cardan shaft and gear Correct setting as shown in service manual. steering wheel in both wheel set. directions. Steering is too slow and Insufficient oil supply to steering unit, pump Replace pump or increase number of revoheavy when trying to turn defective or number of revolutions too low lutions quickly Adjust valve to correct setting Relief valve setting too low Relief valve sticking owing to dirt Clean the valve Spool in priority valve sticking owing to dirt Clean the valve, check that spool moves easily without spring 47866580 11/12/2015

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Steering - Steering control

Problem

Possible Cause Too weak spring in priority valve

Correction Replace spring by a stronger, there are 3 sizes as follows: 4 bar (58 psi) 7 bar (102 psi) 10 bar (145 psi) Hydraulic hoses for the steering cylinders Reverse the hoses have been switched around

Turning the steering wheel activates the steered wheels opposite Pump pressure too low Too little steering force (possibly to one side only) Too little steering cylinder Piston rod area of the differential cylinder too large compared with piston diameter Pump pressure too low Too little steering force (possibly to one side only) Too little steering cylinder Piston rod area of the differential cylinder too large compared with piston diameter Leakage at either Shaft defective input shaft, end cover, gear‐‐wheel set, housing or top part Screws loose Washers or O‐rings defective

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Correct pump pressure Fit a larger cylinder Fit cylinder with thinner piston rod or two differential cylinders Correct pump pressure Fit a larger cylinder Fit cylinder with thinner piston rod or 2 differential cylinders Replace shaft seal

Tighten screws Torque 3-3, t daNm or steering unit (2, 5-3 daNm) Replace washers and O‐rings

Index Steering - 41 Steering control - 101 Steering control - Assemble - Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Cleaning – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Disassemble – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Inspect – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Lubricate – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Remove - Fixed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Remove - Tiltable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Steering - 41 Hydraulic control components - 200

TT4.80 TT4.90

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Contents Steering - 41 Hydraulic control components - 200

SERVICE Steering circuit relief valve Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Steering - Hydraulic control components

Steering circuit relief valve - Test NOTE: There is no relief valve in 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 side lock. 2. Disconnect left-hand side turn feed hose (3) at steering cylinder. 3. Install power steering pressure checking kit (1) (special tool number 380000240 with adapter 271318). As shown in Fig. 1. 4. Start tractor and set engine speed to 1450 RPM. Turn steering wheel to the left with a pull of approximately 22 N (5 lb) and observe the pressure reading. NOTE: The use of a force greater than 22 N (5 lb) 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 are away from specification the relief valve (2) in the steering motor must be adjusted. The pressure reading should be 110 â&#x20AC;&#x201C; 125 bar (1595 â&#x20AC;&#x201C; 1812 psi). 5. If the system pressure is not to specification proceed to relief valve adjustment.

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GNIL14TR04485AB

Steering - Hydraulic control components

Steering circuit relief valve - Adjust Relief valve adjustment 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. Disconnect the steering motor from the steering bracket and remove from the tractor. 2. Fabricate suitable test hose to connect pump pipeline to steering motor. Connect locally procured ‘T’ joint between test hose and steering motor and install pressure gauge as shown in the figure 1. 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 between 1450 – 1500 RPM. Run the tractor until the transmission oil reaches normal working temperature. 6. With the engine running, turn the steering motor shaft to obtain full lock. The pressure gauge reading should read 120 bar (1740 psi). 7. If the pressure readings are not correct, reset the adjuster (11), using an 8.000 mm (0.315 in) hexagon key.

GNIL14TR04486FB

1. 2.

Plug Steering shaft

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Pressure gauge 0-5000 lbf.in2 Swivel running Tee

Steering - Hydraulic control components

3. 4. 5. 6.

Relief valve Fabricated steering motor output hose Tractor tubes to steering cylinder Fabricated hose for pump supply to steering motor

9. Blanking cap 10. Spring 11. Adjuster

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Index Steering - 41 Hydraulic control components - 200 Steering circuit relief valve - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering circuit relief valve - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Steering - 41 Cylinders - 216

TT4.80 TT4.90

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Contents Steering - 41 Cylinders - 216

FUNCTIONAL DATA Steering cylinder Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Steering cylinder Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Steering - Cylinders

Steering cylinder - Component identification

NDIL14TR00786GA

1. 2. 3. 4.

Nut Washer Nut Washer

5. 6. 7.

Cylinder mounting bracket Spacer Bolt

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Steering cylinder - Remove 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. NOTE: Position of flexible pipes and orientation of connectors must be the same upon reassembly. 3. Remove the nut securing the cylinder rod ball joint to the steering arm and separate the joint, Figure Steering cylinder - Component identification (41.216) Figure 1. 4. Remove the nut (3) securing the steering cylinder on front axle beam. 5. Remove the steering cylinder from the tractor and retrieve washer (4), spacer (6) and bolt (pivot pin) (7).

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Steering - Cylinders

Steering cylinder - Install 1. Install the steering cylinder with retrieve washer, spacer and bolt (pivot pin) on the tractor. 2. Install the nut, securing the steering cylinder on front axle beam. 3. Install the nut securing the cylinder rod ball joint to the steering arm. 4. Install the flexible pipes and hose clamps.

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Steering - Cylinders

Steering cylinder - Overhaul

NDIL14TR00787FA

1. 2. 3. 4.

Cylinder Wiper seal Retaining ring Gland nut

5. 6. 7. 8.

Cylinder rod Gland and seal assembly Piston Nut

1. Using appropriate â&#x20AC;&#x2DC;Câ&#x20AC;&#x2122; spanner, unscrew and remove the gland nut. 2. Using a punch, push the steering cylinder gland into the cylinder and remove the wire locking ring. 3. Pull the rod and gland assembly from the cylinder. 4. Remove the nut from the cylinder rod and disassemble to replace seals.

NDIL14TR00788AA

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Steering - Cylinders

5. Inspect the bore of the cylinder and replace if scored. 6. Reassemble the cylinder in the reverse to disassembly, lubricating all components as assembled. Replace all seals supplied in the service seal kit. NOTE: The seal located in the centre of the gland is replaceable.

NDIL14TR00789AA

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Index Steering - 41 Cylinders - 216 Steering cylinder - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

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SERVICE MANUAL Wheels TT4.80 TT4.90

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Contents Wheels - 44

[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1

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Wheels - 44 Front wheels - 511

TT4.80 TT4.90

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Contents Wheels - 44 Front wheels - 511

SERVICE Front wheels Test – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Test – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Wheels - Front wheels

Front wheels - Test – 2WD Wheel camber test Check the front wheel camber considering that when the tractor moves along a straight line, wheels should be tilted by 2 ° relative to the ground, corresponding to a difference (“X”) of approximately 15.0 mm (0.6 in) between the rim edges.

NDIL14TR00822AB

NDIL14TR00823AB

NDIL14TR00824AB

Front wheel toe-in test When the tractor moves along a straight line, wheels should be parallel to the tractor centre line or slightly toe-in until a max. of 0.50 mm (0.02 in), measured between the rim edges. Check the correct toe-in as follows: 1. Inflate front tires to a pressure of 1.7 bar (25.0 psi). 2. Place the steering wheel at mid-travel, with one spoke along the tractor centre line. 3. Check if wheels are parallel to the tractor centre line. 4. Measure the distance (B) between the wheel inner rims at hub height at the front of the wheels. 5. Measure the distance between the wheel inner rims at hub height at the rear of the wheels. The measurement taken should be the same as (B) or greater by up to 5.00 mm (0.20 in) max. 6. If necessary to adjust the front wheel toe-in, proceed as follows: • Loosen the clamp (1) on both end of the track control rod. • Turn the track control rod (2) in or out to shorten or lengthen the track control rod until 0.50 mm (0.02 in) toe-in is achieved. • Tighten the clamp (1).

