JX60

JX70
JX80
JX90
JX95
Tractors

Service Manual

CASE
Print No. 84176554B
 JX60 -- JX70 -- JX80 -- JX90 -- JX95
MODEL TRACTORS
SERVICE MANUAL
SECTIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TRANSMISSION OF MOTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FRONT MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REAR MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
POWER TAKE- OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
AXLE AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

S E R V I C E
 INTRODUCTORY NOTES
-- This manual is divided into sections identified by two--figure numbers and each section has independent
page numbering.

-- The different sections can easily be found by consulting the table of contents on the following pages.

-- The document number of the manual and the edition/update dates are given at the bottom of each page.

-- Pages updated in the future will be identified by the same document number followed by an additional digit:
first standard manual edition 84176554A -- 1 st update 84176554A1 -- 2 nd update 84176554A2 -- etc.
Updated pages can replace or supplement the pages of the standard manual; the necessary information for
the procedure by which to add or replace the pages is given on the frontispiece of the update.
An appropriately updated index will complete the publication.
If it is necessary to issue a new updated manual (2 nd edition) this will have the document number 84176554B,
which indicates that the manual is composed of the standard version 84176554A complete with all the up-
dates: 1 st update 84176554A1 -- 2 nd update 84176554A2 -- etc.

-- The information contained in this manual was current on the date printed on each section. As CASE IH
constantly improves its product range, some information may be out of date subsequent to modifications
implemented for technical or commercial reasons, or to meet legal requirements in different countries.
In the event of conflicting information, consult the CASE IH Sales and Service Departments.

IMPORTANT WARNINGS
-- All maintenance and repair work described in this manual must be performed exclusively by CASE IH service
technicians, in strict accordance with the instructions given and using any specific tools necessary.

-- Anyone performing the operations described herein without strictly following the instructions is personally
responsible for any eventual injury or damage to property.

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

No part of the text or illustrations

may be reproduced

PRINTED IN FRANCE

 CNH GLOBAL N.V.

Print No. 84176554 -- 03 -- 2008

Repair Manual -- JX Series Tractors

CONTENTS

GENERAL SECTION 00

General Instructions and Health and Safety Chapter 1

Section Description Page

00 000 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Notes for spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Notes for equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ENGINE SECTION 10

Engine System (F5C) Chapter 1

Section Description Page

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10 001 10 Engine R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Engine System(NEF) Chapter 1

Section Description Page

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lubrication diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cooling system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
10 001 10 Engine R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
10 001 53 Engine D.A. Checks, measurements and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10 102 70 Crankshaft front seal -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10 102 74 Crankshaft rear seal -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10 106 12 Valve tappet and rocker arm clearance -- Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10 218 30 Engine injector R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10 246 14 Bosch injection pump R.I. Timing. Air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
10 402 10 Coolant pump R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10 402 30 Thermostat valve R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
10 406 10 Radiator R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

84176554 -- 03--2008
10 414 10 Coolant pump and generator drive belts. Tension adjustment . . . . . . . . . . . . . . . . . . . . . . 116

CLUTCH SECTION 18

Clutches Chapter 1
Section Description Page

18 000 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
18 110 10 Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Minimum permissible dimensions after refacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
18 100 40 Adjustment of the main and PTO clutch control linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

GEARBOX SECTION 21

Mechanical Transmission (12x4) Chapter 1

Section Description Page

21 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3&5
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
21 110 Removal -- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see sect 27

Reverser (12x12) Chapter 2

Section Description Page

21 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
21 110 Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Reverser and Creeper (20x12) Chapter 3

Section Description Page

21 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
21 110 Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DRIVE LINES SECTION 23

84176554 -- 03--2008
 Drive Lines Chapter 1
Section Description Page

23 000 Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Torque settings and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cross--Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
23 101 26 Transmission shafts and guard (Disassembly -- Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
23 101 40 Drive gear housing (Removal -- Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
23 101 42 Drive gear housing removed (Disassembly -- Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FRONT AXLE MECHANICAL TRANSMISSION SECTION 25

Front Axle Mechanical Transmission Chapter 1

Section Description Page

25 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
25 100 30 Complete front axle. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
25 100 38 Front axle. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
25 108 46--47 Steering knuckle bearing pins. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Stub axle adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wheel hub bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bevel drive adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
25 102 24 Front axle differential. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
25 100 27 Front axle differential with LIM--SLIP. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Front axle differential with NO SPIN. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
44 511 80 Leading drive wheels toe--in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

REAR AXLE AND TRANSMISSION SECTION 27

Rear Axle And Transmission Chapter 1

Section Description Page

27 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description and operation and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
21.118.10 -- 12 Transmission--gearbox casing Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
21.118.85 Transmission--gearbox casing Disassembly--Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Gearbox driven shaft end float adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Differential lock engagement sleeve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Determining the bevel pinion positioning adjustment ring . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Adjusting the taper roller bearings for the bevel pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . 46
Adjusting the bearings and checking the backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

84176554 -- 03--2008
 Differential pinion and side gear backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

POWER TAKE--OFF SECTION 31

Mechanical Power Take -- Off Chapter 1

Section Description Page

31 000 Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal -- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
31 101 Bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

BRAKING SYSTEM SECTION 33

Braking System Chapter 1

Section Description Page

33 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools -- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
33.206 Front brake assembly mod. JX60 and JX70 removal and refitting --
overhauling on the bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
33.202.60 Service brake removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
33.202.50 Removal--Refitting of front brake pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
33.202.40 Bleeding air from the front braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
33.120.08 Adjusting service brake pedals travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
33.110.08 Parking brake travel adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

HYDRAULIC SYSTEM SECTION 35

Rear Mechanical Hydraulic Lift Chapter 1

Section Description Page

35 000 Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Description and operation of lift phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
35 110.30 Hydraulic lift -- disassembly reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

84176554 -- 03--2008
35.110.40--42--46 Hydraulic lift -- bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjusting the lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
35.110.08 Linkage adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
35.110.30 Pressure relief valve -- disassembly reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
35.110.32 Pressure relief valve -- setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
35.110.14 Lift control valve -- disassembly assembly and overhaul on bench . . . . . . . . . . . . . . . . . . . 36
35.0101.10 Lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Open Centre System Auxiliary Control Valves Chapter 2

Section Description Page

35 000 Main data -- Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Auxiliary control valves -- sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see chapter 1
35 204 46 Auxiliary control valves -- Assembly--Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Spool binding test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Spool leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjustment of the automatic detent release pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Trailer Brake Auxiliary Control Valve Chapter 3

Section Description Page

35 000 Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and operation of valve phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Trailer brake auxiliary control valve linkage adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

STEERING SECTION 41

Steering Chapter 1
Section Description Page

41 000 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
41 204 30 Hydrostatic steering control valve -- Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
41 204 34 Hydrostatic steering control valve -- Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . 14
41 204 38 Hydrostatic steering control valve -- Bench testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hydrostatic steering oil pump -- Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
41 216 20 Steering cylinder (two--wheel drive axle) -- Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . 32
Steering cylinder (four wheel drive axle) -- Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . 33

FRONT AXLE AND WHEELS SECTION 44

Front Axle And Wheels Chapter 1

Section Description Page

44 000 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

84176554 -- 03--2008
 Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Equipment -- Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
44 101 30 Removal--Refitting--Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
44 101 22 Wheel hub disassembly--assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
44 101 46 Stub axle overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
44 101 80 Checking wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

AUXILIARY UNITS SECTION 50

Auxiliary Units Chapter 1

Section Description Page

50 000 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main components of the cab air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Refrigerant recovery--recycling and evacuation--charging stations . . . . . . . . . . . . . . . . . . 20
50 200 04 Drying recharging and checking cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
50 200 03 Functional testing of air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Summary of the cab air--conditioning system charging operations . . . . . . . . . . . . . . . . . . 28
Checking for refrigerant leaks using an electronic leak detector . . . . . . . . . . . . . . . . . . . . . 30
Summary of fault diagnosis and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Air conditioning and heating pipes -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
50 200 04--74 Receiver--drier -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
50 200 04--72 Condenser -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
50 200 04--26 Compressor -- Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
50 200 10 Compressor drive belt tension adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

ELECTRICAL SYSTEM SECTION 55

Instruments Chapter 1
Section Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

55 418 Analogue instruments and introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Transmitter and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Components Chapter 2
Section Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

84176554 -- 03--2008
 55 500 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Starting System Chapter 3

Section Description Page

55 000 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Starting circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
55 201 Removal and re--installation of starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bench tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Charging System Chapter 4

Section Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

55 000 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
System testing and trouble--shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
55 301 Removal, re--installation and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Battery Chapter 5
Section Description Page

55 000 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
55.301.040 Removal and re--installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Battery checking and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery problems -- Frequent causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Electrical Circuits Chapter 6

Section Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

Section Description Page

55 100 Contents . . . . . . . . 1
Fuses (all versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Symbols used in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Electrical wire colour coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Ground locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-- General diagrams (W/Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

-- General diagrams (W/Out Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

84176554 -- 03--2008
 -- Analogue instrument circuit and connector overview . . . . . . . . . . . . . . . . . . . . . . . 19
-- Start--up circuit and connector overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

-- Direction indicator & hazard warning light circuit and connector overview . . . . . 25
-- Windscreen and rear window wiper/washer circuit and connector overview . . . 31
-- Brake light circuit and connector overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

-- Heating and air--conditioning system circuit and connector overview . . . . . . . . . 41

-- Work lamp (without cab circuit and connector overview) . . . . . . . . . . . . . . . . . . . 45

-- Work lamp (without cab circuit and connector overview) . . . . . . . . . . . . . . . . . . . 49
-- Side lights,main and dipped headlights, parking light circuit and connector

overview 53

BODYWORK AND DRIVER POSITION SECTION 90

Bodywork And Driver Position Chapter 1

Section Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

90 000 Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

84176554 -- 03--2008
 SECTION 00 -- GENERAL -- CHAPTER 1 1

GENERAL INSTRUCTIONS

IMPORTANT NOTICE
All maintenance and repair operations described in this manual should be carried out exclusively by the CASE
IH authorised workshops. All instructions detailed should be carefully observed and special equipment indicated
should be used if necessary.
Everyone who carries out service operations described without carefully observing these prescriptions will be
directly responsible of deriving damages.

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

ROTATING SHAFT SEALS

To correctly install rotating shaft seals, observe the following instructions:
-- Let the seal soak into the same oil as it will seal for at least half an hour before mounting;
-- Thoroughly clean the shaft and ensure that the shaft working surface is not damaged;
-- Place the sealing lip towards the fluid. In case of a hydrodynamic lip, consider the shaft rotation direction and
orient grooves in order that they deviate the fluid towards the inner side of the seal;
-- Coat the sealing lip with a thin layer of lubricant (oil rather than grease) and fill with grease the gap between
the sealing lip and the dust lip of double lip seals;
-- Insert the seal into its seat and press it down using a flat punch. Do no tap the seal with a hammer or a drift;
-- Take care to insert the seal perpendicularly to its seat while you are pressing it. Once the seal is settled, ensure
that it contacts the thrust element if required.;
-- To prevent damaging the sealing lip against the shaft, place a suitable protection during installation.

O RINGS
Lubricate the O rings before inserting them into their seats. This will prevent the O rings from rolling over and
twine during mounting which will jeopardise sealing.

SEALERS
Apply one of the following sealers: RTV SILMATE, RHODORSIL CAF 1, or LOCTITE PLASTIC GASKET over
the mating surfaces marked with an X.
Before applying the sealer, prepare the surface as follows:
-- remove possible scales using a metal brush;
-- thoroughly degrease the surfaces using one of the following cleaning agent: trichlorethylene, petrol or a water
and soda solution.

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

ROLL PINS
When fitting straight roll pins, ensure that the pin notch is oriented in the direction of the effort to stress the pin.
Coil roll pins can be installed in any position.
84176554 -- 03--2008
2 SECTION 00 -- GENERAL -- CHAPTER 1

NOTES FOR SPARE PARTS

Use exclusively genuine CASE IH spare parts.

Only genuine parts guarantee same quality, life, safety as original components as they are the same as mounted
in production.
Only the CASE IH genuine spare parts can offer this guarantee.
All spare parts orders should be complete with the following data:
-- tractor model (commercial name) and frame number;
-- engine type and number;
-- part number of the ordered part, which can be found on the “Microfiches” or the “Spare Parts Catalogue”,
which is the base for order processing.

NOTES FOR EQUIPMENT

Equipment which CASE IH proposes and shows in this manual are as follows:
-- studied and designed expressly for use on CASE IH tractors;
-- necessary to make a reliable repair;
-- accurately built and strictly tested to offer efficient and long--lasting working means.
We also remind the Repair Personnel that having these equipment means:
-- work in optimal technical conditions;
-- obtain best results;
-- save time and effort;
-- work more safely.

NOTICES
Wear limits indicated for some details should be intended as advised, but not binding values. The words “front”,
“rear”, “right hand”, and “left hand” referred to the different parts should be intended as seen from the operator’s
seat oriented to the normal sense of movement of the tractor.

HOW TO MOVE THE TRACTOR WITH THE BATTERY REMOVED

Cables from the external power supply should be connected exclusively to the respective terminals of the tractor
positive and negative cables using pliers in good condition which allow proper and steady contact.
Disconnect all services (lights, wind--shield wipers, etc.) before starting the tractor.
If it is necessary to check the tractor electrical system, check it only with the power supply connected. At check
end, disconnect all services and switch the power supply off before disconnecting the cables.

84176554 -- 03--2008
 SECTION 00 -- GENERAL -- CHAPTER 1 3

SAFETY RULES

PAY ATTENTION TO THIS SYMBOL

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 safeguard your safety and personal integrity.
In this manual you will find this symbol together with the following key--words:
WARNING -- it gives warning about improper repair operations and deriving potential
consequences affecting the service technician’s personal safety.
DANGER -- it gives specific warning about potential dangers for personal safety of the
operator or other persons directly or indirectly involved.

TO PREVENT ACCIDENTS if they are certified operators to assist in the

operation to be carried out.
Most accidents and personal injuries taking place in
workshops are due from non--observance of some ◊ Never operate the machine or use attachments
simple and essential prudential rule and safety pre- from a place other than sitting at the operator’s
cautions. For this reason, IN MOST CASES THEY seat.
CAN BE AVOIDED. It suffices to foresee possible
causes and act consequently with necessary caution ◊ Never carry out any operation on the machine
and care. when the engine is running, except when specifi-
The possibility that an accident might occur with any cally indicated.
type of machines should not be disregarded, no mat- ◊ Stop the engine and ensure that all pressure is
ter how well the machine in question was designed relieved from hydraulic circuits before removing
and built. caps, covers, valves, etc.
A wise and careful service technician is the best pre-
cautions against accidents. ◊ All repair and maintenance operations should be
Careful observance of this only basic precaution carried out with the greatest care and attention.
would be enough to avoid many severe accidents.
◊ Service stairs and platforms used in a workshop
DANGER: Never carry out any cleaning, lubrication or in the field should be built in compliance with
or maintenance operations when the engine is run- the safety rules in force.
ning.
◊ Disconnect the batteries and label all controls to
warn that the tractor is being serviced. Block the
SAFETY RULES machine and all equipment which should be
raised.
GENERALITIES
◊ Never check or fill fuel tanks and accumulator
◊ Carefully follow specified repair and mainte- batteries, nor use starting liquid if you are smok-
nance procedures. ing or near open flames as such fluids are flam-
mable.
◊ Do not wear rings, wristwatches, jewels, unbut-
toned or flapping clothing such as ties, torn ◊ Brakes are inoperative when they are manually
clothes, scarves, open jackets or shirts with open released for maintenance purposes. In such
zips which could get hold into moving parts. We cases, the machine should be kept constantly
advise to use approved safety clothing such as under control using blocks or similar devices.
anti--slipping footwear, gloves, safety goggles,
helmets, etc. ◊ The fuel filling gun should remain always in con-
tact with the filler neck. Maintain this contact until
◊ Never carry out any repair on the machine if the fuel stops flowing into the tank to avoid pos-
someone is sitting on the operator’s seat, except sible sparks due to static electricity buildup.

84176554 -- 03--2008
4 SECTION 00 -- GENERAL -- CHAPTER 1

◊ Use exclusively specified towing points for tow- ◊ In case of operations outside the workshop, drive
ing the tractor. Connect parts carefully. Ensure the tractor to a flat area and block it. If working on
that foreseen pins and/or locks are steadily fixed an incline cannot be avoided, first block the trac-
before applying traction. Do not stop near towing tor carefully. Move it to a flat area as soon as pos-
bars, cables or chains working under load. sible with a certain extent of safety.
◊ To transfer a failed tractor, use a trailer or a low ◊ Ruined or plied cables and chains are unreliable.
loading platform trolley if available. Do not use them for lifting or trailing. Always han-
◊ To load and unload the machine from the trans- dle them wearing gloves of proper thickness.
portation mean, select a flat area providing a firm
◊ Chains should always be safely fastened.
support to the trailer or truck wheels. Firmly tie
Ensure that fastening device is strong enough to
the machine to the truck or trailer platform and
hold the load foreseen. No persons should stop
block wheels as required by the forwarder.
near the fastening point, trailing chains or cables.
◊ For electrical heaters, battery--chargers and sim-
ilar equipment use exclusive auxiliary power ◊ The working area should be always kept CLEAN
supplies with a efficient ground to avoid electrical and DRY. Immediately clean any spillage of
shock hazard. water or oil.

◊ Always use lifting equipment and similar of ◊ Do not pile up grease or oil soaked rags, as they
appropriate capacity to lift or move heavy compo- constitute a great fire hazard. Always place them
nents. into a metal container.
Before starting the tractor or its attachments,
◊ Pay special attention to bystanders. check, adjust and block the operator’s seat. Also
◊ Never pour gasoline or diesel oil into open, wide ensure that there are no persons within the trac-
and low containers. tor or attachment operating range.

◊ Never use gasoline, diesel oil or other flammable ◊ Do not keep into your pockets any object which
liquids as cleaning agents. Use non--flammable might fall unobserved into the tractor’s inner
non--toxic proprietary solvents. compartments.
◊ Wear protection goggles with side guards when ◊ Whenever there is the possibility of being
cleaning parts using compressed air. reached by ejected metal parts or similar, use
protection eye mask or goggles with side guards,
◊ Do not exceed a pressure of 2.1 bar, in accor-
helmets, special footwear and heavy gloves.
dance with local regulations.
◊ Do not run the engine in a closed building without ◊ Wear suitable protection such as tinted eye
proper ventilation. protection, helmets, special clothing, gloves and
footwear whenever it is necessary to carry out
◊ Do not smoke, use open flames, cause sparks in welding procedures. All persons standing in the
the nearby area when filling fuel or handling vicinity of the welding process should wear tinted
highly flammable liquids. eye protection. NEVER LOOK AT THE WELD-
ING ARC IF YOUR EYES ARE NOT SUITABLY
◊ Do not use flames as light sources when working
PROTECTED.
on a machine or checking for leaks.
◊ Move with caution when working under a tractor, ◊ Metal cables with the use get frayed. Always
and also on or near a tractor. Wear proper safety wear adequate protections (heavy gloves, eye
accessories: helmets, goggles and special foot- protection, etc.)
wear.
◊ Handle all parts with the greatest caution. Keep
◊ During checks which should be carried out with your hands and fingers far from gaps, moving
the engine running, ask an assistant to seat at the gears and similar. Always use approved protec-
operator’s seat and keep the service technician tive equipment, such as eye protection, heavy
under visual control at any moment. gloves and protective footwear.

84176554 -- 03--2008
 SECTION 00 -- GENERAL -- CHAPTER 1 5

START UP HYDRAULIC SYSTEMS

◊ Never run the engine in confined spaces which ◊ Some fluid slowly coming out from a very small
are not equipped with adequate ventilation for port can be almost invisible and be strong enough
exhaust gas extraction. to penetrate the skin. For this reason, NEVER
USE YOUR HANDS TO CHECK FOR LEAKS,
but use a piece of cardboard or a piece of wood
◊ Never bring your head, body, arms, legs, feet, to this purpose. If any fluid is injected into the skin,
hands, fingers near fans or rotating belts. seek medical aid immediately. Lack of immediate
medical attention, serious infections or dermato-
sis may result.
ENGINE ◊ Always take system pressure readings using the
◊ Always loosen the radiator cap very slowly before appropriate gauges.
removing it to allow pressure in the system to dis-
sipate. Coolant should be topped up only when WHEELS AND TYRES
the engine is stopped or idle if hot.
◊ Check that the tyres are correctly inflated at the
pressure specified by the manufacturer. Periodi-
◊ Do not fill up fuel tank when the engine is running, cally check possible damages to the rims and
mainly if it is hot, to avoid ignition of fires in case tyres.
of fuel spilling.
◊ Keep off and stay at the tyre side when correcting
the inflation pressure.
◊ Never check or adjust the fan belt tension when
the engine is running. ◊ Check the pressure only when the tractor is
Never adjust the fuel injection pump when the unloaded and tyres are cold to avoid wrong read-
tractor is moving. ings due to over--pressure. Do not reuse parts of
recovered wheels as improper welding, brazing
or heating may weaken the wheel and make it fail.
◊ Never lubricate the tractor when the engine is run-
ning. ◊ Never cut, nor weld a rim with the inflated tyre
assembled.

◊ To remove the wheels, block both front and rear

ELECTRICAL SYSTEMS
tractor wheels. Raise the tractor and install safe
◊ If it is necessary to use auxiliary batteries, cables and stable supports under the tractor in accor-
must be connected at both sides as follows: (+) to dance with regulations in force.
(+) and (--) to (--). Avoid short--circuiting the termi-
nals. GAS RELEASED FROM BATTERIES IS ◊ Deflate the tyre before removing any object
HIGHLY FLAMMABLE. During charging, leave caught into the tyre tread.
the battery compartment uncovered to improve
ventilation. Avoid checking the battery charge by ◊ Never inflate tyres using flammable gases as they
means of “jumpers” made by placing metallic may originate explosions and cause injuries to
objects across the terminals. Avoid sparks or bystanders.
flames near the battery area. Do no smoke to pre-
vent explosion hazards.
REMOVAL AND INSTALLATION
◊ Lift and handle all heavy components using lifting
◊ Prior to any service, check for fuel or current equipment of adequate capacity. Ensure that
leaks. Remove these leaks before going on with parts are supported by appropriate slings and
the work. hooks. Use lifting eyes provided to this purpose.
Take care of the persons near the loads to be
lifted.
◊ Do not charge batteries in confined spaces. En-
sure that ventilation is appropriate to prevent acci- ◊ Handle all parts with great care. Do not place your
dental explosion hazard due to build--up of gases hands or fingers between two parts. Wear
releaved during charging. approved protective clothing such as safety
goggles, gloves and footwear.

◊ Always disconnect the batteries before perform- ◊ Do not twine chains or metal cables. Always wear
ing any type of service on the electrical system. protection gloves to handle cables or chains.
84176554 -- 03--2008
6 SECTION 00 -- GENERAL -- CHAPTER 1

CONSUMABLES
QUANTITY
COMPONENT TO BE FILLED OR RECOMMENDED INTERNATIONAL
TOPPED UP liters/dm US PRODUCTS SPECIFICATION
3 IMP gal
gal
Cooling system:
without cab:
Water & liquid
JX 60, JX70 . . . . . . . . . . . . . . . . . . . 12 3.17 2.64
AMBRA
JX 80, JX90, JX95 . . . . . . . . . . . . . . 14 3.69 3.08 AGRIFLU 50% + -
with cab: 50%
(NH 900 A)
JX 60, JX70 . . . . . . . . . . . . . . . . . . . 14 3.69 3
JX 80, JX90, JX95 . . . . . . . . . . . . . . 16 4.22 3.52
Water & cleaning
Windscreen washer bottle . . . . . . . 2 0.53 0.44 -
liquid
Decanted and
Fuel tank . . . . . . . . . . . . . . . . . . . . . . 90 24.3 19.80 filtered -
diesel fuel
AMBRA
Engine sump:
MASTERGOLD
JX 60, JX 70, JX80: . . . . . . . . 8.5 2.25 1.87 API CH-4
SAE 15W -- 40
JX 90, JX95: . . . . . . . . . . . . . . . 10.0 2.64 2.20 ACEA E5
(NH 330H)
AMBRA BRAKE
Brake control circuit . . . . . . . . . . . . . 0.4 0.1 0.09 LHM Oil (NH 610 ISO 7308
A)
Hydrostatic steering circuit . . . . . . . 2.0 0.52 0.44
Front axle:
- axle housing . . . . . . . . . . . . . . . . . . 7.0 1.8 1.54
- final drives (each): . . . . . . . . . . . . . 1.25 0.3 0.28 Oil API GL4
AMBRA MULTI G ISO 32/46
Rear transmission (bevel drive and (NH 410B) SAE 10W--30
brakes), gearbox, hydraulic lift and
PTO . . . . . . . . . . . . . . . . . . . . . . . . . . 46 12.15 10.12
Rear final drives (each) . . . . . . . . . . 5.3 1.40 1.17
Front wheel hubs . . . . . . . . . . . . . . . - - - Grease
AMBRA GR9 NLGI 2
Grease fittings . . . . . . . . . . . . . . . . . - - - (NH 710A)

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 SECTION 10 -- ENGINE -- CHAPTER 1 1

SECTION 10 -- ENGINE
Chapter 1 -- Engine

CONTENTS

Operation Description Page

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

10 001 10 Engine R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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2 SECTION 10 -- ENGINE -- CHAPTER 1

TOOLS

Warning -- The operations described in this section

can only be carried out with ESSENTIAL tools indi-
cated by an (X).
To work safely and efficiently and obtain the best re-
sults, it is also necessary to use the recommended
specific tools listed below and certain other tools,
which are to be made according to the drawings in-
cluded in this manual.

List of specific tools required for the various

operations described in this Section.

380000569 Movable tool for dismantling

tractors with bracket 380000500
and adapter plate 380000844.

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 SECTION 10 -- ENGINE -- CHAPTER 1 3

ENGINE TROUBLESHOOTING

Problems Possible Causes Solutions

Engine does not start. 1. Batteries partially discharged. Check and recharge batteries. Re-
place if necessary.

2. Battery terminal connections cor- Clean, inspect and tighten terminal

roded or loose. nuts. Replace terminals and nuts if
excessively corroded.

3. Injection pump timing incorrect. Adjust injection pump timing.

4. Impurities or water in fuel lines. Disconnect fuel lines from injection

pump and clean thoroughly. If
necessary clean and dry the fuel tank.

5. No fuel in tank. Fill tank.

6. Fuel supply pump malfunction. Check and replace pump if necess-

ary.

7. Air in fuel system. Check fuel lines, unions, supply

pump, filters and injection pump for
air; then bleed the air from the circuit.

8. Starter motor faulty. Repair or replace starter motor.

9. Thermostarter faulty. Check and replace thermostarter if

necessary.

Engine stalls. 1. Idle speed too low. Adjust idle speed.

2. Injection pump delivery irregular. Check injection pump delivery on test

bench.

3. Impurities or water in fuel lines. Disconnect fuel lines from injection

pump and clean thoroughly. If
necessary clean and dry the fuel tank.

4. Fuel filters clogged. Replace the filter cartridges.

5. Incorrect valve -- rocker arm Adjust the clearance between the

clearances. rocker arms and the valves.

6. Burnt or cracked valves. Replace the valves.

7. Air in fuel system. Check fuel lines, unions, supply

pump, filters and injection pump for
air; then bleed the air from the circuit.

8. Injection pump drive mechanism Replace damaged parts.

damaged.
(continued)

84176554 - 03-- 2008

4 SECTION 10 -- ENGINE -- CHAPTER 1

ENGINE TROUBLESHOOTING
(cont)

Problems Possible Causes Solutions

Engine overheating. 1. Coolant pump malfunction. Overhaul pump and replace if

necessary.

2. Thermostat faulty. Replace the thermostat.

3. Radiator inefficient. Remove internal deposits by flushing.

Check for leaks and repair.

4. Deposits in cylinder head and Flush out coolant system.

crankcase coolant passages.

5. Coolant pump and fan drive belt Check and adjust belt tension.
slack.

6. Coolant level low. Top up expansion tank with specified

coolant mixture.

7. Incorrect engine timing. Check and adjust engine timing.

8. Injection pump calibration incor- Calibrate pump on test bench to va-

rect -- delivering too much or too lues specified in calibration tables.
little fuel.

9. Air filter clogged. Clean filter unit and replace filter el-
ement if necessary.

Engine lacks power and 1. Injection pump timing incorrect. Adjust injection pump timing.
runs unevenly.

2. Auto advance regulator in injec- Overhaul injection pump and adjust

tion pump damaged. on test bench to values specified in
calibration table.

3. Control valve journal worn. Overhaul injection pump and adjust

on test bench to values specified in
calibration table.

4. Injection pump delivery irregular. Overhaul injection pump and adjust

on test bench to values specified in
calibration table.

5. All--speed governor damaged. Overhaul injection pump and adjust

on test bench to values specified in
calibration table.

6. Injectors partially obstructed or Clean and overhaul injectors and ad-

damaged. just pressure setting.

7. Impurities or water in fuel lines. Disconnect fuel lines from injection

pump and clean thoroughly. If
necessary clean and dry the fuel tank.
(continued)

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 SECTION 10 -- ENGINE -- CHAPTER 1 5

ENGINE TROUBLESHOOTING
(cont)

Problems Possible Causes Solutions

8. Fuel supply pump damaged. Replace fuel supply pump.

9. Incorrect valve -- rocker arm Adjust the clearance between the

clearances. rocker arms and the valves.

10. Cylinder compression low. Test compression and overhaul en-

gine if necessary.

11. Air filter clogged. Clean filter unit and replace filter el-
ement if necessary.

12. Tie--rod in linkage between accel- Adjust to correct length.

erator and injection pump incor-
rectly adjusted.

13. Fast idling speed screw on injec- Adjust fast idling speed screw.
tion pump incorrectly adjusted.

Engine produces abnormal 1. Injectors partially obstructed or Clean and overhaul injectors and ad-
knocking noises. damaged. just pressure setting.

2. Impurities accumulating in fuel Clean fuel lines and replace severely

lines. dented pipes; clean injection pump if
necessary.

3. Injection pump timing incorrect. Adjust injection pump timing.

4. Crankshaft knocking due to ex- Re--grind crankshaft journals and

cessive play in one or more main crankpins. Fit oversize shell bearings
or big--end bearings or excessive and thrust washers.
endfloat.

5. Crankshaft out of balance. Check crankshaft alignment and bal-

ance; replace if necessary.

6. Flywheel bolts loose. Replace any bolts that have worked

loose and tighten all bolts to the speci-
fied preliminary and angular torque
values.

7. Connecting rod axes not parallel. Straighten connecting rods, check

axes parallelism; replace con rods if
necessary.

8. Pistons knock due to excessive Rebore cylinder liners and fit oversize
wear. pistons.

9. Noise caused by excessive play Fit oversize gudgeon pin, rebore pis-
of gudgeon pins in small--end and ton seats and small--end bushings.
piston bushings. Loose fit of Replace with new bushings.
small--end bushing.

10. Excessive tappet / valve noise. Check for broken springs or excess-
ive play between valve stems and
guides, cam followers and bores; ad-
just valve clearances.
(continued)

84176554 - 03-- 2008

6 SECTION 10 -- ENGINE -- CHAPTER 1

ENGINE TROUBLESHOOTING
(cont)

Problems Possible Causes Solutions

Engine produces excessive 1. Maximum delivery of injection Calibrate pump on test bench to va-
black or dark grey smoke. pump too high. lues specified in calibration tables.

2. Injection pump delivery excess- Adjust injection pump timing or check

ively retarded or automatic ad- automatic advance regulator.
vance regulator damaged.

3. Injection pump delivery excess- Adjust injection pump timing.

ively advanced.

4. Injectors partially or totally ob- Clean and overhaul injectors and ad-
structed or incorrectly adjusted. just pressure setting; replace if
necessary.

5. Air filter clogged. Clean filter unit and replace filter el-
ement if necessary.

6. Loss of engine compression due Replace damaged parts or, if necess-

to: ary, overhaul the engine.
-- piston rings sticking;
-- cylinder liner wear;
-- worn or incorrectly adjusted
valves.

7. High--pressure fuel lines dam- Inspect and replace if necessary.

aged.

Blue, grey--blue or grey-- 1. Injection pump delivery excess- Adjust injection pump timing or check
white smoke. ively retarded or automatic ad- automatic advance regulator.
vance regulator damaged.

2. Injectors obstructed or damaged. Clean, overhaul and calibrate injec-

tors, replace if necessary.

3. Oil leaking past piston rings due Replace damaged parts or, if necess-
to sticking rings or cylinder liner ary, overhaul the engine.
wear.

4. Oil leaking through the inlet valve Overhaul cylinder head.

guides due to guide or valve stem
wear.

5. Engine does not reach correct Replace the thermostat.

operating temperature (thermo-
stat faulty).

Engine runs on after 1. Engine stop electromagnet dam- Replace electromagnet.

switching off. aged.

2. All--speed governor damaged. Overhaul injection pump and adjust

on test bench to values specified in
calibration table.

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 SECTION 10 -- ENGINE -- CHAPTER 1 7

Op. 10 001 10
ENGINE R.I.
DANGER
Lift and handle all heavy parts using suitable lifting
equipment.
Make sure that assemblies or parts are supported by
means of suitable slings and hooks. Check that no
one is in the vicinity of the load to be lifted.

CAUTION
Always use appropriate tools to align fixing holes.
NEVER USE FINGERS OR HANDS.

1. Disconnect the battery negative lead (1).

2. Drain the oil from the transmission--gearbox
housing.

3. Drain the cooling system.

1
4. Remove the exhaust pipe, attach lifting chains
(2) to the bonnet (1) and attach the chain to the
hoist.
2

2
5. Disconnect the electrical connection (1) of
bonnet.

84176554 - 03-- 2008

8 SECTION 10 -- ENGINE -- CHAPTER 1

6. Detach the gas struts (1) from the bonnet.

4
7. Remove the four bonnet hinge bolts (1) and lift
the bonnet clear.

5
8. Remove the three retaining bolts (1) and the
guard (2) on the right--left hand side of the fan.

6
9. Unscrew the nut (1) from the weight retaining pin.
Remove the weights from the front support.

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 9

10. Unscrew the front central and rear retaining bolts

on the front axle shaft guard, then remove the
guard (1).

25038

8
11. Remove the circlip (2) and move the front sleeve
(1) in the direction indicated by the arrow until it 1 2
is released from the groove on the front axle.

25039

9
12. Remove the circlip (2) and move the rear sleeve
(1) in the direction indicated by the arrow until it 1
is released from the groove on the drive.

2
25040

10
13. Remove the propeller shaft central support (1)
retaining bolts and extract the shaft together with
the support.

25041

11

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10 SECTION 10 -- ENGINE -- CHAPTER 1

14. Dicconnect the pressure pipe connection (1) of

the lift pump.

12
15. Disconnect the delivery lines of both hydraulic lift
pump (1) and hydrostatic steering pump (2).

13
16. Detach the cab heating pipes (1) and (2).

14
17. Detach the cab air--conditioning pipes (1) and
(2).

15

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 SECTION 10 -- ENGINE -- CHAPTER 1 11

18. Extract the plastic fasteners (2) and detach the

diesel recovery pipe (3) and delivery pipe (4) to
the diesel pump (1). 3

16
19. Remove two metal clamps (1) and the rigid pipe
of drawing oil from the transmission housing via
lift pump.

17
20. Remove the electrical connection from the brake
fluid reservoir and take the brake fluid reservoir
(1) from the bracket.

18
21. Disconnect the steering oil delivery and return
hoses (1) and (2). Disconnect the steering
cylinder lines (3) and (4).

3
4

19

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12 SECTION 10 -- ENGINE -- CHAPTER 1

22. Disconnect the delivery and return lines (1) to the

power steering cylinders.

20
23. Disconnect rear brakes oil distribution
connection pipes (1) and (2).

21

24. Disconnect brake distributor valve connections

(1) and (2).

22

25. Disconnect A/C compressor inlet (1) and outlet

(2) hoses.

23

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 SECTION 10 -- ENGINE -- CHAPTER 1 13

26. Remove the fusebox (1) from the bonnet

support.

24
27. Remove the electrical oil pressure switch (1).

25
28. Remove the electrical connections of coolant
temperature sender (1).

26
29. Remove the electrical connection of pump
cut--out solenoid sender (1) and hydrostatic
steering pump oil pressure switch (2).

27

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14 SECTION 10 -- ENGINE -- CHAPTER 1

30. Remove the retaining retaining clips (1) and

detach the flexible cables governing the hand
throttle and pedal throttle.
31. Remove the retaining clip (2) and detach the
throttle control tie--rod connected to the injection
pump.

28
32. Disconnect the electrical connection (1) between
the cab and the engine.

29
33. Disconnect the electrical connections from
starter motor (1).

30
34. Disconnect the electrical connections from
alternator (1).

31

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 SECTION 10 -- ENGINE -- CHAPTER 1 15

35. Disconnect the electrical connection of water in

fuel sensor (1).

32
36. Disconnect the electrical connections of dryer
filter sensor (1).

33
37. Remove the electrical connection (1), air filter
clogging sensor (2) and AC compressor
electrical connection (3).

34
38. Remove the two retaining bolts and the support
together with relays protecting system (1).

35

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16 SECTION 10 -- ENGINE -- CHAPTER 1

39. Remove the two connectors of the brake lights

switch (1).

36
40. Loosen the corresponding retaining clamps and
extract the pipes (1), (2), (3) and (4).

37
41. Loosen the corresponding retaining bolts and
remove the bracket (1).

38
42. Hitch the engine to the hoist with the chains
anchouring it to the attachments on the engine.

39

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 SECTION 10 − ENGINE − CHAPTER 1 17

43. Position the movable tool for dismantling tractors

380000569 with the bracket 380000500 and
adapter plate 380000844 under the engine and
place a wooden block in between the points of
contact between the tool and tractor.
1

40
44. Extract the differential lock pedal retaining pin
from the drive shaft (1), remove the pedal and
footboard (2).

2
1

25043

41
45. Unscrew the nuts (1) and the bolts securing the
engine to the transmission. Access is through
the two slots in the cab floor.

1
42
46. Remove the remaining six retaining bolts at the
bottom and side.

43

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18 SECTION 10 -- ENGINE -- CHAPTER 1

47. Seperate the engine from the transmission with

the tool 380000569.

1 2
44
48. Remove the spacer located between the engine
and the transmission.

45
49. Insert the fixed under the balast support and
secure the front wheels with wooden blocks.

1 2
46
50. Loosen the corresponding retaining clamp (1)
and extract the pipes. And remove the bracket
(2).

47

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 SECTION 10 -- ENGINE -- CHAPTER 1 19

51. Remove the bonnet support (1).

48
52. Loosen the retaining clamp and extract the pipe
(1) joining the coolant pump to the bottom of the
radiator.

49
53. Position a fixed stand (3) under the support of the
groove (1) of the front axle drive placing a
wooden plug (2) between the parts (3) and (1).

50
54. Remove the four bolts (2) fastening the front axle
support (1) to the engine (3).

51

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20 SECTION 10 -- ENGINE -- CHAPTER 1

55. Insert the hooks of the lifting chains (1) in the

eyelets shown in the figure, afterwards
tensioning the chains with the hoist.

52
56. Detach the engine (2) from the front axle (3),
trying to avoid incorrect operations with the hoist
so as not to let the engine fan damage the fins of
the radiator (1), left on the axle (3).
57. Then rest the engine on a platform support.

53

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 SECTION 10 -- ENGINE -- CHAPTER 1 21

-- Apply LOCTITE sealing compound on the en-

CAUTION gine/spacer contact surfaces and fit the spacer
on the stud bolts screwed into the engine.
Always use appropriate tools to align fixing holes.
NEVER USE FINGERS OR HANDS.
-- Also apply LOCTITE sealing compound on the
clutch overdrive casing surfaces.

-- Apply the torque settings listed at F5C Engines

-- Position wooden blocks under the rear wheels,
Repair Manual (Print No: 87736548A).
make sure that the handbrake is fully applied and
that all fixed and mobile stands are safely posi-
-- Insert the three hooks of the chain in the eyelets tioned.
on the engine and, using the hoist, lift the assem-
bly off the platform support.
-- The installation phase described here requires
the presence of two or three workers to use the
-- Position the engine on the front axle, trying to movable tool for dismantling tractors 380000569
avoid incorrect operations with the hoist so as not to move the engine/front axle assembly close to
to let the engine fan damage the fins of the radi- the overdrive clutch casing.
ator, then join the two assemblies together with
the four retaining bolts.
-- In the phase of installing the engine/front axle as-
sembly to the overdrive clutch casing, it is
-- Reposition the movable tool for dismantling trac- necessary to push on the front wheels, taking
tors 380000569 under the engine and place a great care in the end phase of coupling over both
wooden block in between the point of contact be- the pipes and the cables/electrical connections
tween the tool and engine. to prevent crushing between the two bodies. Dur-
ing this phase, it is moreover necessary to turn
the crankshaft with the aid of the radiator cooling
-- With the aid of the hoist, place the engine on the
fan to help the coupling between the sleeve and
tool 380000569 and remove the lifting eyelet
the drive shaft.
previously fitted on the front of the engine.

-- Secure both assemblies by tightening all the

-- Remove the fixed stand previously positioned
bolts locking the engine to the overdrive clutch
under the support of the groove of the drive of the
casing.
front axle and the wooden plug.

-- Remove the U--bolt previously fitted under the

-- Refit the pipe joining the coolant pump to the bot-
clutch casing and recover the movable tool for
tom of the radiator and the associated retaining
dismantling tractors 380000569.
clamp.

-- Fit the electric cable connected to the fuse--

-- Refit the oil vapour suction pipe, filter/intake
holder box and the retaining nut.
manifold connecting pipe and the pipe connect-
ing the radiator at the top to the thermostat valve,
re--installing the associated retaining clamps. -- Working from the side of the starter motor, fit the
protective cable housing and the retaining nut.
-- Fit the left--right hand side guard of the engine
fan and the three retaining bolts. -- Fit the electrical connections installed on the
brake pump and on the brake fluid reservoir.
-- Remove the fixed U--bolt fitted beforehand under
the ballast support and the two wooden wedges -- Refit the power steering piping on the engine and
locking the front wheels. reconnect the electrical connections to the pres-
sure switch.
-- Remove the old sealing compound from both
surfaces of the spacer between the engine and -- Refit the power steering return pipe with its
the overdrive clutch housing, and do the same bracket and retaining bolt.
also on the contact surface of the overdrive
clutch housing and on that of the engine.

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22 SECTION 10 -- ENGINE -- CHAPTER 1

-- Refit the brake piping support and the two retain- -- Refit the two right-- and left--hand dashboard
ing bolts. panels and the relevant four fixing knobs.

-- Refit the condenser, air cooler and radiator -- Refit the two power steering cylinder oil delivery
pipes. and return hoses.

-- Refit the dryer filter together with its support and -- Install the electrical connections between the
piping, tightening the two retaining bolts. cab and the engine.

-- Refit the bonnet support, tightening the retaining -- Reconnect the diesel delivery and return pipes to
bolts. the diesel pump and install the relevant plastic
fasteners.
-- Refit the support with the fuse--holder box on the
bonnet support, tightening the two retaining -- Working on the left--hand side of the engine, in-
bolts. stall the lift pump draw pipe and tighten the re-
taining bolts.
-- Refit the support together with the relays protect-
ing the system on the bonnet support, fitting the -- Install the delivery pipe of the services pump on
two retaining bolts. the right--hand side of the engine and tighten its
fitting.
-- Refit the brake fluid reservoir onto the support
and the two retaining clips. -- Refit the rigid pipe for drawing oil from the trans-
mission and the two metal clamps.
-- Refit the silencer together with the exhaust pipe.
-- Refit the power steering/four--wheel drive drain
pipe on both the left-- and right--hand sides of the
-- Secure the silencer to the exhaust manifold with
engine.
the four nuts and connect the air filter dust ex-
tractor pipe to the silencer exhaust, inserting the
retaining clamp. -- Refit the lift pump draw pipe and lock the retain-
ing bolts.
-- Refit the three rear retaining bolts of the exhaust
silencer. -- Refit the propeller shaft with its central support
and the retaining bolts.
-- Fit the cab heater delivery and return pipes and
insert the associated clamps. -- Refit the front axle drive shaft guard, tightening
the front, central and rear retaining bolts.
-- Refit the fitting of the hose delivering power
steering oil to the hydraulic cylinders governing -- Refit the front ballast together with the support
the front wheel steering. and insert the retaining pin and the split pins.

-- Install the flexible cables governing the hand and -- Install the fitting of the cab heater radiator coolant
pedal throttle, inserting the retaining clips. return pipe connected to the bottom of the cool-
ant pump and refill the engine coolant.
-- Reconnect the throttle control tie--rod to the in-
jection pump, inserting the retaining clip. -- Refit the guard on the right--hand side of the fan,
tightening the three retaining bolts.
-- Working from inside the cab, fit the four plugs to
gain access to the upper bolts securing the en- -- Refill the transmission--gearbox housing with oil.
gine, located at the base of the steering column.
-- Install the bonnet. Reconnect the battery nega-
-- Refit the pedal on the differential lock drive shaft, tive lead.
the retaining pin and the footboard.

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 SECTION 10 -- ENGINE -- CHAPTER 1 1

SECTION 10 -- ENGINE
Chapter 1 -- Engine

CONTENTS

Operation Description Page

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Engine views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Lubrication diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Cooling system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

10 001 10 Engine R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

10 001 53 Engine D.A. Checks, measurements and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

10 102 70 Crankshaft front seal -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

10 102 74 Crankshaft rear seal -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

10 106 12 Valve tappet and rocker arm clearance -- Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

10 218 30 Engine injector R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

10 246 14 Bosch injection pump R.I. Timing. Air bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

10 402 10 Coolant pump R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

10 402 30 Thermostat valve R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

10 406 10 Radiator R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

10 414 10 Coolant pump and generator drive belts. Tension adjustment . . . . . . . . . . . . . . . . . . . . . . 116

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2 SECTION 10 -- ENGINE -- CHAPTER 1

GENERAL SPECIFICATIONS 4 Cylinders

Engine, technical type:
-- JX 90 model -- type F4CE9487M*J (BOSCH pump) See data on page
-- JX 95 model -- type F4CE9487N*J (BOSCH pump) See data on page
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diesel, 4--stroke
Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . direct
Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Piston diameter
-- model JX 90, JX 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0944 in. (104 mm)
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1968 in. (132 mm)
Total displacement:
-- model JX 90, JX 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273.67 in3. (4485 cm3)
Compression ratio for Models JX 90, JX 95 . . . . 17.5:1
Maximum power:
-- model JX 90 -- type F4CE9487M*J . . . . . . . . . . . . . . . . . . . . 65 kW (88 HP)
-- model JX 95 -- type F4CE9487N*J . . . . . . . . . . . . . . . . . . . . 70 kW (95 HP)
-- Maximum torque: JX 90 -- type F4CE9487M*J . 375 (Nm)
-- Maximum torque: JX 95 -- type F4CE9487N*J 390 (Nm)

Maximum torque speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1300 rev/min

Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . structural, cast iron
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced, with lobe pump
Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . camshaft
Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . 1:1
Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mesh filter on oil intake and filtering
cartridge on delivery line
Normal oil pressure with motor warmed--up
at slow idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4 psi (1.2 bar)

at fast idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 psi (3.8 bar)

(continued)

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 SECTION 10 -- ENGINE -- CHAPTER 1 3

(cont)

GENERAL SPECIFICATIONS 4 Cylinders

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . coolant circulation

Radiator on Models JX 90, JX 95 . . . . . . . . . . . . . . . . . . 4 lines of vertical pipes with copper fins

Fan, attached to the pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . intake, in plastic with 11 blades

Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal vane--type

Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . . 1:1.977

Coolant thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . coloured scale divided into 3 sections
Temperature ranges corresponding to each section:
-- Initial blue section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 to 140 °F (40° to 60 °C)
-- Middle green section (normal working conditions) . . . . . . . . . 140 to 230 °F (60° to 110 °C)
-- Final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 to 248 °F (110° to 120 °C)

Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . via thermostat valve

-- initial opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177.0 ± 35.6 °F (81 ± 2 °C)

Timing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by tappets, rods

and rocker arms via the camshaft located
in the engine block; the camshaft is driven
by the crankshaft using straight--tooth
gears
Intake:
-- start: before T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10° ± 30’
-- end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10° ± 30’
Exhaust:
-- start: before B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64°
-- end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26°
Valve--rocker arm clearance (with engine cold):
-- intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (0.25 ± 0.05 mm)
-- exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (0.50 ± 0.05 mm)
For further timing system technical data . . . . . . . . . . . . . . . . . . . see page 8
(continued)

84176554 - 03-- 2008

4 SECTION 10 -- ENGINE -- CHAPTER 1

(cont)

GENERAL SPECIFICATIONS 4 Cylinders

Fuel system
Air cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter, with clogged
filter indicator with centrifugal pre--filter
and automatic dust ejector
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with double diaphragm
Fuel filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through wire filter in fuel supply pump, and
replaceable cartridge on delivery line to
injection pump
Minimum fuel flow rate with pump shaft rotating at 1800 rpm . 127.6 l/h
Cam operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . engine timing
BOSCH injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rotating distributor type
All--speed governor, incorporated in pump:
BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal counterweights
Automatic advance regulator, incorporated in pump:
BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydraulic
For further fuel system technical data:
Fixed advance (pump setting for start of delivery before TDC)
-- Pressure setting -- Injection order, and other information
regarding the BOSCH pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refer to the data for the relevant
engine type in the table on page 2

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 SECTION 10 -- ENGINE -- CHAPTER 1 5

FUEL SYSTEM DATA

Turbo Charger:
-- For versions F4CE9487M*J:
-- type HOLSET HX25W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB11H/A085BXL
-- For versions F4CE9487N*J:
-- type HOLSET HX25W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB11K/A11CXL
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rotating distributor with speed governor
and advance regulator incorporated
BOSCH pump:
-- JX 90 model -- type F4CE9487M*J . . . . . . . . . . . . . . . . . . . . VE 4/12 F1250 L2043 (S/N 504218826)
-- JX 95 model -- type F4CE9487N*J . . . . . . . . . . . . . . . . . . . . VE 4/12 F1250 L2023 (S/N 504218827)
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . anticlockwise
Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--3--4--2 (For all models)

JX 90 JX 95

BOSCH--type injectors:

-- F4CE9487M*J . . . . . . . . . . . . . . . . . . . . . . . . 504254390 --
DSLA 145 P 1441
-- F4CE9487N*J . . . . . . . . . . . . . . . . . . . . . . . . 504254390
-- DSLA 145 P 1441
Number of nozzle holes . . . . . . . . . . . . . . . . . . .
7 7
Nozzle hole diameter mm.

-- F4CE9487M*J . . . . . . . . . . . . . . . . . . . . . . . . 0.192 --

-- F4CE9487N*J . . . . . . . . . . . . . . . . . . . . . . . . -- 0.192

Calibration pressure bar . . . . . . . . . . . . . . . . . . . 260 to 272 260 to 272

CRANKCASE/CYLINDER BLOCK DATA in. (mm)

Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cast--iron monobloc with cylinder liners,
crankshaft, camshaft and tappets

Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.09944 to 4.0954

(104.000 to 104.024)

Oversized cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1141 to 4.1151 (104.500 to 104.524)

84176554 - 03-- 2008

6 SECTION 10 -- ENGINE -- CHAPTER 1

Main journal half bearing seat diameter external no. 1--5 3.4638 to 3.4648 (87.982 to 88.008)

internalno. 2--3--4 3.4636 to 3.4650 (87.977 to 88.013)

Camshaft bushing seat diameter:

-- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3315 to 2.3325 (59.222 to 59.248)

-- intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3315 to 2.3325 (59.222 to 59.248)

-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3315 to 2.3325 (59.222 to 59.248)

Diameter of standard tappet bores in crankcase . . . . . . . . . . . . . . 0.6299 to 0.6311 (16.000 to 16.030)

CRANKSHAFT AND BEARINGS DATA in. (mm)

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . balanced with integral counterweights

Standard journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2671 to 3.2682 (82.987 to 83.013)

Journal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0098 to 0.0196 (0.250 -- 0.500)

Main journal half bearing thickness . . . . . . . . . . . . . . . . . . . . . . . . . 0.0966 to 0.0970 (2.456 to 2.464)

Main half bearing undersizes (internal diameter) . . . . . . . . . . . . . . 0.0098 to 0.0196 (0.250 -- 0.500)

Clearance between bearings and main journal no. 1--5 0.0016 to 0.0046 (0.041 to 0.119)

n. 2--3--4 0.0016 to 0.0040 (0.041 to 0.103)

Standard crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7160 to 2.7170 (68.987 to 69.013)

Crankpin undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0098 to 0.0196 (0.250 -- 0.500)

Standard connecting rod half bearing thickness . . . . . . . . . . . . . . . 0.0769 to 0.0774 (1.955 to 1.968)

Connecting rod half bearing undersizes (internal diameter) . . . . . 0.0098 to 0.0196 (0.250 -- 0.500)

Bearing to crankpin clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0012 to 0.0016 (0.033 to 0.041)

Standard crankshaft thrust washer width . . . . . . . . . . . . . . . . . . . . 1.4677 to 1.4716 (37.280 to 37.380)

Width of main bearing for thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0228 to 1.0425 (25.980 to 26.480)

Width of corresponding crankshaft journal . . . . . . . . . . . . . . . . . . . 1.4753 to 1.4783 (37.475 to 37.550)

Crankshaft assembly endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0067 to 0.0094 (0.172 to 0.240)

CONNECTING ROD DATA in. (mm)

Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . printed in steel, oblique--cut type
Diameter of small end bushing seat . . . . . . . . . . . . . . . . . . . . . . . . . 1.6136 to 1.6146 (40.987 to 41.013)
Outside diameter of small end bushing . . . . . . . . . . . . . . . . . . . . . . 1.6251 to 1.6359 (41.279 to 41.553)

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 SECTION 10 -- ENGINE -- CHAPTER 1 7

Interference between small end bushing and seat . . . . . . . . . . . . . 0.0104 to 0.0222 (0.266 to 0.566)

Inside diameter of small end bushing (measured after fitting) . . . 1.4968 to 1.4973 (38.019 to 38.033)
Diameter of big end bearing seats . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8734 to 2.8745 (72.987 to 73.013)

Connecting rod--crankpin end float . . . . . . . . . . . . . . . . . . . . . . . . . 0.0039 to 0.0129 (0.100 to 0.330)

in. (mm)
PISTON DATA
JX 90 -- JX 95
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . light alloy with three compression rings,
including two seal rings and one
scraper ring
Standard piston diameter, measured at 2.4015 in. (61 mm) from
skirt base and perpendicularly to the gudgeon pin axis . . . . . . . . . 4.0944 to 4.0954 (104.000 to 104.024)

Piston clearance in cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0105 to 0.0122 (0.268 to 0.310)

Piston oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0196 (0.500)

Piston protrusion at T.D.C. from cylinder block face . . . . . . . . . . . 0.0110 to 0.0204 (0.280 to 0.520)
Gudgeon pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4958 to 1.4960 (37.994 to 38.000)

Diameter of gudgeon pin seat in piston . . . . . . . . . . . . . . . . . . . . . . 1.4964 to 1.4966 (38.010 to 38.016)

Gudgeon pin to seat clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0003 to 0.0008 (0.010 to 0.022)

Gudgeon pin to small end bearing clearance . . . . . . . . . . . . . . . . . 0.0007 to 0.0015 (0.019 to 0.039)

Piston ring groove depth:

-- 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1064 to 0.1076 (2.705 to 2.735)

-- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0960 to 0.0968 (2.440 to 2.460)

-- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1586 to 0.1594 (4.030 to 4.050)
Piston ring thickness:
-- 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1007 to 0.1025 (2.560 to 2.605)

-- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0925 to 0.0937 (2.350 to 2.380)

-- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1562 to 0.1570 (3.970 to 3.990)
(continued)

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8 SECTION 10 -- ENGINE -- CHAPTER 1

(cont)

in. (mm)
PISTON DATA
JX 90 -- JX 95
Piston ring groove clearance (measured vertically):

-- 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0039 to 0.0068 (0.100 to 0.175)

-- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0023 to 0.0043 (0.060 to 0.110)

-- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0015 to 0.0028 (0.040 to 0.073)

Assembly clearance between piston ring ends in cylinder

sleeves:

-- 1° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118 to 0.0157 (0.30 to 0.40)

-- 2° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0236 to 0.0314 (0.60 to 0.80)

-- 3° ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118 to 0.0216 (0.30 to 0.55)

Spare piston ring oversizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0196 (0.500)

VALVE TIMING GEAR DATA in. (mm)

Inside diameter of camshaft bearings (fitted and reamed):

-- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1292 to 2.1317 (54.083 to 54.147)

-- intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1292 to 2.1317 (54.083 to 54.147)

-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1292 to 2.1317 (54.083 to 54.147)

Diameter of camshaft journals:

-- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1257 to 2.1277 (53.995 to 54.045)

-- intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1257 to 2.1277 (53.995 to 54.045)

-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1257 to 2.1277 (53.995 to 54.045)

Clearance between camshaft journals and bushings . . . . . . . . . . 0.0014 to 0.0059 (0.038 to 0.152)

Camshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0090 ± 0.0051 (0.230 ± 0.130)

Crankshaft to camshaft teeth clearance . . . . . . . . . . . . . . . . . . . . . 0.0029 to 0.0110 (0.076 to 0.280)

TAPPET DATA in. (mm)

Tappet bore in crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6299 to 0.6311 (16.000 to 16.030)
Outside diameter of standard tappet . . . . . . . . . . . . . . . . . . . . . . . . 0.6271 to 0.6283 (15.929 to 15.959)
Tappet running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016 to 0.0039 (0.041 to 0.101)

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 SECTION 10 -- ENGINE -- CHAPTER 1 9

ROCKER ARM -- VALVE DATA in. (mm)

Rocker--arm shaft diameter ............................... 0.7465 to 0.7470 (18.963 to 18.975)
Rocker--arm shaft seat diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.7480 to 0.7490 (19.000 to 19.026)
Rocker arm bore to shaft clearance . . . . . . . . . . . . . . . . . . . . . . . . . 0.0009 to 0.0024 (0.025 to 0.063)
Valve clearance for normal running (engine cold):
-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118 to 0.0019 (0.300 to 0.050)
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0216 to 0.0019 (0.550 to 0.050)
Cam lift:
-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2379 (6.045)
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2849 (7.239)

CYLINDER HEAD DATA in. (mm)

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in cast iron with fitted valve seats and
seats for injectors and thermostat valve
Maximum face re--grinding depth that can be removed from the
cylinder head in the event of reboring . . . . . . . . . . . . . . . . . . . . . . . . . 0.0051 (0.130)
Diameter of valve stem seat in cylinder head . . . . . . . . . . . . . . . . . 0.3157 to 0.3164 (8.019 to 8.039)
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3133 to 0.3141 (7.960 to 7.980)
Assembly clearance between valve stem and seat . . . . . . . . . . . . 0.0015 to 0.0031 (0.039 to 0.079)
Valve seat angle in head:
-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Valve face angle:
-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45°
Diameter on head for fitting valve seat:
-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8498 to 1.8509 (46.987 to 47.013)
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7178 to 1.7190 (43.637 to 43.663)
Valve seat insert outside diameter:
-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8528 to 1.8538 (47.063 to 47.089)
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7209 to 1.7220 (43.713 to 43.739)
Valve stand--in relative to cylinder head face:
-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0132 to 0.0422 (0.336 to 1.072)
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0434 to 0.0330 (0.104 to 0.840)
Interference between valve seat and head:
-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0019 to 0.0040 (0.050 to 0.102)
-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0019 to 0.0040 (0.050 to 0.102)
(continued)

84176554 - 03-- 2008

10 SECTION 10 -- ENGINE -- CHAPTER 1

(cont)

CYLINDER HEAD DATA in. (mm)

Valve head diameter:

-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7665 to 1.7767 (44.870 to 45.130)

-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6484 to 1.6586 (41.870 to 42.130)

Inlet and exhaust valve springs:

-- free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4999 (63.500)

-- length under load of 329 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9299 (49.020)

-- length under load of 641 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5039 (38.200)

Injector protrusion relative to head face:

D injectors: BOSCH DLLA 145 P 1338 --

BOSCH DSLA 145 P 1255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not adjustable

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 11

TIGHTENING TORQUES
Tightening torque
PARTS TO BE TIGHTENED Thread
Nm kgm
Flywheel casing retaining bolts (2, fig. 149) . . . . . . . . . . . . .
M 12 x 1.75 x 100 80 ± 10 8±1
M 16 x 1.50 x 80 200 ± 20 20 ± 2
M 16 x 1.50 x 100 200 ± 20 20 ± 2
M 12 x 1.75 x 78 80 ± 10 8±1

Oil sump retaining bolts (3, fig. 156) . . . . . . . . . . . . . . . . . . . . M 10 x 1.50 x 45 50 ± 5 5 ± 0.5

M 10 x 1.50 70 ± 5 7 ± 0.5

Oil sump threaded plugs (2, fig. 156) . . . . . . . . . . . . . . . . . . . M 22 x 1.5 50 ± 5 5 ± 0.5

Rocker arm support retaining bolts (2, fig. 133) . . . . . . . . . . M 8 x 1.25 25 ± 5 2.5 ± 0.5

Tappet cover retaining bolts (1, fig. 171 -- 172) . . . . . . . . . . . M 8 x 1.25 25 ± 5 2.5 ± 0.5

Exhaust manifold retaining bolts (3, fig. 168) . . . . . . . . . . . . M 10 x 1.50 53 ± 5 5.3 ± 0.5

Intake manifold retaining bolts (2, fig. 171 -- 172) . . . . . . . . M 8 x 1.25 25 ± 5 2.5 ± 0.5

Oil cooler retaining bolts (4, fig. 163) . . . . . . . . . . . . . . . . . . . M 8 x 1.25 25 ± 5 2.5 ± 0.5

Coolant pump retaining bolts (2, fig. 161) . . . . . . . . . . . . . . . M 8 x 1.25 25 ± 5 2.5 ± 0.5

Coolant inlet manifold retaining bolts (2, fig. 159) . . . . . . . . M 10 x 1.50 45 ± 10 4.5 ± 1

Thermostat valve assembly retaining bolts (3, fig. 122) . . . M 8 x 1.25 25 ± 5 2.5 ± 0.5

Fan support retaining bolts (3, fig. 162) . . . . . . . . . . . . . . . . . M 8 x 1.25 x 50 25 ± 5 2.5 ± 0.5
M 10 x 1.50 x 25 45 ± 5 4.5 ± 0.5

Injector fastener (1, fig. 131) . . . . . . . . . . . . . . . . . . . . . . . . . . -- 60 ± 5 6.0 ± 0.5

Fuel pump retaining bolts (5, fig. 170) . . . . . . . . . . . . . . . . . . M 8 x 1.25 25 ± 5 2.5 ± 0.5

Nuts securing turbine mod. (2, fig. 168) . M 8 x 1.25 25 ± 5 2.5 ± 0.5

Alternator retaining bolts (3, fig. 164) . . . . . . . . . . . . . . . . . . . M 10 x 1.50 45 ± 5 4.5 ± 0.5

Starter motor retaining bolts (5, fig. 175) . . . . . . . . . . . . . . . . M 10 x 1.50 55 ± 5 5 ± 0.5

Camshaft plate retaining bolts (3, fig. 98) . . . . . . . . . . . . . . . M 8 x 1.25 25 ± 5 2.5 ± 0.5

Injection pump retaining bolts (3, fig. 142) . . . . . . . . . . . . . . . M 8 x 1.25 12 ± 5 1.2 ± 0.5

Oil pump gear casing retaining bolts (2, fig. 155) . . . . . . . . . M 8 x 1.25 25 ± 5 2.5 ± 0.5

Additional counterweight retaining bolts (3, fig. 146) . . . . . . M 10 x 1.5 48 ± 8 4.8 ± 0.8

Camshaft gear retaining bolts (1, fig. 137) . . . . . . . . . . . . . . . . M 8 x 1.25 36 ± 4 3.6 ± 0.4

84176554 - 03-- 2008

12 SECTION 10 -- ENGINE -- CHAPTER 1

TORQUE SETTINGS WITH ANGLE

Tightening torque
PARTS TO BE TIGHTENED Thread Angle
Nm kgm
Main bearing cap bolts (1, fig. 106)
phase 1 M 12 x 1.5 50 ± 6 5.0 ± 0.6 --
phase 2 M 12 x 1.5 80 ± 6 8.0 ± 0.6 --
phase 3 M 12 x 1.5 -- -- 90° ± 5°

Big end cap bolts (1, fig. 118)

phase 1 M 10 x 1.25 30 ± 5 3.0 ± 0.5 --
phase 2 M 10 x 1.25 50 ± 5 5.0 ± 0.5 --
phase 3 M 10 x 1.25 -- -- 60° ± 5°

Cylinder head bolts (1, fig. 138) . . . . . . . . . . . . M 12 x 1.75 x 70 50 ± 5 5.0 ± 0.5 90°
Note: For the tightening sequence, see
M 12 x 1.75 x 140 40 ± 5 4.0 ± 0.5 180°
page 60, fig. 139.
M 12 x 1.75 x 180 70 ± 5 7.0 ± 0.5 180°

Bolts fastening pulley on crankshaft

M 12 x 1.25 50 ± 5 5.0 ± 0.5 90° ± 5°
(1, fig. 158) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine flywheel retaining bolts (1, fig. 154) . . . M 12 x 1.25 30 ± 5 3.0 ± 0.5 60° ± 5°

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 13

TOOLS X 380000663 Tool to extract crankshaft rear

seal.
Warning -- The operations described in this section X 380000664 Splining tool for fitting rear seal
can only be carried out with ESSENTIAL tools indi- on crankshaft.
cated by an (X).
X 380000665 Tool to extract crankshaft front
To work safely and efficiently and obtain the best re- seal.
sults, it is also necessary to use the recommended
specific tools listed below and certain other tools, X 380000666 Splining tool for fitting front seal
which are to be made according to the drawings in- on crankshaft.
cluded in this manual. X 380000667 Drift for camshaft bushing dis-
assembly and reassembly (use
List of specific tools required for the various with 380000668).
operations described in this Section.
380000668 Grip for interchangeable drifts.

X 380000216 Engine removal and installation X 380000669 Gasket extraction tool.

tool.
X 380000670 Tool for cartridge filter disas-
380000220 Clamp for fitting piston in cylin- sembly.
der liner 2.3622--4.9212 in.
380000671 Injector extraction tool.
(60--125 mm).
X 380000221 Pliers for piston ring disassem- 380000975 Box with full set of tools to re-
bly and reassembly grind valve seats.
2.5590--4.3307 in. 380000976 Spring load test appliance.
(65--110 mm).
380001003 Complete square to check for
380000301 Rotating stand for overhaul connecting rod distortion.
operations (capacity 1000 daN,
torque 120 daN/m). 380001268 Belt tension gauge.
X 380000302 Tool for engine valve disassem-
bly and reassembly.
380000304 Pair of gauges for angular Injection pump bench test.
tightening with 1/2” and 3/4”
square connection. 380000228 Dial gauge 0--019.68 in.
380000362 Crankshaft lifting tool. (0--5 mm).

X 380000364 Dial gauge base for various X 380000914 Dial--gauge holder tool for rotary
measurements (use with injection pump timing (use with
380000228). 380000228).
380000569 Movable tool for dismantling X 380000732 Tool for engine flywheel rotation
tractors with bracket 380000500 (use with 380000988).
and adapter plate 380000844. X 380000988 Plate for engine flywheel rota-
X 380000661 Engine mounting brackets for tion tool with flywheel timing pin
rotating stand 380000301. (use with 380000732).

84176554 - 03-- 2008

14 SECTION 10 -- ENGINE -- CHAPTER 1

MIF1097A

1
View of JX 90 tractor engines of 65 kW (88 HP) and JX 95 of 70 kW (95 HP)

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 15

Oil path under pressure

Oil return path under gravity
MIF1098A

2
Lubrication diagram for engines mod.JX 90 and JX 95

Forced--circulation lubrication is accomplished by -- oil pressure control valve incorporated in the

the following components: cooler assembly;
-- oil pump, housed at the front of the crankcase, -- by--pass valve to cut off clogged oil filter, incorpo-
driven by the grooved bushing keyed onto the rated in the cooler assembly;
shank of the crankshaft; -- cartridge oil filter.
-- water / oil cooler, housed in the crankcase;

84176554 - 03-- 2008

16 SECTION 10 -- ENGINE -- CHAPTER 1

Coolant recirculating in the engine

Coolant entering the pump
MIF1099A

3
Cooling system diagram

The forced circulation, closed--circuit engine cooling -- a centrifugal coolant pump housed at the front of
system is composed of the following components: the crankcase;
-- a lubricating oil cooler; -- a thermostat valve governing coolant circulation.

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 17

MIF1101A

4
Detail of cylinder head with valve seats fitted in engines mod. JX 90, JX 95

1. Exhaust manifold 4. Fitted valve seats

2. Intake manifold 5. Thermostat valve
3. Air heater 6. Injector

84176554 - 03-- 2008

18 SECTION 10 -- ENGINE -- CHAPTER 1

MIF1102A

5
Additional counterweights

1. Retaining bolts 6. Half bearings

2. Support 7. Counter--shaft
3. Retaining bolts 8. Gear
4. Gear 9. Ring
5. Balancing weight 10. O--Ring

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 19

ENGINE TROUBLESHOOTING

Problems Possible Causes Solutions

Engine does not start. 1. Batteries partially discharged. Check and recharge batteries. Re-
place if necessary.

2. Battery terminal connections cor- Clean, inspect and tighten terminal

roded or loose. nuts. Replace terminals and nuts if
excessively corroded.

3. Injection pump timing incorrect. Adjust injection pump timing.

4. Impurities or water in fuel lines. Disconnect fuel lines from injection

pump and clean thoroughly. If
necessary clean and dry the fuel tank.

5. No fuel in tank. Fill tank.

6. Fuel supply pump malfunction. Check and replace pump if necess-

ary.

7. Air in fuel system. Check fuel lines, unions, supply

pump, filters and injection pump for
air; then bleed the air from the circuit.

8. Starter motor faulty. Repair or replace starter motor.

9. Thermostarter faulty. Check and replace thermostarter if

necessary.

Engine stalls. 1. Idle speed too low. Adjust idle speed.

2. Injection pump delivery irregular. Check injection pump delivery on test

bench.

3. Impurities or water in fuel lines. Disconnect fuel lines from injection

pump and clean thoroughly. If
necessary clean and dry the fuel tank.

4. Fuel filters clogged. Replace the filter cartridges.

5. Incorrect valve -- rocker arm Adjust the clearance between the

clearances. rocker arms and the valves.

6. Burnt or cracked valves. Replace the valves.

7. Air in fuel system. Check fuel lines, unions, supply

pump, filters and injection pump for
air; then bleed the air from the circuit.

8. Injection pump drive mechanism Replace damaged parts.

damaged.
(continued)

84176554 - 03-- 2008

20 SECTION 10 -- ENGINE -- CHAPTER 1

ENGINE TROUBLESHOOTING
(cont)

Problems Possible Causes Solutions

Engine overheating. 1. Coolant pump malfunction. Overhaul pump and replace if

necessary.

2. Thermostat faulty. Replace the thermostat.

3. Radiator inefficient. Remove internal deposits by flushing.

Check for leaks and repair.

4. Deposits in cylinder head and Flush out coolant system.

crankcase coolant passages.

5. Coolant pump and fan drive belt Check and adjust belt tension.
slack.

6. Coolant level low. Top up expansion tank with specified

coolant mixture.

7. Incorrect engine timing. Check and adjust engine timing.

8. Injection pump calibration incor- Calibrate pump on test bench to va-

rect -- delivering too much or too lues specified in calibration tables.
little fuel.

9. Air filter clogged. Clean filter unit and replace filter el-
ement if necessary.

Engine lacks power and 1. Injection pump timing incorrect. Adjust injection pump timing.
runs unevenly.

2. Auto advance regulator in injec- Overhaul injection pump and adjust

tion pump damaged. on test bench to values specified in
calibration table.

3. Control valve journal worn. Overhaul injection pump and adjust

on test bench to values specified in
calibration table.

4. Injection pump delivery irregular. Overhaul injection pump and adjust

on test bench to values specified in
calibration table.

5. All--speed governor damaged. Overhaul injection pump and adjust

on test bench to values specified in
calibration table.

6. Injectors partially obstructed or Clean and overhaul injectors and ad-

damaged. just pressure setting.

7. Impurities or water in fuel lines. Disconnect fuel lines from injection

pump and clean thoroughly. If
necessary clean and dry the fuel tank.
(continued)

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 21

ENGINE TROUBLESHOOTING
(cont)

Problems Possible Causes Solutions

8. Fuel supply pump damaged. Replace fuel supply pump.

9. Incorrect valve -- rocker arm Adjust the clearance between the

clearances. rocker arms and the valves.

10. Cylinder compression low. Test compression and overhaul en-

gine if necessary.

11. Air filter clogged. Clean filter unit and replace filter el-
ement if necessary.

12. Tie--rod in linkage between accel- Adjust to correct length.

erator and injection pump incor-
rectly adjusted.

13. Fast idling speed screw on injec- Adjust fast idling speed screw.
tion pump incorrectly adjusted.

Engine produces abnormal 1. Injectors partially obstructed or Clean and overhaul injectors and ad-
knocking noises. damaged. just pressure setting.

2. Impurities accumulating in fuel Clean fuel lines and replace severely

lines. dented pipes; clean injection pump if
necessary.
3. Injection pump timing incorrect. Adjust injection pump timing.

4. Crankshaft knocking due to ex- Re--grind crankshaft journals and

cessive play in one or more main crankpins. Fit oversize shell bearings
or big--end bearings or excessive and thrust washers.
endfloat.

5. Crankshaft out of balance. Check crankshaft alignment and bal-

ance; replace if necessary.

6. Flywheel bolts loose. Replace any bolts that have worked

loose and tighten all bolts to the speci-
fied preliminary and angular torque
values.

7. Connecting rod axes not parallel. Straighten connecting rods, check

axes parallelism; replace con rods if
necessary.
8. Pistons knock due to excessive Rebore cylinder liners and fit oversize
wear. pistons.

9. Noise caused by excessive play Fit oversize gudgeon pin, rebore pis-
of gudgeon pins in small--end and ton seats and small--end bushings.
piston bushings. Loose fit of Replace with new bushings.
small--end bushing.

10. Excessive tappet / valve noise. Check for broken springs or excess-
ive play between valve stems and
guides, cam followers and bores; ad-
just valve clearances.
(continued)

84176554 - 03-- 2008

22 SECTION 10 -- ENGINE -- CHAPTER 1

ENGINE TROUBLESHOOTING
(cont)

Problems Possible Causes Solutions

Engine produces excessive 1. Maximum delivery of injection Calibrate pump on test bench to va-
black or dark grey smoke. pump too high. lues specified in calibration tables.

2. Injection pump delivery excess- Adjust injection pump timing or check

ively retarded or automatic ad- automatic advance regulator.
vance regulator damaged.

3. Injection pump delivery excess- Adjust injection pump timing.

ively advanced.

4. Injectors partially or totally ob- Clean and overhaul injectors and ad-
structed or incorrectly adjusted. just pressure setting; replace if
necessary.

5. Air filter clogged. Clean filter unit and replace filter el-
ement if necessary.

6. Loss of engine compression due Replace damaged parts or, if necess-

to: ary, overhaul the engine.
-- piston rings sticking;
-- cylinder liner wear;
-- worn or incorrectly adjusted
valves.

7. High--pressure fuel lines dam- Inspect and replace if necessary.

aged.

Blue, grey--blue or grey-- 1. Injection pump delivery excess- Adjust injection pump timing or check
white smoke. ively retarded or automatic ad- automatic advance regulator.
vance regulator damaged.

2. Injectors obstructed or damaged. Clean, overhaul and calibrate injec-

tors, replace if necessary.

3. Oil leaking past piston rings due Replace damaged parts or, if necess-
to sticking rings or cylinder liner ary, overhaul the engine.
wear.

4. Oil leaking through the inlet valve Overhaul cylinder head.

guides due to guide or valve stem
wear.

5. Engine does not reach correct Replace the thermostat.

operating temperature (thermo-
stat faulty).

Engine runs on after 1. Engine stop electromagnet dam- Replace electromagnet.

switching off. aged.

2. All--speed governor damaged. Overhaul injection pump and adjust

on test bench to values specified in
calibration table.

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 23

Op. 10 001 10
ENGINE R.I.
DANGER
Lift and handle all heavy parts using suitable lifting
equipment.
Make sure that assemblies or parts are supported by
means of suitable slings and hooks. Check that no
one is in the vicinity of the load to be lifted.

CAUTION
Always use appropriate tools to align fixing holes.
NEVER USE FINGERS OR HANDS.

1. Disconnect the battery negative lead (1).

1
2. Drain the oil from the transmission--gearbox
housing.

3. Drain the cooling system.

6
4. Remove the exhaust pipe, attach lifting chains
(2) to the bonnet (1) and attach the chain to the
hoist.
2

7
5. Disconnect the electrical connection (1) of
bonnet.

84176554 - 03-- 2008

24 SECTION 10 -- ENGINE -- CHAPTER 1

6. Detach the gas struts (1) from the bonnet.

9
7. Remove the four bonnet hinge bolts (1) and lift
the bonnet clear.

10
8. Remove the three retaining bolts (1) and the
guard (2) on the right--left hand side of the fan.

11
9. Unscrew the nut (1) from the weight retaining pin.
Remove the weights from the front support.

12

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 25

10. Unscrew the front central and rear retaining bolts

on the front axle shaft guard, then remove the
guard (1).

25038

13
11. Remove the circlip (2) and move the front sleeve
(1) in the direction indicated by the arrow until it 1 2
is released from the groove on the front axle.

25039

14
12. Remove the circlip (2) and move the rear sleeve
(1) in the direction indicated by the arrow until it 1
is released from the groove on the drive.

2
25040

15
13. Remove the propeller shaft central support (1)
retaining bolts and extract the shaft together with
the support.

25041

16

84176554 - 03-- 2008

26 SECTION 10 -- ENGINE -- CHAPTER 1

14. Remove the retaining bolts (1) of the suction pipe

(2) of the lift pump.

17
15. Disconnect the delivery and return lines from the
hydraulic lift pump.

18
16. Detach the cab heating pipes (1) and (2).

19
17. Detach the cab air--conditioning pipes (1) and
(2).

20

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 27

18. Extract the plastic fasteners (2) and detach the

diesel recovery pipe (3) and delivery pipe (4) to
the diesel pump (1).

21
19. Remove two metal clamps (2) and the rigid pipe
of drawing oil from the transmission housing via
lift pump (1) and power steering pump. Remove
the fitting of the delivery pipe.

22
20. Remove the electrical connection from the brake
fluid reservoir and take the brake fluid reservoir
(1) from the bracket.

23
21. Disconnect the steering oil delivery and return
hoses (1) and (2).

24

84176554 - 03-- 2008

28 SECTION 10 -- ENGINE -- CHAPTER 1

22. Disconnect A/C compressor inlet (2) and outlet

(1) hoses.

25
23. Remove the fusebox (1) from the bonnet
support.

26
24. Remove the electrical connections of
temperature sender (1) and oil switch (2).

27
25. Remove the retaining retaining clips (1) and
detach the flexible cables governing the hand
throttle and pedal throttle.
26. Remove the retaining clip (2) and detach the
throttle control tie--rod connected to the injection
pump.

28

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 29

27. Disconnect the electrical connection (1) between

the cab and the engine.

29
28. Disconnect the electrical connections from
alternator (1) and starter motor (2).

30
29. Disconnect the electrical connections of dryer
filter sensor (1) and water in fuel sensor (2).

31
30. Remove the electrical connection (1) and air filter
clogging sensor (2).

32

84176554 - 03-- 2008

30 SECTION 10 -- ENGINE -- CHAPTER 1

31. Remove the two retaining bolts and the support

together with relays protecting system (1).

33
32. Loosen the corresponding retaining clamps and
extract the pipes (1), (2) and (3).

34
33. Hitch the engine to the hoist with the chains
anchouring it to the attachments on the engine.

35
34. Position a fixed stand under the over drive clutch
housing near the engine attachment flanging and
apply the handbrake.

