New Holland TT55 TT65 TT75 Tractor Service Repair Manual (47899733) - PDF Download by www.heydownloads.com

SERVICE MANUAL TT55 / TT65 / TT75 Tractor

Part number 47899733 1st edition English June 2015

SERVICE MANUAL TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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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 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

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

Transmission.............................................................................. 21 [21.114] Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.140] Mechanical transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.126] Gearbox external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 [21.145] Gearbox internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4

Four-Wheel Drive (4WD) system .................................................. 23 [23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1

Front axle system ....................................................................... 25 [25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2

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[25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3 [25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4

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

Power Take-Off (PTO) ................................................................. 31 [31.101] Rear mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 [31.201] Power Take-Off (PTO) drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2

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

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.100] Main lift system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

Steering..................................................................................... 41 [41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

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

Electrical systems ....................................................................... 55 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 47899733 23/06/2015

[55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7

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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. 47899733 23/06/2015

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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. 47899733 23/06/2015

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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INTRODUCTION

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. 47899733 23/06/2015

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 TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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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 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

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Engine - 10 Engine and crankcase - 001

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Engine - 10 Engine and crankcase - 001

TECHNICAL DATA Engine General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Crankcase General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Engine Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Engine Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

DIAGNOSTIC Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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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

TT75

TT55

IVECO 4 stroke, diesel, naturally aspirated, direct injection, water cooled 75 Hp 55 Hp 4 3 104.000 mm (4.094 in) 104.000 mm (4.094 in) 115.000 mm (4.528 in) 115.000 mm (4.528 in) 3908 cm³ (238 in³) 2931 cm³ (179 in³) 18:1 18:1 1-3-4-2 1-2-3 650 RPM 650 RPM 2770 RPM 2770 RPM 2500 RPM 2500 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 47899733 23/06/2015

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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 - Torque Description

Thread size

Torque

Bolt, cylinder head (C1)

M12 X 1.25

40 N·m (354 lb in)

Bolt, main bearing caps (C2) Bolt, timing cover and case (C3) Bolt, connecting rod caps (C4) Bolt, flywheel (C5) Bolt, rocker shaft bracket (C6) Nut, crankshaft pulley hub (C7) Bolt, fan and alternator drive pulley (C8) Nut, injection pump shaft gear (C9) Nuts, injection pump to support (C10) Retaining screws, additional weights (C11)

M14 X 1.25 M12 X 1.25 M11 X 1.25 M12 X 1.25 M8 X 1.25 M30 X 1.5 M12 X 1.25 M12 X 1.25 M12 X 1.25 M12 X 1.25

80 N·m (708 lb in) 40 N·m (354 lb in) 40 N·m (354 lb in) 40 N·m (354 lb in) 25 N·m (221 lb in) 300 N·m (2655 lb in) 49 N·m (434 lb in) 64 N·m (566 lb in) 23 N·m (204 lb in) 110 N·m (974 lb in)

Angle ( 125 – 135°) + ( 135 – 145°) 90° – 60° 60° – – – – – –

Engine - Sealing Operation description Adopter for oil filter (S1) Adopter for tachometer cable (S2) Flywheel housing to engine block (S3) Timing gear case studs (S4) Timing gear cover dowel pin (S5) Starter motor to flywheel housing (S6) Allen plug in cylinder head thermostat housing (S7) Cylinder head exhaust manifold studs (S8) Oil sump to engine block (S9) 47899733 23/06/2015

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Sealant specification LOCTITE® 270 LOCTITE® 243™ LOCTITE® 510™ LOCTITE® 270 LOCTITE® 270 LOCTITE® 510™ LOCTITE® 243™ LOCTITE® 270 Loctite® 5699

Engine - Engine and crankcase

Operation description Silencer mounting studs on exhaust manifold (S10) Flywheel bolt (S11)

Sealant specification Loctite® 77164 LOCTITE® 243™

Engine - Special tools CAUTION Operations described in this section of the manual must be performed using the following essential tools to work safely and achieve the best technical results with additional savings of time and effort. Tool description Injector tester Sling hook, engine Cylinder head valve spring compressor Tractor splitting trolley Installer rear main oil seal Installer front oil seal Dummy injector Swan neck pipe (fuel timing) Engine mounting bracket (to be used with engine stand 293860) Steering wheel puller Bushes for steering wheel puller Remover, hand accelerator pin Cylinder pressure test Kit Lube pressure check Kit Piston ring compressor Piston ring expander

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Tool number 290284 290740 291050 292320 9970846 9970845 9970364 9970848 9970844 82834312 9971375 9971378 9971410 9971367 Local Local

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 ( TT75 only) 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 - Engine and crankcase

Engine - Static description The engines are with 4 cylinders ( TT75 ) and 3 cylinders ( TT55 ). 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 & 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 3 or 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 and 4 main bearings in TT75 and TT55 engines respectively. The crankshaft is manufactured from steel with machined finished crank webs. End thrust is controlled by a thrust bearing incorporated in the centre main bearing of the crankshaft in TT75 engine and in the second main bearing from flywheel side in TT55 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. 47899733 23/06/2015

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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.

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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 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.

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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.

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Fuel system The diesel fuel system consists of fuel tank, lift pump, fuel filters, mico rotary type fuel injection pump, fuel injectors, and interconnecting tubes and lines. The fuel injection pump is pressure fed from the lift pump. Fuel flows from the fuel tank to the sediment separator (incorporated in lift pump), through the lift pump, then through the primary fuel filter and then to secondary fuel filter. from the filter the fuel passes to the fuel injection pump to supply fuel at high pressure to each injector and also provides extra fuel which lubricates and cools the injection pump. This extra fuel is recirculated to the fuel tank, by means of the injector leak-off line. Also excess fuel that leaks past the needle value of the injectors in directed back to the fuel tank, by means of the injection leaf off-line.

Fuel shut-off (Injection pump) Fuel injection pump is equipped with an electrically operated fuel shut off solenoid is energized by operation of the ignition switch mounted in the instrument panel. With the ignition switched “Off” a spring loaded plunger in the solenoid (held in position by the spring tension), prevents fuel flowing into the pump from the main fuel feed port. With the ignition switched “on” the magnetized plunger is energized by an internal coil and is drawn up into the body of the solenoid. Fuel is then allowed to flow through the open port into the pump.

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

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Fuel Filters Spin-on type fuel filters situated to the right-hand side of the engine, receives fuel from lift pump. From the filter head the fuel is diverted down through the filter element and into the base chamber. The filtered fuel then flows up the centre tube of the element to the filter head outlet and into the injection pump.

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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 - 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. Remove front ballast weights if fitted.

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2. Slide the lock (1) to right, hold and lift the handle (2) to raise the hood.

3. To maintain the hood in the raised position, a gas strut (1) is provided underside the hood.

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4. Disconnect battery terminals (1) and (2). NOTICE: Always disconnect the negative cable (1) first.

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5. Loosen silencer mounting clamp bolts (1) and remove the silencer assembly.

6. Disconnect electric connections of centre harness (1).

7. Remove the split pins and remove the roll pins (1). 8. Unscrew the gas strut bolt (2) and remove the front hood.

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9. Remove tool box (1), tool box mounting bracket (2) and cover plate of self starter (3).

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10. Disconnect electric connections to starter motor (1).

11. Close diesel tap (1) and disconnect hose (2) between diesel tank and feed pump.

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12. Remove the steering wheel cover and remove the nut (1).

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13. Remove the steering wheel using tool number 82834312 (1) (incase of mechanical steering use also tool number 9971375) (2).

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14. Disconnect start safety switch connector (1).

15. Unscrew the rear hood bolts (1) and remove cover strip and fire wall.

16. Remove the accelerator knob (1).

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17. Unscrew all the screws (1) of instrument panel.

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18. Remove the steering hose (1).

19. Pull out the instrument panel from the rear hood.

20. Disconnect all electric wire connections of the switches and unscrew hourmeter cable (1) from instrument panel. 21. Remove fuel tank cap.

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22. Loosen the bolts (1) from both sides and on steering column securing rear hood (2) and remove rear hood carefully from tractor (keeping it parallel to steering column). 23. Remove all electric connections to rear hood.

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24. Unscrew all rear hood securing bolts, lift and remove the rear hood.

25. To remove the throttle cable. First press the foot throttle lever (1).

26. Then, without releasing the foot throttle lever, remove the accelerator cable after disconnecting from Fuel Injection Pump (FIP) and removing bracket.

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27. Disconnect diesel overflow hose pipe (1) and fuel sender electric connections (2). 28. Loosen bolts and release fuel tank strap from steering column. 29. Lift off fuel tank from tractor carefully. NOTE: It is advisable to drain diesel from fuel tank if tank is more than half filled.

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30. Loosen bolts and remove fuel tank support bracket (1).

31. Position splitting trolley (special tool number 292320) with engine supports in position. 32. Block the front wheels both at front and back using suitable wedges.

33. Drain steering oil and disconnect all oil connections from steering motor (1). (In case of power steering).

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34. Support the engine at the back of the front axle and position wedges (1) between axle and support to prevent articulation.

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35. Remove the bolts (1) securing the engine to the transmission housing.

36. Split the engine from transmission by rolling the rear wheels away from engine.

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

1. Disconnect hose (1) from radiator and drain the coolant.

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2. Loosen the clamps (1) and (2) and disconnect the pipe (3) from air cleaner and hose (4) from radiator. 3. Remove the bolt securing radiator support bracket (5).

4. Disconnect power steering hoses (1) and (2) if power steering is fitted.

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5. Cut the plastic clamps and take out complete center wiring to front side. 6. Remove wiring connections of alternator, sensor, WT relay, OPS, FIP and starter solenoid. 7. Support the front axle using a suitable stand. 8. Connect the engine to a suitable hoist.

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9. Remove 4 buckle up bolts (1) coupling engine and front axle support.

10. Detach the engine from front axle carefully and mount on engine stand (special tool number 293860).

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Engine - Engine and crankcase

Engine - Install Reinstall the engine on tractor by observing the following: 1.

Reinstallation follows the removal procedure in reverse from step 10 back to step 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. (10.001).

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.

Refer to Engine - Torque

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Engine - Compression test Test procedure 1. Be sure battery performance meets specifications. 2. Warm up the engine by operating for a minimum of half an hour at 1200 RPM. 3. Stop the engine and remove the injector and seat washer from number 1 cylinder. 4. Clean the injector bore and crank the engine to blow out any loose carbon particles. 5. Install an engine compression test gauge. Fit dummy injector (special tool number 9977364), into the injector bore, using a new seat washer and injector mounting bolts. 6. Connect the gauge and hose to the adapter dummy injector. 7. Crank the engine with the electric fuel shut off to prevent engine start up. 8. Observe the gauge reading and repeat the compression test, steps 5 - 7 for each cylinder.

Test readings 1. All cylinder compressions should be uniform or difference should be within 1.7 bar (24.6 psi) of each other. 2. A reading of more than the 1.7 bar (24.6 psi) below the other cylinders indicates leakage at the cylinder head gasket, piston rings or valves. 3. A reading of more than 1.7 bar (24.6 psi) above the other cylinders indicates excessive carbon deposits on the piston and cylinder head. 4. A low even compression in two adjacent cylinders indicates a cylinder head gasket leak. Check this item before condemning the rings or valves.

Test conclusion To determine whether the rings or the valve are at fault, squirt the equivalent of a table spoon of heavy oil into the combustion chamber. Crank the engine to distribute the oil and repeat the compression test. The oil will temporarily seal any leakage past the rings. If approximately the same reading is obtained as for the first test, the rings are satisfactory, but the valves are leaking. Once they has been established the exhaust manifold can be removed to visually inspect of oil is leaking down the valve stems. If compression has increased over the original reading, there is leakage past the rings. During a compression test, if the pressure fails to climb steadily and remains the same during the first two successive strokes, but climbs higher on the succeeding strokes, or fails to climb during the entire test, suspect a sticking valve.

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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: â&#x20AC;˘ If the oil consumption is below 0.4% no service repair action should be taken. â&#x20AC;˘ If oil consumption is diagnosed the engine should be repaired.

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Engine - Troubleshooting NOTICE: When attending a repair the cause of the problem must also be investigated and corrected to avoid repeat failures. 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

Insufficient oil supply

Low oil pressure Excessive crankshaft end play Flywheel or ring gear run-out excessive Excessive connecting rod or main Bent or twisted connecting rods Crankshaft journals out-of-round Excessive piston-to- cylinder Excessive piston ring clearance Broken rings Excessive piston pin clearance Piston pin retainer loose or missing Excessive camshaft play Imperfections on timing gear teeth Excessive timing gear backlash Engine overheats

Hose connection leaking or collapsed Radiator cap defective or not sealing Radiator leakage Improper fan belt adjustment Radiator fins restricted Faulty thermostat Internal engine leakage Water pump faulty

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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 re-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. Ascertain cause of dilution Check oil level and top up as necessary Overhaul or renew pump as necessary Check oil filter is not clogged Overhaul pump or relief valve as necessary Install new thrust bearing liner Skim flywheel or fit new ring gear Install new bearing inserts and or bearing clearance re-grind crankshaft Renew connecting rods Re-grind crankshaft and fit undersize bearing inserts Re-bore/re-sleeve block and fit i bore clearance new pistons Fit new pistons and rings Fit new rings, check bore and pistons for damage Fit new piston or pin Install new retainer, and check bore/pistons for damage Install new thrust plate Renew timing gear Check and adjust backlash /renew, timing gear Tighten hose connection, renew hose if damaged Renew radiator cap Repair/renew radiator Re-adjust fan belt Clean with compressed air Renew thermostat Check for source of leakage, renew gasket or defective parts Overhaul water pump

Engine - Engine and crankcase

Problem

Possible Cause Exhaust gas leakage into cooling Coolant aeration

Correction Renew cylinder head gasket Tighten all connections and check coolant 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 Remove the obstruction Obstruction to radiator air flow Extended engine idling Do not allow engine to idle for long periods Oil cooler tube blocked Clean Radiator core tubes blocked Check free flow Renew sender switch Water temperature gauge Faulty temperature sender fails to reach normal operating temperature Renew thermostat Incorrect or faulty thermostat Faulty water temperature gauge Renew temperature gauge Low oil pressure Engine oil level low Top up, as necessary Wrong grade of oil Drain and refill with correct grade of oil Blocked oil pump sump screen Clean pump screen Oil pressure relief valve faulty Fit new relief valve Renew oil pump Oil pump worn Excessive oil pump rotor and shaft assem- Overhaul pump bly clearance Excessive main or connecting rod bearing Install new bearings inserts and bearing clearance clearance or re-grind crankshaft if necessary Excessive oil Engine oil level too high Reduce oil level consumption External oil leaks Renew gaskets and seals, where necessary. Check mating surfaces for damage or distortion Worn valves, valve guides or bores Renew Cylinder head gasket leaking Renew gasket. Check head for damage or distortion Oil loss past the pistons and rings Renew rings and or rebore / re-sleeve block as necessary Oil cooler leak Repair/renew oil cooler assembly Engine tends to keep Air cleaner dirty or restricted Clean or renew element firing after fuel is shutâ&#x20AC;&#x201C;off

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

Engine - Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Engine - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Engine - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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Engine - 10 Pan and covers - 102

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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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 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Timing gear housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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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.

NOTICE: In TT75 model before removing oil sump lubricating oil pump strainer have to be removed. To remove, first open oil sump bottom plate (1) and then remove the strainer.

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NDIL14TR00117AA

NDIL14TR00916AB

Engine - Pan and covers

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 oil pan - Install Installation is the reverse of removal but with the following requirements. â&#x20AC;˘ Ensure block face is clear and free of gasket material. Install a new gasket to the oil sump. â&#x20AC;˘ 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. â&#x20AC;˘ In TT75 model, install back oil strainer and oil sump bottom cover plate.

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Engine block cover - Overhaul Cylinder bore 1. Cylinder block plugs and senders, require changing if leaking and rusty, and must be replaced. Clean the old sealant of the block, and fit new plugs with sealer.

NDIL14TR00135AA

NDIL14TR00136AA

NDIL14TR00137AB

2. 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. NOTICE: Pull out the center ring pin, only if sealing surface must be surface-ground.

3. 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-of-roundness, wear, or taper, use a telescopic gauge or dial bore gauge (1).

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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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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NDIL14TR00138AB

Engine - Pan and covers

Engine block cover - 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). ( TT75 ) 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 - Pan and covers

Timing gear housing - Remove NOTE: Timing cover and gears can only be serviced after removing the radiator. 1. Refer to Radiator - Remove (10.400) for radiator removal procedure. 2. Loosen the alternator belt tight adjusting bolt (1) and remove the fan belt.

NDIL14TR00087AB

NDIL14TR00051AB

NDIL14TR00088AB

NDIL14TR00090AA

3. Remove bolt (1) securing alternator mounting bracket with timing cover and bolt (2), and remove alternator.

4. Loosen fan mounting bolts and remove fan (1). 5. Remove fan pulley by gently hammering with mallet or plastic hammer.

6. Loosen dognut and remove pulley using special tool number 82834300.

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Engine - Pan and covers

7. Loosen all the bolts (1) securing front cover and 3 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 front cover, taking care of front oil seal and oil sump gasket.

NDIL14TR00091AB

NDIL14TR00092AA

NDIL14TR00093AB

Timing gear removal NOTE: The crankshaft timing gear cannot be removed without removing crankshaft from the engine. 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).

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

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Engine - Pan and covers

2. Withdraw 3 bolts (1) and remove hub from the rear cover.

NDIL14TR00094AB

NDIL14TR00095AB

Feed pump drive gear 1. Withdraw 3 nuts (1) and remove feed pump along with supporting bracket (2) from the rear side of timing gear case.

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

NDIL14TR00096AB

NDIL14TR00098AA

3. Pull out feed pump drive shaft along with feed pump drive gear. NOTE: Drive gear can be removed from shaft by loosening 4 bolts.

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Engine - Pan and covers

4. Remove bush housing from rear cover.

NDIL14TR00099AA

NDIL14TR00111AB

NDIL14TR00100AA

NDIL14TR00101AB

Fuel Injection pump drive gear 1. Withdraw bolt (A) securing gear to fuel injection pump drive shaft.

2. Remove gear from the shaft using special tool number 82834300.

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

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

NDIL14TR00102AB

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Engine - Pan and covers

Timing gear housing - Inspect 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 re-assembly. 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 pressurised air.

Cam shaft 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. Clamped camshaft (1) between centres and check cam lift by means of a dial gauge (2) for cams. Cam lifts: • Inlet cam - 5.955 mm (0.234 in) • Exhaust cam - 6.027 mm (0.237 in) 3. Check alignment of bearing journals by means of dial gauge. The offset must not exceed 0.020 mm (0.001 in).

NDIL14TR00103AB

NDIL14TR00104AA

4. Straighten 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 Check for excessive wear or damage in the camshaft drive gear teeth, replace gear if necessary. In order to mount the new drive gear it must be heated to 180.0 °C (356.0 °F) in the furnace for about 10 min and must be fitted in the shaft with the plate and the conical washer.

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Engine - Pan and covers

5. Camshaft mounting clearance 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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NDIL14TR00929AB

NDIL14TR00930AB

Engine - Pan and covers

NDIL14TR00103AB

NDIL14TR00104AA

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

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Engine - Pan and covers

NDIL14TR00958AB

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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, using a suitable solvent cleaner and apply a thin coat of grease to the engine block and assemble the cover to the engine and tighten the retaining bolts to the specified torque. 2. Rotate the flywheel to PMS1 position before assembling 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, aligning 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 flywheel is positioned at PMS1 mark while aligning the timing marks. 6. Install the fuel injection pump drive gear by aligning mark 4-4 to the feed pump drive gear when idler gear is aligned with other gears as mentioned in step 5.

7. Tighten the fuel injection pump drive gear bolt to the specified torque. 8. Install the hydraulic and power steering drive gear by following 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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Engine - Pan and covers

Timing gear housing - Timing check Valve timing gear train To check valve timing after overhaul, adjust valve clearance provisionally to 0.450 mm (0.018 in). Turn the crankshaft and using an angle gauge, check that valve opening and closing angles are as specified in the diagram.

NDIL14TR00115AB

NDIL14TR00116AA

Adjust valve clearance as described in Engine - Remove (10.001).

Fuel injection pump timing Please refer to Connecting rods and pistons - Inspect (10.105) under â&#x20AC;&#x153;Fuel systemâ&#x20AC;?.

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

Engine block cover - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Timing gear housing - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Timing gear housing - Timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Valve drive and gears - 106

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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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

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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.

• Free length - 59.50 mm (2.34 in). • Loaded length - 44.00 mm (1.73 in) using a weight of 4.70 – 5.30 kg (10.36 – 11.68 lb).

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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

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

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

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

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Engine - 10 Cylinder heads - 101

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Engine - 10 Cylinder heads - 101

SERVICE Cylinder heads Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Valves Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Inspect â&#x20AC;&#x201C; Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Valve guide Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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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

NOTE: The cylinder head can be removed with the engine installed on the tractor. 1. Disconnect battery negative terminal (1).

NDIL14TR00044AB

NDIL14TR00045AB

NDIL14TR00046AB

2. Remove silencer, front hood, rear hood and fuel tank. 3. Drain the coolant after disconnecting hose (1).

4. Disconnect the air intake hose (1) from the intake manifold.

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Engine - Cylinder heads

5. Remove the radiator supporting bracket (1). 6. Disconnect electric connection on water temperature sensor.

NDIL14TR00047AB

NDIL14TR00048AB

NDIL14TR00049AB

NDIL14TR00050AB

7. Remove the bolts securing flasher unit mounting plate (1). 8. Remove the high pressure fuel pipes (2) between nozzle and fuel Injection pump, after removing clamps (3). NOTICE: Plug the fuel injection pump delivery parts and injectors inlet ports with suitable protective caps, to avoid foreign particles ingress.

9. Remove fuel pipes between feed pump, primary fuel filters, secondary filters and fuel injection pump. 10. Remove primary and secondary fuel filters mounting brackets (1) along with filters.

11. Remove left-hand side cover.

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Engine - Cylinder heads

12. Remove the bolts (1) securing alternator mounting bracket with coolant pump.

NDIL14TR00051AB

NDIL14TR00052AB

13. Remove overflow pipe (1) from injectors.

14. Loosen the 2 bolts securing injector and remove injectors from cylinder head using special tool number 292927.

NDIL14TR00053AA

NDIL14TR00054AB

15. 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. 16. Loosen bolts (1) and remove tappet cover (2).

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

NDIL14TR00055AB

NDIL14TR00056AB

NDIL14TR00057AA

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

19. 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 - Install Installation of cylinder head is the reverse of the removal procedure, but observe the following: 1. Thoroughly clean the mating surfaces and re-position the head gasket with the mark “ALTO” facing towards the cylinder head. 2. Replace the cylinder head and tighten the retaining bolts in sequence and progressively in four stages as shown in figure. 3. 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.

NDIL14TR00927AB

NDIL14TR00928AB

NDIL14TR00083AB

NDIL14TR00085AA

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.

4. Adjust valve clearance setting with each piston in turn at top dead centre and rockers free to move. • Intake valve clearance: 0.30 mm (0.01 in) (warm or cold) • Exhaust valve clearance: 0.30 mm (0.01 in) (warm or cold)

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Engine - Cylinder heads

5. Install the injectors with new seat washers, cork seals. 6. Install the high pressure fuel lines between injectors and fuel injection pump. 7. Install leak off line with new washers. 8. Tighten all bolts and nuts to correct torques.

NDIL14TR00086AA

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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

NDIL14TR00060AA

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. Using the special tool number 291050, remove the retainer locks. 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

NDIL14TR00080AA

NDIL14TR00081AB

2. Lubricate all components with clean engine oil on re-assembly. Use a spring compressor (special tool number 291050 ) to re-assemble the valves, valve springs and retainers, and collets. 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

Valves - Inspect Valve settings 8. 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 9. 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).

Refer general specification.

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Valves - Inspect – Valve springs 11. Checked on a flat surface squareness, should not exceed 1.5200 mm (0.0598 in), between the square and spring at the top edge.

NDIL14TR00791AA

NDIL14TR00076AB

12. Length of valve spring should be checked on both free length and loaded length. Free length = 44.600 mm (1.756 in) Loaded length: • 34.000 mm (1.339 in) using a weight of 26.100 – 28.900 kg (57.541 – 63.714 lb) • 23.800 mm (0.937 in) using a weight of 51.200 – 56.500 kg (112.877 – 124.561 lb) Ensure the valve spring retainer locks are in good condition and replace if worn or damaged.

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Valve guide - Inspect Valve guides 10. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valves - Inspect â&#x20AC;&#x201C; Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Connecting rods and pistons - 105

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Engine - 10 Connecting rods and pistons - 105

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

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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. For cylinder head and oil sump removal procedure, please refer to Cylinder heads - Disassemble (10.101) and Engine oil pan - Remove (10.102) respectively. 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 Inspection and repair 1. Clean the piston and connecting rod assembly in a suitable solvent and inspect for damage to ring lands, skirts or pin bosses. 2. Check connecting rod components for damage and place in the test mandrel to check for distortion and ensure that any distortion is within specifications.

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. 3. 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). • Piston pin outside diameter: 37.983 – 37.990 mm (1.495 – 1.496 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. 47899733 23/06/2015

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4. Wash the piston assembly in a suitable solvent and dry with a clean lint free cloth or compressed air. 5. Inspect the piston ring lands, skirts and pin boses for damage. 6. 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) 7. 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. 8. 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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9. 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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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 - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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Engine - 10 Crankshaft and flywheel - 103

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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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. 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 flywheel - Remove 1. To gain access to the flywheel separate the engine to transmission. 2. Remove clutch assembly from the flywheel. Refer Clutch - Remove (18.110) for removal procedure.

NDIL14TR00148AB

NDIL14TR00149AA

NDIL14TR00150AB

3. Prior to removal and using a dial indicator, rotate the flywheel, figure 2 and measure the flywheel run-out and eccentricity relative to flywheel housing. If not to specification, check crankshaft to flywheel seating.

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

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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 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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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

NDIL14TR00156AB

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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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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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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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 180Â° for 10 min. 8. Please refer figure [Invalid Reference] for more specifications.

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Engine - Crankshaft and flywheel

NDIL14TR00931GB

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NDIL14TR00932GB

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Main bearings - Assemble 1. Place bearing shell (1) in the main bearings. NOTICE: 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. NOTICE: 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). NOTICE: 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

NOTICE: 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°. NOTICE: 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. NOTICE: 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

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Engine - 10 Balancer and damper - 110

SERVICE Balancer Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - Balancer and damper

Balancer - Remove TT75 only 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 - Install TT75 Model only â&#x20AC;˘ Lock weights in correct installation position with pin (1), checking match of reference marks. â&#x20AC;˘ Fit drive coupling (2) and lock assembly tightening bolts to specified torque.

NDIL14TR00124AB

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Engine - Balancer and damper

Balancer - Disassemble TT75 Model only 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 TT75 Model only 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 TT75 Model only 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.

NDIL14TR00123AB

3. When refitting contra-rotating mass unit, timing is undertaken as follows: • Position piston number 1 at T.D.C. • 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 - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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Engine - 10 Fuel injection system - 218

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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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 Install – Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassemble – Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Inspect – Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assemble – Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Injection pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Fuel injectors Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 F 1250 L985 (0 460 414170L774) or VE 4/11 F 1250 LV 15325 (0 460 414 235) VE 3/11F 1250 L814-6 (0 460 413 028) Anti-clockwise

TT75

TT55 Rotation direction Firing order TT75 TT55

1-3-4-2 1-2-3

Injectors Make Nozzle holder Nozzle TT75/TT55 Number of spray orifices Spray orifice diameter Pressure setting

MICO BOSCH KBEL 83S352 260 (apa) DLLA 132S1320 / DLLA 132S1335 5 0.2300 mm (0.0091 in) / 0.2100 mm (0.0083 in) 260 – 272 Kg/cm² (3698 – 3869 psi)

Delivery pipes TT75 Type

4797516 6.000 mm (0.236 in) x 1.500 mm (0.059 in) x 530.000 mm (20.866 in)

Pipe dimensions TT55 Type

500303653 6.000 mm (0.236 in) x 1.500 mm (0.059 in) x 475.000 mm (18.701 in)

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 – 8° B.T.D.C.

Engine - Fuel injection system

Fuel injection system - Remove â&#x20AC;&#x201C; Feed pump NOTE: Ensure that the head pump and areas around the feed pump are clean. 1. Close cock (1) on fuel Intake line.

NDIL14TR00199AB

NDIL14TR00200AB

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

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Engine - Fuel injection system

Fuel injection system - Install â&#x20AC;&#x201C; Feed pump 1. For installation follow the removal procedure in reverse. Refer to Fuel injection system - Remove (10.218).

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Engine - Fuel injection system

Fuel injection system - Disassemble – 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 For re-assembly follow the disassembly procedure in reverse from step 5 back to step 1. Refer to Fuel injection system - Disassemble (10.218).

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Engine - Fuel injection system

Injection pump - Remove NOTE: Ensure that the areas around the injectors and front cover access plate are clean. 1. Close cock (1) on fuel intake line. 2. Remove injection pump drive gear front cover.

NDIL14TR00188AB

NDIL14TR00189AB

NDIL14TR00190AB

3. Disconnect fuel intake and return lines (1), high pressure lines (2) to injectors, throttle control linkage (3) and solenoid connection from the pump. 4. Unscrew pump retaining nut securing pump shaft to drive gear and remove injection pump.

5. Loosen dognut and remove pulley using special tool number 82834300.

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Engine - Fuel injection system

Injection pump - Inspect The pump should not be tampered with in any way. If the pump operation is suspect it should be taken to an approved MICO 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

NDIL14TR00192AA

NDIL14TR00193AA

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 291755 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).

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Engine - Fuel injection system

• 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. NDIL14TR00194AB

• Tighten the pump retaining nuts and cut reference. • Marks into the pump flange and spacer. • Remove gauge, tool and fit plug, tightening to 0.8 – 1.0 kgm (5.8 – 7.2 ftlbs.). • 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

NDIL14TR00239AB

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 9971094 (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 99715001 (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. Refit other parts in the reverse of the dismantling order.

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Engine - Fuel injection system

PV-No. : 1 469 423 012 Test specification Change : 5 08.01.2008 Robert Bosch mechanically-governed distributor GmbH Stuttgart pumps : vorläufig Status Kundendienstvorschrift Date of print : 05.05.2009 Pump : 0 460 423 012 VE 3/12 F 1250 L977 Engine Customer drawing : A460907020 : Series 8000 Power : 48 kw Pist. swept vol. Customer : IVECO – FIAT : 2.9 I Application Customer order no. : Traktoren Test conditions Calibr, nozzle and holder assembly Test fuel-injection tubing Calibrating oil Calibration oil inlet pressure Calibration oil overflow pressure Opening pressure Overflow restriction

Test point

Index

n 1/min.

: 1 688 901 027 : Øa 6.00 x Øi 2.00 x 450mm : ISONORM : 35.00 +/- 5.00 kPa : 55 +/- 1.00 ºC : 25.0 +/- 0.3 MPa : 0.55 mm

Sollwert/ Tolerance

Overflow quantity at pump (l/h) 1250 USMO 31.0 +/ - 9.0 500 USMO 23.0 +/ - 7.0 Supply pump pressure (MPa) 1100 PSEP 0.84 +/ - 0.07 500 PSU 0.55 +/ - 0.07 Timing device travel (mm) N 1100 SVEP 2.0 +/ - 0.6 1250 SVO 3.0 +/ - 0.6 900 SVU 0.8 +/ - 0.6 Full -load start -quantity (mm3/H) STM 120.0 +/ 100 20.0 300 STO 82.0 +/ - 7.0 Full -load (mm3/H) VEP 900 76.7 +/ - 2.5 VEPM 600 76.7 +/ - 3.0 VEPU 600 74.0 +/ - 3.0 1250 VO 68.5 +/ - 3.0 Speed regulation breakaway (mm3/H) AB1 1390 1.5 +/ - 1.5 Electric shut -off (mm3/H) 325 SPE1 1.5 +/ - 1.5 325 SPE2 1.5 +/ - 1.5 LFB -quantity (mm3/H) 1250 Q3 38.5 +/ - 0.5 1250 Q4 28.0 +/ - 0.5 1250 DQ2 -14.0 +/ - 6.0 LFB Timing Device Travel (mm) N 1250 DS2 -0.3 +/ - 0.1 1250 DS3 -0.5 +/ - 0.4 1250 S4 3.1 +/ - 0.5 Control lever spacing - angle

Distribution

DA -Sollwert / Tolerance

</ - 3.5

</ - 5.0

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LDA Pressure hPa

ELA BV

1000 0

12 12

1000 1000

12 12

1000 1000 1000

12 12 12

1000 275 0 1000

12 12 12 12

1000

0 0

1000 1000 1000

12 12 12

1000 1000 1000

12 12 12

TV %

KSB v

Engine - Fuel injection system

Ya Yb Remarks: Pump with 3.5ยบ cam angle RR -KSB

38.9 +/ - 1.0 mm 42.3 +/ - 2.5 mm

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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 two 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 290284, 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 â&#x20AC;&#x201C; 150 bar (1450 â&#x20AC;&#x201C; 2175 psi) in 5 â&#x20AC;&#x201C; 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 MICO service centre for further testing and repair.