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Wheels - Front wheels

Front wheels - Test – 4WD 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 6.000 mm (0.236 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 that the wheels are parallel to the longitudinal axis of the tractor. 4. Make a chalk mark on the front inside edges of both wheel rims, at the height of the wheel hub centres. Measure the distance “1” between the chalk marks. 5. Move the tractor forward to turn both front wheels through 180 °. The chalk marks will now be measure between the rear inside edges of the wheel rims at the height of the wheel hub centres. Mow measure the distance “2” checking that this new measurement is equal to or greater than the distance “1” by a maximum or 6.0000 mm (0.2362 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.

NDIL14TR00437AB

NDIL14TR00438AB

6. If it is necessary to correct the wheel alignment, remove nut (2) and pull the track rod end (1) out of its housing. Slacken off locknut (3) and screw the track rod end (1) in or out to increase or decrease the distance (2) fig. 2. Reposition the track rod end (1) in its housing and re-check alignment as described in points 4 and 5 above. After having adjusted the alignment to within the prescribed limits, tighten locknut (3) to a torque of 180.00 N·m (1593.13 lb in) and nut (2) to 100.00 N·m (885.07 lb in). NOTE: The self-locking nut (2) must be renewed each time it is removed or partially unscrewed.

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Index Wheels - 44 Front wheels - 511 Front wheels - Test – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front wheels - Test – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

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SERVICE MANUAL Electrical systems TT4.80 TT4.90

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Contents Electrical systems - 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8

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Contents Electrical systems - 55 Electrical system - 000

FUNCTIONAL DATA Electrical system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Electrical system Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DIAGNOSTIC Electrical system Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Electrical systems - Electrical system

Electrical system - Overview

GNIL15TR00475FB

1. Hand throttle lever Hand throttle lever should be used during the field operation. Push the lever up to increase the engine speed and down to reduce it.

2. Horn button Press the horn button for warning arrival.

3. Head light switch positions It has 4 positions.

GNIL15TR00476AB

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Electrical systems - Electrical system

Key start switch A three-position ignition switch is provided. Positions of ignition switch are as follows: • Position 1: Electrical equipment Off • Position 2: Accessories on (Head lamp, instrument cluster, horn and gauges) • Position 3: Starter motor engaged

GNIL15TR00477AB

GNIL15TR00478AB

GNIL15TR00479AB

5. Mobile charger socket Socket 12 V / 10 A . is given to connect mobile charger.

6. Turn signal indicator switch Turn indicator switch indicates turn signals and should be moved on to right to operate right turn indicator light and left to operate the left turn indicator light. NOTE: The turn signal will operate only when the ignition switch is turned on.

7. Hazard warning light switch This switch should be used during emergency parking, foggy weather to indicate warning signal to the approaching vehicles and following vehicles. This switch can be operated even when ignition switch in OFF position. This switch has two positions. (See the figure 4).

8. Front work light switch This switch has two positions. (See the figure 5).

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Electrical systems - Electrical system

9. Shuttle shift lever Shuttle shift lever is used to engage the transmission into forward or reverse mode while press the clutch pedal. Move the lever upward for forward and downward for reverse travel. Shuttle lever must be in the neutral position to activate the safety start system and allow the engine to start.

10. Neutral start switch A two position â&#x20AC;&#x2122;ball plunger typeâ&#x20AC;&#x2122; switch (1) is mounted on the left hand side of the transmission housing. It is operated by the high / low range lever.

GNIL15TR00480AB

GNIL15TR00481AB

10. Brake light switch The brake pedal switch (1) is located below the right footboard near the footbrake. It is actuated while applying the brake and is indicated by the light provided on the fender.

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Electrical systems - Electrical system

Electrical system - Overview Electrical system and fuses The electrical system of tractors consists of various wiring harnesses, lights, switches, battery, alternator, starter and instrument cluster. Fuses (1) protect electrical circuits with thin pieces of wire, which heat up and melt when too much current flows through them. This opens circuit and protects the wiring from burning. This can occur in the event of a ‘short circuit’, or by connecting equipment which demands a current greater than the circuit, designed to carry. The fuse is specially designed and in the event of failure, a new fuse of the same rating should be fitted.

GNIL15TR00506AB

NDIL14TR00826AB

NOTICE: The fuse should never be repaired or replaced by a fuse of a higher rating. If the fuse repeatedly ‘blows’ the cause must be investigated and repaired. Fuses are arranged in two separate columns. There are six fuses in one and two spare fuses in the other. Rating 10 A 20 A 20 A 20 A 20 A 10 A

Circuit Brake switch Lamps Horn ACC Plough lamp Turn signal

Spare fuses Rating 15 A 15 A

Details Spare Spare

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Electrical systems - Electrical system

Electrical system - Service instruction Protecting the electrical systems during charging or welding precautions To avoid damage to the electrical systems, always observe the following: 1.

Never make or break any of the charging circuit connections, including the battery connections, when the engine is running.

Never short any of the charging components to earth.

Do not use a slave battery of higher than 12 V nominal voltage.

Always observe correct polarity when installing the battery or use a slave battery to jump charge the engine.

Always disconnect the earth cable from the batteries before carrying out arc welding on the tractor or on any implement attached to the tractor.

Always disconnect the negative cable from the batteries when charging the batteries in the tractor with a battery charger.

NOTICE: Failure to disconnect the earth cable connections at the battery prior to charging the batteries or welding on the tractor or attached implement will result in damage to the electrical system.

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Electrical systems - Electrical system

Electrical system - Test Electrical circuit failures can all be grouped in to four types. 1. Open circuit 2. Resistance fault 3. Short circuit 4. Live short circuit

1. Open circuit This type of failure occurs when a circuit is broken at any point in that circuit.

Failure mode Circuit fails to work at all.

Method of testing First check the simple possible failure cause like fuse, bulb or bulb contacts. With the circuit ‘Live’, a multimeter set to volts can be used to locate and identify the point where the circuit is broken.

2. Resistance fault This type of failure occurs when some part of the circuit becomes corroded or damaged and so restricts the flow of electricity.

Failure mode The circuit often works, but fails to perform satisfactorily.

Method of testing With the circuit ‘live’, connect a multimeter set to volts across suspected part of the circuit. A bad cable or connection will show a voltage reading across it. If the voltmeter shows more than 0.5 V, there is a resistance fault.

3. Short circuit This type of failure occurs when a direct connection occurs between the positive and negative parts of the circuits.

Failure mode In a fused circuit the fuse will ’blow’ and protect the circuit. If the circuit is not fused then burning of the wiring will occur.

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Electrical systems - Electrical system

Method of testing With the circuit open, remove the ground connection from the faulty circuit. (eg. take out the bulb). With the multimeter set to “Buzz”, connect between the suspected wire and ground, The multimeter will buzz if a short circuit is present. Check through the faulty wire until the buzz stops and your have located the fault.

4. Live short circuit This type of failure occurs when a connection is made across two positive sides of a circuit.

Failure mode Several parts of a circuit will try to operate simultaneously. Possibly a ‘fuse’ is the current draw required is greater than the fuse rating.

Method of testing With the circuit “open” and multi-meter set to “buzz” on resistance. Correct meter wires across suspected circuits.