36

84176554 - 03-- 2008

 SECTION 10 − ENGINE − CHAPTER 1 31

35. Position the movable tool for dismantling tractors

380000569 with the bracket 380000500 and
adapter plate 380000844 under the engine and
place a wooden block in between the points of
contact between the tool and tractor.
1

37
36. Extract the differential lock pedal retaining pin
from the drive shaft (1), remove the pedal and
footboard (2).

2
1

25043

38
37. Unscrew the nuts (1) and the bolts securing the
engine to the transmission. Access is through
the two slots in the cab floor.

1
39
38. Remove the remaining six retaining bolts at the
bottom and side.

40

84176554 − 03−2008
32 SECTION 10 -- ENGINE -- CHAPTER 1

39. Seperate the engine from the transmission with

the tool 380000569.

1 2
41
40. Remove the spacer located between the engine
and the transmission.

42
41. Insert the fixed under the balast support and
secure the front wheels with wooden blocks.

1 2
43
42. Loosen the corresponding retaining clamp (1)
and extract the pipes. And remove the bracket
(2).

44

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 33

43. Disconnect the delivery and return lines (1) to the

power steering cylinders.

45
44. Remove the bonnet support (1).

46
45. Loosen the retaining clamp and extract the pipe
(1) joining the coolant pump to the bottom of the
radiator.

47
46. Position a fixed stand (3) under the support of the
groove (1) of the front axle drive placing a
wooden plug (2) between the parts (3) and (1).

48

84176554 - 03-- 2008

34 SECTION 10 -- ENGINE -- CHAPTER 1

47. Fit the lifting eyelet (1) in the threading on the

support (2).

49
48. Remove the four bolts (2) fastening the front axle
support (1) to the engine (3).

50
49. Insert the hooks of the lifting chains (1) in the
eyelets shown in the figure, afterwards
tensioning the chains with the hoist.

51
50. Detach the engine (2) from the front axle (3),
trying to avoid incorrect operations with the hoist
so as not to let the engine fan damage the fins of
the radiator (1), left on the axle (3).
51. Then rest the engine on a platform support.

52

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 35

-- Apply LOCTITE sealing compound on the en-

CAUTION gine/spacer contact surfaces and fit the spacer
on the stud bolts screwed into the engine.
Always use appropriate tools to align fixing holes.
NEVER USE FINGERS OR HANDS.
-- Also apply LOCTITE sealing compound on the
clutch overdrive casing surfaces.

-- Apply the torque settings listed on page 11.

-- Position wooden blocks under the rear wheels,
make sure that the handbrake is fully applied and
-- Insert the three hooks of the chain in the eyelets that all fixed and mobile stands are safely posi-
on the engine and, using the hoist, lift the assem- tioned.
bly off the platform support.
-- The installation phase described here requires
-- Position the engine on the front axle, trying to the presence of two or three workers to use the
avoid incorrect operations with the hoist so as not movable tool for dismantling tractors 380000569
to let the engine fan damage the fins of the radi- to move the engine/front axle assembly close to
ator, then join the two assemblies together with the overdrive clutch casing.
the four retaining bolts.
-- In the phase of installing the engine/front axle as-
-- Reposition the movable tool for dismantling trac- sembly to the overdrive clutch casing, it is
tors 380000569 under the engine and place a necessary to push on the front wheels, taking
wooden block in between the point of contact be- great care in the end phase of coupling over both
tween the tool and engine. the pipes and the cables/electrical connections
to prevent crushing between the two bodies. Dur-
ing this phase, it is moreover necessary to turn
-- With the aid of the hoist, place the engine on the
the crankshaft with the aid of the radiator cooling
tool 380000569 and remove the lifting eyelet
fan to help the coupling between the sleeve and
previously fitted on the front of the engine.
the drive shaft.

-- Remove the fixed stand previously positioned

-- Secure both assemblies by tightening all the
under the support of the groove of the drive of the
bolts locking the engine to the overdrive clutch
front axle and the wooden plug.
casing.

-- Refit the pipe joining the coolant pump to the bot-

-- Remove the U--bolt previously fitted under the
tom of the radiator and the associated retaining
clutch casing and recover the movable tool for
clamp.
dismantling tractors 380000569.

-- Refit the oil vapour suction pipe, filter/intake

-- Fit the electric cable connected to the fuse--
manifold connecting pipe and the pipe connect-
holder box and the retaining nut.
ing the radiator at the top to the thermostat valve,
re--installing the associated retaining clamps.
-- Working from the side of the starter motor, fit the
protective cable housing and the retaining nut.
-- Fit the left--right hand side guard of the engine
fan and the three retaining bolts.
-- Fit the electrical connections installed on the
brake pump and on the brake fluid reservoir.
-- Remove the fixed U--bolt fitted beforehand under
the ballast support and the two wooden wedges
locking the front wheels. -- Refit the power steering piping on the engine and
reconnect the electrical connections to the pres-
sure switch.
-- Remove the old sealing compound from both
surfaces of the spacer between the engine and
the overdrive clutch housing, and do the same -- Refit the power steering return pipe with its
also on the contact surface of the overdrive bracket and retaining bolt.
clutch housing and on that of the engine.

84176554 - 03-- 2008

36 SECTION 10 -- ENGINE -- CHAPTER 1

-- Refit the brake piping support and the two retain- -- Refit the two right-- and left--hand dashboard
ing bolts. panels and the relevant four fixing knobs.

-- Refit the condenser, air cooler and radiator -- Refit the two power steering cylinder oil delivery
pipes. and return hoses.

-- Refit the dryer filter together with its support and -- Install the electrical connections between the
piping, tightening the two retaining bolts. cab and the engine.

-- Refit the bonnet support, tightening the retaining -- Reconnect the diesel delivery and return pipes to
bolts. the diesel pump and install the relevant plastic
fasteners.
-- Refit the support with the fuse--holder box on the
bonnet support, tightening the two retaining -- Working on the left--hand side of the engine, in-
bolts. stall the lift pump draw pipe and tighten the re-
taining bolts.
-- Refit the support together with the relays protect-
ing the system on the bonnet support, fitting the -- Install the delivery pipe of the services pump on
two retaining bolts. the right--hand side of the engine and tighten its
fitting.
-- Refit the brake fluid reservoir onto the support
and the two retaining clips. -- Refit the rigid pipe for drawing oil from the trans-
mission and the two metal clamps.
-- Refit the silencer together with the exhaust pipe.
-- Refit the power steering/four--wheel drive drain
pipe on both the left-- and right--hand sides of the
-- Secure the silencer to the exhaust manifold with
engine.
the four nuts and connect the air filter dust ex-
tractor pipe to the silencer exhaust, inserting the
retaining clamp. -- Refit the lift pump draw pipe and lock the retain-
ing bolts.
-- Refit the three rear retaining bolts of the exhaust
silencer. -- Refit the propeller shaft with its central support
and the retaining bolts.
-- Fit the cab heater delivery and return pipes and
insert the associated clamps. -- Refit the front axle drive shaft guard, tightening
the front, central and rear retaining bolts.
-- Refit the fitting of the hose delivering power
steering oil to the hydraulic cylinders governing -- Refit the front ballast together with the support
the front wheel steering. and insert the retaining pin and the split pins.

-- Install the flexible cables governing the hand and -- Install the fitting of the cab heater radiator coolant
pedal throttle, inserting the retaining clips. return pipe connected to the bottom of the cool-
ant pump and refill the engine coolant.
-- Reconnect the throttle control tie--rod to the in-
jection pump, inserting the retaining clip. -- Refit the guard on the right--hand side of the fan,
tightening the three retaining bolts.
-- Working from inside the cab, fit the four plugs to
gain access to the upper bolts securing the en- -- Refill the transmission--gearbox housing with oil.
gine, located at the base of the steering column.
-- Install the bonnet. Reconnect the battery nega-
-- Refit the pedal on the differential lock drive shaft, tive lead.
the retaining pin and the footboard.

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 37

Op. 10 001 53
ENGINE D.A.
CAUTION
Handle all parts carefully. Do not put your hands or
fingers between parts. Wear the prescribed safety
clothing, including goggles, gloves and safety foot-
wear.

1. Remove the engine as described in operation

10 001 10, proceed as follows.
2. Drain off the engine oil by removing the plug from
the sump and the oil filler plug.
3. Detach the fan unit from the fan pulley.
4. To be able to fit the bracket 380000661 (for fixing
the engine to the overhaul stand) to the crank-
case, it is necessary to remove the wiring (1)
from the left--hand side of the engine.

MIF1103A

53
5. To be able to fit the bracket 380000661 to the
crankcase on the right--hand side, remove the
starter motor (5), oil filter (3), clamp (4), and tur-
bine oil return pipe (1).
6. Secure the engine to the rotary stand 380000301.
Remove the oil delivery pipe (2).

MIF1104A

54

84176554 - 03-- 2008

38 SECTION 10 -- ENGINE -- CHAPTER 1

7. Remove the intake manifold (2).

8. Disconnect the engine oil vapour recovery pipe
from the blow--by (3).
9. Remove the tappet covers (1).
10. Remove the pipes with the quick--fit coupling (6)
and (8).
11. Remove the piping from the LDA system (5).
12. Remove the fuel filter (7).
13. Remove the heater (4).
14. Remove the control unit for the heater (10). MIF1105A

55
15. Remove the fuel filter support (9).

56
16. Act on the fork (1) as shown in the figure 57
(part B) and remove the fitting. To avoid de-
formation, with the fitting removed, put the fork
(1) back in the locking position (part A).

NOTE: Figure 57 shows the connectors for the low--

pressure pipes (6 and 8, figs. 55 and 56).

A = Pipe locking position on connector.

B = Pipe removal position on connector.

MIF0909A

57
17. Remove the injector feed pipe (4) from the injec-
tion pump (3).
18. Remove the brackets on the cylinder head of the
pipe assembly (1), (2) and (6).
19. Remove the priming pump (5).

MIF1107A

58

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 39

20. Detach the fuel pipe assembly (1) from the injec-
tors.
21. Remove the fuel outlet pipe (2) from the injectors
removing the screw (3) and the seal (4).

MIF1108A

59

22. Remove the screws (2) and the turbine (1).

23. Remove the exhaust manifold (3).
24. Remove the belt (3, fig. 61) of the auxiliary
members by loosening the tightener.

MIF1109A

60
25. Remove the alternator (6), fan pulley (2). and
tightener (8). Remove the support (1) of the
pulley (2) and the oil cooler (7).
26. Remove the coolant pump (5).
27. Remove the engine cooling system fitting (4)
from the crankcase.

NOTE: The coolant pump (5) cannot be overhauled.

It must be replaced if there is any irregular operation.

MIF1110A

61
28. Lock the flywheel to stop it turning, remove the
fixing screws (1) from the pulley (2).

MIF1111A

62

84176554 - 03-- 2008

40 SECTION 10 -- ENGINE -- CHAPTER 1

Removing the crankshaft front seal

(Op. 29. to 33.)
29. Apply tool 380000665 (4) on the front shank (2)
of the crankshaft.
30. Perforate the inner seal (1) with a drill bit
(∅
∅ 0.1377 in. (3.5 mm) through the guide holes
of the tool 380000665 (4), for a depth of
0.1968 in. (5 mm).
31. Secure the tool 380000665 (4) to the seal (1) with
the screws (3) provided.
32. Extract the seal (1) by screwing down the screw
(5).
MIF0916A

63
33. Fit the tie rod (3) of the tool 380000669 to the
outer seal (1) as shown in the figure 64 and with
the lever (4), extract it from the front cover (2).

MIF0917A

64
34. Turn the engine over, take out the screws (2) and
remove the oil sump (1).

MIF1117A

65
35. Take out the bolts (2) and remove the oil pump
(1).

NOTE: The oil pump (1) cannot be overhauled.

It must be replaced if there is any irregular operation.

MIF1112A

66

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 41

36. Using the pin (1), lock the additional counter-

weights (2) at the T.D.C.
Unscrew the retaining bolts (3) and remove the
additional counterweights (2).

MIF1113A

67
37. Before removing the injection pump, do the tim-
ing and lock the engine flywheel with cylinder
no. 1 at T.D.C. as shown on page 105, using
tools 380000988 and 380000732. Then loosen
the bolt (2), remove the “L” spacer (1) and lock
the screw (2) in order to keep the pump in time
with the engine flywheel.

NOTE: Keep the “L” spacer with the pump casing.

MIF0920A

68
38. Remove the three nuts (2) (3) (5) securing the in-
jection pump (1) to the crankcase (4) and extract
it from its housing.

MIF0922A

69
39. Remove the screws (2) fixing the engine flywheel
(1) to the crankshaft.

MIF1115A

70

84176554 - 03-- 2008

42 SECTION 10 -- ENGINE -- CHAPTER 1

40. Screw two pins (2) of the appropriate length into

the holes in the crankshaft (3).
41. Extract the engine flywheel (1) so it can be slung
with the lift and put it away in a specific container.

MIF1116A

71
Removing the crankshaft rear seal
(Op. 42. to 45.)
42. Extract the seal, applying tool 380000663 (3)
onto the rear shank (1) of the crankshaft.
43. Perforate the inner seal (5) with a drill bit
(∅
∅ 0.1377 in. (3.5 mm)) through the guide holes
of the tool 380000663 (3), for a depth of
0.1968 in. (5 mm).
44. Secure the tool 380000663 (3) to the seal (5) by
screwing down the screws (2) supplied.
45. Extract the seal (5) by screwing down the screw
(4).
MIF0927A

72
46. Take out the screws (2) and remove the timing
gear box (1), retrieving the injection pump gear.

NOTE: Note down the assembly position of the

screws (2) as they have different sizes.

MIF1125A

73
47. Take out the screws (1) and remove the gears (3)
and (4) from the camshaft (2).

MIF1118A

74

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 43

48. Take out the bolts (1) and remove the hydraulic
pump drive gear (2).

MIF1119A

75
49. For each cylinder, remove the rocker arm as-
sembly (1) loosen the adjuster nuts (3), unscrew
the adjusters (4) and take out the screws (2).

MIF0933A

76
50. Extract the injectors (2) with tool 380000671 (1).

MIF0934A

77
51. Take out the screws (1) fixing the head to the
crankcase.
1

MIF1120A

78

84176554 - 03-- 2008

44 SECTION 10 -- ENGINE -- CHAPTER 1

52. After fitting the brackets (1) and (2) hook the
metal cables and detach the cylinder head from
the crankcase with the hoist.

NOTE: After removing the cylinder head, remove the

brackets (1) and (2).

MIF1121A

79
53. Valves are removed with tool 380000302 (1), ap-
plying pressure on the cap (3) so that, by com-
pressing the springs (4), it is possible to remove
the cotters (2). Then remove the cap (3) and
springs (4).
Repeat this operation on all valves (5).

MIF1122A

80
54. Remove the intake manifold cover and extract
the oil seals (1) fitted on the valve stems.
To remove the valves, turn the head over.

NOTE: Mark the inlet and exhaust valves before re-

moving them.

MIF1123A

81

NOTE: The inlet valves differ from the exhaust

valves in the size of the head and there being an addi-
tional reference mark (1) on the stem.

A = Inlet valve.
B = Exhaust valve.

MIF0948A

82

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 45

55. Remove the thermostat valve (2) from the gov-

ernor body (1) taking out the screws (3).

MIF1124A

83
56. Take out the screws (1) securing the connecting
rod caps (2) and remove them.
57. Extract the pistons together with the connecting
rods from the top of the crankcase.

NOTE: Keep the half bearings in their respective

housings since, if they are used, they must be
mounted in the position found upon disassembly.

MIF0938A

84
58. Remove the rings (1) from the piston (3) with the
pliers 380000221 (2).

MIF0950A

85
59. The piston pin (1) retaining rings (2) should be re-
moved using a marking tool (3).

MIF0951A

86

84176554 - 03-- 2008

46 SECTION 10 -- ENGINE -- CHAPTER 1

60. Take out the screws (1) and remove the main
bearing caps (2).

MIF1126A

87
61. The penultimate main bearing cap (1) and the re-
lated mounting have the half bearing (2)
equipped with a shoulder. Remove the pistons
with the connecting rods.

NOTE: Note down the assembly position of the top

and bottom half bearings since, if they are reused,
they must be mounted in the position found upon dis-
assembly.

MIF0940A

88
62. Using tool 380000362 (1) and a hoist, remove the
crankshaft (2) from the crankcase.

MIF1127A

89
63. Remove the main half bearings (1).
64. Take out the screws (2) and remove the oil
nozzles (3).

MIF0942A

90

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 47

65. Take out the screws (1) and remove the plate (3)
retaining the camshaft (2).

NOTE: Note down the assembly position of the plate

(3).

MIF1128A

91
66. Carefully extract the camshaft (1) from the
crankcase.

MIF1129A

92
67. Extract the tappets (1) from the crankcase.

MIF0945A

93
68. To remove and renew the front and rear bushings
(1) of the camshaft, use the drift 380000667 (2)
and grip 380000668 (3).

MIF1130A

94

84176554 - 03-- 2008

48 SECTION 10 -- ENGINE -- CHAPTER 1

GENERAL NOTES
-- After disassembling the engine, thoroughly clean
the parts.
-- Pages (48--70) show the assembly operations
that require extra attention in order to assemble
parts correctly.
-- The torque settings are shown on pages 11--12.

ALSO REMEMBER THAT:

-- When partially or fully disassembling the engine,
all seals must be replaced.
-- Before inserting rotating parts and seals in seats,
lubricate the parts with engine oil.
-- When fitting the oil filter, lubricate the seal with
engine oil.

CAUTION
Handle all parts carefully.
Do not put your hands or fingers between parts and
use appropriate tools to align fixing holes.
Wear the prescribed safety clothing, including
goggles, gloves and safety footwear.

ENGINE ASSEMBLY ON THE BENCH

FITTING THE BUSHINGS

(Disassembly operation 68.)
-- To remove and renew the front and rear bushings
(1) of the camshaft, use the drift 380000667 (2)
and grip 380000668 (3).

NOTE: The bushings (1) must be directed so that the

lubrication holes coincide with the holes in the seats
in the crankcase.

MIF1130A

95

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 49

FITTING THE TAPPETS

(Disassembly operation 67.)
-- Lubricate the tappets (1) and fit them in their
seats in the crankcase.

MIF1131A

96
FITTING THE CAMSHAFT
(Disassembly operation 65. to 66.)
-- Lubricate the bushings supporting the camshaft
and mount the camshaft (1) taking care that, dur-
ing this process, the bushings or the supporting
seats do not get damaged.

MIF1129A

97
-- Position the plate (1) retaining the camshaft (2)
with the slot facing towards the top of the crank-
case and the punchmark facing the operator.
Tighten the screws (3) to the prescribed torque
stated on page 11.

MIF1132A

98
-- Check that the end float of the camshaft (1)
comes within the tolerance range prescribed on
page 8.

MIF1133A

99

84176554 - 03-- 2008

50 SECTION 10 -- ENGINE -- CHAPTER 1

FITTING THE OIL NOZZLES

(Disassembly operation 64.)
-- Fit the nozzles (2) and tighten the retaining bolts
(1).

MIF0957A

100
FITTING THE CRANKSHAFT
(Disassembly operations 60. to 63.)
-- If any sign of seizure, scoring or too much ovality
is found on the main journals or crankpins, they
must be reground. Before reconditioning the pins
(1), use a micrometer (2) to measure the pins of
the shaft and according to the undersizes given
on page 6, define the diameter to which the pins
must be reduced.

MIF0958A

101
-- Check that the toothing of the grooved bushing
(1), splined onto the crankshaft (2) is neither
damaged nor worn; if it is, remove it with the a
suitable extractor (3).
-- When fitting the new grooved bushing it must be
heated for 60 minutes in an oven at a constant
temperature of 320 °F (160 °C) and spline it onto
the crankshaft.

MIF1134A

102

NOTE: If the main journals of the crankshaft are un-

dersized it is necessary to replace the main bearings
of the same undersize class made.
Do not modify the bearings in any way.

The main bearings (1) are supplied as spare parts

with an undersized inside diameter of
0.0098--0.0196 in. (0.250--0.500 mm).
Carefully clean the main half bearings (1) with a lu-
brication hole and fit them into their respective seats.
The penultimate main half bearing (1) is equipped
with semi--circular thrust washers. MIF0962A

103

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 51

-- Fit the crankshaft (3) with the gear (1) and the
grooved bushing (2).

MIF1135A

104
-- Check the clearance between the main journals
of the crankshaft and their respective bearings,
proceeding as follows:
-- Make sure that all parts are perfectly clean
and remove all traces of oil.
-- Position a length of calibrated wire (3) on the
crankshaft journals (4), parallel to the crank-
shaft centreline.
-- Fit the caps (1) complete with half bearings
(2) on the relevant supports.

MIF0964A

105
-- Insert the pre--lubricated screws (1) and tighten
them in three successive stages.
1st and 2nd phase with a torque wrench to the
torque given on page 12.

MIF0965A

106
-- 3rd phase with tool 380000304 (1) positioned as
in the figure, further tighten the screws (2) with an
angle of 90° ± 5°.

MIF0966A

107

84176554 - 03-- 2008

52 SECTION 10 -- ENGINE -- CHAPTER 1

-- Remove the support caps.

The clearance between the main bearings and the
relevant journals is measured by comparing the
width of the calibrated wire (2), at the point of
greatest crushing, with the graduation of the scale on
the case (1) containing the calibrated wire.
The numbers shown on the scale indicate the mating
clearance in millimetres.
Check that the clearance is the one prescribed on
page 5, then lubricate the main bearings and perma-
nently mount the supports, tightening the retaining
bolts as described above.
MIF1075A

108
The crankshaft assembly end float is checked by set-
ting a dial gauge (2) with a magnetic base on the
crankshaft (3) as shown in the figure, the normal as-
sembly clearance must come within the tolerance
prescribed on page 5.
If the clearance is found to be any greater, change
the main half bearings of the penultimate rear thrust
bearing support (1) and check the clearance again
between the crankshaft journals and main half bear-
ings.

MIF1076A

109

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 53

FITTING THE
CONNECTING ROD -- PISTON ASSEMBLY
(Disassembly operations 58. to 59.)
-- The following references are cut into the crown
of the piston:
1. Spare part number and design modification
number;
2. Arrow showing the direction of assembly of
the piston in the cylinder liner, it must face the
front of the crankcase (auxiliary member
side).
3. Date of manufacture.
4. Stamping indicating testing of the 1st groove MIF0967A
insert. 110
-- Using the pin (3) connect the piston (2) to the
connecting rod (4) so that the reference arrow (1)
for fitting the piston (2) in the cylinder liner is
facing as described in point 2.

MIF0968A

111
-- Insert the rings (2) retaining the pin (1).

MIF1060A

112
-- To fit the rings (1) on the piston (3) use tool
380000221 (2).

NOTE: The piston rings (see page 7 to 8) are sup-

plied as spare parts in the following sizes:
-- standard, marked with yellow paint;
-- oversized by 0.0196 in. (0.5 mm) and marked
with yellow/green paint;

MIF0969A

113

84176554 - 03-- 2008

54 SECTION 10 -- ENGINE -- CHAPTER 1

-- Fit the half bearings (1) on the connecting rod

and cap.

NOTE: If the crankpins of the crankshaft are under-

sized it is necessary to replace the big end bearings
of the same undersize class made.
Do not modify the half bearings in any way.

MIF0970A

114
FITTING THE PISTON CONNECTING ROD
ASSEMBLIES IN THE CYLINDER LINERS
(Disassembly operation 57.)
-- Lubricate the pistons well, including the piston
rings and the inside of the cylinder liners.
-- With the aid of the ring clamp 380000220 (2), fit
the connecting rod--piston assemblies (1) in the
cylinder liners.

MIF0971A

115
-- The ring openings must be staggered apart by
120°;
-- The connecting rod/piston assemblies must all
have the same weight;
-- The arrow (1) stamped on the crown of the pis-
tons must face the auxiliary member side of the
engine and the recess in the piston skirt must
correspond to the position of the oil nozzles.

MIF0972A

116
To measure the clearance proceed as follows:
-- Carefully clean the parts and remove all traces of
oil;
-- Position a length of calibrated wire (2) on the
crankshaft journals (1);
-- Fit the connecting rod caps (3) with the relevant
half bearings (4).

MIF1077A

117

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 55

BIG END CAP ASSEMBLY

(Disassembly operation 56.)
-- Tighten the screws (1) previously lubricated with
engine oil with a torque wrench (2) to the torque
prescribed on page 12.

MIF0973A

118
-- Fit tool 380000304 (1) on the socket wrench and
further tighten the bolts (2) as prescribed on
page 12.

MIF0974A

119
-- Remove the cap and determine the clearance by
comparing the width of the calibrated wire (2)
against the graduated scale printed on the
packet (1) containing the wire.

MIF1078A

120
Check that the clearance is the one prescribed on
page 5, then lubricate the big end half bearings and
permanently mount them, tightening the connecting
rod cap retaining bolts as described on page 12.

NOTE: Before permanently fitting the connecting rod

cap retaining bolts, check that their diameter,
measured at the centre of the length of the thread, is
no less than 0.0039 in. (0.1 mm) of the diameter
measured at approximately 0.3937 in. (10 mm) from
the end of the bolt.

Check by hand that the connecting rods (1) run axial-

ly on the crankshaft journals and their end float
MIF1079A
measured with a feeler gauge (2) is as prescribed on
page 7. 121

84176554 - 03-- 2008

56 SECTION 10 -- ENGINE -- CHAPTER 1

FITTING THE THERMOSTAT VALVE

(Disassembly operation 55.)
-- Assemble the thermostat valve (2) to its asso-
ciated body (1) with the screws (3).

MIF1124A

122
FITTING THE CYLINDER HEAD
(Disassembly operations 51. to 54.)
-- Lubricate the valve stem and insert into the rel-
evant valve--guides according to the position
marked during disassembly.
-- Fit the seals (1).
1

MIF1137A

123
-- Position the following parts on the cylinder head:
spring (4) and top cap (3): using tool 380000302
(1) compress the spring (4) and retain the parts
to the valve (5) with the cotters (2).

MIF1138A

124
-- Check that the mating surfaces (1) of the cylinder
head and crankcase are clean.
-- Do not dirty the cylinder head gasket.

NOTE: Before reusing the cylinder head retaining

bolts, check they show no sign of deterioration or de-
formation and replace them if they do.

MIF1009A

125

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 57

Using the dial gauge 380000364 (1) fitted with its

base 380000228 (2), check the protrusion of the pis-
tons (3) at T.D.C. from the cylinder block face is with-
in the tolerance limits prescribed on page 7.

MIF1080A

126
Since there are two type of head gasket, to choose
its thickness (0.0492 in. (1.25 mm) Type A and
0.0452 in. (1.15 mm) Type B) make the following
measurements:
-- for each piston, as shown in the figure, at a dis-
tance of 1.7716 in. (45 mm) from the centre of the
piston, measure its protrusions S1 and S2 from
the top face of the crankcase and then calculate
the mean:
S1 + S2
Scyl1 =
2
Repeat this operation for pistons 2, 3 and 4 and MIF1086A
calculate the mean value: 127
Scyl1 + Scyl2 + Scyl3 + Scyl4
S=
4
If S is > 0.0157 in. (0.40 mm) use the gasket
type A.
If S is < 0.0157 in. (0.40 mm) use the gasket
type B.
-- Fit the lifting brackets to the cylinder head.
-- Install the gasket, fit the cylinder head on the
crankcase, screwing down the screws (1) with-
out tightening them to torque.

MIF1139A

128
-- Before inserting the control rods, check that the
spherical seat (1) of contact with the rocker arm
adjuster screw and the spherical end (2) of con-
tact with the tappet show no sign of wear; if there
are, then change them. The inlet and exhaust
valve control rods are identical and can therefore
be interchanged.

MIF1011A

129

84176554 - 03-- 2008

58 SECTION 10 -- ENGINE -- CHAPTER 1

-- Spread LOCTITE 5999 sealant between the

cover (2) and the manifold (3) and tighten the
screws (1) to the torque prescribed on page 11.

MIF1094A

130
FITTING THE INJECTORS
(Disassembly operation 50.)
-- On the injector (1), mount a new seal (2) lubri-
cated with Vaseline and a new washer (3).
-- Fit the injectors 2, 3, 4 in the seats on the cylinder
head and tighten them to the torque prescribed
on page 11.

MIF1063A

131
FITTING THE ROCKER ARM ASSEMBLY
(Disassembly operation 49.)
-- Check that the spindle (2) / rocker arm (1) coupl-
ing surfaces are neither too worn nor damaged.

Main spindle--rocker arm data (mm)

MIF1012A

132
-- Check that the tappet adjusters are unscrewed
to prevent them sticking on the rods when fitting
the rocker arm assembly (1).
-- Then mount the rocker arm assembly compris-
ing the support and spindles and secure them to
the head without tightening the bolts (2) to
torque. They will be tightened to torque together
with those fixing the cylinder head.

MIF1013A

133

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 59

FITTING THE TIMING GEAR

(Disassembly operation 47.)
-- Use a marker pen to mark the tooth of the driving
gear (1) mounted on the crankshaft (2) on the
side of which the reference mark (→) is stamped
for timing.

MIF0977A

134
-- Direct the crankshaft (3) and camshaft (4) so that
when mounting the driven gear (1) on the cam-
shaft, the marks stamped on the gears (1 and 2)
coincide.

MIF0978A

135
-- Place the dial gauge (1) on the timing gear (2)
and check that the clearance between the gears
(2) and (3) is between 0.0029 to 0.0110 in. (0.076
to 0.280 mm).

MIF1140A

136
-- Insert the screws (1) fixing the gears (2) to the
camshaft (3) and tighten them to the torque pre-
scribed on page 11.

MIF1141A

137

84176554 - 03-- 2008

60 SECTION 10 -- ENGINE -- CHAPTER 1

-- Tighten the cylinder head fixing screws in the se-

quence shown in Figure 139.

MIF1014A

138
-- Tightening sequence for cylinder head
bolts:
1st stage of tightening with a torque wrench:
M 12 x 1.75 x 70 bolt: 50 Nm to 5 Nm
(ref. 3--6--11--14)

M 12 x 1.75 x 140 bolt: 40 Nm to 5 Nm

(ref. 1--2--7--8--9--10--15--16--17--18)

M 12 x 1.75 x 180 bolt: 70 Nm to 5 Nm

(ref. 4--5--12--13)

2nd stage tightening to an angle of 90° for all the

screws MIF1015A

rd
3 stage additional tightening to an angle of 90° 139
for 5.5118 and 7.0866 in. (140 and 180 mm)
long bolts only.
A = fan side

-- Adjust the clearance between the rocker arms

and valves using an Allen wrench (1), box
wrench (2) and feeler gauge (3).
The working clearance is given on page 9.
-- Move the cylinder to the exhaust stroke and
measure the clearance; the valves in the cylinder
are closed, whilst those on the symmetrical cylin-
der are rocking.
The symmetrical cylinders are 1 -- 4 and 3 -- 2.
-- FIRING ORDER 1 -- 3 -- 4 -- 2
Balance valves
1 3 4 2
of cylinder no. MIF1016A

Adjust valve clearan- 140

4 2 1 3
ce of cylinder no.

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 61

FITTING THE INJECTION PUMP

(Disassembly operations 38.)
-- Before fitting the injection pump, check that the
engine flywheel is still locked and in time with cyl-
inder no. 1 at T.D.C. (as described in oper-
ation 37. page 41), using tools 380000988 and
380000732.
-- Do the timing for the injection pump (1, fig. 142)
in relation to the drive gear, proceeding as de-
scribed on page 106.
-- Then loosen bolt (2), insert the “L” spacer (1) and
lock bolt (2) to make the fuel pump spindle free
to turn.
MIF0920A

141
-- Fix the injection pump casing (1) to the seat of the
gear box (2) with the screws (3).

MIF0981A

142
-- Spline the gear (1) transmitting drive to the
pump. 1

MIF0982A

143
FITTING THE ADDITIONAL COUNTER-
WEIGHTS
(Disassembly operations 36.)

-- After taking the first cylinder to the top dead

centre and doing the timing of the gear of the tim-
ing system as described above, do the timing of
the additional counterweights, making the marks
(A) stamped on the gears coincide as shown in
the figure.

MIF1142A

144

84176554 - 03-- 2008

62 SECTION 10 -- ENGINE -- CHAPTER 1

-- Insert the retaining pin in the hole (B) on the addi-

tional counterweight assembly to block rotation
during the subsequent installation phase.

MIF1143A

145
-- Fit the additional counterweights (2), tighten the
screws (3) to the torque prescribed on page 11
and remove the retaining pin (1) from the hole
(B).

MIF1113A

146
FITTING THE HYDRAULIC PUMP DRIVE
GEAR
(Disassembly operation 48.)
-- Insert the gear driving the hydraulic pumps (2)
into the seat and tighten the bolts (1).
1

MIF1144A

147

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 63

FITTING THE TIMING GEAR CASING

(Disassembly operation 46.)
-- Carefully clean the timing gear box (1) and the
crankcase.
Cleaning the surface to seal is both necessary
and unavoidable in order to obtain an effective
seal. Apply LOCTITE 5999 sealant onto the box 1
to form a bead with a diameter of a few mm as
shown in fig. 148. It must be uniform (no lumps),
with no air bubbles, thin areas or breaks.
Any flaws must be corrected in as short a time as
possible.
Avoid using excess material to seal the joint. MIF1136A
Too much sealant would tend to come out on 148
both sides of the joint and clog the lubricant pass-
ageways.
After applying the sealant, the joints require im-
mediate assembly (10 -- 20 minutes).
-- Refit the box (1) to the crankcase.
-- Tighten the retaining bolts (2) in the position
found during disassembly.

MIF1147A

149
FITTING THE CRANKSHAFT REAR SEAL
(Disassembly operations 42. to 45.)
-- Fit part (6) of tool 380000664 on the rear shank
(3) of the crankshaft. Secure it with the screws
(1) and spline the new seal (2) onto it.
-- Position part (5) on part (6), screw down the nut
(4) until the seal (2) is completely fitted in the fly-
wheel casing.

MIF1145A

150
FITTING THE FLYWHEEL
(Disassembly operations 39. to 41.)
-- Check the clutch plate mating surface; turning is
required if there is any scoring.
-- Check the state of the teeth of the crown gear (2).
If you find any breakage or excessively worn
teeth, replace it. Mount the new one, previously
heated to a temperature of 150 °C for 15 to
20 min.

NOTE: The nominal thickness of the engine flywheel

is 2.7755 in. (70.5 mm).
MIF0990A

151

84176554 - 03-- 2008

64 SECTION 10 -- ENGINE -- CHAPTER 1

-- Screw two pins (2) of the appropriate length into

the holes in the shaft (3) and, using the sling,
mount the engine flywheel (1).

MIF1116A

152
-- Spline the flywheel (1) onto the crankshaft,
tightening the screws (2) by hand.
-- Lock the flywheel appropriately before tightening
the relevant screws to torque.

MIF1115A

153
-- Tighten the bolts (1) securing the engine flywheel
(2) in two stages as described on page 12:
1st phase, tightening with torque wrench to a
torque of 30 ± 5 Nm;
nd
2 phase, tightening to an angle of 60° ± 5°.

NOTE: Tightening to an angle is done with tool

380000304.

MIF1146A

154
FITTING THE OIL PUMP
(Disassembly operation 35.)
-- Insert the seal.
-- Fit the oil pump (1).
-- Insert the tightening screws (2) and tighten them
to the torque prescribed on page 11.

MIF1149A

155

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 65

FITTING THE OIL SUMP

(Disassembly operation 34.) 2
-- Place the new seal on the crankcase.
-- Fit the oil sump (1).
-- Insert the screws (3) and tighten them to the
torque prescribed on page 11.
1
-- Tighten the drain plugs (2) to the torque pre-
scribed on page 11.

MIF1117A

156
FITTING THE CRANKSHAFT FRONT SEAL
(Disassembly operations 29. to 33.)
-- Fit part (4) of tool 380000666 on the front shank
(3) of the crankshaft. Secure it with the screws
(5) and spline the new seal (6) onto it. Position
part (1) on part (4), screw down the nut (7) until
the seal (6) is completely fitted in the front cover
(2).

MIF1001A

157
FITTING THE CRANKSHAFT FRONT
PULLEY
(Disassembly operation 28.)
-- Spline the pulley (2) onto the crankshaft and
tighten the screws (1) to torque and angle (see
page 12), using tool 380000304.

MIF1111A

158
FITTING THE COOLING SYSTEM UNION
(Assembly operation 27.)
-- Position the cooling system fitting so that the pins
(3 and 4) are against the crankcase.
-- Tighten the screws (1 and 2).

MIF1005A

159

84176554 - 03-- 2008

66 SECTION 10 -- ENGINE -- CHAPTER 1

FITTING THE COOLANT PUMP

(Assembly operation 26.)
-- Fit a new seal (2) onto the coolant pump (1).

MIF0997A

160
-- Mount the coolant pump (1).
-- Screw down the screws (2) and tighten them to
the torque prescribed on page 11.

MIF1150A

161
FITTING THE FAN--ALTERNATOR PULLEY
(Disassembly operation 25.)
-- Fit the coolant temperature sensor (1) screwing
it down with a torque wrench.
-- Fit the fan pulley support (2) with the screws (3),
tightening them to the torque given on page 11.

MIF1151A

162
-- Fit on the crankcase: a new gasket (1), the cooler
(2), a new gasket (3) and the oil filter mounting
(5).
-- Insert the screws (4) and tighten them to the
torque prescribed on page 11.

MIF1152A

163

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 67

-- Refit the bracket (1) to secure the alternator (2)

to the crankcase. Tighten the alternator fixing
screws (3) to the torque specified on page 11.

MIF1006A

164
-- Fit the fan pulley (2) on the support (1) with the
screws (3), tightening them to torque.

MIF1153A

165
-- Fit the tightener (1), tightening the bolts (2) and
the tightener nut as directed on page 116.

MIF1154A

166

84176554 - 03-- 2008

68 SECTION 10 -- ENGINE -- CHAPTER 1

FITTING THE AUXILIARY MEMBER DRIVE

BELT
(Disassembly operation 24.)
-- Fit the Poly--V belt (3) on the pulleys of the crank-
shaft, tightener (5) of the coolant pump (4), alter-
nator (1) and fan (2).

NOTE: Tension the belt correctly as indicated in

operation 10 414 10.

MIF1155A

167
FITTING THE EXHAUST MANIFOLD --
TURBINE
(Disassembly operations 22. and 23.)
-- Mount the exhaust manifold (4) and tighten the
screws (3) to the torque prescribed on page 11.
-- Fit the turbine (1) with the screws (2).

MIF1156A

168
FITTING THE INJECTOR FEED PIPES
(Assembly operations 20. to 21.)
-- Fit the injector feed pipe assembly (1). Fit the in-
jector fuel outlet pipes (2), using the seals (4) and
tighten the screws (3).

MIF1108A

169
FIT THE PRIMING PUMP -- FEED PIPES
(Disassembly operations 17. to 19.)
-- Fit the priming pump (5).
-- Fit the injector feed pipes (4) of the injection
pump (3), secure the brackets fixing the pipe as-
sembly (1), (2) and (6) on the cylinder head.

MIF1107A

170

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 69

FITTING THE PIPES BETWEEN THE FUEL

SUPPLY AND INJECTION PUMPS, PRE--
HEATING SYSTEM AND TAPPET COVER
(Disassembly operations 7. to 16.)

-- Fit the fuel filter mounting (9).

-- Fit the control unit for the heater (10).
-- Fit the heater (4).
-- Fit the fuel filter (7).
-- Fit the LDA system piping (5).
-- Connect the pipes with the quick--fit coupling (6)
and (8) following the guidelines of fig. 173. MIF1105A

-- Fit the tappet covers (1). 171

-- Connect the engine oil vapour recovery pipe to
the blow--by (3).
-- Fit the intake manifold (2).

172
-- Press the clip (1) in the direction of the arrow
(part B) and connect the low--pressure pipe. Put
the clip back in its locking position (part A).

NOTE: Figure 173 shows the connectors for the

low--pressure pipes (6) and (8) of figures 171
and 172.

A = Pipe locking position on connector.

B = Coupling pipe removal position.

MIF0909A

173

84176554 - 03-- 2008

70 SECTION 10 -- ENGINE -- CHAPTER 1

FITTING THE STARTER MOTOR

(Disassembly operations 5. and 6.)

-- Fit the oil delivery pipe (2).

-- Fit the turbine oil return pipe (1), the clamp (4),
oil filter (3) and starter motor (5).

MIF1104A

174

175
-- Fit the wiring (1).
-- Fit the fan unit to the fan pulley.
-- Add engine oil through the filler plug.
-- Install the bonnet as described in oper-
ation 90 100 22.

MIF1103A

176

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 71

CHECKS, MEASUREMENTS AND

REPAIRS (CYLINDER BLOCK, LINERS)
CAUTION
Handle all parts carefully.
Do not put your hands or fingers between parts.
Wear the prescribed safety clothing, including
goggles, gloves and safety footwear.

Checks and measurements

After disassembling the engine, thoroughly clean the
crankcase assembly.
Use the specific lifting rings for transporting the as-
sembly.
Carefully check the crankcase is not cracked.
Check the condition of the plugs (3, fig. 180) on the
crankcase. If they are rusty or if there is the slightest
doubt about their seal, change them.
Examine the surfaces of the cylinder liners; they
should show no scoring, ovality, taper or excessive
wear.
To check the internal diameter of the cylinder liners
for ovality, taper and wear, use the bore gauge (1),
fitted with a dial gauge zero--set on the ring gauge (2)
of the diameter of the cylinder liner.

NOTE: If the ring gauge is not available, use a micro-

meter.

MIF1030A

177
Measurements must be taken for each single liner,
at three different heights on the liner and on two ort-
hogonal faces: one parallel to the longitudinal axis of
the engine (A) and the other perpendicular (B); maxi-
mum wear is generally found on this face in corre-
spondence with the first measurement.
If you find any ovality, taper or general wear outside
the tolerance given on page 5, bore and recondition
the cylinder liners. The cylinder liners must be re-
ground in relation to the diameter of the pistons sup-
plied as spare parts (oversized by 0.0196 in.
(0.5 mm) over the nominal value) and to the assem-
bly clearance prescribed on page 5. MIF1031A

178

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72 SECTION 10 -- ENGINE -- CHAPTER 1

MIF1032A

179

TOLERANCES CHARACTERISTIC SUBJECT OF TOLERANCE GRAPHIC SYMBOL

SHAPE Cilindricity /f/
ORIENTATION Perpendicularity
POSITION Location

-- tighten the retaining bolts to the prescribed

NOTE: If regrinding, all the liners must have the torque;
same oversize 0.0196 in. (0.5 mm). -- using an appropriate dial gauge for interiors,
check that the diameter of the seats is as pre-
Check the main bearing seats, proceeding as fol- scribed on page 5.
lows: If the measurement is any greater, change the crank-
-- fit the main bearing caps on the supports without case.
bearings;

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 73

Check that the head mating surface, on the cylinder

block, has no deformation.
This check can be made, after taking out the grub
screws (2), with a calibrated rule (1) and feeler gauge
(4).
After having located deformed areas, level off the
mating surface using a grinding machine.
The flatness error must be no greater than 0.0029 in.
(0.075 mm).

NOTE: The crankcase can be faced only after mak-

ing sure that, after machining, the protrusion of the MIF1033A

piston from the cylinder liner is no greater than as 180

prescribed on page 7.

Check the condition of the cylinder block plugs (3);

if they are rusty or if there is the slightest doubt about
their seal, change them.
After facing, restore the bevel of the cylinder liners as
shown in Figure 179.

84176554 - 03-- 2008

74 SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS

CRANKSHAFT
CAUTION
Handle all parts carefully.
Do not put your hands or fingers between parts.
Wear the prescribed safety clothing, including
goggles, gloves and safety footwear.

Crankshaft
Clean all parts carefully.If even slight cracks are
found, replace the crankshaft.
-- If any sign of seizure, scoring or ovality is found
on the main journals or crankpins, they must be
reground. Before reconditioning, use a micro-
meter (2) to measure the pins of the shaft (1) to
define the diameter to which the pins must be re-
duced.

NOTE: It is advised to note the values on a chart. See

figure 182.

-- The undersize classes are 0.0098--0.0196 in.

(0.250--0.500 mm). MIF0958A

181

MIF0959A

182
Chart on which to note the measurements of the main journals and crankpins (* Nominal value)

All the main journals and crankpins must be ground Undersized main journals with the letter B.
to the same undersizing marked with a stamp on the Undersized crankpins and main journals with the
side of the crank arm No. 1. letters MB.
Undersized crankpins with the letter M.

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 75

MIF1158A

183
* Measured on a radius greater than 1.7913 in.
(45.5 mm).
** ↗ 0,50 between adjacent main journals.

MAIN CRANKSHAFT TOLERANCES

TOLERANCES CHARACTERISTIC SUBJECT OF TOLERANCE GRAPHIC SYMBOL
Circularity f
SHAPE
Cilindricity /f/
Parallelism //
ORIENTATION Perpendicularity
Straightness
POSITION Concentricity or coaxiality
Circular oscillation
OSCILLATION Total oscillation
Taper

CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL 
IMPORTANT
SECONDARY

84176554 - 03-- 2008

76 SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS
AND REPAIRS -- CONNECTING RODS
CAUTION
Handle all parts carefully.
Do not put your hands or fingers between parts.
Wear the prescribed safety clothing, including
goggles, gloves and safety footwear.

Main data (mm) of the connecting rod, piston

pin bushing and half bearings
* Inside diameter to be measured after installing in
the small end and regrinding with a reamer.
** Cannot be measured free.

NOTE: The connecting rod -- connecting rod cap

mating surfaces are knurled for a better coupling. It
is therefore recommended not to remove the knurl-
ing.

Each connecting rod is marked:

-- On the body and cap with a number indicating
their coupling and the cylinder in which it is
mounted.
-- In the event of replacement, number the new rod
MIF1043A
with the same number as the replaced connect-
ing rod. On the body of the connecting rod with 184
a letter indicating the weight class of the connect-
ing rod mounted in production:
-- V, 1600g to 1640g (marked in yellow);
-- W, 1641g to 1680g (marked in green);
-- X, 1681g to 1720g (marked in blue).
Connecting rods are supplied as spare parts in class
W and marked in green.
Removing material is not permissible.

Bushings
Check that the bushing in the small end has not come
loose and shows no sign of scoring or seizure. If this
is not so, change it.
Disassembly and assembly are performed with a
suitable drift.
When driving in, make sure that the oilways in the
bushing and small end coincide. Using a boring
machine, regrind the bushing to obtain the
prescribed diameter.

MIF1044A

185

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 SECTION 10 -- ENGINE -- CHAPTER 1 77

Checking connecting rods

Check the parallelism of the connecting rod (2) axes
using instrument 380001003 (4) as follows.
Fit the connecting rod (2) on the self--centring spindle
(3) of tool 380001003 (4) and lock it with the screw
(5).
Put the spindle (3) on the “V” prisms, setting the con-
necting rod (2) on the stop bar (1).

MIF1045A

186
Checking twisting
Check the twist of the connecting rod (2) by compar-
ing two points (A and B) of the pin (4) on the horizon-
tal plane of the connecting rod axis.
Position the support (1) of the dial gauge (5) so that
this pre--loads by ∼ 0.0196 in. (0.5 mm) on the pin (4)
at point A and reset the dial gauge (5). Move the
spindle (3) with the connecting rod (2) and on the op-
posite side (B) of the pin (4) compare any deviation:
the difference between A and B must be no greater
than 0.0031 in. (0.08 mm).

MIF1046A

187
Checking bending
Check the bend of the connecting rod (3) by compar-
ing two points (C and D) of the pin (4) on the vertical
plane of the connecting rod axis. Position the vertical
support (2) of the dial gauge (1) so that this rests on
the pin (4) at point C as shown in the figure. Swing
the connecting rod to and fro, seeking the highest
position of the pin and reset the dial gauge (1) in this
condition. Move the spindle with the connecting rod
(3) and on the opposite side D of the pin (4) repeat
the check for the highest point. The difference be-
tween points C and D must be no greater than
0.0031 in. (0.08 mm). MIF1047A

188

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78 SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS -- PISTONS

Normal dimensions (mm) piston data engines mod. TL90A and TL100A

189

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 79

CAUTION
Handle all parts carefully.
Do not put your hands or fingers between parts.
Wear the prescribed safety clothing, including
goggles, gloves and safety footwear.

Clean all parts carefully before proceeding with the

operations described below.

Measuring the piston diameter

Using a micrometer (2) measure the diameter of the
piston (1), and check the cylinder liners to determine
the state of wear of the liners and pistons (see
pages 5 and 7).

If the clearance is not within the tolerances stated on

page 7, it will be necessary to ream, rebore the liners
and fit oversize pistons and rings (see pages 7
and 8).

NOTE: The diameter must be measured at a dis- MIF1035A

tance of 2.4015 in. (61 mm) from the base of the pis- 190
ton skirt.

Clearance between the piston and the cylinder liner

can be measured with a feeler gauge (1), as shown
in the figure 191.

MIF1036A

191
Piston pins
Measuring the piston pin (2) diameter using a micro-
meter (1).
When fitting pins on pistons, check that the clear-
ance between the gudgeon pin and its bore in the pis-
ton is within the tolerance specified on page 7.

MIF1037A

192

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80 SECTION 10 -- ENGINE -- CHAPTER 1

Conditions for correct pin--piston coupling

Lubricate the pin (1) and the piston pin boss seat with
engine oil; the pin must go into the piston with a light
pressure of the fingers and must not drop out.

MIF1038A

193
Piston rings
Using a micrometer (1) check that the thickness of
the 1°--2°--3° ring (2) comes within the tolerances
stated on page 7.

MIF1039A

194
Using a feeler gauge (2), check that the clearance
between the rings and their seats on the piston come
within the tolerances prescribed on page 8.

MIF1040A

195
Measuring the clearance X
of the V--ring

Due to the special shape of the first seal with a trap-

ezoidal cross--section, the clearance between the
groove and the ring should be measured as follows;
Make the piston (1) protrude from the crankcase so
that the ring (3) at issue comes approximately half-
way out of the cylinder liner (2).
In this position, using a feeler gauge, check the clear-
ance (X) between the ring and the groove: this clear-
ance must be as prescribed on page 8.
MIF1041A

196

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 SECTION 10 -- ENGINE -- CHAPTER 1 81

Measure the clearance between the ends of the pis-

ton rings (2) introduced in the cylinder liner (3) using
a feeler gauge (1), checking it is as prescribed on
page 8.

MIF1042A

197

84176554 - 03-- 2008

82 SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS

-- CAMSHAFT AND VALVES
CAUTION
Handle all parts carefully.
Do not put your hands or fingers between parts.
Wear the prescribed safety clothing, including
goggles, gloves and safety footwear.

Clean all parts carefully before proceeding with the

operations described below.

Dimensions (mm) of valves and valve guides.

A = Exhaust valve.
B = Inlet valve.

MIF1048A

198
Decarbonizing, checking and grinding valves
Remove all carbon deposits from the valves (2) using
a wire brush (1).
Check that the valves show no signs of seizure,
cracking or burning.
If necessary, grind the bevels on the valve heads
using a grinding machine, removing as little material
as possible.

MIF1049A

199
Using a micrometer (2) measure the valve stem (1)
and check it comes within the range of tolerance
given on page 9.

MIF1050A

200

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 83

MIF1052A

201
Dimensions (mm) of valve seats

MIF1051A

202
Dimensions (mm) of valve seat housings
If the valve seats cannot be reconditioned by just re- Heat the cylinder head to 176 to 212 °F (80 to
grinding, they can be replaced with the ones supplied 100 °C) and, using a suitable drift, insert the new
as spare parts. Using a specific tool and taking care valve seats, previously cooled.
not to nick the cylinder head, remove as much ma- Then regrind the valve seats according to the values
terial as possible from the valve seats until it is poss- given in Figure 201.
ible to extract them from the cylinder head with the A = Exhaust valve.
aid of a punch. B = Inlet valve.

84176554 - 03-- 2008

84 SECTION 10 -- ENGINE -- CHAPTER 1

After regrinding, with the base 380000364 (2) and

dial gauge 380000228 (1), check that the valve re-
cessing (3) in relation to the top face of the cylinder
head comes within the tolerance prescribed on
page 9.

MIF1053A

203
VALVE SPRINGS
The figure shows the main data for checking the inlet
and exhaust valve springs.
Before assembly, check the valve spring flexibility
using tool 380000976. Compare the elastic deforma-
tion and load data with those of the new springs
stated in the following table.

Height Under a load of

mm N
H (free) 63.50 No load
H1 49,02 P1 329 MIF1054A
H2 38,20 P2 641 204

Tappets
The figure gives the main data, in mm, of the tappets
and their seats in the crankcase.

MIF1055A

205

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 SECTION 10 -- ENGINE -- CHAPTER 1 85

Camshaft

MIF1056A

206
Camshaft data
The data given refer to the normal pin diameter (dimensions in mm)

The support journal surfaces on the shaft and cams

must be finely honed; if there are signs of seizing or
scoring, replace the shaft and relative bushings.

Checking cam lift and pin alignment

Set the shaft on tailstocks and, using a dial gauge
with a 1/100 mm scale placed on the central support,
check that the alignment error is no greater than
0.0015 in. (0.04 mm); change the shaft if it is.

Check the diameter of the supporting pins of the

camshaft (2) with the micrometer (1) on two orthogo-
nal axes.

MIF1057A

207

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86 SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS

-- CYLINDER HEAD
CAUTION
Handle all parts carefully.
Do not put your hands or fingers between parts.
Wear the prescribed safety clothing, including
goggles, gloves and safety footwear.

Use tool 380000302 to remove and refit valve

springs.
Clean all parts carefully before proceeding with the
operations described below.

Cylinder head mating surface check

The mating surface of the head (1) with the cylinder
block should be checked with a rule (2) and a feeler
gauge (3).
The deformation measured on the full length of the
cylinder head must be no greater than 0.0078 in.
(0.20 mm).
If it is any higher, regrind the cylinder head according
MIF1058A
to the dimensions and warnings given in the following
figure. 208

Cylinder head thickness

The nominal thickness A of the cylinder head is
3.7401 ± 0.0098 in. (95 ± 0.25 mm) the maximum
permissible amount of metal removed must not ex-
ceed the thickness B of 0.0051 in. (0.13 mm).

NOTE: After regrinding, check the valve recessing

and if necessary regrind the valve seats to obtain the
recessing prescribed on page 9.

MIF1059A

209

TOLERANCES CHARACTERISTIC SUBJECT OF TOLERANCE GRAPHIC SYMBOL

SHAPE Flatness

Cylinder head hydraulic seal check

Check the hydraulic seal using the appropriate tools. NOTE: Before fitting the plugs (3, fig. 180), apply a
water--reactive sealant on their sealing surface.
Using a pump, introduce water heated to
∼ 194 °F (90 °C) at a pressure of 29 to 43.5 psi (2 to
3 bar). If you find any leakage from the cylinder head, it must
If there is any leakage from the cup plugs, replace be changed.
them, using a suitable drift for their disassembly -- as-
sembly.

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 SECTION 10 -- ENGINE -- CHAPTER 1 87

LOW OIL PRESSURE INDICATOR --

Functional checks
The device is composed of the control switch (1,
fig. 210), engine oil pressure gauge (2, fig. 211).
This indicator light (1) indicates the engine oil pres-
sure is too low.
Switch off the engine and look for the cause of the
trouble.
The indicator comes on under the following circum-
stances:
MIF1096B

-- low oil pressure; 210

-- control switch (1, fig. 210) malfunction.

If the red lamp fails to illuminate when the engine is
stopped and the ignition switch is turned to the power
ON position, the possible causes are:
-- blown fuse;
-- blown lamp;
-- interruption in wire to the control switch.

NOTE: When the engine oil pressure is too low, the

indicator light comes on with the ignition key on B
(ready for starting). 211

OIL FILTER -- Replacement

The oil filter (3, fig. 54) is the paper integral cartridge
type.
If the filter gets too clogged, the safety valve opens
to enable the oil to by--pass the filter, keeping the en-
gine lubricated, albeit with non--filtered oil.
Replace the cartridge periodically (every 800 operat-
ing hours), remembering to:
-- oil the outer part of the seal in contact with the
mounting on the crankcase;
-- screw on the new cartridge until the seal is up
against the mounting;
-- tighten the cartridge, by hand only, through a
further 3/4 turn.

84176554 - 03-- 2008

88 SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS

-- COOLING SYSTEM
Clean all parts carefully before proceeding with the
operations described below.
The cooling system is supplied with a permanent
coolant mixture consisting of water and “AKCELA
Premium ” antifreeze (up to 50% in volume). This
mixture prevents freezing down to the following tem-
peratures:
Degrees °F (°C) 17.6 5 --13 --31
(--8) (--15) (--25) (--35)

% in volume of
“AKCELA Premium” 20 30 40 50

This mixture also has anti--oxidant, anti--corrosion,

anti--foaming and anti--scaling properties to ensure
long--term protection of the cooling system.
The same mixture can be kept in the cooling system
for a maximum of 2 years or 1200 operating hours,
whichever comes sooner; after which it must be
changed.

RADIATOR -- Flushing and checks

Two valves are built into the radiator cap, one com-
pression valve and one depression valve. Check the
correct operation of the valves periodically.
When overhauling, remove deposits of lime scale in
the radiator by means of a solution of water and de-
scaling agent in the proportions shown on the con-
tainer.
It is never advisable to limit flushing to the radiator
only -- always extend it to the entire cooling circuit
and top up the engine with the solution referred to
above.
Run the engine for about an hour (with the engine off)
in order to drain the solution through the drain plug.
In the event of leakage, the radiator is checked by
immersing it in a tank of water at a temperature of 68
to 104 °F (20 to 40 °C), introducing air into the radi-
ator at a pressure of 14.21 psi (0.98 bar) for approxi-
mately two minutes (repeat the test at least three
times).

COOLANT THERMOMETER -- Testing

If malfunction is suspected, immerse the bulb of the
thermometer in water and check the readings
against a test thermometer (repeat the test a number
of times with different water temperature to be sure).

THERMOSTAT VALVE -- Replacement

The thermostat valve (5, Fig. 4) is fitted in the cylin-
der head coolant outlet union.
The thermostat valve cannot be adjusted and there-
fore must be replaced if it does not meet the tempera-
ture specifications in the table on page 17.

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 SECTION 10 -- ENGINE -- CHAPTER 1 89

Op. 10 102 70
CRANKSHAFT FRONT SEAL
Replacement

DANGER
Lift and handle all heavy parts using suitable lifting
equipment.
Make sure that assemblies or parts are supported by
means of suitable slings and hooks. Check that no
one is in the vicinity of the load to be lifted.

To access the seal, proceed as follows:

1. Lift the bonnet (1) and disconnect the battery

negative cable.

212
2. Remove air filter (3) and the radiators of the con-
denser (1) and air cooler (2).
3

213
3. Remove the engine radiator (1), as indicated in
operation 10 406 10.

214

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90 SECTION 10 -- ENGINE -- CHAPTER 1

4. Loosen the pivot screws (2) and lock screws (1)

of the tightener (3).

215
5. Loosen the bolt (2) tensioning the belt (1) and re-
move the belt.

216
6. Remove the six retaining bolts (1), the pulley (2)
governing the accessory assemblies and the
fan--alternator--coolant pump pulley (3).

217
7. Apply tool 380000665 (4) on the front shank (2)
of the crankshaft.
8. Perforate the inner seal (1) with a drill bit
(∅
∅ 0.1377 in. (3.5 mm) through the guide holes
of the tool 380000665 (4), for a depth of
0.1968 in. (5 mm).
9. Secure the tool 380000665 (4) to the seal (1) by
screwing down the screws (3) supplied.
10. Extract the seal (1) by screwing down the screw
(5).
MIF0916A

218

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 SECTION 10 -- ENGINE -- CHAPTER 1 91

11. Fit the tie rod (3) of the tool 380000669 to the
outer seal (1) as shown in the figure and with the
lever (4), extract it from the front cover (2).

12. To assemble, proceed as follows:

CAUTION
Always use appropriate tools to align fixing holes.
NEVER USE FINGERS OR HANDS.

MIF0917A

219
To fit the front seal on the crankshaft, proceed as fol-
lows:

-- Fit part (4) of tool 380000666 on the front shank

(3) of the crankshaft. Secure it with the screws
(5) and spline the new seal (6) onto it. Position
part (1) on part (4), screw down the nut (7) until
the seal (6) is completely fitted in the front cover
(2).

MIF1001A

220
-- Fit the fan--alternator--coolant pump pulley, the
accessory assembly pulley and the six retaining
bolts.

-- Refit the transmission belt on the pulleys, adjust

it with the tensioning screw and lock the tigh-
tener, tightening the two retaining and pivot
screws.

-- Refit the engine radiator as described in oper-

ation 10 406 10.

-- Refit the condenser radiator, see oper-

ation 50 200 72.

-- Reconnect the negative battery cable and close

the bonnet.

84176554 - 03-- 2008

92 SECTION 10 -- ENGINE -- CHAPTER 1

Op. 10 102 74
CRANKSHAFT REAR SEAL
Replacement

DANGER
Lift and handle all heavy parts using suitable lifting
equipment.
Make sure that assemblies or parts are supported by
means of suitable slings and hooks. Check that no
one is in the vicinity of the load to be lifted.

To access the seal, proceed as follows:

1. Remove the clutch as described in oper-

ation 18 11 010.

221
2. Remove the eight screws (1) fixing the engine fly-
wheel (2).

222
3. Screw two pins (2) of the appropriate length into
the holes in the crankshaft (3).
Slightly extract the engine flywheel (1) so it can
be slung and then and put down in a specific
wooden container with the hoist.

MIF1116A

223

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 93

4. Apply tool 380000663 (3) on the rear shank (1)

of the crankshaft.

5. Perforate the inner seal (5) with a drill bit

(∅
∅ 0.1377 in. (3.5 mm) through the guide holes
of the tool 380000663 (3), for a depth of
0.1968 in. (5 mm).

6. Secure the tool 380000663 (3) to the seal (5) by

screwing down the screws (2) supplied.

7. Extract the seal (5) by screwing down the screw

(4). MIF0927A

224

8. To assemble, proceed as follows:

CAUTION
Always use appropriate tools to align fixing holes.
NEVER USE FINGERS OR HANDS.

To fit the front seal on the crankshaft, proceed as fol-

lows:

9. Fit part (6) of tool 380000664 on the rear shank

(3) of the crankshaft. Secure it with the screws
(1) and spline the new seal (2) onto it. Position
part (5) on part (6), screw down the nut (4) until
the seal (2) is completely fitted in the flywheel
casing.

MIF1145A

225
10. With a hoist and appropriate slinging, insert the
engine flywheel (1) on the pins (2) described
above, pushing it into contact with the crankshaft
(3).

MIF1116A

226

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94 SECTION 10 -- ENGINE -- CHAPTER 1

11. Manually tighten the bolts (2) retaining the fly-

wheel (1) to the crankshaft.

MIF1115A

227
12. Tighten the bolts (1) securing the engine flywheel
(2) in two successive stages as described on
page 12:
-- 1st phase, tightening with torque wrench to
a torque of 30 ± 5 Nm;
-- 2nd phase, tightening to an angle of 60° ± 5°.

NOTE: Tightening to an angle is done with tool

380001001.

MIF1146A

228
13. Refit the clutch as described in oper-
ation 18 110 10.

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 SECTION 10 -- ENGINE -- CHAPTER 1 95

Op. 10 106 12
VALVE--ROCKER ARM CLEARANCE
Adjustment
CAUTION
Handle all parts carefully. Do not put your hands or
fingers between parts. Wear the prescribed safety
clothing, including goggles, gloves and safety foot-
wear.

1. Remove the bonnet (1) as described in oper-

ation 90 100 22.
2. Disconnect the battery negative lead.

229
3. Remove the clamp (2) and extract the pipe (1)
connecting the intake manifold (3) to the air filter.

230
4. Remove the plastic retaining clamps, from the
cab heater water delivery--return pipes (2) and
those of the electric cables (1), moving the pipes
and cables on the compressor as described in
the figure.

231

84176554 - 03-- 2008

96 SECTION 10 -- ENGINE -- CHAPTER 1

5. Remove the retaining bolt and the front tappet in-

spection cover (1) together with the cover base
seal.

232
6. Remove the two retaining bolts (3) and the cen-
tral tappet inspection cover (2) together with the
engine vapour intake pipe (1) and the cover base
seal.

233
7. Remove the retaining bolt and the rear tappet in-
spection cover (1) together with the cover base
seal.

234
8. After taking off the covers, adjust the clearance
between the rocker arms and valves using an
Allen wrench (1), box wrench (2) and feeler
gauge (3).

The working clearance should be:

-- inlet valves = 0.0118 ± 0.019 in.
(0.30 ± 0.05 mm)
-- exhaust valves = 0.0216 ± 0.0019 in.
(0.55 ± 0.05 mm).
MIF1016A

235

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 SECTION 10 -- ENGINE -- CHAPTER 1 97

9. Take the cylinder where the clearance is to be ad-

justed into the end--of--compression phase; the
valves in the cylinder are closed, whilst those on
the symmetrical cylinder are rocking.

-- The symmetrical cylinders are 1 -- 4 and 3 -- 2.

-- FIRING ORDER 1 -- 3 -- 4 -- 2

Balancing valves
1 3 4 2
of cylinder no.
Adjust valve clear-
4 2 1 3
ance of cylinder no.

For assembly operations proceed as follows:

-- Fit the rear tappet inspection cover together with

the cover base seal and tighten the retaining bolt
to the torque stated on page 11.

-- Fit the central tappet inspection cover together

with the engine vapour inlet pipe and the cover
base seal, then tighten the retaining bolts to the
torque stated on page 11.

-- Fit the front tappet inspection cover together with

the cover base seal and tighten the retaining bolt
to the torque stated on page 11.

-- Reposition the cab water delivery--return pipes

and those of the electric cables, inserting new
plastic retaining clamps.

-- Insert the intake manifold--air filter connecting

pipe on the intake manifold and insert the retain-
ing clamp.

-- Install the bonnet as described in oper-

ation 90 100 22.

-- Reconnect the battery negative lead.

84176554 - 03-- 2008

98 SECTION 10 -- ENGINE -- CHAPTER 1

Op. 10 218 30
ENGINE INJECTOR R.I.

CAUTION
Handle all parts carefully. Do not put your hands or
fingers between parts. Wear the prescribed safety
clothing, including goggles, gloves and safety foot-
wear.

CAUTION
Always use appropriate tools to align fixing holes.
NEVER USE FINGERS OR HANDS.

Proceed as follows:

1. Lift the bonnet and disconnect the battery nega-

tive cable.
2. Disconnect the electrical connection of bonnet
and remove the bonnet (1).

236
3. Remove the diesel delivery (1) and recovery (2)
fittings from the injectors, then remove the rel-
evant pipes.

237
4. Remove the injectors (2) with tool 380000671 (1)
and extract them from the cylinder head.
5. Remove the threaded parts retaining the injec-
tors from the cylinder head.
6. To refit, proceed as follows:

CAUTION
Always use appropriate tools to align fixing holes.
NEVER USE FINGERS OR HANDS.

238

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 99

-- Fit the threaded parts retaining the injectors on

the cylinder head.
-- On the injector (1), mount a new seal (2) lubri-
cated with Vaseline and a new washer (3).
-- Fit the injectors in the seats on the cylinder head
and tighten them with a torque wrench to the
torque prescribed on page 11.

-- Fit the new seals on the fuel manifolds.

239

-- Fit the diesel delivery and recovery pipes and fit-

tings on the injectors.

-- Fit the air filter dust ejector pipe, its clamp and
the four rear nuts retaining the silencer to the ex-
haust manifold.

-- Fit the three rear retaining bolts of the exhaust si-

lencer.

-- Install the bonnet as described in oper-

ation 90 100 22.

-- Lower the bonnet and reconnect the battery

negative cable.

84176554 - 03-- 2008

100 SECTION 10 -- ENGINE -- CHAPTER 1

Op. 10 246 14
BOSCH INJECTION PUMP R.I.

CAUTION
Handle all parts carefully. Do not put your hands or
fingers between parts. Wear the prescribed safety
clothing, including goggles, gloves and safety foot-
wear.

CAUTION
Always use appropriate tools to align fixing holes.
NEVER USE FINGERS OR HANDS.

Proceed as follows:

1. Lift the bonnet and disconnect the battery nega-

tive cable.
2. Disconnect the electrical connection of bonnet
and remove the bonnet (1).

240
3. Remove the accelerator retaining spring (1) and
extract the lever (2).

241

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 101

4. Disconnect the engine stop electromagnet

wire (1).

242
5. Remove the quick couplers (1) on the filter
and (2) on the injection pump, remove the injec-
tion pump supply pipe.
Remove the pipe (3) coming from the tank.

CAUTION
Make the vehicle safe and put the gear into neutral.

MIF1161A

243
6. Remove the quick couplers and pipe (1) installed
between the fuel filter and fuel pump.

244
7. Remove the fittings of the pipes (2) connecting
the injection pump--injectors, the pipe (1) con-
nected to the thermostarter device and the elec-
trical connection of the engine stop device (3).

MIF1163A

245

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102 SECTION 10 -- ENGINE -- CHAPTER 1

8. Disconnect the electrical connection (1) for

measuring the engine oil pressure.

246
9. Remove the four fittings (2) connecting the injec-
tion pump / injectors and the pipes (1).

247
10. Remove the retaining bolts (1) and the three
brackets (2) retaining the pipes, inserted on the
injection pump/injector connection line.

248
11. Remove the fittings (1) of the injector diesel deliv-
ery pipes and the fittings (2) of the injection pump
diesel return pipe, then detach the pipes.
12. Lock the engine flywheel with appropriate
means.

249

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 103

13. Before removing the injection pump, do the tim-

ing and lock the engine flywheel with cylinder
no. 1 at T.D.C. as indicated on page 105, using
tools 380000988 and 380000732. Then loosen
the bolt (2), remove the “L” spacer (1) and lock
the screw (2) in order to keep the pump in time
with the engine flywheel.

NOTE: Keep the “L” spacer with the pump casing.

MIF0920A

250
14. Remove the three nuts (2) (3) (5) securing the in-
jection pump (1) to the engine flywheel casing (4)
and extract it from its housing.

MIF0922A

251
15. To refit the injection pump, proceed as follows.

CAUTION
Always use appropriate tools to align fixing holes.
NEVER USE FINGERS OR HANDS.

-- Respect the tightening torques prescribed on

page 11.

-- When refitting the BOSCH injection pump, insert

the stud bolts in the engine flywheel casing into
the mating holes on the pump flanging.

-- Do the timing for the injection pump in relation to

the drive gear, proceeding as described on
page 106.

-- Then loosen the retaining and safety bolt of the

injection pump timing.

84176554 - 03-- 2008

104 SECTION 10 -- ENGINE -- CHAPTER 1

-- Reinsert the L spacer and tighten the retaining

bolts.

-- Free the engine flywheel, take out the tools

380000988 and 380000732 and refit the starter
motor.

-- Reconnect the pipes and the fittings of the diesel

delivery pipes to the injectors and the fittings of
the diesel return pipe to the injection pump.

-- Fit the three retaining brackets, insert the pipes

on the line that connect the injection pump to the
injectors, tightening the retaining bolts.

-- Reconnect the four pipes connecting the injec-

tion pump / injectors, tightening their fittings.

-- Reconnect the electrical connection for measur-

ing the engine oil pressure.

-- Install the fittings of the pipes connecting the in-

jection pump--injectors, the pipe connected to
the thermostarter device and the electrical con-
nection of the engine stop device.

-- Reconnect the pipe installed between the fuel

filter and the fuel pump and reinsert the quick
couplers.

-- Fit the pipe supplying the injection pump, con-

necting the quick couplers on the filter and on the
injection pump.

-- Fit the pipe coming from the tank.

-- Reconnect the engine stop electromagnet cable.

-- Fit the throttle control lever and its retaining clip.

-- Install the bonnet.

-- Reconnect the battery negative cable and lower

the bonnet.

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 105

Checking injection pump timing

When replacing the injection pump, bear in mind that

it is supplied as a spare part already set for cylinder
No. 1 at T.D.C.

Proceed as follows:

1. Unscrew the bolts (1) and remove the starter

motor (2).

MIF1172A

252
2. Fit the bracket tool 380000988 (1), retaining the
gear for turning the engine flywheel tool
380000732 (2).
3. Slowly turn the engine flywheel (3) and at the
same time press on the pin (4), supplied with tool 2
380000988, in order to insert the pin (4) into the
seat in the engine flywheel (3).

3
MIF1173A

253
4. Remove the retaining bolts (2) and the priming
pump (1) from the crankcase (3).

MIF1174A

254
5. Check through the opening accommodating the
priming pump that the camshaft (1) has the refer-
ence marks (2) indicating cylinder No. 1 at T.D.C.
If there are no reference marks, extract the pin
(4, fig. 253) from the flywheel and turn this
through 360° so that the reference marks (2) are
visible as shown in the figure alongside, then re-
insert the locking pin (4, fig. 253).

MIF1175A

255

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106 SECTION 10 -- ENGINE -- CHAPTER 1

6. Fit the injection pump casing (1), already set, in

the seat of the gear box (2) without tightening the
retaining bolts (3).

With the injection pump fitted in its seat, take the cyl-
inder No. 1 to T.D.C. as follows:

CAUTION
The seal removed at the time of pump disassembly
must not be reused. Always use genuine spare parts.

MIF0981A

256
7. Loosen the screw (1) blocking rotation of the
pump spindle and insert the L spacer (2).
8. Tighten the screw (1), locking part (2) so that the
spindle of the fuel pump can turn freely.

MIF1176A

257
9. Remove the plug on the pump cover.
10. Fit the dial gauge 380000228 (2) and the asso-
ciated tool 380000914 (1), pre--loading the shaft
by 0.0984 in. (2.5 mm).
11. Unhook the pin (4, fig. 253) of tool 380000988,
turn the engine flywheel and move away from the
condition of the 1° cylinder at T.D.C.
12. This operation makes it possible to use the dial
gauge (2) to check that the pumping device in the
pump moves to the bottom limit equivalent to the
lowest indication of the dial gauge pointer.
13. In these conditions, reset the dial gauge and turn
MIF1165A
the crankshaft in the opposite direction to go
back into the condition of the 1° cylinder at the 258
TDC in the phase of the end of compression.
In this position the dial gauge on the pump must
read off a value of 0.0393 in. (1 mm).
14. Turn the pump anticlockwise if the stroke is any
less, or clockwise if the stroke is any greater in
order to obtain the prescribed stroke.
15. Verifying these conditions, lock the pump by
tightening the nuts to the torque shown on
page 11.

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 SECTION 10 -- ENGINE -- CHAPTER 1 107

16. Fit the priming pump (1) on the crankcase (3) and
tighten the retaining bolts (2) to the prescribed
torque.
17. Remove the tools 380000988 and 380000732 for
retaining/rotating the flywheel and place the
starter motor in its seat.

MIF1174A

259
BOSCH INJECTION PUMP
1
Fuel circuit air bleeding

18. Loosen the injector delivery unions (1), make the

engine turn with the starter motor and, after hav-
ing checked that there are no air bubbles, tighten
the unions (1).

MIF1167A

260

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108 SECTION 10 -- ENGINE -- CHAPTER 1

Op. 10 402 10
COOLANT PUMP R.I.
DANGER
Lift and handle all heavy parts using suitable lifting
equipment.
Make sure that assemblies or parts are supported by
means of suitable slings and hooks. Check that no
one is in the vicinity of the load to be lifted.

1. Raise the bonnet (1).

2. Disconnect the battery negative cable.

261
3. Remove the three retaining bolts (1) and the
guard (2) on the right--hand side of the fan.

262
4. Detach the fitting of the return pipe for the cool-
ant from the cab heater radiator connected to the
underside of the coolant pump and drain off the
engine coolant.

5. Loosen the screws (2) and (3) retaining and

pivoting the tightener to the cover (5).

6. Loosen the screw (4) for tensioning the belt (1) 263
and remove the belt.

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 109

7. Remove two retaining screws and the coolant

pump (1).
8. To install the coolant pump, proceed as follows.

264
CAUTION
Always use appropriate tools to align fixing holes.
NEVER USE FINGERS OR HANDS.

-- Respect the tightening torques prescribed on

page 11 and on page 116.

-- Fit a new seal (2) onto the coolant pump (1).

-- Fit the coolant pump, tightening the two retaining

bolts.

-- Fit the belt and adjust it with the tensioning screw.

-- Tighten the screws retaining and pivoting the

tightener to the cover.

-- Reconnect the fitting of the cab heater radiator

coolant return pipe to the bottom of the coolant
pump and refill the engine coolant.

-- Fit the guard on the right--hand side of the fan

and tighten the three retaining bolts.

-- Reconnect the battery negative cable.

-- Close the bonnet.

84176554 - 03-- 2008

110 SECTION 10 -- ENGINE -- CHAPTER 1

Op. 10 402 30
THERMOSTAT VALVE R.I.

CAUTION
Handle all parts carefully. Do not put your hands or
fingers between parts. Wear the prescribed safety
clothing, including goggles, gloves and safety foot-
wear.

1. Raise the bonnet (1).

2. Disconnect the battery negative cable.

265
3. Remove the three retaining bolts (1) and the
guard (2) on the right--hand side of the fan.

266
4. Detach the fitting of the return pipe for the coolant
from the cab heater radiator connected to the un-
derside of the coolant pump and drain off the en-
gine coolant.

5. Remove the clamp (2) and extract the sleeve (1)

connecting the radiator and thermostat valve.

267

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 SECTION 10 -- ENGINE -- CHAPTER 1 111

6. Take out the bolts (1) retaining the thermostat

valve body (2).

268
7. Remove the thermostat valve body (2), seal (3)
and thermostat valve (4).
8. To refit the thermostat valve, proceed as follows.

269
270
Always use appropriate tools to align fixing holes.
NEVER USE FINGERS OR HANDS.

-- Respect the tightening torques prescribed on

page 11.
-- Refit the thermostatic valve, after positioning the
thermostat valve seal.
-- Fit the thermostat valve body and the retaining
bolts.
-- Fit the radiator--thermostat valve connecting
sleeve and the clamp.
-- Install the fitting of the cab heater radiator coolant
return pipe connected to the bottom of the cool-
ant pump and refill the engine coolant.
-- Fit the guard on the right--hand side of the fan
and tighten the three retaining bolts.
-- Reconnect the battery negative lead.
-- Close the bonnet.

84176554 - 03-- 2008

112 SECTION 10 -- ENGINE -- CHAPTER 1

Op. 10 406 10
ENGINE RADIATOR R.I.
DANGER
Lift and handle all heavy parts using suitable lifting
equipment.
Make sure that assemblies or parts are supported by
means of suitable slings and hooks. Check that no
one is in the vicinity of the load to be lifted.

1. Raise the bonnet (1).

271
2. Remove the three retaining bolts (1) and the
guard (2) on the right--hand side of the fan.

272
3. Detach the fitting of the return pipe for the cool-
ant from the cab heater radiator connected to the
underside of the coolant pump and drain off the
engine coolant.

4. Loosen the retaining clamp and extract the pipe

(1) joining the coolant pump to the bottom of the
radiator.

273

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 113

5. Loosen the corresponding retaining clamp (1)

and extract the pipes. And remove the bracket
(2).

274
6. Loosen the corresponding retaining clamps and
extract the pipes (1), (2) and (3), remove the 4
bracket (4).

275
7. Remove the clamp securing the sleeve (1) to the
air filter (2). 1 2

276
8. Take out the two lower retaining bolts (2) and re-
move the air filter (1).

277

84176554 - 03-- 2008

114 SECTION 10 -- ENGINE -- CHAPTER 1

9. Remove the clamp (1) and extract the radiator

coolant compensation reservoir (2).

278
10. Remove the radiator of air cooler (1) and bracket
(3).
11. Remove the condenser (2) without however re-
moving the condenser gas delivery/return pipes
so as not to recover/recharge the system re-
frigerant gas.

3
279
12. Take out the two radiator retaining bolts (2) in-
stalled under the front axle support (1), removing
the bolts, washers and lower rubber blocks.

280
13. Remove the radiator (1).

281

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 115

14. Remove the rubber blocks (1), washers and

upper rubber blocks (2).