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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 293861 and ensure that lower part contacts seat in cylinder head.

4. Position bushing (1), special tool number 293746 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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Index Engine - 10 Fuel injection system - 218 Fuel injection system - Assemble – Feed pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

Fuel injection system - Install – 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

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Engine - 10 Air cleaners and lines - 202

SERVICE Air cleaner Remove – Oil bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inspect – Oil bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install - Oil bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Service instruction - Dry air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Air cleaner - Remove â&#x20AC;&#x201C; Oil bath NOTE: It is not necessary to remove the complete air cleaner body, as described below, to service the air cleaner elements. 1. Slide the lock (1) to right, hold and lift the handle (2) and raise the hood.

NDIL14TR00007AB

NDIL14TR00179AB

2. Loosen the clamp (1) of air cleaner hose (2). 3. Remove the air cleaner securing bolts.

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Air cleaner - Inspect â&#x20AC;&#x201C; Oil bath 1. Check for damage of rubber gaskets, replace if damaged. 2. Check for oil level and condition, top up or replace the oil depending on the condition of oil. 3. Clean the wire mesh with the help of diesel and allow it to dry.

NDIL14TR00180AB

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Engine - Air cleaners and lines

Air cleaner - Install - Oil bath Installation of air cleaner is reverse of the dismantling procedure. Refer to Air cleaner - Remove (10.202)

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Engine - Air cleaners and lines

Air cleaner - Service instruction - Dry air cleaner Service the engine air cleaner outer element NOTE: Under dusty condition, clean the outer element as per method A more often than 300 h. Loss of engine power, excessive smoke and glowing of air cleaner clog light (refer operator manual ), indicates the possible chocking of filter. The dry air cleaner, which is located under the front hood, right-hand side of the hood, consists of an inner and outer paper element within a metal casing. 1. Unlatch the three retaining clips (1).

NDIL14TR00181AB

NDIL14TR00182AB

NDIL14TR00183AB

2. Lift off the air cleaner assembly cover (1).

3. Remove the outer element (1) from the air cleaner assembly by gently twisting the end of the filter anti clockwise to disengage the seal. Then pull the filter straight out of the housing, not at an angle, ensuring the inner element (1), figure 3 remains in place. NOTICE: Do not disturb or remove the inner element (1), figure 4.

4. Clean the outer element using either method A, B, depending on the elementâ&#x20AC;&#x2122;s condition. NOTE: An outer element may be dry cleaned (methods A or B) every 300 h or when warning bulb glows (which ever is earlier). Outer element to be replaced after 3 times of cleaning by method B or max. 900 h inner element to be replaced after 3 outer element replacements or every 2700 h whichever is earlier.

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Engine - Air cleaners and lines

Method A Lightly tap the end of the element against the palm on the hand till accumulated dust not comes out completely see figure 5. NOTICE: Do not tap the element against a hard surface as this will damage the element.

NDIL14TR00184AB

NDIL14TR00185AB

NDIL14TR00186AB

Method B Use compressed air, not exceeding 1.3 bar (18.8 psi). Insert the air line nozzle inside the element. Hold the nozzle at a safe distance from the element and blow the dust from the inside through the element to the outside. See figure 6. Never blow air from outside to inside as this will cause dust to enter inside the element. WARNING Wear eye protection and a face mask when carrying out this operation.

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Engine - Air cleaners and lines

1. Examine the element for damage by placing a light inside the element see figure 7. Discard the element if pin pricks of light can be seen or if there are areas where the paper appears thin. 2. Check the element material for bunching. The metal casing for distortion and the rubber gasket for damage. Discard the filter element if it is 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, to ensure a good seating for the rubber seal on the element. NDIL14TR00187AB

4. Install the cleaned outer element or new outer element by gently pushing it inside the housing in clockwise direction. 5. While fitting back the cover make sure that the dust cup/ejector (2) facing downward Fif (1). 6. Check all the air intake hoses, for damages and replaces necessary. Check clamps for tightness. 7. Replacement of inner element: The inner element to be removed only at the time of replacement. It should never be cleaned. The inner element should be replaced after 3 outer element replacements or every 2700 h whichever is earlier. Follow the similar instruction of removing and fitting outer element from casing to replace inner element.

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Index Engine - 10 Air cleaners and lines - 202 Air cleaner - Inspect – Oil bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air cleaner - Install - Oil bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air cleaner - Remove – Oil bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air cleaner - Service instruction - Dry air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Engine cooling system - 400

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Engine - 10 Engine cooling system - 400

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

SERVICE Radiator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Water pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Test â&#x20AC;&#x201C; Water temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Coolant thermostat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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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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Radiator - 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 clamp (1) and drain the coolant from radiator.

NDIL14TR00255AB

NDIL14TR00256AB

NDIL14TR00257AB

2. Disconnect the battery connections and loosen the battery clamping bolts (1). Remove the battery.

3. Remove the left-hand side / right-hand side covers (1).

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4. Loosen the clamps (1) and (2) and remove the pipe for air cleaner (3) and radiator (4). 5. Remove the radiator support clamp (5). 6. Loosen bolt sand remove radiator top shield.

NDIL14TR00258AB

NDIL14TR00259AB

NDIL14TR00260AB

7. Remove the radiator securing shell (1).

8. Remove the radiator securing bolts (1) below the front axle support. 9. Remove the radiator assembly.

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Radiator - Inspect The radiator cap incorporates two valves: a 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 scale in radiator as follows: 1. Prepare a solution of warm water and sodium bicarbonate ( 30.0000 g/L (0.0030 kg/dm³)) in quality indicated on container. 2. Pour solution into radiator, drain and rinse with abundant water. To check for radiator leakage, submerge radiator in a tank of water at 20 – 40 °C (68 – 104 °F) and apply air at 1.0 Kg/cm² (14.2 psi) for 2 min. 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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NDIL14TR00261AB

Engine - Engine cooling system

Radiator - Install Installation procedure of radiator is reverse of removal procedure. Refer to Radiator - Remove (10.400).

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Engine - Engine cooling system

Water pump - Remove 1. Drain the coolant from engine block. 2. Remove the radiator as explained in Radiator - Remove (10.400). 3. Remove the coolant fan. 4. Remove the hoses and remove the bolts securing water pump.

NDIL14TR00265AA

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Engine - Engine cooling system

Water pump - Disassemble To overhaul the water pump, proceed as follows: 1.

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 291182/1.

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. NDIL14TR00266AB

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Engine - Engine cooling system

Water pump - Assemble Re-assembly follows the disassembling procedure in reverse order. Refer to Water pump - Disassemble (10.400). 1. The bearing (2) requires no lubrication. 2. The impeller (7) must be fitted flush with end of drive shaft.

NDIL14TR00267AB

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Engine - Engine cooling system

Water pump - Install Installation of water pump is the reverse of removal procedure. Refer to Water pump - Remove (10.400), but observing the following requirement. 1.

After 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 sectors corresponding to the following temperature ranges: 1.

White sector 0 – 40 °C (32 – 104 °F)

Green sector 40 – 112 °C (104 – 234 °F)

Red sector 112 – 120 °C (234 – 248 °F)

In normal conditions, pointer should be in green sector. In case of doubt, test instrument be immersing bulb in water and check scale with reference thermometer 291979,repeat test several times.

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Engine - Engine cooling system

Coolant thermostat - Remove 1. Drain the coolant system, below that of the level of the thermostat housing. 2. Remove the hoses (1) and bolts securing the bracket (2).

NDIL14TR00262AB

NDIL14TR00263AB

3. Remove top flange (1) by loosening bolts. 4. 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.

NDIL14TR00264AA

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

Water pump - Test â&#x20AC;&#x201C; Water temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Fan and drive - 414

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Engine - 10 Fan and drive - 414

SERVICE Belt Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Fan and drive

Belt - Tension adjust To check fan, water pump and alternator drive belt, apply a load of 8 – 10 kg (18 – 22 lb) on belt section between alternator and water pump pulleys,the belt should deflect 10.00 – 11.00 mm (0.39 – 0.43 in).If necessary, adjust as follows: 1.

Slacken nut (1) securing alternator to belt tensioner.

Move alternator on tensioner bracket to obtain desired tension, then tighten nut (1).

NDIL14TR00268AB

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Index Engine - 10 Fan and drive - 414 Belt - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Engine lubrication system - 304

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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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 filter Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Engine oil pump Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Engine - Engine lubrication system

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 - Engine lubrication system

Engine lubrication system - Overview Oil pressure warning system The oil pressure warning system includes a sending unit and an oil pressure gauge. If the oil pressure is low, the needle will show on the red zone of the gauge. Alternatively, if the oil pressure is good, the needle will show in green zone of the gauge.

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Engine - Engine lubrication system

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 of a liter of engine oil to 100 liters 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.

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 รท 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 รท C x 100 = Percentage oil consumption. Example: (A) = 2.5 kg. (B) = 2.5 รท 0.88 = 2.840909 liters. (C) = 500 liters of fuel used. (D) = 2.840909500 รท 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. 47899733 23/06/2015

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Engine - Engine lubrication system

Compression test 1. Ensure battery performance meets specifications. 2. Warm up the engine by operating for a minimum of half an hour at 1200 RPM. 3. Stop the engine and remove the injectors and seat washers from all the cylinders. 4. Clean the injector bores and crank the engine to blow out any loose carbon particles. 5. Install a proprietary engine compression test gauge and adaptor into the number one injector bore using the injector mounting bolts and a new seat washer. 6. Connect the gauge and hose to the adaptor. 7. Crank the engine at a minimum of 200 RPM with the engine stop cable pulled out where fitted, or the electric fuel shut-off wire disconnected to prevent engine start up. 8. Observe the gauge reading and repeat steps e to g of the compression test, for each cylinder. The compression figure for a new engine should be 25.9 bar (375.5 psi) with a variance of not more that 1.7 bar (24.6 psi) between the cylinders.

Test readings 1. All cylinders compressions should be uniformly within 1.7 bar (24.6 psi) of each other. 2. A reading of more than the 1.7 bar (24.6 psi) below the other cylinders could indicate leakage at the cylinder head gasket, piston rings or valves. 3. A reading of more than 1.7 bar (24.6 psi) above the other cylinders could indicate excessive carbon deposits on the piston and cylinder head. 4. A low compression in two adjacent cylinders could indicate a cylinder head gasket leak. Check this item before replacing the rings or valves.

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Test conclusion To determine whether the rings or the valves are at fault, squirt the equivalent of a table spoon of heavy oil into the combustion chamber of the cylinder to be retested. Crank the engine to distribute the oil and repeat the compression test for all cylinder. The oil will temporarily seal any leakage past the rings. If approximately the same reading is obtained as for the first test, the rings are satisfactory but the valves are leaking once this has been established the exhaust manifold can be removed to visually inspect if oil is leaking, Once this has been established the exhaust manifold can be removed to visually inspect if oil is leaking down the valve stems. If compression has increased over the original reading, there is leakage past the rings. During a compression test, if the pressure fails to climb steadily and remains the same during the first two successive strokes, but climbs higher on the following strokes, or fails to climb during the entire test, suspect a sticking valve.

Rework 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:NOTE: If the oil consumption is below 0.4% no service repair action should be taken. If oil consumption is diagnosed the engine should be repaired in line with the repair manual pertaining to the particular engine.

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Engine - Engine lubrication system

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 filter - Service instruction The spin on type oil filter (1) is a full-flow unit fitted on the outlet side of the pump. A by-pass valve will enable unfiltered oil to enter the engine, if the filter become obstructed. Every 300 working hours replace the cartridge noting the following points. • Smear the external seal with engine oil. • Fit the cartridge by turning until contact with the mounting flange is established. • Turn the cartridge by hand through a further 3/4 turn. NDIL14TR00253AB

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Engine - Engine lubrication system

Engine oil pump - Disassemble NOTE: Dismantling of engine sump is similar to TT75 / TT55 after removing sump proceed as follows. 1. Remove bolts (1) to remove lubricating pump 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) by pushing with the help of screw driver.

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5. Rotate the engine on stand at 90 unscrew the big end bearing cap bolts (1) and remove big end caps (2) with half shell bearings.

NDIL14TR00230AB

NDIL14TR00231AB

NDIL14TR00232AB

NDIL14TR00233AB

6. Remove 3 spray jets (1) as shown and clean them before refitting. NOTE: Dismantling procedure for all components like con rod etc. is similar with repair manual of TT75 / TT55 .

7. Fix the pump in bench vice and loosen bolts (1).

8. Exploded view of lubricating oil pump.

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9. To remove relief valve remove circuit lock (1) and bolt (2).

NDIL14TR00234AB

10. Check tension or spring or relief valve and replace it found faulty.

NDIL14TR00235AB

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Engine - Engine lubrication system

Engine oil pump - Assemble Install the all parts in reverse sequence from step 10 to 1. Refer to Engine oil pump - Disassemble (10.304)

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Engine - Engine lubrication system

Engine oil pump - Remove NOTE: The oil pump can be removed after removing oil pan bottom cover in case of TT75 model and oil pan has to be removed in case of TT55 model. 1. Remove oil pan bottom cover or oil pan depending on the model.

NDIL14TR00243AB

NDIL14TR00244AB

NDIL14TR00245AB

2. Remove suction pipe strainer support screw (1) on balancer assembly only in case of TT75 model.

3. Loosen screws and remove suction pipe (1).

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4. Loosen two bolts retaining oil pump on cylinder housing and remove pump (1) from the engine.

NDIL14TR00246AB

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Engine - Engine lubrication system

Engine oil pump - Disassemble 1. Loosen two allen screws and two bolts retaining pump face plate to body.

NDIL14TR00247AA

NDIL14TR00248AB

2. Remove driven gear (1) from its associate shaft. 3. Remove rivet (2) and outer drive gear (3). 4. Remove drive shaft (4) along with drive gear (5). 5. Remove pressure relief valve screwing out hexagonal head (6).

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Engine - Engine lubrication system

Engine oil pump - Inspect 1. Wash all parts in a suitable solvent and inspect inside of pump plate and body, for excessive wear or damage. If it is visually okay, check in the following manner. 2. Hold pump body assembly on a vice and place drive and driven gears. Placing a ruler across top, slide a feeler gauge, between ruler and inner rotor. The gap should be within 0.025 – 0.126 mm (0.001 – 0.005 in). If the value exceeds a new pump is required.

NDIL14TR00249AA

NDIL14TR00250AA

NDIL14TR00251AA

3. Check drive and driven gear clearance in the pump body, by inserting a feeler gauge. If the value exceeds 0.030 – 0.170 mm (0.001 – 0.007 in), a new pump is required.

4. Check backlash between gears. NOTE: If not to specification replace the oil pump, as reduced pump pressure through wear could result in reduced engine life.

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Engine - Engine lubrication system

Engine oil pump - Assemble 1. Clean and coat parts in new engine oil. Place gears in pump body, and ensure free rotation. Insert pump face plate into the body and ensure that shaft is fully seated into face plate. 2. Tighten the face plate retaining allen screw and bolts to the specified torque. NOTE: After tightening ensure that the gears rotates freely by hand, if not disassembly and repeat the exercise.

NDIL14TR00252AA

3. Install the pump on engine cylinder block and fit bat suction pipe and strainer. 4. Check relief valve spring free length and loaded length Free length - 45.0 mm (1.8 in) Loaded length ( 9.0 â&#x20AC;&#x201C; 9.6 kg (20.0 â&#x20AC;&#x201C; 21.2 lb) ) 30.5 mm (1.2 in) If not to specification replace the relief valve spring.

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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 filter - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine oil pump - 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 TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Clutch - 18

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

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Clutch - 18 Clutch and components - 110

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Clutch - 18 Clutch and components - 110

TECHNICAL DATA Clutch General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Clutch Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Clutch Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

DIAGNOSTIC Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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Clutch - Clutch and components

Clutch - General specification Type

Double, dry plate, torsion spring Mechanical pedal for transmission hand lever for Power Take-Off (PTO) Dished spring Organic compound

Control Release mechanism Plate material

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

8.800 – 9.600 mm (0.346 – 0.377 in). 8.300 – 8.900 mm (0.326 – 0.350 in) Tangential springs 0.050 – 0.151 mm (0.002 – 0.006 in) 0.072 – 0.205 mm (0.003 – 0.008 in) 2.500 – 5.000 mm (0.098 – 0.196 in) 45.000 – 50.000 mm (1.771 – 1.968 in)

Transmission pedal requirements Pedal pin diameter Supporting bush internal diameter (fitted, non-dressed) Pin/bush play Pedal bracket internal diameter Bush outer diameter Pedal bracket/bush interference fit

27.948 – 28.000 mm (1.100 – 1.102 in) 28.020 – 20.072 mm (1.103 – 0.790 in) 0.020 – 0.124 mm (0.001 – 0.005 in) 32.927 – 32.966 mm (1.343 – 1.297 in) 33.009 – 33.030 mm (1.300 – 1.300 in) 0.043 – 0.103 mm (0.002 – 0.004 in)

Clutch - Torque Description Transmission housing to fly-wheel housing buckle up bolts (C1) Clutch assembly mounting bolts (C2) Bolts, release fork (C3)

Thread size

Torque

M12 X 1.25

100.0 N·m (73.8 lb ft)

M8 X 1.25 M16 X 1.5

26.0 N·m (19.2 lb ft) 210.0 N·m (154.9 lb ft)

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NDIL14TR00269GB

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

Tool number 291184 293763 9971365

Clutch - Sealing Operation description Engine to transmission buckle up (S1) Bolts, release fork (S2)

Sealants specification LOCTITE® 574™ LOCTITE® 243™

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NDIL14TR00270GB

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Clutch - Sectional view

NDIL14TR00271GB

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

Dish spring Power Take-Off (PTO) clutch release fingers Transmission clutch release fingers Release control sleeves with thrust bearings Power Take-Off (PTO) clutch release lever locknuts and adj. link Power Take-Off (PTO) clutch plate

7. 8. 9. 10. 11.

Transmission clutch plate Fly-wheel bearing Power Take-Off (PTO) clutch release fork Transmission clutch release fork Transmission clutch release lever locknut, adjusting screw and lever

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Clutch - Clutch and components

NDIL14TR00272GB

Clutch plate 1. 2. 3. 4.

Clutch facing Facing rivet Segment rivet Hub

5. 6. 7.

Segment Idle damper spring Main damper spring

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Clutch - Clutch and components

Clutch - Overview Description The clutch system is double clutch mechanical type. It includes two dry clutch discs with non-asbestos, organic material pads. One clutch disc is to connect transmission to engine and another for connecting 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 discharges the main clutch fingers. Consequently, the clutch pressure plate backs off and releases the clutch disc from the clutch housing. The transfer of engine power to the transmission is stopped. When the clutch pedal is released, the main clutch release bearing disengages the main clutch finger which acts on the clutch pressure plate and causes the clutch housing, main clutch discs and pressure plates to come in contact. The flow of power from the engine and transmission is re-established. Similarly Power Take-Off (PTO) clutch is engaged and disengaged independent of transmission clutch by operating Power Take-Off (PTO) clutch control lever.

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Clutch - Clutch and components

Clutch - 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

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

NDIL14TR00554AB

NDIL14TR00555AB

NDIL14TR00556AB

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

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

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Clutch - Clutch and components

6. Remove clutch pedal spring (1).

NDIL14TR00557AB

NDIL14TR00277AB

NDIL14TR00559AA

NDIL14TR00560AB

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

8. Jack-up rear left-hand side of tractor and remove lefthand side rear wheel.

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

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Clutch - Clutch and components

Power Take-Off (PTO) clutch lever removal To remove the Power Take-Off (PTO) clutch lever (1), proceed as follows:

NDIL14TR00280AB

NDIL14TR00281AB

1. Remove pin (1) by releasing lock plate and disconnect linkage between Power Take-Off (PTO) clutch lever and Power Take-Off (PTO) clutch cross shaft.

2. Remove the split pin lock (1), take out the pin and remove hand lever from the mounting bracket. 3. Remove bolt (2) from the housing to take out the levers with the bracket.

NDIL14TR00282AB

NDIL14TR00283AA

Cross shafts removal 1. To remove cross shafts, clutch housing has to be splited between engine flywheel housing and transmission housing. Refer to Engine - Remove (10.001) for splitting the tractor.

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Clutch - Clutch and components

2. Remove clips (1) from both the forks locking forks and release bearing.

NDIL14TR00284AB

NDIL14TR00285AB

NDIL14TR00286AB

NDIL14TR00287AB

3. Loosen the Power Take-Off (PTO) clutch fork lock screw (1).

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

5. Loosen the transmission clutch fork lock screw. 6. Pull out the transmission cross shaft (1) from left-hand side of the transmission housing and retrieve fork from the housing.

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Clutch - Clutch and components

7. Slide out both transmission and Power Take-Off (PTO) clutch release bearings (1) and (2) from the shaft.

NDIL14TR00288AB

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Clutch - Clutch and components

Clutch - Install Reassemble the clutch mechanical release control, taking care of the following: 1. Reassembly follows the disassembly procedure in reverse. 2. Ensure that lock clips (1) are properly seated on clutch release forks. 3. Comply with tightening torques indicated on Clutch Torque (18.110).

NDIL14TR00284AB

4. Apply LOCTITEÂŽ 243â&#x201E;˘ sealant to clutch release fork lock-screw and left-hand side brake pedal lock-screw before tightening. 5. Before buckling up the transmission and engine, thoroughly clean and decrease mating surfaces and apply a bead of liquid gasket of approximately 2.00 mm (0.08 in) of diameter following pattern shown in Clutch - Install (18.110) Figure 2.

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Clutch - Clutch and components

Clutch - Adjust Clutch pedal free play should be 30.00 – 45.00 mm (1.18 – 1.77 in) measuring at clutch pedal using special tool number 9971365 as shown. To adjust the free play, proceed as follows:

NDIL14TR00290AA

NDIL14TR00291AB

NDIL14TR00292AB

1. Remove the split pin (1) and disconnect the linkage. 2. Loosen the lock nut (2). 3. Rotate the yoke (3) clockwise to reduce the play and anti-clockwise to increase the play. 4. Connect linkage back to cross shaft.

Power Take-Off (PTO) clutch lever free play 1. Open the parts pin (2) fork (3) and rod (5) separately. 2. Keep lever (1) at the right most position such that the bearing is just touching the clutch fingers. 3. Insert rod (5) into fork (6) and tight the threads up to 15.00 mm (0.59 in). 4. Keep end of lever (7) at 30.00 – 35.00 mm (1.18 – 1.38 in) from edge as shown in fig. 5. Insert fork (3) into rod (5) by keeping rod in static position. 6. Match the hole of fork (3) with hole of lever (1) without disturbing the initial position of lever (1). 7. Insert pin (2) in matching holes and lock lever (1).

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Clutch - Clutch and components

8. Now tight the nut (4) to lock the fork. 9. We can see the play of lever (7) between edge A and end of lever at 30.00 – 35.00 mm (1.18 – 1.38 in) from edge A. This is free play of Power Take-Off (PTO) clutch lever.

NDIL14TR00293AB

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Clutch - Clutch and components

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

NDIL14TR00294AA

NDIL14TR00295AB

NDIL14TR00296AB

2. Remove the 10 bolts (1) which retains the clutch assembly to the engine fly wheel and slacken the two remaining bolts.

3. Insert centralizing pin special tool number 271184 in clutch plate shaft seats, back off the two remaining bolt and remove assembly completely. Retrieve Power Take-Off (PTO) clutch disc.

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Clutch - Clutch and components

Clutch - Install Install the clutch assembly back on flywheel taking care of the following: 1. Check condition of ball bearing (1) pressed in flywheel. Replace in the event of excessive noise or binding. 2. Refit old / new bearing packing the seat with grease. 3. Use centralizing pin while installing clutch assembly with Power Take-Off (PTO) clutch disc on flywheel. 4. Tighten bolt to specified torque refer to Clutch - Torque (18.110). 5. Before buckling up the transmission housing and engine, thoroughly clean and decrease mating surfaces and apply a bead of liquid gasket of approx. 2.00 mm (0.08 in) of diameter following pattern shown in the figure 2.

NDIL14TR00298FA

NDIL14TR00297AB

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Clutch - Clutch and components

Clutch - 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

1. Remove clutch assembly from tractor. Refer to Clutch - Remove (18.110). 2. Loosen the Power Take-Off (PTO) clutch release lever locknuts (1). NOTICE: 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

3. Remove Power Take-Off (PTO) pressure plate (1).

4. Remove disk ring (1) and lock ring (2).

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Clutch - Clutch and components

5. Loosen lock nut (1).

NDIL14TR00302AB

NDIL14TR00303AB

NDIL14TR00304AB

NDIL14TR00305AB

6. Remove transmission clutch pressure plate (1).

7. Remove transmission clutch disc (1) from the housing.

Release fingers disassembly 1. Pull-out dowel pin (1).

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Clutch - Clutch and components

2. Pull out pin (1) from the housing and retrieve spring (2).

NDIL14TR00306AB

NDIL14TR00307AA

3. Remove release fingers from the housing.

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Clutch - Clutch and components

Clutch - Inspect 1. Check clutch driven discs for wear and replace if rivets (2), (refer to Clutch - Sectional view (18.110)) are near or flush with top facing. 2. Discs are also to be replaced if the organic facings are found to be soaked with oil. 3. Check condition of clutch housing and pressure plate friction surfaces. If necessary dress, noting that dimensions of pressure plates and clutch housing must not be reduced below the limits described below, otherwise replace as necessary. Referring to Fig. 1. 1.

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).

Clutch housing under cut - ‘E’ = 2.500 mm (0.098 in).

Dressing allowance - ‘F’ = 69.85 – 70.15 mm (2.75 – 2.76 in).

Calculate Dimension ‘F’ as follows F=A+B+C+S1+S2+P Where S1 = Power Take-Off (PTO) clutch disc thickness S2 = Transmission clutch disc thickness P = Spring dimensions to restore original load = 4.5 mm (0.2 in) (fixed).

Check that value ‘F’ is equal to 69.85 – 70.15 mm (2.75 – 2.76 in).

n restoring value ‘F’ check that clutch housing thickness ‘E’ does not fall below 17.00 mm (0.67 in) i.e. D-F = E ≥ 17.00 mm (0.67 in).

Check that the undercut ‘E’ on clutch housing is deeper than 2.50 mm (0.10 in) and restore as necessary.

10. If necessary dress friction face on flywheel and restore external undercut ‘A’ of 2.00 mm (0.08 in).

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Clutch - Clutch and components

NDIL14TR00308FB

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Clutch - Clutch and components

Clutch - Assemble Re-assembly follows disassembly procedure in reverse from step 7 back to step 1, refer to Clutch - Disassemble (18.110). 1. See figure for correct orientation of clutch discs.

NDIL14TR00309BA

NDIL14TR00310AB

2. Position disk springs (1) correctly and lock-ring (2) on transmission pressure plates as shown in the figure.

3. Using special tool number 291184, centralise clutch discs. 4. Install the clutch assembly on flywheel and do release finger adjustments as described under clutch release finger settings. Refer to Clutch - Adjust (18.110).

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Clutch - Clutch and components

Clutch - Adjust Clutch release fingers settings For correct function of clutch release mechanism, the release fingers must be set at the distances D - 96.00 mm (3.78 in) and 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.

NDIL14TR00311AA

NDIL14TR00312AA

NDIL14TR00313AB

2. Insert centralizer pin special tool number 291184 along with fingers height setting gauge, drive shaft seats, ensuring that 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 0.30 mm (0.01 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 as shown in the figure (b) to set transmission clutch release fingers. The gap between fingers and gauge should be 0.30 mm (0.01 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 - Service instruction 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. 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. CAUTION Machine the bolting surface to the same amount of the running surface to maintain original clamp loads. WARNING Always use suitable tools to align holes. Do not use hands or fingers. 4. Ensure correct alignment of the clutch cover to the flywheel. Use special tool number 291184 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 runout. 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. 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 - Troubleshooting Problem Clutch slips

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 Clutch grabs 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 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 Warped clutch disc Replace clutch disc Clutch noise at engagement and /or disengagement. Damaged clutch disc damper springs Replace clutch disc Excess backlash on clutch disc to hub Replace clutch disc and shaft, as necesmeshing splines sary Worn clutch release bearing Replace bearing Clutch noise at disengagement Hard pedal Clutch control pedal Check and lubricate linkage hardness Broken or disconnected clutch return Replace or hook - up clutch return spring spring

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Index Clutch - 18 Clutch and components - 110 Clutch - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Clutch - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Clutch - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47899733 23/06/2015 EN

SERVICE MANUAL Transmission TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Transmission - 21

[21.114] Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.140] Mechanical transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.126] Gearbox external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 [21.145] Gearbox internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4

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Transmission - 21 Mechanical transmission - 114

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Transmission - 21 Mechanical transmission - 114

TECHNICAL DATA Mechanical transmission General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Mechanical transmission Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Mechanical transmission Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove – 8 + 2 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install – 8 + 2 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove – 12+3 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

DIAGNOSTIC Mechanical transmission Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Transmission - Mechanical transmission

Mechanical transmission - General specification Transmission type Gears Splitter • Reduction ratio Transmission and splitter controls Driven gear bushing external diameter Driven gear internal diameter Bushing clearance in gear Driven shaft diameter Bushing internal diameter Shaft clearance in bushing Power Take-Off (PTO) clutch shaft diameter Bushing fitted internal diameter Power Take-Off (PTO) shaft clearance in bushing Bushing interference fit with drive shaft Shim thickness for adjusting end float of driven gears

8 forward speeds and two reverse speeds Spur Planetary, with three spur pinions 20 : (20 + 52) = 1 : 3.6 Separate levers 42.925 – 49.950 mm (1.690 – 1.967 in) 50.050 – 50.089 mm (1.970 – 1.972 in) 0.100 – 0.164 mm (0.004 – 0.006 in) 39.166 – 39.191 mm (1.542 – 1.543 in) 39.200 – 39.239 mm (1.543 – 1.545 in) 0.0090 – 0.0730 mm (0.0004 – 0.0029 in) 24.964 – 24.958 mm (0.983 – 0.983 in) 25.040 – 25.092 mm (0.986 – 0.988 in) 0.055 – 0.128 mm (0.002 – 0.005 in) 0.037 – 0.091 mm (0.001 – 0.004 in) 3.70 mm (0.15 in)– 4.00 mm (0.16 in) – 4.30 mm (0.17 in)

Washer thickness and inboard and outboard baulk rings for driven gears and planetary gear splitter supports Selector shaft detent ball spring length. • Free • loaded 5.1 – 5.7 kg (11.24 – 12.57 lb) Selector shaft detent ball spring length. • Free • loaded 5.15 – 5.25 kg (11.35 – 11.57 lb) Selector shaft detent ball spring length (splitter only). • Free • loaded 11.7 – 12.9 kg (26 – 28.44 lb)

1.470 – 1.530 mm (0.058 – 0.060 in) 61.500 mm (2.421 in) 48.000 mm (1.890 in) 35.500 mm (1.398 in) 31.500 mm (1.240 in) 35.500 mm (1.398 in) 31.500 mm (1.240 in)

Mechanical transmission - Torque Description Nut, transmission housing to engine Lock-nut, driven gear shaft Nuts for studs securing transmission shaft bearing cover Bolts, transmission housing cover Nuts for studs securing spacer to transmission housing and power train Bolts, securing planetary reduction fixed gear Bolts, splitter shift fork rod bracket

Thread size M12 X 1.25 M24 X 1.5

Torque 100.00 N·m (73.76 lb ft) 255.00 N·m (188.08 lb ft)

M8 X 1.25

18.00 N·m (13.28 lb ft)

M8 X 1.25

25.00 N·m (18.44 lb ft)

M10 X 1.25

60.00 N·m (44.25 lb ft)

M12 X 1.25

100.00 N·m (73.76 lb ft)

M10 X 1.25

60.00 N·m (44.25 lb ft)

Mechanical transmission - Sealing Operation description Rear axle to transmission housing (S1) Transmission to engine (S2) Gear shift cover to transmission housing (S3) Pinion shaft front cover (S4)

Sealant specification LOCTITE® 574™ LOCTITE® 518™ Permatex LOCTITE® 243™

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Transmission - Mechanical transmission

NDIL14TR00314FB

Mechanical transmission - Special tools Tool description Sling hook, gear box Gear box stand Remover, drive shaft Remover, reverse gear shaft Puller, needle bearing reverse gear Jaw 18.00 â&#x20AC;&#x201C; 25.00 mm (0.71 â&#x20AC;&#x201C; 0.98 in)

Tool number 291517 270086 9971348 9971347 292909 292907

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Transmission - Mechanical transmission

Mechanical transmission - Overview 8+2 & 12+3 Transmission The transmission has eight forward and two reverse gears. However 12+3 transmission is available as option that enable 12 forward & 3 reverse speed.

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.

NDIL14TR00315AB

NDIL14TR00871AB

NDIL14TR00316AB

W0130A

The main gearshift lever(the right hand lever) is used to select any one of the four forward gears or one reverse gear. The Hi-Low selector lever is used to select the high (H) or low (L) range, which gives double the number of available gears. To change gear range; depress the clutch pedal, stop the tractor and move the Hi-Low selector lever (1) backward for high or forward for low and to get medium speed towards the mark as shown in Fig. 2. To change the gears in the selected range, depress the clutch pedal and shift main gear lever (2) in the normal way. Third and fourth gears in both ranges are syncromesh in TT75 and optional in TT55 . To select reverse gear (R), first stop the tractor. NOTE: A neutral start switch is provided to prevent operation of the starter motor unless the transmission range lever is in neutral position.