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Electrical systems - Electrical system

Electrical system - Troubleshooting Problem Possible Cause Correction Check battery, charge or renew Several or all lights do not Battery discharged illuminate Loose or defective battery cable connec- Inspect, clean and tighten connections tions Loose harness connectors Check and ensure connectors securely tightened Fuse burned out Inspect and renew, check circuit before re-connecting power Faulty wiring Check lighting circuit, repair or renew Defective light switch Check and renew Several light bulbs burned out due to de- Check and renew voltage regulator fective voltage Individual lights do not Burned out bulb Check and renew illuminate Inspect, clean or renew Defective or corroded bulb contacts Fuse burned out Inspect and renew, check circuit before re-connecting power Loose or broken wires Inspect, secure, repair or renew wiring Poor ground connection Inspect, dean or tighten ground connections Lights bum out repeatedly Loose or corroded wiring connections Inspect, secure, repair or renew wiring Loose bulb or lamp mounting bracket Inspect, tighten or renew Faulty voltage regulator Check and renew voltage regulator Plough light inoperative See the ”individual lights do not illuminate” See the ”individual lights do not illuminate” Flasher lamps do not Fuse blown Inspect and renew, check Circuit before illuminate re-connecting power Flasher unit inoperative Check and renew NOTE: Flasher unit may be bypassed by inter-connecting terminals This enables circuit continuity to be checked Flasher switch in operative Check and renew Inspect circuit, dean and tighten connecDefective wiring or connections tions or renew wiring Burned out bulb Individual flasher lamp Check and renew does not illuminate Inspect, clean, tighten or renew Corroded or loose bulb contacts Poor ground connections or damaged Inspect, clean and tighten connection, rewiring pair or renew wiring

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Index Electrical systems - 55 Electrical system - 000 Electrical system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Harnesses and connectors - 100

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Contents Electrical systems - 55 Harnesses and connectors - 100

TECHNICAL DATA Fuse and relay box General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Wiring harnesses Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Fuse and relay box Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Electrical systems - Harnesses and connectors

Fuse and relay box - General specification Sl.No. 1. 2. 3. 4. 5. 6.

Six fuses housed in the fuse box. Protected circuit Brake switch Lamp Horn Accessories Turn signal Plough lamp

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Ampere 25 A 20 A 20 A 20 A 15 A 20 A

Electrical systems - Harnesses and connectors

Wiring harnesses - Repair Temporary wiring harness repair The following method to repair wiring is a temporary expedient only. Wiring should be replaced as soon as possible. Replacement of temporary repaired cables with new is particularly important if the tractor is to be used for puddling, spraying etc, as water/chemicals can enter the repaired area, travel up the cable and damage electrical components. Do not attempt to repair the wire on any system sensors as these are sealed and should only be replaced with a new component. NOTE: When conducting a cable repair it is important that only resin cored solder is used.Use of other types of solder may result in further cable damage. To carry out a temporary repair, proceed as follows:1. Locate damaged portion of cable then cut away outer protective cover on both sides of the damaged area.

GNIL14TR04711AA

GNIL14TR04712AA

GNIL14TR04713AA

2. Peel back the cable from both ends of the damaged area and carefully cut away the inner cable cover at the damaged area and strip about 13.00 mm (0.51 in) of insulation from the wires. Do not cut away any wire strands. 3. Using a suitable solvent, clean about 50.00 mm (1.97 in) from each cover end. Clean the grey cable cover and the individual leads. 4. Twist two bare leads together for each damaged lead, being careful to match wire colors, then solder the leads using resin cored solder. Tape each repaired lead with vinyl insulation tape, figure 2. 5. Wind a layer of vinyl insulation tape up to the grey cable cover at each end of the repair section. Make a paper trough, figure 3, then apply silicon rubber compound (non hardening sealant) over the repaired section up to the cover ends. Sufficient sealant must be used to fill the ends of the cut away area.

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Electrical systems - Harnesses and connectors

6. Allow the compound to cure, then cover the area with insulating tape taking the tape well over each end of the repair. An overlap of at least 50.00 mm (1.97 in) of tape at each end is necessary, figure 4. 7. Check to ensure the repair is satisfactory and secure the repaired cable so that repeat damage is avoided. NOTE: This is a temporary repair only. Ensure the damaged cable is replaced as soon as possible to prevent ingress of water or chemicals.

GNIL14TR04714AA

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Electrical systems - Harnesses and connectors

Fuse and relay box - Remove 1. Remove the battery. (55.302).

See the Battery - Remove

2. Loosen and remove the bolts (1). Remove the fuse box assembly (2).

GNIL15TR00788AB

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Electrical systems - Harnesses and connectors

Fuse and relay box - Install 1. Install the fuse box assembly (2) with the bolts (1) . 2. Install the side covers. See the Hood - Install (90.100). 3. Install the battery. See the Battery - Install (55.302).

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Index Electrical systems - 55 Harnesses and connectors - 100 Fuse and relay box - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse and relay box - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuse and relay box - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Engine starting system - 201

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Contents Electrical systems - 55 Engine starting system - 201

TECHNICAL DATA Engine starting system General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine starting system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Engine starting system Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Engine starter Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DIAGNOSTIC Engine starting system Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Electrical systems - Engine starting system

Engine starting system - General specification Make Voltage rating Rated output Rotation (viewed from the driver’s end) Number of teeth on pinion Number of poles Field winding Control Operation Pinion travel Solenoid details Winding resistance at 20 °C (68 °F) Pull-in winding Hold-on winding Current consumption at 12 V Pull-in + hold-on instantaneous (maximum) Hold-on continuous (maximum)

BOSCH / PMP 12 V 2.7 kW clockwise 10 4 Electrical excitation Starting relay and ignition switch Pre-engaged direct drive solenoid 18.00 mm (0.71 in)

0.24 Ω 1.05 Ω 60 A 12 A

Engine starting system - Torque Description Starter motor mounting bolts

Thread size M12 x 1.5

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Torque 74 N·m (55 lb ft)

Electrical systems - Engine starting system

Engine starting system - Overview Tractor is fitted with a 12 V, solenoid operated pre-engaged type starter. When the key is turned to the start position, an electrical circuit is made, from the key switch, through gearbox mounted safety start switch to the starter solenoid. The electricity in this circuit energies the solenoid coils and the solenoid plunger is magnetically attracted into the solenoid core. This movement, transmitted through a mechanical linkage pulls the drive pinion to mesh with the flywheel ring gear. When the pinion gear is fully meshed with the ring gear the solenoid plunger reaches the end of its travel and contacts with a switch connecting the battery directly to the starter motor. This switch directs battery power directly to the starter motor, which causes it to rotate and as a consequence, the engine is cranked to start. When the key switch is released, battery power to the solenoid is removed. The solenoid plunger returns to rest position (aided by the solenoid plunger spring) and the starter pinion is released from the flywheel ring gear, this also breaks the battery connection. To protect the starter motor from high engine speed, an over run clutch is fitted between the starter motor and pinion gear.

NDIL14TR00841GB

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Electrical systems - Engine starting system

1. 2. 3. 4. 5.

Ignition/starter switch or driving switch Solenoid switch Return spring Excitation winding series winding Engaging lever

1. Rest position 2. Favorable meshing position

3. Unfavorable meshing position 4. End position

6. 7. 8. 9.

Roller-type overrunning clutch Pinion Battery Armature

No current to starter, pinion demeshed. Pull -in and hold-in windings are energized. A pinion tooth meets a gap in the ring gear, and the pinion meshes immediately. Shown is starter position just before main current is switched on. A pinion tooth meets a ring gear tooth. Engaging lever in end position, meshing spring compressed, pull-in winding not energized. Main current flows, armature rotates. Pinion attempts to mesh with ring gear. Engaging lever in end position, pull-in winding not energized main current flows, pinion is fully meshed. Engine is cranked.

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Electrical systems - Engine starting system

Engine starting system - Remove 1. Remove the battery. (55.302).

See the Battery - Remove

2. Disconnection to the starter motor solenoid switch (3).

GNIL15TR00791AB

GNIL15TR00489AB

3. Loosen and remove the three mounting bolts (1), and remove the starter (2).

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Electrical systems - Engine starting system

Engine starting system - Install Installation procedure of starter motor is reverse of removal procedure. NOTICE: Starter motor should be serviced and repaired only by authorized MICO dealer. 1. Install the starter (2), with the three mounting bolts (1).