282
CAUTION -- Fit the engine oil vapour suction pipe and its
Always use appropriate tools to align fixing holes. clamp.
NEVER USE FINGERS OR HANDS. -- Fit the air filter and tighten the two lower retaining
bolts.
-- Respect the tightening torques prescribed on
page 11. -- Fit the air filter/exhaust ejector connecting pipe
and its clamp.
-- Fit the upper rubber blocks (2), washers and the
rubber block at the base of the radiator. -- Fit the sleeve connected to the intake manifold
and its clamp.
-- Fit the radiator.
-- Fit the sleeve connected to the air filter and its
-- Fit the lower rubber blocks, the washers and the clamp.
radiator retaining bolts installed under the front
axle support. -- Install the fitting of the cab heater radiator coolant
return pipe connected to the bottom of the cool-
-- Fit the radiator coolant compensation reser- ant pump.
voir and the retaining clamp.
-- Refill the engine radiator with coolant.
-- Fit the radiator retaining bracket to the bonnet
supporting bracket, then tighten the retaining -- Refit the guard on the right--hand side of the fan
bolt. and tighten the three retaining bolts.

-- Fit the upper radiator--thermostat valve connect- -- Install the condenser (operation 50 200 72) with
ing sleeve and the relevant clamp. the relevant delivery/return pipes.

-- Fit the sleeve connected to the bottom of the -- Reconnect the battery negative cable and close
water radiator and its clamp. the bonnet.

84176554 - 03-- 2008

116 SECTION 10 -- ENGINE -- CHAPTER 1

Op. 10 414 10
COOLANT PUMP AND GENERATOR
DRIVE BELTS
Adjusting tension
(Disassembly operation 283 to 285)

CAUTION
Handle all parts carefully. Do not put your hands or
fingers between parts. Wear the prescribed safety
clothing, including goggles, gloves and safety foot-
wear.

Rules for tensioning the Polyvee belt

To adjust the Polyvee belt (1) governing the fan --

coolant pump -- oil pump and alternator pulleys, pro-
ceed as follows:

1. Check that the belt (1) is correctly positioned on

the belt tensioning device and on the pulleys.
2. Loosen the screws (2) and (3) retaining and pi-
voting the tightener to the cover (6).
3. Loosen the locking nut (5) and the screw for ten-
sioning the belt (4), checking that its thread is not
defective and has no oxidized/painted parts that
would affect its rotation in its seat in the cover (6).

283
4. Turn the screw (4) and lightly tension the belt (1)
with the tightener.
5. Using a torque wrench, adjust the tensioning
screw of the belt (4) to the following torque set-
tings:

-- With the standard cooling fan

-- 3.8 to 4.4 Nm.

-- With the cooling fan with viscostatic

coupling
-- 4.3 to 4.9 Nm.

84176554 - 03-- 2008

 SECTION 10 -- ENGINE -- CHAPTER 1 117

6. Using a torque wrench, tighten the M 10 nut (5)

to a torque of 55 Nm (5.6 kgm).

7. Check the tension of the Polyvee belt in the posi-

tion (1), shown in the figureNO TAG below, using
the CLAVIS frequency meter 380001268, bear-
ing in mind that the data measured must remain
within the following tolerances:

284
-- With the standard cooling fan.
-- Assembly tension 1100 to 1300 Nm
-- Frequency measured with CLAVIS 158 to 170 Hz

-- With the cooling fan with viscostatic coupl-

ing.

-- Assembly tension 1250 to 1450 Nm

-- Frequency measured with CLAVIS 177 to 191 Hz

285
8. If the measured data are out of tolerance, repeat
operations 5 to 7 described above and check that
the measurements come within the prescribed
tolerances.

9. Using a torque wrench, tighten the M 10 nut (3)

to a torque of 55 Nm (5.6 kgm).

10. Using a torque wrench, tighten the M 8 nut (2) to

a torque of 25 Nm (2.6 kgm).

NOTE: When fitting a new belt, check the tension

again after 50 hours of running.

84176554 - 03-- 2008

118 SECTION 10 -- ENGINE -- CHAPTER 1

84176554 - 03-- 2008

 SECTION 18 -- CLUTCH -- CHAPTER 1 1

SECTION 18 -- CLUTCH

Chapter 1 -- Clutch

CONTENTS

Section Description Page

18 000 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
18 110 10 Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Minimum permissible dimensions after refacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
18 100 40 Adjustment of the main and PTO clutch control linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

GENERAL SPECIFICATIONS, CLUTCH 11”/11”

(Models JX60, JX70, JX80 )

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual clutch consisting of two

single dry plate clutches
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control: pedal operation for
main clutch and hand lever
for power take--off clutch
Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . single Belleville spring
Driven plate lining material for main transmission clutch (11”) . . . .
Models JX60 and JX70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Organic agglomerate
Models JX80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cerametallic
Driven plate lining material for PTO clutch (11”)
Models JX60, JX70, JX80 .................................. Organic agglomerate
Driven plate thickness:
. main clutch (9, fig. 1)
. VALEO
. Organic agglomerate and cerametallic . . . . . . . . . . . . . . . . . . . . mm 10.2 to 10.8
(in.) (0.4016 to 0.4252)
. PTO clutch (11, fig. 1)
. VALEO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 7.3 to 7.9
(in.) (0.2874 -- 0.3110)
. wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ” See pages 22
Clearance between main clutch release sleeve and related seat . . mm 0.050 to 0.151
(in.) (0.0020 to 0.0059)
Clearance between PTO clutch release sleeve and related seat . . mm 0.050 to 0.151
(in.) (0.0020 to 0.0059)
Release lever coplanarity adjustment . . . . . . . . . . . . . . . . . . . . . . . . . See page 23
Clutch control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 25

84176554 -- 03--2008
2 SECTION 18 -- CLUTCH -- CHAPTER 1

GENERAL SPECIFICATIONS, CLUTCH 12”/11”

(Model JX90 and JX95)

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual clutch consisting of two

single dry plate clutches
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . control: pedal operation for
main clutch and hand lever
for power take--off clutch
Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . . . . single Belleville spring
Driven plate lining material for main transmission clutch (12”) . . . . .
Model JX90, JX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cerametallic
Driven plate lining material for PTO clutch (12”)
Models JX90, JX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Organic agglomerate
Driven plate thickness:
. main clutch (9, fig. 1)
. VALEO
. Organic agglomerate and cerametallic . . . . . . . . . . . . . . . . . . . . mm 10.2 to 10.8
(in.) (0.4016 to 0.4252)
. PTO clutch (11, fig. 1)
. VALEO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 7.3 to 7.9
(in.) (0.2874 -- 0.3110)
. wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ” See pages 22
Clearance between main clutch release sleeve and related seat . . mm 0.050 to 0.151
(in.) (0.0020 to 0.0059)
Clearance between PTO clutch release sleeve and related seat . . mm 0.050 to 0.151
(in.) (0.0020 to 0.0059)
Release lever coplanarity adjustment . . . . . . . . . . . . . . . . . . . . . . . . . See page 23
Clutch control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 25

84176554 -- 03--2008
 SECTION 18 -- CLUTCH -- CHAPTER 1 3

LUK 11”/11” ( JX60, JX70, JX80, and JX90 models, see fig. 2) (Not for all markets)
(Single lever PTO option)

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual clutch consisting of two

single dry plate clutches
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical: pedal operated for
main clutch; hand lever for PTO
clutch

Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . . single Belleville spring disc

Driven plate lining material

. main clutch (all models): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cerametallic pads

. PTO clutch (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . organic agglomerate

Thickness of driven plates:

. main clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 -- 10.4

. PTO clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ” 7.4 -- 7.8

Clearance between main clutch release sleeve and relative hou-

sing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.050 -- 0.151
Clearance between PTO clutch release sleeve and relative hou-
sing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.060 -- 0.180

LUK 12”/11” ( JX95 models, see fig. 3) (Not for all markets) (Single lever PTO option)

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual clutch consisting of two

single dry plate clutches
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical: pedal operated for
main clutch; hand lever for PTO
clutch

Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . . single Belleville spring disc

Driven plate lining material

. main clutch (all models): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cerametallic pads

. PTO clutch (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . organic agglomerate

Thickness of driven plates:

. main clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6 -- 10.4

. PTO clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ” 7.3 -- 7.9

Clearance between main clutch release sleeve and relative hou-

sing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.050 -- 0.151
Clearance between PTO clutch release sleeve and relative hou-
sing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.060 -- 0.180

84176554 -- 03--2008
4 SECTION 18 -- CLUTCH -- CHAPTER 1

TIGHTENING TORQUES

Tightening torque
PART Thread
Nm ft lb
Clutch/flywheel retaining bolts
-- mod. JX60, JX70, JX80 and JX90 . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 25 18.439
-- mod. JX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 59 43.5162

Release command fork securing bolt (C3, page 6) . . . . . . . . . . . . M 16 x 1.5 157 115.7972
Retaining bolts securing clutch casing to engine (C2, page 6) . . . M 12 x 1.25 98 72.2811

Clutch casing/engine retaining nuts (3, fig. 1 page 6) . . . . . . . . . . M 12 x 1.25 98 72.2811

Nut for sleeve cover fixing stud (C6, page 6) . . . . . . . . . . . . . . . . . . M 8 x 1.25 17 12.8355

84176554 -- 03--2008
 SECTION 18 -- CLUTCH -- CHAPTER 1 5

380000236 Tractor disassembly stand.

380000612 11”/11” clutch adjustment kit

(pin and gauge).

380000292 Dowel for centring and adjust-

ment of 12”/12” clutches.

380000293 12”/12 Clutch adjustment

gauge.

293650 Clutch overhaul outfit.

380000458 Press for clutch lever release

test.

84176554 -- 03--2008
6 SECTION 18 -- CLUTCH -- CHAPTER 1

LONGITUDINAL SECTION OF CLUTCH VALEO

1
a .Main clutch with driven disc made of organic material. 4. Main clutch release sleeve, complete with thrust
b .Main clutch with driven disc made of cerametallic. bearings.
C2 Bolts securing clutch casing to the engine. 5. PTO clutch release sleeve, complete with thrust
C3 Fork lever retaining bolts. bearings.
6. Power take--off clutch release lever adjustment tie
C6 Nuts for sleeve studs.
rod.
D. Nominal distance of lever (3) from clutch contact sur- 7. Power take--off clutch release lever stop nut.
face on flywheel (mod. JX60, JX70, JX80 and JX90,
11”/11” clutch 98 mm (3.8583 in.) -- mod. JX95 12”/12” 8. Power take--off clutch plate.
clutch 103 mm (4.0551 in.)). 9. Main transmission clutch plate.
D1 Nominal distance of lever (2) from clutch contact sur- 10. Bearing on flywheel.
face on flywheel (mod. JX60, JX70, JX80 and JX90, 11. PTO clutch release sleeve control fork.
11”/11” clutch 123 mm (4.8425 in.) -- mod. JX95 12. Main clutch release sleeve control fork.
12”/12” clutch 137 mm (5.3937 in.)). 13. Main clutch release lever adjuster lever.
L1 Clearance between PTO release lever and related 14. Main clutch release lever adjuster screw.
thrust bearing 2 mm (0.0787 in.). 15. Main clutch release lever adjuster nut.
L2 Clearance between main clutch release lever and re-
lated thrust bearing 2.5 mm (0.0984 in.). WARNING: When refitting the clutch, check that the
clutch plates are positioned as in the drawing.
1. Belleville spring.
2. PTO clutch release lever. NOTE: When refitting, carefully clean and degrease
3. Main clutch release lever. the mating surfaces X and apply sealing compound.
84176554 -- 03--2008
 SECTION 18 -- CLUTCH -- CHAPTER 1 7

Longitudinal section of clutch D1

LUK 11”/11” (Not for all markets)
1 2 D 4 5
3
1. PTO clutch release lever adjuster.
2. Belleville spring disc.
3. Clutch housing/engine retaining nuts and bolts.
4. PTO clutch release levers.
5. Release sleeves for main and PTO clutch, com-
plete with thrust bearings.
6. Nuts for sleeve cover fixing studs.
7. Release fork retaining bolt. E
8. Main clutch release levers.
9. Main friction disc
10. Main clutch release lever adjuster. F
12
11. PTO friction disc.
12. Bearing on flywheel.
D = 98 ٛ 1 mm. Nominal distance of release levers
(8) from clutch contact surface on flywheel.
D1 = 139 ٛ 1 mm. Nominal distance of release levers
(4) from clutch contact surface on flywheel.
E= Engagement travel: 17+2 mm.
E= Release travel: 8.5+2.5 mm.
26163 11 10 9 8 7 6
2

Longitudinal section of the D1

LUK 12”/11” clutch (Not for all markets) D
1 2 3 4 5
1. PTO clutch release lever adjuster.
2. Belleville spring disc.
3. Clutch housing/engine securing nuts and bolts.
4. PTO clutch release levers.
5. Main and PTO clutch release sleeves, complete
with thrust bearings.
6. Nuts for sleeve cover studs.
7. Fork lever securing bolts.
E
8. Main clutch release levers.
9. Main friction disc.
10. Main clutch release lever adjuster. 12 F
11. PTO friction disc.
12. Bearing on flywheel.
D = 103 ٛ 1 mm. Nominal distance of release levers
(8) from clutch contact surface on flywheel.
D1 = 144 ٛ 1 mm. Nominal distance of release levers
(4) from clutch contact surface on flywheel.
E= Engagement travel: 19+2 mm.
E= Release travel: 9.5+2 mm. 11 10 9 8 7 6
25371

84176554 -- 03--2008
8 SECTION 18 -- CLUTCH -- CHAPTER 1

CLUTCH TROUBLESHOOTING

Problems Possible causes Correction

Clutch slips 1. Worn clutch plates (8 and 9, Check and compare the data given on
page 6) and/or worn pres- the pages indicated; replace any
sure plate and flywheel. parts which are worn up to or over the
limit and adjust levers and clutch con-
trol linkage.
2. Belleville spring (1, page 6) Replace the Belleville spring.
distorted or otherwise dam-
aged.
3. Friction linings of discs (8 and Replace discs; identify and eliminate
9, page 6) contaminated with the source of lubricant inside the
oil and grease. clutch housing and thoroughly clean
the friction surfaces.

Fierce clutch 1. Partial seizure of the external Check linkage pivots and lubricate.
control linkage.
2. Friction disc (9, page 6) dis- Replace disc and adjust clutch control
torted. lever.
3. Friction disc (9, page 6) with Replace friction disc.
damaged hub springs or loose
hub rivets.
4. Oil or grease contaminating Replace the discs, identify and elimi-
the friction lining of discs (8 nate the source of lubricant inside the
and 9, page 6). clutch housing and thoroughly clean
the friction surfaces.

Clutch sticks and drags 1. Disc friction linings (8 and 9, Replace and adjust the discs.
page 6) or discs deformed.
2. Seizure of the external control Check, replace defective parts and lu-
linkage. bricate.
3. Controls badly adjusted. Adjust controls (see page 25).

Clutch noisy when engaged 1. Thrust bearing worn. Replace bearing.

and/or disengaged
2. Friction disc (9, page 6) with Replace friction disc.
damaged hub springs or loose
hub rivets.

Clutch pedal too stiff 1. Partial seizure of external con- Check linkage pivots and lubricate.
trol linkages.
2. Stiffening of pedal pivot. Check pivot and lubricate.

84176554 -- 03--2008
 SECTION 18 -- CLUTCH -- CHAPTER 1 9

CLUTCH
Removal--Refitting (Operation 18 110 10)
To access the clutch it is necessary to separate the
engine complete with the front axle from the tran-
smission.

DANGER
Lift and handle all heavy parts using suitable lifting
equipment.
Make sure that assemblies or parts are supported by
means of suitable slings and hooks. Check that no
one is in the vicinity of the load to be lifted.

ATTENTION
Always use suitable tools to align holes. NEVER
USE FINGERS OR HANDS.

Proceed as follows:
1. Disconnect the negative battery lead.
2. Drain off the oil from the gearbox/transmission
casing. 1

25621

3. Drain off the coolant from the engine cooling sys-

tem.
4. Disconnect two flexible houses from the power
steering control cylinder and drain off the oil from
the steering system.
5. Remove the front ballast (1).

1
TRE0159A

84176554 -- 03--2008
10 SECTION 18 -- CLUTCH -- CHAPTER 1

6. To access the engine the hood must be

opened.

TRE0159A

7. Remove the electrical connections (1)

TRE185A

8. After draining off the oil from the power steering

tank, disconnect the oil pipes (1) from the
hydrostatic steering control valve unit.

7
9. Remove the retaining bolts (1) of the suction pipe
(2) of the lift pump.

84176554 -- 03--2008
 SECTION 18 -- CLUTCH -- CHAPTER 1 11

10. Disconnect the delivery and return lines from the

hydraulic lift pump.

9
11. Detach the cab heating pipes (1) and (2). 25183

10
12. Slacken the clamps (1) and disconnect the cab
heating pipes (2), being sure to mark them first.

11

13. Extract the plastic fasteners (2) and detach the

diesel recovery pipe (3) and delivery pipe (4) to
the diesel pump (1).

12

84176554 -- 03--2008
12 SECTION 18 -- CLUTCH -- CHAPTER 1

14. Remove two metal clamps (2) and the rigid pipe
of drawing oil from the transmission housing via
lift pump (1) and power steering pump. Remove
the fitting of the delivery pipe.

13

15. Remove the electrical connection from the brake

fluid reservoir and take the brake fluid reservoir
(1) from the bracket.

14
16. Remove the fusebox (1) from the bonnet
support.

15
17. Remove the electrical connections of
temperature sender (1) and oil switch (2).

16
84176554 -- 03--2008
 SECTION 18 -- CLUTCH -- CHAPTER 1 13

18. Remove the retaining retaining clips (1) and

detach the flexible cables governing the hand
throttle and pedal throttle.
19. Remove the retaining clip (2) and detach the
throttle control tie--rod connected to the injection
pump.

17
20. Disconnect the electrical connections from
alternator (1) and starter motor (2).

18
21. Disconnect the electrical connections of dryer
filter sensor (1) and water in fuel sensor (2).

19
22. Remove the electrical connection (1) and air filter
clogging sensor (2).

20

84176554 -- 03--2008
14 SECTION 18 -- CLUTCH -- CHAPTER 1

23. Remove the two retaining bolts and the support

together with relays protecting system (1).

21
24. Remove the front, centre and rear screws secur-
ing the front axle prop shaft guard and remove 1
the guard (1).

25038

22
25. Remove circlip (2) and move sleeve (1) in the di-
rection shown by the arrow to disengage it from 1 2
the splined shaft of the front axle.

25039

23
26. Remove circlip (2) and move sleeve (1) in the di-
rection shown by the arrow to disengage it from 1 2
the splined shaft of the drive.

290

24

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 SECTION 18 -- CLUTCH -- CHAPTER 1 15

27. Remove the retaining bolts of the central support

(1) of the prop shaft and recover the shaft com- 1
plete with support.

25041

25
28. Position the movable tool for dismantling tractors
380000569 with the bracket 380000500 and
adapter plate 380000844 under the engine and
place a wooden block in between the points of
contact between the tool and tractor.
1

26

29. Extract the differential lock pedal retaining pin

from the drive shaft (1), remove the pedal and
footboard (2).

2
1

27
30. Position a fixed stand (1) under the draw bar sup-
port and pull on the hand brake. 1

25052

28

84176554 -- 03--2008
16 SECTION 18 -- CLUTCH -- CHAPTER 1

31. Unscrew the two nuts and bolts securing the en-
gine to the transmission, working through the
two access slots (1).

1
TRE0413A

29
32. Remove the remaining six retaining bolts at the
bottom and side.

30

33. Seperate the engine from the transmission with

the tool 380000569.

1 2
31
34. Remove the spacer located between the engine
and the transmission. 1

32
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 SECTION 18 -- CLUTCH -- CHAPTER 1 17

35. Using tool 380000612 (1) ,unscrew the retaining

bolts and remove the clutch

33

To refit the engine, proceed as follows:

Check condition of ball bearings pressed in flywheel; Refit the cab heater pipe union on the clutch/engine
replace in the event of excessive noise or binding. distance collar. Connect the flexible rubber hoses to
To install a new bearing,pack lubricate with grease the union.
Position the clutch using tool 380000612 (mod.
JX60, JX70, JX80 and JX90) or with tool 380000292 Refit the two power steering cylinder oil delivery and
(mod. JX95). Fix the clutch to the flywheel with the return connections.
six bolts.
Adjust the coplanarity of the clutch release levers as Refit the rigit pipe for driwing oil from the transmission
described on page 20. and the metal clamps.

Clean the distance collar and the mating surfaces of Connect the flexible pipe to the injector fuel leak--off
the clutch housing, and also scrape all residue of old pipe.
sealing compound from the mating surface of the en-
gine. Fit the electiric cable connected to the fuseholder box
and the retaining nut.
Spread LOCTITE sealing compound on the mating
surfaces of the engine and distance collar.Fit the dis- Fit the electric connections installed on the brake
tance collar on the studs screwed into the engine. pump and on the brake fluid reservoir.
Before Connecting tranmission casing to engine --
front axle assembly, grease discs hubs. Fit the cab heater delivery and return pipes and insert
and associated claps.
Check up the rear wheels with wooden wedges,
check that the hand brake is fully on and that the Connect all the electrical connections
fixed and mobile stands are well positioned.
Connect the throttle cable to the injection pump.
Fit and tighten the bolts securing the clutch housing
to the engine. Refit the 4WD transmission shaft and the relative
guard.
Make sure that no electrical leads or cables are
trapped between the two units. Refit the front ballast and secure with the vertical lock
pin.
Next rotate the crankshaft by turning the cooling fan,
so as to allow the sleeve to engage the splines on the Fiil oil to gearbox/transmission.
power take--off shaft.
Fill the coolant to engine cooling system.
Remove the stands of tool 380000236 from under
the engine and the gearbox/transmission and the
Reconnect the battery negative lead.
stand under the draw bar.

84176554 -- 03--2008
18 SECTION 18 -- CLUTCH -- CHAPTER 1

OVERHAUL
The clutch is removed, refitted and adjusted with the
universal outfit 293650.

Parts of the universal outfit 293650 Necessary

to adjust the VALEO clutch.
A. Plate 293332.
B. Central spacer
293728. ∅ 35mm (1.3779 in.) for 11”/11” clutch
293729. ∅ 40mm (1.5748 in.) for 12”/12” clutch
C. Gauge 293731.
D. Locknut 293730 for central spacer.
E. Side spacers 293726.
F. Studs 293725.
I. Blocks.
L. Handwheel 293739 securing the gauge.
M. Handwheels 293740 securing the side spacers.
N. Spacers for studs.

MDH1883A

Note -- Before fitting the clutch on the outfit 293650

it is advisable to remove the three bolts retaining the
flexible tabs that drive the PTO clutch pressure plate
ring from the supporting housing.

84176554 -- 03--2008
 SECTION 18 -- CLUTCH -- CHAPTER 1 19

To fit the clutch on the universal outfit 293650 pro-

ceed as follows:
-- place the central spacer (B) on the plate (A) and
position it with the gauge bearing surface at a
height of:
132 mm (5.1968 in.) (12”/12” clutches)
123 mm (4.8425 in.) (11”/11” clutch)
and lock it at this height with the locknut (D);
-- measure the thickness (S) of the PTO driven disc
of the relevant clutch and place the adjustable
side spacers (E) on the circumference of 240 mm
positioning them with the upper face at a height
(h) given by:
h = RV + S + B
where:
B additional distance to lower the PTO release
levers by 9 mm so as to use the gauge 293731
(with a difference in height between the PTO re-
lease levers and the transmission release levers
of 25 mm (0.9842 in.)) to check the coplanarity
2.2 mm (0.0886 in.) for 12”/12” clutches
(mod. JX95)
no increase (already using gauge 293731) for
11”/11” clutches
(mod. JX60, JX70, JX80 and JX90)
RV flywheel external lowering distance
2 mm (0.0784 in.) for 11”/11” clutches
(mod. JX60, JX70, JX80 and JX90)
0.5 mm (0.0197 in.) for 12”/12” clutches
(mod. JX95)
S = measured thickness of the PTO driven disc;

-- then lock the adjustable side spacers (E) with the

relevant handwheels (M);
-- rest the clutch assembly (of the PTO driven disc)
with the PTO pressure plate on the plate and se-
cure it with the three stud bolts (F, page 18),
equipped with blocks (I) and spacers (N) of the
necessary size.

10

84176554 -- 03--2008
20 SECTION 18 -- CLUTCH -- CHAPTER 1

Remove the nuts (7; page 6) for the PTO clutch re-
lease lever adjuster tie rods and gradually unscrew
the studs (F, page 18) thereby making it possible to
extend the Belleville spring and break down the
clutch into its parts.

11
Remove the three bolts retaining the flexible tabs
driving the main clutch pressure plate from the clutch
carrier housing and retrieve the pressure plate.

12

ATTENTION
When removing, overhauling and then refitting the
clutch, pay special attention not to move the main
clutch and PTO clutch pressure plate ring driving
tables from their original assembly position on the
pressure plate rings.

Check for wear on the clutch driven discs and replace

them if the retaining rivets are worn down to or ap-
proaching the friction material. Replace the disc
when the oil has soaked into the organic agglomer-
ate surfaces.
Check the friction surface conditions of the pressure
plates and the clutch casing.
If necessary, it is possible to reface them bearing in
mind that the dimensions (A, B, C and D) of the re-
faced parts must not decrease beyond the limits
shown in the figures below, in which case it would be
necessary to replace the parts.
Proceed as follows:
-- reface the surfaces of the pressure plates;
-- replace damaged or worn discs;
-- reface the surface of the clutch housing.

84176554 -- 03--2008
 SECTION 18 -- CLUTCH -- CHAPTER 1 21

Calculate the distance (D), removing material from

the bottom of the clutch housing, using the following
formula.
D = A + B + S1 + S2 + P + L

where:
A and B = distances measured of the two pres-
sure plates after refacing;
S1 and S2 = measurements of the PTO and main
clutch plates:
L = 2 mm (0.0784 in.) for 11”/11” clutches
mod. JX60, JX70, JX80 and JX90 MMH1885B

= 0.5 mm (0.0197 in.) for 12”/12” clutch 13

mod. JX95
Lowering on the flywheel;
P = 4.20 ÷ 4.30 mm (0.1653 ÷ 0.1693 in.)
for 11”/11” clutch
mod. JX60, JX70, JX80 and JX90
= 4.30 ÷ 4.40 mm (0.1693 ÷ 0.1732 in.)
for 12”/12” clutch
mod. JX95 The dimension the spring
must have to restore the original load.
-- check that the value obtained (D) is greater than
or equal to the measurement made on the clutch
to overhaul and that, in order to be able to restore
it, the distance (C, fig. 15 and 17) of the housing
must not decrease under the stated value. If this
is not so, replace one or both of the pressure
plates.
For 11”/11” clutches, check that the distance (E) is
greater than the value given on page 22 fig. 15 and
restore it if necessary.
If required, pass the friction surface over the engine
flywheel, remembering to restore the external lower-
ing of the flywheel on completing this process.
Refit the parts of the clutch using the specific tools of
outfit 293650 and taking care to:
-- position the Belleville spring (1) correctly on the
main clutch pressure plate (3), making the cen-
tring dowels (2) correspond with the notches (4);
-- adjust the clutch as directed below.

Note -- When reassembling, tighten the six bolts

fastening the flexible tabs driving the main and PTO
clutch pressure plates to the supporting housing to
a torque of 1.5 Nm (2.0337 ft lb).
14

84176554 -- 03--2008
22 SECTION 18 -- CLUTCH -- CHAPTER 1

MINIMUM PERMISSIBLE DIMENSIONS

AFTER REFACING PARTS SUBJECT TO
WEAR FOR VALEO CLUTCHES

11”/11” dual clutches

If it is necessary to reface the friction surface on the
flywheel, bear in mind that the maximum amount that
can be removed in relation to the nominal thickness
is 1 mm (0.0394 in.).
Once terminated, moreover, the external lowering
will need to be restored to 2 mm (0.0784 in.) (see
fig. 15).
-- 11”/11” dual clutch
mod. JX60, JX70, JX80, JX90
A. ≥12.50 mm (0.4921 in.)
B. ≥20.00 mm (0.7874 in.)
C. ≥18.00 mm (0.7087 in.)
D. ≥12.50 mm (0.4921 in.)
E. ≥2.50 mm (0.0984 in.)

1. Engine flywheel.
2. PTO clutch pressure plate.
3. Main transmission clutch pressure plate.
4. Supporting housing. 15

12”/12” dual clutches

If it is necessary to reface the friction surface on the A
flywheel, bear in mind that the maximum amount that
0.5 mm

B
can be removed in relation to the nominal thickness
is 1 mm (0.0394 in.).
Once terminated, the external refacing will need to
be re--set to 0.5 mm (0.0197 in.), as shown in fig-
ure 16 and 17.
C

A. = 352 E8 mm (13.8582 in.)

26166
B. = 313 mm (12.3228 in.)
C. = 73.5 mm (2.8937 in.) 16

-- 12”/12” dual clutch

mod. JX95
A. ≥15.50 mm (0.6102 in.)
B. ≥21.50 mm (0.8464 in.)
C. ≥20.50 mm (0.4921 in.)
D. ≥12.50 mm (0.8071 in.)

1. Engine flywheel.
2. PTO clutch pressure plate.
3. Main transmission clutch pressure plate.
4. Supporting housing. 17
84176554 -- 03--2008
 SECTION 18 -- CLUTCH -- CHAPTER 1 23

ADJUSTING THE VALEO CLUTCH

To adjust the clutch correctly it is necessary for the
release levers to be coplanar and set at the distances
(D and D1, page 6) in relation to the bearing surface
on the engine flywheel.

NOTE: For the 12”/12” clutches the distance D1 is re-

duced by 9 mm (0.3543 in.) (137 -- 9 = 128 mm
(5.3937 -- 0.3543 =5.0394 in.), see page 19.), lower-
ing distance of the point of contact with the thrust
bearing of the PTO release levers so as to use the
gauge 293731 where the difference between the re-
lease levers is 25 mm (0.9842 in.).

The adjustment can be made indistinctly with the

clutch on the bench or fitted on the engine flywheel.
1. Adjustment with clutch on bench.
Set the clutch on the plate of the universal outfit
293650 and lock it using the parts as described
above for disassembly.
Fit the gauge (C) and lock it with the handwheel (L)
for the universal outfit 293650.

Screw in or unscrew the adjuster screws (2) of the re-

lease levers for the main clutch (1) to obtain the clear-
ance (V1) between the ends of the gauge pins (C)
and the main clutch release levers. Then lock the
screws with the nuts (3).

C. Gauge.
L. Handwheel 293739.
V1 = 0.1 mm (0.0039 in.) Clearance to obtain between
the ends of the gauge pins (C) and release levers (1)
for 11”/11” clutch (mod. JX60, JX70, JX80, JX90) or:
= 0.1 mm (0.0039 in.) for 12”/12” clutch (mod. JX95).
1. Release levers.
2. Hex wrench.
3. Adjuster screw and locknut. 18

Screw in or unscrew the nuts (2) for the adjuster tie

rods of the release levers for the PTO clutch (1) to ob-
tain the clearance (V2) between the end of each re-
lease lever and the face of the gauge (C).

C. Gauge.
L. Handwheel 293739.
V2 = 0.1 mm (0.0039 in.) Clearance to obtain between
the gauge face (C) and release levers (1) for 11”/11”
clutch (mod. JX60, JX70, JX80, JX90) or:
0.1 mm (0.0039 in.) for 12”/12” clutch (mod. JX95).
1. Release levers.
2. Adjuster nut. 19
84176554 -- 03--2008
24 SECTION 18 -- CLUTCH -- CHAPTER 1

After adjusting the clutch lever, remove the hand-

wheel (L, page 18) for the universal outfit 293650. Fit
the press 380000458 (P) on the plate of the outfit, ad-
just the length of the screws (1) so they are coplanar
and rest on the release levers (3) of the PTO clutch
and use the press lever (P), as shown in the figure,
checking the PTO clutch gets released.
Then rest the screws (2) on the main clutch release
levers (4) and check that this clutch gets released.

20

1. Adjustment with clutch fitted on engine fly-

wheel
Insert the pin of the adjustment kit (pin T1 with gauge
T1 T2
T2) 380000612 (11”/11”, mod. JX60, JX70, JX80 and
JX90) or 380000292 (T1, for 12”/12” clutch, mod.
JX95) into the clutch driven disc shaft seats, making
sure the end makes contact with the bearing (10,
page 6) and press the relevant gauge against it
380000612 (T2, for 11”/11” clutch, mod. JX60, JX70,
JX80 and JX90) or 380000293 (T2, for 12”/12” clutch,
mod. JX95).

21

Then proceed as follows:

1
-- screw in or unscrew the main clutch release lever
adjuster screws so as to create a clearance be-
tween the end of the pins of the gauge (1) and the
main clutch release levers of:

0.1 mm (0.0039 in.) for 11”/11” clutch

mod. JX60, JX70, JX80, JX90

8.1 mm (0.3189 in.) for 12”/12” clutch 2

25366

mod. JX95 22
-- screw in or unscrew the PTO clutch release lever tween the end of the gauge face (1) and the PTO
adjuster screws so as to create a clearance be- clutch release levers (2) of:
84176554 -- 03--2008
 SECTION 18 -- CLUTCH -- CHAPTER 1 25

0.1 mm (0.0039 in.) for 11”/11” clutch

mod. JX60, JX70, JX80, JX90 2 1
8.1 mm (0.3189 in.) for 12”/12” clutch
mod. JX95

25367

23
ADJUSTMENT OF THE MAIN CLUTCH CON-
TROL LINKAGE (Op. 18.100.40) 1
Check that pedal free travel before clutch release is
approximately 40 mm . When free travel is down to
25 mm , adjust clutch as follows:

TRE0048A

24

-- Back off locknut (1) and rotate sleeve (2) counter-

clockwise.

-- Tighten locknut (1) ;

-- Ensure that pedal free travel is 25 mm (0.9842in.).

1 2

TRE0044A

25

84176554 -- 03--2008
26 SECTION 18 -- CLUTCH -- CHAPTER 1

PTO CLUTCH LINKAGE ADJUSTMENT

(VALEO CLUTCH) 1
The only clutch adjustment required is to check and, if
necessary, adjust the clutch lever free travel. This is the
amount of lever movement from fully released (control
cable) position (A) to the point where resistance is first A
encountered.
The clutch free travel (C, fig. 27) must be 4.5 mm
(0.1772 in.). When this distance is down to 2.5 mm
(0.0984 in.), adjust the clutch as follows: B
-- Move the PTO clutch lever (1) fig. 26 to engaged
position (A) (fully raised). TRE0171A

26
-- Loosen the locknut (1) fig. 27 and remove the split
pin (2).

-- Turn the sleeve (3) to completely tighten the cable.

-- Slacken the sleeve (3) for 4 turns (approximately

4.5 mm) to lenghten the cable length. 1
3
-- Lock the split pin (2), so as to restore the travel with 2
no load to 4.5 mm (0.1772 in.) then tighten the lock-
nut (1).
C
TRE0173A

27

84176554 -- 03--2008
 SECTION 18 -- CLUTCH -- CHAPTER 1 27

PTO CLUTCH LINKAGE ADJUSTMENT

(LUK CLUTCH) 1
Single Lever PTO (Not for all markets)
The only clutch adjustment required is to check and, if
necessary, adjust the clutch lever free travel. This is the
amount of lever movement from fully released (control A
cable) position (A) to the point where resistance is first
encountered.
The clutch free travel (C, fig. 27) must be 2.5 mm
(0.0984 in.). When this distance is less or more than 2.5 B
mm (0.0984 in.), adjust the clutch as follows:
-- Move the PTO clutch lever (1) to disengaged TRE0171A
position (A) (fully raised). 28

-- Loosen the locknut (1) and remove the split pin (2)
fig. 29.

-- Turn the sleeve (3) to tighten the control cable

completely.

-- Slacken the sleeve (3) for 2 turns (approximately 1

2.5 mm) to lenghten the cable length. 3
2
-- Lock the split pin (2) so as to restore the travel with
no load to 2.5 mm (0.0984 in.) then tighten the lock-
nut (1). C
TRE0173A

29

PTO CLUTCH LINKAGE ADJUSTMENT

(LUK CLUTCH)
Single Lever PTO (Not for all markets)
(Only for JX95 Model)
Above adjustment procedure is also the same for this
model. Only the difference is the connection point of
sleeve (1) fig. 30 and the lever (2) fig. 30. 2 1
A
The sleeve (1) fig. 30 is connected to the lever (2)
fig. 30 from the upper hole (A) fig. 30. B
TRE3039A

30

NOTE: Connection point of the sleeve (1) fig. 30 to

the lever (2) fig. 30 is point B fig. 30 for the all
remaining models (JX60, JX70, JX80 and JX90).

84176554 -- 03--2008
28 SECTION 18 -- CLUTCH -- CHAPTER 1

84176554 -- 03--2008
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1 1

SECTION 21 -- TRANSMISSIONS

Chapter 1 -- Mechanical Transmission (12 x 4)

CONTENTS

Section Description Page

21 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3&5
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
21 110 Removal -- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see sect 27

21 000 -- MAIN DATA -- TIGHTENING TORQUES -- SECTIONS -- TOOL --

DESCRIPTION AND OPERATION -- FAULT DIAGNOSIS

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--speed, constant--mesh with synchro-

nisers on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helical gears
Range gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordinary gear train with 3 forward
ranges and 1 reverse range those giv-
ing a total of 12 forward and 4 reverse
speeds
-- Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . spur gears
-- Reduction ratios :
D Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23x17
= 1:(5.49)
43x50
D Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23x27
= 1:(2.35)
43x34
D Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gearbox and range gear controls . . . . . . . . . . . . . . . . . . . . . Independent, hand operated levers lo-
cated on right--hand side of operator
Thickness of gearbox driving shaft adjustment ring mm 3.00--3.25--3.50--3.75--4.00
(5, page 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (in.) (0.1181--0.128--0.1378--0.1476--0.1575)
Inside diameter of gearbox driven gears . . . . . . . . . . . . . . . . mm 50.050 -- 50.075
(in.) (1.9705 -- 1.9715)
Outside diameter of bushings (17, page 5) . . . . . . . . . . . . . . . mm 49.925 -- 49.950
(in.) (1.9655 -- 1.9665)
Clearance between gears and bushings . . . . . . . . . . . . . . . . . mm 0.100 -- 0.150
(in.) (0.0039 -- 0.0059)
Diameter of gearbox driven shaft (19, page 5) . . . . . . . . . . . . mm 39.175 -- 39.191
(in.) (1.5423 -- 1.5429)
Inside diameter of bushings (17, page 5) . . . . . . . . . . . . . . . . mm 39.200 -- 39.239
(in.) (1.5433 -- 1.5448)
Clearance between shaft and bushings . . . . . . . . . . . . . . . . . mm 0.009 -- 0.064
(in.) (0.0004 -- 0.0025)

(continued overleaf)
84176554 -- 03--2008
2 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

TRANSMISSION AND RANGE GEAR MAIN DATA

(continued)

Diameter of power take off (PTO) clutch shaft (4, page 5) . . . . . . mm 24.979 -- 25.000
(in.) (0.9834 -- 0.9843)
Inside diameter of fitted bushing (1, page 5) . . . . . . . . . . . . . . . . . . mm 25.040 -- 25.092 (1)
(in.) (0.9858 -- 0.9879)
Clearance between PTO clutch shaft and relative bushing . . . . . mm 0.040 -- 0.113
(in.) (0.0016 -- 0.0044)
Interference fit between bushing on driving shaft . . . . . . . . . . . . . . mm 0.037 -- 0.091
(in.) (0.0015 -- 0.0036)
Springs (16, page 7) for detent balls on gearbox and range gear
control rods :
-- Spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 30
(in.) (1.1811)
-- Length of spring under load of 50--56 N (11.3148--12.5059 lb) mm 25.5
(in.) (1.0039)
Gearbox and range gear control lever retaining springs:
-- Spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 75
(in.) (2.9528)
-- Length of spring under load of 94--104 N (21.1740--23.3796 lb) mm 42
(in.) (1.6535)
(1) Measurement to obtain after fitting without reaming.

TORQUE VALUES

Torque settings
PARTS Thread
Nm ft lb

Retaining bolts for upper cover of rear transmission / gearbox (C1) M 10 x 1.25 59 43.5162

Bolts for securing lift to rear transmission box (C2) . . . . . . . . . . . . . . M 12 x 1.25 98 72.2811

Bolts for securing PTO box to transmission / gearbox (C3) . . . . . . . M 16 x 1.5 221 163.0012

Bolts for securing flexion bar to transmission / gearbox case (C4) M 16 x 1.5 221 163.0012

Nuts for stud bolt securing final drive to transmission / gearbox (C5) . M 12 x 1.25 98 72.2811

Nuts for securing steel plate disc to wheel drive hub (C6) . . . . . . . . . . M 18 x 1.5 255 188.0783

Nuts for bolts securing steel plate disc to drive wheel rim (C7) . . . . . M 16 x 1.5 245 180.7027

Ring bevel gear retaining bolts (C8) ............................ M 12 x 1.25 123 90.7201

Bevel gear pair support retaining bolts (C9) . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 59 43.5162

84176554 -- 03--2008
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1 3

MAIN DATA -- GEARBOX AND RANGE GEAR

C1 59 Nm C2 98 Nm

C4 221 Nm C3 221 Nm

C9 59 Nm
C7 245 Nm

C6 255Nm
C8 123 Nm
C5 98 Nm

TRE0550A

1
TOOLS List of special tools required for the various opera-
tions described in this Section:
Warning -- The operations described in this Section 380000236 Tractor dismantling trolley.
can only be carried out using the ESSENTIAL tools
marked on the right side with an (X). 380000227 Clutch casing lifting hook.
However, for greater safety and to obtain the best re- 380000301 Rotating overhaul stand.
sults while saving time and effort, it is recommended
that these essential tools are used together with the 380000271 Front bracket (with 380000301).
special tools listed here as well as certain tools which
380000272 Rear bracket (with 380000301).
are to be made following the sectional drawings giv-
en in this manual. X 380000838 Adaptor for removal of reverse gear
pin (with 380000549).
84176554 -- 03--2008
4 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

Drift to be made for removal of gearbox driving shaft

(tool to be stamped no. 50006 -- measurement in
mm).
Make in material UNI C40.

26215

Tool to be made for adjustment of gearbox driving

shaft bearings (tool be stamped no. 50007 -- mea-
surement in mm).
Make in material Aq 45.

26216

26217

4
Tool to be made for removal of rear bearing of range gear driving shaft and the driving gear for the slow
speeds (tool to be stamped no. 50028 -- Measurements in mm).
Make in UNI C40.

Note -- Make two parts from the tool shown at Figure 4, uppermost one .

84176554 -- 03--2008
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1 5

5
Longitudinal cutaway section through gearbox and range gear.
1. Power take--off (PTO) shaft support bushing. 11. Retaining half--rings.
2. Seal. 12. Driven gear for reverse speeds.
3. Gearbox driving shaft. 13. Driven gear for low speeds.
4. PTO shaft. 14. Selector sleeve for high and low speeds.
5. Driving shaft adjustment ring. 15. Circlip.
6. Range gear driving shaft. 16. Synchroniser for 1st and 2nd speeds.
7. Control gear for reverse and middle speeds. 17. Support bushings for gearbox driven gears.
8. Upper cover. 18. Synchroniser for 3rd and 4th speeds.
9. Driving gear for middle speeds. 19. Gearbox driven shaft.
10. Bevel pinion shaft.

Note -- On assembly apply sealant to surfaces X following the indications given on page 6 in this Section.

84176554 -- 03--2008
6 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

TRE0556A

Sealing compound application diagram for mating surfaces between engine, clutch casing and rear
transmission--gearbox.
The types of sealing compound to use are indicated on page 1, Sect. 00.
84176554 -- 03--2008
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1 7

TRE0557A

Cross--section through gearbox and range gear

1. Range gear control relay rod. 14. Circlip.

2. Gearbox control relay rod. 15. Upper cover of transmission / gearbox.
3. Low and high speeds selector rod. 16. Spring.
4. Normal and reverse speeds selector rod. 17. Detent ball.
5. 3rd and 4th speed selector rod. 18. Speed control safety pawl.
6. 1st and 2nd speed selector rod. 19. Plug.
7. Range gear driving shaft. 20. Speed control safety pawl.
8. Intermediate gear for reverse speeds. 21. Range control safety pawl.
9. Control gear for normal and reverse speeds. 22. Plug.
10. Driving gear for normal speeds. 23. Selector rod for low and high speeds.
11. Journal of intermediate gear (8). 24. Selector rod for middle and reverse speeds.
12. Journal bolt (11). 25. 3rd and 4th speed selector rod.
13. Bearings. 26. 1st and 2nd speed selector rod.

Note --Before plugs (19 and 22) are bolted in, they must be covered with one of the sealants listed on page 1,
Sect. 00.

84176554 -- 03--2008
8 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

DESCRIPTION AND OPERATION

4--speed gearbox with constant--mesh helical gears The range gear provides 3 forward ranges and 1 re-
controlled by two synchronisers. verse range.
The range gear has cascade--type constant--mesh The gearbox and the range gears are controlled by
spur gears, excluding reverse. two independent levers located on the right--hand
The driven gears of the range gear are keyed directly side of the operator.
onto the bevel pinion shaft.

GEARBOX AND RANGE GEAR TROUBLESHOOTING

Problems Possible causes Remedies

Spontaneous disengagement of 1. Levers and relay linkages in- Adjust correctly.

gearbox and range gear. correctly adjusted.

2. Selector rod retaining springs Replace the springs.

defective.

3. Defective teeth on synchro- Remove the transmission/gearbox

niser or engagement sleeve. and replace the synchronisers or the
engagement sleeves.

4. Incomplete engagement trav- Eliminate the cause and restore full

el. engagement travel.

Difficulty in engaging the gearbox 1. Control levers and linkages in- Adjust correctly.
and range gear. correctly adjusted.

2. Stiffness and / or partial sei- Check pivot points and lubricate.

zure of control levers and link-
ages.

3. Main clutch drag. See page 8, Sect. 18.

4. Synchronisers or engage- Remove the transmission / gearbox

ment sleeves defective. and replace the synchronisers or en-
gagement sleeves.

5. Internal controls do not slide Perform the checks and overhaul for
freely : rods, forks and needed parts.
sleeves.

Gearbox or range gear unduly 1. Internal component/s worn or Remove the transmission / gearbox
noisy. defective. and replace the worn / defective
parts.

84176554 -- 03--2008
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 1

SECTION 21 -- TRANSMISSIONS

Chapter 2 -- Reverser

CONTENTS

Section Description Page

21 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
21 110 Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

21 000 -- MAIN DATA -- TIGHTENING TORQUES -- SECTIONS -- TOOLS -- DESCRIPTION AND

OPERATION -- FAULT DIAGNOSIS

SYNCHRONISER REVERSER MAIN DATA

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical type spur gear unit,

located between the main clutch
and the gearbox. Comprises 1
driving gear, 1 intermediate gear
and
1 idle gear.

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand lever located on left--hand

side of the operator

GEARBOX MAIN DATA

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 speed, constant--mesh, with

synchronisers on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helical

Reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordinary gear train with 3 ranges

providing a total of 12 gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . spur

Gearbox and reduction unit controls . . . . . . . . . . . . . . . . . . . . . . . . Independent, with two hand levers
located on right--hand side of the
operator

For other main data see chapter 1.

84176554 -- 03--2008
2 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

TORQUE VALUES

Torque Settings
PARTS Thread
Nm ft lb

Bolt or nut securing clutch / reverser casing to engine (C1) . . . . . M 12 x 1.25 98 72.2811

Sleeve cover retaining nuts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 17 12.5386

Reverser driven shaft cover retaining bolts (C3) . . . . . . . . . . . . . . . M 8 x 1.25 28 20.6517

Reverser driven shaft plate retaining bolts (C4) . . . . . . . . . . . . . . . M 10 x 1.25 64 47.2040

Bolts securing clutch / reverser housing to gearbox / rear tran-

smission (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 72.2811

C1 98 Nm

C2 17 Nm

C3 28 Nm

C4 6 Nm
C5 98 Nm
TRE0558A

84176554 -- 03--2008
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 3

TOOLS List of special tools required for the various opera-

tions described in this Section :
Warning -- The operations described in this Section
can only be carried out using the ESSENTIAL tools 380000236 Tractor dismantling trolley.
marked with an (X). 380000227 Clutch casing lifting hook.
However, for greater safety and to obtain the best re-
sults while saving time and effort, it is recommended 380000301 Rotating overhaul stand.
that these essential tools are used together with the 380000271 Front support bracket (with
special tools listed here as well as certain tools which 380000301).
are to be made following the sectional drawings gi-
ven in this manual. 380000272 Rear support bracket (with
380000301).

4 5 6
3 7

10
9 8
TRE0559A

Longitudinal cutaway section of synchroniser reverser

1. Synchroniser reverser control shaft. 6. Reverser control synchroniser.

2. Seal. 7. Seal.
3. Roller bearing. 8. Synchroniser reverser driven gear.
4. Synchroniser reverser driving gear. 9. Journal for driven gear (8).
5. Roller bearing. 10. Seal.

Note -- On assembly apply jointing compound to surfaces X as indicated on page 6, chapter 1.

84176554 -- 03--2008
4 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

TRE0560A

Synchroniser reverser sectional views

1. Synchroniser reverser selector fork. 11. Journal of idle gear (7).
2. Reverser synchroniser. 12. Stop plate for journals (11 and 13).
3. External reverser control lever. 13. Synchroniser reverser driven gear.
4. Seal. 14. Synchroniser reverser control rod.
5. Circlip. 15. Spacer.
6. Thrust washer. 16. Reverser synchroniser.

7. Synchroniser reverser idle gear. 17. Detent ball.

8. Roller bearing. 18. Spring for detent ball (17).

19. Detent ball retaining bolt (the bolt must be cov-
9. Thrust washer.
ered in one of the sealants listed on page 1,
10. Seal. Sect. 00).
84176554 -- 03--2008
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 5

DESCRIPTION AND OPERATION

The synchroniser reverser is a mechanical device fected by means of a synchroniser located in the
which makes it possible to obtain 12 forward and 12 group of gears.
reverse gears. It is controlled by a specific lever loca-
ted on the platform to the left of the operator. The synchroniser reverser is installed inside the
clutch casing between the clutch and the gearbox.
The synchroniser reverser is comprised of a group
of three spur gears : driving reverser gear, interme- It is lubricated by the oil in the rear transmission /
diate gear and driven reverser gear. Selection is ef- gearbox.

SYNCHRONISER REVERSER TROUBLESHOOTING

Problems Possible causes Remedies

Spontaneous disengagement of 2. Incorrect adjustment of exter- Adjust correctly.

the synchroniser reverser. nal levers and linkages.

3. Synchroniser engagement Remove the clutch casing and re-

teeth damaged. place the synchroniser.

4. Engagement travel incom- Eliminate the cause and restore full

plete. engagement travel.

Difficulty in engaging the reverser. 1. Incorrect adjustment of exter- Adjust correctly.

nal levers and linkages.

2. Stiffness and / or partial sei- Check pivot points and lubricate.

zure of external levers and
linkages.

3. Dragging of main clutch. See page 8, Sect. 18.

4. Synchroniser damaged. Remove the clutch casing and re-

place the synchroniser.

5. Internal controls do not slide Perform the checks and overhaul for
freely: rods, forks and needed parts.
sleeves.

Synchroniser reverser unduly 1. Worn or damaged internal Remove the clutch casing and re-
noisy. part/s. place damaged part/s.

84176554 -- 03--2008
6 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

CLUTCH/REVERSER CASING
Replacement (Op. 21 110 85)

WARNING
Handle all parts with great care.
Never insert fingers or hands between one piece and
another. Wear suitable safety clothing, i.e., safety
goggles, gloves and shoes.

1. Fix the clutch / reverser casing (1) to stand

380000301 (2) using the two brackets
1 2
380000271 and 380000272.

24984

2. Withdraw the spring pin and recover the link le-

ver (1) and the internal lever (2). 1 2

26185

5
3. Unscrew the retaining bolt (1) and recover the
detent ball and spring. 1

24989

6
84176554 -- 03--2008
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 7

4. Remove the circlip (1) and take out : bearing,

thrust washers, synchroniser assembly together 1
with the selector fork and its rod, the reverser
driven gear (2) complete with roller bearings and
spacer. 2

26186

7
5. Remove the reverser driving gear (1) complete
with roller bearings. 1

24994

6. Remove the circlip (1) securing the reverser driv-

ing shaft. 1

24995

7. Working from the front of the clutch / reverser

casing with an aluminium drift (2), drive out the 1 2
reverser driving shaft (1) and remove it from the
rear of the casing.

24997

10

84176554 -- 03--2008
8 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

8. Detach the retaining springs and withdraw the

sliding sleeves (1). 1

24999

11
9. Unscrew the retaining bolts and remove the
sleeve cover / support (1). 1

25000

12
10. Unscrew the two securing bolts (1) of the sliding
sleeve control forks (2). 1 2

25001

13
11. Withdraw the external clutch control levers (1)
and remove the forks (2). 1

2
25002

14
84176554 -- 03--2008
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 9

12. Relieve the staking and unscrew bolt (1) secur-

ing the stop plate for the journal of the reverser 1
driven shaft (2) and the intermediate gear jour-
nal, removing the latter from the rear of the cas-
ing.

13. Refitting of the synchroniser reverser according

to the following instructions:
— Refer to the illustrations on pages 3 and 4 to
check the correct orientation of the various parts. 2
— Refer to the torque settings on page 2.
— Install the intermediate gear journal complete 25004

with the various associated parts, and the journal 15

of the reverser driven gear and secure with the
relative stop plate and bolt.
— Fit the sliding sleeve control forks on the relative
clutch control levers and fix the previous to the
latter.
— Fit the sliding sleeve cover and its support.
— Fit the sliding sleeve assembly to the relative
support and secure with the springs.
— Insert the reverser driving shaft from the rear of
the casing and fix it to the clutch / reverser casing
with the circlip.
— Position the reverser driving gear complete with
bearings on the driven shaft.
— Fit the reverser driving gear complete with the
bearings and spacers.
— Fit the synchroniser assembly complete with
control forks, rod, thrust washers and bearing,
and fix in position with the relative circlip.
— Fit the detent ball, spring, and bolt in the locked
position after covering the bolt using one of the
sealants listed on page 1, Sect. 00.
— Position the internal lever and link lever and fix
with the relative spring pin.
— Remove the clutch / reverser casing from the
stand 380000301.

84176554 -- 03--2008
10 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

84176554 -- 03--2008
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 3 1

SECTION 21 -- TRANSMISSIONS

Chapter 3-- Reverser and creeper unit

CONTENTS

Section Description Page

21 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
21 110 Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

21 000 -- MAIN DATA -- TIGHTENING TORQUES -- SECTION VIEWS -- TOOLS -- DESCRIPTION AND
OPERATION -- FAULT DIAGNOSIS

SYNCHRONISER REVERSER--CREEPER UNIT MAIN DATA

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical, spur gears, located

between engine and gearbox.
Comprising 1 driving gear, 1
intermediate gear and 1 idle
gear.
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by hand lever located on
left--hand side of operator

CREEPER UNIT MAIN DATA

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordinary gear train with spur

gears, located between main
clutch and gearbox, in series
with the reverser.
Provides 20 forward speeds and
12 reverse speeds
Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18x26
= 1:5.524
55x47

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by hand lever located on

left--hand side of operator

GEARBOX MAIN DATA

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--speed constant mesh,
synchronised on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helical
Range gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordinary gear train with three
ranges for a total of 12 speeds
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . spur gears
Gearbox and range gear controls . . . . . . . . . . . . . . . . . . . . . . . . . Independent, by two hand levers
For further data see chapter 1.

84176554 -- 03--2008
2 SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

TORQUE VALUES

Torque Settings
PARTS Thread
Nm ft lb

Bolt or nut securing clutch casing -- reverser and creeper unit to the
engine (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 72.2811

Sleeve cover nuts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 17 12.5385

Synchroniser reverser -- creeper unit driven shaft cover nuts (C3) M 8 x 1.25 17 12.5385

Gearbox driving and driven shaft bearings cover screws (C4) . . M 8 x 1.25 28 20.6517

Bolt securing clutch casing -- reverse and creeper unit to the rear
transmission--gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 72.281117

TRE0561A

84176554 -- 03--2008
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 3 3

TOOLS List of special tools required for the various opera-

tions in this Section :
Warning -- The operations described in this Section
can only be carried out using the ESSENTIAL tools 380000236 Tractor dismantling stand.
marked with an (X).
However, for greater safety and to obtain the best re- 380000227 Clutch casing lifting hook.
sults while saving time and effort, it is recommended
that these essential tools are used together with the 380000301 Rotating overhaul stand.
special tools listed here as well as certain tools which
are to be made following sectional drawings given in 380000271 Front bracket (with 380000301).
this manual.
380000272 Rear bracket (with 380000301).

Support bracket for installation of gearbox driving

shaft seal (mark tool 50043) (Dimensions in mm).
Part of kit 50043 -- Make tool in UNI C40.

26191

26192

2
Tool for gearbox driving shaft seal (mark tool 50137)
(Dimensions in mm)
make tool in UNI C40.

84176554 -- 03--2008
4 SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

2 3 4 5 6

10 8 7
9

TRE0562A

Longitudinal section through reverser--creeper unit

1. Reverser and creeper unit control shaft. 6. Gearbox driving shaft control gear.
2. Seal. 7. Creeper unit driven gear.
3. Circlip. 8. Thrust washer.
4. Creeper unit control gear. 9. Reverser driven shaft.
5. Reverser--creeper unit synchroniser. 10. Seal.

Note -- On assembly apply sealing compound to the surfaces X following the indications given on page 6 in chap-
ter 1.

84176554 -- 03--2008
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 3 5

TRE0563A

Cross sectional views of synchroniser reverser -- creeper unit

1. Reverser control fork. 12. Roller bearing.

2. Detent ball. 13. Journal for gear (11).
3. Reverser synchroniser. 14. Seal.
4. Seal. 15. Reating screw for journal (13).
5. External reverser control lever. 16. Fast speeds lock pawl.
6. Creeper unit control fork.
17. Reverser and creeper unit control rod.
7. Detent ball.
18. Reverser synchroniser.
8. External creeper control lever.
19. Creeper unit control gear.
9. Seal.
20. Retaining screw for rod (17) (apply one of the
10. Creeper unit control gear. sealing compounds listed on page 1, Sect. 00 to
11. Intermediate gear for reverser. the screw).
84176554 -- 03--2008
6 SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

DESCRIPTION AND OPERATION

The reverser--creeper unit is a mechanical device and is controlled by a hand lever located on the right--
providing the possibility to obtain 20 forward speeds hand side of the operator.
and 12 reverse speeds.
The reverser comprises three spur gears : the re-
The creeper unit engages only in slow and middle verser driving gear, an intermediate gear and the re-
ranges, a mechanical interlock prevents creeper en- verser driven gear; the reverser is engaged by
gagement in the fast ranges. means of a synchroniser located in the gear assem-
bly.
The creeper unit comprises a group of three spurs
gears : a sliding control gear, a synchroniser control The reverser--creeper unit is installed inside the
gear and a driven gear; the unit utilises the same syn- clutch casing between the clutch and the gearbox.
chroniser as the reverser.
Lubrication is provided by the oil contained in the rear
The creeper is installed in series with the reverser transmission--gearbox.

SYNCHRONISER REVERSER--CREEPER UNIT TROUBLESHOOTING

Problems Possible causes Remedies

Spontaneous disengagement of 14. External levers and linkages Adjust correctly.

the reverser--creeper unit. incorrectly adjusted.

15. Synchroniser teeth damaged. Remove the clutch casing and re-
place the synchroniser.

16. Engagement travel incom- Eliminate the cause and restore full
plete. travel.

Difficulty in engaging the revers- 1. External levers and linkages Adjust correctly.
er--creeper unit. incorrectly adjusted.

2. Stiffness and / or partial sei- Check pivot points and lubricate.

zure of external levers and
linkages.

3. Main clutch drag. See page 8, Sect. 18.

4. Synchroniser defective. Remove the clutch casing--gearbox

and replace the synchroniser.

5. Internal control elements do Perform the checks and overhaul for

not slide freely : rods, forks needed parts.
and sleeves.

Reverser--creeper unit unduly 1. Internal component/s worn or Remove clutch casing and replace
noisy. defective. defective parts.
84176554 -- 03--2008
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 3 7

CLUTCH CASING -- SYNCHRONISER

REVERSER AND CREEPER UNIT

Replacement (Op. 21 110 87)

WARNING
Handle all parts with great care.
Never place your hands between one part and anoth-
er. Wear suitable safety clothing, i.e. safety goggles,
gloves and shoes.

To gain access to the synchroniser reverser--creeper

unit, first remove the cab or platform following the in-
structions given in Sect. 27 and remove the clutch
casing as described in Sect. 18, and then proceed as
follows :

1. Fix the casing to the rotating stand 380000301

using the brackets 380000271 and 380000272.

22893

2. Remove circlip (1) and slide out constant mesh

gear (2).

22894

6
3. Remove circlip (1) of reverser transmission driv-
ing shaft.

26198

7
84176554 -- 03--2008
8 SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

4. Remove plug and remove the control lever re-

taining pin (1).

26199

5. Remove the reverser synchroniser assembly (1)

together with control forks and gears.

26200

9
6. Withdraw the driven shaft gear (1) together with
the roller bearings and remove the thrust wash-
er.

26201

10
7. Remove the control fork retaining springs (2) and
withdraw the clutch pressure plate bearing as-
sembly (1).

26202

11
84176554 -- 03--2008
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 3 9

8. Unscrew the retaining screws (2) and remove

the control forks (1).

26203

12

9. Unscrew the retaining screw (15, page 5) and

withdraw the reverser intermediate gear assem-
bly (1).

26204

13
10. Unscrew the retaining bolts and remove the cov-
er (1).

22902

14
11. From the rear of the casing, withdraw the shaft
(1) complete with the relative bearing.

26205

15

84176554 -- 03--2008
10 SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

12. Unscrew the retaining bolts and remove the cov-

er--support (1).

26206

16

13. Remove the circlip (2) and withdraw the drive--

shaft (1) complete with bearing.

26207

17
14. Remove the circlip (1).

26208

18
15. Remove the driveshaft seal (1) using a suitable
implement.

26209

19
84176554 -- 03--2008
 SECTION 21 -- TRANSMISSIONS -- CHAPTER 3 11

16. To refit all the reverser and creeper components

in the casing follow the instructions below :
— Refer to the illustrations on pages 4 and 5 for
the orientation of the various components.
— Adhere to the torque setting values prescribed
on page 2.
— To install the seal (1, fig.19 ) follow the instruc-
tions in steps 17.-- 24.
— Install the driveshaft complete with bearing and
circlips.
— Fit the cover--support.
— Install the reverser and creeper driven gear
shaft.
— Fit the cover for the driven gear shaft and secure
with the relative screws.
— Install the reverser intermediate gear assembly
and secure with the relative screw.
— Install and fix the clutch control forks to the rela-
tive levers.
— Install the pressure plate bearings and hold in
place with the relative springs.
— Install the driven gear complete with bearing and
thrust washer.
— Install the complete synchroniser assembly and
secure with the relative circlip.
— Fit the rod retaining screw coated with one of the
sealing compounds listed on page 1, Sect. 00.
— Install the gear on the reverser driven shaft and
secure with the relative circlip.
— Remove the clutch casing --reverser and creeper
unit from the stand 380000301.

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

17. Fit the circlip (1, fig.18 ) in its seat.

18. Make the bracket of tool 50043 (4) and the tool
50137 (5) (see page 3). 1
19. Fit the bracket (3) on the clutch casing, insert the 5
installation drift (4) in the seal seat in contact with 2
the circlip (1, fig. 18).
20. Screw in nut (1) to obtain a distance (H) between 3
the bracket and nut of 3.3 -- 3.6 mm (0.1299 --
0.1417 in.) and secure the latter with the locknut 4
(5).

26210

20

84176554 -- 03--2008
12 SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

Note -- Leave the drift (1) with the nut in the position
reached on completion of the installation operation,
and on future seal installation operations simply
check that the distance (H, fig. 20) is as prescribed.

21. Remove the drift (1), the bracket (2) and the cir-
clip (1, fig. 18).
22. Locate the new seal in its seat (see page 6 for
correct orientation of seal), refit the bracket (2)
on the clutch casing and insert the drift in the
26211
bracket.
21
23. Force the seal in until the nut (1, fig. 20) reaches
up against the bracket (2).
24. Dismantle the bracket (2), remove the drift (1)
and proceed with the installation of the other
components.

84176554 -- 03--2008
 SECTION 23 − DRIVE LINES − CHAPTER 1 1

SECTION 23 − DRIVE LINES

Chapter 1 − Drive Lines

CONTENTS

Section Description Page

23 000 Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Torque settings and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cross−Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
23 101 26 Transmission shafts and guard (Disassembly − Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . 4
23 101 40 Drive gear housing (Removal − Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
23 101 42 Drive gear housing removed (Disassembly − Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

MAIN SPECIFICATION

Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34/24x24/34= 1 to 1

Relay lever pad width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 7.978 − 8.000
(in.) (0.3141 − 0.3150)
Pad seat width in driven gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 8.280 − 8.370
(in.) (0.3260 − 0.3295)
Pad clearance in seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.280 − 0.460
(in.) (0.0110 − 0.315)

Relay lever pivot diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 15.973 − 16.000

(in.) (0.6289 − 0.6299)
Pivot housing bore in casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 16.016 − 16.059
(in.) (0.6305 − 0.6322)
Pivot clearance in housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.016 − 0.086
(in.) (0.0006 − 0.0124)

Relay lever detent spring length

− Free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 130
(in.) (5.1181)
− Under 178.2 to 197.8 N (40 to 44 lb ) . . . . . . . . . . . . . . . . . . . . . . mm 142.5
(in.) (5.6102)

MAIN SPECIFICATION OF DRIVE SHAFT

Front drive sleeve adjustment see page 4

Front drive sleeve shim thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2.2.−2.5−2.8−3−3.3−3.7−4−4.3

(in.) (0.0866−0.0984−0.1102−0.1181−
0.1299−0.1457−0.1575−0.1693)

84176554A1 − 10 − 2010
2 SECTION 23 − DRIVE LINES − CHAPTER 1

TORQUE SETTINGS

C12

C13

TRE0401A

TRE0400A

Torque setting
PART TO BE TORQUED Thread
Nm ft lb
Transmission shaft central support retaining bolt (C12) . . . . . . . . . M 12 x 1.5 98 72.2811
Drive gear housing retaining bolt (C13) . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 72.2811

TOOLS
380000821 Drive shaft seal key

84176554A1 − 10 − 2010
 SECTION 23 − DRIVE LINES − CHAPTER 1 3

5
22
6
25

x
10
C12 11

30

4
56 39 27
28 29 12
TRE0402A
TRE0403B

Sectional views of transfer box:

C12 = Drive shaft centre bearing capscrew 25. Roll pin

C13 = Axle drive housing capscrew 26. Intermediate shaft
X = On assembly,thoroughly clean and degrease 27. Dust exculuder
mating surface X. 28. Seal
4. Driven gear 29. Retaining ring
5. Intermediate gear 30. Splined driven shaft
6. Needle roller bearing 39. Drive shaft guard
10. Driven shaft 56. Centre bearing
11. Guide screws
22. Dentent plunger

84176554A1 − 10 − 2010
4 SECTION 23 − DRIVE LINES − CHAPTER 1

Op. 23 101 26
TRANSMISSION SHAFTS AND GUARD
Disassembly − Assembly

WARNING
Handle all parts with great care.
Do not place hands or fingers between one part and
another.
Always wear the prescribed safety clothing, including
protective glasses, gloves and shoes.

To remove, proceed as follows:

1.Disconnect the negative battery lead.

1

3
2.Remove the front, centre and rear screws securing
the front axle prop shaft guard and remove the 1
guard (1).
3.Remove circlip (2) fig. 5 and move sleeve (1) in the
direction shown by the arrow to disengage it from
the splined shaft of the front axle.
4.To re−fit the transmission shaft and guard, proceed
as follows:

WARNING
Use suitable tools to align holes. NEVER USE FIN- 25038
GERS OR HANDS.
4

1 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 to 1.5 mm
(0.0394 to 0.0591 in.) (see Section 25 page 9).
25040
− Fit and secure the guard.
5

84176554A1 − 10 − 2010
 SECTION 23 − DRIVE LINES − CHAPTER 1 5

Op. 23 101 40
DRIVE GEAR HOUSING ASSEMBLY
Removal− Installation

WARNING
Handle all parts with great care.
Do not place hands or fingers between one part and
another.
Always wear the prescribed safety clothing, including
protective glasses, gloves and shoes.

To remove, proceed as follows:

1.Carry out operation 23 101 26 Transmission
shafts and guard removal (see page 4)
2.Remove the plug (1) and drain the oil from the 1
transmission box/gearbox.

TRE0404A

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

TRE0405B

7
4.Remove the screws (1) that hold the drive gear
housing (transfer box) to the transmission housing. 1

5.Remove the drive gear housing from the transmis-

sion housing.

TRE0406A

84176554A1 − 10 − 2010
6 SECTION 23 − DRIVE LINES − CHAPTER 1

6.To re−fit the drive gear housing, proceed as fol-

lows:

WARNING
Use suitable tools for aligning holes. DO NOT USE
YOUR HANDS OR FINGERS.
Refer to the tightening torques shown on page 2.
Carefully clean the contact surfaces.

Apply sealing compound (approx. 2 mm (0.0787 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.

Carry out operation 23 101 26 Transmission shafts

and guard installation (see page 4).

Fit the drive shaft guard.

26283

Mastic application diagram for assembly of

drive gear housing to transmission housing.

84176554A1 − 10 − 2010
 SECTION 23 − DRIVE LINES − CHAPTER 1 7

TRANSFER BOX, UNIT REMOVED

Disassembly − Assembly (Op. 23 101 42)

WARNING
Handle all parts with great care.
Do not place hands or fingers between one part and
another.
Always wear the prescribed safety clothing, including
protective glasses, gloves and shoes.

With the transfer box on the bench, proceed as fol-

lows:

1.Carry out operation 23 101 26 Transmission shafts

and guard removal (see page 4).
2.Carry out operation 23 101 40 Drive gear housing re-
moval (see page 5).

25725

10
3.Use the special punch to withdraw the snap ring
1 2 3
(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.

TRE0407A

11
5.Use a screwdriver to remove the dust ring (1).
6.Remove the splined driven shaft, complete with 1
parts, parking brake discs and the driven gear.

TRE0408A

12

84176554A1 − 10 − 2010
8 SECTION 23 − DRIVE LINES − CHAPTER 1

7.To refit the transfer box, proceed as follows:

WARNING
Use suitable tools to align holes. NEVER USE FIN- TRE0119A
GERS OR HANDS.
13

Insert the shaft in the housing, then assemble the

gear unit, washer and circlip.
Fit the internal lever ,the external lever, the cou-
pling pad and secure in position by means of the
washer and relative circlip.
Fit the bearing and relative circlips
Using tool 380000821, fit the seal and dust ring
(use the spacer to fit the dust ring).
Carry out operation 23101 40 Drive gear housing
installation (see page 5).
Carry out operation 23 101 26 Transmission TRE0118A
shafts and guard installation (see page 4).
14

84176554A1 − 10 − 2010
 SECTION 23 − DRIVE LINES − CHAPTER 1 1

SECTION 23 − DRIVE LINES

Chapter 2 − Electrohydraulic 4WD

CONTENTS

Section Description Page

23 000 Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Torque settings and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cross−Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
23 101 26 Transmission shafts and guard (Disassembly − Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . 10
23 101 40 Drive gear housing (Removal − Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
23 101 42 Drive gear housing removed (Disassembly − Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

MAIN SPECIFICATION

Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34/24x24/34= 1 to 1

Relay lever pad width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 7.978 − 8.000
(in.) (0.3141 − 0.3150)
Pad seat width in driven gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 8.280 − 8.370
(in.) (0.3260 − 0.3295)
Pad clearance in seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.280 − 0.460
(in.) (0.0110 − 0.315)

Relay lever pivot diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 15.973 − 16.000

(in.) (0.6289 − 0.6299)
Pivot housing bore in casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 16.016 − 16.059
(in.) (0.6305 − 0.6322)
Pivot clearance in housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.016 − 0.086
(in.) (0.0006 − 0.0124)

Relay lever detent spring length

− Free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 130
(in.) (5.1181)
− Under 178.2 to 197.8 N (40 to 44 lb ) . . . . . . . . . . . . . . . . . . . . . . mm 142.5
(in.) (5.6102)

MAIN SPECIFICATION OF DRIVE SHAFT

Front drive sleeve adjustment see page 10

Front drive sleeve shim thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2.2.−2.5−2.8−3−3.3−3.7−4−4.3

(in.) (0.0866−0.0984−0.1102−0.1181−
0.1299−0.1457−0.1575−0.1693)

84176554A1 − 10 − 2010
2 SECTION 23 − DRIVE LINES − CHAPTER 1

MAIN SPECIFICATIONS − 4WD ELECTROHYDRAULIC ENGAGEMENT

Reduction ratio of drive gear device (on all models) . . . . . . . . . . . . . . . . . 34/34 = 1:1

Internal diameter of sliding sleeve (19) . . . . . . . . . . . . . . . . . . . . . . mm 35.080 ÷ 35.119

Diameter of driving shaft (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 35.002 ÷ 35.027

Internal diameter of sliding sleeve (19) . . . . . . . . . . . . . . . . . . . . . . mm 50.080 ÷ 50.119

Diameter of driving shaft (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 49.975 ÷ 50.000

Internal diameter of fixed sleeve (8) . . . . . . . . . . . . . . . . . . . . . . . . . mm 38.050 ÷ 38.089

Diameter of driving shaft (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 37.925 ÷ 37.950

Length of spring (7, with spring free) . . . . . . . . . . . . . . . . . . . . . . . . mm 82

Spring length (7) under load of 60.5 ÷ 65.5 kg . . . . . . . . . . . . . . . . mm 40

PROPELLER SHAFT DATA

Thickness of rings (33, fig 3) that adjust the position of the front
sleeve (32) on the 4WD propeller shaft . . . . . . . . . . . . . . . . . . . . . mm 1.5 − 1.9 − 2.2 − 2.5 − 2.8 − 3 −
3.3 − 3.7 − 4 − 4.3

Front sleeve end float (L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.0 ÷ 1.5

84176554A1 − 10 − 2010
 SECTION 23 − DRIVE LINES − CHAPTER 1 3

MDF0803A

1
BOLT TORQUES

Tightening torque
PARTS TO BE TIGHTENED Thread
Nm kgm
Propeller shaft central support retaining bolt (C1) . . . . . . . . . . . . . M12x1.5 88 9
Screw with guide pin for brake disk braking sectors (C3) . . . . . . . M12x1.25 25 2.5
Drive gear housing retaining bolt (C4) . . . . . . . . . . . . . . . . . . . . . . . M12x1.25 98 10
Control cylinder oil delivery union (C5) . . . . . . . . . . . . . . . . . . . . . . . M18x1.50 49 5

SPECIAL TOOLS
25
Sm1
CAUTION
The operations described in this section can only be
carried out with the ESSENTIAL tools indicated by
120°

an (X).
35
∅ 70

∅ 63

r5
To work safely and efficiently and obtain the best
results, it is also necessary to use the recommended
specific tools listed below and certain other tools, 10
which are to be made according to the drawings 140

included in this manual.

23927

380000279 Guard for fitting the seal (28, 2

fig. 3) Adapter to make for drive gear spring
380000280 Guard for fitting the seal (27, disassembly−assembly. (Stamp no. 50107)
(Measurements in mm)
fig. 3)
380000285 Splining tool for fitting the seal NOTE: Make the tool in F42 material.
(3, fig. 3)

84176554A1 − 10 − 2010
4 SECTION 23 − DRIVE LINES − CHAPTER 1

Sectional view of drive gear with electrohydraulic coupling

1. Driving shaft. 19. Mobile coupling.
2. Dust ring. 20. Plate.
3. Seal. 21. Circlip.
4. Manifold ring. 22. Control cylinder oil delivery union.
5. Circlip. 23. 24. O rings.
6. Ball bearing. 25. Metal seal rings.
26.

7. 4WD engagement spring. 27. 28. O rings.

8. Fixed engagement. 29.

30. Casing.
9. Intermediate gear journal. 31. Circlip.
10. Idler gear. 32. Front grooved sleeve.
11. Needle bearing. 33. Clearance adjustment ring (L).
12.

13. Ball bearing. 34. Circlip.

14.
15. O−Ring.
16. P

17. Thrust washer. L.. Axial clearance of sleeve (32).

18. Driving gear. M. Gap = 0.75 mm. between parts (18) and (26).

84176554A1 − 10 − 2010
 SECTION 23 − DRIVE LINES − CHAPTER 1 5

DESCRIPTION AND OPERATION OF THE ELECTRO−HYDRAULICALLY ENGAGED DRIVE GEAR

The electrohydraulically operated 4WD is engaged The 4WD is disengaged by turning off the switch on
by pressing the switch on the control panel. the control panel. This sends an impulse to the relay
By turning on the switch, the electrical impulse to the which, in turn, energises the control solenoid valve.
solenoid valve control relay is deactivated. With the With the solenoid valve energized, oil is supplied to
solenoid valve de−energized, the oil supply to the the mobile coupling internal chamber (19, fig. 3) and
mobile coupling internal chamber is interrupted (19, the 4WD disengages.
fig. 3, causing the parts (8 and 19) to engage and the Lubrication is guaranteed by the oil in the rear
oil to drain from the control circuit (see fig. 4). transmission gearbox.

84176554A1 − 10 − 2010
6 SECTION 23 − DRIVE LINES − CHAPTER 1

8
1 3
6

Sectional view of drive gear with electrohydraulic coupling

1. FWD control valve and it’s solenoid. 5. FWD engagement sensor.
2. FWD inlet union to transfer box. 6. Pressure control valve return line.
3. Diff Lock control valve and it’s solenoid. 7. Return oil union to gearbox.
4. Supply pressure pipe to valve block. 8. Pressure control valve

84176554A1 − 10 − 2010
 SECTION 23 − DRIVE LINES − CHAPTER 1 7

4WD engaged operation

1. Differential Lock solenoid 4. Oil outlet to Differential Lock
2. 4WD solenoid 5. Discharge line to tank
3. Oil outlet to 4WD. 6. Oil inlet from steering pump

84176554A1 − 10 − 2010
8 SECTION 23 − DRIVE LINES − CHAPTER 1

4WD disengaged operation

1. Dl solenoid 5. Discharge line to tank
2. 4WD solenoid 6. Oil inlet from steering pump FWD inlet union to
3. Oil outlet to 4 WD transfer box.
4. Oil outlet to rear Differential Lock

84176554A1 − 10 − 2010
 SECTION 23 − DRIVE LINES − CHAPTER 1 9

ELECTROHYDRAULIC DRIVE GEAR TROUBLESHOOTING

Problems Possible causes Solutions

FWD does not engage. Drive gear engage/disengage Replace switch.

switch faulty.

Solenoid valve control contactor Check relay. Replace if necessary.

faulty.

Drive gear solenoid valve control Check solenoid valve. Replace if

jammed in delivery position. necessary.

Spring (7, fig. 3) deformed. Overhaul the unit.

4WD remains engaged. Transmission oil level low. Top up oil.

Clogged oil filter. Replace filter.

Hydraulic pump faulty. Overhaul or replace the pump.

Drive gear engage/disengage Replace switch.

switch faulty.

Lack of power supply to the Check electrical connections and

solenoid valve: connections replace defective parts.
loose or damaged, contactor
faulty.

Drive gear solenoid valve control Overhaul or replace solenoid valve.

jammed in discharge position.

Oil leakage through the seals with Replace damaged seals.

consequent pressure drop:
hub, piston or delivery union
seals, or drive gear shaft seal
rings.

With electrohydraulic 4WD disen- Brake pump pressure switch Replace pressure switch.
gaged, drive cannot be engaged faulty.
by operating the brake pedals.

84176554A1 − 10 − 2010
10 SECTION 23 − DRIVE LINES − CHAPTER 1

Op. 23 101 26
TRANSMISSION SHAFTS AND GUARD
Disassembly − Assembly

WARNING
Handle all parts with great care.
Do not place hands or fingers between one part and
another.
Always wear the prescribed safety clothing, including
protective glasses, gloves and shoes.

To remove, proceed as follows:

Disconnect the negative battery lead.