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Transmission - Mechanical transmission

NOTICE: If it is necessary to tow the tractor, both the Hi-Low selector and main gearshift levers 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 colars. In the synchro-mesh 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 “Sychroniser” to equalise the speed of the mating points before they engage. It permits gear shifting while the tractor is moving. The range gears is a planetary type work much like the solar system. Each of the “Pinions” on planet gears, turns on its own axis and at the same time, rotates around the sun gear.

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NDIL14TR00317AB

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 - Remove â&#x20AC;&#x201C; 8 + 2 Transmission 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

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

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

NDIL14TR00318AA

NDIL14TR00319AB

NDIL14TR00320AA

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

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

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Transmission - Mechanical transmission

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

NDIL14TR00321AB

NDIL14TR00322AB

NDIL14TR00323AA

NDIL14TR00324AB

5. Disconnect clutch pedal (1) and Power Take-Off (PTO) clutch (2) lever linkages.

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

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

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Transmission - Mechanical transmission

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

NDIL14TR00325AB

NDIL14TR00326AB

10. Remove all rail pins and forks, to ease the splitting.

11. Fit lift hook (special tool number 291517) on the transmission housing and connect it to a suitable hoist. 12. Loosen the bolts and stud nuts securing transmission and rear wheel drive housings together. 13. Remove the transmission housing from rear axle housing by moving it forward sufficiently to clear the Power Take-Off (PTO) shaft and rail shafts.

NDIL14TR00327AA

NDIL14TR00328AA

14. Fix the transmission housing on a rotary stand (special tool number 270086) for further inspection and disassembly, if required.

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Transmission - Mechanical transmission

Mechanical transmission - Install â&#x20AC;&#x201C; 8 + 2 Transmission CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Reinstallation follows the removal procedure in reverse.

Before reassembling housings, support and covers, thoroughly clean and decrease mating surface and apply a 2.00 mm (0.08 in) bead of sealant as shown in the figure 1.

Tighten to correct torques as detailed in Mechanical transmission - Torque (21.114).

NDIL14TR00329GB

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Transmission - Mechanical transmission

Mechanical transmission - Remove â&#x20AC;&#x201C; 12+3 Transmission WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

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

NDIL14TR00318AA

NDIL14TR00319AB

NDIL14TR00872AB

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

3. Remove all rail pins and forks remove circlip (1) to ease the splitting and remove nut (2) to split the housing.

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Transmission - Mechanical transmission

4. Fit lift hook (special tool number 291517) on the transmission housing and connect it to a suitable hoist. 5. Loosen the bolts and stud nuts securing transmission and rear wheel drive housings together. 6. Remove the transmission housing from rear axle housing by moving it forward sufficiently to clear the Power Take-Off (PTO) shaft and rail shafts.

NDIL14TR00327AA

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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 to corbrication rect 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 misadjusted 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 - Install – 8 + 2 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Remove – 12+3 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Remove – 8 + 2 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Transmission - 21 Mechanical transmission internal components - 140

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Transmission - 21 Mechanical transmission internal components - 140

SERVICE Transmission shaft Remove – 12+3 Transmission input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install – 12+3 Transmission input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassemble – 12+3 Transmission output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble – 12+3 Transmission output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Transmission - Mechanical transmission internal components

Transmission shaft - Remove â&#x20AC;&#x201C; 12+3 Transmission input shaft 1. Loosen nuts (1) and remove oil seal cover (2). Loosen the screws (3) and remove front bearing cover (4).

NDIL14TR00337AB

NDIL14TR00873AB

NDIL14TR00874AB

NDIL14TR00875AB

2. Remove circlip lock (1).

3. Remove bearing (1).

4. Remove bearing (1).

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Transmission - Mechanical transmission internal components

5. Using mandrill (special tool number 9971348) and mallet, remove the drive shaft out of the housing by hammering gently towards the engine mounting side.

NDIL14TR00340AA

NDIL14TR00341AA

6. Retrieve the gears inside the housing. Remove the bearing from the shaft using suitable puller.

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Transmission - Mechanical transmission internal components

Transmission shaft - Install â&#x20AC;&#x201C; 12+3 Transmission input shaft 1. Re-install drive shaft in transmission housing observing the following. 2. Reassembly follows the removal procedure in reverse. 3. Refer to figure for correct orientation of the different gears, bearings and shims.

NDIL14TR00876AB

NDIL14TR00343AB

4. Install bush (1) if removed using suitable mandrill. Install new seal, if removed using suitable tool.

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Transmission - Mechanical transmission internal components

Transmission shaft - Disassemble â&#x20AC;&#x201C; 12+3 Transmission output shaft 1. Remove forks (1) and (2) for 1st/2nd and 3rd/4th gear.

NDIL14TR00883AB

NDIL14TR00884AB

NDIL14TR00885AB

NDIL14TR00886AB

2. Remove check nut with the help of socket.

3. Remove output shaft.

4. Remove all gear from the transmission housing.

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Transmission - Mechanical transmission internal components

5. Remove bearing (1) and washer (2) from output shaft.

NDIL14TR00887AB

NDIL14TR00888AB

NDIL14TR00889AB

NDIL14TR00890AB

Medium gear - removal 1. Remove cluster gear assembly (1) along with Power Take-Off (PTO) shaft (2) as shown. Take out PTO shaft from cluster gear assembly.

2. Remove washer (1) as shown in cluster gear assembly.

3. Remove bearing (1) fork H/L (2) circlip lock (3) hub H/L gear (4) and low gear (5) as shown in fig.

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Transmission - Mechanical transmission internal components

4. Remove fork (1) from gear.

NDIL14TR00891AB

5. Remove gear (1) along with needle bearings two numbers as shown with mark (2). Remove snap ring to retrieve needle roller bearings.

NDIL14TR00892AB

NDIL14TR00893AB

NDIL14TR00894AB

6. Remove washer (1) on the pinion shaft.

7. Remove circlip lock (1) on pinion shaft as shown.

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Transmission - Mechanical transmission internal components

8. Open check nut lock & remove pinion check nut (1). Using special tool number 293342 and remove the pinion shaft from the housing by hammering it out gently using suitable mandrill. Take out gear (2).

NDIL14TR00895AB

NDIL14TR00896AB

NDIL14TR00897AB

9. Remove bearing (1).

10. Remove circlip lock (1).

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Transmission - Mechanical transmission internal components

Transmission shaft - Assemble â&#x20AC;&#x201C; 12+3 Transmission output shaft Medium gear - assembly 1. Re-assembly follows the removal procedure in reverse.

Output shaft - assembly 1. Fit collar (1) and bearing (2) on the output shaft on bench.

NDIL14TR00898AB

NDIL14TR00899AB

NDIL14TR00900AB

2. Place washer (1) with collar facing collar towards bearing.

3. Place the 3rd/4th gear assembly in housing and place washer (1).

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Transmission - Mechanical transmission internal components

4. Fit 1st/2nd gears as shown.

NDIL14TR00901AA

NDIL14TR00902AB

NDIL14TR00884AB

NDIL14TR00883AB

5. Fit output shaft (1) in the gear box housing.

6. Fit bearing (1) and check nut (2) of output shaft. Tight the check nut at 30 kgm (217 ftlbs.).

7. Fit forks (1) and (2) for 1st/2nd and 3rd/4th gear.

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Index Transmission - 21 Mechanical transmission internal components - 140 Transmission shaft - Assemble – 12+3 Transmission output shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission shaft - Disassemble – 12+3 Transmission output shaft . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission shaft - Install – 12+3 Transmission input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission shaft - Remove – 12+3 Transmission input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Transmission - 21 Gearbox external controls - 126

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Transmission - 21 Gearbox external controls - 126

SERVICE Gearbox control lever Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Transmission - Gearbox external controls

Gearbox control lever - 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

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

NDIL14TR00373AB

NDIL14TR00374AB

NDIL14TR00347AB

2. Remove the roll pin (1). 3. Remove the washer (2) and spring (3). 4. Remove the roll pin (4) with the help of a suitable magnetic tool. 5. Loosen the rubber boot clamps (5). 6. Withdraw the levers from the cover plate. 7. Follow the same procedure for other lever also.

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Transmission - Gearbox external controls

Gearbox control lever - Assemble Assemble the levers in the cover plate and reinstall the cover plate on the transmission housing observing the following: 1. Inspect the rubber boot (1) for cracks or damage, replace if necessary.

NDIL14TR00375AB

2. Reinstallation follows the removal procedure in reverse, refer to Gearbox control lever - Disassemble (21.126). 3. Before fixing cover plate, thoroughly clean and decrease mating surface and apply a 2.0 mm (0.1 in) bead of sealant following the pattern shown in 2. 4. Tighten to correct torque..

NDIL14TR00376FB

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Index Transmission - 21 Gearbox external controls - 126 Gearbox control lever - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox control lever - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Transmission - 21 Gearbox internal components - 145

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Transmission - 21 Gearbox internal components - 145

SERVICE Gearbox internal components Disassemble – Range gear (epi-cyclic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Assemble – Range gear (epi-cyclic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassemble – Gear rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assemble – Gear rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassemble – 12+3 Transmission gear rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assemble – 12+3 Transmission gear rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Drive shaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Driven shaft Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Reverse gears Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Remove – 12+3 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Install – 12+3 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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Transmission - Gearbox internal components

Gearbox internal components - Disassemble â&#x20AC;&#x201C; Range gear (epi-cyclic) 1. Straighten the locking plate (1) and loosen the bolts (2) securing epi-cyclic assembly (3) on transmission housing and remove the complete assembly or first ring gear followed by planetary gear assembly.

NDIL14TR00355AB

NDIL14TR00356AB

2. Pull out the pins (1) and remove the planetary gears (2) from the carrier. Retrieve the brass washers (3).

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Transmission - Gearbox internal components

Gearbox internal components - Assemble â&#x20AC;&#x201C; Range gear (epi-cyclic) Re-assemble the range gear on transmission housing following the removal procedure in reverse. 1. Ensure for correct seating of thrust washer on dowel pin. 2. Tighten the bolts to correct torque as detailed in Mechanical transmission - Torque (21.114).

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Transmission - Gearbox internal components

Gearbox internal components - Disassemble â&#x20AC;&#x201C; Gear rails 1. Remove all rail pins (1) and forks.

NDIL14TR00326AB

NDIL14TR00348AB

NDIL14TR00349AB

NDIL14TR00350AB

NOTE: Rails can be distinguished as shown in figure. (1) I/II gear rail (2) III/IV gear rail NOTE: I/II and III/IV gear rails are similar in appearance. The only difference is that III/IV gear rail is provided with a through hole (5) to accommodate interlock capsules. (3) Reverse gear rail (4) Hi/Lo gear rail

2. Pull the 1st, 2nd and 3rd rails from the housing. 3. Remove the interlock (1) from the middle rail (2). 4. Using a screw driver push the remaining two interlocking balls after (3) removing the plug (4). NOTE: Interlocks are of different size. Two are in ball shape and other in the capsule shape.

5. Remove the high-low rail locking capsules (1) with the help of a suitable magnetic tool after removing the neutral switch.

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Transmission - Gearbox internal components

6. Remove the roll pin from rail and fork.

NDIL14TR00351AA

NDIL14TR00352AA

NDIL14TR00353AB

7. Straighten the lock-plate.

8. Remove the bracket (1) to retrieve the ball and spring (2) from the support bracket, if shifter rod is to be removed from the bracket.

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Transmission - Gearbox internal components

Gearbox internal components - Assemble â&#x20AC;&#x201C; Gear rails Reassembly follows the removal procedure in gear rail removal. 1. Press the ball as shown in the figure and fit both rails into the bracket using tool number 9971346. 2. Insert the high low rail also as explained above.

NDIL14TR00354AA

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Transmission - Gearbox internal components

Gearbox internal components - Disassemble â&#x20AC;&#x201C; 12+3 Transmission gear rails 1. Remove all rail pins (1) and gates.

NDIL14TR00903AB

NDIL14TR00904AB

2. Insert the interlocks and bolts as shown in figure. 1. 2. 3. 4. 5. 6. 7. 8.

Ball Interlock Pin Neutral safety switch 1st / 2nd rail 3rd / 4th rail Reverse rail Medium gear

3. By using the jib crane assemble the transmission housing and differential housing together.

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Transmission - Gearbox internal components

Gearbox internal components - Assemble â&#x20AC;&#x201C; 12+3 Transmission gear rails 1. Re-assembly follow the removal procedure in gear rails removal. 2. Insert the interlock and ball from the hole (1) as shown in figure.

NDIL14TR00905AB

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Transmission - Gearbox internal components

Drive shaft - 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

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. To facilitate disassembly, install the transmission housing on rotary stand (special tool number 290086) as shown.

NDIL14TR00328AA

NDIL14TR00285AB

NDIL14TR00332AB

2. Remove transmission and Power Take-Off (PTO) clutch forks locking screws (1).

3. Push out transmission and Power Take-Off (PTO) clutch forks shafts (1) and remove associated forks from the housing.

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Transmission - Gearbox internal components

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

NDIL14TR00284AB

NDIL14TR00334AB

NDIL14TR00325AB

NDIL14TR00336AB

5. Slide out both transmission and Power Take-Off (PTO) clutch release bearings (1).

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

7. Push the dowell pins and remove range gear rail shaft (1). NOTICE: Donâ&#x20AC;&#x2122;t allow the dowell pins to fall into the transmission housing while pushing down. 8. Take out the shifter forks from the transmission housing.

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Transmission - Gearbox internal components

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

NDIL14TR00337AB

NDIL14TR00338AA

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

NOTE: Before removing the drive shaft, engage two gears and slacken the driven shaft retaining nut (1).

NDIL14TR00339AB

NDIL14TR00340AA

12. Using mandrill (special tool number 9971348) and mallet, remove the drive shaft out of the housing by hammering gently towards the engine mounting side.

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Transmission - Gearbox internal components

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

NDIL14TR00341AA

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Transmission - Gearbox internal components

Drive shaft - Install Re-install drive shaft in transmission housing observing the following: 1. Reassembly follows the removal procedure in reverse. 2. Refer to figure for correct orientation of the different gears, bearings and shims.

NDIL14TR00342AA

NDIL14TR00343AB

NDIL14TR00344AB

NDIL14TR00338AA

3. Install bush (1) if removed using suitable mandrill. 4. Install new seal, if removed using suitable tool.

5. Mount the front oil seal cover (1) complete with gasket/ sealants, making sure that the rear bearing is in perfect alignment. NOTE: Check oil seal for damage before mounting front cover.

6. Select required shim thickness to reduce the end float of the gear and bearing assembly to a minimum. Then mount the corresponding circlip.

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Transmission - Gearbox internal components

7. By shifting the sliding sleeves and inserting two speeds at the same time/torque nut (1) to prescribed torque, lock the nut by punching locking plate and fit the front bearing cover plate with gasket.

NDIL14TR00339AB

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Transmission - Gearbox internal components

Driven shaft - Disassemble Driven gears and shaft 1. Remove range gear assembly from the housing as described earlier.

NDIL14TR00357AA

NDIL14TR00363AA

NDIL14TR00364AA

NDIL14TR00365AB

2. Remove drive shaft from the housing and retrieve gears.

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

4. Remove nut (1).

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Transmission - Gearbox internal components

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

NDIL14TR00366AA

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Transmission - Gearbox internal components

Driven shaft - Inspect Driven gears and shaft 1. Check synchromesh assembly, spring, ball and cage for damage and wear. If necessary, replace. 2. Check the bearings and bushes, if replacement is required, remove the bearing from their seats using suitable pullers. 3. 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.

NDIL14TR00367AA

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Transmission - Gearbox internal components

Driven shaft - Assemble Driven gears and shaft Refer to the figures on the following page and assemble the following: The 3rd / 4th synchromesh: 1. Insert the toothed sector (1) into the baulk ring, matching the cuts of ring and sector.

NDIL14TR00368AA

NDIL14TR00369AB

NDIL14TR00370AB

2. Put the cage on the slotted hole, followed by a spring (1).

3. Press the ball (1) with the help of a screw driver (2). 4. Insert toothed sector partially into the ring. 5. Repeat the same procedure for other cages, springs and balls and then insert completely.

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Transmission - Gearbox internal components

6. Put the synchro cone on to the synchronizer ring (1) and pick up the gear (2) and place it inside the ring.

NDIL14TR00371AB

NDIL14TR00372AB

7. Install the driven shaft, associated gears after complete synchromesh unit.

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Transmission - Gearbox internal components

Reverse gears - Disassemble 1. Remove the range gear assembly.

NDIL14TR00357AA

NDIL14TR00358AB

NDIL14TR00359AB

NDIL14TR00360AB

2. Using special tool number 9971347, remove reverse gear shaft (1) with outer ball bearing.

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

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

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Transmission - Gearbox internal components

6. Using special tool number 292909 and with sliding hammer (special tool number 292907) remove reverse gear shaft needle bearing from the housing.

NDIL14TR00361AA

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Transmission - Gearbox internal components

Reverse gears - Assemble Reinstall reverse gear shaft in transmission housing, following the removal procedure in reverse.

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Transmission - Gearbox internal components

Reverse gears - Remove â&#x20AC;&#x201C; 12+3 Transmission 1. Remove reverse fork (1).

NDIL14TR00877AB

NDIL14TR00878AB

NDIL14TR00879AB

NDIL14TR00880AB

2. Remove circlip lock.

3. Remove bearing (1).

4. Remove reverse gear complete assembly.

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Transmission - Gearbox internal components

5. Remove needle bearing (1) from housing. Using special tool number 292900 and sliding hammer special tool number 292907. 6. Remove complete reverse gear subassembly.

NDIL14TR00881AB

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Transmission - Gearbox internal components

Reverse gears - Install â&#x20AC;&#x201C; 12+3 Transmission 1. Re-install all the components of reverse gear sub-assembly. 2. Check gears and needle roller bearings for defect. If found defect replace with new one.

NDIL14TR00882AB

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Index Transmission - 21 Gearbox internal components - 145 Drive shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driven shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driven shaft - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driven shaft - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox internal components - Assemble – 12+3 Transmission gear rails . . . . . . . . . . . . . . . . . . . . .

Gearbox internal components - Assemble – Gear rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox internal components - Assemble – Range gear (epi-cyclic) . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox internal components - Disassemble – 12+3 Transmission gear rails . . . . . . . . . . . . . . . . . .

Gearbox internal components - Disassemble – Gear rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox internal components - Disassemble – Range gear (epi-cyclic) . . . . . . . . . . . . . . . . . . . . . . .

Reverse gears - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reverse gears - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reverse gears - Install – 12+3 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reverse gears - Remove – 12+3 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47899733 23/06/2015 EN

SERVICE MANUAL Four-Wheel Drive (4WD) system TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

47899733 23/06/2015

Contents Four-Wheel Drive (4WD) system - 23

[23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1

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Four-Wheel Drive (4WD) system - 23 Drive shaft - 314

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Four-Wheel Drive (4WD) system - 23 Drive shaft - 314

TECHNICAL DATA Drive shaft General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Drive shaft Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Drive shaft Disassemble – Transmission shafts and guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble – Transmission shafts and guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove – Drive gear housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install – Drive gear housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assemble – Transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble – Transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - General specification Reduction ratio Relay lever pad width Pad seat width in driven gear Pad clearance in seat Relay lever pivot diameter Pivot housing bore in casing Pivot clearance in housing Relay lever detent spring length • Free • Under 178.2 – 197.8 N (40.1 – 44.5 lb)

34/24x24/34 = 1:1 7.978 – 8.000 mm (0.314 – 0.315 in) 8.280 – 8.370 mm (0.326 – 0.330 in) 0.280 – 0.460 mm (0.011 – 0.018 in) 15.973 – 16.000 mm (0.628 – 0.630 in) 16.016 – 16.059 mm (0.631 – 0.632 in) 0.016 – 0.086 mm (0.001 – 0.003 in) 130.000 mm (5.118 in) 142.500 mm (5.610 in)

Drive shaft Front drive sleeve shim thickness

2.200 mm (0.087 in) - 2.500 mm (0.098 in) - 2.800 mm (0.110 in) - 3.000 mm (0.118 in) - 3.300 mm (0.130 in) 3.700 mm (0.146 in) - 4.000 mm (0.157 in) - 4.300 mm (0.169 in)

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Torque

NDIL14TR00377GB

Part to be torqued Transmission shaft central support retaining bolt (C12) Drive gear housing retaining bolt (C13)

Thread

Torque setting

M12 X 1.5

98 N·m (867 lb in)

M12 X 1.25

98 N·m (867 lb in)

Drive shaft - Special tools Tool description Drive shaft seal key

Tool number 293836

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Sectional view

NDIL14TR00378GB

C12 C13 X 1. 2. 3. 4. 5. 6. 10. 11.

Drive shaft centre bearing bolt Axle drive housing bolt On assembly, thoroughly clean and degrease mating surface X Brake driven discs Brake linings Brake shoe Driven gear Intermediate gear Needle roller bearing Driven shaft Guide screws

12. 22. 23.

Four - wheel drive engagement sleeve Dentent plunger Roll pin

26. 27. 28. 29. 30. 39. 56.

Intermediate shaft Dust excluder Seal Retaining ring Splined driven shaft Drive shaft guard Centre bearing

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Disassemble â&#x20AC;&#x201C; Transmission shafts and guard 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

To remove, proceed as follows: 1. Disconnect the negative battery lead (1).

NDIL14TR00379AB

NDIL14TR00380AB

2. Remove the front, centre and rear screws securing the front axle prop shaft guard and remove the guard (1). 3. Remove circlip (2) and move sleeve (1) in the direction shown by the arrow to disengage it from the splined shaft of the front axle.

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Assemble – Transmission shafts and guard 1. To re-fit the transmission shaft and guard, proceed as follows: WARNING Use suitable tools to align holes. Never use fingers or hands. 2. Fit and secure the transmission shaft in position. NOTE: Move the front splined sleeve (27) against retaining ring (28). Using a feeler gauge, measure gap between the sleeve and the retaining ring (26) and install shim (S5) to obtain sleeve end play (L) of 1.0000 – 1.5000 mm (0.0394 – 0.0591 in).

NDIL14TR00381AB

3. Fit and secure the guard.

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Remove â&#x20AC;&#x201C; Drive gear housing 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

To remove, proceed as follows: 1. Refer to Drive shaft - Disassemble (23.314) and carry out transmission shafts and guard removal. 2. Remove the plug (1) and drain the oil from the transmission box/gearbox.

NDIL14TR00382AB

NDIL14TR00383AA

NDIL14TR00384AB

3. Detach the drive gear engagement control lever (1).

4. Remove the screws (1) that hold the drive gear housing (transfer box) to the transmission housing. 5. Remove the drive gear housing from the transmission housing.

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Install – Drive gear housing 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. To re-fit the drive gear housing, proceed as follows: • Refer to the tightening torques. • Carefully clean the contact surfaces. 2.000 mm • Apply sealing compound (approx. (0.079 in) wide strip) to the contact surface of the drive gear housing. • Fit the drive gear housing to the transmission housing. • Connect the drive gear engagement control lever • Replace the transmission oil drain plug. • Refer to Drive shaft - Assemble (23.314) and carry out transmission shafts and guard installation. • Fit the drive shaft guard.

NDIL14TR00385BA

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Assemble â&#x20AC;&#x201C; Transfer box 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. To refit the transfer box, proceed as follows. WARNING Use suitable tools to align holes. Never use fingers or hands.

NDIL14TR00389AA

NDIL14TR00390AA

2. Insert the shaft in the housing, then assemble the gear unit, washer and circlip. Fit the internal lever the external lever, the coupling pad and secure in position by means of the washer and relative circlip. Fit the bearing and relative circlips. Using tool 293836, fit the seal and dust ring (use the spacer to fit the dust ring ). Refer to Drive shaft - Install (23.314) and carry out drive gear housing removal. Refer to Drive shaft - Disassemble (23.314) and carry out transmission shafts and guard removal.

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Disassemble â&#x20AC;&#x201C; Transfer box With the transfer box on the bench, proceed as follows: 1. Refer to Drive shaft - Disassemble (23.314) and carry out transmission shafts and guard removal. 2. Refer to Drive shaft - Remove (23.314) and carry out drive gear housing removal.

NDIL14TR00386AA

NDIL14TR00387AB

NDIL14TR00388AB

3. Use the special punch to withdraw the snap ring (1), then the pin (2). Remove the roller bearing, the spacer, the thrust washers and the intermediate gear (3). 4. Remove the parking brake control lever.

5. Use a screwdriver to remove the dust ring (1). 6. Remove the splined driven shaft, complete with parts, parking brake discs and the driven gear.

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Index Four-Wheel Drive (4WD) system - 23 Drive shaft - 314 Drive shaft - Assemble – Transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft - Assemble – Transmission shafts and guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft - Disassemble – Transfer box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft - Disassemble – Transmission shafts and guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft - Install – Drive gear housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft - Remove – Drive gear housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47899733 23/06/2015 EN

SERVICE MANUAL Front axle system TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

47899733 23/06/2015

Contents Front axle system - 25

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

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Front axle system - 25 Non-powered front axle - 400

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Front axle system - 25 Non-powered front axle - 400

TECHNICAL DATA Non-powered front axle General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Non-powered front axle Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Non-powered front axle Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Axle wheel hub Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

DIAGNOSTIC Non-powered front axle Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Front axle system - Non-powered front axle

Non-powered front axle - General specification Centrally pivoted U -type centre beam with telescopic outer sections.

Type Track settings

1390 mm (55 in) - 1490 mm (59 in) - 1590 mm (63 in) 1690 mm (67 in) - 1790 mm (70 in) - 1890 mm (74 in) 2629 mm (104 in) - 1510 mm (59 in) - 1610 mm (63 in) - 1710 mm (67 in) - 1810 mm (71 in) - 1910 mm (75 in) 2° corresponding to approx. 15.00 mm (0.59 in) with 406.40 mm (16.00 in) rims 0.000 – 5.000 mm (0.000 – 0.197 in)

TT75 TT55 Wheel chamber Wheel toe-in

Swivel pin assembly Swivel pin (3) diameter at the bushes Press-fit bush (4) inner diameter Swivel pin to bush clearance

37.960 – 38.000 mm (1.494 – 1.496 in) 38.050 – 38.140 mm (1.498 – 1.502 in) 0.050 – 0.179 mm (0.002 – 0.007 in)

Axle pivot pin assembly Pivot pin (9) diameter Press-fit bush (4) inner diameter Pivot pin to bush clearance Thrust washer thickness (bronze) TT75 TT55 Steel washer thickness

37.960 – 38.000 mm (1.494 – 1.496 in) 38.050 – 38.140 mm (1.498 – 1.502 in) 0.050 – 0.179 mm (0.002 – 0.007 in) 3.935 – 4.065 mm (0.155 – 0.160 in) 3.935 – 4.000 mm (0.155 – 0.157 in) 3.925 – 4.000 mm (0.155 – 0.157 in)

Non-powered front axle - General specification Centrally pivoted U -type centre beam with telescopic outer sections.

Type Track settings

TT75 TT55 Wheel chamber Wheel toe-in

Swivel pin assembly Swivel pin (3) diameter at the bushes Press-fit bush (4) inner diameter Swivel pin to bush clearance

37.960 – 38.000 mm (1.494 – 1.496 in) 38.050 – 38.140 mm (1.498 – 1.502 in) 0.050 – 0.179 mm (0.002 – 0.007 in)

Axle pivot pin assembly Pivot pin (9) diameter Press-fit bush (4) inner diameter Pivot pin to bush clearance Thrust washer thickness (bronze) Steel washer thickness

37.960 – 38.000 mm (1.494 – 1.496 in) 38.050 – 38.140 mm (1.498 – 1.502 in) 0.050 – 0.179 mm (0.002 – 0.007 in) 3.935 – 4.000 mm (0.155 – 0.157 in) 3.925 – 4.000 mm (0.155 – 0.157 in)

Non-powered front axle - Torque Description Bolt, front axle carrier to engine (C1) Bolt, axle pivot (C2) Bolt, wheel to hub (C3) Nut, track/drag link, ball joint (C4)

Thread size M18 X 1.5 M10 X 1.25 M18 X 1.5 M14 X 1.5 47899733 23/06/2015

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Torque 320 N·m (236 lb ft) 60 N·m (44 lb ft) 320 N·m (236 lb ft) 100 N·m (74 lb ft)

Front axle system - Non-powered front axle

Description Nut, right-hand side and left-hand side control lever (C5) Axle extension securing bolts (C6)

Thread size

Torque

M14 X 1.5

150 N·m (111 lb ft)

M16 X 1.5

118 N·m (87 lb ft)

NDIL14TR00790GB

Non-powered front axle - Special tools Tool description Slide hammer for centre pin Adopter for slide hammer

Tool number 292927 290793

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Front axle system - Non-powered front axle

Non-powered front axle - Sealing Operation description Front wheel hub sleeve King pin thrust washer

Specification LOCTITE® 638™ LOCTITE® 638™

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Front axle system - Non-powered front axle

Non-powered front axle - Overview The front axle is composed of a reversed U type centre beam (2) with telescopic sections (1) at each end. A number of holes at 50.00 mm (2.00 in) intervals are provided in the telescopic sections for track width adjustment purpose. Adjustment of the front wheel track width is affected by extending or retracting both ends of the axle equally. The centre beam is attached to the front axle carrier by means of a single pivot which allows oscillation on both sides. The front axle is controlled by power/manual steering through swivel pin control lever. The two swivel pins are connected by telescopic track control rod, which contain adjustment for toe-in.

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Front axle system - Non-powered front axle

Non-powered front axle - Sectional view

NDIL14TR00919FB

NDIL14TR00920FB

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Front axle system - Non-powered front axle

1. 2. 3.

Grease fitting Axle pivot bushings Axle pivot pin

4. 5. 6.

Front axle carrier Seal Thrust washer

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Front axle system - Non-powered front axle

NDIL14TR00792GB

1. 2. 3. 4.

Seal assembly Seal assembly Thrust washer Thrust washer

5. 6. 7.

Dust cover seal collar Dust cover seal lower Dust cover seal upper

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Front axle system - Non-powered front axle

NDIL14TR00793FB

1. 2. 3.

Bearing inner Bearing outer Hub cap

4. 5. 6.

Hexagonal nut Washer O-ring

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Front axle system - Non-powered front axle

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

Remove the front axle assembly from the tractor as follows: 1. Open and raise front hood. 2. Disconnect the negative cable (1) from the battery and insulate.

NDIL14TR00794AB

NDIL14TR00795AB

NDIL14TR00796AB

3. Safely block rear wheels. 4. Remove front weights (1) and weight support (2), where fitted.

5. Jack up front tractor and place a stationary stand (1) under the engine sump.

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Front axle system - Non-powered front axle

6. Loosen retaining bolts (1) and remove the front wheels.

NDIL14TR00797AB

NDIL14TR00798AB

NDIL14TR00799AB

NDIL14TR00800AB

7. Remove knuckle joint nut (1) and disconnect drag link (2) from control lever.

8. In case of power steering model, remove hydraulic cylinder (1) by loosening nuts (2) and (3).

9. Remove the axle pivot pin locking bolt (1).

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Front axle system - Non-powered front axle

10. Using a slide puller (special tool number 292927) with adopter (special tool number 290793) withdraw the pivot pin (1) and recover thrust washers and shims provided between axle carrier and centre beam. 11. Remove front axle from tractor using a suitable hoist.

NDIL14TR00801AB

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Front axle system - Non-powered front axle

Non-powered front axle - Install Reinstall the front axle assembly to carrier observing the following: 1. Reassembly follows disassembly procedure in reverse, refer to Non-powered front axle - Remove (25.400). WARNING Always use suitable tools to align holes. Do not use hands or fingers. 2. Check the pivot pin play. It should not exceed 0.25 mm (0.01 in). If play is more, add shims between axle carrier and centre beam. 3. Check for correct toe-in setting. 4. Tighten all fasteners to correct torques. Refer to Nonpowered front axle - Torque (25.400).

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Front axle system - Non-powered front axle

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

Swivel pins can be removed and overhauled with the front axle on the tractor proceed as follows for each wheel: 1. Safely block rear wheels. 2. Jack up front tractor and place a stationary stand (1) under the sump.

NDIL14TR00813AB

NDIL14TR00814AA

NDIL14TR00815AB

3. Loosen retaining bolts and remove front wheels.

4. Remove swivel pin control lever retaining bolt (1). 5. Slide out the control lever (2) from the spindle assembly.

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Front axle system - Non-powered front axle

6. Pull out the swivel axle and hub assembly (1) from axle outer section.

NDIL14TR00816AB

NDIL14TR00817AB

NDIL14TR00818AB

7. Remove the axle outer section (1) attaching bolts.

8. Remove the axle outer section (1).

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Front axle system - Non-powered front axle

Axle wheel hub - Overhaul 1. Fix the axle outer section in a vice and remove the upper seal using suitable tool.