GNIL15TR00489AB

GNIL15TR00791AB

2. Connect the starter motor solenoid switch (3).

3. Connect the battery negative cable. See Battery - Install (55.302).

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Electrical systems - Engine starting system

Engine starter - Test NOTICE: Before carrying out any starting system test, ensure that the battery is fully charged and in good condition.

Starter solenoid feed voltage test 1. Connect voltmeter between starter solenoid battery terminal and chassis ground. 2. If voltmeter shows less than battery voltage, check battery connections to solenoid or chassis ground connections.

NDIL14TR00843AB

NDIL14TR00844AB

NDIL14TR00845AB

Solenoid â&#x20AC;&#x2DC;on loadâ&#x20AC;&#x2122; feed voltage test 1. Connect voltmeter between starter solenoid battery terminal and chassis ground. 2. Crank engine on starter with fuel injection pump fuse pulled out to prevent engine starting. 3. If during cranking voltmeter shows less than 9.6 V, check battery, if battery is good, check for poor connections between battery and starter or a fault in starter motor. 4. If voltage is higher than 11 V and cranking speed is low, check for fault in starter.

Safety start circuit test 1. Connect voltmeter between solenoid safety start connection and chassis ground. 2. Crank engine over on starter. 3. If reading is less than 8.5 V check key switch, safety start switch and connections.

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Electrical systems - Engine starting system

Engine starting system - Troubleshooting Problem Possible Cause Engine will not crank and Battery discharged starting solenoid does not engage Safety inter locks not working Starting circuit open or high resistance Engine will not crank but Battery discharged solenoid engages Defective starter motor connections or loose battery connections Starting motor faulty Starting motor turns but Defective starter motor drive assembly not engages Defective solenoid or pinion engagements levers Defective flywheel ring gear Engine crank slowly Discharged battery Excessive resistance in starting circuit Defective starter motor

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Correction Check battery charge or renew

Check the circuit and repair or renew faulty components Check circuit connections and repair or renew faulty wire connections Check battery charge or renew Check, clean and tighten connections Inspect, repair or renew Inspect and repair / renew Inspect and repair / renew Inspect and repair / renew Check the battery charge or renew Check circuit connections and repair or renew faulty wiring Inspect and repair / renew

Index Electrical systems - 55 Engine starting system - 201 Engine starter - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starting system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starting system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starting system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starting system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starting system - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starting system - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Alternator - 301

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Contents Electrical systems - 55 Alternator - 301

TECHNICAL DATA Alternator General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Alternator Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Alternator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DIAGNOSTIC Alternator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Electrical systems - Alternator

Alternator - General specification Make Rated voltage Rotation (seen from pulley side) Cut-in speed at 12 V & 25 °C (77 °F) Output at 14 V across battery warm-up with fully bedded in brushes Rotor winding resistance between both collector ring ( 20 °C (68 °F)) Alternator speed on tractor (at engine governed speed) Drive ratio Torque requirement for nut securing alternator pulley Voltage regulator Type Alternator-test speed Voltage setting

BOSCH / PMP 14 V Clockwise 1050 – 1150 RPM 23/75 A 3.4 – 3.8 Ω 6000 RPM 1 to 1.992 41 N·m (30 lb ft) Integral with alternator 4000 RPM 13.6 – 14 V

Alternator - Torque Description Alternator mounting bracket bolt nuts Alternator pivot bolt Belt tension adjusting screw

Thread size M12 x 1.5 M12 x 1.25 M8 x 1

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Torque 70 N·m (52 lb ft) 40 N·m (30 lb ft) 20 N·m (15 lb ft)

Electrical systems - Alternator

Alternator - Overview The Alternator is fitted on the right side of the engine and driven by the fan belt. The two electrical cables (1) & (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.

NDIL14TR00846AB

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. 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 in-built regulator is used to limit the maximum voltage to 14 V.

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Electrical systems - Alternator

Alternator - Remove 1. Remove the battery. (55.302).

See the Battery - Remove

2. Loosen and remove the terminal nuts (1), and disconnect electrical connection from alternator.

GNIL15TR00494AB

GNIL15TR01504AB

GNIL15TR00785AB

3. Loosen and remove the two alternator mounting bolts (1). 4. Disconnect the belt (2) and remove the alternator. NOTICE: Alternator should be serviced and repaired only by authorized MICO dealer.

5. Loosen and remove the bolt (1). Remove the alternator lower mounting bracket (2).

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Electrical systems - Alternator

Alternator - Install 1. Install the alternator lower mounting bracket (2)and the bolt (1).

GNIL15TR00785AB

GNIL15TR01704AB

GNIL15TR00494AB

2. Install the alternator and connect the belt (2). 3. Install the two alternator mounting bolts (1).

4. Connect the electrical connection to alternator and install the terminal nuts (1). 5. Connect the battery negative terminal. See the Battery - Install (55.302).

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Electrical systems - Alternator

Alternator - Test NOTE: Ensure that the battery is at least 75 % charged before commencing alternator test.

Quick test 1. Battery warning light should illuminate when the key switch is turned to position 2. 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. 1.

D - Terminal

B+ - Terminal NDIL14TR00850AB

Result Bulb illuminates

Possible cause Alternator faulty

Bulb doesn't illuminate

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)

Possible cause System good

Less than battery voltage

Faulty circuit

Remedy None Check fusible link at starter Check wiring between battery and alternator

If battery voltage is shown, start the engine. Result

Remedy

Possible cause

13.6 – 14.0 V Battery warning light extinguished

System good

None

Less/more than 13.6 – 14.0 V Battery warning light illuminated

Engine Revolutions Per Minute (RPM) low Alternator faulty Faulty circuit

Increase engine RPM Repair or replace alternator Check fusible link and wiring to battery

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Electrical systems - Alternator

Full test Check battery condition and alternator belt as previously described.

Ignition circuit test 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. 1. Disconnect lead from alternator ‘D’ terminal, connect voltmeter between ‘D’ lead and chassis ground. With ignition switch on voltmeter should show 12 V.

NDIL14TR00851AB

NDIL14TR00852AB

NDIL14TR00853AB

If there is a fault with the ignition or warning light circuit. 2. If meter shows 12 V, test the alternator connection. With ‘D’ lead connected to alternator terminal, connect voltmeter between ‘D’ terminal and chassis ground. With key switch on voltmeter should show between 1.0 – 15.0 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 – 14.0 V in order to charge the battery and power accessories. 1. 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 – 14.0 V. If less, then alternator is faulty. If considerably more, then regulator is faulty.

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Electrical systems - Alternator

Alternator Amp. test Remove lead from alternator terminal (2), connect an Ampmeter (min 30 A capacity) between B+ terminal (2) and B+ lead (2). Ampmeter should show 20 â&#x20AC;&#x201C; 23 V 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.

NDIL14TR00854AB

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Electrical systems - Alternator

Alternator - Troubleshooting Problem Alternator charging at high rate (battery overheating) No output from the alternator

Intermittent or low alternator output

Possible Cause Defective alternator /voltage regulator

Correction Check and renew

Alternator drive belt broken

Tension correctly (renew)

Loose connection in the charging circuit Defective alternator Dead battery Alternator drive belt slipping

Check, clean and tighten connections Check and renew Recharge Check and adjust tension and renew

Loose or broken connection in the charging Inspect the circuit and tighten the connecunit tions Defective alternator Check and renew

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Index Electrical systems - 55 Alternator - 301 Alternator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Battery - 302

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Contents Electrical systems - 55 Battery - 302

FUNCTIONAL DATA Battery Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Battery Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DIAGNOSTIC Battery Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Electrical systems - Battery

Battery - Overview Operation Tractors feature a 12 V, negative ground, lead acid type battery of 6 cells connected in series. These cells are assembled in a polypropylene case and covered with a hard plastic top. Each cell contains a group of positive and negative plates insulated from one another by separator plates. The plates are alternately arranged in assembly to form an element. When the element is immersed in electrolyte, the voltage created is slightly higher than 2 volts. The series connection adds the voltage, so producing slightly over 12 V at the battery terminals.