1

10
Remove the front, centre and rear screws securing
the front axle prop shaft guard and remove the 1
guard (1).
Remove circlip (2) fig. 12 and move sleeve (1) in the
direction shown by the arrow to disengage it from
the splined shaft of the front axle.
To re−fit the transmission shaft and guard, proceed
as follows:

WARNING
Use suitable tools to align holes. NEVER USE FIN- 25038
GERS OR HANDS.
11

1 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 to 1.5 mm
(0.0394 to 0.0591 in.) (see Section 25 page 9).
25040
− Fit and secure the guard.
12

84176554A1 − 10 − 2010
 SECTION 23 − DRIVE LINES − CHAPTER 1 11

Op. 23 101 40
DRIVE GEAR HOUSING ASSEMBLY
Removal− Installation

WARNING
Handle all parts with great care.
Do not place hands or fingers between one part and
another.
Always wear the prescribed safety clothing, including
protective glasses, gloves and shoes.

To remove, proceed as follows:

Carry out operation 23 101 26 Transmission shafts
and guard removal (see page 10)
Remove the plug (1) and drain the oil from the trans-
mission box/gearbox.

TRE0404A

13

Remove the 4WD pressure pipe (1).

2

TRE0405B

14
Remove the screws (1) that hold the drive gear hous-
ing (transfer box) to the transmission housing. 1

Remove the drive gear housing from the transmis-

sion housing.

TRE0406A

15

84176554A1 − 10 − 2010
12 SECTION 23 − DRIVE LINES − CHAPTER 1

To re−fit the drive gear housing, proceed as fol-

lows:

WARNING
Use suitable tools for aligning holes. DO NOT USE
YOUR HANDS OR FINGERS.
Refer to the tightening torques shown on page 2.
Carefully clean the contact surfaces.

Apply sealing compound (approx. 2 mm (0.0787 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.

Carry out operation 23 101 26 Transmission shafts

and guard installation (see page 10).

Fit the drive shaft guard.

26283

16

Mastic application diagram for assembly of

drive gear housing to transmission housing.

84176554A1 − 10 − 2010
 SECTION 23 − DRIVE LINES − CHAPTER 1 13

TRANSFER BOX UNIT REMOVED

Disassembly − Assembly (Op. 23 101 42)

ATTENTION
Handle all parts carefully.
Do not put your hands or fingers between parts.
Wear the prescribed safety clothing, including
goggles, gloves and safety footwear.

With the transfer box casing on a workbench,

proceed as follows:
1. Carry out operation 23 101 26 Transmission
shafts and guard removal (see page 10).
2. Carry out operation 23 101 40 Drive gear housing
removal (see page 11).
3. Using a punch, extract the circlip (2), pin (1) and
remove the roller bearing, spacer, thrust 1 2 3
washers and intermediate gear (3).

25726

8
4. Using a screwdriver, remove the dust ring (1).
1

25729

9
5. Remove the oil seal (1).
1

25730

10

84176554A1 − 10 − 2010
14 SECTION 23 − DRIVE LINES − CHAPTER 1

6. Remove the 4WD drive gear disengagement oil

delivery union (1).
1

25731

11
7. Remove the oil delivery manifold ring (1) with a
suitable punch.
1

25732

12
8. Remove the circlip (1). Extract the shaft (2),
complete with parts (6, 7, 19, 20 and 21,
1 2
page 4); remove the parking brake disks (12
and 14), the driven gear (18), fixed coupling (8)
and thrust washer (17).

25733

13
9. Position the driven shaft (1), previously removed
in operation (8), in a hydraulic press, securing
1 2 3
the bearing (2) in the clamps (3) as indicated in
the drawing. Operate the press and extract the
bearing (2).

25737

14

84176554A1 − 10 − 2010
 SECTION 23 − DRIVE LINES − CHAPTER 1 15

10. Rotate the driven shaft through 180_, position on

the press as indicated in the drawing and, after
1 2 3 4
having fitted an adapter 50107 (1) on the shaft,
operate the press to compress the spring (4).
Remove the snap ring (2), plate (3), spring (4)
and mobile toothed coupling (5).
5

25738

15
11. Assembly Procedure.
1 2 3
To reassemble the drive gear components,
follow the disassembly operations described in
reverse order.

ATTENTION
Use suitable tools to align the holes. NEVER USE
FINGERS OR HANDS. 25739

16

− Check all parts and replace if worn.

− Check the seals and replace, if necessary.

− To position the O−rings (27 and 28, fig. 3) in the

seats on the driven shaft, use the specific tools:
380000280 (2) for the seal (3) and tool
380000279 for the seal (1).

− Carry out operation 23101 40 Drive gear housing

installation (see page 11).

− Carry out operation 23 101 26 Transmission

shafts and guard installation (see page 10).

− Lubricate all parts.

− Tighten the retaining bolts to the torque value

indicated on page 3.

84176554A1 − 10 − 2010
xx
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 1

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION

Chapter 1 -- Front axle mechanical transmission

CONTENTS
Section Description Page

25 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
25 100 30 Complete front axle. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
25 100 38 Front axle. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
25 108 46--47 Steering knuckle bearing pins. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Stub axle adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wheel hub bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bevel drive adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
25 102 24 Front axle differential. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
25 100 27 Front axle differential with LIM--SLIP. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Front axle differential with NO SPIN. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
44 511 80 Leading drive wheels toe--in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

MAIN DATA

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . steering, load bearing structure,

pivoting at centre
Bevel gear pair -- differential

Pinion--crown gear ratio: 30 km/h:

-- JX60 and JX70 Models 9/38 = 1:4.2

-- JX80, JX90 and JX95 Models 9/39 = 1:4.3

Pinion--crown gear ratio: 40 km/h:

-- JX60 and JX70 Models 11/38 = 1:3.45

-- JX80, JX90 and JX95 Models 11/39 = 1:3.54

Backlash between bevel gear pair:

-- JX60 and JX70 Models mm 0.18 -- 0.23

(in.) (0.0071 -- 0.0091)
-- JX80, JX90 and JX95 Models mm 0.15 -- 0.20
(in.) (0.0059 -- 0.0079)
Ratio between front wheel revs and rear wheel bevel drive revs
-- JX60 and JX70 Models mm 1.386
(in.) (0.545)
-- JX80, JX90 and JX95 Models mm 1.378
(in.) (0.542)
-- JX95 Model 1.398
(0.550)
(continued overleaf)

84176554 -- 03--2008
2 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

MAIN DATA
Bevel Drive and Differential
-- Thickness of pinion bearing adjustment spacer
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2.5--2.55--2.6--2.65--2.7--2.75--2.8--2
.85--2.9--2.95--3.00--3.05--3.10--
3.15--3.2--3.25--3.3--3.35--3.4--3.45
--3.5--3.55--3.6--3.65-- 3.7
(in.) (0.0984--0.1004--0.1024--0.1043--
0.1063--0.1083--0.1102--0.1122--
0.1142--0.1161--0.1181--0.1201--
0.1220--0.1240--0.1260--0.1280--
0.1299--0.1319--0.1339--0.1358--
0.1378--0.1398--0.1417--0.1437--
0.1457)
JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . . mm 2.2--2.25--2.30--2.35--2.40--2.45--2.5
--2.55--2.6--2.65--2.7--2.75--2.8--2.85
--2.9--2.95--3.00--3.05--3.1--3.15--3.2
--3.25--3.3--3.35--3.4
(in.) (0.0866--0.0886--0.0906--0.0925--
0.0945--0.0965--0.0984--0.1004--
0.1024--0.1043--0.1063--0.1083--
0.1102--0.1122--0.1142--0.1161--
0.1181--0.1201--0.1220--0.1240--
0.1260--0.1280--0.1299--0.1319--
0.1339)
-- Thickness of crown wheel position adjustment spacer
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2.5--2.6--2.7--2.8--2.9--3.00--3.1--
3.2--3.3--3.4--3.5--3.6--3.7
(in.) (0.0984--0.1024--0.1063--0.1102--
0.1142--0.11811--0.1220--0.1260--
0.1299--0.1339--0.1378--0.1417--
0.1457)
JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . . mm 2.2--2.3--2.4--2.5--2.6--2.7--2.8--2.9--
3.0--3.1--3.2--3.3--3.4--3.5
(in.) (0.0984--0.1024--0.1063--0.1102--
0.1142--0.11811--0.1220--0.1260--
0.1299--0.1339--0.1378--0.1417--
0.1457)
-- Clearance between sides of planet and side pinion teeth . mm (in.) 0.15 (0.0059)
-- Thickness of planet pinion thrust washers . . . . . . . . . . . . . mm (in.) 1.470 -- 1.530 (0.0579 -- 0.0602
-- Thickness of side gear thrust washers . . . . . . . . . . . . . . . . mm (in.) 1.50 to 1.60 (0.0591 to 0.0630)
-- Diameter of cross pin for planet pinions
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 21.939 -- 21.960 (0.8637 -- 0.8646)
JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . . mm (in.) 23.939 -- 23.960 (0.9425 -- 0.9433)
-- Side diameter cross pin bore diameter
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 22.040 -- 22.961 (0.8677 -- 0.9040)
JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . . mm (in.) 23.940 -- 23.961 (0.9425 -- 0.9433)
-- Clearance between cross pin and bores . . . . . . . . . . . . . . . 0.080 -- 0.122 (0.0031 -- 0.0048)
-- Diameter of outer axle shafts and corresponding bushes
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 37.961 -- 38.000 (1.4945 -- 1.4961)
JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . . mm (in.) 43.961 -- 44.000 (1.7307 -- 1.7323)
-- Inside diameter of installed bushes 0.77 -- 0.83 (0.0303 -- 0.0327)
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 38.080 -- 38.199 (1.4992 -- 1.5039)
JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . . mm (in.) 44.080 -- 44.119 (1.7354 --1.7370)
-- Clearance between axle shafts and bushes . . . . . . . . . . . mm (in.) 0.080 -- 0.158 (0.0031 -- 0.0062)
(continued overleaf)

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 3

MAIN DATA

Axle shafts and steering knuckles

-- Diameter of outer axle shafts and corresponding bushes
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 29.914 -- 29.935 (1.1777 -- 1.1785)
JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . . mm (in.) 41.975 -- 42.000 (1.6526 -- 1.6535)
-- Inside diameter of installed front bush
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 30.050 -- 30.105 (1.1831 -- 1.1852)
JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . . mm (in.) 42.100 -- 42175 (1.6575 -- 1.6604)
-- Clearance between pin and bush
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 0.115 -- 0.191 (0.0045 -- 0.0075)
JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . . mm (in.) 0.100 -- 0.200 (0.0039 -- 0.0079)
-- Interference fit between bushes and respective bores mm (in.) 0.064 -- 0.129 (0.0025 -- 0.0051)
-- Thickness of steering knuckle bearing adjuster plates . . . . mm 0.10--0.15--0.20--0.25--0.30
(in.) (0.0039--0.0059--0.0079--0.0098--
0.0118)
Planetary Final Drives
-- Reduction ratio
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 15:(15+54) = 1:4.6
0.5906:(0.5906+2.1260) = 1:4.6
JX80 and JX90 Models . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 16:(16+62) = 1:4.88
0.6299:(0.6299+2.4409) = 1:4.88
-- Driven gear thrust washer thickness 0.77 -- 0.83 (0.0303 -- 0.0327)
Axle pivot
Pivotting angle (on either side ) . . . . . . . . . . . . . . . . . . . . . . . . . 11o
Centre pivot and support end float . . . . . . . . . . . . . . . . . . . . . . mm (in.) 0.3 -- 1.1 (0.0118 -- 0.0433)
Max. wear clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 2 (0.0787)
Centre pivot diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 52.652 -- 52.671 (2.0729 -- 2.0737)
Centre pivot front bushing fitted . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 52.720 -- 52.790 (2.0756 -- 2.0783)
Centre pivot working clearance in bushing . . . . . . . . . . . . . . . mm (in.) 0.049 -- 0.138 (0.0019 -- 0.0054)
Rear bevel pinion carrier spigot . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 99.040 -- 99.72 (3.8992 -- 3.9063)
Rear bushing fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 99.146 -- 99.221 (3.9034 -- 3.9063)
Spigot fitted clearance in bushing . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 0.074 -- 0.181 (0.0029 -- 0.0071)
Axle front and rear thrust washer thickness . . . . . . . . . . . . . . mm (in.) 4.95 -- 5.00 (0.1949 -- 0.1969)
Turning radius:
-- Live axle in Brakes on JX60 and JX70 Models . . . . . . . . mm (in.) 3600 (141.732)
Brakes on JX80, JX90 and JX95 Models . . . . mm (in.) 4100 (161.417)
-- Live axle in Brakes off JX60 and JX70 Models . . . . . . . . mm (in.) 5300 (208.661)
Brakes off JX80, JX90 and JX95 Models . . . . mm (in.) 5600 (220.472)
-- Live axle out Brakes on JX60 and JX70 Models . . . . . . . . mm (in.) 4200 (141.732)
Brakes on JX80, JX90 and JX95 Models . . . . mm (in.) 4500 (165.354)
-- Live axle out Brakes off JX60 and JX70 Models . . . . . . . . mm (in.) 4900 (192.913)
Brakes off JX80, JX90 and JX95 Models . . . . mm (in.) 5100 (200.787)

(continued overleaf)
84176554 -- 03--2008
4 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

TIGHTENING TORQUES

Tightening torque
PART Thread
Nm ft lb
Front axle

Lock ring, bevel pinion (C1)

JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 35 x 1.5 294 216.8432

JX80 JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 40 x 1.5 294 216.8432

Capscrew, differential case to axle casing (C2) . . . . . . . . . . . . . . . M 12 x 1.25 113 83.3445

Capscrew, ring gear to differential case (C3) . . . . . . . . . . . . . . . . . M 12 x 1.25 113 83.3445

Steering knuckle capscrew (C5)

-- models JX60 and JX70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 113 83.3445

Wheel hub bearings lock nut (C6):

-- JX60 and JX70 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 45 x 1.5 118 87.0323

-- JX80, JX90 and JX95 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 75 x 2 392 289.11243

Capscrew, planetary final drive housing (C7) . . . . . . . . . . . . . . . . . M 10 x 1.25 64 47.2040

Front axle front and rear pivot support bolt (C9) . . . . . . . . . . . . . . . M 18 x 1.5 392 289.11243
Differential cage support cap bolt (C10) . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 113 83.3445

Front axle support to engine retaining bolt (C11) . . . . . . . . . . . . . . M 18 x 1.5 314 231.5945

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 5

C3 -- 113 Nm C12 -- 64 Nm
C4 (*) C6 (**)

26125

C7 -- 64 Nm

C2 -- 113 Nm C1 -- 294 Nm
26124

C11 -- 314 Nm
C9 -- 314 Nm
26126
C10 -- 113 Nm C9 -- 314 Nm

C5 -- 113 Nm

(*) See pages 25 and 26 (**) See page 27 1

84176554 -- 03--2008
6 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

TOOLS

WARNING: The tools marked below with an (X) are

ESSENTIAL for the operations described in this sec-
tion. 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 opera-

tions described in this section.

380000251 Front axle overhaul stand. X 380000248 Bevel pinion positioning adjustment
tool
380000227 Hook for removal--installation of the
X 380000532 Pinion ring nut wrench mod. JX60
front differential assembly.
and JX70
380000255 Overhaul support for front axle diffe- X 380000268 Pinion ring nut wrench mod. JX80,
rential casing. JX90 and JX95
380000249 Universal gauge for positioning of X 380000257 Pinion grooved profile fastener
front bevel drive pinion. wrench.
X 380000252 Bevel drive bearing preloading ring
nut wrench mod. JX60 and JX70
X 380000253 Bevel drive bearing preloading ring
nut wrench mod. JX80, JX90 and
JX95
X 380000234 Front axle pivot bearing outer ring
removal tool.
X 380000235 Tool for measurement of rolling drag
torque of front axle bearings.
X 380000616 Wheel hub ring nut wrench. (JX60,
JX70 models)
X 380000269 Wheel hub ring nut wrench. (JX80,
JX90 and JX95 models)

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 7

TRE0414A

2
Cross--sectional view of front axle differential
S1 = Bevel pinion bearing shim 1. Bevel pinion
S2 = Bevel pinion position shim 2. Seal
3. Bevel pinion bearing spacer
C1 = Bevel pinion bearing lockring. 4. Ring gear
C2 = Differential carrier capscrew. 5. Axle shaft with universal joint
C3 = Ring gear capscrew. 6. Side gear washers
7. Differential pinion washers
Gd, Gs= R.H. and L.H. Differential bearing 8. Differential pinion journal capscrew
lockring. 60. Side gear
61. Side gear
62. Differential pinion
63. Differential pinion journal

NOTE: During installation, apply sealing compound to surfaces X as shown in Section 00, Chapter 1, page 1.

84176554 -- 03--2008
8 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

3
Cross--sectional view of front axle steering knuckle and hub
S3 = King pin bearing shim 10. Seal
C4 = King pin bearing capscrew. 11. King pin bearing
C5 = Steering knuckle capscrew. 12. Seal
C6 = Wheel hub bearing lockring 13. Seal
C7 = Final drive housing capscrew. 14. Axsule shaft bushing
15. Spacer
5. Wheel shaft
16. Thrust washers
9. Bearing carrier capscrew
17. Planet wheel journals
18. Planet wheel shims
19. Sun gear
NOTE: During installation, apply sealing compound to surfaces X as shown in Section 00, Chapter 1, page 1.

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 9

TRE0416A

Cross--sectional view of front axle pivot

H = 1 mm (0.0394 in.) 22. Front thrust washer

L = 1 to 1.5 mm (0.0394 -- 0.0590 in.) 23. Rear thrust washer
S5 = Sleeve position shim 24. Rear bushing
25. Rear axle pivot support
C9 = Axle pivot support capscrew 26. Retaining rings
C10 = Differential bearing cap capscrew. 27. Front splined sleeve
C11 = Capscrews securing front axle support 28. Retaining rings
to engine. 29. Drive shaft guard
20. Front axle pivot support 30. Drive shaft
21. Front bushing

DESCRIPTION AND OPERATION

JX60, JX70, JX80, JX90 and JX95 models have a The differential has two planet pinions; drive is
centrally pivoting front axle with the pivot and the transmitted to lateral epicyclic final drive units
drive shaft coaxial with the longitudinal axis of the (installed on the wheel hubs) through universal joints
tractor. The drive shaft has no universal joints. which require no maintenance.
84176554 -- 03--2008
10 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

COMPLETE FRONT AXLE

Removal-- installation (Op. 25 100 30)

DANGER
Lift and handle all heavy parts using suitable lifting
equipment with a sufficient lifting capacity.
Check that the assemblies or parts are held firmly
and supported by suitable slings and hooks. Make
sure nobody is standing near to the load.

Proceed as follows:
NOTE: The front axle assembly can be removed
from the tractor either with or without previously re-
moving the drive shaft. The description below refers
to removal of the front axle with the drive shaft instal-
led on the tractor. For removal of the drive shaft refer
to section 23.

1
1. Disconnect the negative battery lead (1).

5
2. Unscrew bolts (1) and remove the front mud-
guard supports (2). 2

25575

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 11

3. Attach nylon slings to the front weights (1).

Loosen the locking screw from each weight, lift
the weights clear of the tractor and place them in
a safe position.

1
TRE0159A

4. Unscrew bolts (1) and remove the drive shaft

guard (2).
1 2

25576

8
5. Remove the circlip (1) from the front of the drive
shaft. Slide the sleeve rearwards and detach the 1
drive shaft from the front axle.

25584

9
6. Pass two nylon slings around the front axle and
attach them to a hoist.

25580

10

84176554 -- 03--2008
12 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

7. Lift the tractor with the hoist and place a stand

under the sump pan.

TRE0417A

11
8. Unscrew unions (1) of the rigid pipes to the
power steering cylinders and detach the two
flexible hoses

TRE0176A

12

9. Unscrew the wheel bolts and remove the front

wheels.

25582

13
10. Unscrew the front axle rear support retaining
bolts (1).
1

25585

14

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 13

11. Unscrew the front axle front support retaining

bolts (1.

25586

15
12. Using a hoist and two nylon cables (one for each
side) detach the front axle from the tractor.
13. Refit the front axle following the instructions
below.

WARNING
Always use appropriate tools to align fixing holes.
NEVER USE YOUR FINGERS OR HANDS.

— Refit the axle and bolt the front and rear supports 25583
in position.
— Reconnect the the power steering pipes. 16
— 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 indicated on
page 4.

84176554 -- 03--2008
14 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

FRONT AXLE
Removal--Installation (Op 25 100 38 ) C6 2 1
JX60 and JX70 Models

WARNING
Handle all parts with care.
Do not insert hands or fingers between one part and
another. Wear suitable safety clothing, i.e. safety
goggles, gloves and shoes.

TRE0418A

17
1. Unscrew the drain plug and drain the oil from the
axle casing. 7 6
5 4
2. Remove the planetary final drive housing (1)
complete with planet wheels.
3. Remove sun gear (2).
3
4. Remove final drive ring gear -- fixed gear unit,
slacken ring nut using wrench 380000616 and
remove assy from knuckle.
5. Remove wheel hub (6) with taper roller bearing
cups (7) and associated seal. Be careful to
prevent seal damage.
TRE0419A

18
6. Remove steering knuckle (10) with wheel hub
support.
7. Remove articulated axle shaft (9) with bearing 6
housing. Back off the capscrew before withdraw-
ing the axle shaft.
8. Replace worn bearings using suitable punches
and universal pullers. Check seal efficiency.

Assembly axle parts referring to

-- Before installing the final drive housing (1)
thoroughly clean and degrease mating surfaces and
apply 2 mm (0.0787 in.) of seaing compound. TRE0420A

19

-- 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--bevel drive
housing with the specifed oil.

8 9
TRE0421A
10
20

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 15

JX80, JX90 and JX95 Models

WARNING
Handle all parts with care.
Do not insert hands or fingers between one part and
another. Wear suitable safety clothing, i.e. safety
goggles, gloves and shoes.

NOTE: For overhaul, the front axle should be moun-

ted on stand No. 380000251. 25587

21
1. Unscrewthe plug (1) and drain the oil from the
axle casing.

1
25588

22
2. Unscrew plug (1) on the left--hand epicyclic final
drive casing. Repeat this operation on the 1
right--hand casing.

25589

23
3. Remove the front axle rear support (1). Remove
the front support and retrieve the washer.

25590

24

84176554 -- 03--2008
16 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

4. Unscrew the two track rod retaining bolts (1).

1

25591

25
5. Using a suitable puller, withdraw the pins from
their bores in the stub axle housing and remove
the track rod.

24080

26
6. Remove the circlips (2) from the cylinder rod
pivot pins, unscrew the pin retaining bolts of the
1 2
cylinder (1), withdraw the pins and detach the
two cylinders.
Retrieve the four pins, washers, spacers and
cylinders, complete with hoses.

25593

27

7. Unscrew the retaining bolts from the left--hand

final drive casing cover (1). Screw in the two 1 2
dowels (2), as shown. Using a slide hammer
screwed into the oil drain plug hole, detach the
cover (1) from the casing.

25594

28

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 17

8. Remove the circlip (1) securing the sun gear (2)

and remove the gear.
1 2

25595

29
9. Remove the inner circlip (1) from the stub axle
shaft.
1

25596
30
10. Remove the staking (1) on the wheel hub bearing
lock ring (2).
1 2

25597

31

11. Remove the wheel hub bearing lock ring using

wrench 380000269 (1) for models JX80, JX90
and JX95. 1

25598

32

84176554 -- 03--2008
18 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

12. Remove the wheel hub (1) with the ring gear (2).
Retrieve all disassembled parts.
1 2

25599

33
13. Unscrew the three retaining bolts (1) of the lower
pin of the stub axle housing. Recover the lower
pivot pin and the related adjustment shims. 1

25600

34
14. Unscrew the three retaining bolts (1) of the
mudguard bracket (2).
2
1

25601

35

15. Withdraw the upper pivot pin (1) and detach the
stub axle housing (2). Retrieve the disassembled 2
parts. 1

25602

36
84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 19

16. Unscrew the axle shaft retaining bolt and remove

the axle shaft.

25604

37
17. Remove bracket (1), unscrew the union (3) and
detach the front brake pipe (2). 1 2 3

25605

38
18. Unscrew two of the bolts fixing the bevel
drive--differential support to the axle casing.
Screw in the two dowels (1). Remove the 2 3
remaining bolts and separate the bevel drive--dif-
ferential support from the axle casing. Attach a 1
cable (2) to the support and take up the strain
with the hoist. Remove the bevel drive--differen-
tial support (3) from the axle casing.

25606

39
19. Install tool 380000255 (1) in the vice on the work
bench. Bolt the bevel drive--differential support
on to the tool. Detach the lifting cable. 1 2
20. Unscrew the bolt (2) and remove the ring nut lock
tab (3).

25607

40
84176554 -- 03--2008
20 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

21. Remove the front brake bolts (1).

TRE0231A

41

22. Remove the front brake housing (1).

1

TRE0422A

42
23. Remove the front brake hub gear (1).

TRE0233A
25609

43
24. Remove the friction discs (1)and metal discs (2).
1

TRE0234A

44

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 21

25. Remove front brake piston (1) and O--rings.

TRE0235A

45
26. Unscrew the two bolts (2) of the crown wheel--dif-
ferential support caps (1).

1
TRE0232A
46
27. Remove the crown wheel--differential assembly 46
(2) from the housing (1). 1 2

TRE0423A

47
28. Remove the circlip (1) from the splined shaft (2).
1 2

25614

48

84176554 -- 03--2008
22 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

29. Straighten the locking tab on the splined shaft-

lock nut (1). 1

25615

49

30. Unscrew the nut using wren8ch 380000268 (1)

while preventing rotation of the bevel drive pinion 1
shaft using wrench 380000257.

25616

50
31. Recover the splined shaft detent ball (1).
1

25617

51
32. Withdraw the bevel drive pinion shaft (1) from the
rear of the casing and recover the spacer, the ad-
justment shims and the bearing.
1

25618

52

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 23

33. Using a screwdriver, detach and recover the dust

seal, the oil seal (1) and the rear bearing. 1

25619

53

Reassemble the front axle adhering to the follow-

ing instructions:

-- Refer to the illustrations on pages 7, 8 and -- Install the bevel drive--differential housing on
9 to check the orientation of the various the front axle casing and fit the external front
components. brake pipe.

-- Respect the tightening torques prescribed on -- Install the axle shaft and relative bolt.
page 4.
-- Fit the stub axle, the adjustment shims, the
-- Carry out the adjustments described on pages upper and lower pivot pins, the mudguard
29 to 36. bracket and related bolts.

-- Install the rear bearing, the seal, the dust seal, -- Fit the wheel hub, the ring gear of the final drive
the adjustment shims, the spacer and the bevel unit and the lock ring. Tighten to the prescribed
drive pinion shaft complete with front bearing. torque value, while simultaneously turning the
wheel hub, to ensure that the bearings are
-- Position the detent ball, screw in the bevel drive correctly seated.
pinion lock nut and secure in position by
staking. Finally, replace the circlip. -- Fit the securing and stop circlips, the sun gear
and the cover of the final drive unit.
-- Install the crown wheel--differential assembly,
the support caps and tighten the relative bolts. -- Fit the pins, washers, spacers and steering
cylinders.
-- Install the front brake friction disc, metal disc
hub gear, piston and front brake housing. -- Install the track rod, the front and rear supports
Tighten the respective bolts. and the oil drain plugs.

84176554 -- 03--2008
24 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

STEERING KNUCKLE PINS AND BEARINGS

Replacement (Op. 25 108 46 or 25 108 47)

WARNING
Handle all parts with great care.
Do not put your fingers or hands between one piece
and another. Wear suitable safety clothing, i.e. safety
goggles, gloves and footwear.

In the event that the steering knuckle pins prove

difficult to remove, proceed as follows.

1. Remove the grease nipples and the steering

knuckle pin retaining bolts.
2. Fit the bolts (1) of tool 380000265.
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.

24596

54
6. Using extractor tool 380000234 (1) remove the
steering knuckle bearings.
1
7. Re--install the steering knuckle bearings using a
suitable drift.

24599

55

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 25

STUB AXLE ADJUSTMENT

WARNING
Handle all parts with great care.
Do not put your fingers or hands between one piece
and another. Wear suitable safety clothing, i.e. safety
goggles, gloves and footwear.

Install the front axle on stand 293460 and proceed as

follows.

1. Smear grease AKCELA MULTI--PURPOSE

GREASE 251H EP on the outer races of the
bearings and fit the upper cover, without the 1 2
adjustment plate, but with tool 380000235 (2).
Tighten the retaining bolts (C5, page 5) to the
following torque values:
JX60 and JX70 64 Nm
(47.2040 ft lb)
JX80, JX90 and JX95 113 Nm
(83.3445 ft lb)

24076

56

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.

24077

57
4. Using a torque wrench and tool 380000235 (1),
check that the torque required to rotate the
casing (ignoring the initial torque) is as follows:
models JX60 and JX70 2.9 Nm 1
(2.1389 ft lb)
(with torque increment of 0.98 Nm -- 0.7228 ft lb)

JX80, JX90 and JX95 15 -- 25 Nm

(11,0634 -- 18.4390 ft lb)

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 24078
cover and the casing adjacent to each of the
three bolts. 58

84176554 -- 03--2008
26 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

6. Calculate the average of the three values

measured. The total thickness of the adjustment
shims (page 8) to be fitted under the lower
cover is to be calculated as follows:

JX60 and JX70 S3= H

JX80, JX90 and JX95 S3= H -- 0.20 mm
(0.0079 in.)

If necessary, round up the value to the next

0.05 mm (0.0020 in.).

7. Partially unscrew the bolts of the lower cover,

insert the selected shims (S3, page 8). Tighten
the bolts (C4, page 5) to the following torque
values:

JX60 and JX70 64 Nm

(47.2040 ft lb)
JX80, JX90 and JX95 113 Nm
(83.3445 ft lb)

8. After having rotated the casing a few times to

allow the components to bed down, check that
24079
the torque necessary to rotate the casing
(ignoring the initial torque) is follows: 59

JX60 and JX70 2.9 -- 7.8 Nm

(2.1389 -- 5.7530 ft lb)

JX80, JX90 and JX95 118 -- 147 Nm

(87.0323 -- 108.4216 ft lb)

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.

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 27

WHEEL HUB BEARING ADJUSTMENT: 1

First class axle mod. JX60 and JX70

Proceed as follows:
-- Install wheel hub and fixed gear unit onto the
steering knuckle;

-- Using a torque wrench and lock ring wrench

380000616 (for JX60 and JX70 models)
progressively tighten the ring nut (C6, page 8)
to 147 -- 196 Nm (15 -- 20 kgm). While tighten- 24093
ing the ring nut, rotate the hub to settle the bea-
60
rings.

-- Fully slacken the lock ring and retighten to 59

Nm (43.5162 ft lb) while rotating hub.
-- 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 )
-- Turn the hub by hand to check for excessive
play or binding.
-- Carefully secure the ring nut.

84176554 -- 03--2008
28 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

Second class axle mod. JX80, JX90 and JX95

Proceed as follows:
-- Progressively tighten the ring nut, using the
torque wrench and wrench 380000269 (1) to ob-
tain a torque value of 392 Nm (289.12432 ft lb);
at the same time, rotate the wheel hub to ensure
that the bearings are correctly seated.
-- Measure the rolling resistance (Rt) of the wheel
hub using the relative torque wrench, or a torque
meter and cord positioned on the base of the
wheel disk flange.

61
-- Loosen the ring nut by half a turn and measure
the rolling resistance (R) as described previous-
ly. The difference between the two measure-
ments is the rolling torque value of the wheel hub
bearings (Rc):
-- Rc = Rt -- R = 5.9 ÷ 14.7 Nm (4.3516 ÷ 10.8416
ft lb) or if measured with a torque meter.

Rc = Rt -- R = 7.5 ÷ 18.75 kg (41.3554 lb).

-- If the measurement is less than 5.9 Nm
(4.3516 ft lb) or with the torque meter on 4.8 kg
(10.5870 lb) it is necessary to replace the af-
fected parts and repeat the check.
-- Progressively tighten the ring nut, using the
torque wrench and wrench 380000269 (1) to ob-
tain a torque value of 392 Nm (289.12432 ft lb);
at the same time, rotate the wheel hub to ensure
that the bearings are correctly seated.
-- Carefully secure the ring nut.

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 29

BEVEL DRIVE ADJUSTMENTS

Adjustment of the preload of the pinion shaft
bearings

M E
WARNING
8 7
Handle all parts with care.
Do not insert hands or fingers between one part and
another. Wear suitable safety clothing, i.e. safety
goggles, gloves and footwear. 9

TRE0424A

Proceed as follows. 61
1. Install the bevel pinion bearing cones (7) and H1
(9) with spacer (8) on tool 293438 (E).
M
NOTE: For JX60 and JX70 models, place the
spacer M outside the bearings. 7
2. Fully tighten tool nut (M). E
8
3. Measure the distance (H1) between the end of
the pin on the bottom of the tool and the top
surface of the tool.
9
TRE0425A

62

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 carier through ten revolutions to settle
the bearings.

6. Measure dimension (H3) of the tool in this

condition.
TRE0426A
1

63

7. Thickness of shims (S1) will be given by: H3

S1= H3 -- H1 + 0.10 mm (0.00039 in.) S1

M
If necessary, round off (S1) to the nearest 0.05 mm
(0.0020 in.) 7
E
G
NOTE On completing the adjustment, do not remove 8
the adjustment tool from the bevel drive--differential
housing. Leave in place for adjustment of the drive 9
pinion position. See following subject matter.
TRE0427A 10
64

84176554 -- 03--2008
30 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

BEVEL DRIVE ADJUSTMENTS

Determining the thickness of the drive pinion
position adjustment shim
Proceed as follows.
3 3
1. Fit tool 380000249 (1) in the bevel drive--differen-
tial housing (2), complete with outer bearing C10
rings, crown wheel bearings adjustment ring,
crown wheel bearings adjustment shim, circlip
and differential housing caps, taking care to
tighten the bolts (C10) to a torque of 113 Nm 1
(84.3445 ft lb).
2. Screw the cones (3) of tool 380000249 (1) in or
out in order to position the micrometer shaft (4) 2
in the direction of the inner bearing ring (5) and 4 5
eliminate end float between the cones and the
outer rings of the bevel crown wheel bearings. TRE0428A

3. Adjust the micrometer so that the shaft (4) is in 66

contact with the inner bearing ring (5) and
measure the distance (H3).
4. Determine the correct distance (H5) between the H3
crown wheel axis and the large diameter base of
the pinion:
H5 = H4 ± C
where:
H4 = Nominal distance between crown wheel
centreline and pinion big end
-- 100 mm for JX60, JX70 models.
-- 15 mm for JX80, JX90, JX95 models.
C = a correction value stamped on the pinion
preceded by a + or -- sign (if other than 0). This TRE0428A

value to be added to or subtracted from the 67

nominal distance (H4) according to the sign.
5. The thickness of the adjustment shim (S2) will be
given by:
S2 = H3 -- H5
where:
H3 = the distance measured using the micro-
meter;
H5 = corrected nominal distance between the
crown wheel axis and the large diameter base of
the pinion.

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 31

Examples (models JX60 and JX70)

Example 1:

-- Distance measured using micrometer H5 = 103.3

mm (4.0669 in.).
-- Nominal distance between crown wheel axis and
large diameter base of pinion H4 = 100 mm
(3.9370 in.).
-- Correction value C = + 0,2 mm (0.0079 in.).
-- Corrected nominal distance H5 = 100 + 0.2 =
100.2 mm (3.9370 + 0.0079 = 3.9449 in.).
-- Thickness of adjustment shim
S2 = 103.3 -- 100.2 = 3.1 mm (4.0669 -- 3.9449
= 0.1220 in.).

Example 2:

-- Distance measured using micrometer H3 = 103.3

mm (4.0669 in.).
-- Nominal distance between crown wheel axis and
large diameter base of pinion H6 = 100 mm
(3.9370 in.).
-- Correction value C = -- 0.2 mm (0.0079 in.).
-- Corrected nominal distance H7 = 100 -- 0.2 =
99.8 mm (3.9370 -- 0.0079 = 3.9291 in.).

-- Thickness of adjustment shim

S2 = 103.3 -- 99.8 = 3.5 mm (4.0669 -- 3.9291 =
0.1378 in.).

Example 3:

-- Distance measured using micrometer H3 = 103.3

mm (4.0669 in.).
-- Nominal distance between crown wheel axis and
large diameter base of pinion H4 = 100 mm
(3.9370 in.).
-- Correction value C = 0 mm (0 in.).
-- Corrected nominal distance H5 = H6 = 100 mm
(3.9370 in.).
-- Thickness of adjustment shim
S2 = 103.3 -- 100 = 3.3 mm (4.0669 -- 3.9370 =
0.1299 in.).

84176554 -- 03--2008
32 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

BEVEL DRIVE ADJUSTMENTS

Adjustment of the crown wheel bearings and

checking the backlash between the pinion and
crown wheel.
Proceed as follows.

1. Install the bevel pinion with all parts (less the

seal but including shims (S1 and S2, page 7)
in the differential carrier. Shim sizes to be as
determined in the procedure described on
pages 29 and 30.
2. Fit pinion retaining tool 380000257.
3. Insert wrench 380000532 on the adjuster ring
nut mod. JX60 and JX70 380000268 mod.
JX80, JX90 and JX95.
4. Using the torque wrench on the pinion retai-
ning wrench, hold the bevel pinion in position
and, using a torque wrench positioned exactly
as in fig. 68 on the ring nut wrench, tighten the 24590

ring nut (C1) to a torque value of 294 Nm 68

(216.84352 ft lb) while simultaneously rotating
the pinion shaft to ensure that the bearings are
seated correctly.

5. With torque wrench 380001633 (1) fitted on

pinion retaining wrench 380000257 (2), check
that the pinion rolling torque, without oil seal
and relative dust seal, is 0.5 ÷ 1 Nm (0.3688
÷ 0.7376 ft lb).
If the rolling torque is less than the prescribed
value, fit a thinner adjustment shim (S1, page
7); on the contrary, if the torque is greater
than the prescribed value, fit a thicker adjust-
ment shim.

6. Unscrew the ring nut and fit the seal and the
TRE0428A
relative dust seal ring. Tighten the nut to a
torque value of 294 Nm (216.84352 ft lb) while 69
simultaneously rotating the pinion shaft to
ensure that the bearings are seated correctly.

7. With torque wrench 380001633 (1) fitted on

pinion retaining wrench 380000257 (2) check
that the pinion rolling torque, with the oil seal
and relative dust seal, is -- 0.50 Nm (0.3688 ft
lb) for mod. JX60 and JX70 or -- 0.75 Nm
(0.5532 ft lb) for mod. JX80, JX90 and JX95.
Finally, secure the ring nut and fit the circlip on
the bevel pinion shaft.

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 33

8. Install the differential unit in the carrier ensu-

ring that ring gear is not forced onto the pinion.
Tighten screws (C10) to 59 Nm (43.5162 ft lb)
then slacken and retighten to 20 Nm (14.7512
ft lb).
9. Lubricate the ring gear bearings, fit the
adjuster shim on the left--hand side (front
brake side for four--cylinder models if this
variant is included in the tractor version),
rotate the bevel drive and tighten the differen-
tial bearing lock ring (GS, page 7).

24591

70

10. Using wrench (1) 380000252, for JX60 or

JX70 models, or wrench 380000253, for JX80,
JX90 or JX95 models, check that the torque is
39 to 59 Nm (28.7649 to 43.5162 ft lb) to
establish the specified axial pre--load.
11. Measure bevel drive backlash (1, fig. 72) using
a dial gauge positioned at right angles to a
bevel gear tooth.
12. Repeat the measurement at two other equidi- 1
stant points, 120° apart. Compare the average
of the three readings with the specified
backlash of 0.15 -- 0.20 mm (0.0059 -- 0.0079
in.) (average 0.18 mm (0.0071 in.)). 24592

71

13. If the measured backlash exceeds the prescri-

bed value, fit a thinner adjustment shim. 1
Note: On three--cylinder models or four--cylinder
models without the front brake, if the clearance va-
lue is not within the prescribed field of tolerance,
unscrew one of the ring nuts, whilst tightening the
other to an equal amount, so as to reset the pre-
scribed clearance.

24593

72

The definitive value to fit on the bevel drive--differ-

ential support will be given by:
S = Sp + {(0.18 -- Gm) x 1.35}
where:
Sp = thickness of test shim installed in the bevel
drive--differential housing.
Gm = average backlash measured between the
sides of the teeth of the bevel drive.
14. If the backlash measured is less than the
prescribed value, it will be necessary to fit a
thicker adjustment shim, the value being given
by:
84176554 -- 03--2008
34 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

S = Sp + {(0.18 -- Gm) x 1.35}

where:
Sp = thickness of test shim installed in the bevel
drive--differential housing.
Gm = average backlash measured between the
sides of the teeth of the bevel drive.
15. Fit a shim of the calculated thickness and with a
1/100 scale dial gauge positioned perpendicular
to the outside edge of one of the crown wheel
teeth, check that the backlash between the
pinion and the crown wheel is within the pre-
scribed tolerance limits 0.15 ÷ 0.20 mm (0.0059
to 0.0079 in.).
16. Using wrench 380000252, for JX60 or JX70
models, or wrench 380000253, for JX80, JX90 or
JX95 models, turn the adjuster ring nut and,
using torque wrench 380001633 fitted on
wrench 380000257 (1, fig. 73), check that the
rolling resistance torque of the crown wheel and
pinion bearings, as measured in the same
conditions used to check only the pinion, is:

A2 = A1 + 1 ÷ 1.5 Nm (0.7376.5 to 1.1063 ft lb)

where:
A2 = pinion--crown wheel rolling resistance torque;
A1 = rolling torque of pinion only, 0.5 Nm (0.3688
lb) for JX60 or JX70 models and 0.75 Nm (0.5532
ft lb) with the pinion fitted with the seal, measured
previously;
1 ÷ 1.5 Nm (0.7376.5 to 1.1063 ft lb) = rolling resi-
stance torque of crown wheel only measured at
the end of the pinion, using wrench 380000257
and torque wrench 380001633.
24587

73

17. Tighten the cap bolts (C1, page 4) to a torque

of 113 Nm (83.3445 ft lb).

18. Fit the safety plates, screwing the adjustment

ring nut in or out, to reach the nearest notch.

19. Attach the differential bevel drive carrier to the

axle casing after having carefully cleaned and
degreased the mating surfaces and apply
sealing compound (approx. 2 mm (0.0787)
along the marked line shown in the drawing
below.
24591

74

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 35

20. Attach the differential bevel drive carrier to the

axle casing after having carefully cleaned and
degreased the mating surfaces and apply
sealing compound (approx. 2 mm) along the
marked line shown in the drawing below.

Sealing compound application diagram for

assembly of bevel drive unit and epicyclic
final drive unit.
The types of mastic to use are listed on page 1 of
section 00.

24596

75

84176554 -- 03--2008
36 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

FRONT AXLE DIFFERENTIAL

Overhaul (Op. 25 102 24 )

When overhauling the differential assembly it is nec-

essary 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 differ-

ential to remove any traces of oil which would
otherwise prevent accurate backlash measure-
ment.

2. Install the two side gears without thrust washers.

3. Fit the planet pinions complete with thrust wash-

ers 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.
24597

76
6. Repeat the above operations to measure the
endfloat on the right--hand side gear (Gd).
The endfloat should be 0.25 mm (0.0098 in.).
Therefore the shims to be inserted in the differ-
ential housing are given by:
Ss = Gs -- 0.25 mm (0.0098 in.) for the left--hand
side gear;
Sd = Gd -- 0.25 mm (0.0098 in.) for the right--
hand side gear.

7. Install shims as near as possible to the calcu-

lated value and, using a dial gauge and following
the procedure described above, check that the 24598

endfloat of the left and right--hand side gears is 77

approximately 0.25 mm (0.0098 in.).

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 37

LIMITED--SLIP, SELF--LOCKING DIFFEREN-

TIAL LOCK
Operation
The differential with Iimited slip Iocking (LlM--
SLlP) is of the two planet gear--type. It is provided
with two multi--disc clutch assemblies fitted be-
tween 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 78
with the differential casing which, in turn, permits
the axle to overcome the unevenness of the LIMITED--SLIP self--locking differential lock
ground.

FRONT AXLE DIFFERENTIAL WITH LlMITED--

SLlP UNIT
Overhaul (Op. 25 102 27 )

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

1. Remove the bevel drive--differential casing

assembly from the front axle and attach to the
support 380000255 (4). Lock the support in a vice
and proceed with disassembly, as follows.
2. Remove the bolts (2) and the left-- and
right--hand ring nut Iock plates (3).
3. Check that the right and Ieft--hand caps (1) are
clearly marked, so as not to mix the parts during
reassembly.
4. Remove the left-- and right--hand bearing
adjustment ring nuts (Gd) from the crown wheel.
5. Remove the bolts (C9), securing the caps (1)
and separate the crown wheel from the bevel 79
pinion support.
6. If necessary, unscrew the retaining bolts (C3,
page 4) and remove the crown wheel.

84176554 -- 03--2008
38 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

Disassemble the LlM--SLlP self--locking differen-

tial Iock as follows:
7. Remove the retaining bolts (1) from the
differential half--casing.
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 (1 0) 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 below.
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 Nm (36.8781 ft lb).

80

LIM--SLIP self--locking differential lock

13. Re--install the crown wheel (if previously

disassembled) to the half--casing (8). Tighten the
screws (C3, page 4) to a torque of 113 Nm
(11.5 kgm).
14. Check the rolling torque of the bevel pinion as
indicated on page 32 and following.
15. Assemble the crown wheel, complete with
LIM--SLIP self--locking differential lock, onto the
bevel drive support. Do not forget to fit the
previously marked crown wheel bearing support
caps in the correct order. Assemble and then
adjust the crown wheel bearings as indicated on
page 32 and following.
Friction parts detail 81

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

Part no. Description Quantity Thickness Maximum wear per disc

mm (in.) mm (in.)
10 Metal discs 10 1.5 (0.0591) --

11 Friction discs 2 2.8 (0.1102) 0.10 (0.0039)

12 Friction discs 8 1.6 (0.0630) 0.15 (0.0059)

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 39

NO SPIN DIFFERENTIAL (optional)

82
Section through differential with NO--SPIN unit

C1 = Case capscrew, tightening torque 56 to 62 Nm (41.3034 to 45.7288 ft lb)

1 -- Case, flange half 8 -- Retaining ring

2 -- Case, cap half 9 -- Cam holdout rings
3 -- Side gear 10 -- Driven clutch
4 -- Side gear 11 -- Centre cam
5 -- Springs 12 -- Stop
6 -- Spring retainer 13 -- Ring gear
7 -- Central driven assembly 14 -- Axle shafts
15 -- Front axle housing

84176554 -- 03--2008
40 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

NOTE:
Check NO SPIN differential unit operation as When the tractor is in a straight forward or reverse
follows: mode of operation, the NO SPIN allows equal
speed to be distributed to both wheels.
-- With the engine off, engage a gear and the front
wheel drive, apply parking brake and raise front When the tractor makes a turn or a front wheel
of tractor. passes over an obstruction, the outer wheel or the
wheel on the obstruction must travel faster and
-- Rotate the front wheels in a forward direction to
farther than the other. To do this it automatically
eliminate play. Hold the L.H. wheel and rotate
disengages, passes over the obstruction or nego-
the R.H. wheel rearwards. The NO SPIN
tiates the curve and re--engages again automati-
differential will disengage and the wheel will
cally.
rotate with an indexing or metallic clicking
sound. If one wheel should Iose traction momentarily, the
opposite wheel, which still has traction, continues
-- Stop the R.H.wheel, then turn forwards slightly. to pull the vehicle until traction is regained by both
The NO SPIN differential will engage and stop wheels.
the wheel. Rotate both wheels backwards to
eliminate play, hold the L.H.wheel and rotate Turning: In a left turn, for instance,the right--hand
the R.H. wheel forwards. The NO SPIN wheel increases speed. The axle shaft (14) (page
differential will disengage and the wheel will 39), transmits this speed increase to the left side
rotate with an indexing or metallic clicking gear (3) to the left driven clutch (10) and to the
sound. associated cam holdout ring (9). When the speed
difference between the two wheels reaches a
-- Stop R.H. wheel, then tum backwards slightly. given value, ring (9) and clutch (10) overcome
The NO SPIN differential will engage and stop spring Ioad and disengage from the centre cam
the wheel. (11), remaining in this position until1he end of the
-- Repeat the above operations while holding the curve.
R.H. wheel.

OPERATlON
NOTE: For correct NO SPIN differential operation,
The NO SPIN differential performs the following key tyres must be equal (within a few millimetres) in
functions: rolling circumference. Small differences may be
corrected by adjusting tyre inflation pressure. To
-- Permits full use of tractor pull. check the rolling circumference of a tyre, proceed as
follows:
-- Prevents wheel--spin when one wheel Ioses
traction. With the tractor on a hard, level surface, mark the
edge of the tyre, with chalk, at the lowest point
-- Compensates for differences in wheel travel
(where it contacts the ground). Mark the ground at
which occur when turning or traveling over
the same spot.
uneven ground.
Move the tractor forward so that the tyre rotates
exactly one revolution, i.e., when the chalk mark on
the tyre contacts the ground again. Measure the
distance travelled. This is the rolling circumference
of the tyre.

Repeat on the opposite wheel to check that both

tyres have the same rolling circumference.

84176554 -- 03--2008
 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 41

FRONT AXLE DIFFERENTIAL WITH NO SPIN

OP. 25 102 26
Overhaul
WARNING
Handle all parts with carefully. Do not put your hands
or fingers between parts.Wear suitable safety clo-
thing, safety goggles, gloves and footwear.

1. Remove the bevel drive--differential casing

assembly from the front axle and attach to the
support 380000255 (4). Lock the support in a vice
and proceed with disassembly, as follows.
2. Remove the bolts (2) and the left-- and
right--hand ring nut Iock plates (3).
3. Check that the right and Ieft--hand caps (1) are
clearly marked, so as not to mix the parts during C10

reassembly.
4. Remove the left-- and right--hand bearing
adjustment ring nuts (Gd) from the crown wheel.
5. Remove the bolts (C10), securing the caps (1 )
and separate the crown wheel from the bevel
pinion support. 83
6. If necessary, unscrew the retaining bolts (C3
page 4) and remove the crown wheel.

Disassemble the NO SPIN self--locking differential

Iock as follows.
7. Remove the retaining bolts (1) from the differen-
tial half--casing.
8. Open the differential casing
9. Remove the central driven (7), retaining the
differential half -- casing.
10. Proceed with self--locking the differantial
assembly oparations, carrying out the previously
desciribed operations in reverse order Tighten the
bolts (C1, fig. 84) torgue value of 56--62 Nm
(41.3034--45.7288 ft lb)

11. Refit the crown wheel bolts (C3, page 4) and

torque to a value of 113 Nm (83.3445 ft lb)
12. Assemble the crown wheel, complete with NO
SPIN self--locking differential lock, onto the bevel
drive support. Remember to fit the previously
marked crown wheel bearing support caps in the
correct order and assemble and then adjust the
crown wheel bearings as indicated on page 32 and
following.
84

84176554 -- 03--2008
42 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

CHECKING THE ALIGNMENT OF STEERING

DRIVE WHEELS (Op 44 511 80 )

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 maxi-
mum of 6 mm (0.2362 in.) as measured at the edges
of the wheel rims.
To check the exact value of the toe--in setting of four--
wheel drive tractors, proceed as follows.

1. Inflate the front tyres 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 1
chalk marks.

5. Move the tractor forward to turn both front

wheels through 180o. The chalk marks will now
2
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 mm.
The rotation of the wheels through 180o is necessary 24666
to eliminate the effect of wear, misalignment or
distortion of the wheel rims on the measurements 84
obtained.

6. If it is necessary to correct the wheel alignment, 1

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. 84.
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 Nm (134.9738 ft lb) and nut (2) to 100 3
Nm (73.7562 ft lb). 2
24667
NOTE: The self--locking nut (2) must be renewed
each time it is removed or partially unscrewed. 85

84176554 -- 03--2008
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 1
SECTION 27 − REAR AXLE AND TRANSMISSION
Chapter 1 − Rear axle and transmission

CONTENTS

Section Description Page

27 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cross−sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description and operation and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
21.118.10 − 12 Transmission−gearbox casing Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
21.118.85 Transmission−gearbox casing Disassembly−Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Gearbox driven shaft end float adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Differential lock engagement sleeve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Determining the bevel pinion positioning adjustment ring . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Adjusting the taper roller bearings for the bevel pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . 48
Adjusting the bearings and checking the backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Differential pinion and side gear backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
27 000 − MAIN SPECIFICATION − TORQUE SETTINGS − SPECIAL TOOLS − SECTIONAL VIEWS −
DESCRIPTION AND OPERATION − FAULT FINDING
MAIN SPECIFICATION OF BEVEL GEAR PAIR AND DIFFERENTIAL
JX60 − JX70 JX80 − JX90 − JX95
Bevel gear pair gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . 9/43 = 1:4.8 (30 kph (18.6 mph))
11/43 = 1:3.9 (40 kph (24.9 mph))
Bevel gear pair tooth clearance . . . . . . . . . . . . . . . . . . . . mm 0.18 − 0.23
(in.) (0.0071 − 0.0091)
Type of differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with two planet gears
Mechanical differential lock control . . . . . . . . . . . . . . . . . by means of pedal
Differential release control for mechanical command . hydraulic, pedal−controlled, service brakes
Electrohydraulically controlled differential lock . . controlled by switch located on control panel
Release for mechanically controlled differential lock . . controlled by foot brake pedals
25.040−25.061
24.040 − 24.061 (0.9858 − 0.9867) (for
(0.9465 − 0.9473) JX80−JX90)
Differential pinion internal seat diameter . . . . . . . . . . . . mm
(in.) 28.040−28.061
(1.1039 − 1.1048)
(for JX95)
Differential pinion pin diameter . . . . . . . . . . . . . . . . . . . . . mm 23.939 − 23.960 24.939−24.960
(in.) (0.9425 − 0.9433) (0.9818 − 0.9823) (for
JX80−JX90)
27.939−27.960
(1.1000 − 1.1007)
(for JX95)
Clearance between differential pinions and their pins . mm 0.080 − 0.122 0.080 − 0.122
(in.) (0.0031 − 0.0048) (0.0031 − 0.0048)
Diameter of side gear hub seats on differential box . . mm 44.080 − 44.119 51.100 − 51.146
(in.) (1.7354 − 1.7370) (2.0118 − 2.0136)
Diameter of side gear hubs . . . . . . . . . . . . . . . . . . . . . . . mm 43.961 − 44.000 50.954 − 51.000
(in.) (1.7307 − 1.7323) (2.0061 − 2.0079)
Clearance between side gears and their seats . . . . . . . mm 0.080 − 0.158 0.100 − 0.192
(in.) (0.0031 − 0.0062) (0.0039 − 0.0076)
(see over)

84176554A1 − 10 − 2010
2 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

MAIN SPECIFICATION OF BEVEL GEAR PAIR AND DIFFERENTIAL

(cont.)

JX60 − JX70 JX80 − JX90 −

JX95
Bevel pinion positioning adjustment . . . . . . . . . . . . . . . . . . . . . . see pages 46− 47
Adjuster shims for bevel pinion positioning . . . . . . . . . . . . . . . . . mm 1.85 − 1.90 − 1.95 − 2.00 − 2.05 −
2.10 − 2.15 − 2.20 − 2.40 − 2.45 −
2.50 − 2.55 − 2.60 − 2.65 − 2.70
(in.) (0.0728 − 0.0748 − 0.0. 768 − 0.0787
− 0.0807 − 0.0827 − 0.0846 −0.0866 −
0.0945 − 0.0965 − 0.0984 − 0.1004 −
0.1024 − 0.1043 − 0.1063)
Adjusting ring bevel gear bearings and bevel gear pair coupling
clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 49

Differential pinion and side gear backlash . . . . . . . . . . . . . . . . . mm 0.15 0.18

(in.) (0.0059) (0.0071)

Thickness of differential side gear clearance adjustment shims mm 1.5−1.6

(in.) (0.0591−0.0630)

Thickness of differential pinion thrust bearings . . . . . . . . . . . . . mm 1.47−1.53

(in.) (0.0579−0.0602)

Adjusting clearance between pinion and side gear teeth . . . . see page 53

Adjusting differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 45

Differential lock control fork adjuster shim . . . . . . . . . . . . . . . . . mm 0.5

(in.) (0.0197)

Spring for differential lock control fork:

− free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 220
(in.) (8.6614)
− length of spring under load of 177−195 N (3.9922−4.3892 lb) mm 157.5
(in.) (6.2008)

Differential lock control fork spring (Electrohydraulic control):

− spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 237
− spring length under a load of 304 P 335 N (in.) (9.33)
(31.0 P 34.2 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 159.5
(in.)
(6.28)

MAIN SPECIFICATIONS OF FINAL DRIVES

JX60 − JX70 JX80 − JX90 −

JX95

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pinion type and spur gears

11:67=1:6.1
Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11:62= 1:5.6 (for JX80−JX90)
11:68=1:6.2
(for JX95)

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 3

TORQUE SETTINGS − Refer to fig. 1 on page 4

Torque settings
PART TO BE TIGHTENED Thread
Nm ft lb

Retaining bolts for rear transmission/gearbox upper cover (C1) . . . M 10 x 1.25 59 43.5161

Bolts for securing lift to rear transmission box (C2) . . . . . . . . . . . . M 12 x 1.25 98 72.2811

Bolts for securing PTO box to transmission / gearbox case (C3) M 16 x 1.5 221 163.0012

Bolts for securing torsion bar to transmission / gearbox case (C4) M 16 x 1.5 221 163.0012

Nuts for stud bolt securing final drive box to transmission /

gearbox case (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 72.2811

Drive wheel hub to disc retaining nuts (C6) . . . . . . . . . . . . . . . . . . . M 18 x 1.5 255 188.0783

Drive wheel rim to disc retaining nuts (C7) . . . . . . . . . . . . . . . . . . . M 16 x 1.5 245 188.7027

Ring bevel gear retaining bolts (C8) . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 123 90.7201

Bevel drive − differential support retaining self−locking bolts (C9) M 10 x 1.25 59 43.5161

Final drive casing cover retaining bolts (C10) . . . . . . . . . . . . . . . . . M 10 x 1.25 59 43.5161

Drive wheel axle retaining nut (C11) . . . . . . . . . . . . . . . . . . . . . . . . . M 55 x 1.5 882 650.5297

M 60 x 2 882 650.5297

Differential lock pedal support retaining bolts . . . . . . . . . . . . . . . . . M 10 x 1.25 49 36.1405

Nuts for drive wheel ballast ring retaining bolts . . . . . . . . . . . . . . . M 14 x 1.5 98 72.2811

84176554A1 − 10 − 2010
4 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

SECTIONAL VIEWS

C1 59 Nm C2 98 Nm

C4 221 Nm C3 221 Nm

C9 59 Nm
C7 245 Nm

C6 255Nm
C8 123 Nm
C5 98 Nm
C10 882Nm

TRE0550A

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 5

SPECIAL TOOLS 380000277 Hook for lifting clutch box.

380000301 Rotating stand for overhaul.
380000271 Rear mounting (with 380000301).
IMPORTANT: The operations described in this Sec-
380000272 Front mounting (with 380000301).
tion must be performed only with the ESSENTIAL
tools marked with (X). X 380000838 Adapter for extracting bevel pinion
To work in complete safety and to ensure optimal (with 380000549).
technical results with a minimum of time and effort,
they must be supplemented by the special tools rec- 380000549 Slide hammer.
ommended below and with those to be specially 380000249 Bevel pinion positioning gauge.
constructed by you and for which the construction
diagrams are given in this manual. 50006 Punch for removing gearbox drive
shaft (see page 4, Sect.21, Chap.
1).
List of special tools required for the various opera-
tions described in this Section : 50007 Tool for adjusting gearbox drive
shaft (see page 4, Section 21,
380000236 Trolley for tractor disassembly. Chapter 1).

HEXAGON CH 22

Tool to make for bevel pinion extraction

(Mark part with No. 50144 − Measurements in mm)
Make in UNI C40 material. Spring pin 3 x 20 mm.

84176554A1 − 10 − 2010
6 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

3
Tool to make for adjusting the bevel drive
(engrave number 50027 on the tool − measurements in mm)
Make in Fe 42 C material.

26260

4
Tool to be constructed for adjusting differential lock sleeve travel
(Mark part with No. 50041 − Measurements in mm)
Make using C40 material

26259

5
Tool to make for adjusting the assembly position of the bevel pinion shaft
(Mark tool with no. 50004 − Measurements in mm)
Make using Aq 45 material.

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 7

TRE0551A

Sectional drawings of transmission−gearbox case

1. Mid−range and reverse gear control rod. 13. Range engagement safety pawl.
2. Slow and fast gear control rod. 14. Plug.
3. 1st and 2nd gear control rod. 15. Reverse gear support pin.
4. Detent balls. 16. Retaining bolt.
5. Spring for ball (4). 17. Reverse idler gear.
18. Thrust bearing.
6. Gear engagement safety pawl.
19. Snap ring.
7. Spring for ball (8).
20. PTO shaft.
8. Detent ball.
21. Reverser drive shaft.
9. 3rd and 4th gear control rod.
22. Engagement gear for mid−range and reverse
10. PTO external control lever. gears.
11. Gear engagement safety pawl. 23. Driving gear for mid−range gears.
12. Plug. 24. Snap ring.

NOTE: Screw in plugs 12 and 14 using one of the sealing compounds listed on page 1, Section 00.

84176554A1 − 10 − 2010
8 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

a b
15
10
C3 14 7 9
15 10
C3 14 7 9 3 6
3 6
16
16
4
4
C4
C4
17
17 11
11 13 5
13 2
X
2 5
C5
C5 18 8 19
18 19
8
1 20
1 X 12 X
12
C1 C1

TRE0552A 1
7

Cross−sectional view of final drive

a. JX60, JX70 models 7. Ball bearing

b. JX80, JX90, JX95 models
C1. Final drive housing cover capscrews 8. Final drive driven gear
C2. Capscrews securing final drive housing to 9. Axle shaft
transmission housing
10. Final drive casing
C3. Nuts securing disc to wheel rim
11,12.Seals
C4. Capscrews securing disc to wheel hub
13. Seal guard
C5. Nut
T Drain plug 14,15,16.Retaining rings

1. Wheel disc 17. Seal thrust ring

2. Wheel shaft 18. Grease nipple
3. Final drive housing cover 19. Lockwasher
4,5. Ball bearings 20. Seal
6. Roller bearing

NOTE: During installation, apply sealing compound to surfaces X as shown in Section 00, Chapter 1, page 1.

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 9

5 4 3 2 1

Rear differential lock disengaged

5 4 3 2 1

Rear differential lock engaged

Pressurised oil
Discharge oil

DESCRIPTION AND OPERATION

The rear transmission transmits power from the lock.
gearbox to the lateral final drives by means of the Final drives are of the pinion type and are controlled
bevel gear pair. The bevel gear pair is of the helical by the bevel gear pair output half−shafts, the same
tooth type and is supported by taper−roller bearings. shafts that control the footbrakes.
The differential has two pinions and is equipped with When the differential lock is not in use, it is kept dis-
a mechanically or hydraulically controlled differential engaged by a spring that exerts a force on the fork.
HYDRAULICALLY CONTROLLED REAR DIFFERENTIAL LOCK
When the differential lock is not being used, it is held piston (2) and spring (4), it moves rod (5), fork (3)
in the disengaged position by the pressure of the and the sleeve, thereby engaging the differential
spring (4) on the fork (3). lock. When the switch is pressed to disengage the
By operating the relative switch on the control panel, differential lock, spring (4) exerts a force on fork (3),
the solenoid valve opens to allow the oil sent from the rod (5) and piston (2), which discharges the oil
pump to enter the chamber (1). After acting on the through the corresponding solenoid valve.

84176554A1 − 10 − 2010
10 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

FAULT FINDING FOR BEVEL GEAR PAIR AND DIFFERENTIAL

Problems Possible causes Remedies

Transmission noisy while the trac- 1. Incorrect adjustment of bevel Remove the rear transmission box
tor is moving, even when the gear- pinion and / or ring bevel gear and adjust the pinion and ring bevel
box is in neutral (not arising from bearings. gear bearings correctly (page 48).
final drives).

Transmission noisy when tractor 2. Excessive clearance between Remove the rear transmission box
ia operated with or without load. pinion and ring gear teeth. and correctly adjust the pinion and
ring gear bearings (page 48).
Differential repeats noise within 3. An internal component is bro- Remove the rear transmission box,
short intervals. ken or defective. replace the worn parts and correctly
adjust the differential gear clearance
(page 46).

Transmission noisy and assembly 4. Pinion and / or ring gear Remove the rear transmission box
overheats. bearing clearances insuffi- and correctly adjust the pinion and
cient. ring bevel gear bearings (page 48).

5. Insufficient coupling clear- Remove the rear transmission box

ance between the teeth of the and correctly adjust the ring bevel
pinion and the ring gear. gear bearings (page 48).

FAULT FINDING FOR FINAL DRIVES

Problems Possible causes Remedies

Final drive noisy when tractor is

6. An internal component is bro- Remove the final drive box and re-
moving, even with the gearbox in
ken or defective. place the damaged parts.
neutral.

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 11

HYDRAULICALLY CONTROLLED DIFFERENTIAL LOCK TROUBLESHOOTING

Problems Possible causes Solutions

The differential lock fails to 1. Transmission oil level low. Top up oil.
engage.
2. Clogged oil filter. Replace filter.

3. Hydraulic pump faulty. Overhaul or replace the pump.

4. Faulty differential lock−unlock Replace switch.

switch.

5. Lack of power supply to the Check electrical connections and

solenoid valve: connections replace defective parts.
loose or damaged, contactor
faulty.

6. Differential lock control sole- Overhaul or replace solenoid valve.

noid valve jammed in dis-
charge position.

7. Oil leakage through the seals Replace damaged seals.

with consequent pressure
drop: cylinder piston or feed
pipe seals.

Differential lock fails to 1. Faulty differential lock−unlock Replace switch.

disengage. switch.

2. Differential lock solenoid Overhaul or replace solenoid valve.

valve jammed in delivery posi-
tion.

3. Disengage spring faulty. Remove the hydraulic lift and

replace the spring.

With the differential lock 1. Differential lock control Replace switch.

engaged, it cannot be switch (connected to brake
disengaged by operating the pump) defective.
brake pedals.

84176554A1 − 10 − 2010
12 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

REAR TRANSMISSION − GEARBOX CASE

Removal−Refitting (Op. 21 118 10 − 21 118 12)
Related service instructions up to item 44 − see
pages from 12 to 29. Also describes removal
operations of suspended cab/platform (Op. 90 110
36) with the exception of heating pipes and air
conditioning components removal.
WARNING
Lift and handle all heavy parts using proper equip-
ment of adequate lifting capacity.
Make sure that the assemblies and parts are sup-
ported by appropriate tools and hooks. Keep person-
nel away from the vicinity of the load to be lifted.

1. Disconnect the negative cable from the battery.

2. Remove the exhaust pipe, attach lifting chains

(2) to the bonnet (1) and attach the chain to the
hoist. 2

10

3. Disconnect the electrical connection (1) of

bonnet.

11

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 13

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

12
5. Remove the four bonnet hinge bolts (1) and lift
the bonnet clear.

13
6. Remove cab heating system hoses (1) be-
tween engine and cab. 1

14
7. Remove both control wires from fuel injection
pump by removing retaining circilip.

15

84176554A1 − 10 − 2010
14 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

8. Drain air condition system gas and remove air con-

dition pipes (1) which are between cab and air con-
dition compressor.
1

16
9. Drain brake fluid and remove hoses (1) which are
between main brake center and fluid tank by re-
moving clamps.

17
10. Remove steering hoses (1) from steering valve.

18
11. Remove harnes (1) which is between cab and
engine.

19

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 15

To remove the gearbox−rear transmission, proceed

as follows:
1. Disconnect the negative terminal from the
battery. Remove the rear transmission drain plug
(1) and the gearbox drain plug (2). Drain the oil
into suitable containers.

TRE0209A

20
2. Remove the drain plug from the 4WD transfer
box (1) and drain the oil into a suitable container.

TRE0564A

21
3. Place the tractor dismantling stand 380000236,
so that the fixed support (1) is beneath the rear
transmission case in supporting the engine
coupling flange and the moveable support (2)
under the engine in supporting the flange
attached to the gearbox case.

25050

22
4. Remove fuel tank by loosening retaining bolts (1)
which are under the tank after drain the fuel.

NOT: If there is an expansion tank also remove the

expansion fuel tank.
1

23

84176554A1 − 10 − 2010
16 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

5. Detach auxilary valves control levers (1) from the

back side of the tractor by removing retaining
pins.

24
6. Detach external lift lever connection (1) by
removing retaining pin from backside of the
tractor. 1

25
7. Detach connections of draft control (1) and posi-
tion control (2) levers.

1 2

26
8. Detach 4WD engagement lever connection (1)
which is under platform.

27

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 17

9. Detach creeper engagement lever connection

(1) under platform.

28
10. Remove differantial lock knob (1) from platform
by removing retaining pin.

29
11. Remove transmission control levers (1) from
above the platform by loosening retaining bolts.

30
12. Remove fuel tank and transmission breather
hoses (1) from back of the cab.

31

84176554A1 − 10 − 2010
18 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

13. Detach ground/engine selection lever connec-

tion (2) of PTO and electrical connections (1)
park brake lever from left back side of the cab.
1

32
14. Detach PTO cluch control wire connection (1)
from under platform left−hand side of the tractor.

33
15. Detach main cluch wire.

34
16. Detach shutle lever connection (1).

35

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 19

17. Detach park brake wire (1) under platform.

36
18. Remove electrical connectors (1) which are con-
necting wires of lights on mudguards. Remove
plastic clamps holding electrical wires on cab
frame.

37
19. Detach brake hoses (1) which are under platform
front right−hand side.

38
20. Remove platform covering plastic retainer plate
(1) by loosening secrews.

39

84176554A1 − 10 − 2010
20 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

21. Open front side of platform covering plastic (1)

by pulling it up. Remove cab front retaining nuts
(2) from both side.

1
2

40
22. Place another moveable stand 380000236 un-
der the front weight carrier to prevent any
possibility of the engine tipping forwards when
the gearbox is removed. Put wooden blocks (1)
between the stands and the tractor body. Turn
the stand height adjustment lever to bring the
blocks (1) into contact with the tractor.
1

25051

41
23. Remove electrical connections (1) going to the
instrument panel.

TRE0185A

42
24. Remove the socket (1) with its cable that passes
from the instrument panel and over the gearbox
to the rear fender.

TRE0216A

43

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 21

25. Remove the support bolt (1) from the injection

pump and disconnect the hand and foot throttle
cables.

TRE0177A

44
26. After retrieving the oil from the power steering
tank, disconnect the hoses (1) from the power
steering pump. (Mark the hoses, before removal,
to facilitate refitting in the correct position).

TRE0160A

45
27. Disconnect the proofmeter drive cable from its
adapter (1) and remove the retaining bolt (2).

TRE0501A

46
28. Remove the filter line (1) and pressure pipe (2)
from hydraulic pump.

TRE0201A

47

84176554A1 − 10 − 2010
22 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

29. After draining off the coolant into suitable

containers, unscrew the clamp (1) and remove
the cab heating system intake pipe.

TRE0178A

48
30. Loosen the clamps (1) and remove the cab
heater outlet pipes (2). (Mark the hoses, before
removal, to facilitate refitting in the correct
position).

TRE0240E

49
31. Remove the wing nut (1) securing the condenser
(2).
1 2

25413

50
32. Remove the compressor retaining bolts (1) and
take out the earth connection. 1

24904

51

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 23

33. Move the disconnected compressor (1), con-

denser (2) Fig. 50 and filter/dryer, together with 1
flexible hoses and valves, onto the platform.

TRE5001A
52
34. Remove the rubber floor mat from the cab/−
platform, then remove the surrounding bolts (1)
securing engine−clutch assembly to the gear-
box−rear transmission case.

TRE0199A

53
35. Place a hydraulic jack (1) underneath the centre
of the fuel tank (2) and lift it, as necessary.

TRE0502A

54
36. Using an Allen key, unscrew the plug (1) and
drain the fuel tank using a suitable container
(Choose a container taking into consideration
the tank capacity of 90 litres (19.7879 gall. Imp.).

TRE0181A

55

84176554A1 − 10 − 2010
24 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

37. Remove the bolts (1) and (2) securing the fuel
tank to the footstep.

TRE0049A

56
38. Remove the bolts (1) and (2) from steel support
bracket beneath the fuel tank.

TRE0206A

57
39. Remove the securing screws and remove the
sheet metal protector (1) from beneath the fuel
tank.

TRE0202A

58
40. Rest the front edge of the fuel tank on the
ground.

TRE0211A

59

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 25

41. Loosen the clamps and remove the inlet (1) and
return (2) pipes from the fuel tank. Remove the
fuel tank completely.

TRE0201A

60
42. Remove the pin (1) and remove the clutch pedal
cable from the upper surface of the cab/platform.

TRE0222A

61
43. Remove the nut (1) from the parking brake
control cable. Remove the slave cylinder pipes 1
(2) on both sides.

TRE0194A

62
44. Remove the reatining pin (1) and disengage the
PTO clutch cable.

TRE0198A

63

84176554A1 − 10 − 2010
26 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

45. Remove the retaining pin (1) from the 4WD

engagement lever and remove the lever.

TRE0040B

64
46. Remove the pin from the mechanical differential
lock pedal and take off the pedal head (1).

1
TRE0240A

65
47. Pull up the plastic boot, remove the retaining bolt
(1) and take out the reverser control lever.

TRE0180A

66
48. Unscrew the retaining bolts (1) and remove the
main and range gear selector levers.

TRE0179A

67

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 27

49. Remove the indicator and light connectors (1)

from both sides of tractor.

TRE0192A

68
50. Disconnect the retaining bolts (1) from the
electrical socket and remove the earth cable bolt
(2).

TRE0503A

69
51. Remove the retaining pins (1) and take out the
auxiliary hydraulic valve control rods.
1

TRE0504A

70
52. Disconnect the auxiliary valve nuts (1) from their
pipes.

TRE0200A

71

84176554A1 − 10 − 2010
28 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

53. Remove the split pins (1) and respective draft

and position control levers.

TRE0505A

72
54. Remove the Lift−o−maticTM control cable (1)
from the lever and from its mounting (2).
1 2

24936

73
55. Remove the retaining pin (2) from the bottom and
the support bracket bolts (1) from the top of the
hydraulic lift control rod. Remove the left− and
right−hand lift rods.

TRE0205A

74
56. Remove the bolt (1) that secures the gearbox
breather pipe clamp.

TRE0126A

75

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 29

57. Remove the bolt (1) that secures each side of the
front supports to the cab/platform. 1

TRE0506A

76
58. Remove four bolts (1) that secure the rear of the
cab/platform to each end of the axle casing.

TRE0193A

77
59. Attach the lifting bar to the lifting rings on the left
and right side of the cab roof. Take all necessary
precautions to prevent to prevent damaging the
structure by using supports, where required.
Raise the cab a little and check that there are no
forgotten parts that will prevent the cab from
being lifted further. If satisfactory, complete the
lifting operation.

TRE0157A

78
60. Attach two hooks to the signal support bar at the
front and clamp the lifting tool to the roll−bar at
the rear.

TRE0190A

79

84176554A1 − 10 − 2010
30 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

61. Remove the front retaining bolts (1), the centre

bolts (2) and the rear retaining bolts from the
4WD drive shaft guard.

TRE0207A

80
62. Remove the snap ring (2) and withdraw the
sleeve (1) from 4WD transfer box, moving it in 2
the direction of the arrow.
1

25039

81
63. Remove the snap ring (2) and withdraw the
sleeve (1) from the 4WD transfer box, moving it 1 2
in the direction of the arrow.

25040

82
64. Unscrew the drive shaft centre support bolts (1)
and remove the shaft complete with support.
1

25041

83

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 31

65. Disconnect the trailer brake pump inlet pipes (1)

and (2) from the transmission−gearbox case.
Remove the coupling from the trailer brake
control valve supply pipe (3).

TRE0507A

84
66. After removing the trailer brake control pipe,
remove the retaining bolts (1) together with the
complete trailer brake valve assembly.

TRE0507A

85
67. Disconnect the trailer brake control pipe (1) and
the auxiliary valve pipes from the support plate 1 2
(2).

25537

86
68. Connect a chain to one of the final drive
assemblies and remove it from the transmis-
sion−gearbox case. Repeat on the other side.

TRE0188A

87

84176554A1 − 10 − 2010
32 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

69. Remove the retaining bolts and lift the hydraulic

housing using the hoist.

TRE0187A

88
70. Use a chain to attach the tow hook and PTO to
the hoist. Remove the three retaining bolts (1)
from both sides and remove the unit from the
rear transmission−gearbox case.

TRE0191A

89
71. Unscrew the nut (1) and remove the bolt.
Remove the right−hand lower link (3) and its
3
spacer (2). Repeat on the left−hand lower link.

25773
2

90
72. Attach a belt to both the ends of the torsion bar
(1). Ensure that belt is strong enough to lift the 1
assembly. Remove the retaining bolts (2) and
take off the assembly.

TRE0508A

91

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 33

73. Remove the bolts securing the gearbox cover

(1). Remove the cover.

TRE0104A

92

74. Unscrew the bolt (1) and remove the internal oil
tank (2) from the rear transmission case. 1

2
25774

93

75. Connect the rear transmission−gearbox case to

the hoist by chain. Remove the rear transmis-
sion−gearbox case using trolley stand
380000236.

TRE0189A

94

84176554A1 − 10 − 2010
 34

84176554A1 − 10 − 2010
SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

TRE0553A

Diagram for application of sealing compound to the rear transmission−gearbox casing 95

The types of sealing compound to be applied are listed on page 1 of Section 00.
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 35

76. Refit the rear transmission−gearbox case as — Fit the rear wheels and remove stand
follows: 380000326.

— Fit the 4WD drive shaft and secure it by means

of the central support and, the front and rear
WARNING sliding sleeves.
Use appropriate tools to align the holes. NEVER
USE YOUR FINGERS OR HANDS. — Fix the guard onto the transfer box shaft.

— Screw in the rear transmission−gearbox case oil

drain plugs and the fuel tank drain plug.

— For the correct orientation of the various parts, — Lower the cab onto the transmission casing and
refer to the illustrations on pages 12 to 26. secure using the retaining bolts.

— Connect the Lift−o−maticTM control cable.

— Before refitting boxes, supports and covers,
thoroughly clean and degrease the mating — Connect the differential lock control rod.
surfaces and apply a strip of sealing compound
of about 2 mm (0.0787 in.) diameter as shown in — Connect the parking brake control cable.
the diagram on page 34.
— Fit the gearbox and final drive control levers and
— Apply the torque settings given on page 3. connect the HI−LO control connection, if
present.
— Using the stand 380000326, refit the rear
transmission−gearbox case onto the clutch box. — Fit the reverser control lever.

— Fit the torion bar support complete with internal — Connect the PTO speed selection cable.
connecting rod.
— Connect the synchronised PTO control lever.
— Position the left and right brake friction discs. Fit
— Connect the auxiliary hydraulic valve control
the brake assembly, and the lateral final drive
levers.
assembly.
— Fix the fuel tank together with fixing brackets,
— Refit the PTO cover to the transmission−gearbox mountings and rear transmission−gearbox
case. breather pipes.
— Fit the internal tank complete with oil discharge — Connect the pipes and connections to the fuel
pipe. tank.
— Fit the lower links and spacers. — Refit and secure the compressor, the condenser
and the filter/dryer.
— Fit the tow hook assembly.
— Connect and secure the heater control pipes.
— Re−install the hydraulic lift complete.
— Connect the gearbox clutch control rod.
— Insert the springs and poppet balls and fit the
gearbox and final drive control rod support cover — Connect the front service brake feed and control
to the rear transmission−gearbox case. pipes.

— Fit and connect the lift control and oil filler pipes. — Connect the throttle control cable.

— Fit the three−point linkage support together with — Make good all electrical socket connections
the quick−release fitting support plate and elec- between the cab and the tractor body.
trical power sockets with related connectors. — Connect up the front headlights.
— Fit the trailer brake valve complete with hydraulic — Screw in the engine cooling system drain plug.
valves. Fit and connect the auxiliary hydraulic
valve and trailer brake valve pipes. — Fill up the fuel tank, the rear transmission−
gearbox case and the cooling system.
— Fit and connect all the hydraulic pump inlet and Recommended products and quantities are
outlet pipes and the connection pipes to the given on page 6 of Section 00.
auxiliary hydraulic valves, hydraulic lift, 4WD
transfer box, etc. — Connect the negative terminal to the battery.