NDIL14TR00819AA

NDIL14TR00820AA

2. Remove the bottom seal using suitable tool and recover thrust washer. 3. Check the swivel bearing bushes for wear. See specifications in Non-powered front axle - General specification (25.400). If bushes require replacement, remove the bushes using suitable tool. 4. Using a suitable drift install new bushings on the axle outer section. 5. Check the swivel pin for wear. If required replace new spindle. 6. Ream the new bushings to suit the swivel pin.

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Front axle system - Non-powered front axle

Axle wheel hub - Install Reinstall the spindle assembly to the front axle following the disassembly procedure in reverse. NOTE: Ensure that the slot (1) in the thrust washer fits on the notch provided on the axle outer section.

NDIL14TR00821AB

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Front axle system - Non-powered front axle

Non-powered front axle - Troubleshooting Problem Premature tire wear

Possible Cause Wrong inflation pressure

Wrong front wheel toe-in Poor tractor stability

Wrong inflation pressure

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Correction Inflate tires to correct pressure refer to values suggested in the operatorâ&#x20AC;&#x2122;s manual. Always comply with values specified by the tire manufacture Adjust toe-in (refer the procedure dealt in this section or adjustment) Inflate tires to correct pressure

Index Front axle system - 25 Non-powered front axle - 400 Axle wheel hub - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle wheel hub - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle wheel hub - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Front axle system - 25 Powered front axle - 100

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Front axle system - 25 Powered front axle - 100

TECHNICAL DATA Four-Wheel Drive (4WD) axle General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Four-Wheel Drive (4WD) axle Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Four-Wheel Drive (4WD) axle Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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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

9/38 = 1:4.2 0.150 – 0.200 mm (0.006 – 0.008 in) 1.386

Bevel drive and differential 2.500 mm (0.098 in) - 2.550 mm (0.100 in) - 2.600 mm (0.102 in) - 2.650 mm (0.104 in) - 2.700 mm (0.106 in) 2.750 mm (0.108 in) - 2.800 mm (0.110 in) - 2.850 mm (0.112 in) - 2.900 mm (0.114 in) - 2.950 mm (0.116 in) 3.000 mm (0.118 in) - 3.050 mm (0.120 in) - 3.100 mm (0.122 in) - 3.150 mm (0.124 in) - 3.200 mm (0.126 in) 3.300 mm (0.130 in) - 3.400 mm (0.134 in) - 3.450 mm (0.136 in) - 3.500 mm (0.138 in) - 3.550 mm (0.140 in) 3.600 mm (0.142 in) - 3.650 mm (0.144 in) - 3.700 mm (0.146 in) 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

0.15 mm (0.01 in) 1.470 – 1.530 mm (0.058 – 0.060 in) 1.500 – 1.600 mm (0.059 – 0.063 in) 21.939 – 21.960 mm (0.864 – 0.865 in) 22.040 – 22.061 mm (0.868 – 0.869 in) 0.080 – 0.122 mm (0.003 – 0.005 in) 37.961 – 38.000 mm (1.495 – 1.496 in) 38.080 – 38.119 mm (1.499 – 1.501 in) 0.080 – 0.158 mm (0.003 – 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

29.914 – 29.935 mm (1.178 – 1.179 in) 30.050 – 30.105 mm (1.183 – 1.185 in) 0.115 – 0.191 mm (0.005 – 0.008 in) 0.064 – 0.013 mm (0.003 – 0.001 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

15.0 mm (0.6 in) :( 19.0 mm (0.7 in) + 54.0 mm (2.1 in)) = 1:4.87 0.770 – 0.830 mm (0.030 – 0.033 in)

Axle pivot Pivotting angle (on either side ) Centre pivot and support end float 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

11° 0.30 – 1.10 mm (0.01 – 0.04 in) 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) 0.049 – 0.138 mm (0.002 – 0.005 in) 99.040 – 99.720 mm (3.899 – 3.926 in) 99.146 – 99.221 mm (3.903 – 3.906 in)

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Front axle system - Powered front axle

Spigot fitted clearance in bushing Axle front and rear thrust washer thickness

0.074 – 0.181 mm (0.003 – 0.007 in) 4.95 – 5.00 mm (0.19 – 0.20 in)

Turning radius Live axle in brakes off (75 HP Models) : 5400 mm (213 in) Live axle in brakes off (55 HP models) : 4800 mm (189 in)

Four-Wheel Drive (4WD) axle - Special tools WARNING The tools marked below are essential for the operations described in this section. To work in safety and obtain the best results whilst saving time and energy, these essential tools should be supplemented by the specific tools listed below and other tools which are to be made from the drawings provided in this manual. List of specific tools required for the various operations described in this section. Tool description Front axle overhaul stand Overhaul support for front axle differential casing Pinion bearing adjustment tool Pinion ring nut wrench Wrench for front differential case bearing adjustment nut Wheel hub ring nut wrench Mounting distance tool Pinion locking tool Idler gear pin removal tool

Tool number 293460 9971257 9971258 9971259 9971260 9971261 9971262 9971263 9971264

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) Steering knuckle bolt (C5) Wheel hub bearings lock nut (C6) Bolt, planetary final drive housing (C7) Bolt, wheel disc to hub (C8) Nut for rim to disc securing bolt Front axle front and rear pivot support bolt (C9) Differential cage support cap bolt (C10) Front axle support to engine retaining bolt (C11)

Thread M35X1.5 M12 X 1.25 M12 X 1.25 M12 X 1.25 M12 X 1.25 M45 X 1.5 M10 X 1.25 M16 X 1.5 M14 X 1.5

Tightening torque 294 N·m (217 lb ft) 113 N·m (83 lb ft) 113 N·m (83 lb ft) 64 N·m (47 lb ft) 64 N·m (47 lb ft) 147 N·m (108 lb ft) 64 N·m (47 lb ft) 260 N·m (192 lb ft) 245 N·m (181 lb ft)

M18 X 1.5

314 N·m (232 lb ft)

M12 X 1.25

113 N·m (83 lb ft)

M18 X 1.5

314 N·m (232 lb ft)

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Front axle system - Powered front axle

NDIL14TR00391GB

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Sectional view

NDIL14TR00392GB

Front axle differential X S1 S2 C1 C2 C3 Gd, Gs 1. 2. 3.

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 lock ring Differential carrier bolt Ring gear bolt Right-hand side and left-hand side differential bearing lock ring Bevel pinion Seal Bevel pinion bearing spacer

4. 5. 6. 7. 8. 60.

Ring gear Axle shaft with universal joint Side gear washers Differential pinion washers Differential pinion journal bolt Side gear

61.

Side gear

62. 63.

Differential pinion Differential pinion journal

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Sectional view

NDIL14TR00393GB

Front axle steering knuckle and hub S3 S4 C4 C5 C6 C7 C8 9. 10.

King pin bearing shim Wheel hub bearing shims King pin bearing bolt Steering knuckle bolt Wheel hub bearing lock ring Final drive housing bolt Wheel hub bolt Bearing carrier bolt Seal

11. 12. 13. 14. 15 16. 17. 18. 19.

King pin bearing Seal Seal Axsule shaft bushing Spacer Thrust washers Planet wheel journals Planet wheel shims Sun gear

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Sectional view

NDIL14TR00394FB

Front axle pivot H L S5 C9 C10 C11 20. 21. 22.

1.000 mm (0.039 in) 1.000 – 1.500 mm (0.039 – 0.059 in) Sleeve position shim Axle pivot support bolt Differential bearing cap bolt Bolt securing front axle support to engine Front axle pivot support Front bushing Front thrust washer

23 24. 25. 26. 27. 28. 29. 30.

Rear thrust washer Rear bushing Rear axle pivot support Retaining rings Front splined sleeve Retaining rings Drive shaft guard Drive shaft

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Overview Tractor models have a centrally pivoting front axle with the pivot and the drive shaft coaxial with the longitudinal axis of the tractor. The drive shaft has no universal joints. The differential has two 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 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

NOTE: The front axle assembly can be removed from the tractor either with or without previously removing the drive shaft. The description below refers to removal of the front axle with the drive shaft installed on the tractor. 1. Disconnect the negative battery lead (1).

NDIL14TR00395AB

NDIL14TR00396AB

NDIL14TR00397AB

2. Attach nylon slings to the front weights (1). Loosen the locking screw from each weight, lift the weights clear of the tractor and place them in a safe position.

3. Unscrew bolts (1) and remove the drive shaft guard (2).

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Front axle system - Powered front axle

4. Remove the circlip (1) from the front of the drive shaft. Slide the sleeve rearwards and detach the drive shaft from the front axle.

NDIL14TR00398AB

NDIL14TR00399AA

NDIL14TR00400AA

NDIL14TR00401AA

5. Pass two nylon slings around the front axle and attach them to a hoist.

6. Lift the tractor with the hoist and place a stand under the sump pan.

7. Unscrew unions (1) of the rigid pipes to the power steering cylinders and detach the two flexible hoses.

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Front axle system - Powered front axle

8. Unscrew the wheel bolts and remove the front wheels.

NDIL14TR00402AA

NDIL14TR00403AB

9. Unscrew the front axle rear support retaining bolts (1).

10. Unscrew the front axle front support retaining bolts (1).

NDIL14TR00404AA

NDIL14TR00405AA

11. Using a hoist and two nylon cables (one for each side) detach the front axle from the tractor.

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Install WARNING Always use appropriate tools to align fixing holes. Never use your fingers or hands. Refit the front axle following the instructions below. • Refit the axle and bolt the front and rear supports in position. • Reconnect the power steering pipes. • Fit the front wheels. • Raise the front of the tractor using the hoist. • Remove the fixed stand. • Detach the nylon cables. • Reconnect the drive shaft and refit the drive shaft guard. • Refit the two front mudguards. • Attach a nylon cable to the front weights, lift, refit to the tractor and secure with the locking screws. • Reconnect the negative battery lead. • Adhere to the tightening torques.

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - 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. Unscrew the drain plug and drain the oil from the axle casing. 2. Remove the planetary final drive housing (1) complete with planet wheels. 3. Remove sun gear (2). 4. Remove planetary final drive ring gear-fixed gear unit , slacken lock ring using wrench 293837 and removing assembly from knuckle. 5. Remove wheel hub (6) with taper roller bearing cups (7) and associated seal. Be careful to prevent seal damage. NDIL14TR00406AB

NDIL14TR00407AB

NDIL14TR00408AB

6. Remove steering knuckle (10) with wheel hub support. 7. Remove articulated axle shaft (9) with bearing housing. Back off the bolt before withdrawing the axle shaft. 8. Replace worn bearings using suitable punches and universal pullers. Check seal efficiency.

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Install • Before installing the final drive housing (1) thoroughly clean and degrease mating surfaces and apply 2.00 mm (0.08 in) of seaing compound. • Insert articulated axle shaft (9) in axle case and install steering knuckle carrier (8). • Adjust king pin bearing pre-load as directed in the appropriate section. • Adjust wheel hub bearing pre-load as directed in the appropriate section. • Fill wheel hubs and differential-level drive housing with the specified oil. NDIL14TR00409AB

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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 - 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

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Front axle system - 25 Front bevel gear set and differential - 102

SERVICE Front bevel gear set and differential Adjust – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Differential Overhaul – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Overhaul – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Limited slip differential Overhaul – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Adjust â&#x20AC;&#x201C; 4WD WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

1. Install the bevel pinion bearing cones (7) and (9) with spacer (8) on tool 293438 (E) with centralizer (G). 2. Fully tighten tool nut (M).

NDIL14TR00417AB

NDIL14TR00418AB

NDIL14TR00419AB

3. Measure dimension (H4) between the tool pin end and top face.

4. Remove the bearing cones and spacer from the tool. Lubricate bearings with engine oil and re-install onto the tool, inserting differential carrier (10) with bearing cups. 5. Fully tighten tool nut (M) while rotating the differential carrier through ten revolutions to settle the bearings. 6. Measure dimension (H3) of the tool in this condition.

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Front axle system - Front bevel gear set and differential

7. Thickness of shims (S1) will be given by: S1= H3 - H4 + 0.1000 mm (0.0039 in) If necessary, round off (S1) to the nearest 0.0500 mm (0.0020 in). NOTE: On completing the adjustment, do not remove the adjustment tool from the bevel drive-differential housing. Leave in place for adjustment of the drive pinion position.

NDIL14TR00420AB

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Front axle system - Front bevel gear set and differential

Bevel drive adjustments Determining the thickness of the drive pinion position adjustment shim. Proceed as follows. 1. Position the differential bearing caps on the shaft (P) of tool 293400 with cones (R). Install caps in differential carrier, tightening bolts (C10) to 113.00 NÂˇm (1000.13 lb in). 2. Tighten or back off tool cones (R) to position 100.00 mm (3.94 in) spindle (L) over the bearing cone (11) and eliminate clearance between cones (R) and the differential bearing caps.

NDIL14TR00421AB

NDIL14TR00422AB

3. Turn the micrometer depth gauge (N) to bring spindle (L) into contact with the bearing cone (11) and measure dimension (H7). H7 = H6 Âą C where: H6 = Nominal distance from ring gear centre line to pinion larger end. â&#x20AC;˘ 100.00 mm (3.94 in).

C = a correction value stamped on the pinion preceded by a + or - sign (if other than 0). This value to be added to or subtracted from the nominal distance (H6) according to the sign. 4. (H7) is the nominal distance from the ring gear centre line to the back of the bearing. 5. The thickness of the adjustment shim (S2) will be given by: S2 = H5 - H7 where: H5 = The distance measured using the micrometer. H7 = Corrected nominal distance between the crown wheel axis and the large diameter base of the pinion.

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Front axle system - Front bevel gear set and differential

Examples Example 1: • Distance measured using 103.3000 mm (4.0669 in).

micrometer

• Nominal distance between crown wheel axis and large diameter base of pinion H6 = 100.0000 mm (3.9370 in). • Correction value C = + 0.2000 mm (0.0079 in). • Corrected nominal distance H7 = 100.2000 mm (3.9449 in). • Thickness of adjustment shim S2 = 103.300 mm (4.067 in) - 100.200 mm (3.945 in) = 3.100 mm (0.122 in). Example 2: • Distance measured 103.3 mm (4.1 in)

using

micrometer

• Nominal distance between crown wheel axis and large diameter base of pinion H6 = 100 mm (4 in). • Correction value C = 0.200 mm (0.008 in) • Corrected nominal distance H7 = 100.000 mm (3.937 in) - 0.200 mm (0.008 in) = 99.800 mm (3.929 in). • Thickness of adjustment shim S2 = 103.300 mm (4.067 in) - 99.800 mm (3.929 in) = 3.500 mm (0.138 in). Example 3: • Distance measured 103.3 mm (4.1 in)

using

micrometer

• Nominal distance between crown wheel axis and large diameter base of pinion H6 = 100 mm (4 in) • Correction value C = 0.200 mm (0.008 in) • Corrected nominal distance H7 = H6 = 100 mm (4 in) • Thickness of adjustment shim S2 = 103.300 mm (4.067 in) - 100.000 mm (3.937 in) = 3.300 mm (0.130 in).

Bevel drive adjustments Adjustment of the crown wheel bearings and checking the backlash between the pinion and crown wheel.

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Front axle system - Front bevel gear set and differential

1. Install the bevel pinion with all parts (less seal 2) but including shims into the differential carrier. 2. Lock the wrench 293524/1 (A) onto the pinion shaft using screws (1). Check that the torque required to rotate the shaft is 0.000 – 0.200 N·m (0.000 – 1.770 lb in).

NDIL14TR00423AB

NDIL14TR00424AB

NDIL14TR00425AB

3. Lubricate the bearings with engine oil and tighten the lock ring (C1) to 294.00 N·m (2602.12 lb in) using wrench 293524/1. 4. Measure the torque using correct torque wrench (C). Ignore the initial torque reading.

NOTE: This revolving torque is applicable only to pinions installed without a seal. When the seal is fitted, this torque should be = 0.5 N·m (0.4 lb ft) . These torques may be measured using a spring balance and a string wound around the ring nut wrench 293520/2 or 293524/1. When pinions are fitted with seals,a balance reading of 22 N (5 lb) should be obtained. 5. Install the differential unit in the carrier ensuring that ring gear is not forced onto the pinion. Tighten screws (C10) to 59 N·m (44 lb ft) then slacken and retighten to 20 N·m (15 lb ft). 6. Lubricate ring gear bearings, rotate the bevel drive and tighten the differential bearing lock ring (GS). At the same time, using wrench 293544. Check that the torque is 39 – 59 N·m (29 – 44 lb ft) to establish the specified axial pre- load.

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Front axle system - Front bevel gear set and differential

7. Measure bevel drive backlash using a dial gauge positioned at right angles to a bevel gear tooth. 8. Repeat the measurement at two other equi-spaced points, 120° apart. Compare the average of the three readings with the specified backlash of 0.150 – 0.200 mm (0.006 – 0.008 in) (average 0.180 mm (0.007 in)).

NDIL14TR00426AB

NDIL14TR00427AB

NDIL14TR00428AB

NDIL14TR00429AB

If bevel drive blacklash is not within the specified tolerance range, back off one lock ring and tighten the other by exactly the same amount to restore axial pre-load and obtain the specified backlash. In these conditions, pinion and differential bearing revolving torque, measured in the same conditions as pinion torque, must be: A2 = A1 + 1.00 – 1.50 N·m (8.85 – 13.28 lb in)) where: A2 = pinion-crown wheel rolling resistance torque A1 = rolling resistance torque of pinion only, as measured previously.

9. 0.000 – 0.200 N·m (0.000 – 0.148 lb ft) with pinion installed without seal. 10. 0.500 N·m (0.369 lb ft) with pinion installed with seal. 11. 1.00 – 15.00 N·m (0.74 – 11.06 lb ft) - ring gear rotating torque measured at the pinion.

NOTE: Should it be required to determine the revolving torque of the pinion/ring gear assy using the spring balance and string method on wrench 293524/1, the balance force reading should be: F2 = F1 + F3 Where: F2 = Pinion/ring gear assembly revolving torque determined by spring balance/string method. F2 =Revolving torque for pinion alone, as measured earlier by balance/string method, namely:

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Front axle system - Front bevel gear set and differential

• 0.000 – 0.600 N (0.000 – 0.135 lb) pinions not fitted with seal. • 16 N (4 lb) pinions fitted with seal.

NDIL14TR00430FB

F3 = 29 – 43 N (7 – 10 lb) (revolving torque for ring gear alone measured at pinion end using balance/string method). 12. Finally, tighten the cap retaining screws (C10) to 113 N·m (83 lb ft) and secure the lock ring with the lock plate. If the plate does not correspond with the notches, tighten the lock ring further until the notches align. Mastic application diagram for assembly of bevel drive unit and epicyclic final drive unit.

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Front axle system - Front bevel gear set and differential

Differential - Overhaul â&#x20AC;&#x201C; 4WD When overhauling the differential assembly it is necessary to adjust the backlash between the teeth of the planet pinions and the side gears. Proceed as follows: 1. Thoroughly clean the components of the differential to remove any traces of oil which would otherwise prevent accurate backlash measurement. 2. Install the two side gears without thrust washers. 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. 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 (0.01 in). Therefore the shims to be inserted in the differential housing are given by. Ss = Gs - 0.25 mm (0.01 in) for the left-hand side gear. Sd = Gd - 0.25 mm (0.01 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 (0.01 in).

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Front axle system - Front bevel gear set and differential

Differential - Overhaul – 4WD WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

1. Remove the bevel drive-differential casing assembly from the front axle and attach to the support 293743 (4). Lock the support in a vice and proceed with disassembly, as follows. 2. Remove the bolts (2) and the left-and right-hand side ring nut Iock plates (3). 3. Check that the right and Ieft-hand side caps (1) are clearly marked, so as not to mix the parts during reassembly. 4. Remove the left-and right-hand side bearing adjustment ring nuts (Gd) from the crown wheel. 5. Remove the bolts (Cg), securing the caps (1) and separate the crown wheel from the bevel pinion support.

NDIL14TR00434AB

NDIL14TR00433AB

NDIL14TR00436AB

6. If necessary, unscrew the retaining bolts (C1).Refer to . Four-Wheel Drive (4WD) axle - Sectional view (25.100) and remove the crown wheel. Disassemble the Limited Slip (LlM-SLlP) self-locking differential Iock as follows. 7. Remove the retaining bolts (1) from the differential halfcasing. 8. Open the differential casing (6). 9. Remove the half-casing (7) the differential pin (4), complete with the planet gears (3), the thrust washers (2) and the pins (9). 10. Remove the side gear (5) the friction disc (11), the metal discs (10) and the friction discs (12) from the half-casing (8). 11. Check the wear on the metal discs (10) and the friction discs (11) and (12). See table 1. Replace any parts that show signs of wear. 12. Proceed with the self-locking differential assembly operations, carrying out the previously described operations in reverse order. Apply LOCTITE® 270 to the threads on the screws (1) and tighten to a torque value of 50 N·m (37 lb ft). 13. Re-install the crown wheel (if previously disassembled) to the half-casing (8). Tighten the bolts (C1) to a torque of 113 N·m (83 lb ft). 14. Check the rolling torque of the bevel pinion.

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Front axle system - Front bevel gear set and differential

Assemble the crown wheel, complete with LlM-SLlP self-Iocking differential Iock, onto the bevel drive support. Do not forget to fit the previously marked crown wheel bearing support caps in the correct order. Assemble and adjust the crown wheel bearings. Table

LIM-SLIP SELF - locking differential lock friction discs Part number

Description

Quantity

Metal discs

Friction discs

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Thickness 1.5000 mm (0.0591 in) 2.8000 mm (0.1102 in) 1.6000 mm (0.0630 in)

Maximum wear per disc â&#x20AC;&#x201D; 0.1000 mm (0.0039 in) 0.1500 mm (0.0059 in)

Front axle system - Front bevel gear set and differential

Limited slip differential - Overhaul â&#x20AC;&#x201C; 4WD The differential with Iimited slip Iocking (LlM-SLlP) is of the two planet gear-type. It is provided with two multidisc clutch assemblies fitted between the side gears and the differential casing. This differential Iock device is totally automatic. It requires no manual operation and significantly reduces (but does not completely eliminate) wheel slip. The difference in speed between the side gears and the differential casing when a wheel loses grip and begins to slip, is prevented by the clutch assemblies that are compressed by axial thrust from the bevel drive torque transmitted to the side gears by means of the teeth on the two planet gears. These torque values may be different, according to the nature of the ground and the route followed by the tractor. Torque may vary in intensity, thereby proportionally varying the axial thrust on the clutches. This causes the side gears to mesh with the differential casing which, in turn, permits the axle to overcome the unevenness of the ground.

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NDIL14TR00433AB

Index Front axle system - 25 Front bevel gear set and differential - 102 Differential - Overhaul – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Overhaul – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front bevel gear set and differential - Adjust – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Limited slip differential - Overhaul – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

SERVICE Steering knuckle and king pin Replace – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjust – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Wheel hub Remove – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Adjust – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Replace â&#x20AC;&#x201C; 4WD 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

In the event that the steering knuckle pins prove difficult to remove, proceed as follows. 1. Remove the grease nipples and the steering knuckle pin retaining bolts. 2. Fit the bolts (1) of tool 293857. 3. Fit the plate (2) of the tool and fix it to the three bolts with nuts (5). 4. Fit the central tie bolt (4) screwing it fully into the grease nipple bore on the pin (6). 5. Screw in the nut (3) to drive the pin out of its bore.

NDIL14TR00410AB

NDIL14TR00411AB

6. Using extractor tool 292161 (1) remove the steering knuckle bearings. 7. Re-install the steering knuckle bearings using a suitable drift.

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Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Adjust – 4WD 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

Install the front axle on stand 293460 and proceed as follows. 1. Smear grease NLGI number 2 on the outer races of the bearings and fit the upper cover, without the adjustment plate, but with tool 292220 (2). Tighten the retaining bolts (C5) to 64 N·m (566 lb in).

NDIL14TR00412AB

NDIL14TR00413AB

NDIL14TR00414AB

2. Fit the lower cover without the adjustment plate and lubricate the three retaining bolts with engine oil. 3. Gradually tighten the lower cover bolts in sequence, while simultaneously rotating the casing to allow excess grease to escape.

4. Using a torque wrench and tool 292220 (1), check that the torque required to rotate the casing (ignoring the initial torque) is 2.9 N·m (25.7 lb in) (with torque increment of 0.98 N·m (8.67 lb in)). If the recorded torque is not as specified, adjust by way of the lower cover bolts. 5. Measure the gap (H) created between the lower cover and the casing adjacent to each of the three bolts.

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Front axle system - Final drive hub, steering knuckles, and shafts

6. Calculate the average of the three values measured. The total thickness of the adjustment shims to be fitted under the lower cover is to be calculated as follows: S3= H If necessary, round up the value to the next 0.0500 mm (0.0020 in). 7. Partially unscrew the bolts of the lower cover, insert the selected shims (S3). Tighten the bolts (C4) to the torque values of 64.00 N·m (566.45 lb in). 8. After having rotated the casing a few times to allow the components to bed down, check that the torque necessary to rotate the casing (ignoring the initial torque) is 2.90 – 7.80 N·m (25.67 – 69.04 lb in).

NDIL14TR00415AB

9. If the torque value measured is greater than the prescribed value, increase the thickness of the shims. If the measured value is less than the prescribed value, reduce the thickness of the shims. 10. Fit the grease nipples in the upper and lower covers and grease the assembly.

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Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Remove â&#x20AC;&#x201C; 2WD 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

Wheel hubs can be removed with the front axle on the tractor. Proceed as follows for each hub. 1. Safely block rear wheels. 2. Jack up front tractor and place a stationary stand (1) under the sump.

NDIL14TR00802AB

NDIL14TR00803AA

NDIL14TR00804AB

3. Loosen retaining bolts and remove front wheels.

4. Remove wheel hub bearing grease cup (1).

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Front axle system - Final drive hub, steering knuckles, and shafts

5. Remove split pin (1).

NDIL14TR00805AB

NDIL14TR00806AA

NDIL14TR00807AB

NDIL14TR00808AB

6. Using the socket spanner loosen the wheel hub bearing. Adjust castle nut.

7. Remove wheel hub (2) and recover bearing (1) and (3).

8. Remove seal (1) and nyloc ring (2) using suitable tool.

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Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Install â&#x20AC;&#x201C; 2WD 1. Replace faulty seals and worn bearing using suitable pullers and drifts. 2. Fill the wheel hub with specified grease. 3. Re-assemble the wheel hub (2) complete with the bearings (1) and (3).

NDIL14TR00809AB

NDIL14TR00810AA

NDIL14TR00811AB

NDIL14TR00812AB

4. Using a torque wrench and socket spanner (1) tighten the castel nut while turning the wheel hub (1) to settle the bearing. Tighten the nut until wheel hub gets slightly tight to rotate. 5. Loosen the castel nut and torque it again to 9.8 NÂˇm (7.2 lb ft) continuing to turn the wheel hub.

6. Insert split pin (1).

7. Reassemble the wheel hub dust cap (1). NOTE: Check the O-ring provided on the dust cap for any cut or damage. If required replace the O-ring.

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Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Adjust – 4WD 1. Install wheel hub and fixed gear unit onto the steering knuckle. 2. Using a torque wrench and lock ring wrench 293837, progressively tighten the lock ring (C6) to 147.00 – 196.00 N·m (1301.06 – 1734.75 lb in). While tightening the lock ring, rotate the hub to settle the bearings. 3. Fully slacken the lock ring and retighten to 59.00 N·m (522.19 lb in) while rotating hub. 4. Secure the lock ring by bending over a lock washer tab (If necessary, further tighten the lock ring to align a slot with the tab). 5. Turn the hub by hand to check for excessive play or binding.

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NDIL14TR00416AB

Index Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108 Steering knuckle and king pin - Adjust – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering knuckle and king pin - Replace – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel hub - Adjust – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel hub - Install – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel hub - Remove – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47899733 23/06/2015 EN

SERVICE MANUAL Rear axle system TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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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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Rear axle system - 27 Powered rear axle - 100

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Rear axle system - 27 Powered rear axle - 100

TECHNICAL DATA Rear axle General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Rear axle Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Rear axle Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Rear axle system - Powered rear axle

Rear axle - 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 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 29.50 – 31.50 kg (65.04 – 69.45 lb)

14/47 = 1 : 3.35 0.150 – 0.200 mm (0.006 – 0.008 in) 2-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) 1.0-1.05-1.10-1.15-1.20-1.40- 1.50-1.70-1.75-1.85-1.901.95- 2.0-2.10-2.2 1.0-1.05-1.10-1.15-1.20-1.40- 1.50-1.70-1.75-1.85-1.901.95- 2.0-2.05-2.10-2.15 0.150 mm (0.006 in) 1.500 – 1.600 mm (0.061 – 0.065 in) 1.500 mm (0.061 in)

188.000 mm (7.673 in) 126.500 mm (5.160 in)

Rear axle - Torque Description Self-locking nuts for bolts securing ring gear (C1) Nut locking bevel pinion shaft (C2) Bolts securing differential assembly/bearing supports (C3) Bolts securing differential lock pedal bracket (C4) Bolts securing final drive housing to rear wheel drive housing (C5) Bolts securing mechanical lift housing on rear wheel drive housing (C6)

Thread size

Torque

M12 X 1.25

115.0 N·m (84.8 lb ft)

M40 x 1

300.0 N·m (221.3 lb ft)

M10 X 1.5

60.0 N·m (44.3 lb ft)

M10 X 1.25

60.0 N·m (44.3 lb ft)

M12 X 1.5

100.0 N·m (73.8 lb ft)

M14 X 1.5

150.0 N·m (110.6 lb ft)

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Rear axle system - Powered rear axle

NDIL14TR00439GB

Rear axle - Sealing Operation description Final drive housing to rear wheel drive housing (S1) PTO rear cover plate (S2) Crown wheel bolts (S3) Mechanical lift housing to rear wheel drive housing (S4) Transmission top cover (S5) Ring nut locking screws (S6)

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Sealant specification LOCTITE® 518™ Permatex LOCTITE® 270 LOCTITE® 518™ LOCTITE® 574™ LOCTITE® 270

Rear axle system - Powered rear axle

NDIL14TR00440GB

Rear axle - Special tools Tool description Sling hook, gear box Installer/puller, pinion bearing Adjuster, bevel pinion bearing Mounting distance setting tool Spring balance, crown pinion pre-loading Wrench, bevel pinion nut Pinion locking tool Compressor, differential lock spring

Tool Number 291517 292911 293101 293400 82834306 293342 9971366 290870

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Rear axle system - Powered rear axle

Rear axle - 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 - Powered rear axle

Rear axle - Remove To remove the rear wheel drive housing, final drive housing, mechanical lift assembly, canopy, fenders, three point linkage, drawbars and Power Take-Off (PTO) assembly has to be removed. 1. Detach the negative cable (1) from the battery and insulate.

NDIL14TR00442AB

NDIL14TR00443AB

NDIL14TR00444AB

NDIL14TR00445AB

2. Remove guard and detach rear electric connections (1) under rear hood.

3. Detach electric connections (1) for left-hand side fender. 4. Detach electric connections for brake switch below right-hand side foot rest. 5. Remove the electric cables from the transmission and rear wheel drive housing.

6. Loosen the bolts (1) and remove operator seat from the hydraulic housing.

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Rear axle system - Powered rear axle

7. Remove three point linkages from the tractor.

NDIL14TR00446AA

NDIL14TR00447AB

NDIL14TR00448AB

NDIL14TR00449AB

8. Loosen the nuts (1) and remove both left-hand side and right-hand side fenders from the tractor.

9. Remove both left-hand side and right-hand side foot rest (1) from the tractor. NOTE: Disconnect foot accelerator linkage before removing right-hand side foot rest.

10. Loosen mechanical lift housing securing bolts (1) and remove housing using a suitable hoist.

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Rear axle system - Powered rear axle

11. Place the wedges at front and back on both sides of the front tires. 12. Drain oil from the transmission housing. 13. Jack up rear tractor and place two suitable stands (1) under the transmission housing to raise the wheels off the ground. 14. Position splitting trolley (special tool number 292320) under the tractor supporting transmission housing and rear wheel drive housing.

NDIL14TR00450AB

15. Remove both left and right-hand side wheels.

NDIL14TR00451AA

NDIL14TR00452AA

NDIL14TR00453AB

16. Disconnect all hydraulic connections to remote control valve and remove remote control valve. NOTE: If remote control valve is not fitted, then disconnect pipe connecting pump and mechanical lift housing.

17. Wrap suitable chain or nylon rope on the final drive housing (1) and connect it to a hoist. Loosen attaching bolts and remove the entire final drive. 18. Repeat for the final drive housing on the other side.

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Rear axle system - Powered rear axle

19. Remove circlip and disconnect clutch pedal linkages (1).

NDIL14TR00454AB

NDIL14TR00455AA

20. Connect the rear wheel drive housing to a suitable hoist using chain with hook (special tool number 291517). 21. 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 Power Take-Off (PTO) drive shaft. Place the housing on a flat wooden surface or mount it on rotary stand. 22. Remove the Power Take-Off (PTO) assembly from the housing. 23. Remove the brake pedal, brake linkages and brake disc assembly.