Construction Battery is constructed in such a manner that each cell consists of one +ve and one -ve plates and each cell is separated by porous material all +ve plates are welded together to form a +ve terminal and similarly a -ve terminal is formed. These plates are submerged in an electrolyte solution i.e. sulfuric acid.

Functions â&#x20AC;˘ To provide a source of current for starting lighting and instruments. â&#x20AC;˘ Helps to control voltage in the electrical system.

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Electrical systems - Battery

Battery - Remove DANGER Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately. Failure to comply will result in death or serious injury. D0117A

1. Release the hood locks and raise the hood. See the Hood - Remove â&#x20AC;&#x201C; Front hood (90.100) 2. Disconnect the battery terminals (1) and (2) and loosen the clamp (3). NOTE: Always disconnect the negative cable first. 3. Remove the battery from the tractor.

GNIL15TR00834AB

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Electrical systems - Battery

Battery - Install Installing process is the reverse of removal procedure. But observe the following: â&#x20AC;˘ Clean the battery case, terminals and clamps before installation. Use a solution of sodium bicarbonate (baking soda) and water. NOTE: Cover the vents while cleaning. Connect negative terminals last. Do not overtighten the battery securing clamp. This may damage the battery case.

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Electrical systems - Battery

Battery - Test Condition of the battery could be checked by these different methods 1.

Hydrometer test (specific gravity)

Voltmeter test

Load test (voltmeter whilst cranking)

Current drain test

Hydrometer test The hydrometer test indicates the battery state of charge by measuring the specific gravity of the electrolyte in the battery cells. Using a hydrometer draw in enough electrolyte to raise the float in the barrel with the bulb fully expanded. NOTE: Do not draw in much electrolyte, as float may get contact with the top of the barrel. Read and record the specific gravity of each cell. The average specific gravity of all cells should be between 1.230 - 1.260. If the average value of all cells is less than 1.230, recharge the battery. If the average specific gravity of all cells is above 1.230, but the variation between cells is more than 0.050, the battery may be faulty. Recheck after fully charging the battery.

NDIL14TR00858FB

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Electrical systems - Battery

Voltmeter test The open circuit voltmeter test indicates the battery ‘state of charge’ by measuring the voltage stored in the battery. Connect a voltmeter across the battery terminals and read the voltage. NOTE: The battery must have been disconnected from any charge for at least 10 h before checking and the temperature has to be 25 °C (77 °F). Due to this restrictions it is not common to measure battery condition this way. The table below shows the open circuit voltage and specific gravity readings relative to the state and charge.

NDIL14TR00859AB

State of charge 100 % 75 % 50 % 25 % 0%

Open circuit voltage 25.0 °C (77.0 °F) 12.78 V 12.53 V 12.28 V 12.02 V 11.71 V

Specific gravity 1.260 1.230 1.200 1.170 1.100

1.280 1.250 1.220 1.190 1.130

Load test NOTICE: The battery must be fully charged before carrying out a load test. Never carry out this test on a battery, which is less than 75 % charged. Connect a voltmeter across the battery terminals. Read the battery voltage whilst cranking the engine for 20 s. Voltmeter should not show less than 9.6 V over the 20 s period. CAUTION Pull the fuel shut of knob and hold while cranking to prevent engine from starting during this process. If battery does not maintain 9.6 V over 20 s, fully charge the battery as described in the battery. Make another load test, as above. if battery again fails to maintain 6 – 9 V replace the battery.

Current drain test The current drain test is used in a situation where the battery and charging system test is ok and yet the battery is continually in a low state of charge. This may be due to a circuit continually drawing current from the battery. To identify, disconnect the cable from the battery negative terminal. Connect the voltmeter between battery negative port and the battery negative cable. With all electrical switches turned OFF the voltmeter should show 0 V. If battery voltage is shown, then a circuit is drawing current. Remove fuses one by one until voltage drops to 0 V volts and the faulty circuit is identified. If by removing the fuses does not cause the voltmeter to drop to zero, disconnect the wires from the electrical accessories, (alternator etc.) until the voltmeter shows 0 V.

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NDIL14TR00860AB

Electrical systems - Battery

Battery - Charging • Current : 7.5 A • Hours for charging : 15 h CAUTION When batteries are being charged an explosive gas mixture forms beneath the cover of each cell. Do not disconnect live circuits at the terminals of the batteries on charge, a spark will occur where the live circuit is broken, which may ignite the gas and cause an explosion. Similarly do not smoke, use welding/grinding equipment near to batteries on charge. A slow charge is the only method to fully charge a battery. A high rate charger can be used to quickly boost the capacity of a battery, but must be followed by slow charge to bring the battery to full capacity. Observe the following when slow charging the battery: • If the battery is to remain in the tractor, disconnect the cables at the battery to prevent damage to the electrical system during charging. • Thoroughly clean the battery. • Make sure the electrolyte is at the correct level. Battery is fully charged when 3 specific gravity readings taken at 1 h intervals indicate no increase in specific gravity.

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Electrical systems - Battery

Battery - Troubleshooting Problem Possible Cause Battery low or discharged Loose or worn out alternator drive belt Defective battery, do not accept or hold charge Excessive resistance due to loose charging system connections Defective voltage regulator / alternator

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Correction Check and adjust tension or renew Check the condition of the battery or renew Check, clean and tighten connections Check and renew

Index Electrical systems - 55 Battery - 302 Battery - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Engine cooling system - 012

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Contents Electrical systems - 55 Engine cooling system - 012

SERVICE Engine coolant temperature sensor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Engine cooling system

Engine coolant temperature sensor - Remove 1. Remove the battery. (55.302).

See the Battery - Remove

2. Remove the water temperature sensor (4).

GNIL15TR00792AB

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Electrical systems - Engine cooling system

Engine coolant temperature sensor - Install 1. Install the water temperature sensor (4).

GNIL15TR00792AB

2. Install the battery. See the Battery - Install (55.302).

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Index Electrical systems - 55 Engine cooling system - 012 Engine coolant temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine coolant temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 External lighting - 404

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Contents Electrical systems - 55 External lighting - 404

TECHNICAL DATA Headlight General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Work light General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Turn signal and/or hazard lights General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - External lighting

Headlight - General specification Asymmetric 55 W H3 type ( 12 V) 55 W H & type ( 12 V)

Reflector Bulb high beam Bulb low beam

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Electrical systems - External lighting

Work light - General specification Plough Lamp Integral White 55 W ( 12 V)

Switch Lens Bulb

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Electrical systems - External lighting

Turn signal and/or hazard lights - General specification Fender lights Front lights (left and right) Parking light Lens Bulb Turn signal light Lens Bulb

White 5 ( 12 V) Amber 21 ( 12 V)

Rear lights (left and right) Parking light + license plate light + stop lamp (Right-hand side only) Lens Bulb Turn signal light Lens Bulb

Red 21 ( 12 V) Amber 21 ( 12 V)

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Index Electrical systems - 55 External lighting - 404 Headlight - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turn signal and/or hazard lights - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Work light - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Warning indicators, alarms, and instruments - 408

TT4.80 TT4.90

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Contents Electrical systems - 55 Warning indicators, alarms, and instruments - 408

TECHNICAL DATA Warning indicators, alarms, and instruments General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Instrument cluster Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Instrument cluster Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

DIAGNOSTIC Warning indicators, alarms, and instruments Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Electrical systems - Warning indicators, alarms, and instruments