84176554A1 − 10 − 2010
36 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

TRANSMISSION−GEARBOX CASE
Removal−Refitting (Op. 21 118 85)

WARNING
Handle all parts with great care.
Never place your hands or fingers between one part
and another. Wear the prescribed safety clothing, in-
cluding glasses, gloves and protective footwear.

1. Secure the transmission box−gearbox to the

rotating stand 380000301 using the front
380000272 and rear 380000271 mountings.
TRE0509A

2. Rotate the casing through 180° unscrew the

bolts (1) and remove the drive casing (2).
1 2

25782

2
3. Turn the box back 180°, then use a punch to
remove the roll pins (1) and take out the rods, the
prongs, the gearbox and final drive control forks.

25783

3
4. Extract the oil inlet union (1), tighten one bolt and
extract the differential lock control piston (2) 2 1
(Electrohydraulic controlled Diff Lock models).

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 37

5. Use a punch to remove the roll pin (2) retaining

the differential lock engagement fork (1). With-
4 3 2 1
draw the rod (4) and remove the helical spring (3)
and the fork.

TRE0511A

5
6. Unscrew the lock rings of the differential support
bearing pre−load ring nuts (2) and slightly
slacken the ring nuts.
7. Unscrew the differential support retaining bolts
(1), retrieve the supports and then remove the
entire differential bevel crown wheel assembly
from the rear of the casing.

27300

6
8. Remove the roll pin (2) and withdraw the external
lever (1) that controls the PTO synchronised with
the gearbox.
1

2
TRE0512A

7
9. Extract the internal lever (2) complete with spring
(1) and sliding block (3).
1 2 3

25791

84176554A1 − 10 − 2010
38 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

10. Straighten out the notches and undo the driven

shaft locking nut (1).
1

25792

9
11. Remove from the rear the snap ring (1) that
retains the final drive driving shaft bearing.
1

25793

10
12. Using a hammer and a brass punch (1) withdraw
the gear (2) for the mid−range speeds together
with the related bearings and engagement
1 2 3
sleeve (3).

25794

11
13. Withdraw the final drive driving shaft (1).
1

25795

12

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 39

14. Remove the snap ring (1) that holds the bearing
(2) onto the gearbox drive shaft.
1 2

25796

13
15. Fit the tool 50006 (2) (see page 4, Section 21,
Chapter 1) onto the driving shaft and use the
1 2
extractor (1) to withdraw the driving shaft.
Remove the bearings, gears and respective
bushings.

25797

14
16. Straighten out the notches in the washer that
retains the nut (1). Loosen the nut. 1

25799

15
17. Screw the adapter 380000838 (2) onto the slide
hammer 380000549 (1) to move the bevel pinion
1 2 3
by a few millimetres in the direction shown by the
arrow.

25901

16

84176554A1 − 10 − 2010
40 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

18. Move the engagement sleeve (1) until it is

possible to gain access with pliers (2) to remove
1 2
the retaining snap ring.

25800

17
19. Move the gear (1) in the direction shown by the
arrow and remove the two retaining half−rings
1 2 3
(2). Undo the nut (3) completely and withdraw
the bevel pinion, removing all parts.

25902

18
20. Undo the bolts (3), take out the support plate (1)
and remove the bearing (2).
1 2

25903

19
21. Use a brass punch (2) and a hammer to move the
driven shaft (1), withdraw the shaft and remove
1 2
all the parts.

22. Mount the rear transmission−gearbox case by

following sectional views and instructions given.
23. Apply the torque settings listed on page 3.

25904

20

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 41

WARNING
Use appropriate tools to align the holes. NEVER 1 2
USE YOUR FINGERS OR HANDS.

24. Position the box vertically, insert the gearbox

driven shaft gear set (2) and insert the shaft (1).

25907

21
25. Turn the box by 90°, fit the front bearing (1) and
the nut (2) and tighten to the prescribed torque.
1 2

25908

22
26. Fit the bearing (2) in its housing on the box (front
end) and lock it using the plate (1).
1 2

25903

23

84176554A1 − 10 − 2010
42 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

27. Insert the gear shift forks (1) and (3) on the
sliding rings (2) and (4) of the synchronisers. 1 2 3
28. Fit the bevel pinion complete with all the parts
and carry out the adjustments given on pages 46 4
to 48.

25912

24

29. Fit the gearbox drive shaft complete with all parts
and the adjuster shim, then position the bearing
(2) and secure it using the snap ring (1).
1 2

25796

25

30. Insert the final drive driving shaft from the rear
end, fit the bearing (2) into its seat and secure 1 2
with the snap ring (1).

25913

26

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 43

31. Fit the lever (1) that controls the PTO synchro-
nised with the gearbox, complete with spring,
pawl and external lever.
1

32. Fit the ring bevel gear complete with support and
adjuster shims (see adjustments on pages 46 to
48.

33. Fit the differential lock engagement control fork

complete with spring−rod unit, external plate and
the corresponding adjuster shims (see page 45).

25791
34. Fit the piston and the corresponding differential
lock control union. 27

35. Fit all the rods, forks and gearbox and final drive
control prongs.

36. Fit the transfer box assembly.

84176554A1 − 10 − 2010
44 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

TRANSMISSION−GEARBOX CASE
Adjusting gearbox driving shaft axial clearance

WARNING
Use appropriate tools to align the holes. NEVER
USE YOUR FINGERS OR HANDS.

Proceed as follows :

NOTE: Once fitted, the driving shaft gears must have

an axial clearance of 0−0.25 mm (0−0.0098 in.). The
bearings must therefore be adjusted to prevent them
from being mounted with an axial preload.
To perform this adjustment, it is recommended ma-
king a tool in the workshop according to the specifica-
tions given in the drawing on page 4, Section 21,
Chapter 1.

1. On the bench mount all the various components

on the driving shaft together with the snap ring
(2), replacing the two rear bearings and the 1 2
adjuster ring with the tool 50007 (1) (see page 4,
Section 21, Chapter 1).
H
2. Insert a screwdriver between the gear and its
bushing and use a feeler gauge to measure the
clearance (H).

3
25910
3. Measure the height (C) of the tool 50007 and the
thickness of the inner rings of the two rear 28
bearings (1 and 2).
4. The adjuster shims to be fitted is given by : B
1 2
S=H+C−A−B
A C
where:
H = measured clearance
A and B = measured thickness of the bearings
C = height of the tool.
Example : H
− measured clearance H = 1.3 mm (0.0512 in.)
− height of tool = 43.5 mm (1.7126 in.)
− thickness of ball bearing (1) = 22.9 mm
25911
(0.9016 in.)
− thickness of roller bearing (2) = 18 mm 29
(0.7087 in.)
Thickness of adjuster ring :
S = 1.3 + 43.5 − 22.9 − 18 = 3.9 mm
(0.0512 + 1.7126 − 0.9016 − 0.7087 = 0.1535 in.)

NOTE: The gears should be mounted with an axial

clearance of 0−0.25 mm. In this instance, it will be
necessary to fit a shim (S) of 3.75 mm to provide an
axial clearance of : 3.9−3.75 = 0.15 mm.

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 45

GEARBOX TRANSMISSION CASING

Adjusting the position of differential lock
engagement sleeve

ATTENTION
Use suitable tools to align the holes. NEVER USE
FINGERS OR HANDS.

Proceed as follows.

1. Assemble the differential lock release

device (mechanically operated model) or the
1
plate (version with hydraulic control) without the
adjusting shim.

2. Insert gauge 50041 (2) fig. 30 (More information

about the gauge 50041 can be seen at fig. 4 page
6) with the 8.1 ÷ 8.2 mm shim between the
sleeve and the differential housing, so that it
makes contact with the sliding surfaces of the
sleeve on the housing. 2

3. Using a crowbar, bring the sleeve into contact 25914

with gauge 50041 and the differential casing,

adjusting the fork (1) to the position of the gauge. 30
4. Using a feeler gauge (1), measure the clearance
between the control pin (2) and the seat on the
rod (3) (mechanically operated model).

26250

31
5. Using a feeler gauge (1), measure the clearance
between the plate (2) and the seat on the
rod (3) (hydraulically operated model).
6. Position the required shim under the differential
lock release control device (mechanically oper-
ated model) or under the plate (2) (hydraulically
operated model) and secure in position using the
bolts.

26251

32

84176554A1 − 10 − 2010
46 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

ADJUSTING THE BEVEL GEAR PAIR

Determining the bevel pinion positioning ad- 1 2
justment ring
Proceed as follows:
1. On the transmission−gearbox case mount the
outer ring of the bearing (1) fig. 33 with the test
shim (2) and the outer bearing ring (3) fig. 34.

25915

33
2. Position the bearing (2) on tool 50004 (1), insert
the bearing (3) and lock the tool (1).
1
2 3

25916

34
3. Position the tool 380000249 (2) with two conical
parts in the ring gear supports and insert the
micrometer (1) with depth rod into its seat and
1 2
lock using the bolt.

25917

35
4. Screw down or unscrew the cones (1) and (2) so
as to align the micrometer rod with the bearing.
Adjust the cones (1) and (2) to lock the tool on the
1
supports and eliminate any axial clearance.
5. Move the depth rod of the micrometer into H1
contact with the bearing and measure the value
(H1).

25918

36

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 47

6. Calculate the corrected nominal distance (H3)

between the ring gear axis and the major base of
the bevel pinion :
H3 = H2 + C
where :
H2 = 145.5 mm (5.7283 in.). Nominal distance
between the ring gear axis and major base of the
bevel pinion.
C = Correction value stamped on the pinion, ex-
pressed in mm and preceded by a + or − sign (if
other than 0) to be added to or subtracted from
the nominal distance (H2) respectively.

7. Thickness of the adjuster ring (S) is given by :

S = H1 + Sp − H3
where :

H1 = Distance measured with the micrometer

gauge.
H3 = Corrected nominal distance between
the ring gear axis and the major base of
the bevel pinion.
Sp = Test ring.

Examples:
1
Distance measured with the micrometer gauge
H1 = 145.9 mm (5.7441 in.).
Thickness of test ring Sp = 1.90 mm (0.0748 in.). H1
Nominal distance between the ring gear axis and
major base of the bevel pinion H2 = 145.5 mm
(5.7283 in.).
a) Correction value C = + 0.2 mm (0.0079 in.). 2
Corrected nominal distance H3 = 145.5 + 0.2 =
145.7 mm (5.7283 + 0.0079 = 5.7362 in.).
Thickness of adjuster ring : 25918
S = 145.9 + 1.90 − 145.7 = 2.10 mm (5.7441 +
0.0748 = 5.7362 in.). 37

b) Correction value C = − 0.2 mm (0.0079 in.).

Corrected nominal distance H3 = 145.5 − 0.2 =
145.3 mm (5.7283 − 0.0079 = 5.7204 in.).
Thickness of adjuster ring :
S = 145.9 + 1.90 − 145.3 = 2.50 mm (5.7441 +
0.0748 − 5.7204 = 0.0985 in.).

c) Correction value C = 0 mm.

Corrected nominal distance H3 = H2 = 145.5 mm
(5.7283 in.).
Thickness of adjuster ring:
S = 145.9 + 1.90 − 145.5 = 2.30 mm (5.7441 +
0.0748 − 5.7283 = 0.0906 in.).

8. Remove the tools 380000249 and 50004; take

out the bearing external rings, the test shim and
two differential supports.

84176554A1 − 10 − 2010
48 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

ADJUSTING THE BEVEL GEAR PAIR

Adjusting the taper−roller bearings for pinion
shaft
1

1. Mount the external track of the bearing together

with the previously calculated adjuster shim (S)
and the bevel pinion complete with its parts.
2. Tighten the bearing adjustment nut (1) while
turning the pinion shaft to allow the bearings to
bed in until rolling torque of 0.73−1.47 Nm
(1.1063−1.4751 ft lb) is obtained.
25799

38
3. Mesh the range selecting sleeve with the slow
range gear. Then measure the rolling torque with
1
a torque meter and a cord wound around the
slow range gear of the pinion; the prescribed
torque corresponds to a force measured with the
torque meter (1) of 8.63 − 17.2 N (1.9409 −
3.8598 lb)

25919

39
4. After obtaining the recommended torque, bend
the securing thrust washer (1) onto the adjuster
nut to prevent it unscrewing and decreasing the
bearing pre−load.

TRE0516A

40

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 49

BEVEL DRIVE ADJUSTMENTS

Adjusting the ring bevel gear bearings and
checking the clearance between the teeth of the
bevel gear pair.
WARNING
Handle all parts with great care.
Never place your hands or fingers between one part
and another. Wear the prescribed safety clothing, in-
cluding glasses, gloves and protective footwear.
WARNING
Always use appropriate tools to align the holes.
NEVER USE YOUR FINGERS OR HANDS.
Proceed as follows :

1. With the bevel pinion fitted, insert the differen-

tial assembly complete with the bevel crown
wheel. Secure the right− and left−hand sup-
ports on the gearbox transmission casing and
bring the relevant ring nuts into contact with
the races of the bearings.
2. Using wrench 50027 (see page 6) slightly
screw the right−hand ring nut (2) onto the
support (1), and then do the same for the
left−hand ring nut. So as to obtain a slight
pre−load on the bearings.

27300

41
3. Using a 1/100 dial gauge (1) measure the
radial clearance on the sides of the bevel drive
teeth (three measurements at 120o and 1
arithmetic mean of the three readings, the
difference between the three measurements
must not exceed 0.05 mm) and compare the
result with the nominal clearance: 0.18 ÷
0.23 mm (0.0071 ÷ 0.0090 in.).
We will initially be looking for a clearance of
0.18 mm (0.0071 in.).

TRE0518A

42
4. Setting high − low backlash depends on the ratio
between the decrease − increase in clearance
and the movement of the differential casing.
As a result, the end displacement (Z) of the
differential unit is:
Z = (G−0.18) x 1.4
where:
1.4 = Ratio between decrease−increase in back-
lash and movement of the differential casing.
G = bevel drive backlash, as previously measu-
red.
After calculating Z, proceed as follows:
if Z < 0 move the crown wheel away from the
pinion.
if Z > 0 move the crown wheel nearer to the bevel
pinion.

84176554A1 − 10 − 2010
50 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

5. One complete turn of the ring nut corresponds to

a 2 mm axial movement of the crown wheel. A
60° turn of the ring nut, equivalent to one side of
the ring nut hexagon, corresponds to an axial
movement of the ring nut of:
Z = (60 : 360) x 2 = 0.33 mm (0.0130 in.)

TRE0519A

43
6. Making the differential turn, unscrew the right−
hand ring nut with tool 50027 (2) and tighten the 2
left−hand ring nut (1) by the same amount if Z > 1
0, otherwise unscrew the left−hand ring nut (1)
and tighten the right−hand ring nut by the same
amount if Z < 0 in order to obtain a backlash
initially of 0.18 mm.
Z = (60 : 360) x 2 = 0.33 mm (0.0130 in.)
7. On obtaining a clearance of 0.18 mm, tighten the
right−hand ring nut to obtain a rolling torque of:

28118

44

Pinion rolling torque on Total rolling torque of pinion

Pinion rolling torque crown wheel (with bearings not measured on crown wheel (with
pre−loaded) bearings not pre−loaded)
ft lb Nm ft lb Nm ft lb Nm
torque
torque measured
measured on
on pinion
0.5421 to 2.8934 to pinion
0.735 to 1.471 3.923 to 6.865 +
1.0849 5.0634 +
(0.7235 to
(0.981 to
1.4463)
1.961)

8. Making sure you do not drive the shafts of the

gearbox, it is possible to check the rolling torque
with a torque meter (1) and a cord wound around
the outer diameter of the differential casing, 1
keeping to the values stated in the table:

TRE0517A

45

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 51

Differential casing j 187 mm (7.3622 in.)

Force of the pinion at the tor-

Force of the pinion at the torque meter
que meter measured on the
Pinion rolling torque measured on the crown wheel (with bea-
crown wheel (with bearings
rings pre−loaded)
not pre−loaded)

ft lb Nm lb N lb N

Force on pinion Force on pinion

0.5421 to 0.735 to 9.4401 to 41.97 to
+ +
1.0849 1.471 16.5201 73.45
(2.36 to 4.72) (10.49 to 20.99)

Differential casing j 206 mm (8.1102 in.)

Force of the pinion at the tor-

Force of the pinion at the torque meter
que meter measured on the
Pinion rolling torque measured on the crown wheel (with bea-
crown wheel (with bearings
rings pre−loaded)
not pre−loaded)

ft lb Nm lb N lb N

Force on pinion Force on pinion

0.5421 to 0.735 to 8.5578 to 38.05 to
+ +
1.0849 1.471 14.9982 66.68
(2.1394 to 4.2789) (9.51 to 19.02)

9. Using a 1/100 dial gauge (1), check the

clearance between the teeth of the bevel
drive; if this backlash remains between 0.18 ÷
0,23 mm (0.0071 ÷ 0.0090 in.) (0.21 mm TRE0518A
(0.0083 in.) on average) fine, otherwise: 46

— if the backlash is any greater, use the wrench

50027 (1) to unscrew the right−hand ring nut and
tighten the left−hand one by an equal amount. 1
— if the backlash is any lower, unscrew the
left−hand ring nut and tighten the right−hand one
by an equal amount.

NOTE: It is important to unscrew one ring nut and

alternately tighten the opposite one by an equal
amount so as not to change the bearing pre−load
that has already been calculated.

TRE0520A

47

84176554A1 − 10 − 2010
52 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

10. Lock the right and left−hand ring nuts in

position with the lock ring (1).

48

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 53

ADJUSTING THE BEVEL GEAR PAIR

Differential pinion and side gear backlash ad-
justment

With the distmantled differential on the bench, pro-

ceed as follows :

IMPORTANT
All parts of the differential must be cleaned so that oil
residue does not effect the accuracy of the
adjustment.

1. Mount the side gears (2) and (5) without rings (1)
and (6) on the differential box. Insert the 1 2 3 4
differential pinions (3) and (8) complete, with 5
their related clearance rings and with the pin (7).
Tighten the retaining bolt (4) by a few turns in 6
order to prevent the pin from moving.

8
25920

49
2. Manipulate the RH side gear so that it comes into
contact with the side pinion and, using a depth
micrometer, measure the distance (H1), making
two diametrically opposed measurements and
taking the arithmetic mean of the two values
measured.

H1
25921

50
3. Push the side gear so that it touches the
differential casing and measure the dis-
tance (H2).

4. Repeat the same operations for the left−hand

side gear.

25922
H2
51

84176554A1 − 10 − 2010
54 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

5. Axial movement of each side gear (2) and (5)

without shims is given as : 1 2 3 4 5
Gs or Gd = H1 − H2
where : 6
Gs = axial movement of LH side gear;
Gd = axial movement of RH side gear;
H1 and H2 = distances measured on LH or RH side 7
gear (steps 2 and 3).
8
The normal clearance envisaged between the sides
of the pinion and side gear teeth is 0.15 mm 25920
(0.0059 in.) for JX60 and JX70 models. It is 0.18 mm
(0.0071 in.) for JX80, JX90 and JX95 models. 52

Bear in mind that the average ratio between the nor-

mal clearance of differential pinion−side gear and the
equivalent axial movement of the side gears is 1−1.7.
The axial movement of the side gears corresponding
to the normal prescribed clearance between the
teeth is :
0.15 x 1.7 = 0.25 mm (0.0059 x 1.7 = 0.0098 in.) for
JX60 and JX70 models;
0.18 x 1.7 = 0.30 mm (0.0071 x 1.7 = 0.0118 in.) for
JX80, JX90 and JX95 models.
Thickness of the spacer rings (1) and (6) to be in-
serted on the differential box are :
Ss = Gs − 0.25 mm (0.0098 in.)
(for LH side gear of JX60 and JX70
models)
Sd = Gd − 0.25 mm (0.0098 in.)
(for RH side gear of JX60 and JX70
models)
Ss = Gs − 0.30 mm (0.0118 in.)
(for LH side gear of JX80, JX90 and
JX95 models)
Sd = Gd − 0.30 mm (0.0118 in.)
(for RH side gear of JX80, JX90 and
JX95 models)

Available shims are 1.5 and 1.6 mm to use for the

side gear as shown on page 2. Fit shims of the
closest thickness for the LH and RH side gears
according to calculations).

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 55

TRE0554A

53

Longitudinal and Cross Sectional Views of Bevel Gear Pair and Differential Unit
a. JX60 and JX70 models 12. Side gear shim
b. JX80, JX90 and JX95 models 13. Side gear shim
c. Longitudinal section for all models 14. Differential box
C1. Ring gear retaining screw 15. Bevel pinion shaft
C2. Differential support retaining screw 16. PTO shaft
S. Bevel pinion positioning shim 17. PTO control sleeve
1. Differential support 18. Fork
2. Differential support 19. Differential lock shaft
3. Taper roller bearing 20. Range gear retaining ring
4. Taper roller bearing 21. Bevel pinion securing plate
5. Differential lock sleeve 22. Differential bearing ring nut
6. Ring gear 33. Reverse driven gear
7. Side gear 34. Driven gear for slow speed gears
8. Side gear 35. Engagement sleeve for slow and fast speed
9. Differential pinion gears
10. Differential pinion shaft 36. Transmission driven shaft ring
11. Differential pinion shaft retaining screw 37. Retaining half−ring

84176554A1 − 10 − 2010
56 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

FINAL DRIVE REMOVAL

WARNING
Handle all parts with great care.
Never place your hands or fingers between one part
and another. Wear the prescribed safety clothing, in-
cluding glasses, gloves and protective footwear.

WARNING
Always use appropriate tools to align the holes.
NEVER USE YOUR FINGERS OR HANDS.

CAUTION
Raise and handle all heavy components using a
suitable lift.
Ensure that units or parts are supported by suitable
slings or hooks. Ensure that there is no one in the
vicinity of the load to be lifted

Remove the final drive as follows :

6. Drain oil from rear transmission and final drive

housings.

7. Position a support stand under transmission

housing and remove ROPS frame, wheels,
fenders and platform.
8. Take out capscrews (C5) Fig.1, Page 4 and
remove final drive assembly as shown at Fig.54.

TRE3011A

54
Disassembly (Cover) (Final drive on tractor)

Remove the final drive as follows :

9. Connect a suitable lifting chain and hoist to two
of the wheel attaching bolt holes as shown in the
photo. Use two of the original wheel attaching
bolts or source locally if longer bolts are needed.
Bolt size and thread is M18 x 1.5.
10. Take off capscrews (C1) Fig. 7, Page 8 and
remove final drive cover (3) Fig. 7 with driven
gear (8) Fig. 7.

55

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 57

11. Take out the final drive housing cover to driveline

cap screws and then remove the cover assembly
(cover, wheel shaft and final drive gear) from the
driveline.

56
12. To hold the wheel shaft from rotating while
loosening the final drive gear nut, find a suitable
piece of iron to attach to the end of the wheel
shaft. Using 2 wheel bolts (or locally supplied
bolts if different length is required) attach the iron
bar to the wheel shaft.
Bolt size and thread is M18 x 1.5.

57
13. Hold the iron bar from rotating by securing in a
B
vice or otherwise wedging it to the floor. With the
iron bar and wheel shaft properly secured,
remove the final drive gear nut. This will require
a large breaker bar as the assembly torque on
this nut is from 491 to 882 Nm. depending on nut
size.

C5
58
14. Move the cover assembly near to a suitable
hydraulic press. The press must have a mini-
mum capacity rating of 30 tons. Normally the
following procedure will require approximately 20
tons of pressure.

59

84176554A1 − 10 − 2010
58 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

15. Find a suitable steel ring to support the final drive

housing during the pressing process to remove
the wheel shaft. This ring must be a minimum
91/2 inch inside diameter, and approximately 10
1/2 inch outside diameter and a minimum 4
inches tall.
16. Check the ring fit to be certain it fits over the
outside of the wheel shaft with plenty of material
on the housing edge.

60
17. Set the ring on the table surface of the hydraulic
press.Position the cover assembly on top of the
steel ring.Apply pressure to the end of the wheel
shaft pushing shaft down into the steel ring until
it drops free of the housing. It will require
approximately 20 tons to push the shaft.

61
18. Lift final drive gear out of cover and then lift cover
off steel ring. The shaft can now be lifted out
inside of steel ring. You can now replace the seal
or damaged bearings.

62
Assembly final Drive
19. First install seal, washer, ball bearing and snap
ring into the wheel shaft bore. Also, install the
small roller bearing in the axle shaft bore.

63

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 59

20. Carefully align and guide the wheel shaft up

through the center of the seal and ball bearing to
avoid seal damage. Insert until the bearing
shoulder (1) on the wheel shaft begins to enter
the ball bearing.

64
21. Position the final drive gear onto the wheel shaft
while aligning the shaft and gear splines.

65
22. Take the entire assemble to a press and using a
suitable driver bushing press the final drive gear
and ball bearing down into position on the wheel
shaft. The gear and bearing must bottom on the
wheel shaft. It will require approximately 20 tons
of pressure to fit the gear and bearing into
position.

66
23. To hold the wheel shaft from rotating while
tightening the final drive gear nut, find a suitable
piece of iron to attach to the end of the wheel
shaft. Using 2 wheel bolts (or locally supplied
bolts if different length is required) attach the iron
bar to the wheel shaft.

67

84176554A1 − 10 − 2010
60 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

24. Hold the iron bar from rotating by securing in a

vice or otherwise wedging it to the floor.
25. Torque the nut
If nut size is M42 torque to 491 Nm
If nut size is M60 torque to 882 Nm
If nut size is M55 torque to 882 Nm

C5
68
26. Apply sealant to the final drive housing cover as
shown in photo. Attach the final drive housing
cover to the driveline while aligning axle shaft
and gear. Torque the M10 x 1.25mm housing
retaining bolts to 89Nm.

69
27. Fill the cavity between the shaft and housing with
grease as shown.

70
28. You can fill this cavity after the shaft is installed
by pumping grease trough the wheel bolt holes
as show in the picture.
Fill bolt hole until grease can be seen in bolt holes
alongside, then move to the next set of holes.
29. Install drive wheel to drive wheel shaft. Torque
the M18 x 1.5 retaining bolts to 255Nm.

71

84176554A1 − 10 − 2010
 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1 61

ASSEMBLY
1
Carry out the above operations in the reverse order,
bearing in mind the following:

30. Place the roller bearing (1) Fig. 72 outer ring in

its seat in the final drive cover with mark on the
outside;

31. Install the other bearings, using appropriate

installers;
TRE3014A
32. Fit the half shaft and wheel shaft, taking care not
to damage the seals (11−12) Fig. 7; 72

33. Fit the roller bearing internal ring (1) Fig.73, on

the half shaft (2) Fig. 73 having heated it in the
oil to 80−90 °C (176−194°F);

TRE3015A

73
34. Tighten the gear locknut (C5) Fig. 7 page 8,
using wrench (B) Fig. 74, previously used for B
disassembly.
35. Tighten all the nuts and screws to the torque
values given on page 3.
36. Clean and grease the surfaces in contact
between the housing (10) Fig. 7 page 8 and the
cover (3) Fig. 7 page 8, inserting a new seal (20)
Fig. 7 page 8;
37. Throughly clean and grease the surfaces (X)
Fig.95 page 34, applying jointing compound.
TRE3012A C5

74

84176554A1 − 10 − 2010
62 SECTION 27 − REAR AXLE AND TRANSMISSION − CHAPTER 1

84176554A1 − 10 − 2010
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 1

SECTION 31 -- POWER TAKE--OFF

Chapter 1 -- Mechanical Power take--off

CONTENTS

Section Description Page

31 000 Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal -- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
31 101 Bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

31 000 -- MAIN SPECIFICATION -- TORQUE SETTINGS -- TOOLS -- SECTIONAL DRAWINGS --

DESCRIPTION AND OPERATION -- TROUBLESHOOTING

MECHANICAL POWER TAKE--OFF

JX60 and JX70 JX80, JX90 and

JX95
540 rev/min PTO
1) Independent of tractor travel
speed
Type (Independent and ground speed PTO) . . . . . . . . . . . . . or:
2) Synchronized with gearbox

Engagement and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical by means of hand

levers located on RH and LH side of
driver’s seat (see page 10 and 11)
Direction of rotation (viewed from rear of tractor) . . . . . . . . . clockwise
Engine speed with PTO shaft rotating at 540 rev/min . . . . . rev/min 2200
PTO speed with engine at maximum power (2500 rev/min) rev/min 614
Ground speed PTO. Rear wheel speed with PTO shaft wheel
rotating at 540 rev/min speed
(30 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 8.2 8.9
Ground speed PTO. Rear wheel speed with PTO shaft wheel
rotating at 540 rev/min speed
(4WD 40 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 6.73 7.25
Diameter of PTO shaft at position of bearings . . . . . . . . . . . mm 49.938 -- 50.000
(in.) (1.9661 -- 1.9685)
Diameter of PTO shaft at splined end . . . . . . . . . . . . . . . . . . 13/8 in. (6--spline)
(continued overleaf)
84176554 -- 03--2008
2 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

MECHANICAL POWER TAKE--OFF

(continued)
JX60 and JX70 JX80, JX90 and
JX95
2--speed 540/750 rev/min PTO (option -- all models)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . as for single--speed PTO
Engagement and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . as for single--speed PTO
Direction of rotation (viewed from rear of tractor) . . . . . . . . . as for single--speed PTO
Speed selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of hand lever located to
rear RH side of driver’s seat
Engine speed with PTO shaft rotating at 540 rev/min . . . . . rev/min 2200
Engine speed with PTO shaft rotating at 750 rev/min . . . . . rev/min 2382
PTO speed with engine at maximum power speed (2500
rev/min:
-- for 540 rev/min PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 614
-- for 750 rev/min PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 787

Ground speed PTO. Rear wheel speed with PTO shaft wheel
rotating at 540 rev/min speed see 540 rev/min PTO
(30 and 40 km/h versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min
Ground speed PTO. Rear wheel speed with PTO shaft wheel
rotating at 750 rev/min speed
(30 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 10.51 11.4
Ground speed PTO. Rear wheel speed with PTO shaft wheel
rotating at 750 rev/min speed
(40 km/h 4WD version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 8.59 9.36

Diameter of driven shaft at grooved terminal . . . . . . . . . . . . 13/8 in. (6--spline)

2--speed 540/1000 rev/min PTO (option -- all models)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . as for single--speed PTO
Engagement and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . as for single--speed PTO
Direction of rotation (viewed from rear of tractor) . . . . . . . . . as for single--speed PTO
Speed selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of hand lever located on
rear RH side of driver’s seat
Engine speed with PTO shaft rotating at 540 rev/min . . . . . rev/min 2200
Engine speed with PTO shaft rotating at 1000 rev/min . . . . rev/min 2380
PTO speed with engine at maximum power
(2500 rev/min):
-- for 540 rev/min PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 614
-- for 1000 rev/min PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 1050

(continued overleaf)

84176554 -- 03--2008
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 3

MECHANICAL POWER TAKE--OFF

(continued)
JX60 and JX70 JX80, JX90 and
JX95
Ground speed PTO. Rear wheel speed with PTO shaft wheel
rotating at 540/750 rev/min speed as for single--speed PTO
(30 and 40 km/h versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min

Ground speed PTO. Rear wheel speed with PTO shaft wheel
rotating at 1000 rev/min speed
(30 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 14.1 15.2

Ground speed PTO. Rear wheel speed with PTO shaft wheel
rotating at 1000 rev/min speed
(40 km/h 4WD version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 11.5 12.4

Diameter of PTO shaft at splined end:

-- 540 rev/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/8 in. (6--spline)
-- 750 rev/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/8 in. (6--spline)
-- 1000 rev/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/8 in. (21--spline)

External diameter of driven gear support bushings . . . . . . . mm 49.925 -- 49.950

(in.) (1.9655 -- 1.9665)
Internal diameter of driven gears . . . . . . . . . . . . . . . . . . . . . . mm 50.050 -- 50.089
(in.) (1.9705 -- 1.9720)
Clearance between driven gears . . . . . . . . . . . . . . . . . . . . . . mm 0.100 -- 0.164
(in.) (0.0039 -- 0.0065)

Diameter of driven shaft at front and centre bushings . . . . . mm 39.166 -- 39.191

(in.) (1.5420 -- 1.5429)
Diameter of driven shaft at rear bushing . . . . . . . . . . . . . . . . mm 34.984 -- 35.000
(in.) (1.3773 -- 1.3780)
Internal diameter of front and centre bushing . . . . . . . . . . . . mm 39.200 -- 39.239
(in.) (1.5433 -- 1.5448)
Internal diameter of rear bushing . . . . . . . . . . . . . . . . . . . . . . mm 35.009 -- 35.048
(in.) (1.3783 -- 1.3798)
Clearance between shaft and front and centre bushings . . mm 0.009 -- 0.073
(in.) (0.0004 -- 0.0029)
Clearance between shaft and rear bushing . . . . . . . . . . . . . . mm 0.009 -- 0.064
(in.) (0.0004 -- 0.0025)

TOOLS 380000227 Hook for lifting PTO

Important -- The operations described in this section 380001597 Guide pins for PTO unit
must be performed solely with the ESSENTIAL tools
marked below with (X).
To work in complete safety and to ensure optimal 380000233 Installer for PTO driving shaft
technical results with a minimum of time and effort, bearings
they must however be supplemented with the
specific tools recommended below and with those to
be specially constructed by you and for which the
construction diagrams are given in this manual.

84176554 -- 03--2008
4 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

TORQUE SETTINGS

C1 -- 221 Nm C2 -- 25 Nm C3 -- 162 Nm

C4 -- 294 Nm

Single--speed 540 rev/min PTO 2--speed 540/750 rev/min PTO

26276

TORQUE SETTINGS

Torque setting
PART TO BE TORQUED Thread
Nm ft lb
PTO box fixing screws (C1, fig. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 221 163.0012
PTO guard fixing screws (C2, fig. 1) . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 25 18.439
Grooved endpiece self--locking nuts (2--speed PTO) (C3, fig. 1) M 12 x 1.25 162 119.485
Driven gear shaft locknut:
(C4, fig. 1) for single-- or 2--speed PTO . . . . . . . . . . . . . . . . . . . . . M 32 x 1.5 294 216.8432
Bearing support fixing screws (2-- and 3--speed PTO) (C5, fig. 38) M 12 x 1.25 98 72.281
84176554 -- 03--2008
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 5

1 2

28 3

4
27
5
26
6
25
24
7
23
22
21
8
20
19 9
18
X X
10
17
16
11
15
14 13 12

a -- single--speed 540 rev/min PTO b - 2-- speed 540/750 rev/min PTO

26278

Sectional diagrams of single-- and 2--speed PTO

a. Sectional diagram of single--speed PTO. 13. Rear transmission support.
b. Sectional diagram of 2--speed PTO. 14. Driven gear.
1. 540 rev/min PTO cover. 15, 27, 28, 16 and 5. Snap rings.
2. 540/750 rev/min PTO cover. 17. PTO guard retaining screws.
3. PTO unit fixing screw. 18. 540 rev/min PTO driven shaft
4. Drive shaft bearings. 19. Driven gear support bushings.
6. Self--locking nut to secure splined shaft. 20. Driven shaft lock nut.
7. 540 rev/min splined shaft. 21. Fixed gear.
8. 750 rev/min splined shaft. 22. Coupling sleeve.
9. Seal. 23. Driven gear for 750 rev/min speed.
10. Driven shaft bearings. 24. Driven gear for 540 rev/min speed.
11. Cover locating pin. 25. Double drive gear.
12. Rear transmission casing. 26. Drive gear.

NOTE: When installing use sealing compound of the type shown on page 1 section 00 on surface X as shown above.

84176554 -- 03--2008
6 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

4
27
5

6
25

24
7
23

22

21
8
20

19 9

X
10

11

2--speed 540/1000 rev/min PTO

13 12
26278

Sectional diagram of single-- and 2--speed PTO

2. 540/1000 rev/min PTO cover. 12. Rear transmission casing.
3. PTO unit retaining screw. 13. Rear transmission support.
4. Drive shaft bearings. 19. Driven gear support bushings.
5. Snap ring. 20. Driven shaft lock nut.
6. Self--locking nut to secure splined shaft. 21. Fixed gear.
7. 540 rev/min splined shaft. 22. Coupling sleeve.
8. 1000 rev/min splined shaft. 23. Driven gear for 1000 rev/min speed.
9. Seal. 24. Driven gear for 540 rev/min speed.
10. Driven shaft bearings. 25. Double drive gear.
11. Cover locating pin. 27. Snap ring.

NOTE: When installing use sealing compound of the type shown on page 1 section 00 on surface X as shown above.

84176554 -- 03--2008
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 7

TRE0308A

Sectional diagram of single-- and 2--speed PTO

17. PTO speed selector lever. 20. Rear cover.
18. Roll pin. 21. Fork.
19. Shaft. 22. O--ring.

84176554 -- 03--2008
8 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

2
10
3

11 1
9

TRE0990A

Section views -- 540 -- 1000 rev/min PTO North American version (available on request), not
synchronised with gearbox, with speed selection by replacement of splined output shaft.
1. Splined 1 3/8” output shaft (6 splines) for 540 rpm
PTO, or 1 3/8” output shaft (21 splines) for 1000 6. Return spring.
rpm PTO.
7. Return rod.
2. Driven shaft. 8. Speed selector lever support.
3. Snap ring securing part . 9. Speed selector lever.
4. Speed selector rod. 10. Speed selector sleeve.
5. Speed selector sleeve control fork. 11. Thrust washer.

84176554 -- 03--2008
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 9

1 2

TRE0990A

6
Section view of rigid coupling sleeve for single lever PTO (North American version,available on
request), not synchronised with gearbox.
1. PTO Coupling sleeve
2. Sleeve fixing ciclip.

84176554 -- 03--2008
10 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

DESCRIPTION AND OPERATION OF

MECHANICAL PTO

The PTO, located at the rear of the tractor, transfers

power to the implement being transported or towed.
It can be controlled either directly from the engine 1 2
clutch or from the gearbox clutch. The PTO is shown
with the safety cap (1) and the guard (2) in position.
The safety cap must be removed to couple up an
implement to the PTO shaft.

The PTO with mechanical engagement /

disengagement is available in three versions:

— single--speed PTO, 540 rev/min (standard)

26280

7
— two--speed PTO, 540/750 rev/min (option)

— two--speed PTO, 540/1000 rev/min (option).

Independent PTO

Proceed as follows:
— with the PTO clutch disengaged, i.e. with the
control lever (1) fig. 8, forward at position D;
— move the PTO selector lever (1) fig. 9, to
position B so as to engage the PTO sleeve (3)
fig. 10, with the toothed coupling of the shaft (2) A
which is driven by the engine;
— engage the PTO by slowly moving the lever (1) D
fig. 8, backward to position A. 1

TRE0106A
When engaged, the PTO shaft rotates and the PTO
warning lamp on the instrument panel lights up. 8

In these conditions the operation of the PTO is

completely independent of the travel of the tractor, so:

— the tractor can be stopped without stopping the

PTO;
— the PTO can be stopped without stopping the
tractor (by disengaging the PTO clutch). 1
To disengage the PTO move the PTO clutch control C
lever (1) fig. 8, forwardward to position D then move
the speed selector (1) fig. 9, to the central position
E
E.

TRE0043A

9
84176554 -- 03--2008
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 11

Ground speed PTO

Proceed as follows:
— with the PTO clutch control lever (1) fig. 8, at
position D;
— fully depress the gearbox/engine clutch pedal;
— wait briefly, then move the PTO speed selector
(1) fig. 9, forward to position C and release the
gearbox/engine clutch pedal;
In these conditions the PTO coupling sleeve (3) fig.
10, is turned directly by the toothed coupling of gear
(1) in the gearbox.
When the tractor is stationary the PTO shaft does not
turn. When changing from forward to reverse gear,
the direction of rotation of the PTO shaft reverses.

NOTE: When the PTO is not being used, move the

lever (1) fig. 9, to position E (the neutral position of
the PTO engagement sleeve (3) fig. 10).
26281

10

PTO speed selector lever (2) fig. 11

To change PTO speed, proceed as follows: 2

— lift the spring--loaded collar (1) upwards;

— move the lever (2) forward to position (3) to select 1
750 or 1000 rev/min PTO speed. 3
This activates the external control lever (17) fig. 4
by means of a tie--rod. The external control lever in
turn rotates the internal fork device (21) and
selects the PTO speed by means of the coupling
sleeves TRE0089A

11

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12 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

SINGLE LEVER POWER TAKE--OFF --

(OPTIONAL) Figs. 12 and 13

To operate the power take--off, proceed as follows:

-- disengage the power take--off clutch by moving

the lever (1) fig. 12 to the UP position;
1
-- engage the clutch slowly by moving lever (1)
fig. 13 to DOWN position so as to start the
splined output shaft turning.

In this case, operation is totally independent of the 12

tractor ground speed, and you can therefore:

-- stop the tractor without stopping the power

take--off;

-- stop the power take--off without stopping the

tractor (by disengaging the power take--off
clutch).

The shaft rotates clockwise, as seen from the rear of

the tractor.
To disengage the power take--off, move the selector
lever (1) fig. 12 to the UP position.
1
WARNING
When the power take--off is not in use, the clutch
control lever (1) fig. 12 should be in the disengaged
position (UP).

DANGER
Always check that the plastic guards on the drive 13
shaft are in perfect condition.

IMPORTANT
To prolong release bearing life RAISE the PTO clutch
control lever (1), fig. 12, when the PTO will not be
used for long periods of time .

TROUBLESHOOTING FOR MECHANICAL PTO

Faults Possible causes Remedies

Slipping with loss of speed of PTO Wear of clutch disc or of engine Check the data given in the
output shaft. flywheel pressure plate. appropriate pages of section 18,
Poor adjustment of PTO clutch replace the worn parts and adjust the
control lever. clutch control lever.

Difficulty in selecting PTO speed External control stiff. Check the control lever.
by means of lever (2) fig. 11.
84176554 -- 03--2008
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 13

540/750 MECHANICAL PTO

Removal -- Refitting (Op. 31 112 20)

WARNING
Lift and handle all heavy parts using lifting tackle of
sufficient capacity.
Make sure that the units or parts are supported by
suitable harnesses and hooks. Check that no one is
in the vicinity of the load to be lifted.

1. Disconnect the negative cable from the battery.

2. Remove the top link (1) of the three--point

linkage.

TRE0819A

14
3. Remove the tow hook (1), if fitted.

24953

15
4. Remove the tow bar (1), if fitted.
1

24954

16

84176554 -- 03--2008
14 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

5. Remove the six tow hook support fixing

screws (1) (Three on left and three on right
side).

TRE0809A

17
6. Drain out the transmission/gearbox oil from the
drain plug (1) and collect it in a suitable
container. 1

24956

18
7. Remove the PTO speed selector control lever
(1).

TRE0002A

19
8. Remove the screws (2) that fasten the retaining
bracket (1) for the PTO speed selector control.

1
2

TRE0002B

20
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 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 15

9. Remove the two upper screws (1) which fasten

the PTO unit to the transmission.

1
TRE0820A

21
10. Insert the two guide pins 380001597 (1) and re-
move the two lower screws (2) (Fig. 3 Page.6)
which fasten the PTO unit to the transmission.

1
24958

22
11. Engage the lever (1) fig. 9, in position (C), ground
speed PTO, so that the sleeve (3) fig. 10, rests on 1
the shaft (2) during the removal operation.
Withdraw the PTO unit by a few centimetres and
detach using the hook with lifting chain 380000227
(1).
To reinstall proceed as follows:
— Clean the mating surfaces between the trans-
mission and PTO cover and apply sealing com-
pound as shown in figure 24.
— Raise the PTO unit and position it directly behind
the transmission casing. Slide the PTO cover
onto the guide pins 380001597, for ease of as- 24961
sembly.
— Remove the hook with chain (1) fig. 23, and 23
fasten the PTO unit using the two lower screws.
— Remove the two guide pins 380001597 and
install the two upper screws.
— Reinstall the bracket (1) fig. 20, that retains the
PTO speed selector control lever.
— Refit the tow bar support.
— Refit the tow bar, the tow hook and the three--
point linkage top link.
— Screw in and tighten the oil drain plug and fill the
transmission/gearbox with oil.
— Reconnect the negative battery cable.

26282

24

84176554 -- 03--2008
16 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

MECHANICAL PTO (540/750 rpm PTO)

Bench overhaul (Op. 31 112 45 -- 31 112 48)

WARNING
Handle all parts with great care.
Do not place hands or fingers between one part and
another.
Always wear the prescribed safety clothing, including
protective glasses, gloves and shoes.

1. Place the PTO unit in the vice on the work

bench (1). 1

24962

25
2. Use a punch to straighten the corrugations (1) on
the ring nut that retains the driven shaft
components.
1

24963

26
3. Remove the ring nut (1) from the driven shaft.
1

24964

27
84176554 -- 03--2008
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 17

4. Remove the four PTO unit internal support fixing

screws (1). 1

24965

28
5. Remove the pin (1) securing the fork rod.

TRE0153A

29
6. Withdraw the rod (1) from the rear cover.
1

24967

30
7. Partially withdraw the PTO output shaft (1) and
remove the internal support (3) together with the 1 2
drive shaft (2), the driven gears (4), the sleeve
and the engagement/disengagement/neutral
control fork of the 540/750 PTO. Also, retain the
thrust washer from the gear (11) fig 5, for reuse
during reassembly.

3
24968

31

84176554 -- 03--2008
18 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

8. Remove the rear bearing thrust washer (1) and

remove the secondary shaft (2) complete with 1 2
PTO output shaft.

24969

32

9. Remove the retaining snap ring, the bearing (1)

and the seal (if it needs replacing) from the rear 1
cover.

24970

33

To reinstall, Refer to fig. 2b and proceed as follows:

— Mount the seal (9) (if removed in step 20), the
rear bearing and the retaining snap ring (5) on
the rear cover.
— Refit the thrust washer on the driven shaft.
— Refit the driven shaft gear (23), the fixed gear
(21), the sleeve (22), the fork and the fork
support rod.
— Insert the gear (24) onto the driven shaft, mount
the internal support (13) complete with drive
shaft (25). Fasten the support (13) using the four
screws, tightening them to the torque setting
specified on page 4.
— Mount the thrust washer on gear (11) fig 5, and
install the bearing on the internal support (13) of
the driven shaft.
— Fasten the rod that supports the PTO speed se-
lector control fork pin as removed in step 5.
— Tighten the driven shaft locknut to the torque
specified on page 4, then, using a suitable
punch, notch the safety thrust washer in order to
prevent it from loosening.

84176554 -- 03--2008
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 19

MECHANICAL PTO (540/1000 rpm PTO) (Inter-

changeable PTO Shaft) (NASO Version)
Bench overhaul (Op. 31--114)

WARNING
Handle all parts with great care.
Do not place hands or fingers between one part and
another.
Always wear the prescribed safety clothing, including
protective glasses, gloves and shoes.

1. Place the PTO unit in the vice on the work

bench (1). 1

24962

34
2. Remove the bolts (1) and take off the cover (2).
1

2
TRE1000A

35
3. Remove the spacer (1).

TRE1001A

36

84176554 -- 03--2008
20 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

4. Remove the two socket head screws (1) and

take off the PTO engagement mechanism (2)
completely. 2

TRE1002A

37
5. Withdraw two rods (1) from the cover.
C4: Shaft securing nut tightening torque: 255Nm
(188.0783 ft lb)
C6: Cover retaining bolts tightening torque: 98 Nm 1
(72.2811 ft lb)

C4

C6

TRE1003A

38
6. Remove the nut (1) securing the shaft and take
off the 4 bolts (2).

TRE1004A

39
7. Remove the socket head screw bolt (1) on the
side of the cover.
1

TRE1005A

40
84176554 -- 03--2008
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 21

8. Remove the cover (1).

TRE1006A

41
9. Remove the washer (1) and take off the gear (2).
2
1

TRE1007A

42
10. Remove the rod (1), spring (2), fork (3) and the
synchroniser (4). 4 3
1

TRE1008A

43
11. Remove the driven gear (1).
1

TRE1009A

44

84176554 -- 03--2008
22 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

12. Remove the circlip (1).

TRE1010A

45
13. Remove the drive shaft(1).
1

TRE1011A

46
14. Remove both bearings (1) and (2) .
2

TRE1012A

47
15. Remove the shaft (1) and the plate (2).

1 2

TRE1013A

48
84176554 -- 03--2008
 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 23

To reinstall, reverse the removal procedure and refer

to fig. 5 and proceed as follows:
— Mount the shaft (1) and the plate (2) on the rear
cover (fig. 48).
— Refit the two bearings (1 and 2) (fig. 47).
— Refit the drive shaft (1) (fig. 46)
— Install the circlip (1) securing the bearing (fig.
45)
— Insert the gear (1) (fig. 44).
— Install the rod (1), spring (2), fork (3) and the syn-
chroniser (4) (fig. 43).
— Install the washer (1) and the gear (2) (fig. 42)
— Install the cover (1) fig. 41.
— Install the socket head screw (1) on the side of
the cover (fig. 40)
— Install the nut (1) securing the shaft and refit the
4 bolts (2, fig. 39). Tighten the nut (1) to 255Nm
(188.0783 ft lb) and bolts (2) to 98 Nm
(72.2811 ft lb).
— Install the two rods (1) fig. 38.

— Refit the PTO engagement mechanism (1) and

install the socket head screws securing the
mechanism fig. 37.
— Install 1000 rpm PTO shaft with related circlip.
1
NOTE: The adjustment procedure should be done
ONLY with the 1000 rpm PTO shaft is installed.

— Using a screwdriver (1) and a spanner (2) adjust

the distance X to “0 mm (0 in.)” fig. 49.
X
— Install the spacer (1) fig. 36. 2
TRE1014A
— Install the cover (2) fig. 35 and tighten the bolts
49
(1).
— Use suitable hooks to assemble the unit to the
tractor fig. 34.

84176554 -- 03--2008
24 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

84176554 -- 03--2008
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 1

SECTION 33 -- BRAKING SYSTEM

Chapter 1 -- Braking system
CONTENTS
Section Description Page

33 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools -- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
33.206 Front brake assembly mod. JX60 and JX70 removal and refitting --
overhauling on the bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
33.202.60 Service brake removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
33.202. Removal--Refitting of front brake pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
33.202.40 Bleeding air from the front braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
33.120.08 Adjusting service brake pedals travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
33.110.08 Parking brake travel adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
33 000 -- MAIN SPECIFICATION -- TORQUE SETTINGS -- TOOLS -- SECTIONAL DRAWINGS --
DESCRIPTION AND OPERATION -- TROUBLESHOOTING
MAIN SPECIFICATION

Type:
-- service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with oil bath discs acting on
differential half--shafts
-- parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with oil bath discs acting on
differential half--shafts
with oil bath discs acting on the
bevel pinion shaft by means of a
gear ( Optional )
Control:

-- service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical, with independent

pedals (connected by means of a
pin)

-- parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical, by means of a hand

lever
Disc material for service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . organic agglomerate

Disc material for parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . steel

Mobile sector material for parking brake . . . . . . . . . . . . . . . . . . . . . sintered

or
organic agglomerate

Disc thickness:

-- service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4
(in.) (0.1575)
Discs for service brake:
-- JX60 and JX70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . no 3

-- JX80, JX90 and JX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . no 4

(see over)
84176554 -- 03--2008
2 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

MAIN SPECIFICATION
(cont.)

Thickness of mobile sectors for independent parking brake:

-- lateral sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 3.1 -- 3.4

(in.) (0.122 -- 0.1339)
-- intermediate sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4.2 -- 4.5
(in.) (0.1653 -- 0.1772)
Front brakes (with 4WD models -- on request)
Hydrostatic control
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with 2 control pumps operated in-
dependently by means of
the brake pedals

Adjusting the control pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 24

Bleeding air from the front brake circuits (Optional) . . . . . . . . . . . . see page 23

TORQUE SETTINGS

Tightening torque
PARTS TO BE TIGHTENED Thread
Nm ft lb
Nuts securing final drive box to transmission box (C1) . . . . . . . . . M 12 x 1.25 98 72.281
Brake box retaining bolt (C5, page 8) . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 70 51.6293

TRE0300A
C1 -- 98 Nm
1

84176554 -- 03--2008
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 3

20 20

TRE0301A

Sectional drawing of service and parking brakes

a. models JX60 and JX70. 6. Back--up discs
b. models JX80, JX90 and JX95. 7. Actuator return spring.
1. Brake link. 8. Differential support.
2. Pin. 9. Axle shaft.
3. Ball. 10. Boot cover plate.
4. Brake actuator. 11. Boot.
5. Brake discs. 20. Differential support retaining bolt.
Note. -- When mounting apply sealing compound to surfaces X as shown on page 18.

84176554 -- 03--2008
4 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

84176554 -- 03--2008
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 5

BRAKES

3
4

4 8 b
6
5
9
12

Lm

Pd Ps 1 3
a
MS c

PARK BRAKE & SLAVE CYLINDER

1 SL
14

13

15

View of service and park brake controls

a. R.H. brake pedal in rest position and L.H. brake applied. SL. Slave cylinder 4. Brake actuator. 9. Axle shaft.
b. Brakes applied. MS. Master cylinder 5. Brakes discs. 12. Final drive housing.
c. Brakes in rest position. T. Parking brake link. 6. Back--up discs. 13. Park brake control lever.
Lm. Parking brake hand lever. 1. Brake links. 7. Actuator return spring. 14. Park brake control cable.
M. Brake pedal return springs. 3. Actuator ball. 8. Differential support. 15. Brake pivoting shaft.
Pd. R.H. brake pedal.

84176554 -- 03 -- 2008
 6 SECTION 33-- BRAKING SYSTEM -- CHAPTER 1

84176554 -- 03 -- 2008
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 7

FRONT LIVE AXLE DRIVE SHAFT BRAKE (JX60 & JX70 MODELS)

1 3 6 5 7 8

2 9

12975

Section through the brake fitted on drive shaft to front live axle

1. Self--centering brake disc 6. Front washer.

2. Disc retaining screw 7. Rear washer.
3. Shaft/sleeve assembly
4. Carrier. 8. Outer retaining ring.
5. Bearing. 9. Inner retaining ring

84176554 -- 03--2008
8 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

FRONT BRAKE (MODELS JX80, JX90 and JX95)

C5 C5

4
View of brake mounted in front axle.
a. Cross--sectional view of axle with differential. 4. Seal.
b. Cross--sectional view of axle with NO--SPIN as- 5, Piston contact spring.
sembly. 6. Centring ring.
c. View of oil delivery union and brake bleed. 7. Gear.
C5 Brake box retaining bolt. 8. Circlip.
1. Brake box. 9. Drive oil inlet pipe union.
2. Brake drive piston. 10. Plug pipe with breather.
3. Seal. 11. Splined shaft.
Note. -- When mounting apply sealing compound to surfaces X.

84176554 -- 03--2008
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 9

DESCRIPTION AND OPERATION

SERVICE BRAKES tor discs to turn, ball (3) in the tapered seats to force
the discs apart as shown in detail (c).
The service brakes are hydraulic with oil bath discs.
As a result, two simultaneous actions compress the
The two control pumps (one for each pedal) are brake discs against the differential support (8) and
housed in the front section of the cab and are con- the back up discs, immediately upon releasing the
nected to their respective pedals by means of two pedal spring (7), pull the actuator (4) back into the
rods. rest position (figure b and detail d) and as a result the
discs are released. The action is similar when the
These pumps can be actuated either independently right--hand brake pedal is pressed (Rd).
or together. If actuated together, the pedals are con-
nected by a pin. The brake discs (one for each rear wheel) are posi-
A connecting pipe between the two pumps ensures tioned between the rear transmission box and the lat-
balanced braking even when the brake discs are not eral final drive box and are splined onto the differen-
equally worn. tial output half--shafts.

The two control pumps are fed from a single tank lo-
cated above the pumps. PARKING BRAKE
Refer to the illustrations on page 5. The service
brakes are slave cylinder operated. When the left-- Refer to the illustrations on page 5. When the hand
hand brake pedal (fig. a ) is depressed, the master brake lever (Lm) is pulled, the control cable (14) pulls
cylinder (MS) sends the oil to the slave cylinder (SL). the control lever (13), at the direction of arrow. Then
The brake links (1) move as indicated by the arrows, the brake links (1) acts on the brake
by the help of slave cylinder (SL) this causing actua- discs.

84176554 -- 03--2008
10 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

TOOLS

WARNING -- The operations described in this sec- List of special tools necessary for the various op-
tion must be performed only with the ESSENTIAL erations described in this section.
equipment marked with (X). X 380000822 Driver for boot installation.
To operate safely and achieve best results howev-
er, while saving time and effort, essential equip- 380000227 Lifting hook.
ment must be used in conjunction with the special
tools recommended below, and tools which you
must make yourself and for which you will find the
design in this manual.

BRAKE TROUBLESHOOTING

Problems Possible causes Remedies

Braking ineffectual. 1. Friction material on brake Replace the brake discs.

discs worn.

Unbalanced braking. 1. Incorrect tyre pressure. Inflate the tyres to the correct pres-
sure.
2. Friction material on one of the Replace the discs.
brake discs worn.

Braking noisy. 1. Friction material on brake Replace the discs.

discs worn.

1. Brake discs worn. Replace the brake discs.

Parking
g brake does not lock.

1. Brake discs seized on brake Release and replace damaged parts.

Brakes locked on when the park- discs.
ing brake is disengaged.

84176554 -- 03--2008
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 11

FRONT BRAKE ASSEMBLY MOD: JX60 AND

JX70
Removal--Installation (Operation 33--206

DANGER
Lift and handle all heavy components using lifting
equipment of adequate capacity.
Make sure that the units or parts are supported by
appropriate harnesses and hooks. Check that no one
is in the vicinity of the load to be lifted.

Proceed as follows to remove the unit:

1. Apply the handbrake.

10
2. Unscrew the retaining bolts and remove the 13
guards from the propeller shaft.

Note. -- Should the caliper (11) not need any 11

servicing, back off its retaining screws (13) and 13
disconnect taking care not to uncouple the hose (12): 12
rest on suitable stand or suspend by wire.

TRE0950A

5
3. Disconnect wire (10) fig. 5 of the brake pad wear
warning indicator and remove the pads (14 and
15) fig. 6.

15
14

TRE0951A

6
4. Remove the front sleeve rear retaining ring and
back off the two screws (16) retaining the brake 16
sleeve assembly carrier.
5. Slide the front sleeve along the drive shaft and
remove the complete assembly (shaft and bra-
ke/bearing carrier).

TRE0952A

84176554 -- 03--2008
12 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

6. Take the two drive shafts out of the carrier and

clamp the latter in a vice.

18

17

TRE0953A

8
7. Unscrew the retaining bolts (17, fig. 8) of the calli-
per bracket and remove the bracket.
8. Unscrew the retaining bolts (2) of the brake disc
and remove the disc (4).

TRE0954A

9
9. Take out retaining rings (8 and 9) from the sup-
port (4)
4

8 4 9

TRE0955A

10
10. Using a suitable puller, remove the shaft/sleeve
assembly (3) from the support (4).
11. Remove the bearing (5) using a suitable puller 4 3
and take out the washer (6) Fig. 3.

5 4

TRE0956A

11
84176554 -- 03--2008
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 13

Bench overhaul (Operation 33--206)

DANGER
Always use suitable tools to align holes. NEVER
USE FINGERS OR HANDS.
Reverse the removal operation sequence minding 5
the following points:
1. Position the shaft/sleeve assy (3) Fig. 3, upright,
introduce the support (4) fig. 12, followed by the 4
washer (6) Fig. 3 in the bearing seat with the
TRE0957A
chamfered side facing outwards.
12
2. Insert bearing (5) fig. 3 on assembly (3) fig. 13
and bring into contact with seat using a suitable
drift or press tool; lock with the retaining ring (9)
fig. 3.
3. Clamp the carrier in a vice then, using a suitable
drift or press tool, locate properly against washer
(6) Fig. 3. Position washer (7) Fig. 3 with the 4
chamfered side facing the bearing (5) and lock
the assembly with the retaining ring (8) fig. 3. 3

TRE0958A

13

84176554 -- 03--2008
14 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

SERVICE BRAKE
Removal -- Installation (Operation 33 202 60)

DANGER
Lift and handle all heavy components using lifting
equipment of adequate capacity.
Make sure that the assemblies and parts are
supported by appropriate tools and hooks. Check
that no one is in the vicinity of the load to be lifted.

Proceed as follows to remove the final drive box.

1. Disconnect the negative battery cable (1).

2. Chock the front wheels using suitable wheel
stops.
1

14
3. Remove the vertical rod (1) and the LH stabiliser
strut (2).

26253

15
4. Raise the rear section of the tractor and place a
stand (1) beneath the tow bar support.

25647

16
84176554 -- 03--2008
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 15

5. Undo the retaining bolts and remove the rear LH

wheel.

25646

17
6. Undo the bolts (1) securing the cab to its mount-
ing
7. Raise the cab slightly and place a suitable piece
of wood between the hydraulic lift and the cab,
taking care to avoid contact with pipes.

TRE0193A

18
8. Remove the plug (1) and drain the oil from the
rear transmission--gearbox casing.
1

25622

19
9. Undo the bolts securing the cab to its mounting
(1).

TRE0193B

20

84176554 -- 03--2008
16 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

10. Position a stand (1) underneath the rear section

of the fuel tank.
1

25505

21

11. Fit lifting hooks (1) 380000227 onto the final dri-
ve box. Connect a hydraulic lift to the hooks, un-
do the retaining bolts and remove the LH final dri-
ve box from the transmission box.

TRE0188A

22

12. Remove the pin (1).

TRE0214A

23

84176554 -- 03--2008
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 17

13. Back off the link (1) and remove the complete
brake unit. 1

14. Check actuator and brake discs for wear.

ATTENTION TRE0215A
Always use appropriate tools to align fixing holes.
NEVER USE FINGERS OR HANDS. 24

15. Refit the final drive box to the rear transmission

box as follows:
— Refer to the illustrations on page 3 for the correct
orientation of the various components.
— Before refitting the final drive box to the rear tran-
smission box, thoroughly clean and degrease
the mating surfaces and apply a strip of sealing
compound of diameter about 2 mm as shown in
the illustration on page 18.
— Apply the torque settings given on page 2.
— Using tool 380800022 (A) as shown, position
boot (11) correctly on brake link (1). (see fig. 25)
— Fit the brake disc and spacers.
— Using tool 380000227 and a hydraulic lift, refit TRE0303A

the final drive complete with axle shaft. 25

— Fit the rear cab mounting retaining bolts.
— Remove the piece of wood between the cab and
the lift body.
— Tighten the bolt securing the cab to the rear LH
support.
— Fit the LH wheel.
— Fit the stabiliser strut and the vertical rod.
— Remove the stands.
— Screw in the oil drain plug and refill.
— Connect the battery negative lead.

84176554 -- 03--2008
18 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

TRE0304A

26
Diagram for application of sealing compound when fitting braking assembly between the final drive
housing and the rear transmission box.

The types of sealing compound to be applied are listed on page 1 of Section 00.

84176554 -- 03--2008
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 19

HYDRAULIC FRONT BRAKE PUMP

(OPTIONAL)
Removal -- Installation (Operation. 33 202 50)

ATTENTION
Handle all parts carefully.
Do not insert fingers or hands between one part and
another. Always wear the prescribed safety clothing,
including protective glasses, gloves and shoes.

Proceed as follows to remove the hydraulic pump.

1. Disconnect the negative battery cable (1).

2. Chock the front wheels using suitable wheel
stops.
1

27
3. Disconnect the electrical connections from the
plug (2) of the tank (1) and after retrieving the oil, 2
remove the service brake control pipes (3). 1

TRE0305A

28
4. Remove the steering wheel (1) retaining nut and
remove the steering wheel and hand throtltle
lever.

25758

29

84176554 -- 03--2008
20 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

5. Remove the four securing screws (1) from the

instrument panel (2).

25759

30

6. Disconnect the electrical leads (1) from the rear

of the instrument panel. Unscrew the the
tachometer cable (2). Remove the instrument
panel and store in a safe place.

2
TRE0435A

31
7. .Unscrew the rear hood screws (1)

8. Take off the complete rear hood (2). 2

TRE0436A

32
9. Remove the electrical connections:from the
pressure sensor (1) and remove the service
brake control pipes (2).
1

10

TRE0436A

33
84176554 -- 03--2008
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 21

10. Remove the retaining pins and withdraw the

brake pump control fork articulation dowels (1).
11. Undo the bolts (2) that secure the brake control
pumps to the cab and withdraw the pumps from
the engine side.

WARNING
Use appropriate tools to align the holes. NEVER
USE YOUR FINGERS OR HANDS.
26273

34

24664

35
Sectional drawing of service brake control pump (Master cylinder)

1. Spring. 4. Rear seal.

2. Pump body. 5. Central seal.
3. Control piston. 6. Front seal.

12. Refit the hydraulic brake control pump unit as fol-

lows.
— Fit the pumps, secure them, then connect them
to the control pedals.
— Connect the control pipes and the tank and pres-
sure sensor connections.
— Connect the negative battery cable.
— Carry out the following adjustment and bleed the
air from the circuit, observing the points de-
scribed on page 23.

84176554 -- 03--2008
22 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

HYDRAULIC BRAKE SLAVE CYLINDER 3 4

Removal--Refitting (Op. 33 202 50)
2
Proceed as follows to remove the hydraulic brake
slave cylinder:.

13. Remove the pin (1).

1
14. Remove the bolts securing the pump (2).
15. Take off the pipe connections (3) and (4).

TRE0214A

36
16. Withdraw the slave cylinder (1) from link.

TRE0213A

37
17. Remove the front hydraulic pump internal parts.
Check the seals and piston.

WARNING
Use appropriate tools to align the holes. NEVER
USE YOUR FINGERS OR HANDS.
TRE0306A

38
18. Refit the hydraulic brake slave cylinders as fol-
lows.
— Insert the master cylinder (1) from link.
— Fit the pin (1).
— Assembly the bolts securing the pump (2).
— Assembly the pipe connections (3) and (4).

84176554 -- 03--2008
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 23

HYDRAULIC FRONT BRAKE SYSTEM

(Optional) 2

Air bleeding (Op. 33 202 04 ) 1

Air must be bled whenever work is carried out on the

front brake hydraulic system.
Proceed as follows.

1. Thoroughly clean the external parts of the unit

around the bleed screws (1) fig. 40, (1) fig. 42
and the hydraulic oil tank lid (1) fig. 39. TRE0305A

2. Make sure that the hydraulic oil tank (1) is filled 39

up before and during the bleeding operations.

N.B. -- Filter all drained oil before reusing.

3. Depress the LH brake pedal, slowly and to the

end of its travel, so that the oil is placed under
pressure.

4. Keeping the pedal depressed, undo the bleed

screw (1) by half a turn and allow the oil mixed
with air bubbles to flow out.

5. Retighten the screw (1) and repeat the above op-

erations until the oil that comes out is free of air
bubbles.

6. Depress the LH brake pedal again to place the

circuit under pressure: this occurs when the trav-
el of the pedal returns to normal.
7. Repeat the above operations for the RH brake
pedal from the bleed screw (2). TRE0307A

40

8. Depress the LH and RH brake pedal, slowly and

to the end of its travel, so that the oil is placed un- 1
der pressure.

9. Keeping the pedals depressed, undo the bleed

screw (1) on the RH brake slave cylinder by half
a turn and allow the oil mixed with air bubbles to
flow out.
10. Retighten the screw (1) and repeat the above op-
erations until the oil that comes out is free of air
bubbles.
11. When the operation has been completed, re- TRE0237A
plenish the oil in the tank (1) fig. 39.
41

84176554 -- 03--2008
24 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

12. Depress the LH and RH brake pedal, slowly and

to the end of its travel, so that the oil is placed un- 1
der pressure.

13. Keeping the pedals depressed, undo the bleed

screw (1) by half a turn and allow the oil mixed
with air bubbles to flow out.
14. Retighten the screw (1) and repeat the above op-
erations until the oil that comes out is free of air
bubbles.

15. When the operation has been completed, re-

plenish the oil in the tank (1) fig. 39. TRE0237A

42
16. For JX60 & JX70 models front brake bleeding
screw (1) is located on front wheel drive shaft
that is shown on fig. 43.

TRE0237A

43
SERVICE BRAKE PEDALS
Adjusting height of service brake pedals
(Op. 33 120 08 )
1. With the brake pedals connected to their
respective forks and the pedal connecting pin
removed, check that the height (A) from the
centre of the pedals to the top of the carpet is:
162 mm for tractors fitted with cab or 205 mm for A
tractors without cab.

44

2. If adjustment is required, slacken the lock nuts

(2) and tighten or slacken bolt (1) until the re-
quired height (A) is obtained. Lastly tighten the
lock nuts.

2 1

45

84176554 -- 03--2008
 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 25

3. The length of the brake links must be

190mm ±1mm. If adjustment is required, fully 1
release the handbrake (lever down). Remove
the connecting pin (3). Slacken the lock nuts (1) 2
and turn the hexagon sleeves (2) until the length
of brake links is 190 mm. Finally, tighten the lock
nuts (1). 3

TRE0229A

46

SECTIONAL VIEW OF SLAVE CYLINDER

84176554 -- 03--2008
26 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

HAND BRAKE CONTROL

Adjusting travel (Op. 33 110 08)

The travel of the parking brake control lever must be

adjusted whenever work is carried out on the unit and
when the lever is not on the third notch of the gear
sector when the brake is engaged.

Proceed as follows.

1. Slacken the lock nut (1).

2. Tighten or slacken the adjusting screw (2) until 2
the control lever is locked on the third notch.
3. Tighten the lock nut (1).

TRE0217A

47

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 1

SECTION 35 -- HYDRAULIC SYSTEM

Chapter 1 -- Rear mechanical hydraulic lift

CONTENTS

Section Description Page

35 000 Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Description and operation of lift phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
35 110.30 Hydraulic lift -- disassembly reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
35.110.40--42--46 Hydraulic lift -- bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjusting the lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
35.110.08 Linkage adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
35.110.30 Pressure relief valve -- disassembly reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
35.110.32 Pressure relief valve -- setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
35.110.14 Lift control valve -- disassembly assembly and overhaul on bench . . . . . . . . . . . . . . . . . . 36
35.0101.10 Lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

35 000 -- MAIN SPECIFICATION -- TORQUE SETTINGS -- TOOLS -- SECTIONAL DRAWINGS --

DESCRIPTION AND OPERATION -- TROUBLESHOOTING
MAIN SPECIFICATION OF REAR MECHANICAL HYDRAULIC LIFT

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . position or draft control with a

combination of the two
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . two independent levers
LIFT--O--MATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . provides fast lifting/lowering
operations using pushbuttons,
without using the position or
draft control levers
Single--acting cylinder:
-- rated diameter and stroke:
All models mm 100x128
(in.) (3.9370x5.0394)
-- capacity:
All models cm3 1005
(in.3) (61.33)
Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 186 -- 191
psi (12697.69 -- 2770.21)
Cylinder safety valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 210 -- 215
psi (3045.78 -- 3118.30)
(continued overleaf)
84176554 -- 03--2008
2 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

MAIN SPECIFICATION OF REAR MECHANICAL HYDRAULIC LIFT

(continued)
Lift piston diameter:
-- All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 99.980 -- 100.000
(in.) (3.9362 -- 3.9370)
Internal diameter of cylinder liner:
-- All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 100.036 -- 100.071
(in.) (3.9384 -- 3.9398)
Clearance between piston and liner . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.036 -- 0.091
(in.) (0.0014 -- 0.0036)
Diameter of lift arm shaft (11, fig. 3) at position of bushings:
-- right--hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 54.970 -- 55.000
(in.) (2.1642 -- 2.1654)
-- left--hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 62.670 -- 62.700
(in.) (2.4673 -- 2.4685)
Internal diameter of bushings fitted on lift body:
-- right--hand side (8, fig. 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 55.100 -- 55.184(1)
(in.) (2.1693 -- 2.1726)
-- left--hand side (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 62.800 -- 62.884(1)
(in.) (2.4724 -- 2.4757)
Clearance between lift arm shaft and bushings . . . . . . . . . . . . . . . mm 0.100 -- 0.214
(in.) (0.0039 -- 0.0084)
Interference between bushings and their seats . . . . . . . . . . . . . . . mm 0.065 -- 0.185
(in.) (0.0026 -- 0.0073)
Axial clearance of shaft complete with lift arms . . . . . . . . . . . . . . . mm 0.2 -- 1.4
(in.) (0.0079 -- 0.0551)
External diameter of draft control idler shaft . . . . . . . . . . . . . . . . . . mm 21.967 -- 22.000
(in.) (0.8648 -- 0.8661)
Internal diameter of seats in support . . . . . . . . . . . . . . . . . . . . . . . . mm 22.020 -- 22.072
(in.) (0.8669 -- 0.8690)
Clearance between draft control idler shaft and position control mm 0.020 -- 0.105
idler shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (in.) (0.0008 -- 0.0041)
Diameter of position control idler shaft . . . . . . . . . . . . . . . . . . . . . . . mm 13.973 -- 14.000
(in.) (0.5501 -- 0.5512)
Internal diameter of position control idler shaft . . . . . . . . . . . . . . . . mm 14.016 -- 14.059
(in.) (0.5518 -- 0.5535)
Clearance between draft control idler shaft and position control
idler shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.016 -- 0.086
(in.) (0.0006 -- 0.0034)
Clearance between control valve block pin (8, fig. 4) and its seat
on the control valve block body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.008 -- 0.012(2)
(in.) (0.0003 -- 0.0005)
Clearance between lift control valve (10) and its seat on the con-
trol valve block body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.008 -- 0.012(2)
(in.) (0.0003 -- 0.0005)
Control valve block pin return spring (5, fig. 4):
-- free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 50.5
(in.) (1.9882)
-- spring length under load of 31.7 -- 35 N (7.1242 -- 7.8741 lb) mm 34
(in.) (1.3386)
Control valve return spring (9, fig. 4)
-- free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 44
(in.) (1.7323)
-- spring length under load of 103 -- 114.7 N mm 29
(in.) (1.1417)

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 3

MAIN SPECIFICATION OF IMPLEMENT HITCHING DEVICE

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . three--point linkage

Category:
-- All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Draft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of lower arms
with flex bar
Maximum liftable load with centre of gravity 610 mm from the
lower arm link ends: with arms horizontal
(with top link connected to hole on upper support):
-- JX60, JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg 2260
(lb) (4982.45)
-- JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . kg 2700
(lb) (5952.48)
Maximum liftable load: with arms horizontal
(with top link connected to upper support pin):
-- JX60, JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg 3000
(lb) (6613.87)
-- JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . kg 3565
(lb) (7859.48)
Flex bar diameter:
-- JX60, JX70, JX80, JX90, JX95 Models . . . . . . . . . . . . . . . . . . mm 24.867 -- 24.900
(in.) (0.9790 -- 0.9803)
Axial clearance of flex bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.2 -- 4.1
(in.) (0.0472 -- 0.1614)
MAIN SPECIFICATION OF HYDRAULIC PUMP (All models)

Filter
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . fixed to the pump housing on
suction side
Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear type with oil suction from
transmission casing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flanged on the rear left--hand
side of the engine
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOSCH
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A31
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of the engine gears
Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . left (counter clockwise)
Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 0.931
Maximum speed of pump rotation (with engine at maximum
power equivalent to 2500 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 2328
Bench output at 1450 rpm and pressure of 172 bar ( 175 kg/cm2):
-- for new or reconditioned pump . . . . . . . . . . . . . . . . . . dm3/min (in.3/min) 19 (1159.5)
-- for worn pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (in.3/min) 13.3 (811.6)
-- test oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C°(F°) 55 -- 65 (131 -- 149)
-- test oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 20
(continued overleaf)
84176554 -- 03--2008
4 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

MAIN SPECIFICATION OF HYDRAULIC PUMP (All models)

(continued)
Driven and driving gear shaft diameter . . . . . . . . . . . . . . . . . . . . . . mm 17.400 -- 17.418
(in.) (0.6850 -- 0.6857)
Internal diameter of seats in supports . . . . . . . . . . . . . . . . . . . . . . . mm 17.450 -- 17.470
(in.) (0.6870 -- 0.6878)
Clearance between gear shafts and their seats . . . . . . . . . . . . . . . mm 0.032 -- 0.070
(in.) (0.0013 -- 0.0025)
-- maximum clearance due to wear . . . . . . . . . . . . . . . . . . . . . . . . mm in.) 0.1 (0.0039)
Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . . . . . mm 0.020 -- 0.064
(in.) (0.0008 -- 0.0025)
Maximum wear on pump body, suction side, at position of gears mm(in.) 0.1 (0.0039)
Width of gears (5, fig. 104) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 24.000 -- 24.015
(in.) (0.9449 -- 0.9455)
Width of supports (4 and 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 24.490 -- 24.510
(in.) (0.9642 -- 0.9650)
Width of pump body (3) for gear seats and supports . . . . . . . . . . mm 73.135 -- 73.160
(in.) (2.8793 -- 2.8803)
Axial clearance of gears complete with supports in pump body
(recondition if necessary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.100 -- 0.180
(in.) (2.8793 -- 2.8803)

LIFT HYDRAULIC PUMP (OPTIONAL) DATA

Filter
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . fixed to the pump housing on
suction side
Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear type with oil suction from
transmission casing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flanged on the rear left--hand
side of the engine
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rexroth
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of the engine gears
Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . left (counter clockwise)
Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 1.080
Maximum speed of pump rotation (with engine at maximum
power equivalent to 2500 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 2700
Nominal flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/turn (in.3/turn) 0.01950 (1.1930)
Corresponding rated output for new pump . . . . . . . dm3/min (in.3/min) 48 (2929.14)
Corresponding rated output for pump with 300 hours
of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (in.3/min) 43 (2624.02)
Bench output at 1500 rpm and a pressure of 2175 psi (150 bar):
-- for new pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (in.3/min) 24.8 (1513.39)
-- for pump with 300 hours of work . . . . . . . . . . . . dm3/min (in.3/min) 22.3 (1360.83)
-- test oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °F 131 to 149
(°C) (55 to 65)
-- test oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CST

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 5

TORQUE SETTINGS
Torque setting
Thread
Nm ft lb
Lift
Capscrew, lift to rear transmission case (C1, Fig.1) . . . . . . . . . . . . . M 12 x 1.25 98 72.28
Capscrew, control valve body to lift (C3, Fig.28) . . . . . . . . . . . . . . . . . M 8 x 1.25 26 19.18
Capscrew, lift arm plates (C2, Fig.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . M 14 x 1.5 147 108.42
Plug, max. arm raising adjustment (3, Fig.28) . . . . . . . . . . . . . . . . . . M 12 x 1.25 103 75.97
Nut, position control shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 59 43.52
Nuts for lever quadrant bracket securing stud bolts (2, Fig.32) . . . . M8x1.25 25 18.44
Lift cylinder securing bolts: M14x1,5 211 155.63
M16x1.5 260 191.77
Securing bolts for top link attachment bracket . . . . . . . . . . . . . . . . . . M14x1.5 147 108.42
Inner lift arm securing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 61 44.99
Capscrew, suction connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 72.28
Capscrew, delivery connection on lift control valve . . . . . . . . . . . . . . M 10 x 1.25 59 43.52
Capscrew, lift pump (Fig.86) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x1 8 5.90
Nut, pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 41 30.24
Capscrew, flexion bar support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 221 163.00
Capscrew, chain support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 221 163.00
Capscrew, check link support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 221 163.00
Nut, tow bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 18 x 1.5 343 252.98
Control valves
Nut, control valve links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 20 14.75
Connection, outlet to fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 20 14.75
Plug, relief bar spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 20 14.75

84176554 -- 03--2008
6 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

TOOLS
HYDRAULIC LIFT EQUIPMENT X 380000225 Ring for fitting piston with lift seals.
X 380000274 Union for checking control valve
seal.
Warning -- The operations described in this section
cannot be carried out without the ESSENTIAL tools X 380000262 Punch for fitting lift arm shaft seals.
marked below with (X).
X 380000261 Punch for fitting needle bearings on
However, to ensure greater safety and obtain the control valve block control lever
best results while saving time and effort, we recom- bushing.
mend that these essential tools are used in conjunc- X 380000260 Punch for fitting needle bearings to
tion with the specific tools listed below as well as cer- upper/lower draft control levers and
tain tools which are to be made following the to draft control link rod.
construction drawings given in this manual.
X 380000230 Wrench for cylinder safety valve
setting ring nut.
X 380000217 Union for lift pressure relief valve
calibration.
X 380000218 Union for cylinder safety valve
380000215 Hand pump for valve calibration. calibration.