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Rear axle system - Powered rear axle

Rear axle - Install Re-install the rear axle housing to the transmission housing observing the following. • Re-installation follows the removal procedure in reverse, from step 23 back to step 1. Refer to Rear axle - Remove (27.100). • Before reassembling housings, supports and covers, thoroughly clean and degrease mating surfaces and apply a bead of liquid gasket of approximate 2.000 mm (0.079 in) of diameter following the patterns shown in the figure 1. • Renew the two gaskets between transmission and rear axle housing. • Tighten to correct torques.

NDIL14TR00456GA

Pattern for application of sealant 47899733 23/06/2015

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Rear axle system - Powered rear axle

Rear axle - 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

1. Remove mechanical rear wheel drive housing from tractor by following the procedure described in Rear axle - Remove (27.100). 2. Remove Power Take-Off (PTO) assembly, brake pedal, brake assembly and linkages.

NDIL14TR00457AA

NDIL14TR00458AB

NDIL14TR00459AB

3. Loosen the bolts (1) and remove differential lock pedal (2).

4. Remove spindle (1) using a punch and mallet, if necessary, from the left-hand side of the transmission housing after having removed the plug.

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Rear axle system - Powered rear axle

5. Collect the differential spring (1) and the shift fork (2) from the housing.

NDIL14TR00460AB

NDIL14TR00461AB

NDIL14TR00462AA

NDIL14TR00463AB

6. Loosen the securing bolts and remove the differential bearing supports (1) from both the sides by gently hammering.

7. Remove the differential assembly along with crown wheel from the rear axle housing.

8. Loosen the crown wheel attaching bolts (1).

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Rear axle system - Powered rear axle

9. Detach the crown wheel (1) from the differential housing.

NDIL14TR00464AB

NDIL14TR00465AB

NOTE: Differential assembly can also be disassembled without removing crown wheel. 10. Screw out the locking screws (1) securing differential journal retaining pin.

11. Remove dowel pin from the differential housing by using suitable tool.

NDIL14TR00466AA

NDIL14TR00467AB

12. Remove the differential journal (1) by pushing it out gently.

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Rear axle system - Powered rear axle

13. Withdraw the differential gears and thrust washers.

NDIL14TR00468AA

NDIL14TR00469AA

NDIL14TR00470AA

NDIL14TR00471AA

14. Withdraw the side gears and thrust washers.

15. Using suitable pullers, remove the bearings from both the sides.

16. Remove the differential lock clutch from the housing.

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Rear axle system - Powered rear axle

Rear axle - Inspect Check all items for good condition. Replace damaged bearing, thrust washers and gears.

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Rear axle system - Powered rear axle

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

Re-install all the components of the differential assembly observing the following • Reassembly follows the disassembly procedure in reverse, from step 16 back to step 1. Refer to Rear axle - Disassemble (27.100). • Set crown / pinion backlash and total preload setting as explained in Bevel pinion - Adjust (27.106). • Use suitable tools to fit bearings. • Use special tool number 290870 to install differential lock spring, figure 1. • Tighten to correct torques. • Use thread sealant ( LOCTITE® 270) on crown wheel bolts.

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NDIL14TR00472AB

Index Rear axle system - 27 Powered rear axle - 100 Rear axle - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear axle - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear axle - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear axle - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear axle - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Rear axle system - 27 Rear bevel gear set and differential - 106

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Rear axle system - 27 Rear bevel gear set and differential - 106

FUNCTIONAL DATA Rear bevel gear set and differential Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Bevel pinion Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

DIAGNOSTIC Rear bevel gear set and differential Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Rear axle system - Rear bevel gear set and differential

Rear bevel gear set and differential - Sectional view

NDIL14TR00441FB

Crown wheel and differential assy. 1. 2. 3. 4. 5. 6. 7. 8. 9.

Bolt Ring gear Differential journal Spring Differential lock shift fork Differential lock sliding sleeve Taper roller bearing Taper roller bearing Bevel pinion

10. 11. 12. 13. 14. 15. 16. 17. 18.

Differential support Taper roller bearing Thrust washer Differential pinion Thrust washer Side gear Differential housing Taper roller bearing Differential support

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Rear axle system - Rear bevel gear set and differential

Bevel pinion - 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

1. To remove pinion shaft, first differential assembly has to be removed from the rear axle housing. Refer to differential assembly removal procedure.

NDIL14TR00473AA

NDIL14TR00474AB

NDIL14TR00475AA

2. Remove nut (1) using special tool number 293342.

3. Remove the pinion shaft from the housing by hammering it out gently using suitable mandrill.

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Rear axle system - Rear bevel gear set and differential

4. Retrieve spacer (1) and shims (2) from the pinion shaft.

NDIL14TR00476AB

NDIL14TR00477AA

NDIL14TR00478AA

5. Remove outer race of the bearings from the case using suitable puller.

6. Remove the tapper roller bearings from the pinion shaft using special tool number 292911.

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Rear axle system - Rear bevel gear set and differential

Bevel pinion - Adjust Pinion Shaft Pre-loading Calculation of clearance adjustments shims for pinion shaft bearings: 1. Fit the special tool number 293101 on a vice and insert pinion bearings (1) and spacer (2). 2. Tighten the nut (1) by hand and measure dimension H1 using depth gauge.

NDIL14TR00479AB

NDIL14TR00480AA

NDIL14TR00481AB

3. Remove the spacer (1) from the tool and fit the tool in the rear axle housing only with bearings. 4. Tighten the nut once again by hand and measure dimensions H2 using depth gauge.

5. The shim thickness Sp for clearance adjustment can be calculated by the following formula. Sp = H2 - H1 + 0.05 where 0.05 is the increase required to compensate preloading of the bearings. 6. Calculated thickness shim (1) should be added to the pinion shaft.

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Rear axle system - Rear bevel gear set and differential

Adjustment of pinion position 1. Without disturbing the special tool number 293101 already fixed in the housing, fix special tool number 293400 in the rear wheel drive housing. 2. Measure dimension H5 (distance between pinion bearing cone and the crown center locking tool).

NDIL14TR00482AA

NDIL14TR00483AB

NDIL14TR00484AA

3. Establish the correct nominal dimension H6 using formula. H6 = H + C where H = 128 mm (5 in) (standard) C = Compensation dimension stamped on the piston. 4. Calculate the thickness of clearance adjustment shim â&#x20AC;&#x2DC;Sâ&#x20AC;&#x2122; using the formula S = H5 - H6. 5. Calculated thickness shims (1) should be added to the pinion shaft.

Differential pinion and side gear backlash adjustment Fit the two side gears (15) in the differential carrier without the shims (12). Install differential pinions (13) complete with thrust washer (14) and journal (3) and tighten bolts (1) a few turns to prevent journal work out. Bring left-hand side gear into full contact with differential pinion. Using a depth gauge measure dimension (H1) at two diametrically opposed points and average the two readings.

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Rear axle system - Rear bevel gear set and differential

Then push side gear into contact with differential carrier and measure dimension (H2). 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 1.7 = 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.

NDIL14TR00485AA

NDIL14TR00486AB

NDIL14TR00487AB

Adjustment of bevel wheel bearings With pinion shaft, differential assembly with crown wheel bearing supports fitted. 1. Screw out two Allen screws (1) and remove lock plate from both the sides.

2. Tighten left-hand side ring nut (1) using special tool number 9971349 until minimum back lash between the bevel teeth is 1.000 mm (0.039 in).

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Rear axle system - Rear bevel gear set and differential

3. Measure the backlash using dial gauge and magnetic stand as shown in the figure.

NDIL14TR00488AA

NDIL14TR00489AA

NDIL14TR00490AB

4. Tighten right-hand side ring nut until achieving rolling torque of the pinion bevel wheel 98 â&#x20AC;&#x201C; 147 N (22 â&#x20AC;&#x201C; 33 lb). 5. This torque can be measured using a spring balance and a chord wound around the differential housing and pull the spring balance. The value at which differential housing starts rotate is the rolling torque.

6. Fit the lock plate (1) back on the bearing supports. apply thread lock sealant Loctite 274 to the allen screws (2).

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Rear axle system - Rear bevel gear set and differential

Bevel pinion - Assemble Re-install all the components of the differential assembly observing the following. • Reassembly follows the disassembly procedure in reverse, from step 6 back to step 1. Refer to Bevel pinion - Disassemble (27.106). • Refer differential housing installation procedure. • Set tapper roller bearing pre-load and crown/pinion backlash. • Use suitable tools to fit the bearings.

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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 misadtractor is moving and also justment when transmission in neutral (not originationg 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear bevel gear set and differential - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear bevel gear set and differential - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Rear axle system - 27 Planetary and final drives - 120

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Rear axle system - 27 Planetary and final drives - 120

TECHNICAL DATA Final drive housing General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Final drive housing Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Final drive housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

DIAGNOSTIC Final drive housing Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Rear axle system - Planetary and final drives

Final drive housing - General specification Type Gears Reduction ratio

Planetary, single reduction Spur TT75 TT55

11/68 = 1: 6.18 11/62 = 1: 5.636 0.150 – 0.250 mm (0.006 – 0.010 in)

Backlash

Final drive spline fits 0.050 mm (0.002 in) 0.048 mm (0.002 in)

Interference Clearance

Final drive housing - Torque Description Bolts, final drive cover (C1) Bolts securing final drive housing to transmission housing (C2) Bolts securing wheel disc to wheel shaft (C3) Lock-nut securing final drive driven gear to disc spindle (C4)

Thread size M10 X 1.25

Torque 60 N·m (44 lb ft)

M12 X 1.5

100 N·m (74 lb ft)

M16 X 1.5

260 N·m (192 lb ft)

M55 X 1.5

900 N·m (664 lb ft)

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NDIL14TR00491GB

Final drive housing - Sealing Operation description Final drive housing to rear wheel drive housing (S1)

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Sealant specification LOCTITE® 574™

Rear axle system - Planetary and final drives

NDIL14TR00492FB

Final drive housing - Special tools Tool description Installer, trumpet housing seal 1 Installer, trumpet housing seal 2 Puller, bull gear remover Bull gear nut spanner Remover, final drive bearing Installer, final drive cover sealâ&#x20AC;&#x201C; TT75 Installer, final drive cover sealâ&#x20AC;&#x201C; TT55

Tool number 9971350 9971351 292904 9971360 292927 9971362 9971380

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Rear axle system - Planetary and final drives

Final drive housing - Sectional view

NDIL14TR00493GB

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

Wheel shaft Cover Ball bearing Ball bearing Roller bearing Roller bearing Final drive driven gear (bull gear)

8. 9. 10 11. 12. 13.

Rear axle shaft Rear axle housing (final drive) Disc brakes Seal Seal Driven gear retaining nut

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Rear axle system - Planetary and final drives

Final drive housing - Overview The outboard final reduction gear set is controlled by the bevel pinion and crown wheel output half - shaft, which also controls the brakes. Outboard reduction helps in improving traction and increasing brakesâ&#x20AC;&#x2122; life. It also gives more ground clearance and is sealed against water and dust. In this cascade arrangement bull pinion is integral part of the axle shaft. The wheel shaft can withstand bending and twisting loads due to its small length. The final drive housing can be located in various positions relative to the axle sleeves, which makes it possible to change in a stepwise fashion the wheel base and clearance of the tractor. The following three clearance settings are possible: basic (medium - height), high and low. The tractor can be made to have low clearance setting by turning the final drive housings either fully backward or fully forward, provided the fenders is removed and the track width of the rear wheels is set at its minimum. In this case, one should bear in mind that turning the final drive housing forward improves the manoeuvrability of the tractor but impairs its stability, and vice-versa turning them backward improves the stability of the tractor but impairs its manoeuvrability.

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Rear axle system - Planetary and final drives

Final drive housing - 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

Remove the rear axle housing as follows. 1. Detach the negative cable (1) from the battery and insulate.

NDIL14TR00495AB

NDIL14TR00496AB

NDIL14TR00497AB

2. Detach rear electric connection (1) under rear hood.

3. Detach electric connection (1) between left and righthand side fenders.

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4. Remove three point linkage check chains from final drive housing.

NDIL14TR00498AA

NDIL14TR00499AB

NDIL14TR00500AB

NDIL14TR00501AB

5. Remove bolts (1) securing footrest to fender. NOTE: Disconnect foot accelerator linkage before removing right-hand side foot rest.

6. Loosen bolts (1) and remove fenders from the tractor.

7. Place the wedges at front and back on both sides of the front tires. 8. Jack up rear of the tractor and place two suitable stands (1) under the transmission housing to raise the wheels off the ground.

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Rear axle system - Planetary and final drives

9. Remove rear wheels.

NDIL14TR00502AA

NDIL14TR00503AB

10. Drain transmission oil from rear wheel drive housing by opening drain plug (1).

11. Drain oil from final drive housing by opening drain plug (1) and (2).

NDIL14TR00504AB

NDIL14TR00505AB

12. Wrap suitable chain or nylon rope on the final drive housing (1) and connect it to a hoist. Remove attaching bolts and separate final drive assembly from the rear wheel drive housing and place it securely on a flat surface.

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Rear axle system - Planetary and final drives

NOTE: If remote control valve is fitted, then before removing right-hand side final drive assembly from tractor, all hydraulic connection to remote control valve should be disconnected and valve assembly should be removed from the tractor.

NDIL14TR00506AA

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Rear axle system - Planetary and final drives

Final drive housing - Install Re-install the final drive assembly on tractor observing the following. • Reinstallation follows the removal procedure in reverse, refer to Final drive housing - Remove (27.120). • Replace the brake discs before inserting rear axial shaft into rear wheel drive housing. • Before reassembling housings, supports and covers, thoroughly clean and decrease mating surfaces and apply a 2.00 mm (0.08 in) bead of sealant following the patterns shown in the figure. • Tighten to correct torques as detailed on Final drive housing - Torque (27.120).

NDIL14TR00507GB

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Rear axle system - Planetary and final drives

Final drive housing - 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

1. Remove the final drive assembly from the tractor.

NDIL14TR00508AA

NDIL14TR00509AB

NDIL14TR00510AB

2. Loosen bolt (1) and remove final drive cover (2) with bull gear.

3. Unscrew bull gear retaining nut using special tool number 9971360. NOTE: Tighten two M16 X 1.5 screws into two of the wheel disc holes on hub and clamp wheel shaft in vice to avoid rotation of shaft while loosening nut.

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Rear axle system - Planetary and final drives

4. Withdraw driver gear (1) from wheel shaft using puller - special tool number 292904.

NDIL14TR00511AB

NDIL14TR00512AB

NDIL14TR00513AB

NDIL14TR00514AB

5. Withdraw spacer (1).

6. Knock out wheel shaft using lead hammer.

7. Remove seal (1) using suitable tool.

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Rear axle system - Planetary and final drives

NOTE: In TT55 model rear axle, extra sleeve and nylon washer provided to protect water entry for wet land cultivation.

NDIL14TR00515AA

NDIL14TR00516AB

8. Use suitable puller to withdraw roller bearing (1) from cover.

9. Withdraw the bearing (1) from cover, having first removed circlip (2).

NDIL14TR00517AB

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Rear axle system - Planetary and final drives

Rear axle housing - disassembly 10. Remove the bearing (1) from the housing using a suitable puller.

NDIL14TR00518AB

NDIL14TR00519AB

NDIL14TR00520AB

NDIL14TR00521AB

11. Remove circlip (1).

12. Withdraw axle shaft (1) together with bearing in the direction shown by the arrow. 13. Remove ball bearing (2) from axle shaft using suitable puller.

14. Remove roller bearing (1) internal ring from the axle shaft, using puller - separator (special tool no. 292911).

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Rear axle system - Planetary and final drives

Final drive housing - Inspect 1. Check and replace damaged and worn parts. 2. Check lip seals (1) and (2) and replace if necessary.

NDIL14TR00522AB

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Rear axle system - Planetary and final drives

Final drive housing - Assemble Reassemble final drive assembly observing the following. 1. Reassembly follows disassembly procedure in reverse refer to Final drive housing - Disassemble (27.120). 2. Place the roller bearing (1) in its seat in the final drive cover with the makerâ&#x20AC;&#x2122;s logo faces outside.

NDIL14TR00523AB

NDIL14TR00524AA

NDIL14TR00525AA

NDIL14TR00526AB

3. Install other bearings, using appropriate installers. 4. Install final drive cover seal using installer special tool number 9971362 for TT75 model and 9971380 for TT55 model.

5. Install rear axle housing seal using installer, special tool number 9971350 and 9971351.

6. Fit the rear axle shaft (1) and wheel shaft (2), taking care not to damage the seals.

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7. Fit the roller bearing internal ring on the axle shaft having heated it in oil to 80 – 90 °C (176 – 194 °F). 8. Tighten the bull gear retaining nut to 900 N·m (664 lb ft) using special tool number 9971360.

NDIL14TR00527AA

NDIL14TR00528AB

9. Clean and grease the surfaces in contact between the housing and the cover and insert a new gasket (1).

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Final drive housing - Troubleshooting Problem Possible Cause Wheel axle shaft bearing misadjusted Noisy final drives when the tractor is moving and also with transmission in neutral Faulty or defective inner components. Excess bull and pinion gear backlash

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Correction Remove final drive case and adjust bearings Remove final drive case and replace damaged parts Remove final drive case and replace damaged parts

Index Rear axle system - 27 Planetary and final drives - 120 Final drive housing - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive housing - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive housing - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive housing - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive housing - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive housing - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive housing - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive housing - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive housing - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive housing - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47899733 23/06/2015 EN

SERVICE MANUAL Power Take-Off (PTO) TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Power Take-Off (PTO) - 31

[31.101] Rear mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 [31.201] Power Take-Off (PTO) drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2

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Power Take-Off (PTO) - 31 Rear mechanical control - 101

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Power Take-Off (PTO) - 31 Rear mechanical control - 101

TECHNICAL DATA Rear mechanical control General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Rear mechanical control Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Rear mechanical control Remove - Power Take-Off (PTO) lever and internal linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install â&#x20AC;&#x201C; Power Take-Off (PTO) lever and internal linkages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Power Take-Off (PTO) - Rear mechanical control

Rear mechanical control - General specification Type Clutch control Output shaft engagement Rotation (looking from tractor rear end) Engine speed at 540 RPM (standard) Power Take-Off (PTO) speed Power Take Off-(PTO) speed at engine max. power rating

Independent Hand lever By lever situated on transmission housing cover Clock wise 1967 RPM 686 RPM

Output shaft Number of splines Shaft diameter

6 1 3/8 (6 spines)

Power Take-Off (PTO) clutch shaft 24.964 – 29.985 mm (0.983 – 1.181 in) 25.040 – 25.092 mm (0.986 – 0.988 in) 0.055 – 0.128 mm (0.002 – 0.005 in) 0.037 – 0.091 mm (0.001 – 0.004 in)

Shaft diameter Bushing fitted internal diameter Power Take-Off (PTO) shaft clearance in bushing Bushing interference fit with drive shaft

Rear mechanical control - Torque Description Bolts securing transmission housing rear cover (C1) Bolts securing transmission housing rear cover (C2) Nuts securing Power Take-Off (PTO) shaft driven gear (C3)

Thread size

Torque

M12 X 1.5

100.0 N·m (73.8 lb ft)

M16 X 1.5

230.0 N·m (169.6 lb ft)

M22 X 1.5

260.0 N·m (191.8 lb ft)

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Power Take-Off (PTO) - Rear mechanical control

NDIL14TR00529GB

Rear mechanical control - Sealing Operation description Transmission rear covers (S1) Transmission top cover (S2)

Sealant specification Permatex LOCTITE® 574™

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Power Take-Off (PTO) - Rear mechanical control

NDIL14TR00530FB

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Power Take-Off (PTO) - Rear mechanical control

Rear mechanical control - Sectional view

NDIL14TR00531GB

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

Sliding gear for Power Take-Off (PTO) engagement Drive shaft Drive gear for ground Power Take-Off (PTO) (optional) Driven shaft Oil seal Driven gear Spacer

8. 9. 10.

Transmission rear cover Power Take-Off (PTO) release lever Pad for Power Take-Off (PTO) release lever

11. 12. 13.

Plain roller bearing Plain roller bearing Ball bearing

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Power Take-Off (PTO) - Rear mechanical control

Rear mechanical control - Overview Description and operation 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 Power Take-Off (PTO) driven equipment is designed to run. The Power Take-Off (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 Power Take-Off (PTO) input shaft is connected to the Power Take-Off (PTO) output shaft through reduction gears. Standard speed of 540 RPM Power Take-Off (PTO) can be obtained at engine 1967 RPM. DANGER To avoid inadvertent movement of the implement, disengage the Power Take-Off (PTO) after each use. WARNING Whenever operating Power Take-Off (PTO) equipment, observe the following precautions: 1. Follow the operator instructions supplied by the implement manufacturer. 2. Do not wear loose clothing when operating Power Take-Off (PTO) driven equipment. 3. Do not approach, clean or adjust Power Take-Off (PTO) driven equipment while the tractor engine is still running. Stop the engine wait until the Power Take-Off (PTO) and the equipment stop turning before getting down from the tractor or before working on the Power Take-Off (PTO) or the equipment. 4. Apply the parking brake, place both gear shift levers in neutral and block all four wheels before operating any stationary Power Take-Off (PTO) equipment. 5. To avoid accidental engagement of the implement, ensure the Power Take-Off (PTO) engagement lever is in the neutral position. 6. Do not cross between the implement and tractor. 7. Never allow anyone on or near the implement.

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NDIL14TR00532AB

Power Take-Off (PTO) - Rear mechanical control

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

1. Screw out transmission cover plate bolts (1) and open the cover.

NDIL14TR00533AB

NDIL14TR00534AB

NDIL14TR00535AB

2. Push out the dowel pin from the internal lever (1).

3. Pull out the lever assembly and retrieve the lock pin (1) and spring (2) from the lever cage.

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Power Take-Off (PTO) - Rear mechanical control

4. Power Take-Off (PTO) engagement sliding sleeve (1) can be removed only after removing Power Take-Off (PTO) shaft assembly. Refer to Power Take-Off (PTO) drive shaft - Remove (31.201) for Power Take-Off (PTO) shaft removal.

NDIL14TR00536AB

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Power Take-Off (PTO) - Rear mechanical control

Rear mechanical control - Install â&#x20AC;&#x201C; Power Take-Off (PTO) lever and internal linkages 1. Installation is reversal of the removal procedure. Refer to Rear mechanical control - Remove - Power TakeOff (PTO) lever and internal linkages (31.101). Before fixing transmission top cover, thoroughly clean and decrease mating surfaces and apply a 2.00 mm (0.08 in) bead of sealant following the pattern shown in the figure 1.

NDIL14TR00537FA

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Index Power Take-Off (PTO) - 31 Rear mechanical control - 101 Rear mechanical control - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear mechanical control - Install â&#x20AC;&#x201C; Power Take-Off (PTO) lever and internal linkages . . . . . . . . . . .

Rear mechanical control - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear mechanical control - Remove - Power Take-Off (PTO) lever and internal linkages . . . . . . . . . .

Rear mechanical control - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear mechanical control - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear mechanical control - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Power Take-Off (PTO) - 31 Power Take-Off (PTO) drive shaft - 201

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Power Take-Off (PTO) - 31 Power Take-Off (PTO) drive shaft - 201

SERVICE Power Take-Off (PTO) drive shaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Power Take-Off (PTO) - Power Take-Off (PTO) drive shaft

Power Take-Off (PTO) drive shaft - Remove 1. Drain oil from the transmission and rear wheel drive housing by opening drain plugs (1) and (2).

NDIL14TR00538AB

NDIL14TR00539AB

NDIL14TR00540AB

NDIL14TR00541AB

2. Open transmission top cover plate (1).

3. Remove circlip (1) from the Power Take-Off (PTO) input shaft.

4. Remove Power Take-Off (PTO) cover bolts (1). 5. Pull out the Power Take-Off (PTO) shaft assembly along with Power Take-Off (PTO) cover. NOTICE: While pulling out Power Take-Off (PTO) shaft assembly, hold the Power Take-Off (PTO) engagement sliding sleeve (1) to prevent from dropping into the housing.

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Power Take-Off (PTO) - Power Take-Off (PTO) drive shaft

Power Take-Off (PTO) drive shaft - Disassemble 1. For correct disassembly install Power Take-Off (PTO) assembly on rotary stand (special tool number 290086 and 290092). 2. Loosen nut (1) and pull out gear (2) from Power TakeOff (PTO) shaft. NOTE: Nut (1) is locked by punching at the end of the nut. Unlock the nut using suitable tool before removing.

NDIL14TR00542AB

NDIL14TR00543AB

NDIL14TR00544AB

NDIL14TR00545AA

3. Push the Power Take-Off (PTO) shaft out of the cover plate by hammering with mallet. 4. Remove circlip (1), bearings (2) and spacer (3) from Power Take-Off (PTO) shaft.

5. Remove oil seal (1) from transmission rear cover using suitable tool.

6. Remove circlip from the transmission rear cover.

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Power Take-Off (PTO) - Power Take-Off (PTO) drive shaft

7. Unscrew four bolts securing Power Take-Off (PTO) input shaft cover (1) on PTO assembly cover plate.

NDIL14TR00546AB

NDIL14TR00547AB

NDIL14TR00548AB

8. Remove circlip (1) and push the input shaft out of the cover plate.

9. Inspect the bearings, shafts and gears for wear out, damage, scouring and pitting. Replace the parts as necessary. 10. Remove the bearings (1) and (2) from shafts and cover plate using suitable puller and drifts.

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Power Take-Off (PTO) - Power Take-Off (PTO) drive shaft

Power Take-Off (PTO) drive shaft - Assemble Reassemble and install Power Take-Off (PTO) assembly on rear housing observing the following. 1.

Reassembly and installation follows the removal procedure in reverse from step 10 back to step 1. Refer to Power Take-Off (PTO) drive shaft - Disassemble (31.201).

Refer to figure for correct orientation of the gears, bearings, oil seals and sleeve.

Fit new oil seal.

Replace the sliding sleeve and circlip on input shaft before inserting pullers.

Before reassembling Power Take-Off (PTO) cover, thoroughly clean and decrease mating surfaces and apply a 2.00 mm (0.08 in) head of sealant following the pattern shown in the figure.

Inspect the input shaft cover gasket (1) and replace if necessary.

Comply with tightening torques specified in Rear mechanical control - Torque (31.101).

NDIL14TR00549FA

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Index Power Take-Off (PTO) - 31 Power Take-Off (PTO) drive shaft - 201 Power Take-Off (PTO) drive shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Take-Off (PTO) drive shaft - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Take-Off (PTO) 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

47899733 23/06/2015 EN

SERVICE MANUAL Brakes and controls TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Brakes and controls - 33

[33.120] Mechanical service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2

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Brakes and controls - 33 Mechanical service brakes - 120

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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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 Brake control pedals and shafts Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Brake controls Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Mechanical service brakes Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Brake control pedals and shafts Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Adjust â&#x20AC;&#x201C; Brake pedal free play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

DIAGNOSTIC Mechanical service brakes Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Brakes and controls - Mechanical service brakes

Mechanical service brakes - General specification Type Wet disc acting on differential axle shafts Wet disc acting on differential axle shafts

Service brake Parking brake Control

Mechanical, independent pedal control (or latched for joint operation) Mechanical, hand lever with pawl release (Sector fitted on right-hand side of transmission housing)

Service brake Parking brake Number of discs per side TT75 TT55

4 3

Brake oil specification (Common for transmission and brakes) Service brake/ parking brake disc material Nominal brake disc thickness Service/ parking brakes disc discard thickness Brake pedal free play

API GL4 20W/40 Organic compound 4.6500 – 4.8000 mm (0.1831 – 0.1890 in) 4.3000 mm (0.1693 in). 50.0000 – 55.0000 mm (1.9685 – 2.1654 in)

Brake pedal support Right-hand side pedal inner diameter (I.D) Bushing thickness Right-hand side pedal bushing fitted I.D. (without reaming) Right-hand side pedal bushing/housing clearance 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 Left-hand side brake shaft bushing fitted I.D. (without reaming) Left-hand side brake bushing fitted Bushing thickness Left-hand side pedal bushing/housing clearance Left-hand side pedal bushing/housing interference Handbrake shaft diameter Left-hand side brake bushings Diameter of bushing housing in transmission casing I.D. of Left-hand side brake shaft support bushing in transmission casing (without reaming) Bushing thickness Clearance between bushings and transmission casing Interference between bushings and transmission casing

40.0000 – 40.0250 mm (1.5748 – 1.5758 in) 1.9320 – 1.9680 mm (0.0761 – 0.0775 in) 36.0640 – 36.1610 mm (1.4198 – 1.4237 in) 0.0970 mm (0.0038 in) max. 0.0970 mm (0.0038 in) max. 35.9610 – 36.0000 mm (1.4158 – 1.4173 in) 0.1030 – 0.1610 mm (0.0041 – 0.0063 in) 36.0250 – 36.0870 mm (1.4183 – 1.4207 in) 0.0640 – 0.0870 mm (0.0025 – 0.0034 in) 22.0520 – 22.1370 mm (0.8682 – 0.8715 in) 25.0000 – 25.0210 mm (0.9843 – 0.9851 in) 1.4420 – 1.4740 mm (0.0568 – 0.0580 in) 0.0640 mm (0.0025 in) max. 0.0850 mm (0.0033 in) max. 21.9670 – 22.0000 mm (0.8648 – 0.8661 in) 0.0520 – 0.1700 mm (0.0020 – 0.0067 in) 40.0000 – 40.0250 mm (1.5748 – 1.5758 in) 36.0640 – 36.1610 mm (1.4198 – 1.4237 in) 1.9320 – 1.9680 mm (0.0761 – 0.0775 in) 0.0970 mm (0.0038 in) max. 0.1030 – 0.1610 mm (0.0041 – 0.0063 in)

Mechanical service brakes - Torque Description Rear axle housing to differential housing bolts (C1) Fender bolts (C2) Bottom cover plate bolts (C3) Screw (C4)

Thread size

Torque

M12 X 1.5

100 N·m (74 lb ft)

M16 X 1.5 M8 X 1.25 M16 X 1.5

200 N·m (148 lb ft) 26 N·m (19 lb ft) 210 N·m (155 lb ft)

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Brakes and controls - Mechanical service brakes

NDIL14TR00550GB

Mechanical service brakes - Sealing Operation description Buckle up of rear axle housing to differential housing (S1) Bottom cover plate sealing (S4) Thread lock for locking screw (S3)

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Sealant specification LOCTITE® 518™ LOCTITE® 518™ LOCTITE® 518™

Brakes and controls - Mechanical service brakes

NDIL14TR00551GB

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Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - 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.

NDIL14TR00553GB

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.

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Brakes and controls - Mechanical service brakes

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

Brake controls - Sectional view

NDIL14TR00934GB

1. Rear wheel drive housing 2. Brake actuating linkage 3. Actuating disc 4. Axle shaft 5. Brake disc 6. Back up disc 7. Final drive housing

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Brakes and controls - Mechanical service brakes

Mechanical service brakes - Disassemble To remove brake assembly, final drive assembly has to be removed from the rear wheel drive assembly. 1. Remove final drive assembly (1) from rear axle housing.

NDIL14TR00563AB

NDIL14TR00564AA

NDIL14TR00565AB

NDIL14TR00566AB

2. Retrieve outer brake discs and back-up discs from the brake assembly.

3. Remove split pin (1) and spring (2), disconnect brake linkage.

4. Loosen two bolts and remove cover (1).

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Brakes and controls - Mechanical service brakes

5. Loosen and remove locking screw (1).

NDIL14TR00567AB

NDIL14TR00568AB

NDIL14TR00569AA

6. Slide out actuating shaft (1) from the housing.

7. Remove the brake actuating assembly, along with inner brake discs and back-up discs from housing.

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Brakes and controls - Mechanical service brakes

Mechanical service brakes - Inspect 1. Inspect the brake flange friction face for wear and damage, replace if necessary. 2. Inspect the brake discs, if badly scored, worn or cracked, replace. 3. Check O-ring on actuating shaft for any damage and replace if necessary. NOTE: Brake discsâ&#x20AC;&#x2122; thickness should be minimum 4.30 mm (0.17 in).

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Brakes and controls - Mechanical service brakes

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

1. Reinstall the brake assembly and rear axle housing to the differential housing taking the following into consideration: • Reassembly follows the disassembly procedure in reverse, refer to Mechanical service brakes - Disassemble (33.120). • Refer the figure to orient the different parts. • Before reinstalling the rear axle housing, thoroughly clean and decrease mating surfaces and apply a bead of liquid gasket of approx. 2.0 mm (0.1 in) of diameter following patterns shown in figure 2. • Check seals for wear and damage and replace if necessary. • Tighten to correct torques. After brake assembly fitted in differential housing, check brake discs for free movement between brake discs.

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NDIL14TR00570AA

Brakes and controls - Mechanical service brakes

NDIL14TR00571GA

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Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Remove 1. Remove brake pedal spring (1). 2. Remove split pin (2) and disconnect linkage (3). 3. Remove circlip (4) and pull out right-hand side brake pedal.