Warning indicators, alarms, and instruments - General specification Gauges and warning lights Charge indicator light Lens Bulb Oil pressure indicator bulb High beam indicator Lens Bulb Water temperature gauge bulb Fuel gauge bulb Position light Turn trailer Indicator bulb Parking Brake bulb Air cleaner clogging bulb Service Indicator bulb Instruments Fuel level Instrument type Sender Type Oil Pressure Instrument type Sender rating Water temperature Instrument type Sender type Controls Fuel stop Type Rating Indicator and flasher Type Rating Ignition switch Type Rating Light switch Type Rating Turn signal switch Type Rating Brake switch Type Rating Neutral start switch Type Rating Work lamp switch Type Rating Hazard switch Type Rating PTO

Red 1.7 ( 12 V) 1.7 ( 12 V) Green 1.7 ( 12 V) 3W 3W Green / 1.7 ( 12 V) 1.7 ( 12 V) 1.7 ( 12 V) 1.7 ( 12 V) 1.7 ( 12 V)

Gauge Variable resistance Gauge 1 bar (14 psi) Gauge Variable resistance

Solenoid switch 1 ( 12 V, DC) Solid state 12 V 3 position key 12 V 4 position key 12 V Left-off-right 12 V Plunger operated 12 V High / low gear lever 12 V Rocker, 2 position (on/off) 12 V 1 ( 12 V, DC) 2 position (on/off) 12 V

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Type Rating Parking brake switch Type Rating

Plunger (NO/NC) 12 V Plunger 12 V

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Overview

GNIL15TR00508FB

Instrument panel consists of the following: 1. 2.

Tachometer Right turn indicator

9. 10.

Water temperature gauge

11.

4. 5. 6. 7. 8.

Digital hour meter Engine oil pressure Position lights Service reminder Battery charging indicator

12. 13. 14. 15.

Head light high beam indicator light Turn trailer indicators / hazard warning Power Take-Off (PTO) clutch lever Indicator (If fitted) Parking brake Air cleaner clog light Fuel gauge Left turn indicator

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Engine oil pressure gauge A pressure sensor (1) is installed on left-hand side of engine into the main oil gallery. Change in oil pressure affect the resistance of this sensor. The gauge then measures the resultant current in the circuit and indicates it on the indicator as oil pressure. Below 0.5 bar (7.2 psi), the sensor switch closes fully, the indicator will glow.

Battery Charging Indicator This is used to indicate if the alternator is operating correctly. A 1.4 W bulb is connected into the key switch alternator circuit. This will illuminate when key switch is turned to position 2. It should go off once engine is started and alternator begins to change the battery.

GNIL14TR04716AB

GNIL14TR04717AB

GNIL14TR04719AA

Left/right indicator lights Left and right turn, 1.4 W lamps are mounted in the instrument console. These are connected to the left/right turn indicator circuit and flash whenever the turn signals are operated. Both the indicator lights flash when hazard warning switch is used.

High beam indicator light A 1.4 W lamp is connected to the head light high beam circuit. When high beam is selected the lamp should illuminate.

Temperature gauge A temperature sensor (1) installed at the cylinder head water jacket outlet, changes in resistance according to the temperature of the water. The gauge indicates the water temperature according to the electrical current flowing through the sensor and displays it on the dial.

Fuel level gauge A sensor inside the fuel tank changes is resistance according to the fuel level. The gauge measures the resultant current and indicates it as fuel level on the dial.

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Remove 1. Remove the steering wheel cap (1) using screw driver.

GNIL15TR00951AB

GNIL15TR00952AB

GNIL15TR00953AB

GNIL15TR00954AB

2. Remove the steering wheel nut (1).

3. Remove the steering wheel using the special tool (1).

4. Pull out the rubber boot (1).

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Electrical systems - Warning indicators, alarms, and instruments

5. Remove the screws and accelerator knob (1). 6. Remove the screws and power shuttle shifter knob (2).

GNIL15TR00955AB

GNIL15TR00956AB

GNIL15TR00957AB

GNIL15TR00958AB

7. Remove the allen key screws (1) from the instrument cluster.

8. Remove the instrument panel (1) from rear hood.

9. Disconnect the instrument panel connector (1) from the main harness.

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Electrical systems - Warning indicators, alarms, and instruments

10. Pull out and remove the shuttle lever boot and power shuttle lever (1).

GNIL15TR00960AB

11. Lift the dashboard and disconnect the ignition connectors from the main harness.

GNIL15TR00961AA

GNIL15TR00962AA

12. Disconnect the high beam, hazard warning, side indicator, head lamp selector connectors and horn switch from the dash board. 13. Remove the dashboard.

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Instrument cluster - Install 1. Install the dashboard. 2. Connect the horn switch, head lam selector connectors, side indicator, hazard warning and high beam on the dash board.

GNIL15TR00962AA

GNIL15TR00961AA

GNIL15TR00960AB

GNIL15TR00958AB

3. Connect the ignition connectors to the main harness and close the dashboard.

4. Install the power shuttle lever (1) and the shuttle lever boot.

5. Connect the instrument panel connector (1) on the main harness.

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6. Install the instrument panel (1)on rear hood.

GNIL15TR00957AB

GNIL15TR00956AB

GNIL15TR00955AB

GNIL15TR00954AB

7. Install the allen key screws (1) on the instrument cluster.

8. Install the accelerator knob (1) and screws. 9. Install the power shuttle shifter knob (2).

10. Install the rubber boot (1).

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11. Install the steering wheel using the special tool (1).

GNIL15TR00953AB

12. Install the steering wheel nut (1).

GNIL15TR00952AB

GNIL15TR00951AB

13. Install the steering wheel cap (1) using screw driver.

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Warning indicators, alarms, and instruments - Troubleshooting Problem Warning lights and gauges inâ&#x20AC;?â&#x20AC;?operative

Possible Cause Faulty key start switch

Correction Inspect and renew

Fuses burned out

Sender line short circuit

Inspect and renew, check circuit before reconnecting power Inspect circuit, tighten connections/ renew wiring. Inspect circuit, tighten connectors / renew wiring Check the circuit

Pressure switch faulty

Connection not ok

Check and renew

Check and correct

Loose or broken wiring Gauges erratic or inoperative Gauges always show maximum reading (fuel gauge and water temperature gauge) Oil pressure gauge showing in green zone without starting tractor with ignition switch in position- 1

Loose or broken wiring

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Index Electrical systems - 55 Warning indicators, alarms, and instruments - 408 Instrument cluster - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument cluster - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument cluster - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning indicators, alarms, and instruments - General specification . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning indicators, alarms, and instruments - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

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SERVICE MANUAL Platform, cab, bodywork, and decals TT4.80 TT4.90

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Contents Platform, cab, bodywork, and decals - 90

[90.118] Protections and footboards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.114] Operator protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.120] Mechanically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4 [90.116] Fenders and guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5

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TT4.80 TT4.90

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Contents Platform, cab, bodywork, and decals - 90 Protections and footboards - 118

SERVICE Protections and footboards Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Platform, cab, bodywork, and decals - Protections and footboards

Protections and footboards - Remove 1. Remove the fuel tank. See the Fuel tank - Remove (10.216). 2. Remove the plastic locks (1) using a screw driver, and remove mats (2) of tractor from both left-hand and righthand side.

GNIL15TR00665AB

GNIL15TR00666AB

GNIL15TR00667AB

GNIL15TR00668AB

3. Remove footboard right-hand side by removing: • Two bolts (1) from top joining front platform with rear one.

• Three bolts (1) below footboard (two slotted and one normal).

• Two bolts (1) clamping footboard with fenders. NOTE: Use the bubble sheet or some cloth with magnets to avoid any scratch on fenders.

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Platform, cab, bodywork, and decals - Protections and footboards

4. Similarly remove the right-hand side footboard.

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Platform, cab, bodywork, and decals - Protections and footboards

Protections and footboards - Install 1. Install footboard right-hand side by installing. – Two bolts (1) clamping footboard with fenders.