X 380000267 Wrench for maximum lift screw lock-

nut.
380000224 Lifting hook.
X 380000263 Draft control setting tool.
380000238 Hook adapter 380000224. X 380000264 Position control setting tool.

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 7

TRE0700A

Sectional drawing of lift

C1. .Lift capscrews. 8. L.H.Bushing.

C2 .Thrust plate capscrews. 10. Thrust washers.
G = 0.2 to 1.4 mm (0.0079 to 0.551 in.) 11. Top link support.
Shaft end float.
12. Piston rod pin.
1. Inner arm.
13. Travel limit adjusting screw.
2. Cross shaft.

3. Link arm. 14. Travel limit adjusting screw locknut.

4. Arm thrust plates. 15. Travel limit control rod.

5. R.H.Seal. 16. Control valve link pin.

6. L.H.Seal. 18. Draft control inner lever pivot.

7. R.H.Bushing. 19. Set screw.

84176554 -- 03--2008
8 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

TRE0701A

Sectional drawing of hydraulic lift control valve block

a. Detail of O--ring and arm lowering adjuster valve 14. Ring.
anti--extrusion ring.
15. Cylinder safety valve.
1. Spool valve.
16. Response control valve.
2. Spool valve seat.
17. Arm lowering speed control valve.
3. Plug.
18. Ball.
4. Spool return spring.
19. Response control valve adjusting pin.
5. Valve plunger.
20. Delivery connection.
6. Plunger spring.
7. Plug. 21. Check valve spring.
8. Piston seat. 22. Check valve.
9. Piston. 23. Check valve seat.
10. Spring cup. 30. .Retaining ring.
11. Draft sensitivity adjustment valve spring. 31. .Roll pin.
12. Draft sensitivity adjustment valve. 32. .Back--up ring.
13. Plug. 33. .O--ring.

Note -- Install the O--ring 33 and anti--extrusion ring 32 as illustrated in the drawing (a) using the protection device
380000266 and heating the ring 32 in oil at 50 °C.
Take care to install ring 32 with the flat surface facing upwards and concave surface facing O--ring 20. Take ne-
cessary precautions not to damage them.

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 9

DESCRIPTION AND OPERATION

The mechanical lift can operate with controlled Draft control is actuated by the flex bar positioned in
position or draft control and with a combination of the the special box mounted under the rear
two. The lift is controlled by two levers located on the transmission.
operator’s right. It also features the Lift--O--Matic The lower lift arms and corresponding control rods
device which raises and lowers the implement are connected to the flex bar.
without the need to use the position and draft control
levers.
Static oil
Oil in suction
Tractor brake circuit oil (brakes off)

Pressurised oil
Exhaust oil flow

5
1
9

8
7
26428
6
3
HYDRAULIC LIFT CIRCUIT
1. Delivery line to control valve (3). 6. Lift control valve.
2. Trailer brake control valve. 7. Suction line.
3. Auxiliary control valves. 8. Oil filter.
4. Auxiliary control valve lines. 9. Hydraulic pump.
5. Trailer brake control valve line.
84176554 -- 03--2008
10 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

22 T

T1

9 1
T3

V
T2
5 6
P 8

Pressurised oil

Oil in suction, delivery or return

Static oil

TRE0702A

ARM LIFT PHASE

F. Filter. 5. Plunger.
P. Hydraulic pump. 6. Plunger spring.
T. Lift arm piston. 8. Piston seat.
V. Reliefvalve. 9. Piston.
1. Valve spool. 22. Check valve.

When the position control lever (located on the Oil flow to piston (9) is cut off and plunger (5) is forced
operator’s right--hand side) is used to raise the arms, to the left by spring (6), thus closing the exhaust port.
the movement shown by the arrows is transmitted by Pressure oil opens check valve (22) and operates
the internal lever mechanisms to the control valve piston (T) to raise the arms.
block pin (1).
84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 11

18 17 22
15

12
1

V 5
9
P 6

Pressurised oil

Oil in suction, delivery or return

Static oil TRE0703A

NEUTRAL PHASE

F. Filter. 9. Piston.
P. Hydraulic pump. 12. Draft sensitivity valve.
V. Relief valve. 15. Cylinder safety valve.
1. Valve spool. 17. Arm lowering speed control valve.
5. Plunger. 18. Ball.
6. Plunger spring. 22. Check valve.

With spool (1) in the neutral position, oil is delivered and directs oil flow to the tank in the rear transmission
through the response adjusting valve (12) to piston housing rather than to the cylinder.
(9), which overcomes spring reaction (6) and moves
plunger (5) to the right. This opens the exhaust port
84176554 -- 03--2008
12 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

17 T

F1
4 1

12

V 9 5
P

Pressurised oil

Oil in suction, delivery or return

Static oil
TRE0704A

ARM LOWERING PHASE

F. Filter. 5. Plunger.
P. Hydraulic pump. 9. Plunger spring.
T. Lift arm piston. 12. Draft sensitivity valve.
V. Relief valve. 17. Arm lowering speed control valve.
1. Valve spool. F1. .Spool port
4. Spool return spring.

When the operator lowers the position control lever Unscrewing the screw (16) decreases the load on
on his right, the return spring (4) pulls spool (1) to the the spring (15), therefore the valve (14) can vibrate
right. Cylinder oil is exhausted under piston pressure faster, slowing down the descent speed. Tightening
(T) through lowering speed adjustment valve (17) the screw (16) slows down the vibration of the valve
and the port uncovered by spool. (14) that increases the descent speed of the arms
since the valve (14) can remain in position in corre-
Through spool port (F1) and draft sensitivity valve spondence with the larger orifice where the oil flows
(12) oil flows to piston (9), which holds plunger (5) in out from the cylinder.After adjusting the arm descent
the position shown, thus allowing pump delivery to be speed it will not depend on the weight bearing on the
exhausted past plunger (5). arms but will be virtually constant.

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 13

HYDRAULIC LIFT DIAGNOSTICS

Problems Possible causes Remedies

The lift does not raise. 1. Oil filter clogged. Replace filter.

2. Control valve jammed in dis- Release control valve.

charge position.

3. Hydraulic pump defective. Overhaul or replace pump.

The lift operates jerkily. 1. Oil filter clogged. Replace filter.

2. Air has got into the pump suc- Check that the couplings are airtight
tion line. and the seals are effective.

The lift raises too slowly. 1. Oil filter clogged. Replace filter.

2. Oil leaking past piston seals or Replace all defective seals.

seals on discharge fitting to
cylinder, with consequent loss
of pressure.

3. Hydraulic pump defective. Overhaul or replace pump.

The lift operates too quickly. 1. Foreign matter between the Take off the valve, remove the foreign
ball and its seat on the dis- matter and inspect the oil filter.
charge control valve.

2. Discharge control valve ball Replace discharge control valve.

seal defective.

3. Discharge control valve piston Take off the valve and free the piston.
jammed.

The lift operates too slowly. 1. Discharge ports on the dis- Take off the valve, unblock the holes
charge control valve blocked. and inspect the oil filter.

2. Discharge control valve piston Take off the valve and free the piston.
jammed.
(continued overleaf)

84176554 -- 03--2008
14 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

HYDRAULIC LIFT DIAGNOSTICS

(continued)

Problems Possible causes Remedies

The lift is unable to keep the load 1. Defective seal on check valve. Take off, check, clean and if neces-
raised (with
( the engine
g running,
g sary replace the parts concerned.
th load
the l d moves up and d down
d
rhythmically; with the engine 2. Oil leaking past the seals on Replace seals.
turned off, the load lowers). the control valve block pin
seat.
3. Control valve block pin seal Take off and clean the seal and
defective. replace the control valve block pin
and its seat if defective.

4. Oil leaking past the lift piston Replace the seals.

seal or the seals on the
cylinder oil discharge fitting.
5. Defective seal or cylinder safety Replace the valve.
valve set to very low value.

The pressure relief valve cuts in 1. Lift arm travel set incorrectly. Set correctly.
when the lift arms reach their com-
pletely raised position.

Lift has poor lifting capacity. 1. Pressure relief valve set Replace the valve.
incorrectly.

2. Cylinder safety valve set Replace the valve.

incorrectly.
3. Poor pump efficiency (gener- Overhaul or replace the pump.
ally accompanied by a consid-
erable increase in lift time).

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 15

REMOVAL -- REFITTING -- OVERHAUL OF REAR MECHANICAL HYDRAULIC LIFT ASSEMBLY

REAR HYDRAULIC LIFT ASSEMBLY
Removal--Refitting (Op. 35 110 30)

DANGER
Lift and handle all heavy parts using suitable lifting
equipment with sufficient hoisting capacity.
Check that the assemblies or parts are held firmly
and supported by suitable slings and hooks. Make
sure nobody is standing near to the load.

To remove the hydraulic lift assembly from the rear

transmission casing, proceed as follows.
1. Disconnect the negative cable (1) from the
battery.

7
2. Remove the top link (1).
1

TRE0112A

8
3. Undo the bolts (1) and use a chain and hoist to
remove the pick--up hitch hook (2) from the PTO 2
box.
1

TRE0113A

9
84176554 -- 03--2008
16 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

4. Remove the split pins and withdraw the shafts

(1). Remove the lift rods (2) and the lateral
stabiliser struts (3).
1

TRE0114A

10
5. Unscrew: the trailer brake control pipe (1) and
the auxiliary control valve pipes from the support
1 2
plate (2).

25537

11
6. Remove auxiliary control valve pipes (2) from
their support (1).

TRE0140A

12
7. Undo the two bolts (1) that secure the seven--
pole socket (2) and remove the socket.
1
2

TRE0122A

13

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 17

8. Undo the bolts (1) and remove the support (2).

1
2

TRE0115A

14
9. Undo the bolt (1) and disconnect the breather
pipe connection.

TRE0126A

15
10. Remove the electric socket (1).

TRE0123A

16
11. Remove the retaining springs (1) and detach the
two control rods (2) from the lift levers.

TRE0127A

17

84176554 -- 03--2008
18 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

12. Remove the LIFT--O--MATIC control rod (1).

TRE0117A

18
13. Connect a suitable hoist (2) to the cab lifting
hooks (1) and tension the hoist. 2
1

TRE0137A

19
14. Unscrew the two cab front securing bolts (1).

TRE0129A

20
15. Unscrew the two cab rear securing bolts (1).
Raise the cab approximately 5--6 cm
(0.1969--0.2362 in.) and place wooden blocks
(1) between the cab upright and the housing.
Lower the hoist so that the cab rests securely on
1
the wooden block.

TRE0128A

21

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 19

16. Remove the pipes on the lift (1) and the control
valve body (2).

TRE0138A

22
17. Unscrew the bolts (1) that secure the hydraulic
lift assembly to the transmission casing.
1

25556

23
18. Fit tool 380000237 (1) on the lift and tighten the
four bolts (2).
1 2

25558

24
19. Fit tool 380000224 (1) onto tool 380000238 (2).
Attach the hoist to tool 380000224, raise the
1 2
hydraulic lift by a few centimetres and pull it
backwards, tilting it so that it clears the breather
pipe (3) without damaging it.

25559

25

84176554 -- 03--2008
20 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

20. Refit the hydraulic lift assembly to the transmis-

sion casing as follows.

WARNING
Always use appropriate tools to align fixing holes.
NEVER USE YOUR FINGERS OR HANDS.

Before refitting the hydraulic lift assembly to the

rear transmission casing, clean and degrease
the mating surfaces thoroughly and apply a strip
of sealing compound of about 2 mm (0.0787 in.)
diameter as shown in fig. 26.

Apply the torque settings listed on page 5.

Use tools 380000224 and 380000238 to fit the

hydraulic lift assembly to the transmission casing
26295
and tighten the bolts securely.
26
Insert the electric leads into their clips on the lift
body.
Diagram showing application of sealing
compound when fitting the hydraulic lift
Fit the lift control pipe. assembly to transmission casing.
The types of sealing compounds to be applied are
Raise the cab by a few millimetres, remove the specified on page 1, section 00.
wooden blocks and tighten the bolts to secure
the cab.

Fit the trailer brake control pipe (if fitted) and the
oil filler pipe.

Connect the Lift--o--Matic control rod.

Connect the lift control levers to their linkages.

Fit the windscreen washer tank and transmission

breather pipes onto the cab upright.

Fit the top link attachment bracket and the quick--

fitting support plate for auxiliary control valves.

Fit the seven--pole socket, the earth leads, the

quick--fittings and the trailer brake control pipe to
their corresponding support brackets.

Fit the additional control valve rods and the PTO

operating mode rod.

Fit the ground lift control lever.

Fit the lift rods and the lateral stabiliser struts.

Fit the pick--up hitch hook and the top link.

Connect the negative cable to the battery.

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 21

REAR HYDRAULIC LIFT ASSEMBLY

Disassembly--Assembly
(Op. 35 110 40 -- 35 110 42 -- 35 110 46)

1
DANGER
Handle all parts with the utmost care.
Do not place your hands or fingers between one part
and another. Wear the prescribed safety clothing,
including glasses, gloves and protective footwear.
To disassemble the hydraulic lift, proceed as follows.
TRE0143A

27
1. Position the hydraulic lift on a stand (1) fig. 27,
that will allow the assembly to be rotated.
2. Unscrew the securing bolts (1) and remove the
control valve block (2) fig. 28. 1
2

TRE0133A

28
3. Unscrew the two cylinder securing bolts posi-
tioned outside the cylinder body. Turn the lift
assembly and unscrew the lateral bolt (3).
1 2
4. Undo the bolts (1) that secures the internal
linkage (2) to the lift cylinder.

25626

29
5. Remove the cylinder (1) complete with piston.
1

25627

30

84176554 -- 03--2008
22 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

6. Remove the retaining pin from the internal draft

lever, unscrew the nut (1), then remove the unit
complete with internal linkages and the LIFT--
O--MATIC control lever.
1

TRE0134A

31
7. Take off the snap ring and remove the internal
position control lever (1). 1
Unscrew the nuts (2) and remove the spring and
fixing bracket (4).
8. Take off the snap ring and remove lever (3), the
friction discs, lever (5) and the stud bolts.

3 2
TRE0132A 4
32
9. Slacken the eccentric pin (2) retaining bolt (1),
withdraw the eccentric pin and remove the
internal linkage. 1
10. Unscrew the bolt (3), remove the washer (4), 2
withdraw the lift arm (5) and remove the thrust
washer. Repeat on the other lift arm. 3
4
5

25631

33
11. Remove the crimping on the internal arm locking
bolt (1) and unscrew the bolt. Withdraw the shaft
(2) and remove the seals (3).
1 2

3
25632

34

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 23

12. Use compressed air to remove the piston (2)

from its cylinder (1). 2
1

26297

35
13. Use striker tool 380000260 (1) to replace the
bearings in the internal draft control lever (2). 2
1
14. Use striker tool 380000261 to replace the control
valve block control lever bearings.
15. Fit the hydraulic lift as follows.

WARNING
Always use appropriate tools to align fixing holes.
NEVER USE YOUR FINGERS OR HANDS.
26298

36
16. Insert the piston (1) into its cylinder (3), using tool
380000225 (2).
1 2

25634

37
17. Fit the lift arm shaft (2) and the internal arm (1)
inside the lift box, matching up the reference
marks, as shown. Tighten the securing bolt.

26299

38

84176554 -- 03--2008
24 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

18. To avoid damaging the internal seal lips, use a

flexible brass sheet (1) of size 200 x 90 mm 1
(7.8740 x 3.5433 in.) and thickness
0.05 -- 0.1 mm (0.0020 -- 0.0039 in.). Roll the
sheet up and insert the seal inside. Position the
unit on the spline and push the seal manually into
its seat. Then remove the sheet.

2
26300

39

19. Use striker tool 380000262 (1) to complete the

fitting of the seals into the their seats on the lift
1
arm shaft.

26326

40

20. Fit the lift arms (1) on the shaft, matching up the
reference marks, as shown. Secure them by
tightening the bolts.

25633

41

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 25

21. Fit the internal linkages and the corresponding

eccentric pin. Fasten the eccentric pin by
tightening the securing bolts.
22. Fit the control levers complete with friction discs,
snap rings and stud bolts.
23. Fit the spring and use the bracket to secure the
lever unit.
24. Fit the internal position control lever.
25. Fit the internal linkages and the Lift--o--Matic
control lever.
26. Fit the cylinder complete with piston and secure
it.
27. Fit the internal linkages and fasten them to the
cylinder.
28. Clean the mating surfaces thoroughly and apply
a 2 mm (0.0787 in.) diameter strip of sealing
compound to the lift box, as shown in fig. 42.
The types of sealing compound to be used are
shown on page 1, section 00.
Fit the hydraulic control valve block on the lift box TRE0705A
and secure it using the screws.
Make the following adjustments. 42

NOTE -- The adjustments must be made in the order

specified.

84176554 -- 03--2008
26 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

ADJUSTING THE LIFT

The following adjustments refer to a lift assembly
without hydraulic control valve block and mounted on
a rotary stand.
These adjustments must be made in the order
specified.
The LIFT--O--MATIC device must be kept turned off
(external control lever (1) locked in the vertical
position) until otherwise specified.

1
TRE0131A

43
Adjusting position control
Proceed as follows:
2
1. Move the external position control lever (1) fully
forward, against the spacer for the stud bolt
securing the spring retaining bracket. Move the 1
external draft control lever (2) fully rearward
against the spacer.
2. Turn the lift arm control shaft until the internal
arm is in contact with the lift body.

TRE0135A

44
3. Use tool 380000267 (1) figure 45, to slacken the
lock nut (4) figure 46. Loosen the end stop
1
adjusting screw (5) until it is no longer in contact
with the control valve block control lever (3).

TRE0706A

45

1 2 3 4

5
F1

L1

25638

46

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 27

4. Fit tool 380000264 (4) fig 47, to the lift body. The
tool has a plunger operating in a tube, the outer 1 2 3
end of which has two reference surfaces (1) and
(5).
5. Using two spanners (2) and (3), unscrew the lock
nut (1) fig. 46 and tighten or loosen the
adjustable push rod (2) fig. 46, so that the end of 6
the plunger (5) fig 47, is flush with the outer
register surface (6) of the tool.

NOTE -- This corresponds to a distance (L1 fig. 46)

5
of 82.0 -- 82.1 mm (3.2283--3.2323 in.) between the 4
end of the lever (3) fig. 46 and the front surface of 25639
the lift body when a force (F 1 fig. 46) of
4 -- 4.5 da N (25.40 -- 39.82 in.lb) is applied to the 47
end of the lever.

6. Tighten the lock nut (1) fig. 46.

7. Move the external position control lever (1) fully 1
rearwards against the stud bolt spacer. Turn the
lift arm control shaft so that the piston is fully
forward and check that the plunger (5) fig. 47 is
flush with or slightly inside the inner reference
surface (1) of the tool (4).

NOTE -- This corresponds to a distance (L1) fig. 46,

of greater than 86.5 mm (3.4055 in.) between the TRE0136A

end of the lever (3) and the front surface of the lift
48
body when a force (F 1) of
4 -- 4.5 da N (25.40 -- 39.82 in.lb) is applied to the
end of the lever.

Adjusting the maximum height of the lift arms

Proceed as follows.
2
8. With tool 380000264 (4) fig. 47 fitted on the lift
body, move the external draft control lever (2)
fully rearward, against the spacer. Move the
external position control lever (1) fully forward
1
against the spacer.
9. Turn the lift arm control shaft until the internal
arm touches the lift body.

TRE0135A

49
84176554 -- 03--2008
28 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

10. Connect the fitting (5) of tool (2) to the workshop

compressed air system. Feed air into the
1
cylinder barrel to make the piston perform its
complete lifting stroke and use the air pressure
to keep it in this position.
11. Using tool 380000267 (1), tighten the screw (5) 5
fig. 46, until the end of the plunger (4) is flush with
the inner reference surface (3) of the tool (2) or
up to 0.5 mm (0.0197 in.) further in. 4
2
3
TRE0707A

50
NOTE -- This corresponds to a distance (L1) of
86.3--86.7 mm (3.3976--3.4134 in.) between the end 1 2 3 4
of the lever (3) and the front surface of the lift body.

5
12. Tighten the lock nut (4) to a torque of 15 Nm F1
(11.0624 ft lb).
L1

25638

51
Adjusting draft control
Proceed as follows:
1 2
13. Remove the end section of the draft control rod
(3) and mount it on the rod (5) of tool 380000263
(1). Fasten it using lock nut (4).
5 L3
14. Place the tool 380000263 (1) complete with its
rod (5) and the end section of the draft control rod 4
(3) on a surface plate. Using a micrometer depth
gauge (2), measure the distance (L3) between
3
the upper surface of the rod and the micrometer
gauge bearing surface on the tool (be sure to
tighten rod (3) onto rod (5) so that the surface of 25645
rod (5) is a few mm lower than the micrometer
52
bearing surface on the tool).
15. With tool 380000264 (2) fig. 50 mounted on the
lift body and disconnected from the compressed 2
air system, move the position control lever (1)
fig. 53 and the draft control lever (2) fully back 1
against the spacer.
16. Move the eccentric pin (1) fig. 58, connected to
the internal draft control lever, to the horizontal
position with the eccentric cam pointed towards
the rear of the lift assembly.

TRE0136A

53

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 29

17. Fit tool 380000263 (1) to the lift body and fasten
it to the two holes in the box as shown in figure
54. 1

25642

54
18. Turn the screw (2) fig. 54 on the internal draft
control lever (3) fig. 54 until the end of the plunger
(1) fig. 55 is flush with the inner reference surface 2
(3) of tool 380000264 (2). 1
3

TRE0708A

55
19. Turn the eccentric pin (1) slightly to withdraw the
end of the plunger of tool 380000264 as far as
possible.

20. Again turn the screw (2) fig. 54 to adjust the 2 3 1

internal draft control lever (3) until the end of the
plunger fig. 56 is flush with the inner reference
surface (3) of the tool 380000264.

21. Finally turn the eccentric pin (1) fig. 56 until the
end of the plunger is flush with the outer register
surface (2) of the tool 380000264.

TRE0709A

56
22. Insert rod of tool 380000263 (1) into the internal
draft control lever seat (2).
1 L2
23. With the end of the plunger of tool 380000264
flush with the outer reference surface (2) fig. 56,
set the adjustable linkage (3) fig. 57 and use a 2
micrometer depth gauge to measure the dis-
tance (L2) between the upper surface of the rod 3
and the micrometer gauge bearing surface on
the tool 380000264 (1).

26348

57

84176554 -- 03--2008
30 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

24. The distance (L2, page 29) must be:

L2 = L3 +L4
where:
L3 = distance measured with tool 380000263
mounted on a surface plate:
L4 = 22.9 -- 23.1 mm (0.9016 -- 0.9094 in.). Oper-
ating distance between the lift box bearing sur-
face on the transmission casing and the rod rest-
ing surface on the lever (3, fig. 57).

NOTE -- This corresponds to a distance (L1, fig. 46)

of 82.0 -- 82.1 mm (3.2283 -- 3.2323 in.) between the
end of the lever and the front surface of the lift body,
measured with a force (F1) of 4 -- 4.5 da N
(25.40 -- 39.82 in. lb) applied to the end of the lever.
2 3 1
WARNING -- Always make sure that when the plung-
er of tool 380000264 is flush with the outer reference
surface (2) the the distance (L2, fig.57 ) is:
L2 = L3 +L4
where:
L3 = distance measured with the tool 380000263
mounted on the reference surface;
L4 = 22.9 -- 23.1 mm (0.9016 -- 0.9094 in.). Operating
distance between the lift box bearing surface on the TRE0710A
transmission casing and the rod bearing surface on 58
the lever (3) fig. 57.
If these conditions are not met, adjust the eccentric
pin (1) and the knurled screw (2) fig. 57 of tool
380000263 until they are.

1
25. Fit the threaded dowel (3) and tighten the screw
(1) without bending over the safety washer (2). 3 2
26. Remove the tools 380000264 and 380000263
and fit the hydraulic control valve block on the lift
body. 26350

59
Proceed to mount the lift assembly onto the tractor
as follows.
1
WARNING -- First position tool 380000263 (1) on a
surface plate and use a micrometer depth gauge (2)
2
to measure the distance (L5) between the surface
plate and the point where the micrometer gauge
rests on the tool.
Make a note of the measured distance (L5). L5

26352

60

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 31

27. Fit the draft measuring device complete with

transmission lever (3) and draft control lever (2),
but without the flex bar, onto the rear transmis-
sion casing. L6 L7
28. Rest the transmission lever (3) on the draft 1
measuring device box and fit tool 380000263.
Fasten it to two holes on the box so that the draft
control rod (2) fits exactly inside the tool hole as
shown in figure 62
29. Using a micrometer depth gauge (2) fig.62,
measure the distance (L8) fig.62, between the 2
top end of the rod (3) fig.62 and the micrometer
gauge resting surface on the tool.

NOTE -- The distance (L6) the top end of rod (2) pro- 3
trudes with respect to the transmission casing (with
flex bar removed) is given by:
L6 = L5 -- L8
where: 26353

L5 and L8 = distance measured with tool 380000263

61
fitted on the surface plate (L5) fig. 60 or on the trans-
mission casing (L8) fig. 62.

30. Fit the flex bar and measure the new distance
(L9) between the top end of the rod (3) and the 1
micrometer gauge resting surface on the tool.
2
NOTE -- The distance (L7) fig. 61, that the top end of
the rod (2) fig. 61, protrudes with respect to the trans- L8/L9
mission casing (with flex bar fitted) is given by:
L7 = L5 -- L9
where: 3
L5 and L9 = distance measured with tool 380000263
mounted on surface plate (L5) fig. 60 or on the
transmission casing (L9). 26354

62
31. Check that the distance (L7) is at least 5 mm
(0.1969 in.) greater than the distance (L6).
32. Slacken the lock nut (1) fig. 61 and adjust the
length of the draft control rod until it protrudes by
a new distance (L7 = 18.3 -- 18.5 mm (0.7205 --
0.7283 in.)).
33. This distance (L7) can be calculated by subtrac-
tion using tool 380000263:
L10 = L5 -- L7
where:
L7 = 18.3 -- 18.5 mm (0.7205 -- 0.7283 in.).
Distance the end of the rod (2) fig. 61, protrudes
with respect to the transmission casing during
operation.
L5 = distance measured with tool 380000263
mounted on the surface plate.
L10 = distance to be measured with the
micrometer gauge on tool 380000263.
34. Tighten the lock nut (1) fig. 61, and mount the lift
on the tractor.
84176554 -- 03--2008
32 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

ADJUSTING LINKAGES (Op. 35 110 08)

Adjusting position control linkage.
Proceed as follows.
1. Move the position control lever (1) fully forward
on the quadrant and check that the distance (L) L
is between 15 and 20 mm
(0.5906 and 0.7874 in.).
1

TRE0108A

63
2. Move the external position control lever (1) fully
rearward, against the spacer.
3. Connect the control linkage and adjust its length,
if necessary.
4. Fasten the linkage using the lock nuts.

2
1

TRE0121A

64
Adjusting draft control linkage
Test conditions:
engine running at medium speed;
allow the oil in the system to reach a temperature
1
2
of 30 -- 40 °C (86 -- 104 °F).
Then proceed as follows:
5. Move the position control lever (1) fully forward
on the quadrant and the draft control lever (2) to
a distance (L1) of 15 -- 20 mm L1
(0.5906 -- 0.7874 in.) from the beginning of the
slot.
TRE0116A
6. Move the draft control lever (2) fully back against
the spacer. 65
7. Connect the control linkage and adjust its length
if necessary.

1 2

TRE0121A

66

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 33

8. Move the draft control lever (2) to a distance (L2)

of 95 -- 105 mm (3.7402 -- 4.1338 in.) from the 2
beginning of the slot and check that at this
position the arms start to rise.
L2
9. If they do not, adjust the eccentric pin (1) fig. 58,
to restore this distance.
1
10. Fasten the eccentric pin using the securing bolt
(1) fig. 59.

67
Adjusting LIFT--O--MATIC device
Proceed as follows: 1
11. Move the position control lever (1) and the draft
control lever (2) fully forward in the sector.

TRE0116A

68
12. Raise the lift arms by means of the lever (1).

1
2

TRE0017A

69
13. Tighten the nut (1) fig. 70, until the arms lower.
14. With the lever (1) fig. 69, still in the same
position, unscrew the nut (1) fig. 70, until the
arms begin to rise.
15. Unscrew the nut (1) by another 1.5 turns.
1
16. Using the levers (1) and (2) fig. 69, lower and
raise the arms a few times to ensure that the
system is operating correctly.

TRE0117A

70

84176554 -- 03--2008
34 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

LIFT PRESSURE RELIEF VALVE

Removing--Refitting (Op. 35 110 30)
Auxiliary control valve blocks. The lift pressure relief
valve (1) is located as shown in fig.71)
If defective, remove and change the valve.
1

TRE0139A

71

LIFT PRESSURE RELIEF VALVE

Calibration (Op. 35 110 32) 1
Proceed as follows.
1. Run the engine until the oil reaches a tempera-
ture of about 50°C (122 °F).
2. Insert the fitting 380000554 (1) in a quick--fit
female half--coupling and connect it to the 0 --
3555.84 psi scale pressure gauge supplied with
kit 380000240.
3. Activate the half--coupling control valve block
lever until the pressure relief valve cuts in. TRE0142A

4. With the engine running at medium speed the 72

pressure gauge must show a pressure of about
186 -- 191 bar (2697.69 -- 2828.22 psi). If the val-
ve setting does not correspond to the prescribed
value, it is best to change it immediately. If ne-
cessary it can be adjusted by turning the cap, af-
ter removing the plastic sealing and unscrewing
the locknut, with a 4mm hex wrench. Tighten it to
increase the valve setting, unscrew it to decrea-
se the setting.
Pressure relief valve section.
1. One--way valve.
2. Additional control valve body.
3. Pressure relief valve body.
4. Valve spring.
5. Locknut.
6. Adjustable needle (4 mm wrench).
7. Plastic sealing.

73

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 35

NOTE -- The pressure relief valve setting can be

bench tested as follows: 1 2 3
8. Fit the pressure relief valve (1) on the valve union
380000217 (2) and connect the union to the hand
pump 380000215 (3).
9. Operate the hand pump (3) and check that the
pressure relief valve opens at a pressure of about
186 -- 191 bar (2697.69 -- 2828.22 psi).
Warning -- During assembly, the pressure relief valve
is calibrated using oil flow and the check using hand
pump 380000215 is to be considered only approxi-
mate. It is therefore advisable to check the pressure
relief valve setting with the valve fitted on the tractor
as described above.

25720

74

84176554 -- 03--2008
36 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

LIFT CONTROL VALVE BLOCK, DETACHED

Disassembly--Assembly (Op. 35 110 14)
Proceed as follows.

WARNING
Handle all parts with the utmost care.
Do not place your hands or fingers between one part
and another. Wear the prescribed safety clothing, in-
cluding glasses, gloves and protective footwear.

1. Before removing the control valve, first remove

the transmission cover (1).
1

TRE0104A

75
2. Before disassembly, thoroughly clean the sur-
faces of the control valve block. Lock the control
valve block in a vice.

3. Unscrew the cap (1) and remove the spring (2)

and the control valve (3).
1 2 3

25707

76

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 37

4. Take off the cylinder safety valve (4) and remove

the arm lowering speed adjustment valve (3), the
spring (2) and the pin (1).
1 2 3 4

25709

77
5. Remove the check valve union (1), spring (2) and
ball (3).
1 2 3

25711

78
6. Take off the control valve block pin (1) and
remove the seat (3) and the spring (2). 1 2 3

25713

79

84176554 -- 03--2008
38 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

7. Check the wear of the seals on the control valve

block pin seat. If damaged, replace them using 1
protection device 380000275 (1), following the
instructions given on page 9.

8. Check the efficiency of the control valve block pin

as follows.

25714

80
9. Fit the control valve block pin (2) complete with
seat (3) on the tool 380000274 (1).
1 2 3

25715

81
10. Fit the control valve block pin spring (1) and the
cap (2) of tool 380000274. Tighten the cap as far
as it will go and check that the control valve block
1 2
pin slides in its seat.

25716

82
11. Fit tool 380000274 (2) on the hand pump
380000215 (3), supplied with HYDROSYSTEM
68 oil. Connect a dial gauge (1) and secure it with
1
its screw.
2

25717

83

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 39

12. Operate the hand pump and at the same time

tighten screw (1) on the tool until oil stops flowing
out through the control valve block pin seat
outlet.

13. Now zero the dial gauge.

14. Tighten the screw (1) on the tool further to move
the control valve block pin by 1.8 -- 2 mm
1
(0.0709 -- 0.0787 in.), using the dial gauge to
read this distance.

25718

84
15. Operate the hand pump until the oil in the system
is at an initial pressure of 245 bar -- 3553.41 psi.
Using the pressure gauge, check that it takes
more than six seconds for the pressure to fall
from 196 bar -- 2842.73 psi to
98 bar -- 1421.36 psi. If it takes less than this,
replace the control valve block pin. Bear in mind
that this part is supplied together with its seat.

25719

85

84176554 -- 03--2008
40 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

16. Fit the cylinder safety valve (1) on the valve union
380000218(2) and connect it to the hand pump
380000215 (3).
1 2 3
17. Operate the hand pump (3) and check that the
cylinder safety valve opens at a pressure of
210 -- 215 bar (3045.78 -- 3118.30 psi). If the
valve setting does not correspond to the speci-
fied value, it is best to replace the valve straight
away. If necessary, however, it can be adjusted
by turning the threaded cap using spanner
380000230. Tighten to increase the valve setting
value, or slacken to decrease the value.
18. Fit the hydraulic control valve block as follows:

WARNING
Always use appropriate tools to align fixing holes.
NEVER USE YOUR FINGERS OR HANDS.
Refer to the illustrations on page 8 for the
orientation of the various components:
Apply the torque settings listed on page 5.
Fit the complete control valve block pin.
Fit the check valve.
Fit the cylinder safety valve.
Fit the control valve.
Fit the complete pressure control valve.
Fit the cover on the control valve block.

25720

86

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 41

24622

87

Hydraulic lift control pump components

1. Front cover. 11. Driving shaft seal.

2. Cover seals. 12. Snap ring.
3. Pump body. 13. Safety washer.
4. Gear support. 14. Nut.
5. Driven and driving gear shafts. 15. Bolt.
6. Gear support. 16. Washer.
7. Bushing. 17. Key.
8. Control side cover. 18. Bushing.
9. Driving shaft seal. 19. Safety washer.
10. Spacer. 20. Nut.

HYDRAULIC LIFT CONTROL OIL PUMP

Removal -- refitting with pump removed 6. Remove the seals (2) and the anti--extrusion
(Op. 35 0101 10) rings.
Proceed as follows:
1. Remove the cover fastening nuts (20), then the
bolts (15) and the safety washers.
2. Remove the nut (14) that fastens the sleeve to the
pump driving shaft and the safety washer.
3. Remove the front cover (8), the snap ring (12)
and the seals (9 and 11).
4. Mark parts 3, 4, 5 and 6 to enable them to be
remounted in the same position if they are in
good condition.
5. Remove the supports (4 and 6) and the gears (5)
from the rear cover (8) and the pump body (3).
84176554 -- 03--2008
42 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1

Once the parts are removed, proceed as follows:

7. Check that the gear contact surfaces are flat and

perpendicular to their supports. Insert a thin layer
of carbon black. Small rough spots can be
removed using extremely fine and well lubricated
abrasive paper.

8. Check that the axial play of the gear--support unit 2

in the pump body is 0.090 -- 0.160 mm
(0.0035 -- 0.0063 in.). The distance (2) must be
0.090 -- 0.160 mm (0.0035 -- 0.0063 in.) smaller
than the distance (1).
If necessary, true the flat surfaces involved using
lubricated abrasive paper to remove extremely small
quantities of material. Ensure that axial play is still
within the limits of 0.090 -- 0.160 mm 25227

(0.0035 -- 0.0063 in.). 88

9. Clean all constituent parts thoroughly.

10. Replace the seals (2, 9 and 11).

11. Lubricate the parts with the same oil as the

system. Refit the pump, referring to fig. 87 and
proceed as follows:

12. refit, performing operations 6 to 1 in reverse

order;

always ensure maximum cleanliness to prevent

foreign matter from entering, as this could dam-
age the pump;

fit together previously marked parts (3), (4), (5)

and (6) fig.87; see procedure on page 41 to refit
them in their original position;

mount the gear supports (4) and (6) fig. 87, in the
pump body. Mount them with the fittings on the
external circumference matched up with the dis-
charge pipes and the front faces with lubrication
millings in contact with the gears;

fit the plastic anti--extrusion rings on the seals (2)

fig. 87:

mount the seals (9) and (11) fig. 87, on the control
side cover (8), complete with spacer (10). Mount
them so that the cavity is between the seal lips
on the opposite side from this spacer. Finally fill
the cavity with AKCELA Multi--Purpose
Grease 251H EP grease.

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2 1

SECTION 35 -- HYDRAULIC SYSTEM

Chapter 2 -- Open centre system auxiliary control valves

CONTENTS

Section Description Page

35 000 Main data -- Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Auxiliary control valves -- sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see chapter 1
35 204 46 Auxiliary control valves -- Assembly--Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Spool binding test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Spool leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjustment of the automatic detent release pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

35 000 -- MAIN DATA -- TORQUE DATA -- TOOLS -- SECTIONAL VIEWS

-- DESCRIPTION AND OPERATION

MAIN DATA

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . full--flow filter, with paper

cartridge, (common to the
hydraulic lift circuit)
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear pump (common to the
hydraulic lift circuit, see chapter 1)
Auxiliary control valves
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . valve stack (up to a maximum of
3 valves) attached to the rear of
the centre housing
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . manually with hand lever
Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 186--191
(psi) (2697.70 -- 2770.22)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . convertible for operation of single--
or double--acting cylinders,
convertible for operation of single--
and double--acting cylinders and
with automatic detent release, for
operation of double--acting
cylinders with float control and
automatic detent release

TOOLS List of specific tools required for the various

operations described in this section.
WARNING: The operations described in this section
must only be carried out using the ESSENTIAL tools 380000240 Universal pressure testing kit.
marked below with an (X).
For greater safety and to obtain the best results while
saving both time and effort, we recommend that
these essential tools are used in conjunction with the
specific tools listed below, and with certain tools
which are to be made following the constructional
drawings in this manual.

84176554 -- 03--2008
2 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

TRE0711A

Auxiliary control valves -- Section views

a. Auxiliary control valve for convertible single/ 11. Spool return spring.
double--acting cylinder. 12. Spring cup.
b. Auxiliary control valve for convertible single/ 13. Seal.
double--acting cylinder with automatic hydrauli- 14. Seal.
c release. 15. Control lever
16. Control lever support.
17. Tapered needle.
NOTE: Section view of auxiliary control valve 18. Seal.
configured for operation of double--acting cylinder 19. Spring.
with float and automatic detent release was shown 20. Detent balls.
at page 3 . 21. Detent ball support.
22. Seal.
23. Internal plunger.
1. Cover. 24. Spring.
2. Spacer. 25. Cover.
3. Spool. 26. Detent release pressure adjuster screw.
4. Check valve. 27. Spool return spring.
5. Single/double--acting conversion valve body. 28. Spring cup.
6. Seal. 29. Seal.
7. Seal 30. Seal.
8. Single/double--acting switchover screw. 31. Detent notch body.
9. Single/double--acting operation adjusting spool 32. Detent screw locknut.
10. Valve body. 33. Circlip.
84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2 3

DESCRIPTION AND OPERATION

The auxiliary control valves serve to control hydraulic 3. Neutral -- When the lever is released from the
loads external to the tractor. lifting and lowering positions it will automatically
Up to a maximum of three auxiliary control valves may return to neutral position.
be mounted at the rear of the centre housing.
The auxiliary control valves are operated by hand 4. Float -- Push the lever forward beyond the
levers located to the right of the driving position. “lowering” position to select “float position”. In this
position the only force exerted on the implement
Each control lever will have three or four positions will be that created by its own weight, thus allowing
depending on the type of control valve it operates. the implement to follow the profile of the terrain.
1. Lifting -- Pull lever back to lift the implement.
2. Lowering -- Push the lever forward to lower the The operation of the hydraulic control valves is
implement. described in the following pages.

OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR OPERATION OF A DOUBLE--ACTING

CYLINDER WITH AUTOMATIC DETENT RELEASE AND FLOAT POSITION

TRE0750A

Section view
2. Spool.
23. Internal plunger. NOTE: Some parts releated with automatic detent
24. Spring. release are not shown in this view. Automatic detent
25. Cover. release working principle of valve shown in Fig. 2 is
26. Detent balls. same as the valve shown at Fig. 9 & Fig. 10.
27. Spool return spring.
28. Spring cup.
32. Float mode selection groove.

FLOAT CONTROL OPERATION

To select float control operation, push the control le- exhaust lines T. No pressure applied to both ports. In
ver (located in the cab) fully forward. The control this condition, the only force acting on the attached
valve spool (2) will move and detent balls (26) will en- implement is that created by its own weight and the
gage in the grooves (32) where they will be held in hydraulic lift may be operated. Automatic detent re-
position by the support and the spring (24). In this lease does not occur during float control as there is
position the spool directs the oil at A and B ports to no pressure inside the auxiliary control valve.

84176554 -- 03--2008
4 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR OPERATION A DOUBLE-- ACTING

CYLINDER AUTOMATIC DETENT RELEASE AND FLOAT POSITION

TRE0750B

LIFTING
When the spool (2) moves to left, the detent balls (26) exhaust line (T) by way of line (A), intercepting the
engage the groove (33), where they are held in place supply of oil to the hydraulic lift control valve. Automatic
by the support (28) and spring (24). The movement of detent release working principle is explained at
the spool (2) connects: the pressure line (P) with the page 6.
line (B), and also the upper cylinder chamber with the

TRE0750C

LOWERING
When the spool (2) moves to right, the detent balls line (B), while the upper chamber is connected with
engage in the groove (34) where they are held in the pressure line (P) by way of line (A). On
position by the support (28) and the spring (24). In completion of the lowering operation, the detent will
this condition the oil contained in the lower chamber be automatically released as explained at Page 6.
of the cylinder can flow to the exhaust (T) by way of
84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2 5

OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR OPERATION OF A DOUBLE--ACTING

CYLINDER (FIGS. 5 & 6) AND SINGLE --ACTING CYLINDER (FIGS. 7 & 8)

1. LIFTING -- On pulling back the control lever, (located

in the cab) the control valve spool (2) moves to
connect: pressure line (P) with the lower chamber of
the cylinder by way of line (A), and also exhaust line (T)
by way of line (B), intercepting the supply of oil to the
lift control valve. Keep the lever pulled back, to extend
the cylinder to its full stroke. On releasing the lever it
will automatically return to neutral position, under the
action of the return spring, and the entire flow from the
pump will be conveyed to the lift control valve by way
of line (P).

TRE0712A

5
2. LOWERING -- To lower the implement, push the
control lever (located in the cab) forward. The control
valve spool (2) will move to the position indicated in
fig. 6, thus allowing the oil in the lower cylinder
chamber to flow to the exhaust (T) through line (A),
while the upper chamber is connected to the
pressure line (P) through line (B) .

3. LIFTING -- On pulling the control lever back, the

control valve spool (2) fig. 7 moves to connect the
cylinder with the pressure line (P) by way of line (A).
TRE0713A
Line (C), for the control of single--acting cylinders, is
used in this stage as it is permanently connected to the 6
exhaust (T) by the open position of the switching valve
(1).

4. LOWERING -- On pushing the control lever forward,

the spool (2) will move to the position indicated in fig.
8. The oil contained in the cylinder, pressurised by the
weight of the lifted implement, will flow to the exhaust
(T) by way of line (A), while the entire flow from the
pump is also conveyed to the exhaust (T) through the
line (B).
TRE0714A

Pressurised oil

Suction, delivery or exhaust oil

Static oil

NOTE: To operate a double--acting cylinder, tighten

screw (1) fully home. To operate a single--acting TRE0715A
cylinder, fully undo screw (1).
8

84176554 -- 03--2008
6 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

OPERATING STAGES OF AUXILIARY CONTROL VALVE OPERATING A DOUBLE--ACTING CYLINDER

WITH AUTOMATIC DETENT RELEASE

TRE0716A

LIFTING
On pulling back the control lever, the spool (2) moves through port (V), it overcomes the resistance of the
and the detent balls (26) engage the groove, where spring of the needle valve (23). Inside chamber (D), the
they are held in place by the support (28) and spring oil pressure increases and, acting on the detent ball
(24). The movement of the spool (2) connects: the support (28), it overcomes the resistance of the spring,
pressure line (P) with the line (B), and also the upper thus moving the support (28). In this condition the two
cylinder chamber with the exhaust line (T) by way of detent balls (26) drop onto the support, releasing the
line (A), intercepting the supply of oil to the hydraulic lift spool (2) which, under the action of spring (6) returns
control valve. to neutral position. Consequently the entire flow from
On completion of the lifting movement, the oil pressure the pump is conveyed to the lift control valve through
increases to 170--175 bar (173--178 kg/cm2). Acting lines (P).

TRE0717A

10

LOWERING
To lower the implement, push the control lever by way of line (B), while the upper chamber is
forward. The control valve spool (2) moves and the connected with the pressure line (P) by way of line
detent balls engage in the central groove where they (A). On completion of the lowering operation, the
are held in position by the support (28) and the spring detent will be automatically released in the manner
(24). In this condition the oil contained in the lower described previously.
chamber of the cylinder can flow to the exhaust (T)
84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2 7

AUXILIARY CONTROL VALVES (REMOVED FROM TRACTOR)

Disassembly -- Assembly (Op. 35 204 46)
of valves removed from tractor

3
6

7
8

1
2 7

4
TRE1100A

11

Convertible single/double--acting auxiliary control WARNING

valve.
Handle all parts with care.
Do not insert fingers or hands between one part and
Disassemble the auxiliary control valve into its another.
component parts referring to the sectional views Wear suitable safety clothing, i.e., safety goggles,
(fig. 1) and the following instructions: gloves and shoes.

1. Remove cover (3) and O--rings (7). WARNING

2. Remove the control lever support (4) and take out Always use suitable tools to align holes. NEVER USE
YOUR FINGERS OR HANDS.
the seal (7).
3. Withdraw the spool (8).
4. Remove plug (6) and extract the single/double
acting switching valve (5).
5. Remove relief valve block (1) and check valve (2)
6. Remove the valve housing (9)
7. Check the condition of the seals before re--
assembly.

84176554 -- 03--2008
8 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

Convertible single/double--acting auxiliary control valve with float control and detent release.

WARNING
Handle all parts with care.
Do not insert fingers or hands between one part and
another.
Wear suitable safety clothing, i.e., safety goggles,
gloves and shoes.

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

6
3
5

7
9

8
7
8

1
2

TRE1101A 4
12
1. Pressure relief valve.
2. Check valve
3. Kick--out (detent) and float control assembly
4. Control lever support
5. Single double acting converting valve
6. Oil return valve
7. Spool O--ring kit
8. Kick--out control assembly.

Disassemble the auxiliary control valve into its

component parts referring to the sectional views
(fig. 1) and the following instructions:

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2 9

WARNING
During the overhaul and disassembly--assembly of 1
the units, put special protective devices between the
bits of the vice, for preventing any damage to the
valve components.

1. Remove Allen screws (1) Fig.14.

TRE1102A

14
2. Remove both covers (1) Fig.15

TRE1103A

15
3. Remove both spacers (1) Fig.16
1

TRE1104A

16
4. Remove the circlip (1) and take the cover (2)
Fig.17 of the valve (Float & detent release) 2
1

TRE1105A

17

84176554 -- 03--2008
10 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

5. Withdraw the spool assembly (1) Fig.18.

1

TRE1106A

18
6. Complete spool assembly (Float & detent
release) is shown at Fig.19.

TRE1107A

19
7. Remove circlip (1) and take off the washer (2)
Fig. 20. Disassamble the unit to all its
components.
2

TRE1108A

20
8. Disassambled unit (Float & detent release) is
shown at Fig.21.

TRE1109A

21

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2 11

9. Remove circlip (1) Fig.22.

TRE1110A

22
10. Take off the cover (1) Fig. 23.
1

TRE1111A

23
11. Remove the spool assembly (Detent release) (1)
Fig.24. 1

TRE1112A

24
12. Remove the nut (1) Fig.25 fixing the assembly.
1

TRE1113A

25

84176554 -- 03--2008
12 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

13. Remove the spring and the detent body (1)

Fig.26. 1

TRE1114A

26
14. Remove the nut fixing the detent body (1) Fig.27

TRE1115A

27
15. Complete spool assembly (Detent Release) is
shown at Fig.28.

TRE1116A

28
16. Remove oil return valve (1) Fig.29.

TRE1117A

29

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2 13

17. Take off oil return valve (1) Fig.30

TRE1118A

30
18. Remove relief valve (1) Fig.31.

TRE1119A

31
19. Withdraw relief valve (1) Fig.32.

The relief valve can be checked when the engine is 1

running. When the relief valve is tested as explained
Section 35 Chapter 1 Page 35 the pressure gauge
must show a pressure of 186--191 bar
(2697.69 -- 2828.22 psi).
If the valve does not correspond to the prescribed
value, it is best to change it immediately.

TRE1120A

32
20. Slacken, single--double acting converting valve
(1) Fig.33.

TRE1121A

33

84176554 -- 03--2008
14 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

21. Remove, single--double acting converting valve

(1) Fig.34.

TRE1122A

34
22. Take off the ball of, single--double acting convert-
ing valve (1) Fig.35.
1

TRE1123A

35
23. Slacken the allen screws (1) fixing the cover the
cover (2) Fig.36.

TRE1124A

36
24. Withdraw the cover (1) and the spacer (2) Fig.37.
25. Check the condition of all seals before reas- 1
sembly.
2

TRE1125A

37

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2 15

Double--acting auxiliary control valve with float

control and automatic detent release.
Disassemble the auxiliary control valve into its
component parts referring to the sectional views (fig. 1)
3. Withdraw the spool (10).
and the following instructions:
4. Remove the valve housing and extract the check
1. Unscrew the retaining screws and remove the
valve and spring.
cover (11) and the distance piece.
2. Unscrew the retaining screws and remove the 5. Check the condition of the seals before re--
control lever support (12) and related seal. assembly.

SPOOL BINDING TEST

N 2 2 T
0 0
M 1 1

A
D
T

A B A B

TRE0719A

38

Control valve spool binding test (fig. 38). tion) the flow goes through the valve from inlet to
Install the auxiliary control valve assembly and the test outlet (tank line) (P) to (T). Now regulate the
apparatus as indicated in the diagrams (fig. 38 ) and re- maximum pressure of the VS (main relief valve)
ferring to the following instructions: valve inside bank A (in the schematic). This
pressure is the maximum pressure that can be
— The test is carried out with mineral oil in obtained with the type of valve and spring used.
accordance with DIN 32 norm. Flow rate is the Now move each single spool in each section.
nominal for the valve (for VDM07 it is 50 l/min). With the ports closed, the pressure will rise until
Connect line P (pump line) to the inlet port of the the relief valve opens. In this situation check if
valve and close the working ports A and B of spools move to the neutral (central) position
each section (see schematic) with plugs. without sticking, under the action of springs and
Start the test, increasing the flow coming from flow forces only. The relief valve D, in line before
the pump until nominal flow plus 25% is reached the directional valve, has to substitute the VS in
(in the case of VDM07 it is 75 l/min). With the A in case of problems or in case of directional
control lever in the neutral position (mid--posi- valve without VS.

84176554 -- 03--2008
16 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

SPOOL LEAKAGE TEST

2 2 T
N
0 0
M 1 1

D A

C C

B B

C C

TRE0720A

39

Valve leakage test seconds). From this stroke, calculate the volume of
oil per minute through that section of the cylinder.
After the binding test (with hot oil and valve), This check has to be carried out for each section
measure the leakage rate for each section. It is (each spool).
important to do this with the system hot. Connect After this check, with the pump disconnected, move
working ports A and B of each section to the cylinders the spool to its working position: now test the check
(one for each section). Alongside each cylinder lay a valve (VU:Check Valve) of the distributor. This valve
ruler to measure the stroke. closes the connection from P to T (N), also the
Supply oil to the cylinder, moving the spool to the connection P with A or P when B is open (spool in
working position (oil flowing from A or B) until it working position). If the check valve is working
reaches the end of its stroke and the main relief valve correctly, the normal flow rate will be seen (the same
opens. Now that the oil column is pressurised from value observed with spool in the neutral position). If
the working section to the cylinder allow the lever to it is see that one or more sections operates more
return to the neutral position (called 0). The spool than in a previous check, it means that check valve
closes A and B ports. Now check the position of the is not working properly (does not close completely).
cylinder observing the ruler beside it. As the cylinder
moves, check the stroke in a fixed time (say 60

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2 17

ADJUSTMENT OF THE AUTOMATIC DETENT RELEASE PRESSURE

After servicing the detent regulating valve or if the will fluctuate and the handle return to the neutral
control levers and spool are returning to neutral pre- position. Note the gauge reading immediately
maturely, the detent regulating valve should be prior to the needle fluctuation. The reading
should be within the specified value
tested as follows: (1741--1886 lbf/in2) 120 bar+10 bar--0 bar.

NOTE: Detent release pressure is ONLY adjustable

on one spool in the valve that is NOT fitted with float.
The spools fitted with kick out and float have no
visible means of adjustment. -- If the reading is not to specification adjust the
detent pressure as follows:

-- Install inlet hose of flowmeter (1) into lift coupler . . . . . Remove the circlip (33) and the cover (25),
of valve to be tested. (Fig.1. Page.7) of the valve .

. . . . . Loosen locknut (32) on detent regulating ad-

-- Install return hose from flowmeter into lift coupler juster screw (26).
of the same valve on tractor.
. . . . . Turn detent regulating valve adjusting screw
(26) to change pressure setting.
-- Ensure load valve on flow meter is fully open;

-- Start tractor and set engine speed to 1700

rev/min;

-- Pull lever of remote control valve to be tested,

fully rearwards, to extend position.

-- Adjust load valve (2) on flowmeter until pressure 1

is 80 bar (1161lbf/in2) and run until hydraulic oil
is at an operating temperature of 65_C ٛ 5_C.
2
TRE1126A

40
-- With lever of remote control valve to be tested in
the cylinder extend position slowly close the
flowmeter load valve while observing the
flowmeter pressure gauge.

-- The pressure should steadily rise until the detent

regulating valve opens, at which point the needle

84176554 -- 03--2008
18 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 2

NOTES

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3 1

SECTION 35 -- HYDRAULIC SYSTEM

Chapter 3 -- Trailer brake auxiliary control valve

CONTENTS

Section Description Page

35 000 Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Description and operation of valve phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Trailer brake auxiliary control valve linkage adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Section view of auxiliary control valve for trailer

braking

1. Flow control valve.

2. Piston.
3. Check valve.
4. Relief valve.

TRE0721A

DESCRIPTION AND OPERATION

The trailer brake valve is mounted on the rear The trailer brake valve has priority over the auxiliary
transmission casing forward of the hydraulic lift. It is control valves and the hydraulic lift.
supplied by the same pump as the lift circuit. The hydraulic operation of these valves is described on
pages 3 and 4.

84176554 -- 03--2008
2 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

HYDRAULIC DIAGRAM OF TRAILER BRAKE AUXILIARY CONTROL VALVE

Static oil
Oil in suction
Tractor brake circuit oil (brakes off)

Preeurised oil
Exhaust oil flow
3

5
1
9

8
7
6

26428

Diagram of the hydraulic trailer brake circuit

1. Delivery line to control valve (3). 6. Lift control valve.
2. Trailer brake control valve. 7. Suction line.
3. Auxiliary control valves. 8. Oil filter.
4. Auxiliary control valve lines. 9. Hydraulic pump.
5. Trailer brake control valve line.
84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3 3

TRAILER BRAKES OFF -- When tractor brakes are

inactive, pressure limiter (4) and slide piston (2) take 11 1 9
up the positions shown in fig 3.
Pf P1 10
Oil from hydraulic pump (8, fig 2) is directed to fitting
N 4
(P1) through diaphragm (11) and restriction (9) which F
causes a pressure drop to move flow control valve
(1) to the right.

Most of the oil flows through connection (N) to the R

auxiliary control valves. The remaining output is 2
drained into the hydraulic lift through port (10), piston
(2) and union (R).

TRE0722A

Trailer brakes off 3

Pressurised oil
N. To auxiliary control valves.
Oil in suction, delivery or return
P1. From hydraulic pump to lift circuit.
R. To lift return line. Static oil

START OF BRAKING -- On operating the tractor

brake pedal (Pf), the fork (F) shifts the pressure relief 3 11 12
1 9
valve (4) and the slide piston (2) to the left, which in
its turn closes the passage between the oil return
port (R), trailer brake port (B) and the line (10). P1
10
N 4
F
Pf
The oil inside the flow control valve (1) is maintained
at a uniform pressure and so the valve element,
B
under the action of the spring, shifts to the left to
assume the position indicated in fig.4.
R
13
2
Part of the oil from the hydraulic pump in union (P1)
flows to the auxiliary control valves through union
(N). while the remaining part arrives at the trailer
braking element via the diaphragm (11), line (12),
TRE0723A
check valve (3) and port (B).
4

As the pressure of the oil in the trailer brake union (B) Start of braking
increases, it acts on the active surface (13) of the
spool (2), opposing the effect of control fork (F) on B. To trailer brake.
relief valve (4) N. To auxiliary control valves.
P1. Oil from the hydraulic pump to lift circuit.
R. Discharge line.

84176554 -- 03--2008
4 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

BRAKING -- Continued brake pedal application

causes an increase in oil pressure at trailer brake
connection (B) which, acting on active surface (13) 11 12
3 1
of slide piston (2), moves the latter to the right threby 9
overcoming the opposition of relief valve springs (8).
P1 10
N 8 4
Pf F

13 R
When the trailer brake circuit oil pressure is equal to 2
spring (8) pressure, slide piston (2) stabilises as shown
in fig 5 and establishes communication between oil
from pump and lift drain through connection (P1),
TRE0724A
diaphragm (11), restriction (9), port (10) and
connection (R). Pressurised oil 5

Oil in suction, delivery or return

Static oil
Braking
B. To trailer brake.
N. To auxiliary control valves.
Diaphragm (11) and restriction (9) cause a pressure P1. Oil from the hydraulic pump to lift circuit.
drop in flow control valve (1) which moves to the right R. Discharge line.
to close line (12) and consequently, check valve (3).

Further pressure on the tractor brake pedals (Pf)

causes a leftward movement of relief valve (4) and
piston (2), with a consequent increase in trailer brake
circuit oil pressure as the sequence described in
paragraph b START OF BRAKING on page 3.

Upon releasing brake pedals, system returns to the

conditions shown in fig 3 at page 3.

84176554 -- 03--2008
 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3 5

TRE0725A

Trailer brake remote control valve linkage adjustment

C. Wrench flats on link (6) 3-- Delivery line to trailer brake

G = 0,3--0,5mm. Clearance between fork (7) and pis- 4-- Cup
ton (10)
5-- Locknut
M Pressure gauge with 0 to 250 kg/cm2 scale of kit
380000240 6-- Link

V Trailer brake control valve 7-- Fork

1-- Connection 380000841 supplied in kit 380000240 8-- Brake pedals

2-- Connection 380000840 supplied in kit 380000240 10-- Trailer brake control valve piston

84176554 -- 03--2008
6 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 3

TRAILER BRAKE REMOTE CONTROL VALVE LINKAGE ADJUSTMENT

Proceed as follows: 7. Start the engine and take the oil up to a tempera-
ture to 50 -- 60 0C (122 -- 140 oF).
1. Adjust the brake pedal (8) free travel as indicated
before in Section 33. 8. Run engine at around 2000 rpm.
9. Check that pressure gauge (M) reading is zero
2. Adjust parking brake lever as indicated before in
when brake pedals (8) are not applied.
Section 33.
10. Depress brake pedals until pedal free travel is
3. Fully tighten cup (4), slacken lock nut (5) and ad- taken up and check on pressure gauge (M) that
just lenght of link (6), using wrench flats (C) to ob- pressure is 100 bar (1450.37 psi)
tain a clearance (G) of 0,3 to 0,5 mm (0.0118 to 11. Repeat this operation at least three times, check-
0.0197 in.) between fork (7) and piston (10). ing that system pressure reading drops to zero
4. Tighten loc nut (5). when pedals (8) are released.
5. Disconnect trailer brake oil delivery line (3) from 12. Apply parking brake (9) a few times without de-
brake control valve body (V). pressing brake pedals and check that pressure
reading on pressure gauge (M) remains at zero.
6. Connect pressure gauge (M) with 0 to 250 kg/
cm2 scale of kit 380000240 to control valve body,
using connections 380000841 (1) and
380000840 (2) (Both connections belong to kit
380000240)

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 1

SECTION 41 -- STEERING
Chapter 1
CONTENTS
Section Description Page

41 000 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
41 204 30 Hydrostatic steering control valve -- Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
41 204 34 Hydrostatic steering control valve -- Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . 14
41 204 38 Hydrostatic steering control valve -- Bench testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hydrostatic steering oil pump -- Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
41 216 20 Steering cylinder (two--wheel drive axle) -- Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . 32
Steering cylinder (four wheel drive axle) -- Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . 33

PRINCIPAL DATA

HYDROSTATIC STEERING

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . independent hydrostatic control,

Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . feed by hydraulic pump
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . metal cartridge, built
into oil reservoir

Control valve
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DANFOSS OR ORSTA
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rotary valve controlled directly
from the steering column; the
steering continues to function
even if the pump is
non--functional
Outfit code:
-- DANFOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OSPC 100
-- ORSTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LAG--B 100--LVP16--2

Pressure relief valve setting (22) fig. 2

-- 2WD models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 bar (1450.37 psi)
-- 4WD models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 bar (1812.96 psi)

84176554 -- 03--2008
2 SECTION 41 -- STEERING -- CHAPTER 1

MAIN SPECIFICATIONS OF HYDRAULIC PUMP C25

Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear type with oil suction from
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . transmission casing
behind timing gear cover

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C 25
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOSCH
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . governed by timing gears
Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . . . . . . clockwise
Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:0.931
Maximum speed of rotation (with engine at maximum power) rev/min 2328
Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . . l/min (in.3/min) 26.4 (1611.03)

Bench output at 1450 rev/min and pressure of

153 bar (156 kg/cm2):
-- for new or reconditioned pump . . . . . . . . . . . . . . . . . . . . l/min (in.3/min) 15.3 (933.66)
-- for worn pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/min (in.3/min) 10.7 (652.95)
-- test oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C (°F) 55 -- 65 (131 -- 149)
-- test oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 20
Diameter of driven and driving gear shafts . . . . . . . . . . . . . . . . mm (in.) 17,400 -- 17,418 (0.6850--0.6857)
Internal diameter of seats in supports . . . . . . . . . . . . . . . . . . . . mm (in.) 17,450 -- 17,475 (0.6870--0.6880)
Clearance between gear shafts and their seats . . . . . . . . . . . . mm (in.) 0,032 -- 0,075 (0.0013--0.0030)
-- maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . . mm (in.) 0,1 (0.0039)
Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . . mm (in.) 0,020 -- 0,064 (0.0008--0.0025)
Maximum wear on pump body, suction side,
at position of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 0,1 (0.0039)
Cylinder
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double acting, located behind
front axle
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEBER or SIMA or ERBER
Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 mm (1.89 in)
Piston rod diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 mm (0.866 in)
Maximum piston stroke
WEBER or ERBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 mm ( 8.464 in)
SIMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 mm (8.425 in)
Maximum piston stroke
WEBER or ERBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 mm (7.874 in)
SIMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 mm (7.638 in )

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 3

TORQUE SETTINGS

Torque setting
PART Thread
Nm ft lb
Bolt fixing hydrostatic steering to tractor . . . . . . . . . . . . . . . . . . . . . . . . 3/8”--16 UNC 44 32.4527

Bolt fixing cover to hydrostatic steering housing (13, fig. 2) . . . . . . . . M8x1 34 25.0771
M 8 x 1* 29 21.3893

Hydrostatic steering control pump fixing bolt . . . . . . . . . . . . . . . . . . . . M6x1 8 5.9005

Nut for bolt fixing cover to pump housing (20, fig. 1) . . . . . . . . . . . . . . M 10 x 1,25 39 28.7649

Nut for securing thrust sleeve to pump drive shaft (14, fig. 1)) . . . . . 7/16 in
--20UNF--2B 28 20.6517

Nut, power cylinder pivot pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 18 x 1.5 294 216.8433

Nut, power cylinder piston rod to steering arm . . . . . . . . . . . . . . . . . . . M 14 x 1.5 147 108.4216

Nut, piston to rod

--WEBER cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 83 61.2177
--SIMA cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 98 72.2811
--ERBER cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 98 72.2811

Capscrew, contol valve support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 147 108.4216

Capscrew, LVP safety valve block to body . . . . . . . . . . . . . . . . . . . . . . -- 64 47.2040

* ORSTA

84176554 -- 03--2008
4 SECTION 41 -- STEERING -- CHAPTER 1

1
Hydrostatic steering -- Oil pump components

1. Front cover 11. Driving shaft seal

2. Cover seals 12. Snap ring
3. Pump body 13. Lock washer
4. Gear support 14. Nut
5. Driven and driving gear shafts 15. Bolt
6. Gear support 16. Washer
7. Bushing 17. Key
8. Control side cover 18. Bushing.
9. Driving shaft seal 19. Safety washer
10. Spacer 20. Nut.

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 5

24725

Hydrostatic steering -- Control valve components 2

1. Dust seal
2. Reflux valve balls 12. Rotor control shaft -- sleeve trim pin
3. Reflux valve pins 13. Cover fixing screws
4. Control valve body, rotary valve and rotary 14. Check valve seat screw
valve seat sleeve 15. Washers
5. Check valve ball 16. Cover
6. Threaded plug of check valve 17. O--rings
7. O--ring seal 18. Rotor and fixed ring for rotor
8. Support ring for O--ring (7) 19. Thrust washer
9. Thrust bearing components 20. O--ring
10. Retaining ring for springs (11) 21. Rotor control shaft
11. Springs for returning sleeve to neutral position 22. Pressure relief valve complete with spring

84176554 -- 03--2008
6 SECTION 41 -- STEERING -- CHAPTER 1

26 M S

27

D1

TRE0431A

3
General hydraulic diagram
H Power steering cylinder 26 Oil in intake line
D1 Hydrostatic steering control valve 27 Oil in delivery line from pump
E Filter
T Oil tank M Oil delivery to control valve
P Pump S Oil at lubrication pressure

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 7

OPERATION direct mechanical connection between the column

and the steered wheels.
The oil taken in by the rear axle is pushed into the Neutral position
pump through a filter, pressurized by the rotating When the steering wheel is stationary, the leaf
gears and expelled from the delivery side of the springs in the steering motor push the spool and the
pump to the steering motor. Once in the steering sleeve in, and keep them in the neutral position. This
motor, the pressurized oil is directed to the steering ensures that no further oil is supplied to the steering
cylinder when the steering wheel is turned. cylinder. The sleeve also blocks the oil inside the
cylinder, keeping the wheels in a set position, fig. 4.
Inside the steering motor, there is a measuring
device which controls the volume of oil supplied to Oil in intake line
the cylinder so that it is proportional to the angular
movement of the steering wheel. The metering valve Oil in delivery line from pump
together with the intake valves also allows MANUAL Oil at static rest
operation of the steering, without pressurized oil
being emitted by the pump. Oil returning to reservoir
The system is totally hydrostatic and as such, has no

a
1
13

12

5
11
10
6
TRE0432A 9 7
8
4

Diagram of hydrostatic steering operation

a 2WD models 7. Pump

1. Equalization valve 8. Filter
2. Steering cylinder 9. Return line to reservoir
3. Metering valve 10. Pressure relief valve
4. Check valve 11. Control valve external rotor
5. Non--return valve 12. Control valve internal rotor
6. Resonance damper 13. Anti--cavitation valves

84176554 -- 03--2008
8 SECTION 41 -- STEERING -- CHAPTER 1

Steering to the right (fig. 5) Steering to the right manually

When you turn the steering wheel clockwise, the
springs (11) fig. 2 deform, allowing the valve (12) fig. If there is a fault or loss of oil pressure at the
4 to rotate in relation to the sleeve (11). hydrostatic steering pump, steering can also be
In this state, the following takes place: performed manually.
-- de--synchronisation of the internal ducts with When you turn the steering wheel clockwise, the
parts (11) and (12) fig. 4, which were aligned in the rotor inside the hydrostatic steering control valve (3)
neutral phase, resulting in interruption of the flow fig. 4 performs the function of a hand pump, sending
of oil to the outlet. oil to the control cylinder rod side (2), thus allowing
-- alignment with the same number of internal ducts the wheels to be steered to the right manually.
connected moment by moment with the rotor Steering to the left manually
compartments at intake from the pump (7) fig. 4
and in the delivery line to the steering cylinders When you turn the steering wheel anticlockwise, you
(2), thus allowing the wheels to be steered to the act upon the rotor inside the hydrostatic steering
right. control valve which, by operating as a hand pump as
Steering to the left previously described, sends oil to the control cylinder
piston side, thus allowing the wheels to be steered to
When you turn the steering wheel anticlockwise, the
the left manually.
grooves inside parts (11) and (12) fig. 4 and the
delivery lines to the steering cylinders are reversed,
thus allowing the wheels to be steered to the left.

25162

5
Diagram showing operation of the hydrostatic steering
a 2WD models Oil in intake line
A Steering to the right Oil in delivery line from pump
B Steering to the left Oil in delivery line to hydraulic cylinder
Oil returning to reservoir

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 9

HYDROSTATIC STEERING FAULT DIAGNOSIS

Refer to fig. 2 for component identification

Problem Possible causes Corrective action

Oil leaking from hydrostatic 13. O--ring seal defective (7). Renew the seal and the stop ring
steering unit: using special tool 380000836.
a. Control side.
b. Cover side.
14. Screws (13) not sufficiently Tighten the screws to the prescribed
tight. torque
(24--36 Nm, 17.7015--26.5522 ft lb).
15. Sealing washers (15) or Renew the washers and seals.
O--rings (17) defective.
Steering wheel excessively stiff 1. Hydraulic pump inefficient. Repair the pump.
2. Check valve (5) held open by Eliminate foreign bodies and clean
foreign bodies or open due to the filter; put a new ball into the seat
absence of ball. (if missing).
3. Pressure relief valve (22) Reset the valve.
incorrectly set.
4. Pressure relief valve (22) Eliminate foreign bodies and clean
jammed or held open by for- the filter.
eign bodies.
5. Steering column has become Eliminate the causes.
stiff on its bushing due to
rusting, seizing, etc.
Excessive play of steering wheel 1. Excessive play between the Renew the worn parts.
steering column and the
coupling with the rotary valve
(4).
2. Excessive play in the coupling Renew the worn parts.
between shaft (21) and trim
pin (12).
3. Excessive play in the splined Renew the worn parts.
coupling between the shaft
(21) and the rotor (18).
4. Combination of excessive Renew the most worn parts.
play as described above.
5. Leaf springs (11) broken or Renew the springs.
fatigued.
The steering wheel turns normally, 1. Inadequate seal of control Renew the seal.
but steering is: cylinder.
a. Slow. 2. Cylinder rod broken. Renew the damaged part.
b. No steering. 3. Rotor control shaft (21) or pin Renew the damaged part.
(12) broken.
With the engine stopped, the 1. Excessive wear between rotor Renew the worn parts.
steering wheel can be turned and fixed ring (18).
without turning the wheels.
2. Check valve damaged. Renew the control valve.

(continued)

84176554 -- 03--2008
10 SECTION 41 -- STEERING -- CHAPTER 1

HYDROSTATIC STEERING FAULT DIAGNOSIS

Refer to fig. 2 for component identification

(continuation)
Problem Possible causes Corrective action

Steering wheel jolts, steering 1. Incorrect synchronization of Synchronize correctly.

uncontrollable, wheels steering in hydrostatic steering. Correct the connections.
the opposite direction to the 2. Hoses to cylinder reversed.
desired direction.

The wheels do not maintain the 1. Hydraulic cylinder piston seal Renew the seal.
desired alignment and continual worn.
correction with the steering wheel 2. Reflux valve (2) damaged or Eliminate the foreign bodies and
is necessary. held open by foreign bodies. clean the filter or renew the control
valve.
3. Mechanical wear of control
valve. Renew the control valve.

Neutral phase of hydrostatic 1. Leaf springs (11) for returning Renew the pack of leaf springs.
steering unobtainable. During sleeve (4) to neutral position
manual control, operation is broken or fatigued.
normal. When stopping manual 2. Sleeve and rotary valve (4) Eliminate the foreign bodies and
control, the steering wheel moves blocked in delivery position by clean the filter.
on its own or remains stationary, foreign bodies.
but steering continues slowly in
3. Crushing of sleeve (4) on Check the setting of the pressure
the direction first turned
rotary valve due to excessive relief valve (22).
(motoring), so the steering wheel
pressure.
must be continually corrected.

Front wheel vibration (shimmy). 1. Air pockets in the hydraulic Bleed the air and eliminate the causes
cylinder. of possible infiltration.
2. Wear of mechanical joints of Renew the worn parts.
steering tie rods.
3. Reflux valve (2) damaged or Remove the foreign bodies and clean
held open by foreign bodies. the filter or renew the control valve.

Difficulty in steering in general, or 1. Insufficient pressure. Check the hydraulic pump and the
in one direction. setting of the pressure relief valve
(22).
2. Excessive leakage inside the Renew the control valve.
control valve.

List of special tools necessary for the various

TOOLS operations described in this section.

WARNING: The operations described in this section

must be performed only with the ESSENTIAL X 380000307 Hyd. steering rotor retaining lever.
equipment marked with (X). X 380000223 Steering wheel extractor.
To operate safely and achieve best results, while
saving time and effort, essential equipment must be X 380000240 Universal pressure checking kit.
used in conjunction with the special tools X 380000305 Tool for fitting hydrostatic steering
recommended below, and tools which you must toroidal seal.
make yourself and for which you will find the design 380000306 Plug for fitting hydrostatic steering
in this manual. rotary valve return springs.

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 11

HYDROSTATIC STEERING CONTROL VALVE

Removal--Refitting (Op. 41 204 30)
WARNING
Handle all parts with great care. Do not put your 1
hands or fingers between one part and another.
Wear the recommended safety clothing such as
goggles, gloves and safety boots.

To remove the hydrostatic steering control valve,

proceed as follows:
1. Disconnect the negative cable (1) from the
battery.
2. Drain the oil from the steering system.
6
3. To access the engine the hood must be
opened.

4. Disconnect the oil pipes from the hydrostatic

steering control valve unit (1).

TRE0434A

8
5. Remove the steering wheel (1) retaining nut and
remove the steering wheel and hand throttle
lever.

25758

84176554 -- 03--2008
12 SECTION 41 -- STEERING -- CHAPTER 1

6. Remove the four securing screws (1) from the

instrument panel (2).

25759

10
7. Disconnect the electrical leads (1) from the rear
of the instrument panel. Unscrew the the
tachometer cable (2). Remove the instrument
panel and store in a safe place.

TRE0435A
2
11
8. .Unscrew the rear hood screws (1)

TRE0436A

12

9. Take off the complete rear hood.

10

TRE0437A

13

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 13

10. Remove the hydrostatic steering unit support

bolts and take of the hydrostatic steering unit.

TRE0028A

14

-- To refit the control valve, proceed as follows:

-- Refit the hydrostatic steering unit

-- Refit the complete rear hood.

-- Secure the rear hood with the screws previously

removed.

-- Reconnect the electrical leads and reconnect

the the tachometer cable.

-- Re--install the four screws securing the

instrument panel.

-- Re--install thehand throttle and steering wheel.

Secure the wheel with the central retaining nut.

-- Reconnect the oil pipes to the hydrostatic

steering control valve unit.

-- Fill the the steering system with oil.

-- Reconnect the negative cable to the battery and

close the hood.

84176554 -- 03--2008
14 SECTION 41 -- STEERING -- CHAPTER 1

HYDROSTATIC STEERING CONTROL VALVE

Disassembly--Assembly on the bench
(Op. 41 204 34 )
To disassemble the hydrostatic steering control
valve, proceed as follows:

1. Remove the control valve cover retaining bolts.

24701

15
2. Remove the cover by sliding to one side.

24702

16
3. Remove the rotor fixed ring, the rotor and the
inner spacer.

4. Remove the two O--ring seals on the rotor fixed

ring.

24703

17
5. Extract the rotor drive shaft

24704

18

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 15

6. Extract the thrust washer.

24705

19
7. Remove the threaded plug on the non--return
valve seat.

24706

20
8. Extract the O--ring seal from the control valve
body.

24707

21
9. Position the control valve body and the rotor
drive shaft so that the sleeve--control shaft trim
pin is in a horizontal position.
10. Push the rotary valve inwards, so that the valve,
the valve seat sleeve and the thrust bearing can
be extracted from the control valve body.

24709

22

84176554 -- 03--2008
16 SECTION 41 -- STEERING -- CHAPTER 1

11. Extract the thrust bearing from the rotary valve,

complete with the two external rings. Remove
the spring retaining ring from the valve seat
sleeve.

24710

23
12. Extract the valve--sleeve trim pin.

24711

24

WARNING: On assembly, two reference marks

(arrowed) were made on the rotary valve and the
sleeve, corresponding to the neutral position
maintained by the springs. Before removing the
springs, check that the marks are clearly visible. If
not clear, make new reference marks.

24712

25
13. Extract the rotary valve from the valve seat sleeve.

24713

26

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 17

14. Remove the neutral position springs, extracting

them from their seats.

24714

27
15. Remove the dust seal and the O--ring seal from
their seats in the control valve body.

20428

28
16. Using a 6 mm Allen wrench, remove the
threaded plugs from the two cylinder safety
valves and extract the seals.

20429

29
17. Using a 6 mm Allen wrench, remove the setting
adjuster screws from the cylinder safety valves.
See also fig. 31.

18. Turn the control valve body over and extract the
balls, the springs and the spring guides from the
two cylinder safety valves.

20432

30

84176554 -- 03--2008
18 SECTION 41 -- STEERING -- CHAPTER 1

Cylinder safety valves components (order of

disassembly--assembly).
1 2 3 4 5
1. Cylinder safety valve ball.

2. Pressure spring.

3. Setting adjuster screw.

4. Seal.

5. Plug.
25790

31
19. Using a 6 mm Allen wrench, remove the
threaded plug on the pressure relief valve and
extract the seal.

20434

32
20. Remove the pressure relief valve adjuster screw.

21. Turn the control valve body over and complete

disassembly by extracting the spring and the
pressure relief valve piston.

20436

33
Pressure relief valve components (order of
assembly).
1 2 3 4 5
1. Pressure relief valve.

2. Pressure spring.

3. Setting adjuster screw.

4. Seal.

5. Plug.
27099

34

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 19

22. Thoroughly clean all control valve component

parts.

23. Replace the washers and seals.

24. Carefully check all mechanical parts, replacing

components that show signs of wear.

25. Before refitting, lubricate the components with

hydraulic oil.

26. Re--fit the rotary valve on the sleeve, checking

that the reference marks indicated in the drawing
coincide.

24726

35
27. Use tool 380000306 to insert the flat and curved
springs (12) fig. 2.
(Diagram for fitting springs (12) fig. 2 neutral position
for OSPC 80 ON--150N 1058 hydrostatic steering).

24728

36
28. After inserting the springs in the seat, align and
centre (as shown in the drawing).

24729

37

84176554 -- 03--2008
20 SECTION 41 -- STEERING -- CHAPTER 1

29. Fit the neutral position spring retaining ring on

the valve seat sleeve, remembering that the ring
must rotate freely without being impeded by the
springs.

24730

38

30. Insert the sleeve--rotor drive shaft trim pin.

24731

39
31. Fit the thrust bearing, following the order
indicated in fig. 41.

24732

40
1. Bearing external ring.
1
2. Thrust bearing.
2
3. Bearing internal ring with bevel facing contact
surface of part (5). 3

4. Rotary valve. 4
5. Rotary valve seat sleeve. 5

24733

41

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 21

32. Position the control valve body so that the

housing seat on the rotary valve sleeve is
positioned horizontally, then insert the guide
bushing (1) of tool 380000305.