NDIL14TR00554AB

NDIL14TR00555AB

NDIL14TR00556AB

NDIL14TR00557AB

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

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

6. Remove clutch pedal spring (1).

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Brakes and controls - Mechanical service brakes

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

NDIL14TR00558AB

NDIL14TR00559AA

NDIL14TR00560AB

8. Jack-up rear left-hand side of tractor and remove lefthand side rear wheel.

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

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Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Adjust – Brake pedal free play Measure free play of the brake pedals as shown in figure 1 and should be 35.00 – 45.00 mm (1.38 – 1.77 in).With the brake pedals locked together, the tractor should stop in a straight line when brakes are applied. Adjustment is made to the brake pull rods beneath the tractor. Block the wheels , front and rear, unlock the brake pedals and release the parking brake lever. Unlock nut (1) and rotate screw (2) to adjust play. • Screw in to reduce the play. • Screw out to increase the play. NDIL14TR00572AA

NDIL14TR00573AB

Repeat the same procedure for the left brake pull rod. Lock the brake pedals together and road test to ensure that the brakes are balanced and will stop the tractor in a straight line. Any further adjustment necessary to balance the brakes should be carried out on the right brake.

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Brakes and controls - Mechanical service brakes

Mechanical service brakes - Troubleshooting Problem Possible Cause Brake actuate only when In correct 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 control pedals and shafts - Adjust â&#x20AC;&#x201C; Brake pedal free play . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake control pedals and shafts - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake control pedals and shafts - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake controls - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical service brakes - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Brakes and controls - 33 Parking brake or parking lock - 110

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Brakes and controls - 33 Parking brake or parking lock - 110

SERVICE Parking brake or parking lock Remove – Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inspect – Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install – Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Remove â&#x20AC;&#x201C; Linkage 1. Remove split pin from hand brake linkage. 2. Pull out hand brake lever along with linkage rod from the linkage assembly.

NDIL14TR00561AB

NDIL14TR00562AB

3. Loosen the bolt (1) and remove hand brake pawl (2).

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Inspect â&#x20AC;&#x201C; Linkage Clean the brake pedal assembly thoroughly and check for bush and support rod wear, replace as necessary.

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Install – Linkage Re-install the brake pedals taking the following into consideration. • Reassembly follows the disassembly procedure in reverse. • Carry out adjustment as detailed in Brake control pedals and shafts - Adjust – Brake pedal free play (33.120).

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Index Brakes and controls - 33 Parking brake or parking lock - 110 Parking brake or parking lock - Inspect – Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake or parking lock - Install – Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake or parking lock - Remove – Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47899733 23/06/2015 EN

SERVICE MANUAL Hydraulic systems TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.359] Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.100] Main lift system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

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Contents Hydraulic systems - 35 Hydraulic systems - 000

FUNCTIONAL DATA Hydraulic systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview â&#x20AC;&#x201C; Open center hydraulic circuit and mechanical lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Overview The hydraulic system on tractors is for mechanical lift assembly to raise and lower the lift arms in turn three point linkages and for remote control valves. The high pressure hydraulic circuit is of open centre load sensing type. In this system hydraulic lift and remote control valve are connected in series and pump flow is continuously circulating through the hydraulic system even when the circuit are not being operated. The priority of operation is given to the order of components in the circuit, that is remote valves and hydraulic lift. This means for example when fully operating a remote valve the lift will not operate at the same time. The open centre high pressure hydraulic circuit with mechanically controlled hydraulic lift.

Pump Open centre hydraulic pump assembly is of high pressure gear pump (1).

NDIL14TR00574AB

NDIL14TR00575AB

NDIL14TR00576AB

Filter Full-flow spin on type filter (1) directly mounted on suction side of the pump.

Mechanical hydraulic lift assembly Mounted on top of transmission housing comprising of following components. â&#x20AC;˘ Position control lever (1) â&#x20AC;˘ Draft control lever (2)

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Hydraulic systems - Hydraulic systems

• Distributor (3) • Response control valve (4) • Sensitivity control valve (5) • Diverter valve (6)

NDIL14TR00577AB

NDIL14TR00578AB

NDIL14TR00579AB

NDIL14TR00580AB

• Lift-o-matic switch (7)

• Draft sensing unit (8) • Lift arms (9) and internal linkages and cylinder assembly. • Internal mechanical linkages, relief valves, hydraulic cylinder assembly are mounted inside the hydraulic lift housing which must be remove to obtain access.

Remote control valve Mounted in between right-hand side fender and hydraulic lift housing comprising of following components. • Control lever (1) to operate remote control valve.

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Hydraulic systems - Hydraulic systems

• Pressure relief valve (2).

NDIL14TR00581AB

NDIL14TR00582AB

• Couplers (3) for remote cylinder hoses.

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Overview â&#x20AC;&#x201C; 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, 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. For further details on operation of the mechanical hydraulic lift assembly, refer to Main lift system - Overview (35.100).

NDIL14TR00583FB

1. 2. B. D.

Suction line drawing from transmission housing Delivery line to control valve Lift arm Control valve

F. P. V.

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Oil filter Hydraulic pump Relief valve

Hydraulic systems - Hydraulic systems

NDIL14TR00584GB

Hydraulic circuit diagram F. P. V. 1. 4. 5. 6. 8.

Filter Hydraulic pump Relief valve (installed on lift body or on remote control valve) Spool Spool return spring Control valve plunger Plunger spring Control valve position seat

9. Control valve position 12. Sensitivity control valve 13. Ball 15. 17. 22. 25. 29.

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Cylinder safety valve Arm response adjacent valve Check valve Adjusting pipe lever Arm response adjusting pin knob

Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema

NDIL14TR00907FB

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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Overview â&#x20AC;&#x201C; Open center hydraulic circuit and mechanical lift . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Fixed displacement pump - 104

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Hydraulic systems - 35 Fixed displacement pump - 104

TECHNICAL DATA Pump General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Pump Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Hydraulic systems - Fixed displacement pump

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 1450 RPM and 166 bar (2407 psi) • New or reconditioned • Used • Test oil temperature • Test oil grade Pump gear journal dia Journal housing bore dia. in bearing Journal clearance in bearing Maximum wear clearance Gear in pump body Max pump body wear on suction side Gear flank width Bearing width Pump body width Gear and bearing end float (applicable to new and reconditioned pumps)

Gear, drawing from rear transmission housing Behind timing cover A31 HEMA Valve timing gear driven Anti-clockwise 1:0.931 2328 RPM 32.800 L/min (8.665 US gpm) 19.100 L/min (5.046 US gpm) 13.100 L/min (3.461 US gpm) 55 – 65 °C (131 – 149 °F) SAE 20 W 30 / API - GL4 17.400 – 17.418 mm (0.685 – 0.686 in) 17.450 – 17.470 mm (0.687 – 0.688 in) 0.032 – 0.070 mm (0.001 – 0.003 in) 0.100 mm (0.004 in) 0.020 – 0.064 mm (0.001 – 0.003 in) 0.100 mm (0.004 in) 24.000 – 24.015 mm (0.945 – 0.945 in) 24.490 – 24.510 mm (0.964 – 0.965 in) 73.135 – 73.160 mm (2.879 – 2.880 in) 0.100 – 0.180 mm (0.004 – 0.007 in)

Pump - Torque Description Nut, pump drive gear (C1) Nut, pump mounting on timing case (C2) Bolt, pump cover (C3) Screw, filter mounting bracket (C4) Screw, delivery pipe to pump (C5)

Thread size

Torque

M6 X 1

8 N·m (5.9 lb ft)

M10 X 1.25 M8 X 1.25 M6 X 1

42 N·m (31 lb ft) 25 N·m (18 lb ft) 10 N·m (7 lb ft)

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Hydraulic systems - Fixed displacement pump

NDIL14TR00585FB

Pump - Special tools Tool description Adopter hydraulic pressure checking

Tool number 990877

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Hydraulic systems - Fixed displacement pump

Pump - Static description Hydraulic pumps are spur gear type with fixed displacement according to e rpm. Pump is mounted on the engine timing gear case. It is driven by engine timing gears. Oil is drawn by pump from the transmission housing by pump via oil filter. Pump comprises of four main components: the end cover. The body, the bush/gear assembly and the mounting flange, the whole being held together by four tie bolts. The bush gears is 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.

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Hydraulic systems - Fixed displacement pump

NDIL14TR00586FB

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 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 clamp screws (1) and disconnect supply pipe (2) from filter bracket.

NDIL14TR00587AB

NDIL14TR00588AB

NDIL14TR00589AB

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 (1) from the timing case.

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Hydraulic systems - Fixed displacement pump

Pump - Install Installation of hydraulic pump is reverse of the removal procedure. 1. Clean and decrease the mating surfaces thoroughly. 2. Replace the packing seal if necessary. 3. Tighten all fasteners to correct torque as detailed on Pump - Torque (35.104).

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Hydraulic systems - Fixed displacement pump

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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Hydraulic systems - Fixed displacement pump

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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Hydraulic systems - Fixed displacement pump

Pump - Assemble Reassemble the pump referring to figure 1 and observe the following: 1. Assembly follows the disassembly procedure in reverse, from step 12 back to 1. Refer to Pump Disassemble (35.104). 2. Always work in very clean conditions, to prevent contamination from foreign matter which could damage the pump. 3. Match the components (5) , (6) and (7) shown in figure Pump - Disassemble (35.104) marked, to reassemble them in their original position. 4. 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. 5. Install seals in their locations. 6. Assemble seal (17) on front end cover.

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NDIL14TR00591AB

Hydraulic systems - Fixed displacement pump

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 292870 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.

NDIL14TR00592AB

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 5.0 L (10.6 US pt) measuring jar. Simultaneously starting a stop watch. 8. Note the time to fill 5.0 L (10.6 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, 11.000 – 12.000 L/min (0.388 – 0.424 cfm) at 166 bar (2407 psi). • The minimum acceptable deliveries of a used pump is 7.0 L/min (1.8 US gpm) at 166 bar (2407 psi). The maximum permissible time to fill a 5.0 L (10.6 US pt) jar is 43 s. • If more than 43 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.

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Index Hydraulic systems - 35 Fixed displacement pump - 104 Pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Main control valve - 359

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Hydraulic systems - 35 Main control valve - 359

FUNCTIONAL DATA Main control valve Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Main control valve Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DIAGNOSTIC Main control valve Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Hydraulic systems - Main control valve

Main control valve - Sectional view Nomenclature

NDIL14TR00908FB

1. 2. 3. 4. 5.

Control kit PDS kit Working section Load drop check valve Tie rod

6. Outlet cover 7. Blanking plug 8. Lever kit 9. Main relief valve 10. Inlet valve

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Hydraulic systems - Main control valve

Cut section

NDIL14TR00909FB

1. 2. 3. 4.

Outlet cover Lever kit Spool Main releif valve

5. 6. 7. 8.

Inlet cover Control kit PDS kit Load drop check valve

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Hydraulic systems - Main control valve

Working

NDIL14TR00910FB

1. To cylinders 2. To tank (Outlet)

3. From cylinder 4. From pump(Inlet)

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Hydraulic systems - Main control valve

Position neutral

NDIL14TR00911FB

NDIL14TR00912FB

Position drawing (position P-A)

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Hydraulic systems - Main control valve

Position drawing (position P-B)

NDIL14TR00913FB

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Hydraulic systems - Main control valve

Main control valve - Service instruction Doâ&#x20AC;&#x2122;s and dontâ&#x20AC;&#x2122;s 1. Always dismantle the valve before repair. 2. Plug all ports and hoses down the valve. 3. Place on a clean table before repair. 4. Never file/hone any spool or bore. 5. Clean components only in diesel or kerosene. 6. Always change O-Ring after dismantle. 7. Do not tamper the relief valve settings. Increase in relief valve setting will results the failure of pump/cylinder/structure.

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Hydraulic systems - Main control valve

Main control valve - Troubleshooting Problem Possible Cause Absolutely no functioning Engine is not running of the control valve Low oil level in the tank

Spool in the control valve may be jam

Check the oil level and refill to specified limit Check the coupling Set main relief valve to required pressure (pressure setting can be done by connecting the pressure gauge to the inlet of control valve and actuating any one operation at fully RPM) Disassemble the main relief valve clean it with kerosene and assemble it. Or replace the main relief valve 1. Remove the spool and clean it

Linkages may not be properly adjusted Linkages may not be properly adjusted

2. Check the contamination level Check the linkages Check the linkages

Pump coupling may be disengage Main relief valve may be unscrewed fully

Main relief valve may be jam Any one operation not functioning Cycle time slow in all operations

Uncontrolled movement in any operation

Main relief valve pressure may have leak- Replace the main relief valve age Insufficient oil supply Check the oil level Cavitation generating in the system

Required load not lifting

Correction Check the engine

Engine RPM may be less Main relief valve pressure may be less

Contact supplier to introduce anti cavitation valve Check the engine RPM Set the main relief valve pressure to design pressure NOTE : Increase in main relief valve pressure more than design pressure may damage the pump or cylinder or structure Check the seals and replace if it damaged

External leakage seen on Seals may be damaged or missing the control valve Fittings or components are not tighten to Check the fitting and components torque required torque Pump or cylinder or Main relief valve pressure may be tam- Check the main relief valve pressure control valve failure at the pered or jam end stroke Due to spike generated in the system Check the port relief setting

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Index Hydraulic systems - 35 Main control valve - 359 Main control valve - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main control valve - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main control valve - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Remote control valves - 204

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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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 valves Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Remote control valves Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Hydraulic systems - Remote control valves

Remote control valves - General specification Type Make Location Control Relief valve setting Valve plunger clearance in body Relief valve spring length Free Under 241 – 347 N (54 – 78 lb) Valve plunger return spring length Check valve spring length

Spool, (automatic return to neutral) HEMA On right-hand side final drive Hand levers 11 – 186 bar (160 – 2697 psi) 0.0030 – 0.0060 mm (0.0001 – 0.0002 in) 39.400 mm 38.200 mm 42.800 mm 15.900 mm

(1.551 in) (1.504 in) (1.685 in) (0.626 in)

Remote control valves - Special tools Tool description Hydraulic pressure testing kit

Tool number 292870

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Hydraulic systems - Remote control valves

Remote control valves - Dynamic description The remote control valves are used to control external hydraulic implements connected to the tractor. Tractor is equipped with two remote valves, which are secured by the upper right-hand side of the rear axle housing. The remote valves are operated by means of control lever located at the operations right-hand side behind the hydraulic lift control levers.

NDIL14TR00683GA

Single acting cylinder control and Double acting cylinder control Remote valve control lever has three positions. A. Raise Pulling the lever forward will extend the cylinder and raise the implement. B. Neutral By releasing, the lever automatically returns to neutral position due to spring loaded and deactivate the cylinder connected.

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Hydraulic systems - Remote control valves

C. Lower Pushing the lever backward will retreat the cylinder and lower the implement. NOTE: By shuffling the cylinder connection to remote control valve will reverse the lever function. ie. forward movement will lower the implement, backward will raise the implement. NOTE: The remote control valve uses the same hydraulic fluid as the hydraulic lift unit, but is operated independently by means of the hand lever (c). It is not possible however, to operate the remote control valve and the hydraulic unit lift unit simultaneously.

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Hydraulic systems - Remote control valves

Remote control valves - Remove 1. Loosen screws (1) and disconnect hydraulic delivery pipe. 2. Loosen banjo bolt (2) and disconnect hydraulic line to lift housing.

NDIL14TR00685AB

NDIL14TR00686AB

NDIL14TR00687AB

3. Disconnect hydraulic line (1) between remote control valve and distributor.

4. Loosen bolts (1) two numbers retaining remote control valve bracket on rear axle housing and remove remote control valve assembly from the tractor.

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Hydraulic systems - Remote control valves

Remote control valves - Install 1. Installation of remote control valve is reverse of the removal procedure. â&#x20AC;˘ Renew all the sealing washers on hydraulic connections.

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Hydraulic systems - Remote control valves

Remote control valves - Assemble 1. Re-assembly follows the disassembly procedure in reverse from step 10 back to step 1. â&#x20AC;˘ Check pressure relief valve setting.

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Hydraulic systems - Remote control valves

Remote control valves - Disassemble 1. Remove the remote control valve from tractor as described earlier. 2. Loosen bolt (1) and remove the remote valve clamp. 3. Loosen the banjo bolts (2) and remove the remote valves from the housing. 4. Loosen the two bolts (3) and remove the bracket for remote valves.

NDIL14TR00688AB

NDIL14TR00689AB

NDIL14TR00690AB

NDIL14TR00691AB

5. Loosen the lock-nut (1) and remove the hand lever (2).

6. Retrieve the hand lever return spring (1) from the housing.

7. Loosen the three bolts and remove the plate and spool housing (1) from the base plate.

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Hydraulic systems - Remote control valves

8. Pull out the spool shaft (1) from the spool housing.

NDIL14TR00692AB

NDIL14TR00693AB

9. Loosen and remove the pressure relief valve (1) from the spool housing. 10. Retrieve relief valve spring from the spool housing.

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Hydraulic systems - Remote control valves

Remote control valves - Inspect 1. Inspect O-rings and seals and replace if necessary.

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Index Hydraulic systems - 35 Remote control valves - 204 Remote control valves - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valves - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valves - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valves - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valves - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valves - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valves - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valves - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Main lift system - 100

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Hydraulic systems - 35 Main lift system - 100

TECHNICAL DATA Main lift system General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Main lift system Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Sectional view - Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Dynamic description –Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Dynamic description – Internal linkage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SERVICE Main lift system Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Disassemble – External controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Assemble – External controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Disassemble – Internal controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Assemble – Internal controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Disassemble – Cross shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Assemble – Cross shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Disassemble –Distributor (control valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Inspect – Distributor (control valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Assemble – Distributor (control valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Adjust – Distributor (control valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

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Main lift system Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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Hydraulic systems - Main lift system

Main lift system - General specification Type Control Lift sensitivity adjustment Lift-o-matic 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 clearance 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 Right-hand side bushing interference fit in housing Left-hand side bushing interference fit in housing Cross shaft end float with lift arms in position Draft control shaft O.D Shaft housing bore dia. in lift body Shaft clearance in body Position control shaft diameter Shaft housing bore dia. on draft control shaft Shaft clearance in body Draft control lever pin and draft control inner lever hinge pin dia. at needle roller bearings Control valve link arm and draft control inner lever I.D. at needle roller bearings Valve spool clearance in body Lift valve clearance in control valve body Valve spool return spring length: • Free • Under 31.7 – 35.0 N (7.1 – 7.9 lb) Control valve return spring length: • Free • Under 103.0 – 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 15.8 – 17.6 N (3.6 – 4.0 lb) Check valve return spring length: • Free • Under 35.3 – 39.2 N (7.9 – 8.8 lb)

Position control, draft control and combined position / draft control Two independent levers External four-position lever on control valve Permits rapid lift arm up/down movement by push button without operating draft or position control levers Knob on control valve 90.0 mm (3.5 in) x 110.0 mm (4.3 in) 700 cm³ 181 – 191 bar (2624 – 2770 psi) 210 – 215 bar (3045 – 3118 psi) 89.980 – 90.000 mm (3.543 – 3.543 in) 90.036 – 90.071 mm (3.545 – 3.546 in) 0.036 – 0.091 mm (0.001 – 0.004 in) 47.975 – 48.000 mm (1.889 – 1.890 in) 54.970 – 55.000 mm (2.164 – 2.165 in) 48.100 – 48.184 mm (1.894 – 1.897 in) 55.100 – 55.184 mm (2.169 – 2.173 in) 0.100 – 0.209 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 – 14.000 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 – 14.000 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) 13.0 mm (0.5 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) 18.0 mm (0.7 in)

Hydraulic systems - Main lift system

Sensitivity adjustment pin lever outer spring length: • Free • Under 61.8 – 67.7 N (13.9 – 15.2 lb)

20.5 mm (0.8 in) 13.8 mm (0.5 in)

Implement attachment Type Category ( TT75 ) Category ( TT55 ) Draft control Max. lift capacity with lower links horizontal ( TT75 ) Max. lift capacity with lower links horizontal ( TT55 )

3-point linkage II I and II Top link sensing 1920 kg (4233 lb) 1525 kg (3362 lb)

Main lift system - Torque Description Bolt, lift to rear transmission housing (C1) Bolt, control valve body to lift (C2) Bolt, lift arm (C3) Plug, max. rise adjustment (C4) Nut, position control shafts (C6) Nut, lever bracket studs (C7) Bolt, spring to top link support (C8) Bolt, spring to lift body (C9) Bolt, shaft to top link support (C10) Bolt, suction connection (C11) Bolt, delivery connection on lift control valve (C12) Bolt, pump (C13) Nut, pump cover (C14) Nut, check chain bracket (C15) Nut, check chain to lower link arms (C16) Top retaining screw, tow-bar cross link (C17) ( TT75 ) Bottom retaining nut, tow-bar cross link (C18) ( TT75 ) Bolt, rear cover and tow-bar support (C19) ( TT75 ) Bolt, front tow hook to axle support (C20) ( TT75 ) Nut, control valve stay bolts (C21) Connection, oil outlet to lift (C22) Plug, relief valve spring (C23) Bolt, control lever support (C24) Plug, single/double acting change over valve (C25) ( TT75 )

Thread size. M14 X 1.5 M8 X 1.25 M14 X 1.5 M12 X 1.25 M10 X 1.25 M8 X 1.25 M14 X 1.5 M14 X 1.5 M16 X 1.5 M12 X 1.25 M10 X 1.25 M6 X 1.0 M10 X 1.25 M14 X 1.5 M18 X 1.5 M20 X 1.5 M20 X 1.5 M16 X 1.5 M16 X 1.5 — — — —

Torque 150 N·m (111 lb ft) 27 N·m (20 lb ft) 150 N·m (111 lb ft) 105 N·m (77 lb ft) 15 N·m (11 lb ft) 26 N·m (19 lb ft) 22 N·m (16 lb ft) 22 N·m (16 lb ft) 20 N·m (15 lb ft) 10 N·m (7 lb ft) 6 N·m (4 lb ft) 8 N·m (6 lb ft) 42 N·m (31 lb ft) 15 N·m (11 lb ft) 320 N·m (236 lb ft) 48 N·m (35 lb ft) 40 N·m (30 lb ft) 22.5 N·m (17 lb ft) 22.5 N·m (17 lb ft) 20 N·m (15 lb ft) 20 N·m (15 lb ft) 20 N·m (15 lb ft) 6 N·m (4 lb ft)

—

20 N·m (15 lb ft)

Thread size. M14 X 1.5 M8 X 1.25 M14 X 1.5 M12 X 1.25 M10 X 1.25 M8 X 1.25 M14 X 1.5 M14 X 1.5 M16 X 1.5 M12 X 1.25

Torque 150 N·m (111 lb ft) 27 N·m (20 lb ft) 150 N·m (111 lb ft) 105 N·m (77 lb ft) 15 N·m (11 lb ft) 26 N·m (19 lb ft) 22 N·m (16 lb ft) 22 N·m (16 lb ft) 20 N·m (15 lb ft) 10 N·m (7 lb ft)

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Description Bolt, delivery connection on lift control valve (C12) Bolt, pump (C13) Nut, pump cover (C14) Nut, check chain bracket (C15) Nut, check chain to lower link arms (C16) Nut, control valve stay bolts (C21) Connection, oil outlet to lift (C22) Plug, relief valve spring (C23)

Thread size. M10 X 1.25 M6 X 1.0 M10 X 1.25 M14 X 1.5 M18 X 1.5 — — —

Torque 6 N·m (4 lb ft) 8 N·m (6 lb ft) 42 N·m (31 lb ft) 15 N·m (11 lb ft) 320 N·m (236 lb ft) 20 N·m (15 lb ft) 20 N·m (15 lb ft) 20 N·m (15 lb ft)

Main lift system - Sealing Operation description Lift housing to rear axle housing (S1) Front cover to lift housing (S2) Distributor assembly to front cover (S3)

Sealant specification LOCTITE® 574™ LOCTITE® 574™ LOCTITE® 574™

NDIL14TR00964FB

Main lift system - Special tools Tool description Installer, lift shaft housing seal Installer, lift piston with seal Adjuster, position/draft control Main spool leakage testing tool Adopter, over pressure relief valve Adopter, cylinder safety valve Cylinder safety valve pressure adjusting tool Wrench, lift arm maximum height adjustment 47899733 23/06/2015

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Tool number 292535 292547 293846 293982 290824 290828 291862 293870

Hydraulic systems - Main lift system

Tool description Installer, lever needle bearing Installer, needle bearing main spool lever ‘C’ spring tensioning lever Hydraulic ‘C’ spring travel gauge Installer, hydraulic housing ‘C’ spring bush 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 / remover, hydraulic housing shaft bush left-hand side Installer / remover, hydraulic housing shaft bush right-hand side Installer, response pin seal

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Tool number 293838 293839 290819 9971359 9971352 291215 292870 293449 292060 293168 291318 293247 292246 291328 9971353 9971355 293858

Hydraulic systems - Main lift system

Main lift system - Sectional view

NDIL14TR00595GB

Draft control spring A. B. Control valve B1. Lift sensitivity adjustment lever B2. Response control knob C1. Lift retaining screw C2. Thrust plate retaining screw G = 0.200 â&#x20AC;&#x201C; 1.400 mm (0.008 â&#x20AC;&#x201C; 0.055 in), shaft end float 1. Inner arm 2. Arm Lifting arms 3. Arm thrust plates 4. Right-hand side seal 5. 6. Left-hand side seal Right-hand side bushings 7.

8. 10. 11. 12. 13. 14. 15. 16. 18. 19. 20. 27. 28.

Left-hand side bushings Thrust washers Top link support Piston rod pin Travel limit adjusting screw Travel limit adjustment screw lock-nut Travel limit control rod Control valve link pin Draft control inner lever pivot Set screw Front cover Screw retaining spring to top link support Screw retaining spring to lift body

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Main lift system - Sectional view - Control valve

NDIL14TR00596GB

1. 2. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Valve spool Valve spool seat plug Valve spool return spring Valve plunger Plunger spring Plug Piston seat Valve piston Spring cup Draft sensitivity adjusting valve spring Draft sensitivity adjusting valve Plug Spool seat ring Cylinder safety valve

18. 19. 17. 21. 22. 23. 25. 26. 27. 28. 29. 30. 31. 30.

Ball Response control adjusting pin Delivery connection Check valve spring Check valve Check valve seat descent ball Adjusting pin lever Sector Plug Adjusting pin Response control adjustment knob Retaining ring Roll Pin Back-up ring

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16. Response control adjusting valve spring 17. Response control adjusting valve

33. O-ring C3. Bolt

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Main lift system - Overview Hydraulic system This is a live hydraulic system, where gear type hydraulic pump is mounted directly to timing case. Transmission lubrication oil is used also as hydraulic oil. This system described here mechanically senses changes in the draft loading via the top link of the three point linkage. The system allows the operator to select position control, draft control, combined position and draft control and float. CAUTION Hydraulic filter is to be changed at regular intervals as recommended. Hydraulic and transmission parts may get damaged if filter is choked. Always use genuine NEW HOLLAND filters.

NDIL14TR00597AB

NDIL14TR00598AB

NDIL14TR00599AB

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).

Pre-operation checks DANGER Before starting the engine, always ensure that the lift-o-matic fast raise button is pushed in, to prevent inadvertent raising of three point linkage. NOTICE: Some mounted or semi-mounted equipment may interfere with and cause damage to tractor sheet metal. To avoid damage check for clearance between tractor and implements.

Position control operation Position control provides accurate control of implements such as sprayers, rakes, rotary tillers etc. that operate above the ground. Once set, position control will maintain the selected implement height. NOTICE: Always set the system to position control at any time when not actually operating in draft control, such as when attaching or transporting equipment or when no equipment is attached. Fully open the divertor valve (6) figure 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 quadrant. An adjustable stop (3) is provided to enable the lever to be returned to the required working position.

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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 soil resistance will cause draft loading on the implement to increase or decrease. When starting work, fully open the diverter valve and move the position control lever (2) fully forward. Lower the implement in to the work using draft control lever (1). push the lever forward to increase the draft loading. Pull rearwards to reduce the draft loading. Forward movement of the draft control lever will increase the implement depth and rearward movement will reduce the depth.

NDIL14TR00600AB

NDIL14TR00601AB

NDIL14TR00600AB

Once set, tractor hydraulic system will automatically adjust the implement depth to maintain an even pull on the tractor and minimise 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 implement to the required depth by means of the draft control lever (1), as previously described. When the implement reaches the required depth, raise the position control lever (2) back until the lift arms tends to rise. The lift linkage is now operating in draft control but the implement is prevented, by the position control function, from sinking too far when draft reduces.

Float operation Move the position control lever (2) and the draft control lever (1) fully forward. The 3-point linkage will now be free to â&#x20AC;&#x2DC;floatâ&#x20AC;&#x2122; or follow the ground contour, a feature useful for scraper blades etc.

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Lift-o-matic The lift-o-matic is used for automatic repositioning of implement after turn. It helps in saving the time and adds comfort to the operator. Further it maintains uniform depth and prepares a better seedbed. To raise the implement at the end of each pass, or whenever required, move the latch (1) rearward to release the fast raise button (2). The 3-point linkage (and implement) will raise to the full height without need to move either the position or draft control lever. To lower the implement, simply press the fast raise button (1) fully in, and the implement will lower to the preset depth, set by the position control lever or draft control lever.

NDIL14TR00603AB

NDIL14TR00604AB

NDIL14TR00605AB

CAUTION When transporting equipment on 3-point linkage, raise the implement using the position control lever. The hydraulic system will maintain the equipment height set by the position control lever and prevent the equipment lowering and becoming damaged.

Sensitivity control To adjust the sensitivity of hydraulic system when working in draft control, lever (1) needs to be adjusted. Lever up- Reduces sensitivity Lever down- Increases sensitivity

Response control The response control knob (1) varies the speed of drop of the lower links. Clockwise rotation - Increases speed of drop. Anticlockwise rotation - Decreases speed of drop NOTICE: To lock implements in transport position when driving on road, fully raise position control lever (2) figure 1, and screw in (rotate clockwise) knob (1) figure 10.

NDIL14TR00606AB

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Use of diverter valve and external supply port The diverter valve (2), figure 10 is used to divert oil, normally flowing to the left cylinder of the 3 point linkage, to the external supply port. A single acting cylinder can be connected to this external port and be operated by the draft control lever.

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Main lift system - Dynamic description â&#x20AC;&#x201C;Distributor The distributor is pre-set to perform three phases. A. Neutral phase B. Lifting phase C. Lowering phase

A. Neutral phase Refer to figure 1. In this phase the control valve keeps pressure on the oil coming from the pump to flow freely to the tank. In this phase the control spool (1) is in such a position, oil is delivered through sensitivity control valve (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 on the road with 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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NDIL14TR00607GB

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B. Lifting phase Refer to figure 2. 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 ports, (and) are free and oil may be discharged quickly through all three ports (T1), (T2) and (T3), with consequent short reaction time resulting in increased sensitivity.

NDIL14TR00608GB

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C. Lowering phase Refer to figure 3. 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).

NDIL14TR00609GB

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Main lift system - Dynamic description – Internal linkage system Functioning of internal linkage system are as follows: A. Position control B. Float control C. Draft control D. Combined position and draft control

A. Position control Refer to Fig. 1. 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), upwards. As the cam (28) on arm cross-shaft is stationary at the beginning of 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 arm lift 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 (4), refer to Main lift system - Dynamic description –Distributor (35.100) Figure 3 in the direction indicated by the 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 neutral through adjusting screw (3) before the piston reaches mechanical travel limit stop. The same movements occur in reverse when lever (P) is moved forward to lower arms.

B. Float control Refer to Fig. 1. With position control lever (P) and draft control lever (F) fully forward: • The draft control linkage is not activated. • Lever (14), link (9) and lever (6) are moved in the direction opposite to that indicated by the solid arrows, and control valve is held in lowered position (refer to Main lift system - Dynamic description –Distributor (35.100) Figure 3), thereby letting arms swing freely and associated implement float on the surface of the soil.

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NDIL14TR00610FB

C. Draft control Refer to Fig. 2. 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 force on the lower links will increase. This will then cause a greater top link thrust against the spring (20) which, compressing, transmits motion in the direction of the solid arrows, to the lever (22), the lever (18), the link (17), 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 force reduces the compression of spring (20) and causes lever (22) to rotate in the opposite direction, allowing lever (6) to move backwards, pulled by the control valve spool spring. Control valve returns to neutral and arms stop lifting. Once the hard stretch has been left behind, the draft control spring (20) returns completely to its original position and lever (6) moves further back. The control valve returns to the discharge position (refer to Main lift system - Dynamic description â&#x20AC;&#x201C;Distributor (35.100) Figure 3) so that the arms lower the implement 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.

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NDIL14TR00611FB

D. Combined draft and position control Refer to Fig. 1 and 2. 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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Main lift system - 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

Remove the hydraulic lift from the rear axle housing as follows: 1. Remove operatorâ&#x20AC;&#x2122;s seat (1).

NDIL14TR00612AB

NDIL14TR00613AA

NDIL14TR00614AB

2. Remove three-point linkages. (Top link and lift arms).

3. Disconnect oil supply line at (1) between remote control valve and distributor.

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4. Disconnect remote control valve return line at hydraulic lift housing (1).