GNIL15TR00668AB

GNIL15TR00667AB

GNIL15TR00666AB

GNIL15TR00665AB

– Three bolts (1) below footboard (two slotted and one normal).

– Two bolts (1) from top joining front platform with rear one.

2. Install the mats (2) of tractor to the both left-hand and right-hand and install the plastic locks (1) using a screw driver.

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Platform, cab, bodywork, and decals - Protections and footboards

3. Install the fuel tank. (10.216).

See the Fuel tank - Install

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Index Platform, cab, bodywork, and decals - 90 Protections and footboards - 118 Protections and footboards - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protections and footboards - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Platform, cab, bodywork, and decals - 90 Operator protections - 114

TT4.80 TT4.90

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Contents Platform, cab, bodywork, and decals - 90 Operator protections - 114

SERVICE Operator protections Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Roll Over Protective Structure (ROPS) frame Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Platform, cab, bodywork, and decals - Operator protections

Operator protections - Remove Canopy removal 1. Loosen and remove the three mounting bolts (1) on either side. Remove the canopy (2).

GNIL15TR00523AB

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Platform, cab, bodywork, and decals - Operator protections

Operator protections - Install Canopy install 1. Install the canopy (2) with the three mounting bolts (1) on the either side.

GNIL15TR00523AB

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Platform, cab, bodywork, and decals - Operator protections

Operator protections - Remove 1. Remove the canopy. See the Operator protections Remove (90.114). 2. Remove bolts (1), three on each side. Remove lefthand side and right-hand side frame (2).

3. Loosen and remove the three bolts (1). canopy bracket (2).

GNIL15TR00524AB

GNIL15TR00525AB

Remove

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Platform, cab, bodywork, and decals - Operator protections

Operator protections - Install 1. Install the canopy bracket (2) with the bolts (1).

GNIL15TR00525AB

GNIL15TR00524AB

2. Install the left-hand side and right-hand side frame (2) with the bolts (1).

3. Install the canopy. See the Operator protections Install (90.114).

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Platform, cab, bodywork, and decals - Operator protections

Roll Over Protective Structure (ROPS) frame - Remove 1. Remove the operator seat. See the Operator seat Remove (90.120). 2. Remove the canopy and its frames. See the Operator protections - Remove (90.114). 3. Remove the fenders. (90.116).

See the Fender - Remove

4. Remove the quadrant cover, see the hydraulic section. Remove the following levers to facilitate the removal of rear platform/ footboard extension. See the Protections and footboards - Remove (90.118). • Range and speed lever. See the Gearbox external controls - Remove (21.126) • Differential lock pedal • 4WD lever. See the Master clutch housing - Remove (21.110). See the • Power Take-Off (PTO) clutch lever. Two-speed rear Power Take-Off (PTO) - Remove (31.114). • Parking lever boot and parking lever sensor. See the Hand brake lever - Remove (33.110). 5. Remove the rear platform. See the Protections and footboards - Remove (90.118). 6. Loosen and remove the four bolts of ROPS mounting bracket (1) from either side. Remove the ROPS structure (2).

GNIL15TR00526AB

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Platform, cab, bodywork, and decals - Operator protections

Roll Over Protective Structure (ROPS) frame - Install 1. Install the ROPS structure (2) with the ROPS mounting bracket (1) and bolts.

GNIL15TR00526AB

2. Install the rear platform. See the Protections and footboards - Install (90.118). 3. Install the following levers. A. Parking lever boot and parking lever sensor. See Hand brake lever - Install (33.110). B. Power Take-Off (PTO) clutch lever. See the Two-speed rear Power Take-Off (PTO) - Install (31.114). C. 4WD lever. See the Master clutch housing - Install (21.110) D. Range and speed lever. See the Gearbox external controls - Install (21.126). 4. Install the fenders. See the Fender - Install (90.116). 5. Install the canopy and its frames. See the Operator protections - Install (90.114). 6. Install the operator seat. See the Operator seat - Install (90.120).

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Index Platform, cab, bodywork, and decals - 90 Operator protections - 114 Operator protections - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator protections - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator protections - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Roll Over Protective Structure (ROPS) frame - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Roll Over Protective Structure (ROPS) frame - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Platform, cab, bodywork, and decals - 90 Mechanically-adjusted operator seat - 120

TT4.80 TT4.90

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Contents Platform, cab, bodywork, and decals - 90 Mechanically-adjusted operator seat - 120

SERVICE Operator seat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

Operator seat - Remove 1. Loosen and remove bolt (1) from the operator’s seat bracket.

GNIL15TR00527AB

GNIL15TR00528AB

2. Slide the operator’s seat on the inclined track. Remove the operator’s seat.

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Platform, cab, bodywork, and decals - Mechanically-adjusted operator seat

Operator seat - Install 1. Slide the operator’s seat (1) on the inclined track. Position the operator’s seat.

GNIL15TR00528AB

GNIL15TR00527AB

2. Install the operator’s seat bracket with the bolt (1).

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Index Platform, cab, bodywork, and decals - 90 Mechanically-adjusted operator seat - 120 Operator seat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator seat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

TT4.80 TT4.90

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Contents Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

SERVICE Hood Remove – Front hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install – Front hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remove – Rear hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install – Rear hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Remove â&#x20AC;&#x201C; Front hood 1. Using the hood removal key, release the hood locks (1). 2. Hold and lift the hood handle to raise the hood.

GNIL15TR00747AB

GNIL15TR00748AB

GNIL15TR00530AB

GNIL15TR00531AB

3. To maintain the hood in the raised position, a gas strut (1) is provided underside the hood.

4. Disconnect the battery negative terminal. See the Battery - Remove (55.302). 5. Loosen the nut (1) of gas strut and remove the gas strut end from the bracket. NOTE: Hold the front hood in raised position by means of a rope or a bar.

6. Loosen and remove the two lower nuts (1) and the two upper bolts (2) of front hood mounting bracket. 7. Remove the front hood.

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Install â&#x20AC;&#x201C; Front hood 1. Position the front hood. NOTE: Hold the front hood in raised position by means of a rope or a bar. 2. Install the front hood mounting bracket with the two lower nuts (1) and the two upper bolts (2).

GNIL15TR00531AB

GNIL15TR00530AB

3. Install the gas strut on the bracket with the nuts (1).

4. Connect the battery negative terminal. See the Battery - Install (55.302).

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Remove Side cover 1. Release the hood locks and raise the hood. See the Hood - Remove â&#x20AC;&#x201C; Front hood (90.100) 2. Loosen the bolts (1) and remove the left-hand side cover (2). 3. Follow the step 2 for the removal of right-hand side cover.

GNIL15TR00761AB

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Install Side cover 1. Install the left-hand side cover (2) the bolts (1).

GNIL15TR00761AB

2. Follow the step 1 for the installation of right-hand side cover. 3. Lower the hood. See the Hood - Install â&#x20AC;&#x201C; Front hood (90.100).

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Remove â&#x20AC;&#x201C; Rear hood Prior operation: Remove the steering assembly, See Steering control - Remove (41.101). Prior operation: Remove the instrument panel, See Instrument cluster - Remove (55.408). 1. Remove the screws (1) and bolts from the rear hood. 2. Lift and remove the rear hood.

GNIL15TR00963AB

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Install â&#x20AC;&#x201C; Rear hood 1. Install the rear hood with the bolts and screws (1).

GNIL15TR00963AB

2. Install the steering assembly, See the Steering control - Assemble - Steering motor (41.101). 3. Install the instrument panel, See Instrument cluster Install (55.408).