1
24734

42
33. Lubricate the support ring (1) and O--ring seal (2)
with hydraulic oil and fit them on the head (3) of
the tool 380000305, as shown in the drawing.

2
1

Support head for support and seal rings

(part of tool 380000305)
24735

43

34. Insert the complete drift in the guide bushing

previously installed.

24736

44

84176554 -- 03--2008
22 SECTION 41 -- STEERING -- CHAPTER 1

35. Holding the external bushing in position

manually, press fully down, whilst simultaneously
rotating the drift, in order to facilitate the entry of
the O--ring seal in the control valve body seat.

24737

45
36. Extract the components of tool 380000305
(external bushing and drift).

NOTE: The support head of the support and seal

rings remains on the control valve body (see fig. 43).

46
37. Insert the parts that were previously fitted in
operations 26 -- 31 on the control valve body.
Hold the sleeve--to--rotor drive shaft trim pin in a
horizontal position, to prevent it from slipping out
and jamming in the slots inside the control valve
body.

24739

47
38. Press the rotary valve so as to bring the thrust
bearing into contact with the control valve body.
This operation simultaneously expels the head
(1) of tool 380000305, inserting the rings (1) and
(2) fig 43 into the seat of the control valve body
(see operation 33).

25795

48

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 23

39. Rotate the control valve body and insert the

non--return valve ball into the seat indicated by
the arrow.

24741

49
40. Screw the threaded plug into the non--return
valve seat until the upper surface is below the
coupling surface of the control valve body.

24742

50
41. Lubricate the O--ring seal and insert into the seat
on the control valve body.

24746

51
42. Fit the thrust washer, so that the holes coincide
with the holes in the control valve body.

24747

52

84176554 -- 03--2008
24 SECTION 41 -- STEERING -- CHAPTER 1

43. Make a reference mark on the upper part of the

teeth (1), in line with the seat (2), to indicate the
exact position of the valve--to--sleeve trim pin.

24748

53
44. Fit the rotor drive shaft into the control valve
body. Insert tool 380000307 for retaining and
centring the rotor drive shaft, between the rotor
drive shaft and the thrust washer. Rotate the
shaft so as to facilitate coupling between the seat
(2) fig. 53 and the trim pin installed in the sleeve.

24749

54

45. To refit the rotor, proceed as follows:

a) each time the hydrostatic steering is

disassembled, turn the rotor over so as to limit
wear to the splined coupling;

b) in the drawing below, the rotor shaft has been

removed in order to show the phasing between the
rotor, rotor drive shaft and the trim pin;

c) fit the rotor on the drive shaft, remembering that

phasing is obtained by aligning the teeth (1), on the
trim pin axis plane (shown in fig. 53) with the centre
line of one of the recesses between the lobes of the
rotor.

24750

55

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 25

46. Lubricate the two O--ring seals (1) with hydraulic

oil and insert them in the rotor fixed ring seat. Fix
in position by aligning the retaining holes (2) with
those on the thrust washer.

24751

56
47. Fit the cover, aligning the retaining holes with
those on the rotor fixed ring.

24753

57
48. Remove retaining tool 380000307 and fit the
special screw and washer in the non--return
valve seat, shown in the drawing.

24754

58
49. Fit the other six cover retaining bolts with the
washers and tighten in diagonal sequence to the
torque setting value shown in the table on page 3.

24755

59

84176554 -- 03--2008
26 SECTION 41 -- STEERING -- CHAPTER 1

50. Turn over the control valve body and insert the
pressure relief valve piston in the seat, as
indicated in the drawing. See fig. 34 for
component assembly order.

24756

60
51. Insert the pressure relief valve spring.

24757

61
52. Using an 8 mm Allen wrench, insert the pressure
relief valve setting screw.

NOTE: Setting should be carried out on the

workbench or on the tractor to the values shown in
the table on page 1.

24758

62
53. Tighten the plug (2), with the associated seal,
using an 8 mm Allen wrench. Tighten to the
1
prescribed torque value 40 -- 60 Nm
(29.5025 -- 44.2537 ft lb), after having carried out
the setting on the workbench or on the tractor.
54. Insert the balls (1) into the two cylinder safety
2
valve seats, indicated by the arrows. See fig. 64
component assembly order.

25789

63

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 27

Cylinder safety valves components (order of

assembly)
1 2 3 4 5
1. Cylinder safety valve ball.
2. Pressure spring.
3. Setting adjuster screw.
4. Seal.
5. Plug.

25790

64
55. Insert the springs (2, fig. 69) in the cylinder
safety valve seats.
56. Using a 6 mm Allen wrench, tighten the two
cylinder safety valve setting adjuster bolts
(3, fig. 69).

NOTE: Setting should be carried out on the

workbench or on the tractor to the values shown in
the table on page 1.

20475

65
57. Tighten the two plugs (5, fig. 69) and the
relative seals (4) using a 6 mm Allen wrench.
Once setting is completed, tighten to the
prescribed torque value of 30 Nm
(22.1269 ft lb).

20429

66
58. When the unit has been assembled, insert the
dust seal in the seat in the control valve body.

24764

67

84176554 -- 03--2008
28 SECTION 41 -- STEERING -- CHAPTER 1

HYDROSTATIC STEERING CONTROL VALVE

Bench testing (Op. 41 204 38 )
Test conditions.
Oil type . . . . . . . . . . . . . . . . . . . IDRAULICAR AP51
Oil viscosity . . . . . . . . . . . . . . . . . . . . . . . SAE 20 W
Oil temperature . . . . . . . . . . . . . . . . . 60_C (140_F)
Hydraulic pump capacity . . . . . . . . . . . litres/min 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . (gall. imp/min 2.64)
Speed of electric motor . . . . . . . . . . . . . . . rpm 1450

2
1

24912

Installation diagram of equipment for testing the rotary valve, 68

seals and for setting the pressure relief valve.
1. Splined control shaft 4. Restriction
2. Torque wrench 5. Pressure adjustment handwheel
3. Delivery line
A -- CHECKING ROTARY VALVE WEAR
1. Make the connections shown in fig. 68 and
complete the circuit as in fig. 69. Using the
splined control shaft (1), hold the steering control
valve in steering position (right or left).
2. Using the handwheel (5), increase the circuit
pressure to as near as possible the pressure
relief valve cracking pressure (page 1) without
the valve actually opening.
3. Using a torque wrench (2), apply a torque of
approx. 34 Nm (25.8147 ft lb) to the control shaft
(1), and check that the rotary valve takes more
than 10 seconds to complete one full rotation. If
it takes less than 10 seconds, change the rotary
valve (4, fig. 2) and the sleeve .

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 29

B -- CHECKING RETURN TO NEUTRAL POSITION

In the same test conditions as A, check that the valve
automatically returns to neutral position when the 1
control shaft (1) is released after each simulated
steering movement.
C -- CHECKING SEAL EFFICIENCY
7
In the same test conditions as A, hold the valve in
steering position with the control shaft (1) for about
three minutes and check the seals for leaks. 6 2
D -- SETTING THE PRESSURE RELIEF VALVE
1. Make the connections as shown in figure (68)
and complete the circuit as in figure (69).
2. Using the control shaft (1), simulate a steering
cycle (to right or left) so as to interrupt the oil flow
to the outlet.
3. Gradually increase the pressure in the circuit by
turning the handwheel (5) fig. 68, and check on
the pressure gauge that the pressure relief valve
(22, fig. 2) cuts in at the pressure shown on 5
page 1. If not, increase or reduce the pressure
relief valve setting by tightening or slackening
the adjuster screw.
3

4
24911

1. Splined control shaft 69

2. Plug G 1/2”
3. To throttle
4. Outlet
5. Three--way coupling G 1/2”
6. From delivery line
CHECKING THE HYDROSTATIC STEERING 7. Outlet coupling G 1/2”
PRESSURE RELIEF VALVE WITH STEERING
CONTROL VALVE INSTALLED ON TRACTOR.
Proceed as follows: 3
4 5
1. Start the engine and run until the oil temperature 1 2
reaches approx. 50_C (122_F).
2. Switch off the engine and unscrew the oil delivery
pipe union (4) on the hydraulic cylinder (5).
3. Fit union (2) in place of union (4), and connect the
pressure gauge (1) with a 0 -- 21.3350 psi scale
by way of union (3).
4. Start the engine again, bring the speed up to
medium rpm, and apply full--steering lock to
bring the hydraulic cylinder to the stroke--end 24915

position. 70
In this condition, the pressure relief valve (22, fig. 2) 1. Pressure gauge (supplied in kit 380000240)
should open and the pressure gauge should indicate 2. Union 380000618 (supplied in kit 380000240) to
the value given on page 1. be fitted in place of original union
5. If the pressure gauge reading deviates signifi- 3. Union 380000613 (supplied in kit 380000240)
cantly from the prescribed value, adjust the valve 4. Hydraulic cylinder oil feed pipe
opening pressure by way of the adjuster screw. 5. Hydraulic cylinder.

84176554 -- 03--2008
30 SECTION 41 -- STEERING -- CHAPTER 1

Hydrostatic steering oil pump components 71

Hydrostatic steering oil pump components

1. Front cover 11.Driving shaft seal.

2. Cover seals 12. Snap ring
3. Pump body 13. Safety washer
4. Gear support 14. Nut
5. Driven and driving gear shafts 15. Bolt
6. Gear support 16. Washer
7. Bushing 17. Key
8. Control side cover 18. Bushing
9. Driving shaft seal 19. Safety washer
10. Spacer 20. Nut

Proceed as follows:
1. Remove the cover fastening nuts (20), then the
bolts (15) and the safety washers.
2. Remove the nut (14) that fastens the sleeve to the
pump driving shaft and the safety washer.
3. Remove the front cover (8), the snap ring (12)
and the seals ( 9 and 11 ).
4. Mark parts 3, 4, 5 and 6 to enable them to be
remounted in the same position if they are in good
condition.

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 31

5. Remove the supports (4 and 6) and the gears

(5) from the rear cover (8) and the pump body (3).
6. Remove the seals (2) and the anti--extrusion
rings.Once the parts are removed, proceed as
follows:
7. Check that the gear contact surfaces are flat
and perpendicular to their supports. Interpose a
thin layer of carbon black. Small rough spots can
be removed using extremely fine and adequately
lubricated abrasive paper.
8. Check that the axial play of the gear--support
unit in the pump body is 0.100 -- 0.180 mm
(0.0039 -- 0.0189 in.). The distance (Fig 72, 2)
must be 0.100 -- 0.180 mm (0.0039 -- 0.0189 in.)
smaller than the distance (Fig 72, 1).If necessary, 2
true the flat surfaces involved using lubricated
abrasive paper to remove extremely small
quantities of material
9. Clean all constituent parts thoroughly.
10. Replace the seals (2, 9 and 11).
11. Lubricate the parts with the same oil as the
system Refit the pump, referring to fig. 71 and
proceeding as follows: 25227
12. refit, performing operations 6 to 1 in reverse
order;-- always ensure the maximum cleanliness 72
to prevent foreign matter from entering, as this
could damage the pump;-- fit together previously
marked parts (3, 4, 5 and 6, fig. 71); see op. page
45 to refit them in their original position;-- mount
the gear supports (4 and 6 fig. 71) in the
pump body; orient them with the fittings on the
external circumference matched up with the
discharge pipes and the front faces with
lubrication millings in contact with the gears;-- fit
the plastic anti--extrusion rings on the seals
(2, fig. 71);-- mount the seals (9 and 11, fig. 71) on
the control side cover (8) complete with spacer
(10); orient them so that the cavity is between the
seal lips on the opposite side from this spacer;
lastly fill this cavity with AKCELA Multi--Purpose
Grease 251H EP grease.Install the pump on the
tractor. Fill the suction pipe and the pump housing
with AKCELA NEXPLORE oil in order to facili-
tate priming and prevent the risk of seizure during
initial operation.

84176554 -- 03--2008
32 SECTION 41 -- STEERING -- CHAPTER 1

FRONT AXLE STEERING CYLINDER

(Two wheel drive axle) (Op. 41 216 20)
Removal--Refitting

WARNING
Handle all parts with great care. Do not put your
hands or fingers between one part and another.
Wear the recommended safety clothing such as
goggles, gloves and safety boots.

To remove the front axle steering cylinder, proceed

as follows:
24768
1. Remove the exhaust pipe, lift the hood and
disconnect the negative cable from the battery. 73
2. Unscrew the unions securing the oil delivery and
return hoses (1) to the cylinder (2).
3. Remove the nut securing the cylinder rod ball
end to the steering arm (1).

24858

74
4. Using a suitable puller (1), separate the cylinder
rod ball end from the steering arm.

24859

75
5. Remove the pin securing the steering cylinder
(1) to the axle and remove the cylinder.
6. To refit the steering cylinder, follow the removal
procedure in reverse order.

24860

76

84176554 -- 03--2008
 SECTION 41 -- STEERING -- CHAPTER 1 33

FRONT AXLE STEERING CYLINDER

(Four wheel drive axle)
Removal--Refitting 1

WARNING
Handle all parts with great care. Do not put your
hands or fingers between one part and another.
Wear the recommended safety clothing such as
goggles, gloves and safety boots.

To remove the front axle steering cylinder, proceed

as follows:
1. Disconnect the negative cable from the battery.
24863
2. Unscrew the unions securing the delivery and
return hoses to the steering cylinder. 77
3. Remove the snap ring (1) and remove the
cylinder rod articulation pin (2) connected to 2
the stub axle housing.

24861

78
4. Remove the retaining screw and extract the pin
(1) securing the steering cylinder to the axle.
Remove the steering cylinder. 1

NOTE: Should you want to remove both steering

cylinders complete with supply pipes, omit step 3
described above and carry out steps 2 and 4 for the
other cylinder too.

24862

79
5. Remove the two actuator cylinders complete
with supply pipes.

24864

80

84176554 -- 03--2008
34 SECTION 41 -- STEERING -- CHAPTER 1

84176554 -- 03--2008
 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1 1

SECTION 44 -- FRONT AXLE AND WHEELS

Chapter 1 -- Front axle and wheels

CONTENTS

Section Description Page

44 000 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment -- Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
44 101 30 Removal--Refitting--Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
44 101 22 Wheel hub disassembly--assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
44 101 46 Stub axle overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
44 101 80 Checking wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

PRINCIPAL DATA

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inverted U--section, telescop-

ic
and oscillating at centre
Wheel angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2°,, corresponding to 15 mm
2
(0.5906 in.) for 16 in. wheels
Toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in.) 0 -- 5 (0 -- 0.1969)

Stub axle articulation

Diameter of stub axle pin (7, page 7) at bushing . . . . . . . . . . . . . . mm 37.961 -- 38.000
(in.) (1.4945 -- 1.4961)

Bore of installed bushings (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 38.050 -- 38.140 (*)

(in.) (1.4980 -- 1.5016)

Clearance between stub axle pin and relative bushings . . . . . . . . mm 0.050 -- 0.179
(in.) (0.0020 -- 0.0070)

Axle articulation
Diameter of axle articulation pin (1, page 7) . . . . . . . . . . . . . . . . . . mm 37.961 -- 38.000
(in.) (1.4945 -- 1.4961

Bore of installed bushings (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 38.050 -- 38.140 (*)

(in.) (1.4980 -- 1.5016)

Clearance between stub axle pin and bushing . . . . . . . . . . . . . . . . mm 0.050 -- 0.179

(in.) (0.0020 -- 0.0070)
(*) Value to be obtained without refacing.

84176554 -- 03--2008
2 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

MAIN DATA
(cont.)

Standard Alternative track settings mm (in.)

MODEL Tyres wheel tracks
mm (in.) A B C D E F

JX60 1500 1400 1500 1600 1700 1800 1900

7 50 16 in.
7.50--16 in
JX70 (59.0550) (55.1180) (59.0550) (62.9920) (66.9290) (70.8660) (74.8030)

JX80
1510 1410 1510 1610 1710 1810 1910
JX90 7.50--18
7.50 18 in.
(59.4487)
(59 4487) (55.5117)
(55 5117) (59
(59.4487)
4487) (63
(63.3857)
3857) (67
(67.3227)
3227) (71
(71.2597)
2597) (75
(75.1967)
1967)
JX95

DIAGRAM OF 2WD FRONT WHEEL TRACKS

23928

84176554 -- 03--2008
 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1 3

26155

Sections of stub axle, articulation pin and front axle

1. Axle articulation pin 10. Bronze thrust ring
2. Axle articulation bushing 11. Seal
3. Steering transverse tie rod 12. Wheel hub
4. Stub axle control lever 13. Steel thrust washer
5. Axle support 14. Grub screw for cap (11) and thrust washer (12)
6. Bushing 15. Taper roller bearing for wheel
7. Stub axle pin 16. Bearing cover for greasing and adjustment
8. Support ring grub screw (13) 17. Cylinder fulcrum pin (18)
9. Cap 18. Power steering cylinder installation position

84176554 -- 03--2008
4 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

C1 -- 49 Nm C2 -- 115 Nm

C6 -- 186 -- 206 Nm

C5 -- 186 -- 206 Nm

C3 -- (*)

C4 -- 186 -- 257,7 Nm

26157

Front axle torque settings

C1 Axle articulation pin fixing screw C5 Nut for stub axle pin control lever fixing screw
C2 Retaining bolt holding the disc to the wheel C6 Nut securing cylinder to fulcrum pin
hub
C3 Bearing adjuster nut
C4 Axle end fixing nut
* See operations 11. and 12. page 15.

84176554 -- 03--2008
 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1 5

TORQUE SETTINGS

Torque setting
PART Thread
Nm ft lb

Front axle
Bolt securing axle to engine (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 18 x 1,5 353 478.6045

Bolt securing axle articulation pin (9) . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1,25 49 66.4352

Nut for axle end fixing screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1,5 211 155.6256

Nut securing LH and RH levers on the stub axles (4) . . . . . . . . . . . . M 16 x 1,5 294 216.8433

Nut securing ball end for transverse steering tie rod . . . . . . . . . . . . . M 14 x 1,5 118 87.0323

Nut securing transverse steering tie rod . . . . . . . . . . . . . . . . . . . . . . . M 20 x 1 176 129.8109

Retaining bolt holding the disc to the wheel hub (2) . . . . . . . . . . . . . M 18 x 1,5 115 84.8195

EQUIPMENT

List of special tools necessary for the various

WARNING: The operations described in this section operations described in this section.
must be performed only with the ESSENTIAL
equipment marked with (X).
To operate safely and achieve best results, while
X 380000541 Adaptor (M12x1.25) for axle
saving time and effort, essential equipment must be
articulation pin (use with slide
used in conjunction with the special tools
hammer 380000549)
recommended below and tools which you must make
yourself and for which you will find the design in this
manual.
380000237 Wheel lifting hook.

FAULT DIAGNOSIS

Problem Possible cause Corrective action

Abnormal wear of tyres. 1. Incorrect tyre pressure. Inflate the tyres to the correct
pressure, referring to the pressures
recommended in the Use and
Maintenance handbook, and more
especially, to the pressures
recommended by the manufacturer of
2. Incorrect toe--in of front the tyres fitted.
wheels. Correct the toe--in.

Poor stability of tractor. 1. Incorrect tyre pressure. Inflate the tyres correctly as detailed
above.

84176554 -- 03--2008
6 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

FRONT AXLE
Removal--Refitting (Op. 44 101 30)
DANGER
Lift and handle all heavy parts with lifting equipment
of suitable capacity. Make certain that the units or
parts are supported by appropriate slings and
hooks. Ensure that there are no persons in the
vicinity of the load to be lifted.
To remove the complete axle from the tractor,
proceed as follows:
1. Disconnect the negative cable from the battery
and isolate it; chock the rear wheels.

2. Lift the front of the tractor.

24765

4
3. Place a stand (1) beneath the engine sump,
inserting a block of wood between the engine
sump and stand.

1
24766

5
4. Remove the front wheel fixing bolts (1).

24767

84176554 -- 03--2008
 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1 7

5. Disconnect the hoses (1) of the power steering

cylinder (2).

1 2

24768

7
6. Remove the axle articulation pin securing bolt (1).

24769

8
7. Secure the axle by means of a sling (1).

24770

9
8. Take out the axle articulation pin (1) using slide
hammer 380000549, equipped with adaptor
380000541 and extension.

24771

10

84176554 -- 03--2008
8 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

9. Remove the complete axle (1).

1

24772

11
10. To refit the complete axle, follow the disassembly
procedure in reverse order. Install the axle
articulation pin (1) using a bronze punch.
11. Fit the screw fixing the axle articulation pin.

24769

12
12. Reconnect the hoses (1) of the power steering
cylinder (2).

1 2

24768

13

84176554 -- 03--2008
 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1 9

AXLE WHEEL HUB

Removal--Refitting (Op. 44 101 22)
Removal:
WARNING
Handle all parts with great care. Do not put your
hands or fingers between one part and another.
Wear the recommended safety clothing such as
goggles, gloves and safety boots.
The wheel hubs can be removed with the axle
installed on the tractor. Proceed as follows for each
wheel.
1. Disconnect the negative cable of the battery and
isolate it; chock the rear wheels.

2. Lift the front of the tractor.

24765

14
3. Place al stand (1) beneath the engine sump,
inserting a block of wood between the engine
sump and stand.

1
24766

15
4. Remove the front wheel fixing bolts.

24767

16

84176554 -- 03--2008
10 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

5. Remove the wheel hub bearing cover (1).

1
24775

17
6. Remove the grease nipple as shown in figure.

TRE4001A

18
7. Remove the split pin (1) securing the wheel hub
bearing adjuster nut.

TRE4002A

19
8. Using a socket wrench, unscrew the wheel hub
bearing adjuster nut.

24777

20

84176554 -- 03--2008
 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1 11

9. Remove the wheel hub bearing adjuster nut (1).

1

TRE4003A

21
10. Remove the wheel hub bearing washer (1).
1

TRE4004A

22
11. Remove the wheel hub (2) and take out the
bearings (1 and 3).
1 2 3

24778

23
12. Remove the bearing (1).
1

TRE4005A

24

84176554 -- 03--2008
12 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

13. Remove black (Twin lip) wheel bearing seal (1).

1

TRE4006A

25

14. Remove white back up ring (1).

1

TRE4007A

26

15. Renew worn bearings and seals, using suitable

extractors and punches.

24780

27

84176554 -- 03--2008
 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1 13

AXLE WHEEL HUB

Removal--Refitting (Op. 44 101 22)
Refitting:

1. Place a hydraulic jack beneath the stub axle and

unscrew the bolt (1) fixing the control lever (2) to
the stub axle pin.

24782B

28
2. Withdraw the control lever (1) from the stub axle
pin (2).

24783B

29
3. Lower the hydraulic jack and remove the stub
axle (1).

1
24784

30
4. Put the stub axle on a suitable vice and install
white back up ring (1).
1

TRE4008A

31

84176554 -- 03--2008
14 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

5. Install black (Twin lip) wheel bearing seal (1).

1

TRE4008A

32
6. Install both black (Twin lip) wheel bearing seal
and white back up ring together with a suitable
installer and a hammer.

TRE4008A

33
7. Install bearing with a suitable installer and a
hammer.

TRE4008A

34
8. The wear sleeve (1) for the seal must be installed
in the hub with a high strength bearing fit
adhesive compound (loctite) to ensure the 1
secure retention in the hub.

The hub and the wear sleeve must be throughly

clean and dry. Apply high strength bearing fit
compound. Press in the wear sleeve, using a
suitable press.
After installing the wear sleeve, the compound must
be allowed to cure for a minimum of three hours prior
to assembling the bearings and seals in the hub.
TRE4008A

35

84176554 -- 03--2008
 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1 15

9. Pack the wheel hub with AKCELA Multi--Pur-

pose Grease 251H EP grease.
1 2 3
10. Refit the wheel hub (2) complete with bearings
(1 and 3).

24778

36
11. Install a new nut and, using a torque wrench,
tighten the nut to a torque of 196 Nm
(265.7407 ft lb), turning the wheel hub (1)
simultaneously in order to settle the bearings. 1
12. Loosen the nut slightly and tighten it again to a
torque of 24 -- 29 Nm (32.5397 -- 39.3188 ft lb)
while continuing to turn the wheel hub.
Note -- the nut must be changed each time the wheel
hub is fitted.

13. Check the rolling torque R, bearing in mind that:

R ≤ 5.7864 ft lb 24779

37
14. Install the split pin (1) securing the wheel hub
bearing adjuster nut and bend it over the nut to
prevent turning the nut.

24776

38
15. Install the grease nipple as shown in figure.

TRE4001A

39

84176554 -- 03--2008
16 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

16. Install the wheel hub bearing cover (1).

1
24775

40
STUB AXLE
Overhaul (Op. 44 101 46)
WARNING
Handle all parts with great care. Do not put your
hands or fingers between one part and another.
Wear the recommended safety clothing such as
goggles, gloves and safety boots.

The stub axles can be removed with the axle

installed on the tractor. Proceed as follows for each
wheel.
1. Disconnect the negative cable of the battery and
isolate it; chock the rear wheels.

2. Lift the front of the tractor.

24765

41
3. Place al stand (1) beneath the engine sump,
inserting a block of wood between the engine
sump and stand.

1
24766

42

84176554 -- 03--2008
 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1 17

4. Remove the front wheel fixing bolts (1).

24767

43
5. Place a hydraulic jack beneath the stub axle and
unscrew the bolt (1) fixing the control lever (2) to
the stub axle pin.

24782

44
6. Withdraw the control lever (1) from the stub axle
pin (2).

24783

45
7. Lower the hydraulic jack and remove the stub
axle (1).

1
24784

46

84176554 -- 03--2008
18 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

8. Unscrew the axle end securing bolts (1).

24785

47
9. Remove the axle end (1).

24786

48
10. Clamp the end of the axle in a vice and using a
slide hammer, take out the stub axle pin
articulation bushing (1).

24787

49
11. To refit the stub axle, follow the disassembly
procedure in reverse order, using a suitable
hammer to fit the new bushings on the axle ends.

24788

50

84176554 -- 03--2008
 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1 19

12. Fit the axle end (1).

24786

51
13. At the base of the stub axle refit the cap (9, fig. 1),
then the levelling rings (1), inserting them on the
stop grub screws (8 and 14, as shown in figure 1).

24789

52
14. Fit the stub axle on the axle end.
15. Position the control lever (1) on the stub axle pin
(2) and tighten the securing screw.

24783

53

84176554 -- 03--2008
20 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

CHECKING THE ALIGNMENT OF THE FRONT

WHEELS (Op. 44 511 80)
A
Check the alignment of the front wheels, bearing in
mind that for driving in a straight line, the wheels must
be at an angle of 2° to the vertical. This corresponds
to a difference of approximately 15 mm (0.5906 in.) for A+X
16 in. wheels, between the top edge of the rim (A) and
bottom edge (A + X).
When driving in a straight line, the wheels must be B2
parallel to the longitudinal axis of the tractor or have
a maximum of 5 mm (0.1968 in.) toe--in at the front,
measured between the wheel--rims.

To check the toe--in, proceed as follows:

B1
1. Inflate the front tyres to a pressure of 2.5 bar
(36.25 psi).
8821

2. Position the steering wheel in the middle of its 54

travel, with one spoke along the longitudinal axis
of the tractor.

3. Check that the wheels are parallel with the

longitudinal axis of the tractor.
4. With the tractor parked on a flat, level surface,
measure the distance (B1) between the front of
the wheel rims, at hub height. Make a chalk mark
on the rims where the measurement has taken
place. Move the tractor forward to rotate both
wheels exactly 180o and check the
measurements again at the chalk marks B2 (now
positioned at the rear of the wheels). This will
eliminate wheel rim run--out errors.

5. Correct the toe--in, if necessary, by adjustment

of the end of the transverse steering tie--rod.

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 1

SECTION 50 --AUXILIARY UNITS

Chapter 1 -- Auxiliary units

CONTENTS

Section Description Page

50 000 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Operating principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Main components of the cab air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Refrigerant recovery--recycling and evacuation--charging stations . . . . . . . . . . . . . . . . . . 20

50 200 04 Drying recharging and checking cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

50 200 03 Functional testing of air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Summary of the cab air--conditioning system charging operations . . . . . . . . . . . . . . . . . . 28

Checking for refrigerant leaks using an electronic leak detector . . . . . . . . . . . . . . . . . . . . . 30

Summary of fault diagnosis and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Air conditioning and heating pipes -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

50 200 04--74 Receiver--drier -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

50 200 04--72 Condenser -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

50 200 04--26 Compressor -- Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

50 200 10 Compressor drive belt tension adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

84176554 -- 03--2008
2 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

CAB AIR CONDITIONING SYSTEM

SAFETY — freezing of the skin caused by contact with liquid

refrigerant can be treated by gradually warming
the injured area with cold water followed by
application of a greasy cream. Seek medical
Refrigerant must be handled with extreme care to assistance.
avoid injury; always wear safety gloves and goggles.

— the air conditioning system contains a mixture of

Liquid refrigerant can cause freezing of the skin and refrigerant and oil under high pressure; under no
serious damage to the eyes, even blindness in some circumstances loosen pipe fittings/couplings or
cases. work on pipes without having first evacuated the
system.

Keep refrigerant containers away from heat sources, — for the same reason, never unscrew the
as the increase of internal pressure due to heating compressor oil level plug when the system is
could cause the container to explode. charged.

— do not heat the refrigerant container. Above 50°C

In contact with a naked flame or hot metal surfaces (122°F) the pressure increases very rapidly.
the refrigerant may give off a toxic gas. If inhaled this
gas can cause serious harm.
— keep the air conditioning system away from heat
sources to prevent possible explosion due to the
increase of pressure in the system.
To avoid the possibility of accidents take the simple
precautions described below.

The operation of emptying the system must be When transferring refrigerant from one container to
carried out in a well--ventilated area, well away from another, only use homologated liquid refrigerant
any naked flames. containers equipped with safety valves.

During the charging and emptying operations, take

Never fill liquid refrigerant containers over 80% of
the necessary precautions to protect the face and
their maximum capacity.
above all the eyes from accidental contact with
refrigerant.

Do not modify the settings of safety valves and the

In case of accident, proceed as follows:
control devices.

— if has entered the eyes, wash immediately with

a few drops of mineral oil, then wash them
thoroughly with a solution of boric acid and water Never connect the recovery/recycling and
(one spoonful of acid in 1/4 cup of water) and evacuation/charging stations to electrical power
seek medical assistance immediately. outlets with voltages other tan those specified; do not
leave the stations powered on unless they are to be
used immediately.

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 3

CAB AIR CONDITIONING SYSTEM CHARACTERISTICS

SANDEN SD 7H15 Compressor

Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3(in.3) 155 (9.46)

Maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 6000

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg (lb) 6,5 (14.33)

Quantity of lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3(in.3) 185 (11.29)

Type of lubricating oil (code) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAG SP 20

Air conditioning system Gas HFC134a

Quantity of HFC--134a refrigerant . . . . . . . . . . . . . . . . . . . . . . . gr (lb) 1600 (3.5274)

System delivery side pressure . . . . . . . . . . . . . . . . . . . . . . . . bar (psi) 16--24 (232.06 -- 348.09)

System suction side pressure . . . . . . . . . . . . . . . . . . . . . . . . bar (psi) 0,5--3 (7.25--43.51)

Pressure switch setting (high pressure) . . . . . . . . . . . . . . . . bar (psi) 25 (362.59)

Pressure switch setting (high pressure) . . . . . . . . . . . . . . . . bar (psi) 2 (29.01)

Temperature of refrigerant fluid at outlet of compressor . . . . oC(oF) 60--120 (140--248)

Temperature of refrigerant fluid at outlet of condenser . . . . . oC(oF) 40--60 (104--140)

Temperature of refrigerant fluid at outlet of evaporator . . . . . oC(oF) 0--15 (32--59)

Maximum capacity of electric centrifugal fan I, II, III speed . m3/min 3,5--8,5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (in.3/min) (21.36--51.87)

Remember that altitude affects pressure, as shown Altitude Absolute atmospheric Correction
in the table on the right. (m) pressure (psi) (psi)
To obtain the effective pressure in the system,
subtract the corresponding correction value from the s.l.m.
pressure gauge reading. 0 14.63 0
300 14.13 -- 0.50
600 13.64 -- 1.00
900 13.14 -- 1.49
1200 12.64 -- 2.00
1500 12.14 -- 2.50
1800 11.64 -- 3.00
2100 11.25 -- 3.39
2400 10.85 -- 3.82

84176554 -- 03--2008
4 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

TOOLS REQUIRED FOR SERVICING THE AIR CONDITIONING SYSTEM

Warning -- The operations described in this section cannot be carried out without the ESSENTIAL tools marked
(X) in the following list.
To work in safety and to obtain the best possible results whilst saving both time and energy, we recommend that
the other specific tools in the list are also used.

List of specific tools for the various operations in this section

X 294030 Evacuation and charging station

X 294048 Recovery and recycling station

294044 Set of flexible hoses for 294030 and 294048

294043 Tool kit for 294030

294042 Receiver--drier for 294048

294036 Gas leak detector with audible leak indication

293826 Athermal tape for expansion valve

X 293831 Combs for cleaning and straightening the fins on the condenser
and evaporator

293825 Oil for pumps of stations 294030 and 294048

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 5

OPERATING PRINCIPLES As regards the purity of the air, there are no precise
limits, but it is important to remember that the human
The function of the air conditioning system is to
metabolism alters the composition of the
create and maintain optimum working conditions
surrounding air, increasing the humidity and the
inside the tractor cab.
quantity of carbon dioxide, while decreasing the
percentage of oxygen, etc..
These conditions regard four main factors:
— temperature; By drawing in small quantities of fresh air from
— humidity; outside the cab, it is possible to eliminate impurities
— speed; in the air, particularly important in the case of
— purity of the air in the cab. agricultural tractors, where dust from earth, hay etc.
can cause extreme discomfort, by installing dry
filters on the external air inlets.
Obviously ”ideal” conditions will vary from person to
person, and so it is not possible to specify optimum
values for the above factors; however, we can Air conditioning systems in tractors and agricultural
specify a range of values within which the majority of vehicles in general thus serves to neutralise the heat
people will feel most comfortable. and humidity generated in the cab by controlling the
temperature and humidity of the air in --or drawn into--
the cab to create comfortable working conditions for
As regards temperature and humidity, it is possible
the operator.
to define a zone, known as the ”comfort zone”, within
which the temperature--humidity combination
corresponds to pleasant environmental conditions. The operating principle of an air conditioner is similar
to that of a domestic refrigerator: to cool an
environment, heat must be removed by means of a
From the diagram it can be seen that humidity should
physical process (evaporation of a liquid) which
be within the range of 30% to 70% (below 30% there
absorbs heat from the surrounding air.
is excessive dehydration of the mucous tissues of
the nose and throat, while above 70% the subject has
an uncomfortable sensation of dampness in many The liquid used in this process, known as the refriger-
areas of the body) whereas temperature can vary ant, is product with a high refrigeration coefficient,
between 18 and 28°C ( 64.4 and 82.4°F). low toxicity, which mixes well with lubricating oil.

The air flow speed must not be so high as to cause The various components of the system are
discomfort; speeds of 0.07 -- 0.25 m/s connected by suitable pipes which ensure that the
(0.2296 -- 0.8200 ft/s) are normally acceptable pressure of the system is maintained.

Simplified psychrometric diagram Relative humidity %

1. Sensation of unbearable cold.

2. Sensation of cold.
3. Comfort zone.
4. Sensation of heat.
5. Sensation of unbearable heat.

25372 Temperature oC

84176554 -- 03--2008
6 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

There are five main components of the air (depending on the ambient temperature) which thus
conditioning system: changes its state from a vapour to a liquid.
1. compressor;
2. condenser; The refrigerant, in liquid state at high pressure, is
purified by passing through the receiver--drier (3)
3. receiver--drier; from where it flows to the expansion valve (4), which
4. expansion valve; restricts the flow of refrigerant and thus reduces its
5. evaporator. pressure.

To understand the operating cycle of the system, As it passes through the expansion valve (4), part of
follow the flow of the refrigerant starting from the the refrigerant is transformed into vapour and the low
compressor (1). temperature mixture of vapour and liquid thus
formed enters the evaporator (5).

The compressor draws in refrigerant in vapour form

at a pressure of 0.5 ÷ 3 bar (7.25 ÷ 43.51 psi) and it Here the electric fan causes a continuous circulation
compresses it to a pressure of 16 ÷ 24 bar of the cab air over the fins of the evaporator (5),
(232.06 ÷ 348.09 psi). helping the refrigerant to absorb heat from the air and
thus change completely from a liquid to vapour.

The refrigerant, heated by compression to hot

The evaporation process removes heat from the air
vapour with a temperature of 60÷120 °C
passing over the evaporator (5) and thus reduces
(140÷248 °F), enters the condenser coil (2) located
the temperature inside the cab.
forward of the engine radiator.

The flow of air over the cold surface of the evaporator

The air flow passing over the condenser fins and (5) also condenses some of the moisture in the air
tubes produced by the forward movement of the and therefore reduces the humidity in the cab.
tractor cools the refrigerant.

On leaving the evaporator (5) at 0÷15 °C (32÷59 °F),

This action cools the refrigerant to the point of the low pressure mixture is aspirated by the com-
condensation between 40÷60 °C (104÷140 °F) pressor (1) to repeat the cycle.

5 4 3 2
25372

2
Simplified system diagram
1. Compressor. 4. Expansion valve with thermostatic sensor.
2. Condenser. 5. Evaporator.
3. Receiver--drier.

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 7

AIR CONDITIONING SYSTEM FAULT DIAGNOSIS

THE SYSTEM DOES NOT WORK

1. Check fuses.
2. Check compressor drive belt
tension.
3. Check if the clutch coil is
receiving power.
4. Check that the earth contact is
efficient.

5. Check the system control

devices -- the relays, wiring,
thermostat, etc.
6. Visually check the condition of
all fittings, unions and pipes.
7. Check the clearance between
the front disc and pulley of the
electromagnetic clutch..

1 2 3

10 4

9 8 7 6 5
25374

Schematic of air conditioning system.

1. Compressor. 6. Receiver--drier.
2. Compressor inlet pipe (low pressure). 7. Sight glass.
3. Compressor outlet pipe (high pressure). 8. Expansion valve with thermostatic sensor.
4. Hot air. 9. Evaporator.
5. Condenser. 10. Cool, dehumidified air.

84176554 -- 03--2008
8 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

AIR CONDITIONING SYSTEM FAULT DIAGNOSIS (cont.)

INSUFFICIENT
COOLING

HIGH DISCHARGE PRESSURE DISCHARGE PRESSURE LOW DISCHARGE PRESSURE

AND/OR HIGH SUCTION AND/OR SUCTION PRESSURE NORMAL AND/OR SUCTION
PRESSURE LOW PRESSURE NORMAL

CHECK THE INSPECT THE

SIGHT GLASS (7, fig. 3) SIGHT GLASS (7, fig. 3)

EXCESS REFRIGERANT BUBBLES VISIBLE IN SIGHT Note: during testing, the low
IN SYSTEM GLASS pressure gauge reading could fall to
Insufficient quantity of refrigerant in negative values or remain normal.
Note: the sight glass may contain system. Possibly due to small leaks. HUMIDITY IN SYSTEM
bubbles. Evacuate refrigerant until 1. Check system for leaks and 1. Evacuate the refrigerant from the
a large number of bubbles appear in eliminate if found. system.
the sight glass, then add refrigerant 2. Add refrigerant until the bubbles 2. Replace the receiver--drier.
to the system until the bubbles disappear and both pressure 3. Bleed air from the system then
disappear gauges indicate normal pressure. re--charge.

CONDENSER
1. Fins could be clogged thus
restricting the flow of air over the
condenser. Clean condenser fins.
2. The condenser must be
positioned at the distance from the
radiator specified in the system
design.

EXPANSION VALVE
Check the valve as indicated on
page 17.
1.If the valve fails the test, replace it.

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 9

AIR CONDITIONING SYSTEM FAULT DIAGNOSIS (cont.)

INSUFFICIENT
COOLING

HIGH DISCHARGE PRESSURE DISCHARGE PRESSURE HIGH DISCHARGE PRESSURE

AND/OR NORMAL SUCTION AND/OR SUCTION PRESSURE NORMAL AND/OR
PRESSURE LOW SUCTION PRESSURE NORMAL/
HIGH

Note: the pressure reading of the OBSTRUCTION ANTI--FROST

high pressure gauge should be Water or ice forms downstream of SWITCH
constant without any decrease. the obstruction (on receiver--drier or With ambient temperature below
on the pipe between the condenser 30_C (86_F) the electromagnetic
AIR outlet and the expansion valve). clutch is permanently engaged.
IN SYSTEM 1.Remove the obstructed 1. Check as described on page 18.
1. Recover--recycle the refrigerant component and eliminate the 2.Replace the anti--frost switch
in the system. obstruction or renew component. (1, fig. 13) if it does not function
2. Replace the receiver--drier. correctly, being careful not to crush
3. Evacuate the system and then the capillary tube, and install new
re--charge. switch in the same position and at
the same depth inside the
evaporator as the previous switch.

84176554 -- 03--2008
10 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

AIR CONDITIONING SYSTEM FAULT DIAGNOSIS (cont.)

COMPRESSOR AND
ELECTROMAGNETIC CLUTCH

ABNORMAL NOISE NO COOLING ABNORMAL NOISE

WHEN CLUTCH ENGAGED WITH CLUTCH DISENGAGED
OR VIBRATION

1. Check all compressor mountings.

2. Check engine components in the 1. Check electrical power supply.
vicinity of the compressor. The compressor runs noisily or
3. Check if the electromagnetic 2. Check the clearance between the
does not run. front disc and the pulley.
clutch operates intermittently or
slips.

1. Check the condition and tension

4. Check the clutch bearing. of the compressor drive belt
2. Check the clearance between the
5. Check that the electromagnetic front disc and the pulley of the
clutch pulley runs smoothly.
6. Check the oil level in the electromagnetic clutch.
3. Check the clutch supply voltage,
compressor. the current draw, the supply lead,
the earth point.

4. Check that the electromagnetic

clutch pulley runs smoothly.
5. Check that there is a sufficient
quantity of refrigerant in the system.
6. Check the compressor for leaks.
7. Check the system for leaks.

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 11

CAB HEATING AND VENTILATION CONTROLS

VENTILATION
Turn on cab ventilation by operating switch (2) fig. 4
1 2
and direct the air flow as required by positioning the
front vents (3, fig. 5).

The operator may select outside air or inside air by

adjusting the rear air recirculation vents (1, fig. 6)
which can assume two positions.
— vents closed: air is drawn from outside the cab
through the lateral filters.
— vents open: the greater part of the air is drawn TRE0024A

from inside the air through the vents.

4
Fresh air drawn into the cab from outside is always
filtered. 3

With the fan in operation, and the doors, windows

and recirculation vents closed, the pressure inside
the cab is greater than the external pressure and thus
air can only enter the cab through the lateral filters
after it has been suitably filtered.

Note -- To increase the pressure inside the cab,

select outside air only
(air recirculation vents 1, fig. 6 closed). TRE0011A

Fan
The fan control switch (1, fig. 7) is powered when 1
the ignition switch (fig. 8) is in position B.
A. Low speed.
B. Medium speed.
C. High speed.

TRE0025A
Air filter
6

DANGER
Remember that the filters of the cab provide no 1 2
protection against antiparasitic chemicals in general.
Therefore complete protection against these
products can only be achieved by the adoption of
additional specific safety measures for the individual
product. This applies to all types of filter, for which the
prescriptions for use and maintenance must be
followed scrupulously.Even the use of active carbon
filters does not exempt the operator from adopting
the personal safety precautions recommended for TRE0024A
the product in question.
7

84176554 -- 03--2008
12 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

HEATING
The heating control knob (1, fig. 4) allows the
operator to regulate the temperature of the air by
increasing or decreasing the circulation of coolant
from the engine.

The fan control switch (1, fig 7) allows the operator

to adjust the quantity of air blown into the cab through
the vents (3, fig 5)

Temperature control knob (1)

— Turned fully counter--clockwise = minimum
temperature (circulation of hot water shut off).

— Turned fully clockwise = maximum temperature

(circulation of hot water fully open).

Note -- The total capacity of the cooling system (*in-

cluding the cab heating system) is 14 litres in the
JX60 model or 16 litres in JX70, JX80, JX90 and
JX95 models.

IGNITION SWITCH
The ignition switch (1) can assume four different
positions:

P A B
A. No circuits powered (key can be removed).
Engine stop:automatic operation of fuel injection C
shut--off device.

B. Predisposition for engine starting. Turn signals

and instruments operational. Various devices
powered.

8
C. Start engine: key returns automatically to
position (B) when released.

P. Parking lights on, control panel illuminated,

auxiliary lights switch powered (key can be
removed).

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 13

3 2 C

B
A
TRE0012A

CAB AIR CONDITIONING CONTROLS

SWITCHING ON THE AIR CONDITIONING
AND TEMPERATURE CONTROL

Air conditioning and temperature control

button.
Operational when ignition switch is in the starting
position.
With fan control knob (1, fig 9) in positions A--B or C,
turn knob (2, fig 9) to switch on the air conditioning.

Heating control knob (fig 4)

Turn the knob (1) fully clockwise for maximum
heating.
Turn knob (1) fully counter--clockwise to shut off the
flow of water to the heater and thus switch the
heating off.

3--speed fan control knob

Operational when ignition switch is in starting
position.
A. Low speed .
B. Medium speed.
C. High speed.

Note -- To pressurise the cab see the chapter

Ventilation on page 11 of this section.

84176554 -- 03--2008
14 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

USE OF THE AIR CONDITIONING SYSTEM

The air conditioning system provides cool, To lower the temperature and, at the same time, the
dehumidified air or warm dehumidified air. humidity of the air inside the cab, turn knob (2, fig. 9)
counter--clockwise until the desired temperature is
To operate the system proceed as follows.
obtained.

Warning -- Before starting the engine, check that the

Warning -- The air conditioning system is not
air conditioning knob (2 fig. 9) is in the ”off” position.
operational when the engine is not running as the
compressor is driven by the engine.

Note --When working in very dusty conditions, to

increase the pressure inside the cab to prevent dust
SWITCHING ON THE AIR CONDITIONING entering, it is advisable to close the recirculation
With the engine running, turn knob (2, fig. 9) to start vents.
the air conditioning.

If you wish to use the dehumidifying function without

Warning -- Before switching on the conditioner, lowering the air temperature, turn knob (2, fig. 9)
always switch on the fan. clockwise to obtain the desired temperature.
When the fan control knob is in the ”off” position, the
air conditioning cannot function.
After prolonged operation in hot sunshine, to bring
the air inside the cab back to the optimum
After a few minutes of operation, liquid visible in the temperature, without the tractor moving switch on
sight glass (7, fig. 3) on top of the filter should be clear the air conditioner and open the rear window or hatch
and free of bubbles. If not, consult the specialised to discharge the hot air.
personnel at your dealer.

ADJUSTMENT SWITCHING OFF THE AIR CONDITIONING

SYSTEM
To obtain correct cab air conditioning, when the
system is in operation keep the recirculation vents Before stopping the engine, always switch off the air
open and keep the doors, hatch and rear window conditioner by turning knob (2, fig. 9), then turn the
closed. fan control knob (1, fig. 9) to the ”off ” position.

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 15

MAIN COMPONENTS OF THE AIR

CONDITIONING SYSTEM
1 2 3 4 5

Axial flow reciprocating piston compressor

SANDEN SD 7H15
1. Combined inlet and discharge valve.
2. Piston with seal ring.
3. Drive gear.
4. Swash--plate.
5. Cam rotor. 25375

10
Compressor
The compressor serves to pressurise the refrigerant
and force it through the system.

SANDEN SD 7H15

Axial reciprocating piston type, driven from the

engine crankshaft via a v--belt.

The operating principle of the compressor is as

follows:

The swashplate (4), on which pivot the ball ends of

the connecting rods of the pistons (2), rests on the
cam rotor (5).

As the cam rotor rotates it exerts a continuous thrust

on the swashplate which cannot rotate as it is held by
the fixed gear (3).

The angle of the swashplate relative to the axis of

rotation causes the pistons to reciprocate in their
bores.

A reed valve (1) in the cylinder head with seven lobes

(one for each piston) controls the inlet and discharge
stages of the cylinders.

The automatic opening and closing of these valves is

obtained by preloading of the reeds.

The rotating parts of the compressor are lubricated

by special oil, inserted during assembly, some of
which circulates through the system mixed with the
refrigerant.

84176554 -- 03--2008
16 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

Condenser

In the condenser the refrigerant is transformed from

a vapour to a liquid state.

As this occurs by transfer of the heat from the

refrigerant to the ambient air, the condenser
functions in a similar way to the engine radiator.

The condenser consists of a series of tubes through

which the refrigerant circulates and a finned block
which is pressed onto the tubes to covers them
completely in thin aluminium fins to help dissipate
heat to the ambient air.

The condenser is installed in front of the engine

cooling radiator so as to benefit from the air flow
caused by forward motion of the tractor.

Receiver--drier

The receiver--drier, installed between the condenser

and the expansion valve, performs two basic
functions, acting as a filter to remove dirt and
moisture from the refrigerant and as a temporary
storage container during variable charge stages.

Water in the system can cause corrosion and

damage to system components.

For this reason the filter contains substances to

absorb humidity. 1

Solid contaminants, such as sand, metal particles

resulting from wear of compressor components,
oxides, particles from the pipes, etc., can cause
damage to the system and therefore must be
removed by suitable filters.

2
Receiver--drier
1. Sight glass. 3
2. Upper screen.
3. Disc. 4
4. Drying agent.
5. Lower screen.
5

25376

11

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 17

Thermostatic expansion valve

Serves to reduce the pressure of the refrigerant as it
enters the evaporator so that it can change state and
thus remove heat from the surrounding air.

The expansion valve performs two basic functions:

— metering: the calibrated orifice (6, fig. 12) in the

valve body creates a difference in the pressure of
the refrigerant at the inlet (4) (liquid state) and the
outlet (7) (mixed liquid/vapour); the calibrated
orifice (6) also serves to atomise the refrigerant
to facilitate subsequent evaporation;
— modulation: inside the valve body a thermostatic
sensor controls the valve aperture so that the
right quantity of refrigerant enters the evaporator
to ensure complete evaporation.

If the thermostatic sensor (2, fig. 12) detects an

increase in the cab temperature, the flow of
refrigerant is increased.

A drop in the temperature or an increase in the

compressor capacity (due to an increase in the
engine speed) will cause a reduction in the flow of
refrigerant into the evaporator.

The expansion valve is installed on the evaporator

inlet fitting (7), and as the internal refrigerant flow
control system is completely automatic, it requires no
special maintenance.

To perform functional testing, with the system is fully

charged, check that the system operating pressures
are those indicated on page 3.

Note -- In case of malfunction, replace the valve.

Expansion valve block.

1. From evaporator outlet. 1 2
2. Thermostatic sensor.
3. To compressor suction inlet. 3
4. From receiver--drier.
5. Spring.
6. Calibrated orifice and ball.
7. To evaporator inlet. 4
7
6 5
25389

12

84176554 -- 03--2008
18 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

Thermostatic switch (ANTIFROST)

1 2

The thermostatic switch is a safety device equipped

with a sensor (1) which is inserted between the fins of
the evaporator (2) where it constantly monitors the
temperature.

25377

13

The bulb of the sensor (1) is filled with a special gas

which expands or contracts according to the
temperature and thus acts on a membrane
connected to a complex mechanism which opens or
closes a switch in the electrical circuit of the magnetic
clutch to switch the compressor on or off as required.

The thermostatic sensor (1) thus prevents ice

from forming on the evaporator and obstructing
the flow of air into the cab.

For this reason it is very important to insert the

sensor (1) between the fins of the evaporator (2) as
shown in figure 13.

Note -- In case of malfunction, replace the entire

thermostatic switch.

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 19

Evaporator WARNINGS REGARDING SERVICING AND

REPAIR OF THE AIR CONDITIONING SYSTEM

The cycle is completed inside the evaporator.

Switching on the air conditioning system when the

ambient temperature is low can damage the
The refrigerant leaving the expansion valve is a low compressor. Only operate the air conditioner when
temperature, low pressure mixture of vapour and the engine is hot and the temperature inside the cab
liquid. is at least 20 °C (68 °F).

As it passes through the evaporator it absorbs heat When disassembling pipes, plug the ends with
from the ambient air, vaporises and, having plastic caps to prevent moisture and dust getting
performed its cooling function, is aspirated by the inside.
compressor as a vapour.

Handle the tube of the thermostatic sensor with great

The operation of the evaporator is controlled by the care to avoid damage which could prevent the entire
expansion valve which delivers the exact quantity of system from operating correctly.
refrigerant needed to produce the required air
conditioning effect.

When unscrewing pipe fittings and unions, always

use two spanners to avoid undue torsion.
The evaporator performs the opposite function to the
condenser, but its basic construction is the same, the
only differences being its overall dimensions and the
layout of the internal pipes.
Do not use engine oil of any type to lubricate the
system or the compressor.

The evaporator also performs another function:

dehumidification of the cab.
Do not leave the compressor oil container open.
Make sure that the cap is replaced and fully
tightened. The oil will absorb moisture, which is
The air passing over the evaporator contains a harmful to the system.
certain quantity of moisture, and this must be kept
within certain limits for operator comfort.

Do not transfer compressor oil from its original

container to another.
Part of the moisture condenses on the fins
evaporator and is thus removed from the air.

Do not add any substances to the refrigerant or

The centrifugal fan draws the ambient air through the compressor oil. Any additives might contain
fins of the evaporator (where it is cooled and elements incompatible with the refrigerant and thus
dehumidified) and into the cab. alter its characteristics.

The housing around the evaporator is equipped with

a condensate trap from which the condensate is Check that the thermostatic sensor is correctly
carried outside the vehicle through discharge tubes. inserted between the fins of the evaporator.

84176554 -- 03--2008
20 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

REFRIGERANT RECOVERY--RECYCLING AND 2--way pressure gauge unit, with refrigerant flow
EVACUATION--CHARGING STATIONS indicator and pressure gauges (1 and 2) controlling
the pressure in the cylinder and at the inlet.
WARNING
Never under any circumstances use 294053, Humidity indicator (15) for checking the
recovery/recycling or evacuation/charging stations decontaminated refrigerant.
designed for a different refrigerant than that used
in the system, as the different chemical
compositions of different types of refrigerant render
them incompatible with each other. Low pressure switch for automatic cycling of the
compressor.
When connecting the stations to the system service Graduated container for the discharge of recovered
valves, always connect the low pressure blue pipes contaminated oil.
(11, fig. 15, or 17, fig. 16) to the service valve on the
suction side of the compressor (S--Suction), and the Switch (5) 1--0--2 for recovery and cylinder heating.
high pressure red pipes (12, fig. 15, or 15, fig. 16) to
the service valve on the discharge side of the Indicator lights.
compressor (D--Discharge).
294044 flexible service pipes (11, 12 and 16) with
Important: check the seals in the pipe safety cocks.
connectors (11, 12, 16, fig. 15), or (15, 17, 24, fig.
16) and replace if faulty. (kit 294052) Recovery capacity: 200 grams/minute
Remember that the pipe fittings fitted with seals (0.4411 lb/minute).
are to be hand--tightened only without forcing,
otherwise the seal will be damaged. Power supply: 220 V (50 Hz).

RECOVERY AND RECYCLING STATION (294048)

Maintenance
Description (Refer to figure 15)
The station is designed for the recovery and
Replacement of refrigerant decontamination
recycling of refrigerants used in the cab air filter (3)
conditioning systems.
The recovered refrigerant is first separated from the Refer to figure 15 and proceed as follows:
system oil by means of a process of vaporisation
which takes place in a suitable container.
Warning -- Every 12 months or earlier if the humidity
In the filter section, the acidity is neutralised, indicator (15) turns yellow and stays yellow
moisture is absorbed and solid particles are throughout the recovery/recirculation stage, renew
screened out. the filter (3).
The decontaminated refrigerant is then stored in the
metering cylinder.
6. Close all the valves including the yellow service
TECHNICAL CHARACTERISTICS valve (9) installed below the distillation cylinder
(4).
Recovery compressor equipped with oil level 7. If refrigerant is present in the circuit set
indicator, discharge valve and service connection. pushbutton (5) to position ”1” and carry out the
refrigerant recovery operation. The compressor
will stop automatically when the pressure gauge
294042 anti--acid decontaminating filter (3), with a (2) drops to --0.3 bar (--4.35 psi).
high moisture absorption capacity.
8. Remove and replace the contaminated filter (3).
9. Carry out a normal evacuation operation for
Refrigerant/oil distillation cylinder (4) with heating
about 30 minutes using the evacuation/charging
element, automatic device for return of oil to the
system (294030) proceeding as follows:
recovery station compressor and automatic flow
connect the pipe (17, fig. 16) to the service valve
control valve for refrigerant entering the station. (14, fig. 15), open the cock installed on the pipe
itself and cocks (4, 10 and 9, fig. 16).
Graduated cylinder (19) for recovered refrigerant, On completion of the evacuation operation, close
2.2 kg (4.8524 lb) capacity, with heater and a safety cocks (4, 10 and 9), the cock on the pipe (17) and
valve. disconnect pipe (17).

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 21

Check filter connections for leaks (3) 8. Record the operation on the appropriate service
report card.
Refer to figure 15 and proceed as follows:

10. To check for leaks at the connections of the

previously replaced filter (3) open the yellow
service cock (9) on the distillation cylinder (4).
EVACUATION/CHARGING STATION (294030)
11. Perform a brief recycling operation on the
refrigerant contained in the cylinder (19),
proceeding as described in the operations Description (Refer to figure 16)
18÷21, on page 23 and check with a leak detector
for leaks at the connections of the new filter.
The station is designed for the evacuation and
12. Record the operation on the appropriate service subsequent charging of refrigerant in the cab air
report card. conditioning systems.

The system must first be evacuated to remove any

moisture and impurities.
Changing the compressor oil in the
recovery/recycling station The new refrigerant from the external cylinder is
transferred to the graduated cylinder before being
Refer to figure 15 and proceed as follows: pumped into the air conditioning system.

Warning --The oil in the compressor of the Technical characteristics

recovery/recycling station should be replaced with
new oil (code 293825) every 12 months to maintain Double--acting, ballasted, rotary vacuum pump (21)
the station’s refrigerant treatment capacity and to in oil bath.
protect the compressor.
Charging cylinder (31) with maximum level indicator
and graduated scale for measurement of quantity of
refrigerant.
1. Open cock (13), and drain the oil into a container
to be disposed of in accordance with local 5--way pressure gauge manifold with 2 pressure
regulations for waste oil disposal. gauges (5 and 6) and 1 vacuum meter.
2. Close cock (13).
294044 flexible service pipes (17, 15 and 24) with
3. Remove the caps from the service valves (14) on safety cocks:
the side of the compressor and (13) on the sight
glass.
Power supply: 220V (50 Hz).
4. Connect the service pipe of the evacuation
station (294030) to valve (14) and connect a
pick--up pipe from kit 294043to valve (13) on the
sight glass. Maintenance
Check level and change oil in pump of
5. Perform the evacuation operation with the pump evacuation/charging station (periodic check)
in operation. The new oil can be aspirated from
an external container by means of the pick--up Refer to figure 16 and proceed as follows:
pipe.

6. Once the compressor has been filled with correct Periodically check the level and condition of the oil.
quantity of oil (half--way up the sight glass) close Drain off the old oil, if necessary, through plug (18).
valve (13), disconnect the pick--up pipe, and Old oil must be disposed of in accordance with local
replace the cap on service valve (13). Continue regulations.).
the evacuation for approx. 30 minutes.
Remove cap (13) and fill the vacuum pump (21) with
7. On conclusion, close the cocks, switch off the new oil of the type indicated by the pump
pump, disconnect the service pipe and replace manufacturer up to the half--way line on the sight
the cap on service valve (14). glass (14).

84176554 -- 03--2008
22 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

AIR CONDITIONING SYSTEM 7. Connect the blue service pipe (11) to the valve on
Dehydration, recharging and refrigeration check the suction (low pressure) side of the
(Op. 50 200 04) compressor (marked ”S”).

8. Connect the red service pipe (12) to the valve on

Recovery of refrigerant from the cab air the discharge (high pressure) side of the
conditioning system using the compressor (marked ”D”).
recovery/recycling station 294048
9. Switch on the cab ventilation fan at maximum
Note -- the recovery operation can be performed speed to assist the transfer of heat between the
more quickly and completely if the system is ambient air and the evaporator coil.
previously heated, as heat will cause the refrigerant 10. Open cock (10) on pipe (12).
to evaporate and thus be more easily evacuated
from the system. 11. Slowly open cock (6--LOW) on the pressure
gauge manifold. Pressure gauge (2) will indicate
Refer to figure 15 and proceed as follows: the presence and pressure of any refrigerant in
the system; if the needle is near the ”0”, the
1. If possible, operate the air conditioning system system is empty.
for a few minutes with the tractor engine running
and the hood down, so that the heat produced is 12. Set switch (5) to position ”1” (RECOVERY) --
gradually transferred to the various components green indicator light will illuminate. The recovery
in the system, thus allowing any pockets of very compressor will now start.
cold fluid in the system to evaporate.
During the recovery operation, the refrigerant will
2. Stop the engine. pass through the distillation cylinder (where it will
separated from the oil) and into the decontamination
DANGER filter (where it will partially cleaned of impurities) to
arrive finally in the graduated cylinder.
The recovery operation must only be performed
with the tractor engine stopped. The compressor will stop automatically when the
pressure gauge (2) indicates a pressure of --0.3 bar
(--4.35 psi).
3. If the charging cylinder (19) already contains
refrigerant, check that there is still sufficient free 13. Wait a few minutes to allow any pockets of liquid
volume to contain all the refrigerant in the system refrigerant left in the system to evaporate and be
(maximum cylinder capacity is 2 kg (4.4112 lb)); evacuated.
if not, transfer the excess refrigerant to an exter-
nal cylinder in the manner described on page 24. 14. Check the pressure gauge (2): if the pressure
has risen above the previous value of --0.3 bar
4. Connect the station’s supply lead to a power
(--4.35 psi), the station will automatically start a
outlet.
second recovery operation; if on the contrary
5. Make sure that all cocks are closed except the the pressure has remained near the value
service cock (9). obtained during the first recovery operation, this
indicates that all the refrigerant has been re-
moved from the system and therefore the opera-
tion is complete.

Note -- If after 10 minutes of operation the station has

not recovered more than 1 kg (2.2056 lb) of refriger-
ant, check pressure gauge (1). If the pressure read-
ing is over 10 bar (145 psi) open cock (21) and dis-
charge air, then check that pressure gauge (1) does
not exceed a maximum of 10 bar (145 psi) through-
out the entire recovery operation.

25379
15. Close all the cocks except cock (9), disconnect
14 the service pipes (11 and 12) from the air
conditioning system compressor and switch off
6. Remove the caps from the service valves the station.
installed on the suction and discharge lines of the
compressor. 16. Switch off the cab ventilation fan.

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 23

Recycling recovered refrigerant 19. Connect the 2 ends of the yellow (16) and blue
(11) pipes with connector supplied.
On completion of the recovery operation, the 20. Slowly open the cock (18--REF) and the blue
refrigerant, which has already been through an oil cock (6--LOW) on the pressure gauge manifold,
separation process, must now be completely and the cocks on the two previously connected
decontaminated. service pipes (16 and 11).
WARNING 21. Set switch (5)to position ”1” (RECOVERY) --
At this stage the recovered refrigerant has not yet green indicator light on.
been completely decontaminated and therefore The recovery compressor will start to operate
must not be used in the air conditioning system in this and the refrigerant will pass from the graduated
condition.
cylinder to the recovery circuit (distillation
Proceed as follows: cylinder, filter and compressor) and then return
to the graduated cylinder.
17. All cocks must be closed, with the exception of
22. Continue the operation until the circular sector of
cock (9, fig. 15) and the station must be switched
the humidity indicator (15) turns green.
off -- switch (5) in position ”0” and green indicator
If after 15 minutes the circular sector of indicator
light off.
(15) still has not turned green, replace the filter
18. Connect the end of the yellow service pipe (16) (3) as described on page 20.
without the cock to the free connector (17)
located on the left--hand side of the pressure
gauge manifold.

1 2 3

21 4

20 5

19 6

18 7

9
17
16 15 14 13 12 11 10
25378

15
Refrigerant recovery and recycling station
1. Cylinder pressure gauge. 12. Red service pipe for connection to discharge
2. Recovery control pressure gauge. side of compressor.
3. Anti--acid and decontamination filter. 13. Recovered compressor oil discharge cock.
4. Recovered refrigerant/oil distillation cylinder. 14. Recovery compressor service valve (suction).
5. Switch. 15. Humidity indicator.
6. Refrigerant inlet control cock (LOW). 16. Yellow service pipe for refrigerant transfer.
7. Recovered oil discharge cock (yellow). 17. Fitting for refrigerant transfer.
8. Recoveered oil discharge pipe. 18. Cock (REF) for refrigerant transfer and
9. Oil return to compressor control cock (yellow). recycling.
10. Quick--fit connectors. 19. Refrigerant cylinder.
11. Blue service pipe for connection to suction side 20. Safety valve.
of compressor. 21. Cylinder (gaseous stage) discharge cock
(yellow).

84176554 -- 03--2008
24 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

and connect the other end (with the cock) to the

Note -- The circular sector of the humidity indicator red connector of the external cylinder.
(15, fig. 15) must remain green throughout the 29. Set switch (5) to position ”2” HEATING
recycling operation. CYLINDER to switch on the refrigerant heater
If the colour of the sector tends to vary between fitted to the cylinder (19) so as to facilitate the
yellow and green, or turns completely yellow, this transfer of the refrigerant from the cylinder to the
means that the filter is saturated with moisture and external cylinder.
therefore must be replaced.
30. Open the yellow cock (18--REF), the yellow cock
on the service pipe and red cock on the external
cylinder.
23. On completion of the decontamination operation,
close the yellow cock (18--REF) and continue to 31. On completion of the transfer, close all cocks and
recover the refrigerant.The compressor will stop switch off the station by turning switch (5) to
automatically when .the pressure gauge (2) position 0.
shows a reading of --0.3 bar (--4.35 psi).
Evacuation and charging the cab air
24. Close the cock (6--LOW), the two cocks on the conditioning system using the evacuation/
ends of the yellow (16) and blue (11) service charging station 294030.
pipes, disconnect pipes (16 and 11) and switch
off the station, turning switch (5) to position ”0”.

Note -- Operations 32 ÷ 34, must only be carried out

Discharge of recovered oil if the graduated cylinder (31) is empty of refrigerant.
The presence of contaminated recovered oil can be
seen in the distillation cylinder (4). The recovered oil
must always bee discharged and disposed of Evacuation of the graduated cylinder (31) of the
evacuation/charging station
according to local regulations.
Refer to figure 16 and proceed as follows:
Proceed as follows: 32. Close cocks (4, 22 and 27).

25. Slowly open the yellow cock (7) and discharge 33. Open cocks (3, 9 and 10).
the recovered oil in the graduated container. 34. Start the pump by turning switch (19) to position
“1” to evacuate the cylinder (31). After 5 minutes
26. If no refrigerant leaks, whether major or minor,
close cocks (3, 9 and 10) and switch off the
have ever been detected in the system, on
pump.
recharging, replace the contaminated oil with
same quantity of new oil (see page 26).
Charging the graduated cylinder (31) of the
Transfer of decontaminated refrigerant from evacuation/charging station
cylinder (10) to an external cylinder
If the decontaminated refrigerant in the
If for any reason the decontaminated refrigerant is recovery/recycling station is to put back into the
not to be put back into the air conditioning system tractor air conditioning system immediately, it must
immediately, for reasons of safety it must be be transferred from cylinder (19, fig. 15) to cylinder
transferred from cylinder (19) to a homologated (31, fig. 16) of the evacuation/charging station,
refillable gas container. proceeding as follows:
35. With reference to figure 16, connect the end
Proceed as follows: (without cock) of the yellow service pipe (24) to
the free connector (28) on the left--hand side of
the pressure gauge manifold of the evacuation/
27. Check that all the cocks are closed with the charging station..
exception of cock (9) and that the station is
switched off. Check that the container (cylinder) 36. Connect the other end (with cock) of the service
is large enough to contain all the refrigerant to be pipe to the free connector (17, fig. 15) on the
transferred without exceeding the permitted left--hand side of the pressure gauge manifold of
safety level. the recovery/recycling station.
37. With reference to figure 15, check that all the
28. Connect the end of the yellow service pipe (16) cocks of the recover/recycling station are closed
without the cock to the free connector on the with the exception of cocks (9 and 18) and that
left--hand side of the pressure gauge manifold, on the pipe (16).

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 25

38. Check that all the cocks of the 42. Check the quantity of refrigerant in the graduated
evacuation/charging station are closed, with the cylinder (31).
exception of cock (27). 43. From the total quantity of refrigerant required in
39. Check that the stations are switched off with the air conditioning system indicated in the note
switches (5 and 19) in position ”0”. on page 26, calculate the quantity of refrigerant
that must be added to the cylinder (31) to make
40. With reference to figure 15, turn switch (5) to up the total amount required.
position ”2” HEATING CYLINDER to switch on
44. Transfer refrigerant from the external cylinder to
the refrigerant heater installed on cylinder (19),
the graduated cylinder (31) proceeding as
to facilitate the transfer of refrigerant to cylinder
follows.
(31) of the evacuation/charging station.
45. Connect the yellow pipe (24) to connector (28)
41. On completion of the refrigerant transfer and to the external cylinder containing the
operation, close all the cocks with the exception refrigerant (upside down if not equipped outlet
of cock (9, fig. 15) and switch off the valve).
recovery/recycling station by turning the switch 46. Open the cock on the external cylinder, the cock
(5)to position ”0”. on the charging pipe (24) and cock (27).

1 2 3 4 5 6 7 8
9
31
10
30
11
29
12
28
13
27
14
26
25 15

24 23

16
25378
22 21 20 19 18 17
16

Evacuation/charging station.

1. Safety valve. 17. Blue service pipe for connection to suction side
2. Cylinder pressure gauge. of compressor.
3. Refrigerant charging cock. 18. Oil drain plug.
4. Low pressure side cock (LOW). 19. On/Off switch (I), heater (II).
5. Low pressure gauge. 20. Oil meter connector.
6. High pressure gauge (red). 21. Vacuum pump.
7. %--way pressure gauge manifold. 22. High pressure side cock (HIGH).
8. Vacuum meter. 23. Sight glass.
9. Vacuum test cock (VAC). 24. Yellow service pipe.
10. Vacuum meter test cock. 25. Cylinder heater.
11. Vacuum meter safety valve. 26. External ring.
12. Oil charging cock. 27. Refrigerant transfer cock (REF).
13. Oil filler cap. 28. Refrigerant transfer connector.
14. Sight glass. 29. Glass rod.
15. Red service pipe for connection to discharge 30. Outer casing (Plexiglas).
side of compressor. 31. Refrigerant charging cylinder.
16. Quick--fit cocks.

84176554 -- 03--2008
26 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

47. Rotate the outer casing (30) so that pressure Refer to figure 16 and proceed as follows:
value indicated on the graduated scale
corresponds with the value shown on pressure 56. Pour the oil into the graduated oil meter of kit
gauge (2). 294043.

48. When the refrigerant in the cylinder has reached 57. Connect the oil meter to the oil meter (20).
the required level, as indicated on the glass rod
(29), close the cock of the external cylinder, the 58. Close cocks (4 and 10).
cock on the charging pipe (24) and cock (27).
59. Set switch (19) to position ”2” to switch on the
refrigerant heater on cylinder (31).

Note -- If excessive time is required to transfer 60. Open cock (12) and the cock on the graduated
refrigerant from the external cylinder to cylinder (31), oil meter.
slightly open valve (1) and discharge air from the
61. Check the quantity of oil flowing from the oil
cylinder (31); the pressure reading on gauge (2) meter, and once the required quantity has been
should not exceed 5 bar. reached, close cocks (12) and the cock on the oil
meter, and remove the graduated meter.

Evacuation of the cab air conditioning system

(previously discharged using the recovery/recycling Charging the cab air conditioning system with
station) refrigerant (after evacuation)
49. Remove the caps from the service valves on the
suction and discharge lines of the compressor.
Note -- The quantity of refrigerant to be put into the
Refer to figure 16 and proceed as follows: system is 1600 grams (3.5274 lb)
(refrigerant R134a).
50. Connect the blue service pipe (17) to the valve on
the low pressure side of the compressor marked
“ S ”. Refer to figure 16 and proceed as follows:

51. Connect the red service pipe (15) to the valve on 62. Keep switch (19) in position 2, with the refrigerant
the high pressure side of the compressor marked heater in cylinder (31) on, and heat the
“ D ”. refrigerant for approx. 10 ÷ 15 minutes to
facilitate transfer from the cylinder to the air
52. Open the quick--fit cocks (16). conditioning system on the tractor.
53. Open cocks (4 -- 9 -- 10 -- 22). 63. According to the refrigerant type, rotate the outer
casing (30) so that the graduated scale and the
54. Start the pump by turning switch (19) to position pressure values correspond with the pressure
“I” and evacuate the system for at least thirty reading on gauge (2).
minutes; pressure gauges (5 -- 6 -- 8) should
show a negative reading. If the evacuation 64. Move the external ring (26) along the cylinder
procedure dose not function correctly, check all glass to mark the quantity of refrigerant to be
connections. charged.
55. Close cock (9), switch off the pump by turning 65. Open cock (22) and charge from the high
switch (19) to position ”0” and check the vacuum pressure side.
seal for at least five minutes using vacuum meter
(8). This done, close all cocks. 66. Open cock (3), charge approx. 300 grams
(0.6617 lb) of refrigerant, close cock (3) and
check for leaks.
Charging the cab air conditioning system (after
evacuation) with new oil 67. If there are no leaks, continue charging up to the
prescribed quantity.
If no refrigerant leaks, whether major or minor, have
ever been found in the system, on recharging, 68. On completion of charging, turn switch (19) back
replace the contaminated oil previously recovered in to position ”0”, close cocks (3 and 22),
operations (25 and 26, page 24) with the same disconnect pipes (17 and 15), and replace the
quantity of new oil. If, on the contrary, significant caps on the service valves.
leaks have occurred in the past, proceed with the Carry out functional tests with the system set to
compressor oil level check procedure. maximum performance levels, as described below.

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 27

FUNCTION TESTING OF CAB AIR

CONDITIONING SYSTEM
(Op. 50 200 03)

With the pressure gauges connected to the system in

the manner described previously and the cocks
closed, proceed as follows:

1. Start the engine and bring it up to a speed of 1500

rpm.
2. Set the cab ventilation fan (1, fig. 9) to the 25380
maximum speed.
17
3. Turn knob (2, fig. 9) to switch on the air
conditioning.

After about 15 minutes of operation, take the

following readings:

4. Pressure on suction side of compressor as

indicated by low pressure gauge. 10. Check that the compressor does not make
undue noise; there should be an audible click
when the drive is engaged..
5. Pressure on discharge side of compressor, as
indicated on high pressure gauge.
The sight glass on the receiver--drier can provide
6. Ambient air temperature. useful information about system operation.

The four main possible conditions of the sight glass

7. Ambient relative humidity. are shown in figure 17.

8. Temperature of air leaving vents inside the cab.

A. Glass clear: indicates that the system is correctly
charged, or that there is no refrigerant in the system
The pressure values will depend on the external ( in the latter case the cooling action of the evaporator
ambient conditions and the altitude. would be absent). In some cases, the glass may be
clear when the system has been charged with an
excessive quantity of refrigerant; in this case it would
The system is to be considered as functioning be necessary to check the pressure readings.
correctly if the pressure readings are within the value
ranges indicated on page 3, and the temperature
readings are within the value ranges indicated on B. Bubbles: the formation of vapour or foam
page 29. bubbles indicates that the system contains an
insufficient quantity of refrigerant or the presence of
air in the system; bubbles may also be seen on
9. Check also the temperature of the low and high switching on the system and on disengagement of
pressure sides of the system: the electromagnetic clutch.
— the high pressure side, from the compressor
discharge to the expansion valve on the
C. Threads of oil: indicates a lack of refrigerant and
evaporator, should be uniformly hot to the touch;
that the compressor oil is circulating the system.
— the low pressure side, from the evaporator outlet
to the suction side of the compressor, should be
uniformly cold to the touch. There should not be D. Fluid appearance not uniform, streaky:
excessive condensation on the suction pipe and indicates that the drying agent in the filter has
the low pressure pipe connector on the escaped, as a result of the containment discs
compressor. breaking,, and is circulating in the system.

84176554 -- 03--2008
28 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

SUMMARY OF THE AIR CONDITIONING

SYSTEM CHARGING OPERATIONS

Note -- The pressure readings reported below are

valid for an ambient temperature of 25 °C (77 °F).

— Pressure gauge readings on completion of

refrigerant recovery and recycling operation.
25381

18
— pressure gauge readings with cocks (4 -- 10 -- 22
and 9, fig. 16 page 25) open, cylinder (31) with
2000 gr (4.4112 lb) of refrigerant, red and blue
service pipes connected to tractor system, cocks
(16) closed and compressor off.

25382

19
— Pressure gauge readings with cocks (4 -- 10 -- 22
and 9, fig. 16) open, cylinder (31) with 2000 gr of
refrigerant, red and blue service pipes connected
to tractor system, cocks (16) open and
compressor on (initial evacuation stage).

25383

20
— Pressure gauge readings with cocks (4 -- 10 -- 22
and 9, fig. 16) open, cylinder (31) with 2000 gr
(4.4112 lb) of refrigerant, red and blue service
pipes connected to tractor system, cocks (16)
open and compressor on (final stage of evacua-
tion after 30 minutes).

25384

21

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 29

— Pressure gauge readings with cocks (4 -- 10 -- 22,

fig. 16) open, cylinder (31) with 2000 gr
(4.4112 lb) of refrigerant, red and blue service
pipes connected to tractor system, cocks (16)
open, compressor off and cock (9) closed (check
on vacuum meter that no pressure drops occur
over a period of 5 minutes).

25385

22

— Pressure gauge readings (start of charging -- end

of charging). All previously opened cocks are to
be closed, with the exception of (4 and 3, fig. 16),
compressor off. The level of refrigerant in the
charging cylinder can be seen to drop; proceed
until only 600 gr of refrigerant remain in the
charging cylinder (1400 transferred). The
reading of vacuum meter (8) remains the same
from the beginning to the end of the charging
operation.

25386

23

Checking the temperature of the air coming out external ambient air temperatures specified, the
of the vents inside the cab. system is functioning efficiently.

If the temperature of the air at the vents exceeds the

If the temperature of the air measured at the vents is maximum value indicated in the table, refer to the
within the value range indicated in the table for the fault diagnosis guide in the following pages.

AIR CONDITIONING SYSTEM OPERATING TEMPERATURE VARIATIONS

External ambient temperature 20 °C 27 °C 28 °C 35 °C 36 °C 43 °C

(68 (80.6 (82.4 (95 (96.8 (109.
°F) °F) °F) °F) °F) 4 °F)

Temperature of air at vent outlets 4 -- 8 °C 6 -- 12 °C 12 -- 20 °C

(inside cab) (39.2--46.4 °F) (42.8--53.6 °F) (53.6--68 °F)

84176554 -- 03--2008
30 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

CHECKING FOR REFRIGERANT LEAKS

USING AN ELECTRONIC LEAK DETECTOR
Leak detector (294036)
The leak detector 294036 is supplied in its own
carrying case which also contains the two power
supply batteries, the sensitivity test phial and an ear
plug connection for audible leak indication.
The instrument consists of a hand--held unit with a
flexible probe which houses the sensing tip.
To orient the flexible probe, first slacken off the lock
ring on the lower left--hand corner of the case. 25387

The front of case mounts the sliding on/off switch, the 24

red indicator led, and the audible leak indicator.
The rear of the case mounts the ear plug connection
socket.The battery compartment also houses a Maintenance
sensing tip and a number of spare felt pads.
Use Always make sure that the instrument is switched off
Switch the unit ON: start looking for leaks; the before replacing the sensing tip. To remove the tip,
frequency and the amplitude of the audible signal will unscrew it in a counter--clockwise direction. Fit a new
increase if gas is detected. tip and a new felt pad, screwing them in a clockwise
direction onto the flexible probe.
In areas affected by gas leaks, switch the instrument
on and off; the detector will automatically select a
Do not switch on the instrument unless the sensing
new acoustic level.. Perform this test each time the
tip is firmly screwed on to the end of the flexible
instrument is to be used.
probe.
Hold the sensing tip near the open phial to test
sensitivity; when the instruments starts to emit a
On fitting the tip, check that there is no grease or dirt
signal, switch it on and then off.
in the connecting hole between the probe and the tip.
Refrigerant leak test
In this stage the instrument automatically regulates
its sensitivity in accordance with the presence of gas
in the environment around the sensing tip, and the
test is performed solely by means of the on/off
switch.
In ventilated areas, it can be extremely difficult to
trace a large leak due to the rapid dispersion of gas
1 2 3 4
from the source; in this case, place screens around
the suspected source to enable more precise
localisation of the leak.
In cases where large leaks obscure the presence of
smaller leaks, locate and repair the large leaks first,
and then locate the small leaks.