NDIL14TR00615AB

NDIL14TR00616AB

NDIL14TR00617AA

5. Loosen the hydraulic lift housing retaining bolts (1).

6. Lift the housing using suitable hoist and place it on a clean flat surfaced table or fix it on stand. NOTICE: Never lift the housing by holding distributor knobs and delicate parts.

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Main lift system - Install 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. Refit the hydraulic lift on the transmission housing as follows. • Reinstallation follows the removal procedure in reverse. • Before refitting the hydraulic lift in the rear transmission casing, clean and de grease the mating surfaces thoroughly and apply a strip of sealing compound of about 2.0 mm (0.1 in) diameter as shown in the figure 1. • Apply the torque settings listed on Main lift system - Torque (35.100).

NDIL14TR00618FA

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Hydraulic systems - Main lift system

Main lift system - Disassemble â&#x20AC;&#x201C; External controls 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

With hydraulic lift assembly on tractor. 1. Remove nuts (1) and lift-o-matic button (2).

NDIL14TR00619AB

NDIL14TR00620AB

NDIL14TR00621AB

2. Loosen nuts (1) and remove support plate (2).

NOTE: To remove plate (2), lift-o-matic lever shaft nut (1) should be loosened to clear the plate.

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3. Retrieve springs (1) and clutch plate and remove locknut (2).

NDIL14TR00622AB

NDIL14TR00623AA

NDIL14TR00624AB

4. Remove position control lever, clutch plates draft control lever and spacer.

5. Retrieve position and draft control lever keys. 6. Remove quadrant plate (1). NOTE: To remove lift-o-matic lever (1), lift housing have to be removed from the tractor. See removal of Internal controls on Main lift system - Disassemble (35.100) for procedure.

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Main lift system - Assemble â&#x20AC;&#x201C; External controls Reassembly follows the disassembly procedure in reverse from step 6 back to step 1. (Refer to Main lift system - Disassemble (35.100)). See Main lift system - Overview (35.100) and Main lift system - Adjust (35.100) for lift-o-matic button settings and adjustments.

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

1. Remove the lift assembly from the rear axle and fix on a rotary stand. Refer to Main lift system - Remove (35.100). 2. Remove external control levers. Refer to Main lift system - Disassemble â&#x20AC;&#x201C; External controls (35.100).

NDIL14TR00617AA

NDIL14TR00626AB

NDIL14TR00627AB

3. Loosen two Allen screws (1) and remove diverter valve assembly (2).

4. Retrieve pipe (1) and O-rings.

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5. Loosen four screws (1) and remove distributor (control valve) assembly (2).

NDIL14TR00628AB

NDIL14TR00629AB

NDIL14TR00630AA

NDIL14TR00917AB

6. Loosen four bolts (1) and remove lift housing front cover.

7. Remove piston and cylinder from the housing. NOTE: To remove piston, lower the lift arm by hand to push out the piston out of lift housing. NOTE: To remove cylinder, gently hammer out the cylinder using plastic hammer or aluminium rod.

8. Using special tool number 291215 A, remove lift-omatic spring (1).

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9. Remove lift-o-matic shaft dowel pin (1).

NDIL14TR00632AB

NDIL14TR00633AB

10. Pull out lift-o-matic shaft (1) from the housing.

11. Retrieve lift-o-matic linkage (2) from the housing.

NDIL14TR00634AB

NDIL14TR00635AB

12. Open lock and remove pin (1) by screwing out bolt (2).

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13. Retrieve linkages (1) from the housing.

NDIL14TR00636AB

NDIL14TR00637AA

NDIL14TR00638AA

NDIL14TR00639AA

14. Open lock and remove sector plate.

15. Open lock and remove draft control plate.

16. Take out position control lever shaft and draft control lever shaft from the housing.

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17. Disconnect draft sensing linkage (1) by removing circlip (2) and loosening bolt (3).

NDIL14TR00640AB

NDIL14TR00641AB

NDIL14TR00642AB

NDIL14TR00643AB

18. Pull out draft sensing shaft (1) from the housing.

19. Retrieve draft sensing linkages (1) from the housing.

20. Loosen Allen screws (1) and remove stopper assembly (2).

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NOTE: Piston connecting rod can be removed only after removing cross shaft from the housing. Refer to Main lift system - Disassemble â&#x20AC;&#x201C; Cross shaft (35.100) for cross shaft removal procedure.

NDIL14TR00644AB

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Hydraulic systems - Main lift system

Main lift system - Assemble – Internal controls 1. Re-assembly follows disassembly procedure in reverse from step 20 back to 1. • Check O-rings and needle bearing for wear and damage. • Refer to Main lift system - Adjust – Distributor (control valve) (35.100) for position, draft and lifto-matic control adjustments.

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Hydraulic systems - Main lift system

Main lift system - Disassemble â&#x20AC;&#x201C; Cross shaft 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. With lift assembly on tractor, remove bolt (1) and thrust plate (2) from both sides of the lift arm.

NDIL14TR00645AB

NDIL14TR00646AA

NDIL14TR00647AA

2. Remove lift arms from shaft using suitable puller or by hammering gently.

3. Remove lift arm shaft by tapping on the right-hand side end of the shaft with mallet.

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Hydraulic systems - Main lift system

4. Retrieve piston rod and cam sleeve from the housing. 5. Remove seal from the housing using suitable tool.

NDIL14TR00648AA

NDIL14TR00649AA

6. Remove left-hand side and right-hand side shaft bushes from the housing using special tool number 9971353 for left-hand side bush and 9971355 for right-hand side bush.

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Hydraulic systems - Main lift system

Main lift system - Assemble – Cross shaft Reinstall the shaft and lift arm in the lift housing observing the following : 1. Reinstallation follows the removal procedure in reverse from step 6 to step 1. Refer to Main lift system Disassemble (35.100). • Fix new seals using special tool number 292535.

NDIL14TR00650AA

NDIL14TR00651AA

NDIL14TR00652AB

2. Fix bushes using special tool number 9971353 and 9971355.

3. Ensure that dimensions ‘A’, ‘B’ and ‘C’ are as shown in figure. Bushings do not require reaming after installation. 4. On completing assembly, check cross shaft end float is 0.200 – 1.400 mm (0.008 – 0.055 in).

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Hydraulic systems - Main lift system

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

1. Disconnect hydraulic line between distributor and remote control value at (1).

NDIL14TR00653AB

NDIL14TR00654AB

NDIL14TR00655AB

2. Loosen Allen screw (1) and remove diverter value (2).

3. Retrieve pipe (1) and O-rings.

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4. Loosen screws (1) and remove distributor from the lift housing.

NDIL14TR00656AB

NDIL14TR00657GB

5. Remove cylinder safety valve (15), response control valve (17) and pin (19) after removing knob (29).

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6. Remove fitting (20), retrieving check valve (22) and seat (23). 7. Remove plug (3), retrieving valve spool (1), seat (2), spring (4) and ring (14). 8. Remove draft sensitivity control valve plug (13) and plug (7), retrieving plunger (5), spring (6), piston (9) and seat (8). 9. Remove retaining ring (30) and retrieve spring cup (10), spring (11) and draft sensitivity control valve. 10. Unscrew plug (27), remove roll pin (31), and retrieve draft control valve pin (28).

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Main lift system - Inspect â&#x20AC;&#x201C; Distributor (control valve) Thoroughly check seals, replacing if necessary Check valves for wear and clearance in associated seats. If replacement is required, note that spare valve spools (1), are supplied together with matching seats (2) and that valve plunger (5) is supplied together with the control valve body. Check efficiency of spool (1) as described in Main lift system - Adjust (35.100). Check cylinder safety and relief valve setting as described. Valve may be integral with remote control valves or installed on front cover.

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Main lift system - Assemble â&#x20AC;&#x201C; Distributor (control valve) 1. Re-assemble control valve as shown in figure ( Main lift system - Disassemble â&#x20AC;&#x201C;Distributor (control valve) (35.100)) and install the front cover only after carrying out the adjustments specified.

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Main lift system - Adjust – Distributor (control valve) 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 (2) with O-ring, and spool (1) in connection fitting 293982, checking that seals in bottom of seat prevent leakage through the connection fitting itself and connect the latter to hand pump. 2. Push spool (1) into contact with seat (2) and lock the spool (1) 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

NDIL14TR00659AA

NDIL14TR00660AB

Position control adjustment With lift unit removed from tractor. 1. Remove distributor assembly 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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3. Carefully mark the position on the arm (S2) and on the housing (S1).

NDIL14TR00661AA

NDIL14TR00662AB

NDIL14TR00328AB

NDIL14TR00663AA

4. Slacken lock-nut (10) and unscrew the maximum lift height adjuster screw (6) using special tool number 293870, until it is no longer in contact with control valve lever (7).

5. Install special tool 293846 (A) on lift housing.

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6. Using two wrenches, back off lock-nut (8), Fig. 15 and tighten or slacken adjustable link rod ( (9), Fig. 15) so that the plunger (P1) is aligned with outer scale (R1) of tool (special tool number 293846).

NDIL14TR00664AB

NDIL14TR00665AB

NOTE: This condition corresponds to a gap (L1) of 82.000 – 82.100 mm (3.228 – 3.232 in) between lever end (7) and lift housing front face measured applying a force (F1) of 4.0 – 4.5 kg (8.8 – 9.9 lb) to lever end. 7. Tighten lock-nut (8).

8. Bring position control lever (P) fully forward on quadrant. 9. Rotate arm shaft to bring piston fully forward and check that moving rod (P1) of tool 293846 is no more than 1.300 – 1.700 mm (0.051 – 0.067 in) back from the inner register (R2) of the tool.

NDIL14TR00664AB

NDIL14TR00667AB

NOTE: This condition corresponds to a gap (4) of 86.300 – 86.700 mm (3.398 – 3.413 in) between lever end (7) and lift housing front face measured applying a force (F1) of ( 4.0 – 4.5 kg (8.8 – 9.9 lb)) to lever end.

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Maximum lift arm travel adjustment (on bench) 1. Install special tool 293846 (A) on lift body.

NDIL14TR00663AA

NDIL14TR00669AB

NDIL14TR00670AB

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 293870 (C), tighten screw (6) until plunger (P1), Fig. 10) stand-in is not more than 1.300 – 1.700 mm (0.051 – 0.067 in) from the inner register ( (R2), 10 of the tool 293846. 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 end top cover front face.

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Maximum lift arm travel adjustment (on tractor) 1. Raise the hydraulic lift arms by hand to maximum height position. Make two corresponding marks, one on lift body (S1) and one on lift arm (S2). 2. Set position and draft control levers (P) and (F) 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 (S1) and (S2) 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 between (S1) and (S2).

NDIL14TR00671AB

NDIL14TR00672AB

NDIL14TR00673AB

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 293870 to obtain distances specified above. 7. Tighten lock-nut (10). 8. Reinstall plug (19).

Draft control spring travel adjustment 9. Disengage stop block (1) and with draft control spring (2) free, check that distance (L2) between plate (3) and spring (2) is 12.700 – 13.000 mm (0.500 – 0.512 in). If necessary, adjust shim (H1) thickness, reducing them if it is lower and adding to them if it is higher.

10. Put spring completely under traction using a suitable rod applied to top link support and check that distance (L3) between plate (16) and spring (94) is in the 19.200 – 19.700 mm (0.756 – 0.776 in) range. If it is lower, reduce the shims (H2) between the spring and the top link support fork. If higher, increase them.

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Draft control linkage adjustment (on bench) Having carried out the position control, maximum lift arm travel and draft control spring adjustments, adjust draft control as follows: 1. Remove distributor (control valve) assembly and fix special tool number 293846. 2. Fit outer draft control link (1).

NDIL14TR00674AB

NDIL14TR00675AB

NDIL14TR00664AB

NDIL14TR00677AB

3. Put position control lever (P) fully forward on quadrant and pull back the draft control lever (F) 184 – 186 mm (7.244 – 7.323 in) (L2) measured from the beginning of the slot and the edge of the lever (F). 4. Adjust link (22) to 70.000 – 70.500 mm (2.756 – 2.776 in) (L3).

5. Adjust outer draft control link ( (1), Fig. 22) so that the end (P1) of tool 293846 (A) is on the same plane as the outer register (R1). NOTE: This condition corresponds to a gap (L1) of 82.000 – 82.100 mm (3.228 – 3.232 in) between lever end (7) and lift housing front face measured applying a force ( (F1), figure 23) of 4.0 – 4.5 kg (8.8 – 9.9 lb) to lever end.

6. Tighten the lock-nut (1). 7. Install the distributor.

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Hydraulic systems - Main lift system

Lift - o- matic adjustment. 1. Apply a 50 kg (110 lb) load to lifting arm swivel bearings. 2. Run engine at medium speed ( 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 (L5) of 9.000 – 12.000 mm (0.354 – 0.472 in). NDIL14TR00678AB

NDIL14TR00679AB

NDIL14TR00680AB

Start to lift check 5. Place position control lever ((P), Figure 22) fully forward on quadrant. 6. Place lift - o- matic lever (1) in position shown in figure.

7. Check by means draft control lever (F) that lifts starts with lever 184.00 – 186.00 mm (7.24 – 7.32 in) from end of slot in quadrant. 8. Otherwise, adjust link (1) to obtain specified length and tighten lock-nut (2).

Valve check Relief and cylinder safety valve setting check on the bench 9. Relief valve (installed on remote control valve in TT75 and on a support on right-hand side of lift housing in TT55 ) may be checked either on bench or on tractor, while cylinder safety valve setting check may only be carried out on bench.

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Hydraulic systems - Main lift system

10. To bench test cylinder safety valve and relief valve incorporated in remote valve use hand pump 290284 (A), with fittings 290828 (C) and 290824 (B). 11. 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 peened area, and using wrenches 291862 and 291863 for cylinder safety valve and relief valve respectively. NDIL14TR00681AB

CAUTION When travelling on the road with mounted implements, completely unscrew knob (1) to block implement in transport position.

NDIL14TR00682AB

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Main lift system - Service instruction Following improvements have been made in the hydraulic cylinder area to prevent oil leakage from the cylinder cover plate mounting joint. 1. Replace the O–ring and back–up ring by new square seal.

NDIL14TR00960AA

NDIL14TR00961AB

NDIL14TR00962AA

2. Replace the cylinder cover plate mounting screws (Qty 4) of 8.8 grade with new 10.9 grade screws (1).

3. Use LOCTITE® 243™ on threads of these screws while tightening. Use lock washers (2) with the mounting screws. In case if unable to fit lock washer for the screw towards hydraulic distributor at the bottom side (Fig. 3), the distributor body flange need to be grinded slightly with a suitable hand grinder to prevent fouling of lock washer. 4. Tighten the screws to a torque of 13.8 kgm (99.8 ftlbs.).

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5. Apply LOCTITE® 518™ on the cylinder cover plate as shown in figure 4. NOTE: Note: In case of using Loctite 5188 instead of LOCTITE® 518™, it is recommended to apply, primer Loctite 7649 on the front plate for faster curing of Loctite 5188.

NDIL14TR00963AB

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Main lift system - Troubleshooting Problem Lift fails to operate

Erratic upward lift movement Erratic upward lift movement

Possible Cause Governor blocked open Inefficient pump Clogged oil filter Air entering suction line Oil leakage past spool seals

Correction Remove foreign particles from drain holes and inspect filter Disassemble and inspect Inspect filter and replace cartridge if necessary Check for faulty connections or seals Replace 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 Adjust travel Lift arm travel adjustment error

Relief valve blows with lift arms in max. raised position Insufficient or inaccurate Incorrect relief valve setting lifting Incorrect safety setting Poor pump performance

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Replace or adjust Replace valve Check pump and overhaul or replace

Index Hydraulic systems - 35 Main lift system - 100 Main lift system - Adjust – Distributor (control valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Assemble – Cross shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Assemble – Distributor (control valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Assemble – External controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Assemble – Internal controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Disassemble – Cross shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Disassemble – External controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Disassemble – Internal controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Disassemble –Distributor (control valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Dynamic description – Internal linkage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Dynamic description –Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Inspect – Distributor (control valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Sectional view - Control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main lift system - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

47899733 23/06/2015 EN

SERVICE MANUAL Steering TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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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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Steering - 41 Steering control - 101

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Steering - 41 Steering control - 101

TECHNICAL DATA Steering control General specification – Mechanical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification – Hydrostatic Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque – Mechanical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Torque – Hydrostatic Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Special tools – Mechanical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Special tools – Hydrostatic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Steering control Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Overview – Hydrostatic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SERVICE Steering control Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Test – Hydrostatic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Remove – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Install – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Disassemble – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Cleaning – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Inspect – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Lubricate – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Assemble – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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DIAGNOSTIC Steering control Troubleshooting – Mechanical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Troubleshooting – Hydrostatic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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Steering - Steering control

Steering control - General specification – Mechanical steering Type Make Reduction ratio Steering column angle Number of balls Ball diameter Inner column bearings Sector shaft bearings Oil capacity (approx.) Oil type Oil change period Inner column bearing pre-load Total frictional torque after assembling of sector shaft

Manual re-circulating ball RANE 35.0 constant 61° 81 74.00 mm (3.02 in) Angular contact bearings Bearing bushes 1050.0 mL (35.5 US fl oz) SAE 90 / SAE 140 1200 h 4 to 7 kg cm 6 to 9 kg cm

Steering control - General specification – Hydrostatic Steering Type Make Hydraulic circuit Oil reservoir Oil filter

Hydrostatic DANFOSS Independent, separate pump Transparent plastic on right-hand side of engine In oil reservoir, gauze

Hydraulic pump Type Model Make Drive Rotation (seen from rear) Drive ratio Rated speed (at engine governed speed) Rated output at maximum rated speed On-bench output at 1450 RPM 70 102 Kg/cm². • New or reconditioned pump • Used pump • Test oil temperature • Test oil viscosity Drive/driven gear journal diameter Bearing bore diameter Gear journal clearance in bearing Maximum wear clearance Gear clearance in pump body Bearing width Gear width Pump body width Bearing and gear end clearance in pump body (to be restored on overhaul) Control valve Type

Gear C-25 HEMA From engine valve gear Clockwise 1 to 0.931 2328 RPM 26.4 L/min (7.0 US gpm) 15.3 L/min (4 US gpm) 10.7 L/min (3 US gpm) 55 – 65 °C (131 – 149 °F) SAE 20 17.400 – 17.418 mm (0.685 – 0.686 in) 17.450 – 17.470 mm (0.687 – 0.688 in) 0.032 – 0.070 mm (0.001 – 0.003 in) 0.100 mm (0.004 in) 0.020 – 0.064 mm (0.001 – 0.003 in) 19.812 mm (0.780 in) 18.348 mm (0.722 in) 58.072 – 17.424 mm (2.286 – 0.686 in) 0.1 – 0.2 mm (0.004 – 0.008 in) DANFOSS With steering column operated rotary valve (permitting steering also in case of pump failure)

Outfit code

OSPC 1 00

• DANFOSS (with valves in control valve) Relief valve setting Power cylinder overload valve setting

100 bar (1450 psi) 200 bar (2900 psi)

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Steering - Steering control

Type Make Cylinder bore diameter Piston rod diameter Maximum piston stroke with cylinder make:

Double acting, located behind front axle OGNIBENE 48 mm (2 in) 22 mm (1 in) 214

Steering control - Torque – Mechanical steering Description Outer column bolts (C1) Cover plate bolts (C2) Adjuster screw lock nut (C3) Drop arm nut (C4) Steering wheel nut (C5) Steering assembly mounting bolts (C6)

Thread size M12 X 1.25 M8 X 1.25 M14 X 1.5 M30 X 1.5 M18 x 1.25 M16 X 1.5

NDIL14TR00694FB

Torque 50 N·m (37 lb ft) 20 N·m (15 lb ft) 30 N·m (22 lb ft) 350 N·m (258 lb ft) 70 N·m (52 lb ft) 145 N·m (107 lb ft)

Steering control - Torque – Hydrostatic Steering Description Bolt, control valve support (C1) Bolt, control valve to tractor (C2) Bolt, cover to control valve (C3) Nut, power cylinder pivot pin (C4) Nut, power cylinder piston rod to steering arm (C5) Nut, piston to rod (C6) Bolt, steering pump to engine (C7) Nut, cover to pump body (C5) Nut, drive sleeve to pump drive shaft (C5)

Thread size M16 X 1.5 3/8"-16 UNC M8 X 1 M18 X 1.5

Torque 150 N·m (111 lb ft) 45 N·m (33 lb ft) 35 N·m (26 lb ft) 300 N·m (221 lb ft)

M16 X 1.5

210 N·m (155 lb ft)

M16 X 1.5 M12 X 1.25 M6 X 1 7/16"-20 UNF-2B

100 N·m (74 lb ft) 8 N·m (6 lb ft) 50 N·m (37 lb ft) 28 N·m (21 lb ft)

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Steering - Steering control

Steering control - Special tools â&#x20AC;&#x201C; Mechanical steering Description Steering wheel puller Steering wheel puller sleeve Hand accelerator dowel remover Steering arm puller

Tool number 82834312 9971375 9971378 9971363

Steering control - Special tools â&#x20AC;&#x201C; Hydrostatic steering Description Steering wheel puller Adopter, power steering pressure check (includes in the set of hydraulic pressure kit 292870) Installer, power steering rotor spring

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Tool number 82834312 291318 292927

Steering - Steering control

Steering control - Overview This is an anti-friction re-circulating ball constant ratio sector type steering gear. A hardened and precision ground single star worm shaft which forms lower part of the inner column is supported in the steering gear housing by angular contact bearings assembly at each end. The upper part of the inner column is supported by bearing bush. Adjustment of the bearing preload on these bearings is achieved by shims between the outer column and steering housing. The inner column is provided with spline and taper construction for fittment of the steering wheel. As the steering wheel is turned the inner column rotates and moves the main nut in the axial direction on the inner column. The main nut employs two independent ball circuits. The transfer tubes guides the ball at the end of the circuit for re-entering them to the start of the respective helical path and are positioned that the balls leave and re-enter on a line tangential to the pitch circle. The transfer tubes re-clamped in place by the retainer. The rack on one side of the main nut meshes with the taper tooth gear of the sector shaft, so that the sector shaft rotates during axial movement of the main nut. The sector shaft teeth are conical and are designed specially to provide true rack and sector action when main nut is positioned at a slight angle. This construction permits backlash adjustments by shifting sector shaft slightly along its axis by means of a adjuster screw. The sector shaft is supported on its longer side by two bushes fitted in the housing. There is a taper spline at the shaft end to which drop arm is fitted and is retained in position by nut and tab washer.

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Steering control - Overview â&#x20AC;&#x201C; Hydrostatic steering

NDIL14TR00728FB

D1. E. H. M.

Control valve Filter cartridge Power cylinder Pump outlet line

P. S. T. V.

Hydraulic pump Return to tank Reservoir Steering wheel

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Steering control - Hydraulic schema

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NDIL14TR00959JB

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A. B.

11. 12.

Operation in straight-ahead driving position Right-hand side (Sd) and left-hand side (Ss) steer Right-hand side and left-hand side emergency steer (Sed) and (Ses) Operation diagram for straight-ahead driving Operation diagram for two-stage right-hand side steering Filter cartridge

Steering system schematics

18.

Power cylinder

19.

Pump outlet line

20.

C. d. e, f.

P. S. T. V. a.

Hydraulic pump Return to tank Reservoir Steering wheel Section through control unit with valve (5) in neutral b. Sections through control unit with valve (5) in right-hand side steer position (for left-hand side steer, valve rotation is symmetrical in opposite direction) G1, G2. Gap between pin (1) and rotary valve (5) r1, r2. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Sections through DANFOSS OSPC 100 control valve Drive pin Sleeve return springs Control valve body Check valve Rotary valve Valve seat sleeve Rotor drive shaft Rotor cam ring Rotor Thrust ring

13, 14. 15. 16. 17.

21. 22. 23. 24. 25.

Cover Spacer Oil ports Rotor inlet passages ( 6 off) Connecting port ( 12 off) communicating with passages ( (15) and (17)) alternatively Pressure passages (6 off) to power cylinder communicating with the rotor recesses and ports ( (18) and (20)) Right-hand side power cylinder chamber outlet or exhaust ports (6 pairs) Power cylinder exhaust passages ( 6 off) communicating with ports ( (18) and (20)) Left-hand side power cylinder chamber outlet or exhaust ports ( 6 off) Oil passage from ports (16) to rotor recesses Supply ports for passages (15) Check valve Relief valve Washer

26.

Oil passage to left-hand side power cylinder chamber

27. 29.

Oil passage to right-hand side cylinder chamber, piston rod side Thrust bearing

31. 32. 33. 34. 35. 36. 37. 38.

Seals Dust excluder Cylinder safety valves Make-up valves O-rings Valve adjusting screw Plugs Valve adjusting screw

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Steering control - Dynamic description 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 pressurized 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 drawn from the reservoir (4) and into the pump through a filter (3), pressurized by the rotation of the gears and expelled through the pump outlet port to the steering control valve. The pressurized 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.

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), (refer to Steering control - Hydraulic schema (41.101) section A-A) and the following conditions exist: • Pin (1), (refer to Steering control - Hydraulic schema (41.101) section B-B) is central in the valve (5) aperture. • Ports (13) and (14) are in alignment (refer to Steering control - Hydraulic schema (41.101) section C-C) and the oil pressure from pump (P) is returned to tank. • Passages (15), (17) and (19) on the valve (refer to Steering control - Hydraulic schema (41.101) 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), (refer to Steering control - Hydraulic schema (41.101) section A-A) deflect allowing valve (5) to rotate relative to sleeve (6) until gap (G),(refer to Steering control - Hydraulic schema (41.101) section B-B) is taken up. Thus: • Ports (13) and (14), (refer to Steering control - Hydraulic schema (41.101) section C-C) go out of alignment to discontinue oil return. • Six passages (15), (refer to Steering control - Hydraulic schema (41.101) 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), (refer to Steering control - Hydraulic schema (41.101) section E-E) line up with ports (18) communicating with the power cylinder. Moreover, the oil pressure passages communicate with the remaining ports (16), (refer to Steering control - Hydraulic schema (41.101) section D-D) connected instant by instant with the rotor recesses during the actuation phase. • Six exhaust passages (19) line up with ports (20), (refer to Steering control - Hydraulic schema (41.101) section E-E) communicating with the power cylinder.

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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), (refer to Steering control - Hydraulic schema (41.101) 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. Operation of the above valves eliminates continuous steering wheel correction and prevents front wheel shimmy, hydraulic circuit failure and damage to the steering linkage.

NDIL14TR00730FB

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Steering control - 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. Detach the negative cable (1) from the battery and insulate.

NDIL14TR00698AB

NDIL14TR00699AB

NDIL14TR00700AA

2. Remove the nut (1).

3. Remove the steering wheel using special tool number 82834312 and 9971375.

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4. Remove the electrical couplers (1) for rear lamps, flasher unit, fuse box etc.

NDIL14TR00702AB

NDIL14TR00703AA

NDIL14TR00704AB

NDIL14TR00705AB

5. Disconnect electric connections to fenders below rear hood.

6. Disconnect Revolutions Per Minute (RPM) meter cable connection (1) to instrument panel, by opening instrument panel from rear hood.

7. Loosen the rear hood securing bolts (1) on both sides and (2) on steering column and remove rear hood carefully from tractor (keeping it parallel to the steering column).

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8. Disconnect diesel over flow hose pipe (1) and fuel sender electric connections (2). 9. Remove nut (3) and dismantle fuel tank strap from steering column journal. 10. Remove hand accelerator cable.

NDIL14TR00706AB

NDIL14TR00707AB

11. Close diesel tap (1) and disconnect hose (2) between diesel tank and feed pump. 12. Remove fuel tank from the tractor. NOTE: It is advisable to drain diesel from fuel tank if tank is more than half filled.

13. Remove drop arm nut (1).

NDIL14TR00708AB

NDIL14TR00709AA

14. Remove drop arm from steering roller shaft using special tool number 9971363. NOTE: Before removing the drop arm from steering roller shaft, note the position of the drop arm relative to the shaft. This is normally shown by marking line on the arm and on the end face of the steering roller shaft. If this mark is not provided make a mark on drop arm and end face of the shaft before removing. This is required to mount back the drop arm in original position relative to the shaft.

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15. Remove the bolts (1) securing steering assembly on clutch housing. 16. Remove the steering assembly from clutch housing.

NDIL14TR00710AB

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Steering control - Install Installation of steering assembly is the reverse of the removal procedure, refer to Steering control - Remove (41.101), but observe the following: 1. Drop arm should be fitted on the steering roller shaft so that the marking lines are correspond to each other. 2. The splined section and the thread on the shaft should be well lubricated with lubricating oil before pushing arm on the splines. 3. If the position of the drop arm is not marked the following method should be used. The steering gears should be turned exactly to the middle position. The front wheels should also be brought as close as possible to the straight-ahead position. The drop arm can then be placed in the required position on the steering roller shaft. Special care should be taken at this time that neither the position of the steering nor the front wheels is altered. Small discrepancies can be balanced out by adjusting the length of the track rod. 4. It should be finally checked whether on full lock to left and right. The stop takes place on the relevant axle stop (1). Under no circumstance may the stop be in the steering gear as otherwise there is danger of grave mechanical breakage.

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NDIL14TR00711AB

Steering - Steering control

Steering control - Disassemble 1. Remove steering assembly from tractor as described earlier. 2. Remove oil drain plug (1) and drain oil by tilting steering assembly.

NDIL14TR00712AB

NDIL14TR00713AB

NDIL14TR00714AA

NDIL14TR00715AA

3. Rotate the inner column and keep the gear in mid gear position. 4. Loosen the adjuster screw locknut (1), remove the four bolts (2) which retains the side cover.

5. Withdraw the cover plate with rocker shaft by gently tapping the end of the shaft with a mallet.

6. Loosen the adjusting lock nut further and remove cover plate from sector shaft.

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7. Remove the four bolts (1) which retains the outer column with housing.

NDIL14TR00716AB

NDIL14TR00717AB

NDIL14TR00718AB

NDIL14TR00719AB

8. Withdraw the outer column (1) assembly along with top bearing cage assembly, retrieve the shims (2).

9. Take out the bottom bearing cage from the housing.

10. Remove the inner column assembly (1) from the steering housing.

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11. Remove the bearing races (1) from the inner column with a suitable extractor.

NDIL14TR00720AB

12. Screw out the transfer tube retainer clamp screws from the main nut.

NDIL14TR00721AA

NDIL14TR00722AB

NDIL14TR00723AB

13. Remove the transfer tubes (1) from the main unit.

14. Dislodge main nut ball by rotating the main nut (1) on either direction. Collect the main nut balls (81 Nos). 15. After dislodging all the main nut balls, remove the main nut from the inner column.

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16. Remove the oil seal (1) from the housing by carefully levering at diametrically opposite points.

NDIL14TR00724AB

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Steering control - Inspect 1. In the interest of safety and reliability all steering gear components must be in good condition and if there is any damage to components is noticed, it should not be rectified, rather to be replaced. 2. Wash all parts prior to inspection. Inspection, repair and assembly of steering parts must not be attempted in dirty surroundings. Parts must be kept absolutely clean. 3. Examine the steel balls, bearing tracks of main nut and inner column for undue wear and pitting, If damage to anyone of the either component in the form of pitting or grooving is evident , the inner column and main nut assembly must be renewed as a set. 4. Check for wear on the rack teeth portion of the main nut. 5. Check for damages on the serration and threads of the inner column. If any damage is observed, check serration of the corresponding mating serration of the steering wheel also for damages. 6. Check sector shaft for wear and damages at gear teeth, spline and threads. 7. Check adjuster screw visually for any bend and threads for damage and replace if necessary. 8. Check for axial play of the adjuster screw in the sector shaft â&#x20AC;&#x2DC;Tâ&#x20AC;&#x2122; slot. In case of excess play replace the spacer. 9. Examine the bearing and races for wear, pitting, cracked, deformed cages. If evidence of the above are found the bearing must be renewed. It is advisable to replace both worm bearing together when renewal is required. 10. Check fit of the sector shaft in the housing bush. If a slack fit is apparent, replace both the bushes in the housing. 11. Check fit of inner column upper bearing area in the outer column bush. If a slack fit is apparent the rubber sleeve in the outer column assembly should be driven out and the bush to be replaced. 12. Check the transfer tube for any damages or wear especially at the tip and ball entry points.

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Steering control - Assemble 1. Clean all components before assembly. Care to be taken to clean the shimming face of the housing and outer column and cover plate seating area. 2. Insert the main nut in to the inner column and align the nut and worm tracks. Ensure that the ball circuit with shorter pitch towards top. 3. Fit the top and bottom inner race on the inner column 4. Count serial numbers of 9/32â&#x20AC;? dia steel balls and insert 23 number in the shorter pitch circuit and 38 numbers in the longer pitch circuit. The remaining 20 numbers are to be placed in the two sets of transfer tube (10 numbers. in each sets) with sufficient grease to keep them in position. 5. Ensure that the balls are assembled properly in the right track. The track from the end of the top circuit to the beginning of bottom circuit is called as â&#x20AC;&#x153; no ball zoneâ&#x20AC;? and are should be taken to see that the balls does not slips in to this zone. Any balls present in this zone will damage the transfer tube leading to failure of the steering mechanism. 6. Insert the transfer tubes in to position in the main nut, Keep the transfer tube retainer in position over the transfer tubes and secure with screw and washers. Check for free movement of the main nut on the worm shaft. 7. Press the bottom bearing outer race in to position in the housing and place bearing cage over it. 8. Press the top bearing outer race in to position in the outer column. 9. Insert the inner column assembly in to the box and place the top cage over the inner race. 10. Fit the outer column in to the housing without shims and tighten the bolts to finger tight. Ensure proper seating of the bearings and faces in position. 11. Measure the gap between the housing face and outer column with a feeler gauge to determine the shim pack thickness. Deduct 0.002" from the determined thickness. 12. Remove the outer column bolts and take out the outer column assembly. 13. Apply an uniform coat of Anabond 666 on the housing and outer column face.