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Index Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100 Hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hood - Install – Front hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hood - Install – Rear hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hood - Remove – Front hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hood - Remove – Rear hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Platform, cab, bodywork, and decals - 90 Fenders and guards - 116

TT4.80 TT4.90

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Contents Platform, cab, bodywork, and decals - 90 Fenders and guards - 116

SERVICE Fender Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Platform, cab, bodywork, and decals - Fenders and guards

Fender - Remove 1. Disconnect the battery negative terminal. 2. Disconnect the rear fender (both left-hand and righthand) wiring harness connections (1).

GNIL15TR00541AB

GNIL15TR00542AB

GNIL15TR00543AB

GNIL15TR00545AB

3. Loosen the bolts (1) used for mounting fender with ROPS.

4. Loosen the bolts (1) used for mounting fender with ROPS.

5. Loosen and remove the bolts (1) attaching the footboard to the fender.

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Platform, cab, bodywork, and decals - Fenders and guards

6. Remove the right-hand side fender (1). 7. Repeat Step 1 to 6 for the left-hand side fender removal.

GNIL15TR00544AB

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Platform, cab, bodywork, and decals - Fenders and guards

Fender - Install 1. Position the right-hand side fender (1).

GNIL15TR00544AB

GNIL15TR00545AB

GNIL15TR00543AB

GNIL15TR00542AB

2. Install and tighten the bolts (1) attaching the footboard to the fender.

3. Tighten the bolts (1) used for mounting fender with ROPS.

4. Tighten the bolts (1) used for mounting fender with ROPS.

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Platform, cab, bodywork, and decals - Fenders and guards

5. Connect the rear fender (both left-hand and right-hand) wiring harness connections (1). 6. Connect the battery negative terminal. See the Battery - Install (55.302).

GNIL15TR00541AB

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Index Platform, cab, bodywork, and decals - 90 Fenders and guards - 116 Fender - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fender - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47866580 11/12/2015 EN

SPECIAL TOOL INDEX Genuine 380000301 [Rotating Engine Stand] 380000549 [Slide Hammer] 380000302 [Cylinder Head Valve Spring Compressor] 380000302 [Cylinder Head Valve Spring Compressor] 380000549 [Slide Hammer] 380200424 [Timing tool ] 380200424 [Timing tool ] 380200424 [Timing tool ] 380000834 [Injection Holder Cap Rolling Beater] 380000830 [Guide Socket ] 380000215 [Hand Pump Assembly for Valve Calibration] 380000223 [Water Pump Puller used on 4.5L & 6.7L NEF Engines] 380000612 [Clutch Centralizer and Clutch Registers (2) for the 11" clutch] 380000256 [Clutch Adjusting Wrench Set] 380200583 [Clutch setting tool] 380000612 [Clutch Centralizer and Clutch Registers (2) for the 11" clutch] 380000612 [Clutch Centralizer and Clutch Registers (2) for the 11" clutch] 380200583 [Clutch setting tool] 380000612 [Clutch Centralizer and Clutch Registers (2) for the 11" clutch] 380200582 [Power shuttle valve pressure checking guages] 380200585 [Power shuttle unit lifting tackle] 380200584 [Tool for bellevelle washer compressing tool in power shuttle] 380200586 [Piston Pressing tool ] 380200584 [Tool for bellevelle washer compressing tool in power shuttle] 380200584 [Tool for bellevelle washer compressing tool in power shuttle] 380200584 [Tool for bellevelle washer compressing tool in power shuttle]

Reference

PAGE

Engine - Remove

10.1 / 13

Cylinder heads - Remove Cylinder heads - Disassemble

10.4 / 3 10.4 / 5

Cylinder heads - Assemble

10.4 / 7

Cylinder heads - Install Injection pump - Install Injection pump - Timing check Injection pump - Timing check Fuel injectors - Inspect

10.4 10.10 10.10 10.10 10.10

/ / / / /

9 13 15 16 19

Fuel injectors - Inspect Fuel injectors - Overhaul

10.10 / 19 10.10 / 22

Water pump - Disassemble

10.14 / 22

Clutch - Special tools

18.1 / 6

Clutch - Special tools

18.1 / 6

Clutch - Special tools

18.1 / 6

Clutch - Assemble – Mechanical version

18.1 / 35

Clutch - Adjust – Mechanical version

18.1 / 36

Clutch - Adjust – Mechanical version

18.1 / 36

Clutch - Replace - Mechanical version

18.1 / 37

Power shuttle transmission - Special tools

21.2 / 3

Clutch - Special tools

21.5 / 3

Clutch - Special tools

21.5 / 3

Clutch - Special tools

21.5 / 3

Clutch - Remove - Forward shuttle clutch

21.5 / 5

Clutch - Install - Forward shuttle clutch

21.5 / 6

Clutch - Remove - Reverse shuttle clutch

21.5 / 8

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Genuine 380200324 [DIFF NUT TIGHTENING TOOL] 380200328 [SP TOOL - PTO NUT TIGHTENING] 380200330 [SP TOOL - PTO SHAFT ROTATION] 380200581 [Hydraulic actuated brake adjuster tool] 380200592 [Hydraulic pump flow & Pressure checking tool] 380000240 [Hydraulic Pressure Test Kit] 380000240 [Hydraulic Pressure Test Kit] 380000262 [RETAINER INSTALLER] 380000274 [Union for Checking Distributor Valve Seal] 380000217 [Lift Relief Valve Adapter ] 380000218 [Union for Cylinder Safety Valve Calibration] 380000230 [Wrench For Cylinder Safety Valve Setting Ring Nut] 380000267 [Wrench for Arms Height Adjustment] 380000261 [Punch for Fitting Needle Bearings on Control Valve Block Control Lever Bushing] 380001769 [Straight Reduction 22L-15L] 380000240 [Hydraulic Pressure Test Kit] 380000613 [Steering Adapter Fitting] 380000614 [PTO Adapter Fitting] 380000266 [Lift Arm Speed Adjusting Pin Seal Installer] 380000274 [Union for Checking Distributor Valve Seal] 380000240 [Hydraulic Pressure Test Kit] 380000218 [Union for Cylinder Safety Valve Calibration] 380000217 [Lift Relief Valve Adapter ] 380000230 [Wrench For Cylinder Safety Valve Setting Ring Nut] 380000240 [Hydraulic Pressure Test Kit] 380000613 [Steering Adapter Fitting] 380000549 [Slide Hammer]

Reference

PAGE

Rear bevel gear set and differential - Adjust

27.2 / 17

Two-speed rear Power Take-Off

31.1 / 10

Two-speed rear Power Take-Off

31.1 / 10

Brake actuators - Overhaul

33.1 / 20

Pump - Special tools

35.2 / 4

Pump - Test

35.2 / 15

Remote control valves - Special tools

35.3 / 3

Main lift system - Special tools

35.4 / 5

Main lift system - Special tools

35.4 / 5

Main lift system - Special tools

35.4 / 5

Main lift system - Special tools

35.4 / 5

Main lift system - Special tools

35.4 / 5

Main lift system - Special tools

35.4 / 5

Main lift system - Special tools

35.4 / 5

Main lift system - Special tools

35.4 / 5

Main lift system - Special tools

35.4 / 5

Main lift system - Special tools

35.4 / 5

Main lift system - Special tools

35.4 / 5

Main lift system - Special tools

35.4 / 5

Main lift system - Adjust

35.4 / 41

Main lift system - Adjust

35.4 / 42

Main lift system - Adjust

35.4 / 46

Main lift system - Adjust

35.4 / 46

Main lift system - Adjust

35.4 / 46

Steering control - Special tools

41.1 / 3

Steering control - Special tools

41.1 / 3

Steering control - Special tools

41.1 / 3

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Genuine 380000305 [Power Steering KIN_RING Seal Installer] 380000240 [Hydraulic Pressure Test Kit]

Reference

PAGE

Steering control - Special tools

41.1 / 4

Steering circuit relief valve - Test

41.2 / 3

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47866580 11/12/2015 EN