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14. Assemble the outer column assembly in to the housing by placing shims between the housing face and outer column. Tighten the outer column bolts to 50 N·m (37 lb ft) after applying a thin cotting of hold tight on bolts. 15. Ensure smooth rotation of the inner column with out axial movement. Adjust the shims if necessary to get smooth rotation. 16. Insert the spacer in to the adjuster and fit to the T-slot of the sector shaft. Check for axial play of the adjuster screw. If play exists, replace the spacer with thick one. Adjuster screw should not be jammed and should be free to rotate by hand. 17. Set the steering in the mid gear position. 18. Insert the spacer in the correct position, so that centre teeth of the sector shaft engages with the middle portion of the main nut rack. 19. Apply a uniform coat of Anabond 666 on the housing and assemble the cover plate in to the housing by engaging adjuster screw thread provided in the cover plate. 20. Draw out the sector shaft adjuster screw fully. 21. Provide a thin coating of hold tite on bolts and tighten the cover plate to 20 N·m (15 lb ft). 22. Drive in the adjuster screw until the required pre-load of 60-90 Kg cm is achieved and tighten the adjuster screw lock nut. Ensure that the adjustment is done in the mid gear position only. 23. Drive new seals in position in to the sector shaft side of the housing. 24. Fit the dust sleeve and fix the drop arm by matching the mark already made. 25. Place the tab washer and tighten the lock nut to 350 N·m (258 lb ft) and fold the tab washer. 26. Fill the steering gear assembly with specified grade of oil and check for smooth operation.

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Steering control - Adjust Provision is made in the design for adjustments, so that there is no back lash in the Straight-Ahead Position (SAP). But back lash will apparent away from the SAP and will be increasing towards the steering locks. If there is excess free play on the steering wheel at SAP, check and adjust the back lash as per procedure given below. 1. Rock the steering wheel and look for visual lift in the ball joints. If lift is in excess, the ball joint requires replacement. 2. Keep the vehicle in SAP. It is most important to ensure this, since the sector shaft is machined to give more back lash at the extremity of each lock. Therefore if back lash adjustment is carried out at any position other than at SAP severe binding would occur at SAP. 3. Disconnect the drag link from drop arm. 4. Check the drop arm small end for any lash by rocking in the direction of movement. 5. Loosen the adjuster screw lock nut and screw in the adjuster screw until the play in the drop arm just stops. 6. Tighten the adjuster screw lock nut. 7. Pull the drag link.

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Steering control - Test â&#x20AC;&#x201C; Hydrostatic steering When the hydrostatic steering system is in operation, the pressure of oil supplied by the steering pump, to the steering motor, can rise towards the maximum setting of the steering motor relief valve, which is 120 bar (1740 psi) depending on tractor model.

Steering pump There is no relief valve in the steering / low pressure pump. The following practical test will determine if steering pump output is sufficient to allow satisfactory operation of the steering system.

Steering test 1. 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.

NDIL14TR00725AA

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Steering control - Remove – Steering motor 1. Position the tractor on a hard level surface and apply the parking brake.

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

2. To gain access to the steering motor: • Remove tractor rear hood • Remove fuel tank 3. Disconnect the four supply / return tubes and O-ring seals from the steering motor and cap the ends of the tubes and steering motor to prevent entry of foreign particles. T.

To tank

From pump

Left port

R. Right port

NDIL14TR00731AB

NDIL14TR00732AB

4. Remove the four bolts (1) at the base of the steering column and slide out the steering motor from the steering column.

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Steering control - Install â&#x20AC;&#x201C; Steering motor Reinstall the steering motor following the removal procedure in reverse. Refer to Steering control - Remove â&#x20AC;&#x201C; Steering motor (41.101).

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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).

NDIL14TR00733AA

NDIL14TR00734AA

NDIL14TR00735AA

NDIL14TR00736AA

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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6. Remove distributor plate.

NDIL14TR00737AA

NDIL14TR00738AA

NDIL14TR00739AA

NDIL14TR00740AA

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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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.

NDIL14TR00741AA

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.

NDIL14TR00742AA

NDIL14TR00743AA

NDIL14TR00744AA

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 Fig. 12) If the mark is not visible, remember to leave a mark of your own on sleeve and spool before the neutral position springs are dismantled.

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13. Carefully press the spool out of the sleeve.

NDIL14TR00745AA

NDIL14TR00746AA

NDIL14TR00747AA

NDIL14TR00748AA

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 control - Cleaning â&#x20AC;&#x201C; Steering motor Clean all parts carefully in Shellsoi K or the like.

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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 â&#x20AC;&#x201C; 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.

NDIL14TR00749AA

NDIL14TR00750AA

NDIL14TR00751AA

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.

NDIL14TR00752AA

NDIL14TR00753AA

NDIL14TR00754AA

NDIL14TR00755AA

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.

NDIL14TR00756AA

NDIL14TR00757AA

8. Fit the cross pin into the spool / sleeve.

9. Fit bearing races and needle bearing as shown on below drawing.

NDIL14TR00758AA

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Assembly pattern for standard bearing 1. Outer bearing race 2. Needle bearing 3. Inner bearing race 4. Spool 5. Sleeve * The inside chamfer on the inner bearing race must face the inner spool

NDIL14TR00759FB

NDIL14TR00760AA

NDIL14TR00761AA

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.

2. Grease O-ring and king ring / roto glyd with hydraulic oil and place them on the tool.

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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.

NDIL14TR00762AA

NDIL14TR00763AA

NDIL14TR00764AA

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 WARNING Always use suitable tools to align holes. Do not use hands or fingers. 1. Lubricate the lip seal with hydraulic oil and place it on the assembly tool.

NDIL14TR00765AA

NDIL14TR00766AA

NDIL14TR00767AA

NDIL14TR00768AA

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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Steering - Steering control

5. The spool set will push out the assembly tool guide. The O-ring and kin ring / roto glyd are now in position.

NDIL14TR00769AA

NDIL14TR00770AA

NDIL14TR00771AA

NDIL14TR00772AB

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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Steering - Steering control

9. Place a new pin in the same two holes.

NDIL14TR00779AA

NDIL14TR00773AA

NDIL14TR00774AA

NDIL14TR00775AA

10. Grease the O-ring with mineral oil approximate viscosity 500.00 mm² (0.78 in²)/s at 20 °C (68 °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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Steering - Steering control

13. Place the cardan shaft as shown so that it is held in position by mounting fork.

NDIL14TR00776AA

NDIL14TR00777AA

NDIL14TR00778AA

NDIL14TR00780AA

14. Grease the O-ring with mineral oil approximate viscosity 500.00 mm² (0.78 in²)/s at 20 °C (68 °F) and place them in the two grooves in the gear rim. Fit the gearwheel and rim on the cardan shaft.

NOTE: Fit the gearwheel (rotor ) and cardon shaft so that a tooth base in the rotor is positioned in relation to the shaft slot as shown. Turn the gear rim so that the seven through holes match the holes in the housing.

15. Fit the spacer, if any.

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Steering - Steering control

16. Place the end cover in position.

NDIL14TR00781AA

NDIL14TR00782AB

NDIL14TR00783AA

NDIL14TR00784AA

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 2.4 â&#x20AC;&#x201C; 3.6 daN (5.4 â&#x20AC;&#x201C; 8.1 lbf). 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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Steering - Steering control

20. Press the plastic plugs into the connection ports. Do not use a hammer.

NDIL14TR00785AA

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Steering - Steering control

Steering control - Troubleshooting – Mechanical steering Problem Wobbling

One side pulling

Hard Steering

Possible Cause Knuckle joint pin wears off King pin / spindle bush wear off Steering play Wrong wheel alignment Steering roller shaft loose / play Tire pressure less Knuckle joint wears off Wrong wheel alignment Spindle bush tight Play between arm and spindle Wheel bearing play More wear on a tire Rim run out Axle bearing broken / damaged / tight Oil level / quality Tire pressure Grease less Wheel alignment Spindle seize in bush Excessive wear of tire Thrust washers damaged Wrong play setting in steering assembly

Correction Renew knuckle joint Renew bushes Adjust the play by adding or removing shims at worm shaft flange. Check and correct toe-in Adjust the play Check tire pressure and inflate accordingly Renew knuckle joint Check and correct toe-in Check and renew bushes Renew the worn-out parts Check bearing pre-loading and adjust Renew the wear off tire Change rim Renew bearings Check and replace / top-up Check and inflate to correct pressure Clean and grease Check toe-in setting Renew bush / repair spindle Retread / change tire Renew thrust washers Check and adjust

Steering control - Troubleshooting – Hydrostatic steering Problem Steering wheel is heavy to turn

Possible Cause No or insufficient oil pressure a) Pump does not run b) Pump defective c) Pump runs in the wrong the direction d) Pump is worn out e) Pump is under dimensioned Pressure relief valve is stuck in open position or setting pressure is too low Priority valve is stuck in open position Too much friction in the mechanical parts of the vehicle

Regular adjustments of the steering wheel are necessary (“snake-like driving”)

Neutral position of steering wheel cannot be obtained, i.e. there is a tendency towards “Motoring”

Emergency steering balls missing Combination: Downstream system + steering unit with suction valve and differential cylinder are inexpedient Leaf spring without spring force or broken

Spring in double shock valve broken Gear wheel set worn Cylinder seized or piston seals worn Steering Column and steering unit out of line

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Correction Start up pump (loose V-belt) Repair or replace pump Correct direction of rotation of pump or replace pump Replace pump Install a larger pump (examine pressure need and flow) Repair or clean pressure relief valve. Adjust the valve to the correct pressure Repair or clean the priority valve Lubricate bearings and joints of steering gear or repair if necessary. Check steering column installation Install new balls Change cylinder type (through going piston rod). If necessary use two differential cylinders Replace leaf springs

Replace shock valve Replace gear wheel set Replace defective parts Align the steering column with steering unit

Steering - Steering control

Problem

“Motoring” effect. The steering wheel can turn on its own

Backlash

“Shiny”-effect. The steered wheels vibrate. (Rough tread on tires gives vibrations)

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 Too little or no play between steering column and steering unit input shaft Pinching between inner and outer spools Leaf springs are stuck or broken and have therefore reduced spring force

Correction Adjust the play and, if necessary, shorten the splines journal. Contact your authorised NEW HOLLAND Replace 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 NEW HOLLAND dealer Reduce return pressure, change cylinder type or use a non-reaction control unit

Mechanical connections or wheel bearings Replace worn parts worn 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

One or both shock valves are leaky or are missing in OS PC or OVP/OVR Steering is too slow and Insufficient oil supply to steering unit, pump heavy when trying to turn defective or number of revolutions too low quickly Relief valve setting too low Relief valve sticking owing to dirt Spool in priority valve sticking owing to dirt Too weak spring in priority valve

“Kick-back” in steering wheel from system. Kicks from wheels Heavy kick-back in steering wheel in both directions Turning the steering wheel activates the steered wheels opposite Hard point when starting to turn the steering wheel

Replace cardan shaft Replace leaf springs Replace steering column Bleed cylinder. Find and remove the reason for air collection

Fault in the system

Replace or repair cylinder Replace gear wheel set Install spacer Clean or replace defect or missing valves

Clean or replace defective or missing valves Replace pump or increase number of revolutions Adjust valve to correct setting Clean the valve Clean the valve, check that spool moves easily without spring Replace spring by a stronger (There are 3 sizes: 4 bar (58 psi), 7 bar (102 psi) and 10 bar (145 psi) Contact your authorised NEW HOLLAND

Wrong setting of cardan shaft and gear Correct setting as shown in service manual wheel set Hydraulic hoses for the steering cylinders Reverse the hoses have been switched around Spring force in priority valve too weak

Replace spring by a stronger one ( 4 bar (58 psi) , 7 bar (102 psi) and 10 bar (145 psi)) Air in LS and /or PP pipes Bleed LS and PP pipes Clogged orifices in LS or PP side priority Clean orifices in spool and in connecting valve plugs for LS and PP Let motor run until oil is warm Oil is too thick (cold)

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Steering - Steering control

Problem Possible Cause 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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Correction 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 - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Assemble – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Cleaning – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Disassemble – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - General specification – Hydrostatic Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - General specification – Mechanical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Inspect – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Install – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Lubricate – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Overview – Hydrostatic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Remove – Steering motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Special tools – Hydrostatic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Special tools – Mechanical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Test – Hydrostatic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Torque – Hydrostatic Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Torque – Mechanical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Troubleshooting – Hydrostatic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering control - Troubleshooting – Mechanical steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Steering - 41 Hydraulic control components - 200

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Steering - 41 Hydraulic control components - 200

SERVICE Steering circuit relief valve Adjust â&#x20AC;&#x201C; Hydrostatic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjust â&#x20AC;&#x201C; Hydrostatic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Steering circuit relief valve - Adjust – Hydrostatic steering Steering relief valve pressure test NOTICE: 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 at steering cylinder. 3. Install power steering pressure checking kit. (special tool number 292870 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 in the steering motor must be adjusted. The pressure reading should be 110 – 125 bar (1595 – 1812 psi). 5. If the system pressure is not to specification proceed to relief valve adjustment.

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NDIL14TR00726AB

Steering - Hydraulic control components

Steering circuit relief valve - Adjust – Hydrostatic steering 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 Fig. 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.

NDIL14TR00727FB

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 â&#x20AC;&#x201C; Hydrostatic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering circuit relief valve - Adjust â&#x20AC;&#x201C; Hydrostatic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Steering - 41 Cylinders - 216

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Steering - 41 Cylinders - 216

FUNCTIONAL DATA Steering cylinder Component identification – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Steering cylinder Remove – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Overhaul – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Steering cylinder - Component identification â&#x20AC;&#x201C; 2WD

NDIL14TR00786GA

1. 2. 3. 4.

Nut Washer Nut Washer

5. 6. 7.

Cylinder mounting bracket Spacer Bolt

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Steering - Cylinders

Steering cylinder - Remove â&#x20AC;&#x201C; 2WD 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. 3. Remove the nut securing the cylinder rod ball joint to the steering arm and separate the joint, refer to Steering cylinder - Component identification â&#x20AC;&#x201C; 2WD (41.216) Figure 1. NOTE: Position of flexible pipes and orientation of connectors must be the same upon re-assembly. 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 â&#x20AC;&#x201C; 2WD Installation is the reversal of the removal procedure. Refer to Steering cylinder - Remove â&#x20AC;&#x201C; 2WD (41.216).

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Steering - Cylinders

Steering cylinder - Overhaul – 2WD

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 ‘C’ spanner, unscrew and remove the gland nut (4). 2. Using a punch, push the steering cylinder gland into the cylinder and remove the wire locking ring (3). 3. Pull the rod (5) and gland assembly (6) 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 – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Install – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Overhaul – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering cylinder - Remove – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47899733 23/06/2015 EN

SERVICE MANUAL Wheels TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

47899733 23/06/2015

Contents Wheels - 44

[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1

47899733 23/06/2015

Wheels - 44 Front wheels - 511

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Wheels - 44 Front wheels - 511

SERVICE Front wheels Test – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Check – 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 - Check – 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 - Check – 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front wheels - Test – 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47899733 23/06/2015 EN

SERVICE MANUAL Electrical systems TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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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 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.408] Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7

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Electrical systems - 55 Electrical system - 000

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Electrical systems - 55 Electrical system - 000

FUNCTIONAL DATA Electrical system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview â&#x20AC;&#x201C; Control switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Electrical system Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DIAGNOSTIC Electrical system Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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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.

NDIL14TR00825AA

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 5 fuses in one and two spare fuses in the other. Rating 10 A 15 A 10 A 10 A 10 A

Circuit Instrument cluster Lamps Horn Turn signal Plough lamp

Spare fuses Rating 15 A 15 A

Details Spare Spare

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Electrical systems - Electrical system

Electrical system - Overview â&#x20AC;&#x201C; Control switches

NDIL14TR00836FB

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

Left/right indicator switch Horn Hand throttle lever Key start/stop switch Head light switch Hazard warning light switch

Left/right turn switch This is used to switch on, the left or right turn signal circuits. It has 3 positions. 1. 2. 3.

Right Centre Left

Right turn Off Left turn

Hazard light switch This is used on both left and right turn signal circuits. This allows to operate as a warning to other road traffic.

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Electrical systems - Electrical system

Key start switch A three-position key-start switch is installed. The key-start switch positions are as follows: Position 1 Electrical equipment Off Position 2 Accessories on (head lamp, instrument cluster, horn and gauges, brake lights, turn signal) Position 3 Starter motor engaged

NDIL14TR00837AB

NDIL14TR00838AB

NDIL14TR00839AB

NDIL14TR00840AB

Horn switch A push button switch is used to complete the horn signal circuit.

Light switch A turn type switch is used to switch the light circuits. It has 4 positions. Position 1 Position 2 Position 3 Position 4

Off Parking lights and instrument panel lights. Low beam High beam

Neutral start switch A two position â&#x20AC;&#x2DC;bal plunger typeâ&#x20AC;&#x2122; switch (1) mounted on left-hand side of transmission housing, operated by the high/low range lever.

Brake light switch The brake pedal switch (1) is located below the right foot board near the foot brake. It is actuated while applying brake and is indicated by the light provided on the fender.

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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.

WARNING Battery acid causes burns. Batteries contain sulfuric acid. Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling. Failure to comply could result in death or serious injury. W0120A

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 NOTE: Whenever effecting a repair, the reason for the cause of problem must be investigated and corrected to avoid repeat failures. Problem Possible Cause Correction Several or all lights do not Battery discharged Check battery, charge or renew 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, “Individual lights do not illuminate” See “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 interconnecting tenninals. This enables circuit continuity to be checked. Flasher switch inoperatIve 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 â&#x20AC;&#x201C; Control switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical system - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Harnesses and connectors - 100

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Electrical systems - 55 Harnesses and connectors - 100

TECHNICAL DATA Fuse and relay box General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Wiring harnesses Electrical schematic sheet 01 – Centre harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrical schematic sheet 02 – Front harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Electrical schematic sheet 03 – Rear harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Electrical schematic sheet 04 – Instrument cluster circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Electrical schematic sheet 05 – Charging and starting circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SERVICE Wiring harnesses Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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Electrical systems - Harnesses and connectors

Fuse and relay box - General specification Five fuses housed in the fuse box. Sl.no 1 2 3 4 5

Protected circuit Instrument cluster Lamp Horn Turn signal Plough Lamp

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Ampere 10 A 15 A 10 A 10 A 10 A

Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 01 â&#x20AC;&#x201C; Centre harness

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Electrical systems - Harnesses and connectors

NDIL14TR00861JB

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Fuse description Fuse 1 Fuse 2 Fuse 3 Fuse 4

Headlight low beam Headlight high beam Brake lamp Indicator lights

Fuse 5 Fuse 6 Fuse 7 Fuse 8

Horn, fuel gauge and engine shut off Hazard lights Work lamp Parking lights

Key to wiring diagram 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Connector to front harness Connector to front harness Connector to front harness Alternator warning lamp Left indicator warning lamp Hour meter gauge Fuel gauge Panel lights Tachometer Main beam indicator warning lamp Right indicator warning lamp Oil pressure guage Engine temperature guage Connector to instrument panel

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

Connector to instrument panel Fuel level sender Horn switch Connector to rear harness Start/ignition switch Connector to start switch Connector to safety start switch Connector to light switch Light switch Hazard light switch Hazard light connector Connector to indicator switch Indicator switch Flasher unit

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 02 â&#x20AC;&#x201C; Front harness

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Electrical systems - Harnesses and connectors

NDIL14TR00862JB

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Key to wiring diagram 1. 2. 3. 4. 5. 6. 7. 8.

Right head lamp Right head lamp connector Horn Horn connector Left head lamp Left head lamp connector Battery Alternator

9. 10. 11. 12. 13. 14. 15.

Temperature sender Oil pressure switch Starter solenoid Chassis connection Connector to centre harness. Located front of fuel tank Connector to centre harness. Located front of fuel tank Connector to centre harness. Located front of fuel tank

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 03 â&#x20AC;&#x201C; Rear harness

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Electrical systems - Harnesses and connectors

NDIL14TR00863JB

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Key to wiring diagram Rear right indicator lamp Rear right park lamp Right brake lamp Connector, located behind lamp housing Work lamp Connector, located behind rear lamp housing 6. assembly 7. Plough lamp switch 8. Left brake lamp 9. Rear brake lamp 10. Rear left indicator lamp 11. Connector, located behind lamp housing 12. Connector, located behind lamp housing 1. 2. 3. 4. 5.

13. 14. 15. 16. 17.

Left front indicator lamp Left front park lamp Connector, located under left foot-plate Connector, located under left foot-plate Brake light switch

18.

Right front park lamp

19. 20. 21. 22. 23.

Right front indicator lamp Connector, located behind lamp housing Connector to front harness To front harness Safety start switch

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 04 â&#x20AC;&#x201C; Instrument cluster circuit

NDIL14TR00864FB

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 05 â&#x20AC;&#x201C; Charging and starting circuit

NDIL14TR00865FB

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Electrical systems - Harnesses and connectors

Wiring harnesses - 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. 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.

NDIL14TR00827AA

NDIL14TR00828AA

NDIL14TR00829AA

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 1. 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 2, 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 3. 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.

NDIL14TR00830AA

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Index Electrical systems - 55 Harnesses and connectors - 100 Fuse and relay box - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 01 – Centre harness . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 02 – Front harness . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 03 – Rear harness . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 04 – Instrument cluster circuit . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 05 – Charging and starting circuit . . . . . . . . . . . . . . .

Wiring harnesses - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Engine starting system - 201

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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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 starter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 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 No of poles Field winding Control Operation Pinion travel

MICO 12 V 2.7 kW (3.7 Hp) Clockwise 10 4 Electrical excitation Starting switch on vehicle Pre-engaged direct drive solenoid 18.0 mm (0.7 in)

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 (max.) Hold-on - continuous (max.)

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 74.00 N·m (54.58 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 starter - Remove 1. Disconnect battery from electric circuit. 2. Disconnect connections (1), (2) and (3). 3. Loosen the three retaining bolts and remove starter motor from the tractor. NOTICE: Starter motor should be serviced and repaired only by authorised MICO dealer.

NDIL14TR00842AB

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Electrical systems - Engine starting system

Engine starter - Install Installation of starter motor is reversal of removal procedure. Refer to Engine starter - Remove (55.201).

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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 Key start switch safely start switch, solenoid inoperative 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 - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Engine starter - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starting system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starting system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starting system - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starting system - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Alternator - 301

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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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 and 25.00 °C (77.00 °F) Output at 14 V across battery after warm-up with fully bedded in brushes Rotor winding resistance between both collector rings 20.00 °C (68.00 °F) Alternator speed on tractor (at engine governed speed) Drive ratio Torque requirement for nut securing alternator pulley

MICO 14 V Clockwise 1050 – 1150 RPM 23 A 3.4 – 3.8 Ω 6000 RPM 1 to 1.992 41.00 N·m (30.24 lb ft)

Voltage regulator Type Alternator-test speed Voltage setting

Integral with alternator 4000 RPM 13.60 – 14.00 V (13.60 – 14.00 V)

Alternator - Torque Description Alternator mounting bracket nuts Alternator pivot bolt Belt tension adjusting screw

Thread size M10 X 1.25 M10 X 1.5 M8 X 1.25

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Torque 40.00 N·m (29.50 lb ft) 80.00 N·m (59.00 lb ft) 24 N·m (17.7 lb ft)

Electrical systems - Alternator

Alternator - Overview The alternator is fitted on the right-hand side of the engine and driven by the fan belt. The two electrical cables (1) and (2) connects the alternator to the electrical system. The small wire (1) is connected from the key start switch through the battery warning light. The other larger wire (2) is connected to the battery.

Alternator function When the key switch is turned on, a 12 V electrical circuit is made through a 1.4 W bulb, used as the battery warning light, to the alternator. This circuit illuminates the bulb and supplies a small electrical current, which partially magnetizes the rotor of the alternator. 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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NDIL14TR00846AB

Electrical systems - Alternator

Alternator - Remove 1. Disconnect battery from electric circuit. 2. Disconnect connections (1) and (2). 3. Loosen bolts and remove belt guard (3).

NDIL14TR00847AB

NDIL14TR00848AB

4. Slacken and remove the nut and bolt (1) fastening the alternator to the belt stretcher (2). 5. Move the alternator to reduce belt tension and remove it from the alternator pulley. 6. Screw out the alternator mounting bolts and remove the alternator. NOTICE: Alternator should be serviced and repaired only by authorised MICO dealer.

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Electrical systems - Alternator

Alternator - Install Installation is reversal of removal procedure. Tighten the belt to 10.00 â&#x20AC;&#x201C; 13.00 mm (0.39 â&#x20AC;&#x201C; 0.51 in) deflecion when moderate finger pressure is applied to the longest run of the belt.

NDIL14TR00849AB

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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 Alternator drive belt slipping

Check, clean and tighten connections Check and renew Check and adjust tension and renew

Loose of broken connection in the charging Inspect the circuit tighten the connections circuit 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

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Electrical systems - 55 Battery - 302

TECHNICAL DATA Battery General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Battery Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Battery Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

DIAGNOSTIC Battery Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Electrical systems - Battery

Battery - General specification Type Voltage Capacity (at 20 h rating) Location

Lead acid 12 V 88 â&#x20AC;&#x201C; 100 AÂˇh In front of radiator

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Electrical systems - Battery

Battery - Overview Description 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 V. 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 1. Remove the air pre-cleaner (1).

NDIL14TR00855AB

NDIL14TR00856AB

NDIL14TR00857AB

2. To maintain the hood in the raised position, a gas strut (1) is provided inside the hood.

3. Disconnect battery terminals. NOTICE: Always disconnect the negative cable (1) first. 4. Loosen clamp (2) and remove the battery from the tractor.

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Electrical systems - Battery

Battery - Install Installation of battery is reversal of removal procedure (refer to Battery - Remove (55.302)), but observe the following: • Clean the battery case and battery terminals and clamps before installation, by using a solution of sodium bicarbonate (baking soda) and water. NOTICE: Cover vents while cleaning. • Connect negative terminal last. • Do not over tighten the battery securing clamp as 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. 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 - Service instruction During scheduled maintenance checks of tractor, the battery should also be given careful attention. Battery life can be extended by regularly performing the following maintenance procedure. 1. Loosen the battery terminal clamps and disconnect the cables from the battery. Always disconnect the negative cable first and reconnect last. 2. Clean the battery case, battery terminals and cable clamps using a solution of sodium bicarbonate (baking soda) and water. NOTICE: Cover vents while cleaning. 3. Heavy corrosion of battery terminals and cable clamps may be cleaned with a wire brush. 4. Heavy corrosion of battery terminals and cable clamps may be cleaned with a wire brush. 5. Inspect cable condition and cable connections. Pay attention to both ends of cables. Remove any corrosion and ensure clean contact. Check both negative to chassis and positive to starter cables. 6. Maintain the electrolyte level midway between plates and top cover. Add distilled water if necessary. Do not use well / tap water. Do not top up with acid. 7. Battery securing clamps must be used to keep the battery secure. Do not over-tighten, as this may damage the battery case. 8. Ensure vent caps are tightened and wipe down the battery. Battery should be kept clean and dry. 9. Coat the terminal and cable clamps with petroleum jelly (vaseline) to prevent corrosion. Do not use grease. 10. Batteries should not be allowed to discharge completely. If the tractor is to be stored for a period of more than 2 weeks, the battery should be removed from the tractor and stored in a dry location on a wooden platform. Trickle charge every 2 to 3 weeks to maintain the battery in good condition.

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

Battery - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 External lighting - 404

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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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 60 W/ 55 W ( 12 V)

Reflector Bulb (double filament)

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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 Rear lights (left and right) Parking light + license plate light (Right-hand side only) Lens Bulb Turn signal light Lens Bulb Stop signal light Lens Bulb Reflector

White 21 W ( 12 V) Orange 21 W ( 12 V) Red 21 W ( 12 V) Orange 21 W ( 12 V) Red 21 W/ 5 W ( 12 V) Integral to stop light lens

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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

TT55 2WD tractor , TT55 4WD tractor , TT65 2WD tractor , TT65 4WD tractor , TT75 2WD tractor , TT75 4WD tractor

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Contents Electrical systems - 55 Warning indicators, alarms, and instruments - 408

TECHNICAL DATA Instrument cluster General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Instrument cluster Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overview â&#x20AC;&#x201C; Control switches (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DIAGNOSTIC Instrument cluster Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - General specification Lights, signals and accessories Instruments Fuel level Instrument type Sender type

Gauge Variable resistance

Instrument type Sender rating

Gauge (switch) 1 bar (14 psi)

Instrument type Sender type

Gauge Variable resistance

Instrument type Sender type

Gauge Direct

Oil pressure

Water temperature

Voltmeter

Controls Fuel stop Type Rating

Solenoid switch 1.5 ( 12 V, current draw)

Type Rating

Solid state 12 V

Type Rating

3 Position key 12 V

Type Rating

4 Position key 12 V

Type Rating

Left-off-right 12 V

Type Rating

Plunger operated 12 V

Type Rating

High/Low gear lever 12 V

Indicator and flasher

Ignition switch

Light switch

Turn signal switch

Brake switch

Neutral start switch

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Overview

NDIL14TR00831FB

Instrument panel consists of the following : 1. 2. 3. 4. 5. 6.

Left indicator lights Position lights High beam indicator light Engine oil pressure gauge Battery charging Indicator Right indicator lights

7. 8. 9. 10. 11.

Fuel level gauge Tachometer Hour meter Water temperature gauge Air cleaner clog light

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Electrical systems - Warning indicators, alarms, and instruments

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 (4), figure 1 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 charge the battery.

NDIL14TR00832AB

NDIL14TR00833AB

NDIL14TR00834AB

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.

Tachometer Cable (1) driven from engine, indicates engine speed and hours worked.

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Electrical systems - Warning indicators, alarms, and instruments

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.

NDIL14TR00835AA

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Overview â&#x20AC;&#x201C; Control switches TT55 TT55 TT75 TT75

2WD 4WD 2WD 4WD

tractor tractor tractor tractor

NDIL14TR00836FB

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

Left/right indicator switch Horn Hand throttle lever Key start/stop switch Head light switch Hazard warning light switch

Left/right turn switch This is used to switch on, the left or right turn signal circuits. It has 3 positions. 1. 2. 3.

Right Centre Left

Right turn Off Left turn

Hazard light switch This is used on both left and right turn signal circuits. This allows to operate as a warning to other road traffic.

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Electrical systems - Warning indicators, alarms, and instruments

NDIL14TR00837AB

NDIL14TR00838AB

NDIL14TR00839AB

NDIL14TR00840AB

Horn switch A push button switch is used to complete the horn signal circuit.

Light switch A turn type switch is used to switch the light circuits. It has 4 positions. Position 1 Position 2 Position 3 Position 4

Off Parking lights and instrument panel lights. Low beam High beam

Neutral start switch A two position â&#x20AC;&#x2DC;bal plunger typeâ&#x20AC;&#x2122; switch (1) mounted on left-hand side of transmission housing, operated by the high/low range lever.

Brake light switch The brake pedal switch (1) is located below the right foot board near the foot brake. It is actuated while applying brake and is indicated by the light provided on the fender.

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Electrical systems - Warning indicators, alarms, and instruments

Instrument cluster - Troubleshooting Problem Warning lights and gauges in-operative

Possible Cause Faulty key start switch

Correction Inspect and renew

Fuses burned out

Sender line short circuited

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

Check and renew

Connection not okay

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 â&#x20AC;&#x201C; 1

Loose or broken wiring

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Index Electrical systems - 55 Warning indicators, alarms, and instruments - 408 Instrument cluster - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument cluster - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument cluster - Overview â&#x20AC;&#x201C; Control switches (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrument cluster - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Plot No. 03, Udyog Kendra, Greater Noida - 201306 Distt. Gautam Budh Nagar, U.P. India SERVICE - Technical Publications & Tools

47899733 23/06/2015 EN

SPECIAL TOOL INDEX Genuine 290740 [Engine Lifting Hook] 291050 [Cylinder Head Valve Spring Compressor] 292909 [Special Tool] 292909 [Special Tool] 292904 [Set Of Adjustable Pullers] 292904 [Set Of Adjustable Pullers]

Reference

PAGE

Engine - Special tools Engine - Special tools

10.1 / 5 10.1 / 5

Mechanical transmission - Special tools Reverse gears - Disassemble Final drive housing - Special tools

21.1 / 4 21.4 / 22 27.3 / 5

Final drive housing - Disassemble

27.3 / 14

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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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