25388

25

Leak detector probe

1. Flexible probe.
2. Sensing tip.
3. Felt pad.
4. Cover.

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 31

AIR CONDITIONING SYSTEM AIR CONDITIONING SYSTEM FAULT

DIAGNOSIS SUMMARY

Testing for leaks with leak detector 294036 and

elimination of leaks (Op. 50 200 06) There are three main ways in which the system can
malfunction:

With the system charged and the pressure gauges

connected, proceed as follows: — the system does not work at all;
— the system does not provide sufficient cooling;
1. Start the engine. — the compressor operates irregularly.

Bearing in mind that insufficient cooling may also

2. Set the ventilation fan to maximum speed. result from causes external to the air conditioning
system, generally a mechanical check and visual
3. Turn knob (2, fig. 9) to switch on the air inspection will provide useful information about the
conditioner. efficiency of the system.

4. Bring the engine up to a speed of approximately

1500 rpm. This information can then be completed by electrical
testing.

5. Switch on the electronic leak detector.

If at this stage the problem has still not been

identified, it will be necessary to carry out a more
6. Move the probe around all pipe connections and detailed search by analysing the pressure readings
all possible points of leakage: in the various parts of the system.

— The presence of refrigerant, and thus al leak, is

signalled by an increase in the frequency of the Visual inspection of components
audible signal.

These checks are to be carried out with the engine

stopped and with the heating and air conditioning
system switched off.
Not -- Refrigerant is heavier than air, and so it is
— Check the compressor mountings and the
easier to detect below the leak rather than above it. relative support, pulley alignment, belt tension..
— Look for visible signs of refrigerant leakage
(presence of oil on fittings).
— Look for visible leaks of liquid refrigerant.
7. If leaks are found in the pipe connections, tighten — Inspect the condition of the pipes, particularly
the fittings to eliminate them. those in contact with the engine, as well as pipe
fittings/connectors and hose clamps.
— Check that the evaporator, the heater matrix,
and the condenser are clean and remove any
foreign bodies.

Warning -- If any of the system components requires — Check the condition and position of the
replacement, it is always necessary to perform the thermostatic sensor (fig. 13) in the evaporator.
recovery, recycling and charging operations — Check that external air intakes are not blocked.
described on pages. 22 to 27.
— Check the condition of the condensate discharge
pipes.

84176554 -- 03--2008
32 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

MAINTENANCE OF THE AIR CONDITIONING

SYSTEM
Note --Carry out the same checks on the
At the start of the season in which the system will be EVAPORATOR (9) and CONDENSER (5).
used, check that the system is functioning correctly
and efficiently efficiency.
If the system has been out of use and charged for a 3) RECEIVER--DRIER: the sight glass on the
prolonged period, oil may have flowed out of the receiver--drier can provide useful information
compressor to other parts of the system and regarding system operation; see page 27. Replace
consequently this oil must be returned to the the receiver--drier after the system has been
compressor. repaired on two occasions.
To do this, start the engine and run it at approximately
1500 rpm for about 10 minutes. 4) EXPANSION VALVE: does not require
Switch on the ventilation fan at maximum speed. maintenance; in the case of malfunction, check the
Turn control knob (2, fig. 9) to switch on the air valve and thermostatic sensor as described on
conditioning. pages 17 and 18 or refer to specialised personnel of
service network.
Check that the relative temperatures of the external
ambient air and the air flowing out of the vents inside If the temperature of the air at the vent outlets does
the cab correspond to the values indicated in the not conform to the indications given in the table on
table on page 29. page 29, proceed with the system fault diagnosis
If so, the system is operating efficiently, and a visual procedure outlined on page 31.
inspection of the main components will be sufficient:
1) COMPRESSOR: check the mountings, drive belt
tension and oil level.
Warning -- Should one or more system components
2) CONDENSER: check mounting, and that the fins require replacement, in all cases it will be necessary
are free from excessive deposits. Straighten any
to carry out the recovery, recycling and charging
bent fins using the special comb 293831.
operations described on pages 22 to 27.

1 2 3

10 4

9 8 7 6 5
25374

26

Schematic of the air conditioning system.

1. Compressor. 6. Receiver--drier.
2. Suction line (low pressure). 7. Sight glass.
3. Discharge line (high pressure). 8. Expansion valve with thermostatic sensor.
4. Hot air. 9. Evaporator.
5. Condenser. 10. Cool, dehumidified air.

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 33

AIR CONDITIONING AND HEATING

PIPES
Replacement (Op. 50 200 04 -- 50 206 56 --
50 206 51-- 50 206 66 -- 50 200 40 -- 50 200 60)

DANGER
When recovering refrigerant from the system adhere
to the safety rules on page 2.

1. Disconnect the negative battery lead.

2. Recover the refrigerant from the system using
the recovery/recycling station 294048 as
described on page 22.

3. Drain off approx. 3 litres (0.6599 gall. Imp.) of

coolant from the drain plug (1) on the engine
1
block.

27
4. Remove the 4 cab roof retaining bolts (1).

TRE0124A

28
5. Remove the cab roof as shown in the figure 29.

TRE0152A

29

84176554 -- 03--2008
34 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

6. Remove plate fastening screws and take of the

plate (1)

TRE0155A

30
7. Remove A/C assembly fastening screws (1).

TRE0255A

31
8. Remove A/C inlet and outlet pipes (1).Remove
front retaining screws (2).
2

TRE0224A

32
9. Remove heater pipe connections (1) and take off
the pipes.
1

TRE0226A

33

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 35

10. Remove the bracket (1) that secures the pipe.

TRE0227A

34
11. Remove all electric connectors and take off the
A/C assembly (1) completely.

TRE0228A

35
12. A/C assembly is shown in fig 36.

TRE0223A

36
13. To reassemble, clean all parts and proceed as follows:
— Refit A/C assembly completely and refit all electric connectors.
— Assembly the bracket that secures the heater pipe.
— Assembly the heater pipe connections refit the pipes.
— Refit A/C assembly inlet & outlet pipes.
— Refit A/C assembly fastening screws.
— Refit top cover plate.
— Assembly the cab roof.
— Refit the 4 cab roof retaining bolts.
— Pour the previously drained coolant back into the radiator.
— Reconnect the negative battery lead.
— Charge the air conditioning system with HFC 134 a refrigerant, using the evacuation/ charging station
294030 as described on page 24.

84176554 -- 03--2008
36 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

RECEIVER--DRIER
Replacement (Op. 50 200 04 -- 50 200 74)

DANGER
When recovering the refrigerant from the system
adhere to the safety instructions on page 2.

1. Recover the refrigerant from the system using

station 294048 as described on page 22.
2. Detach the exhaust pipe and raise the hood.
3. Disconnect the negative battery lead.

4. Disconnect the electrical connector (1) from the

receiver--drier.

24887

37
5. Detach the flexible pipe (1) connecting the
condenser to the receiver--drier. 1

24888

38
6. Detach the flexible pipe (1) connecting the
receiver--drier to the evaporator.

24889

39

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 37

7. Remove the screw (1) securing the

receiver--drier band clamp.

1
24890

40

8. Recover the complete receiver--drier (1).

24891

41

To refit proceed as follows:

— Replace the receiver--drier in the support clamp.
— Reconnect the two flexible return and delivery
pipes. Connect the electrical connections on the
filter.
— Connect the negative battery lead.
— Evacuate the system then charge with HFC
134a refrigerant, using the evacuation/charging
station 294030,as described on page 24.
— Close the hood.

84176554 -- 03--2008
38 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

CONDENSER
Replacement (Op. 50 200 04 -- 50 200 72) 2

DANGER
Recover the refrigerant from the system adhering to
the safety instructions on page 2.

1. Disconnect the negative battery lead.

2. Recover the refrigerant from the system using
the station 294048 as described on page 22.
3. Detach the flexible refrigerant delivery (1) and re-
1
turn pipes (2) from the condenser. 24892

42
4. Unscrew the wingnut (1) securing the
condenser. 1

24893

43
5. For tractors equipped with front mudguards,
remove the two screws (1) securing the top 1
bracket of the condenser (for tractors without
front mudguards turn the steering wheel to full
right--hand lock and withdraw the condenser
from the right--hand side of the tractor).

24894

44
6. For tractors with front mudguards, remove the
condenser group (1) with the top bracket.
To refit proceed as follows: 1
— Refit the condenser and the relative bracket, and
secure the condenser with the wingnut and the
bracket with the two retaining screws.
— Reconnect the two flexible pipes to the condenser.
— Connect the negative battery lead.
— Evacuate the air conditioning system and charge
with HFC 134 a refrigerant, using the evacuation/
charging station 294030 as described on page 24.
— Close the hood. 24895

45

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 39

COMPRESSOR
Removal--Refitting (Op. 50 200 04 -- 50 200 26)
1
DANGER
Recover the refrigerant from the system adhering to
the safety instructions reported on page 2.

1. Recover the refrigerant from the system using

station 294048 as described on page 22.
2. Raise the hood.
3. Disconnect the negative battery lead.
4. Disconnect the flexible pipes (1) from the TRE0838A

compressor.
46
5. Remove the right--hand guard retaining screws (1).

24903

47
6. Remove the two securing nuts (1) of the
compressor belt tensioner arm.
1

24904

48
7. Disconnect the earth lead (1) from the
compressor. 1

24905

49

84176554 -- 03--2008
40 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1

8. Loosen the bolt (1) securing the compressor to

the engine and remove the drive belt from the 1
pulleys.

24906

50
9. Remove the compressor bolt (1) and recover the
compressor. 1
To refit proceed as follows:
— Refit the compressor, the support/belt tensioner
arm. Reconnect the earth lead..
— Refit the right--hand guard.
— Reconnect the two flexible pipes to the
compressor.
— Connect the negative battery lead.
— Evacuate the air conditioning system and charge
with HFC 134a refrigerant, using the
24907
evacuation/charging station 294030 as
described on page 24. 51
— Close the hood.

COMPRESSOR OIL -- TYPE AND QUANTITY

The tractor is equipped with a SANDEN SD 7H15
compressor for refrigerant R134a.
The compressor is filled during assembly with
185cm3 (11.29in.3) of PAG SP 20 lubricating oil.
In case of top up or oil change only use this type of
oil.
It is not necessary to check the compressor oil level
unless the system develops significant gas leaks.

Warning -- If the system develops significant leaks

of R134a refrigerant, there will also be a significant
loss of compressor oil PAG SP20. It will therefore be
necessary to check the compressor oil level, bearing
in mind that, on average, only 130 ÷ 135 cm3
(7.93 ÷ 8.24 in.3), of the total quantity of lubricating
oil (185 cm3 (11.29 in.3)) will be present in the com-
pressor, as the remaining 50--55 cm3 (3.05--3.36 in3)
will be in circulation through the various system com-
ponents. For problems of this type, we recommend
that you seek assistance from an authorised service
centre.

84176554 -- 03--2008
 SECTION 50 -- AUXILIARY UNITS -- CHAPTER 1 41

COMPRESSOR DRIVE BELT

Tension adjustment (Op. 50 200 10)

12÷13mm
The tension and condition of the belt transmitting
drive from the engine to the compressor is
particularly important as regards the correct
operation of the air conditioning system.

This drive belt therefore requires careful attention as

follows:
23927

1) Fit the belt correctly. 52

2) Check the tension.

3) Check the condition of the belt.

Periodic checking of drive belt

When checking the tension, also check the amount

of drive belt wear.
The main problems are as follows:
Fitting the compressor drive belt

a) Belt shiny : smooth sides may slip on pulleys.

When first fitted, the belt must not be forced, pulled

with a screwdriver, or rolled over the edge of the b) Belt cracked : may break suddenly due to splits
pulley, as this would stretch the less deformable on the inner surface caused by excessive
fabric in the belt thus causing subsequent breakage flexure.
of the other fabrics.
c) Worn sides : with the sides worn or the inner
When first fitted, the belt must more installed at a surface cracked, the belt can break at any
greater tension than normal to compensate for initial moment.
stretching during the running--in period. The belt
must therefore be checked again after 50 hours of
operation and adjusted to the normal tension. d) Belt impregnated with grease : the belt will
wear more rapidly as the grease will cause
This check is absolutely essential as if the belt is too softening of the internal part.
taut, in addition to damaging the pulley bearings, it
will cause premature fatigue of the reinforcement
fabrics and thus early deterioration of the belt. Take the following action:
a) If the belt is too slack, tension it correctly; if the
If on the contrary the belt is too slack, it will start to belt is very hot, renew it.
slip and overheat, and it will therefore wear out very
quickly. b) If cracking is deep, extending to half the
thickness of the belt, renew the belt.
c) Renew the belt.
d) try cleaning the belt without using any solvents.
Checking compressor drive belt tension
If the problem persist and the pulley slips,
change the belt.
Check the tension only when the belt is cool (at a
temperature below a 40 0C (104 0F)). If the belt squeaks when running, check the tension
and adjust if necessary. If the noise continues, renew
Check the tension by applying a load of 78÷98 N the belt.
(17.6450÷22.0562 lb) to the centre of the belt run in-
dicated in the figure: the belt should deflect ≅ 12÷13 If the belt has been over--stretched and it is not
mm (0.0394÷0.0426 ft). possible to tension it sufficiently, renew it.

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 1 -- INSTRUMENTS

CONTENTS

Description . Page

Analogue instruments Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Transmitter and switch 4 .

ANALOGUE INSTRUMENTS

INTRODUCTION

1 1

The instrument panel consists of four display sections:

1) Warning and indicator lights;

2) Fuel level gauge;

3) Proofmeter;

4) Engine coolant temperature gauge.

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 2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

3
2

Condition Indicator 10
8
3
1 -- Main beam headlights Fixed (blue)
2 -- Side ligts Fixed (green) 4
3 -- Battery charging system Fixed (red)
4 -- Left turn indicator Flashing (green)
5 -- First trailer direction indicator Flashing (green) 5
6 -- Second trailer direction indicator Flashing (green)
7 -- Low engine oil pressure indicator Fixed (red) 6 9 7
8 -- Water in fuel indicator Fixed (red)
9 -- Not used. 2
10-- Not used.

11 12 13 14 15

11-- Dry air filter warning light Fixed (amber)

12-- Low brake fluid level indicator Fixed (amber)
13-- Not used.
14-- Not used.
15-- Right turn indicator Flashing (green)
16-- Not used.
17-- Hand brake ON light Fixed (red) 16 17 18
18-- Not used.

Fuel level gauge (Fig. 4).

This instrument shows the level of fuel in the tank.

When the tank is full, the hand moves completely to

the right.

When the tank is less than 1/4 full, the hand moves
into the yellow area.

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 3

Proofmeter (Fig. 4).

Engine speed indicator and chronograph with a six

figure hourmeter. The figures on black background
count hours of work done and the figure on red
background (far right) shows tenths of an hour.

The green, blue and yellow sectors show the

engine speed at which optimum power take--off
performance is achieved (respectively 540, 540E
and 1000 rev/min).

-- Green symbol = power take--off at 540 rev/min

-- Blue symbol = power take--off at 540E rev/min.

5
-- Yellow symbol = power take--off at 1000
rev/min.

Engine coolant temperature gauge (Fig. 5).

-- Green area = normal temperature.

-- Blue area = temperature too low.

-- Red area = engine overheating.

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 4 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

TRANSMITTERS, SENSORS AND SWITCHES

A. MAIN FUSE BOX

The tractors fuses relays are housed under a plastic cover.

B. BATTERY
The tractors are fitted with maintenance--free batteries. Keep the top part clean and dry. Check that the level
of electrolyte reaches the top mark and never falls below the lower mark.

C. ALTERNATOR
This provides a square wave signal and recharges the battery. It also provides power required by electric
devices.

D. TRANSMISSION CLUTCH PEDAL SWITCH

This switch is activated when the clutch pedal is pressed and it prevents starting if the clutch pedal is not
lowered.

E. AIR CLEANER CLOGGED SENSOR

This is activated when the vacuum in the air operating system exceeds a pre--set value. It lights up the
warning light.

F. WATER IN FUEL SENSOR

Activated when water gets into the fuel filter and the relevant warning light comes on.

G. ENGINE OIL PRESSURE SWITCH

This is activated as soon as oil pressure in the engine drops less than 0.68 bar (9.86psi). It lights up the
warning light. This switch is usually closed.

H. FUEL TANK LEVEL TRANSMITTER

A signal from the transmitter potentiometer defines the level of fuel in the tank. The level is shown by the
gauge.

I. ENGINE COOLANT TEMPERATURE

The temperature transmitter resistance varies in proportion to the coolant temperature, generating a
modulated voltage signal picked up by the gauge.

J. BRAKE LIGHT SWITCHES

These are activated when the brakes are on.

K. BRAKE OIL LEVEL SWITCH

This switch is activated when the fluid level drops below the minimum value and lights up the warning light.

L. PARKING BRAKE SWITCH

Activated when the parking brakes are applied, switching on the indicator light on the dashboard.

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 5

TRANSMITTERS AND SWITCHES

26608

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 6 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

TRANSMITTERS AND SWITCHES

26608

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 7

TRANSMITTERS AND SWITCHES

26608

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 8 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 2 -- COMPONENTS
CONTENTS

Section Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

55 500 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

55 500 INTRODUCTION

The components described in this section are located on the instrument console (rear hood), in the cab roof and
on the right--hand fender, inside the cab.

COMPONENT DESCRIPTION

INSTRUMENT CONSOLE CONTROLS

1. Lights control lever.
The lever operates external lights, horn and the
direction indicators.

TRE0067A

REAR HOOD CONTROLS

Starter switch
To operate the four switch functions, turn the key
A
(1) through the following positions: P B
C
A. No power to circuits (key can be removed).
Engine stopped: automatic activation of fuel
injection cut--off.
B. Control instrument and indicator power supply.
Power supplied to various circuits.
C. Starting the engine: when released, the key TRE0018B

returns automatically to position (B). 2

P. Parking lights on, instrument panel lighted (key
removable).

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 2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

1. Starter switch.
2. Thermostarter.
3. Hazard warning lights switch. 2
3
4. Cigar lighter

TRE0018B

1. Beacon on/off switch (tractors without cab)

1
TRE0020A

IN--CAB CONTROLS 4
2
1. Fender--mounted controls
3
1. Windscreen washer,
2. Windscreen wiper,
3. Rear working lights,
4. Front working lights and
5. Beacon controls (with cab)

1 5
TRE0042D

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 3

2. Heating and air--conditioning controls

1. Electric fan speed control 2 3 1

2. Heating control
3. Air--conditioning control

TRE0012B

3. Radio

TRE0077B

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 3 -- STARTING SYSTEM

CONTENTS

Section Description Page

55 000 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Starting circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
55 201 Removal and re--installation of starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bench tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

55 000 TECHNICAL INFORMATION

CHARACTERISTICS JX60 JX70 JX80 JX90 JX95

Starter motor BOSCH
Power (kW) 2.5 3.5
Maximum current drain with- 60 A 160
out load (Amp) at 11,6 V at 11.5 V
and 8600 rev/min and 8000 rev/min
Minimum brush length (mm)
(in.) -- 7.0 (0.2756)
Minimum switch diameter
(mm) (in.) 42 (1.6535) 42.5 (1.6732)
Maximum armature shaft end
play (mm) (in.) 0.5 -- 0.8 (0.0197 -- 0.0315) 0.4

TIGHTENING TORQUES

Nm

Starter motor and engine block fastening bolts 34 (25.0771)

Box on starter motor/earth (ground) cable side 16 (11.8010)
Solenoid valve wire nuts 7 (5.1629)
Box nuts on starter motor side 10 (7.3756)
Solenoid valve fastening bolts 5 (3.6878)

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 2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

DESCRIPTION AND OPERATION means of an flexible joint mechanism, makes the

driving pinion engage the flywheel ring gear. The
moment the pinion touches the ring gear, the plunger
closes a series of contacts and powers all four field
windings directly from the battery, thus giving full
power to the starter motor.
The starting system installed depends on the type of
gearbox fitted on the tractor. All systems consist of
an ignition key switch, heavy--duty wiring, a starter
motor with solenoid, a start--up relay and a clutch
pedal switch. These are the basic circuit components
used on versions with mechanical gearbox. More
sophisticated systems include other components,
which ensure the engine can be started only under
the proper conditions.
At this stage, one end of the pull--in coil is connected
to the positive battery pole through the starter switch,
while the other end in connected to the positive pole
through the solenoid valve contacts. The pull--in coil
is thus bypassed, without absorbing power, and the
hold--in coil alone keeps the plunger in position.

There are four types of gearbox: with range reduction

gear (synchro command), with range reduction gear
and inverter (shuttle command). The starting circuit
is illustrated in figure 1.

The starter motor includes a series of contacts and a

two--part solenoid plunger which completely closes
the contacts even if the pinion teeth are not perfectly
in line with the ring gear. When this happens, a clutch
spring compresses the pinion, forcing it to connect
completely as soon as the starter motor starts
turning.
There are two available types of starter motors: 2.5
kW or 3.5 kW rating. They both have four poles, four
brushes with integrated solenoid and positive mesh
engagement control.

When the key ignition switch is released, power is

taken from both the solenoid and the motor. The
solenoid return spring, acting on the flexible joint
mechanism, frees the driving pinion from the gear
and opens the solenoid valve contacts again.
The solenoid consists of two coils connected in
parallel. The low resistance pull--in coil is earthed
(grounded) via the engine, while the high resistance
hold--in coil is earthed (grounded) via the solenoid
body.
A roller type clutch is incorporated to the driving
pinion group. This prevents the pinion from
overspeeding if it stays engaged with the flywheel
ring gear after the engine has been started.

When the ignition switch is closed, with the clutch

pedal depressed and gear in neutral (except in the
case of mechanical gearboxes), the coils are
energised and the plunger is magnetically drawn
inside the solenoid. This movement, transmitted by

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 3

STARTING CIRCUIT

6,0 N

30

57 15/54
58/57 50

35
16.0 NFUSE
2
6,0 N
6,0 N 6,0 N
13
B+
12

3,0 N/P
D+ 0,5 N/Y 0,5N/Y
16

16.0 N

14
1

3.0 B
31
11 2,5W/R 2,5W/Y

STARTING CIRCUIT

1 -- Instrument panel
2 -- Starter switch
11 -- Battery
12 -- Starter
13 -- Alternator
14 -- Over voltage circuit breaker (DIODE)
31 -- Starter inhibitor unit
35 -- Main Fuse

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 4 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 5

26629
TRE0069A

Fuse panel 2 Starter motor 3

SYSTEM TESTS
STARTING SYSTEM ON TRACTOR TEST
To easily and quickly trouble--shoot the starting
system problems and reach conclusive results, it is
recommended that you use a battery/starting tester
(high discharge multimeter) with incorporated
0--20V voltmeter and 0--500 A ammeter.

When using testing devices, follow test procedures

recommended by the manufacturer. If you do not
have access to testing devices, carry out the
following test using a normal 0--20V voltmeter and a
0--500 Amp ammeter in order to check correct
starter motor functioning without removing it from
the engine.

Before carrying out the test:

• check the battery is fully charged;

• check that no wires in the starting system are

broken or frayed and that there are no loose
connections;

• check the engine is not seized.

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 6 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

POWER ABSORPTION IN STARTER MOTOR

CIRCUIT (Fig. 4)
1. Disconnect earth (ground) (negative) battery
cable (3).
5 1
2. Disconnect positive battery cable from starter
solenoid. Connect the positive ammeter point
(1) to the positive battery terminal clamp and
the negative point to the solenoid input
terminal. 4
3. Reconnect earth (ground) (negative) cable to
negative battery terminal clamp (3).

4. Connect the positive voltmeter point (2) to the

positive battery terminal clamp and the 3
negative to the negative battery terminal
2
clamp. 26630

4
5. Disconnect the wire from the injection pump
shut--off solenoid.

6. Run the engine and note voltmeter and

ammeter readings. Voltage must be constantly
about 12V and absorption in the range of
250--300 A.

• If absorption corresponds to the readings

above, then the starter motor (4) fig. 4, is
working correctly. If voltage drops during the
test, follow “Resistance in starting system
circuit” procedure (see relative paragraph).
• If absorption is higher than the readings above,
check the circuit as follows. If the starting
system circuits are in good condition, then the
starter motor is malfunctioning and must be
removed for further examination.
• If absorption is lower than the readings above,
the starter motor is malfunctioning and must be
removed for further examination.

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 7

RESISTANCE IN IGNITION SYSTEM CIRCUIT

(VOLTAGE DROP) (Fig. 5)

If there is a higher than necessary power absorp-

tion, check the circuit to find the cause of the volt-
age drop occurring within circuit components.

IMPORTANT: Disconnect the injection pump sole-

noid fuel closing wire. 2 1

POSITIVE BATTERY CABLE V

1. Connect the positive voltmeter point (1) to the
positive battery terminal clamp (2).
3
2. Connect the negative voltmeter point to starter
motor solenoid terminal (3).

3. Run the engine and check the readings on the

voltmeter. If voltage is higher than 0.2 V., check
26631
and tighten wire connections. Check voltage
again and if it is still high install a new battery 5
cable.

STARTER MOTOR EARTH (GROUND) (Fig. 6)

2 1
1. Connect the positive voltmeter point (1) to the
starter motor casing (2).

2. Connect the negative voltmeter point to the

engine block (3).

3. Run the engine and check the readings on the

voltmeter. If voltage is higher than 0.2 V., check
earth (ground) connections between the starter
motor flange and the rear engine cover.

26632
3

6
BATTERY EARTH (GROUND) CABLE (Fig. 7) 1
2
1. Connect the positive voltmeter point (1) to the
engine block (2). V
2. Connect the negative voltmeter point to the
negative battery terminal clamp (3).

3. Run the engine and check the readings on the

voltmeter. If voltage is higher than 0.2 V., check
and tighten the earth (ground) cable
connections. Check the voltage again and if it is
still higher, then install a new earth (ground) 3
cable. 26633

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8 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

STARTER MOTOR REMOVAL AND

RE--INSTALLATION (Fig. 8) (Op. 55 201 50) 2 3

1. Disconnect negative battery cable.

2. Unscrew the nut and bolt (1) and remove the 6

protection cover (2) from starter motor (3).

3. Unscrew the nut and remove power clamp (5)

and emergency switch clamp (4). 1
4. Remove the starter motor securing bolts (6) 4
and remove the starter motor.
26634
5
5. To re--install the starter motor, reverse the
order of removal. 8

26635

Starter motor components 9

1. Solenoid 7. Field windings and casing
2. Solenoid bolts 8. Brush holder
3. Bolt and stud group 9. Brush plate
4. Control side support 10. Armature
5. Lever 11. Clutch
6. Reducer

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 9

SERVICING 7. Remove the motor casing from the armature and

the control side bracket.
DISASSEMBLY (Op.55 201 54)
8. Remove the control lever knuckle pin from the
Refer to figure 9. control side of the casing.

1. Place the starter motor in a vice with protected 9. Remove the retaining ring which holds the
jaws. control group and the inner plate from the
armature shaft, by first removing the pressure
2. Disconnect the biggest braided wire which runs collar perpendicularly from the retaining ring
from the field winding casing to the solenoid. support by means of an appropriately sized tube.
Then lever the retaining ring from the groove.
3. Remove the three screws from the front casing
and remove the solenoid. Note that the plunger 10. Remove armature and control group.
will remain connected to the control lever.

4. Remove solenoid plunger from the control lever REASSEMBLE

by holding and lifting it at the front in order to
unclip it from the lever. 1. To reassemble the starter motor, reverse the
removal procedure.
5. Remove the two nuts from the rear casing and
the two screws which fasten the rear cover and Before reconnecting, test the armature shaft end
brush plate to the casing. Remove clamp C and play and test the starter motor without load.
armature shaft end play spacers, leaving the
brush gear on the commutator. Remove the thin
metal washer on the commutator side of the ARMATURE SHAFT END PLAY
armature.
1. Place the starter motor in a vice with protected
6. At this stage of the procedure, check the brushes
jaws and connect a dial gauge to the flange on
and commutator. Check that the brushes are not
the control side of the casing. Position the dial
sticking and, if necessary, clean the brushes and
gauge pointer on the end of the armature shaft.
their respective channels with a rag and solvent.
Check the brushes are not worn. If they are worn 2. Push the armature forward and reset the gauge
and minimum length is less than that shown in to zero. Push the armature back as far as it will
the technical information table, it will be go and note the gauge reading.
necessary to change the starter motor.
3. Readings must fall within the limits specified in
NOTE: The brushes are not serviced separately. the technical information table. If the value is
They are welded to their support and will not be higher, check that armature and brush plate are
changed for the whole operating life of the starter not worn. Change the worn components, as
motor. necessary, and check end play again.

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10 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

STARTER MOTOR TEST WITHOUT LOAD (Fig.

10) 6 7

NOTE: A fully charged battery and a battery/start- 1

ing tester (high discharge multitester) with carbon
battery (variable load resistance) are needed to
carry out this test. 5
2
1. Place the starter motor in a vice with protected
jaws.

2. Connect negative battery cable (4) to the

starter motor flange. 3
4
26636
3. Bridge the solenoid contacts (6) with a short
wire (7). 10

4. Connect the positive voltmeter point (3) to the

positive battery terminal clamp and the
negative voltmeter point to the negative battery
terminal clamp. Connect the ammeter positive
point (1) to the positive battery clamp (4) and
the negative point to the battery or to the starter
motor terminal clamp.

5. Place a manual tachometer (5) on the end of

the armature shaft. Check maximum power
absorption. This value is specific for each
starter motor and must be included in the range
of values in the TECHNICAL INFORMATION
table. Regulate carbon battery voltage (2) and
armature speed according to the information in
the technical information table.

6. If the starter motor does not work according to

the technical information specification, check if
there are earthed (grounded) field windings, if
the armature is scuffed or scraped or if the shaft
is misshapen or otherwise damaged.
BENCH TESTS
ARMATURE (Fig. 11)

1. The commutator surface must be clean and

not burnt. If burning needs to be removed, use
fine sandpaper and not abrasive fabric (emery
cloth). Finally, clean the commutator with a
rag and solvent.

2. If the commutator needs refacing, check it is

not smaller than the minimum value specified
in the TECHNICAL INFORMATION table.
After refacing, the commutator must be
polished with sandpaper and cleaned with a
rag and solvent.
NOTE: Do not cut the armature metal when mak-
ing insulation slots.

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 11

3. Armature insulation can be checked by

connecting an ohmmeter (1) between 1
commutator segments and armature shaft.
This reading should show infinity, in other
words there should be no continuity.

4. To test there are no short circuits, use an

appropriate testing device. The only alternative
is to try changing the armature.

5. If the armature circumference has obviously

been in contact with pole pieces, the pole
bearings are probably worn. First check the
pole pieces are fixed and that the armature 26637
spins well in a lathe. If necessary, change the
armature bearing. 11

FIELD WINDINGS (Fig. 12)

1. To test field winding insulation, connect an
ohmmeter to each of the coil brushes in turn
and to a clean and unpainted area of the
casing. There should be no readings, that is,
there should be no continuity.

2. To test coil continuity, connect an ohmmeter to

each of the coil brushes in turn and to the main
power clamp (biggest braided wire). The
reading should be 1 Ω.

3. If there is a failure in the field windings, then it

will be necessary to change the whole box and 26638
1
field winding system.
12

BEARING BUSHINGS
1. Check if the bushing on the brush plate and in
the box on the pinion side are worn. Assemble
the armature shaft and note play. Change the
bushing if there is too much play. Check the
field poles to see if there are any signs of
scraping against the casing. This can also be
caused by a worn bushing.

DRIVING PINION
1. Check the roller clutch operation. The pinion
must spin clockwise only. If the pinion is either
seized or spins in both directions, or if the
pinion teeth are damaged, assemble a new
control group.

If there is clear evidence of damage to the pinion

teeth, check the flywheel ring gear, as described in
section 10, Engines.

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 4 -- CHARGING SYSTEM

CONTENTS

Section Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

55 000 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
System testing and trouble--shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
55 301 Removal, re--installation and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

55 000 TECHNICAL INFORMATION

TYPE OF ALTERNATOR
CHARACTERISTICS BOSCH
14V--45, 65 and 85A
Polarity Negative earth
Nominal voltage (V) 14
Max rotation speed (rpm) 15.000
Maximum output (A) 45 65 85
Regulator controlled voltage (V) 13.6 -- 14 13.6 -- 14.4
Rotor field winding resistance (Ω) 3.4-- 3.8 2.9
Stator field winding resistance (Ω) -- 0.2
New brush length (mm) (in.) -- 20 (0.7874)
Minimum brush length (mm) (in.) -- 5 (0.1969)
Brush spring force (N) (lb) -- 1.3--2.7
(0.29---0.60)

TIGHTENING TORQUE

Nm (ft lb)

Alternator fastening bolts 5.5 (4.0566)

Pulley fastening nut 70 (51.6293)
Rectifier fastening screws 4.0 (2.9502)
Brush box and regulator screws 2.7 (1.9914)
Terminal nuts 2.7 (1.9914)

84176554 -- 03--2008
 2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

DESCRIPTION AND OPERATION

ALTERNATOR DESCRIPTION

Either a Magneti Marelli or a Bosch, 45 or 65 A,

alternator, with external cooling fan, is fitted on all
models. Stator winding is ventilated with an air
conducting diaphragm in the support on the rectifier
bridge side and peripheral openings in the support
on the control side. The alternator, installed on the
left side of the engine, is operated by a pulley and a
V--type driving belt. Alternators are fitted with a
built--in regulator. 26639

45 or 65 A alternator 1
1. Battery connection (B+ terminal)
2. Terminal protection sheath
3. Alternator charge indicator connection
(D+ terminal)

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 3

5
2

4
26640

Alternator charging circuit 2

1. Ignition switch B+ Battery connection

2. Alternator charge warning light D+ Alternator charge indicator
3. Battery
4. Alternator
5. Alternator electronic voltage regulation circuit

ALTERNATOR FUNCTIONING The direct current is then reintroduced into the circuit
to increase current flow through the rotor field
winding.
See figure 2.

This action causes a constant increase in the rotor

magnetic field and a fast increase of current and
When the ignition key is turned, a small current voltage output.
passes from the battery through the rotor field
winding wiring. The circuit closes powering the
charge warning light, the alternator D+ terminal, the
rotor field winding, the alternator regulator and earth As the generated voltage output (reflected by D+
(ground). terminal) increases, the warning light intensity de-
creases and when the voltage at the D+ terminal
equals that on the battery side of the warning light,
the light goes out.
At this stage, the warning light comes on and the
rotor is partially magnetised.

Voltage increases until it reaches the pre--set

regulated voltage level.
When the engine starts and the rotor, partially
magnetised, turns inside the stator windings and
generates three--phase alternating current. A
constant quantity of this current is transformed into If the driving belt breaks, there will be no voltage
direct current by three field diodes built into the accumulation in the alternator. The charge warning
rectifier. light will stay on, thus indicating a fault.

84176554 -- 03--2008
 4 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

3
3

4
4
1 2
26641 26642

3 4
Fan belt tensioner
Fig. 3. Belt for versions without air conditioning Fig. 4. Belt for versions with air conditioning

1. Alternator 3. Belt tensioner securing nut

2. Belt tensioner 4. Belt

SYSTEM TESTING AND TROUBLE--SHOOTING

PRECAUTIONS 1. CHECKING THE BATTERY

To avoid damaging alternator charging system Check all battery elements with a densimeter. The
components, take the following precautions: battery must be at least 70% charged and efficient.

• DO NOT MAKE OR INTERRUPT any charging 2. CHECKING THE DRIVING BELT

circuit connection, including the battery, while
the engine is running. Inspect the alternator driving belt and pulley, check-
ing that they are both clean, with no traces of oil or
• NEVER SHORT--CIRCUIT the alternator
lubricant and in good condition.
positive terminal to check if it is working.

• ALWAYS DISCONNECT battery cables when Check the alternator driving belt tension regularly. If
recharging the battery in the tractor with a you suspect the belt is not tight, check the tensioner
battery charger. as follows:

• ALWAYS CHECK battery polarity when

Belt for versions without air conditioning (Fig. 3)
installing a battery or using a supplementary
battery to start the engine. -- slacken the nut (3) which secures the
alternator to the tensioner bracket (2).
• DO NOT SHORT--CIRCUIT regulator input/ -- with a lever, move the alternator (1) on the
output terminals when the alternator is working. tensioner bracket (2) to reach correct belt
tension and tighten the securing nut (3) to 55
• CONNECT POSITIVE TO POSITIVE AND Nm (40.5659ft lb).
NEGATIVE TO NEGATIVE.
Belt for versions with air conditioning (Fig. 4)
PRELIMINARY CHECKS -- slacken the belt tensioner securing nuts (3)
-- hold the belt tensioner arm (2) and move it on
Before carrying out these electrical tests, carefully the bracket to reach the correct belt tension,
inspect the charging system and the electrical then tighten the securing nuts (3) to 55 Nm
system in general. (40.5659ft lb).
Check continuity in all conductors and connections. Correct deflection values, measured by applying the
Check they are all clean and well fastened. following loads to the middle of the belt:

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 5

If the warning light stays on, check there is no short

Version with- circuit between D+ wire ending and warning light.
out cab or Version with
with cab with- cab and air PRELIMINARY TESTS
out air condi- conditioning
tioning These preliminary tests can be carried out without
Load (N) (lb) 78 -- 98 60 -- 75 removing any components from the tractor charging
(17.20--21.61) (13.28--16.53) circuit. These tests check:
Deflection 10--11 10
(mm) (in.) 0.3937--0.4331) (0.3937) • the alternator wire connections

• alternator charging current and controlled

voltage
3. CHECKING THE WARNING LIGHT
• voltage drop in the alternator charging circuit
Turn the ignition key and check the light is completely
lit. • maximum alternator output

If the warning light does not light completely, check The following testing devices are required:
the light bulb. If the light bulb has not blown, carry out
the alternator wiring connection tests as described in • 0--30V moving coil voltmeter
the paragraph “PRELIMINARY TESTS” in this
section. • 0--1V millivoltmeter

If the light is on, start the engine and run it above • 0--110 A moving coil ammeter
minimum speed. The warning light should go out.
• 1.5 ohm, 110 A varying load resistance
If the warning light does not go out, stop the engine
and disconnect the D+ terminal wire. If the warning NOTE: Most testing devices on the market today
light goes out now, one of the alternator components combine several electrical test functions
is malfunctioning. Carry out “ALTERNATOR COM- (multimeters). When using these devices, follow the
PONENT TESTS” described in this section. manufacturer’s instructions.

84176554 -- 03--2008
 6 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

1. ALTERNATOR WIRE CONNECTIONS TEST

See figure 5.
1. Disconnect the battery.

2. Disconnect B+ (2) and D+ (3) alternator

terminals.

3. Reconnect the battery and turn the ignition key

into position ON but without starting the engine.
Connect a voltmeter (4) between each terminal
and earth (ground) (1). There must be voltage
26643
at the battery.
5
If there is no voltage at the battery, check for a
continuity fault in the external wiring. See circuit
diagram in figure 2.

4. Connect D+ terminal, warning light wire (red)

and earth (ground). The warning light should
illuminate.

5. Disconnect the battery and reconnect the

cables to the alternator at (2) and (3) fig. 5.

NOTE: If the warning light does not light up when

the wire is connected to the alternator, this means
that there is a fault either in the alternator regulator
circuit or in the rotor circuit. Check D+ terminal is
clean and then test the alternator components as
described in this section.

2. CHARGING CURRENT AND REGULATED VOLT-

AGE TESTS

See figure 6.
1. Check that all tractor electrical devices are
switched off and the ignition key is in the OFF
position.

2. Disconnect the negative battery terminal clamp

and the B+ negative alternator terminal.

3. Connect an ammeter (1) between the

disconnected wire (red) (4) and the B+ 26644
alternator terminal (3).
6
4. Connect a voltmeter (2) between the B+
alternator terminal (3) and earth (ground).

5. Reconnect the battery. Start the engine and run

it at 2000 rev/min. Note the readings on the
voltmeter and the ammeter.

The voltmeter reading should be higher than the

battery voltage and when the ammeter reading falls
below 10 A, the voltmeter reading should stabilise
at 13.6 -- 14 V (Magneti Marelli alternator) or 13.6 --
14.4 V (Bosch alternator).

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 7

If the voltmeter reading is higher than 14 V or 14.4

V, for Magneti Marelli or Bosch alternators respec-
tively, the alternator regulator must be changed, as
described in this section. (After installing a new
regulator, carry out tests 4 and 5).

If the voltmeter reading is less than 13.6 V, there is

either a faulty component in the alternator or a
failure due to excessive resistance in the external
charging system connections.

If the ammeter reads zero amps, then one of the

alternator components is malfunctioning. Turn the
engine off and carry out the alternator component
test, as described in this chapter.

3. CHARGING CIRCUIT VOLTAGE DROP TESTS

(a) Insulated side voltage drop test

See figure 7.

Check the ignition key is in OFF position.

1. Disconnect the negative battery cable and the

B+ alternator wire (1).
2. Connect a millivoltmeter (5) between the
positive battery terminal clamp and D+ wire (3)
(positive side of the wire) 26645
3. Connect an ammeter (2) between the B+
alternator terminal and the D+ wire (negative 7
side of the wire).
4. Reconnect the negative battery cable and
connect a varying load resistance (4) with
cursor in minimum current absorption position
(maximum resistance) through the battery
terminal clamps.
5. Start the engine and increase speed to 2000
rev/min.
6. Decrease resistance charging load (decreas-
ing resistance) slowly until the ammeter reads
45 or 65 A. according to the type of alternator.
7. Note the reading on the millivoltmeter. This
must not be higher than 400 millivolts.

A reading higher than 400 millivolts indicates mal-

functioning due to excessive resistance in the
external circuits.

If the alternator does not output required power and

the millivoltmeter reading is less than 400 millivolts,
there is a malfunctioning component in the alterna-
tor. Carry out the alternator component tests, as
described in this section.
8. Stop the engine.

84176554 -- 03--2008
 8 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

(b) Ground side voltage drop test

See figure 8.

1. Check the ignition key is in OFF position.

2. The circuit is the same as that described in the

previous test, except that the millivoltmeter (4)
is now connected between the negative battery
terminal clamp and the alternator casing
(negative side of casing).

NOTE: Check the varying load resistance (3) is in

26646
minimum current absorption position (maximum
resistance). 8

3. Start the engine and increase speed to 2000

rev/min.

4. Increase resistance current load (decreasing

resistance itself) slowly until the ammeter (2)
reads 45 or 65 A. according to the type of
alternator.

5. Note the reading on the voltmeter. This must

not be higher than 200 millivolts.

A reading higher than 200 millivolts indicates

malfunctioning due to excessive resistance in the
external circuits.

If the alternator does not output required power and

the millivoltmeter reading is less than 200 millivolts,
there is a malfunctioning component in the alter-
nator. Carry out the alternator component tests as
described in this section.

6. Stop the engine.

4. MAXIMUM ALTERNATOR OUTPUT TEST

See figure 9.

1. Check the ignition key is in the OFF position.

2. Disconnect the negative battery cable and the

B+ alternator wire (4).

3. Connect an ammeter (5) between B+

alternator terminal (4) and D+ wire (1)
(negative side of the wire).

4. Connect a voltmeter (4) between the B+ 26647

alternator terminal (5) and earth (ground).
9
5. Reconnect the negative battery cable. Start the
engine and increase speed to 2000 rev/min.

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 9

6. Increase resistance current load (2)

(decreasing resistance) slowly until the
ammeter reads 45 or 65 A., according to the
type of alternator.

7. Note the reading on the voltmeter. This must

not be less than 13.6 V.

A reading lower than 13.6 V. shows there is a

malfunctioning component in the alternator. Carry
out the alternator component tests, as described in
this section.

ALTERNATOR COMPONENT TESTS

These alternator tests must be carried out only if

the PRELIMINARY TESTS have shown a malfunc-
tioning alternator component. These tests check:
• the regulator,
• rotor field winding continuity,
• rotor brushes, springs and contact rings.
NOTE: The previously described component tests
can be carried out with the alternator installed in the
tractor. In order to carry out the other alternator
tests, it will be necessary to remove the alternator
from the tractor. Refer to the section “FUNC-
TIONAL TESTS” in this chapter.

84176554 -- 03--2008
10 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

REMOVAL, REASSEMBLY AND

SERVICING (Op. 55 301 10)
IMPORTANT NOTE: Before disconnecting the
alternator wires, check that the ignition key is in the
OFF position.
REMOVING THE ALTERNATOR
See figures 10 and 11.

1. Disconnect the negative battery cable.

2. Disconnect B+ (1) and D+ (2) wires from the

alternator.

26648

10
1. Slacken and remove the nut and bolt (3)
securing the alternator to the belt tensioner (4).

2. Move the alternator to reduce belt tension (5)

and remove it from the alternator pulley (6).

3. Unscrew and remove the nut and bolt (7).

Remove the alternator.

26649

11

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 11

1 2 3 4 5 6 7 8

10 9

26650

Alternator components 12

1. Pulley retaining nut 6. Stator 10. Electronic voltage regulator with

2. Pulley 7. Rear support plate built--in brushes
3. Cooling fan 8. Rectifier bridge
4. Front support plate 9. Protection guard
5. Rotor

Firmly fix the alternator horizontally to an appropri-

ate holder with internal surfaces protected with soft
material.

Remove the guard (1) after unscrewing the nuts

which fasten it to the alternator (Fig. 13)

Before dismantling the alternator completely, carry

out the operations and tests described on the
following pages.

26651

13

84176554 -- 03--2008
12 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

ROTOR AND REGULATOR FIELD CIRCUIT

TEST

The following testing devices are required:

¯ 12 volt battery
¯ multitester
¯ 2 watt test lamp.

See figure 14.

1. Disconnect all alternator wires.

2. Connect a 12 V. battery and a 2.2 watt test lamp 26652

(2) in series to D+ (1) and alternator casing
(negative side of the casing). 14
3. The test lamp should light up.

If the test lamp does not light up, then the rotor
circuit is faulty. Check brushes, contact rings and
rotor field winding continuity.

If the test shows these components are satisfacto-

ry, then the regulator may be faulty.

CHECKING THE CONTINUITY OF THREE

STATOR WINDINGS
Ω
Position the points of an ohmmeter (regulated on Ω
x1 scale) so that they touch the stator phase ends
(a -- b -- c) in the three possible ways shown in
figures 15, 16 and 17. Each reading should show a
certain resistance value which should be the same
for all three readings.

If resistance shows infinity or zero, the measured

phase is either interrupted or short--circuited and
the stator needs to be changed. 26653

15

26654

16

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 13

26655

17
CHECKING THE DIODES

Disconnect the terminal wire connector (1) of the

excitation diodes from the positive brush pin (Fig.
18)

26656

18
Unweld stator winding terminals (2) from the recti-
fier bridge (Fig. 19).

26657

19
EXCITATION DIODES TEST

Insert an ohmmeter point in the connector men-

tioned above (1) (Fig. 18). The second point must
be put in contact successively with each of the three
terminals (A--B--C): Repeat the three measure-
ments after reversing the instrument points (Fig.
20).

26658

20

84176554 -- 03--2008
14 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

POSITIVE POWER DIODES TEST

Put an ohmmeter point in contact with the positive

(X) alternator terminal and the other successively
with each of the three terminals (A--B--C) (Fig. 21).

Repeat the three measurements after reversing the

instrument point connections.

26659

21
NEGATIVE POWER DIODES TEST

Put an ohmmeter point in contact with the negative

(Y) diodes plate and the other successively with
each of the three terminals (A--B--C) (Fig. 22).

Repeat the three measurements after reversing the

instrument point connections.

26660

22
In the three tests described above, the instrument
should show resistance at each terminal (A--B--C).
Reversing the instrument point connection, there
should be no resistance (Fig. 22). If there is resis-
tance in both cases, this means short--circuited
diodes. Otherwise, with a R=0 value (interrupted
diode), change the whole rectifier bridge.

ROTOR

CHECK ON ROTOR WINDING RESISTANCE

MEASURED BETWEEN PINS CONNECTED TO
BRUSHES

Disconnect the excitation diode terminal wire

connector (1) from the pin connected to the positive
brush. Put both points of an ohmmeter (regulated
on Ω x 1 scale) in contact with the two voltage
regulator--brush holder pins. If resistance reading is
different from the indicated value or if it shows
infinity (interrupted circuit), check and, if necessary, 26661
change the rotor (Fig. 23).
23

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 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 15

DISASSEMBLY (Op. 55 301 12)

Place a suitable Allen wrench in the hexagonal hole

in the alternator shaft to prevent the alternator shaft
from turning. With another wrench, unscrew the fan
and rotor pulley fastening nut. Draw out the above
mentioned parts, spacing collars and alternator
washers (Fig. 24).

26662

24
Disconnect the excitation diode terminal wire
connector (2) from the pin connected to the positive
brush. Unscrew and remove the screws (3) secur-
ing the electronic voltage regulator (4), complete
with brushes, to the rear alternator support.
Unscrew nuts (5) and remove the screws fastening
the alternator main external parts (Fig. 25).

26663

25
ELECTRONIC VOLTAGE REGULATOR (Fig. 26)

a. Brushes
b. Pins

26664

26
Separate the parts (as illustrated) bearing in mind
that it is necessary to apply a considerable degree
of pressure on the rotor shaft to free the front
support plate (6) and the rotor (7) (Fig. 27).

If you do not have a press, use a brass drift, to avoid

damaging the thread.

26665

27

84176554 -- 03--2008
16 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

Unscrew the screws (9) which fasten the rectifier

bridge (10) to the rear support plate (8) (Fig. 28).

The rectifier bridge must not be dismantled: the

spare part is supplied as a complete unit.

26666

28
Separate the rectifier bridge (10) from the rear
support plate. Unweld the stator winding terminals
(11) (Fig. 29).

26667

29
Separate the stator (12) and the terminals (11) from
the rear support plate (8) (Fig. 30).

26668

30
INDUCTOR COIL INSULATION TEST

Put both ohmmeter points (fixed at Ω x 1 scale) in

contact respectively with a slip ring and the rotor
casing (see arrows). The instrument should show
infinity resistance. If this is not the case, change the
rotor (Fig. 31).

26669

31

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 17

Check rotor inductor resistance on slip rings

Put both ohmmeter points (fixed at Ω x 1 scale) in
contact respectively with the slip rings (see ar-
rows). The instrument should show a certain
degree of resistance (Fig. 32).

If the instrument reading is different from the

prescribed value or shows infinity (interrupted
circuit), change the rotor.

26670

32
Check the ball bearing moves freely, without sticking
or noise. Check the collectors have not been
damaged by the brushes. If this is the case, change
the whole rotor.

REASSEMBLY

To reassemble, reverse the order of the operations

described.

SERVICING 4
1. Check the rotor and stator poles are not worn. If
this is the case, it means the ball bearings are 2
worn, the casings are not in line or the rotor
shaft is misshapen.

NOTE: alternator ball bearings cannot be serviced

separately. When necessary, therefore, both must
be changed.
1
2. Unscrew the screws (1) securing plate (2) that
3
locks bearing (3). Remove it from the front
26671
support plate (4) (Fig. 33). Check if it is worn or
damaged; if so, change it. Before installing the 33
ball bearing, check the front support plate
holder and clean it carefully.

3. Installation of bearing (5) on support plate side

is different from the one described above. A
new rotor complete with bearing must be
installed (Fig. 34).

26672

34

84176554 -- 03--2008
 18 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

RE--INSTALLATION D Check the negative (ground) battery cable is

disconnected from the battery while re--installing
1. Re--install the alternator by reversing the the alternator.
removal procedure.
D Adjust the alternator drive belt, as described
During re--installation, remember to: previously in this chapter.

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 5 -- BATTERY

CONTENTS

Section Description Page

55 000 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
55.301.040 Removal and re--installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Battery checking and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery problems -- Frequent causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

55 000 TECHNICAL INFORMATION

TYPE OF BATTERY
CHARACTERISTICS JX95 model
JX60/JX70/JX80/JX90
(optional for
models
other models)
Voltage (V) 12
Cold start amperage (C.C.A) 1x760 1x800
Capacity (Ah) 105 120
Number of elements 6
Number of plates per element 16 21
Energy reserve (SAE) (min.) 160 210
Weight (kg) (lb) 25 (55.12) 35 (77.16)
Earth (ground) terminal Negative

DESCRIPTION AND OPERATION

Both types of battery are of the “sealed, • to supply electricity when the power required is
maintenance--free” type. higher than that produced by the alternator.
• to support inactive loads from radio and
105 Ah batteries are fitted on JX60, JX70, JX80 and microprocessor memory.
JX90 models. The battery is positioned in front of the
radiator, in the front axle support compartment Each element of the battery consists of positive and
(Fig. 1). negative plates, positioned alternatively, one next to
the other. Each positive plate is separated from the
adjacent negative plate by means of a porous
120 Ah batteries are fitted on JX95 models with cab
insulating spacer. If one of the positive plates
air conditioning and are optional for JX60, JX70,
touches a negative plate in the element, the element
JX80 and JX90 models. The battery is installed
will short--circuit and be irreversibly damaged. The
above the front axle support (Fig. 2).
positive plates are welded to a collecting bar and
form a positive terminal. The negative plates are
NOTE: “Maintenance--free” means that the battery welded to a similar collecting bar and form a negative
electrolyte, in normal conditions of use, does not terminal.
leak. It could leak if the battery is loaded over 14.4 V.
This, in fact, causes the water to boil due to gas
formed as the battery charges up completely. It can Each positive plate consists of a lead grid with lead
be caused by a faulty charging system, by quick peroxide pasted to the grid holes. The negative
charging or topping up. plates consist of a lead grid with lead sponge pasted
to the grid holes.
The four main functions of a battery are:
The plates are covered by an electrolyte which
• to supply a source of electricity for starting, consists of diluted sulphuric acid solution.
ignition and instrument lighting and functioning.
• to control voltage in the electrical system. The battery casing is made of polypropylene.
84176554 -- 03--2008
 2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

REMOVAL AND RE--INSTALLATION

(Op. 55 301 40)

REMOVAL

105 Ah and 120 Ah batteries fitted in front of the

radiator (Figures 1 and 2)

1. Lift the engine hood.

2. Disconnect earth cable (ground) from tractor 1

structure and position it safely, away from the
structure itself.

3. Slacken the bolts on both terminal clamps and

disconnect the positive and negative battery
cables. Make sure they do not touch the battery
itself.

4. Lift the battery from the tractor by the two

handles at each end of the battery.

RE--INSTALLATION

Applicable to all types of battery.

1. To re--install the battery, reverse the removal 2

procedure, with the following precautions:

• Check that the battery is clean, there are no

signs of electrolyte leak and the breather covers
are completely installed. Coat the terminals and
clamps with a petroleum jelly (such as Vaseline).
Do not use traditional lubricants as they can lead
to electrolytic corrosion.

• Check the battery compartment or support. The

clamps should be clean and there should be no
stones or other small objects, which could pierce
the battery casing.

• Check that terminal polarity is correct. Check

terminal clamp connections are not too tight.

• If a radio is installed, it will lose all saved data and

will need to be reprogrammed. Electronic panels
and microprocessors, for those models to which
they are fitted, will not lose their memory
function.

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 3

BATTERY CHECKING AND MAINTE- Table 1

NANCE
Temperature Fully charged battery
performance
RELATIVE DENSITY
25.0 °C (77.0 °F) 100%
--4.5 °C (23.9 °F) 82%
The relative density of the battery electrolyte shows --24.0 °C (--11.2 °F) 64%
the charge level of the battery. When the battery is --27.5 °C (--17.5 °F) 58%
fully charged, the relative density of the electrolyte, at --31.0 °C (--23.8 °F) 50%
25°C (77°F), is at least 1.280. --34.5 °C (--30.1 °F) 40%
--37.5 °C (--35.5 °F) 33%

Alternatively, approximate charge can be measured

using a digital voltmeter (± 0.01 V) as follows:

less than 10.5 V unusable battery* Maximum battery life can be obtained by paying the
less than 11.8 V flat battery right attention and by carrying out regular checks.
less than 12.3 V half--charged battery The energy capacity output must not be exceeded by
more than 12.6 V fully--charged battery constant overload and charging requirements must
be respected.
* See notes to paragraph “TESTS” for instructions on
how to recuperate a slightly sulphurized battery.

BATTERY MAINTENANCE
Battery voltage must be registered on a flat battery
considering the following:
A) the battery must be flat for at least 4 hours
B) if the vehicle has been used recently, or if the
battery has been charged recently, switch the WARNING: Batteries contain sulphuric acid and
headlights on for 2 minutes. generate a highly explosive hydrogen and oxygen
mix during charging.

When a battery is flat, the sulphuric acid in the • Do not use devices producing flames or sparks
electrolyte combines chemically with the plates and to inspect the electrolyte level.
this decreases the relative density of the solution.
• Do not remove battery caps without protecting
your hands and your eyes.

A battery densimeter will determine the relative

density of the electrolyte in an element. A reduction in
the amount of sulphuric acid in the solution will show During battery maintenance, follow the steps below:
the degree of charge of that element.
1. Keep the electrolyte level 17 mm (0.6993 in.)
(over the plates. If this is not respected, the acid
concentration will vary, which could damage
The lower the temperature at which the battery
spacers and cause a deterioration in plate
operates, the more necessary it is to keep the battery
performance.
fully charged. For example, a battery with a relative
density of 1.225 at 27°C (80°F) can start the engine
at mild outside temperatures but might not do so at 2. Use distilled or de--mineralized water only. Never
lower temperatures because of lower battery use tap water or rain water or water from any
performance. other source.

3. Keep the battery charged at least 75% to avoid

Table 1 shows the effect of temperature on battery plate sulphurization, performance loss and
performance. possible freezing at low temperatures.
84176554 -- 03--2008
 4 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

4. Avoid overcharging the battery. Excessive NORMAL CHARGING (TOP UP)

charge will generate high internal heat which will
cause grid deterioration and water loss. 1. Charge the battery completely with a slow
battery charger at 3 to 6 amperes for the required
5. During quick recharge, check the battery time. This can last 36 hours, or more, if the
temperature does not exceed 50°C (122°F). battery is very flat. A severely sulphated battery
may not charge. When the battery is completely
6. Do not add sulphuric acid to an element unless charged, the elements will produce gas freely
some electrolyte has been spilt. Before filling, and the relative density will remain constant.
check the solution has the correct relative Disconnect the battery charger after three
density. Slow recharge is the only way to consecutive densimeter readings, recorded
recharge the battery completely. You can use a every hour, showing that relative density has
high amperage battery charger to charge the stabilised.
battery with high current intensity for short
periods of time. Use a slow charge to bring the 2. When using a fast or high ampere charge, follow
battery to its full capacity. the manufacturer’s instructions carefully. High
charging amperage increases electrolyte
temperature and, if the battery charger is not
equipped with an automatic time or temperature
DRY CHARGED BATTERIES switch, it can cause the electrolyte temperature
to rise above 50°C (122°F). This can cause
violent boiling in the battery and damage internal
Dry charged batteries must be prepared as followed: components.
3. Check electrolyte level in each element again
1. Remove the breather caps from each battery and, if necessary, top up with distilled water.
element.
WARNING: Explosive gas is formed when a battery
2. Fill each element to the recommended level with is charged. Do not smoke or use naked flames when
electrolyte at a relative density of 1.260. checking electrolyte level. Check that the battery
charger is switched off, before connection and dis-
connection, to avoid sparks which could ignite the
NOTE: The electrolyte consists of diluted sulphuric gas.
acid, preferably at a temperature of 21° -- 32°C (69.8
-- 89.6°F).
3. After filling, leave the battery to rest for 15 CHARGING VERY FLAT BATTERIES
minutes. Check the electrolyte level and top up, if
necessary.
To recharge a Pb--Ca maintenance--free battery we
4. Charge the battery for 4 hours at 5--8 A., recommend using a constant voltage battery
checking that all the elements are producing gas charger. For very flat batteries, charge for 48 hours,
freely. at 16 V., with current limitation (50 A. for 105 Ah and
66 A for 120 Ah).
5. Replace the breather caps.

This method is self--regulating. High current is

provided at the beginning (when the battery voltage
CHARGING THE BATTERY is very low). Current decreases progressively when
the battery is fully charged (and its voltage is high).

Before charging a battery:

If only constant voltage battery chargers are
available, we recommend using voltage levels and
1. Clean the battery casing and element covers times shown in table 2. These figures refer to very flat
carefully with ammonia diluted in warm water batteries. If the battery is only 50% discharged, use
and clean the terminals; half the time shown (slow charging programme). For
other conditions, reduce charging time
2. Check the electrolyte level and, if it is below the proportionally. When feasible, use the slowest
plate level, top up with distilled water to cover the charging programme for increased battery life.
plates.
If violent boiling occurs during charging, due to gas
formation or electrolyte leakage, or if the battery box

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 5

is hot (50°C (122°F) or higher), temporarily reduce or Example 1:

stop battery charging to avoid damaging the battery. Temperature below 30 °C (86 °F)
Battery electrolyte temperature 19 °C (66.2 °F)
Densimeter reading 1.270
Subtract 11.0 x 0.004
5.5
Correct relative density = 1.262
Table 2
Type of battery
105Ah 120Ah
(760 cca) (800 cca)

Slow charging 25 hrs at 5A 30 hrs at 5A Example 2:

programmes 12,5 hrs at 15 hrs at 10A Temperature above 30 °C (86 °F)
10A Battery electrolyte temperature 40 °C (104 °F)
Densimeter reading 1.220
Fast charging pro- 7 hrs at 10A Add 10.0 x 0.004 0.007
10 hrs at 18A 5.5
grammes (emer-
Correct relative density = 1.227
gency use only)

2. Use the following table to determine the charge

TESTS
level.

Before carrying out battery tests, check the breath-

ers are not blocked, there is no rust, the breather Correct Correct
caps are not open and the casing is not cracked. Charge relative relative Average
condition density at density at battery
15°C (86°°F) 25°C (86°°F) voltage

100% 1.295 1.287 12.66

Required testing equipment: 75% 1.253 1.246 12.45
50% 1.217 1.210 12.30
25% 1.177 1.170 12.00
Flat 1.137 1.130 11.84
• Densimeter
• Battery starter tester (high amperage tester)
• Thermometer
NOTE: Relative density should not vary more than
• Battery charger 0.025 points between cells.

Relative density: This test shows the charge level of 4. If relative density is 1.280 or higher, the battery is
a battery. fully charged and in good working condition.

5. If the correct relative density is less than 1.280,

1. With the float in a vertical position, note the charge the battery and check the charging
reading. system, to find the cause of low battery load.

2. Regulate the densimeter reading for battery NOTE: If distilled water has recently been added, the
electrolyte temperature variations subtracting 4 battery must be charged for a short period of time to
points (relative density 0.004) for every 5.5 °C obtain precise densimeter readings.
(41.9 °F) below the temperature the densimeter
is calibrated at and adding 4 points (relative
density 0.004) for every 5.5 °C (41.9 °F) above If the battery has been loaded and kept still, the
this temperature. battery electrolyte will be thicker at the base of the
elements. The battery must be shaken periodically to
mix the electrolyte. This will improve charging
The following examples have been calculated with a amperage and allow more precise densimeter
densimeter calibrated at 30 °C (86 °F). readings during tests.
84176554 -- 03--2008
 6 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Performance tests 3. Turn the battery charger timer to more than a 3

minute charge and then back to a 3 minute
Performance tests help to understand if a battery can charge.
adequately run the engine. Voltage readings show
battery condition. Before carrying out the test, check
the battery electrolyte level is correct and the open
circuit voltage is 12.5V or more. The battery can be
tested in the tractor or removed.
4. Set the charging amperage as close as possible
to 40 A.

1. Switch the battery start tester current control to

“off” (high amperage discharge tester). Calibrate
the voltage selection switch to the nominal 5. After a 3 minute fast charge, read the voltmeter.
battery voltage or slightly higher. Connect the
positive tester conductors to the positive battery
terminal and the negative conductors to the • If the total voltage is higher than 15.5 V., the
negative battery terminal.
battery is not satisfactory. It is probably
sulphated or worn and must be changed.
2. Turn the current control knob until the ammeter
reading reaches half the cold start battery
amperage and note the voltage reading. NOTE: A slightly sulphated battery can be renewed
using a multiple type battery charger, with upper
open circuit voltage limit of 50V. A sulphated battery
has high resistance and for this reason it will be
• If the reading shows 9.6 V. or higher after 15 necessary to set a high voltage at the beginning to
seconds, the battery has adequate power output overcome resistance. At the beginning there may be
and can easily be charged following the normal no visible sign of charging. After some minutes of
procedure. inactivity, a low charge will show. This is followed by a
fast rise in amperage. Amperage must not exceed
• If the reading is lower than 9.6 V., battery is not 14.0 A. and the battery electrolyte temperature must
satisfactory for use and the charge must be not exceed 50°C (122°F). When amperage
tested as follows. stabilizes, set the voltage until amperage
corresponds to 5 A. Continue this amperage until the
relative density of the battery electrolyte stabilises
(1.275 -- 1.280 at 20°C (68°F)). This could take
WARNING: Do not leave a high discharge tester on approximately 48 hours. Let the battery rest for 24
the battery for more than 15 seconds. hours and then carry out the previously described
performance test.

• If the total voltage is less than 15.5 V., check the

relative density of each element and recharge
the battery according to the following scale:

Test charging: This test is only for those batteries

which have not passed the performance test above.
Relative density Fast charge up to:

1.150 or less 60 minutes

1. Connect the positive battery charger tester from 1.151 to 1.175 45 minutes
conductors (high amperage discharge tester) to
the positive battery terminal and the negative from 1.176 to 1.200 30 minutes
conductors to the negative battery terminal.
from 1,200 to 1.225 15 minutes
(slow charge only)

2. Connect the positive battery charger conductor

to the positive battery terminal and the negative
conductor to the negative battery terminal.
NOTE: When there are problems with a battery,
check fan belt tension and the complete charging
system.

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 7

BATTERY PROBLEMS -- FREQUENT 5. Crystals are formed when batteries are left flat.
CAUSES High temperature and long periods with the
battery flat increase this condition. If a battery is
1. Internal open circuit. left at room temperature for a week it can rarely
be charged in the vehicle. Battery recharge
requires higher constant voltage. After three
2. Internal short--circuit. weeks the battery will be permanently
jeopardized and it will be necessary to follow the
3. Battery electrolyte leakage. procedure described for “very flat batteries”.

4. Grid active material separation.

Fully charged batteries have longer a life. A

5. Accumulation of sulphate crystals too big to be lead--calcium battery discharges 3% a month. This
dispersed. means that in 16 months it will reach 50% charge. In
the tractor, inactive load is approximately 50 mA. To
forecast discharge on a vehicle not in use add
approximately 8 Ah a week to this value.
These problems are commonly caused by the
following:

1. Component failure inside the elements.

2. Excessive crystal growth which can pierce the
spacers and cause short circuits. It is worth noting that if a battery is weak during
engine start--up, it is best to let the battery rest for two
3. Excessive overload (bad charging system, high
minutes. This rest time increases as the temperature
voltage fast charging, high operating
decreases.
temperatures).
4. Battery electrolyte freezing.
A fully charged battery freezes at --65 °C
(--85 °F). A 50% charged battery freezes
between --17 °C and --27 °C (16.6 °F). A
completely flat battery freezes between -- 3 °C When two batteries are installed, do not use an old
(26.6 °F) and --11 °C (12.2 °F). Excessively fast battery with a new one. One battery will always stop
charging and boiling caused by gas formation before the other one. If the battery has lasted as
cause the separation of active material from the forecasted, charge both batteries. If one has stopped
grids. Separation destroys the battery chemical before the forecasted time due to a defect, then
function. change only the defective battery.

84176554 -- 03--2008
 8 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 1

SECTION 55 -- ELECTRICAL SYSTEM

Chapter 6 -- ELECTRICAL CIRCUITS

CONTENTS

Section Description Page

55 100 Contents . . . . . . . . 1
Fuses (all versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Symbols used in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical wire colour coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ground locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- General diagrams (W/Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
-- General diagrams (W/Out Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
-- Analogue instrument circuit and connector overview . . . . . . . . . . . . . . . . . . . . . . 19
-- Start--up circuit and connector overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
-- Direction indicator & hazard warning light circuit and connector overview . . . . 25
-- Windscreen and rear window wiper/washer circuit and connector overview . . . 31

-- Brake light circuit and connector overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

-- Heating and air--conditioning system circuit and connector overview . . . . . . . . . 41
-- Work lamp (without cab circuit and connector overview) . . . . . . . . . . . . . . . . . . . 45
-- Work lamp (without cab circuit and connector overview) . . . . . . . . . . . . . . . . . . . 49
-- Side lights,main and dipped headlights, parking light circuit and connector
overview 53

84176554 -- 03--2008
 2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

FUSES AND RELAYS MAIN BOX

1 10

2 11

3 12
KORNA ROLESI
13 III
4 HORN RELAY

5 14

6 15 UZUN FAR ROLESI

HIGH BEAM RELAY II
7 16

8 17
KISA FAR ROLESI
LOW BEAM RELAY
I
9

31

Fuses PROTECTED CIRCUITS Amps

1 Main beam headlights 15
2 Dipped beam headlights 10
3 Front right and rear left side lights 10
4 Front left and rear right side lights 7.5
5 Engine shut--down solenoid 7.5
6 Instruments, turn signal switch, horn 10
7 Hazard warning switch, fuel sedimentor 10
8 Relays 20
9 Hazard warning switch 15
10 Beacon lamp, (radio, interior lamps-- with cab models) 15
11 Cigarette lighter 15
12 Power for cab (with cab models) 30
13 Thermostart 7.5
14 Power socket (with cab models) 40
15 Power for cab (with cab models) 30
16 Turn signal switch 20
17 Brake lights 15
I Dipped beam relay --
II Main beam relay --
III Horn relay --

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 3

FUSES AND RELAY BOX (INSIDE CAB) Fuses and protected circuits are listed below:
FIG-- 32 -- 33
Fuses PROTECTED CIRCUITS Amps
1 1. Front wiper 10
2. Washer 7.5
2
3. Beacon lamp, interior lamps, 15

3 4. Heater/Air Conditioning, radio 20

5. Rear wiper 7.5
4 6. Working lamps switches 10
7. Front working lamps 15
5
8. Rear working lamps 25
6

32

Relays and related circuits are listed below:

Relays CIRCUITS
1. Front work lights
2. Rear work lights
3. Power supply
4. Power supply

1 2 3 4

TRE0847A

33

84176554 -- 03--2008
 4 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

SYMBOLS

THERMOSTARTER SWITCH
HEADLAMPS WATER TEMP. GAUGE SENDING UNIT
BRAKE SWITCH

HANDBRAKE SWITCH
ENGINE OIL PRESSURE SWITCH
STARTER SWITCH
FRONT SIGNAL AND PARKING LIGHT

SOLENOID
FUEL SEDIMENTER

REAR INDICATOR LIGHT

SPEAKER
INTERIOR LIGHTS (LAMPS)

BEACON LAMP

LIGHTER
COMPRESSOR

NUMBER PLATE LAMP

SWITCHES
GROUND

RELAY
WORKLAMPS

REAR WIPER

MAIN FUSE
STARTER SWITCH

WASHER HORN

THERMOSTARTER
STARTER
FUEL LEVEL SENSOR

HEATER

ALTERNATOR

FRONT BRAKE OIL UNIT

DIODE

AIR FILTER RESTRICTION SWITCH

BATTERY

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 5

ELECTRICAL WIRE COLOUR CODING

B Black
G Green
K Pink
LG Light green
LN Tan
N Brown
O Orange
P Purple
R Red
S Grey
TQ Turquoise
U Blue
W White
Y Yellow

GROUND LOCATIONS (Pages 6 -- 8)

1. Instrument cluster ground point

2. Fuse box ground point

3. Cab floor ground point

4. Steering pump pressure sensor ground point

5. Battery ground point

6. Windscreen washer pump ground point.

7. 7 pin trailer connector ground point

8. Evaporator top ground point

9. Upper cab ground point

10. Protective diode ground point

84176554 -- 03--2008
 6 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

GROUND LOCATIONS

1 2

84176554 -- 03--2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 7

6 7

84176554 -- 03--2008
 8 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

8 9

10

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 9

GENERAL DIAGRAM --CENTRE(WITH CAB)

1,0 B
19 1,0 U/W
1,0 U/R

1,0 P/N
32

1,0 B
C 1,0 U/R
1,5 U/W 2,0 U/W 1,0 U/W
1,0 P/N 1,0 P/N 1,0 B
2,0 B 2,0 B
1,5 U/R 2,0 U/R

6 1,0 LG/W
1,5 U/W 15A 1,5 U/W
85 30

1.5 P/W 86 87 1,5 U/R 1,5 U/R 10A 1,5 U/R

1,0 B 1,0 W/S 1,5 R 10A 1,5 R/W 9
1,0 R
7 1,5 Y/W
7.5A 1,0 R/B
7.5A 1,5 P/Y
85 30

86 87

1.5 P/W 1,5 U/W 1.5 Y/W

1,0 B 1,0 W/G 10A 1.5 G
1,5 Y/W 10A 1,0 G
3,0 Y/W 20A 3,0 P/W 1,0 R
B
1,0 P/N 1,5 N 15A 1,5 P
85 30

86 87

1,0 P/W 1,0 P/G

1,0 B 1,0 P 2,0 Y/W 1,0 LG/W
2,0 N 5,0 Y/W
15A 5,0 Y/W
8 1,5 N
5,0 N
15A 1,5 P 5,0 B
30A 5,0 Y/W
2,5 N/R 15A 2,5 N/R
6,0 N 1,5 R
40A 6,0 N 2,0 Y/W
5,0 N
30A 5,0 Y/W
1,5 Y/W
20A 1,5 S 6,0 N
1,5 G/O 15A 1,5 G/O 1,5 G/O 1,5 G
6,0 B
B 1,0 B
30 33 20 R 1,0 R
G/W 1,0 G/W
5
2,5N/R

1,5 P
0,5 R 1,5 B
D
6,0 B A
28 6,0 B 1,0 P/G
0,5 G/B
0,5 R/K
1,5 G
1,0 G/R
1,5 R
56 E 1,0 G/W
B 1,0 B 1,0 R/B
2,0 B
R/B 1,0 R/B
G/R 0,5 W/B
1,0 G/R

36
0,5 B 0,5 W/B 20
0,5 R/K 19
1,5 U 0,5 G 18
1
1,0 G/W 0,5 W/B 17
2
1,0 G/R 0,5 N/Y 16
3
1,0 W/G 0,5 W/N
3 4
5 1,5 S 16 15
14
1,5 LG/N 0,5 B 0,5 B/S 0,5 B/S 13
6
1,0 W/S 6,0 N 0,5 G/W
7 12
1,0 P/B 0,5 U
8 11
9
1,0 P 30 1,0 R 0,5 G/B
10 1
1,5 U 1,5 U 57 15/542,5 N/U 0,5 U 9
6,0 Y/W

1.5 R 58/5750 50 1,0 B 8

0,5 G/U 7
0,5 B
2,5 W/Y

6
35 6,0 N
18 0,5 LG/Y 5
16,0 NFUSE
6,0 N 2 0,5 LG/R 4
6,0 N 2,5 N/U 2,5 N/R 0,5 G/R 3
6,0 N 6,0 N 0,5 R/W 2
13 0,5 U/W 1

B+
12
3,0 N/P

D+0,5 N/Y

0,5 W/N
0,5 G/U

1,5 P/Y
16,0 N

1,5 LG/N
0,5 LG/R
14 0,5 LG/Y 17 15

1.5 O
1,0 B

1,5 LG/N
1,0 G/W
1,0 G/R

0.5 R/B
3.0 B

31

1,0 G
1.5 O
1,0 B

1,5 P
11

10,0 B
2,5 W/R 2,5 W/Y 27
10
4

84176554 -- 03--2008
10 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 11

GENERAL DIAGRAM --CENTRE(WITH CAB)

37 40

1,0 LG/B
1,0 R/W

1,5 P/R

1,0 LG
1,0 R
1,5 B

1,0 LG/B
1,0 LG
1,5 U/LG

1,0 B

1,0 B
1,0 R/W

1,5 P/G

1,0 G

1,0 G
1,0 R
55

1,0 B
1,0 B
86 87
5,0 Y/W 5,0 Y/W

85 30

1,5 U/LG
1,5 U/LG
1,0 R 1,0 W/B
38
54

86 87
5,0 Y/W 4,0 Y/W 25 A4,0 P/U

85 30
5,0 Y/W
1,0 R 1,0 W/B 3,0 Y/W 15 A3,0 P/U 1,0 R/W
1,0 Y/W 10 A 1,0 R
53 1,5 Y/W 7.5 A1,5 U/LG 48 49

86 87
4,0 G/N 2,5 Y/W 20 A 2,5 G

85 30
4,0 P/U
1,0 R 1,0 W/B 2,5 W/Y 15 A 1,5 P/G
1,0 Y/W 1,5 P/R
1,5 W/K
7,5 A 1,5 B
52 1,5 Y/W 10 A 1,0 P/W

86 87
2,5 P

85 30
3,0 P/U 1,0 G
1,0 R/W 1,0 W/B 1,5 U/LG
1,0 G/N
1,0 B

1,0 G/N
B 1,0 B
1,0 LG/W 1,0 LG/W
5,0 Y/W 2,5 G 41
5,0 Y/W 1,5 G
5,0 B 2,5 B 47 1,0 G/N
1,0 B
1,5 R
2,5 Y/W

1,0 B
1,0 G/N
6,0 N
1,0 B
6,0 B

A
1,0 P/G 1,0 P/G

6,0 B
0,5 G/B 1,0 B 24
0,5 R/K
1,5 G
1,0 G/R
1,5 R
1,0 G/W
1,0 R/B 0,5 B 0,5 G/B 23
2,0 B
0,5 W/B

29
1,0 B

1,0 P/W
0,5 B 0,5 R/K 1,0 B

1,0 B
1,5 W/K
1,0 G/N 22
F
1,5 G
4,0 N
1,5 N
1,5 R
4,0 N

1,5 B
4,0 B
4,0 B
1,5 R
1,0 G/W 1,0 G/W
1,0 G/P 1,0 G/P 34
1,0 B 1,0 B
46
G
44
1,0 R/B 1,0 R/B 1,0 P
1,0 G/R 1,0 G/R 1,0 G

1,0 P/W
1,0 G/P 1,0 G/P 21

1,0 B
1,0 B 1,0 B
1,0 P/B
1,0 B 1,0 G/W
0,5 W/B 1,0 R/B 26

1,5 W/LG
1,5 R/LG
1,5 U/LG
1,0 B
1,0 P

1,0 B
51 1,0 P

1,0 G/W
1,5 R/G

1,0 P/B
0,5 B

1,0 G
1,0 P
1,0 LN/W
1 39
2
1,5 B
3
1,0 LN/R 4
25
1,0 B
1,5 B

1,0 R 5
1,0 G/P
6
1,0 R/B
7
42 45 43

84176554 -- 03--2008
12 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 13

GENERAL DIAGRAM --CENTRE(WITH CAB)

1-- Instrument panel 27-- Engine shut off solenoid
1-- High beam 28-- Thermostarter
2-- Park 29-- Hand brake switch
3-- Left signal 30-- Brake stop light switch
4-- 2 nd trailer 31-- Starter inhibitor unit
5-- 1 st trailer 32-- Headlamps
6-- Earth 33-- Lighter
7-- Fuel gauge 34-- Rear right parking,turn signal and stop lights
10-- Engine water temperature gauge 35-- Main fuse
12-- Right signal 36-- Front brake oil unit
13-- Air filter 37-- Rear wiper
15-- Oil pressure 38-- Cabin fuse box
18-- Battery charge indicator 39-- Canin plug
19-- Parking brake 40-- Switches
41-- Rear work lamps
2-- Starter switch 42-- Front work lamps
3-- Turn signal switch 43-- Speaker
4-- Hazard warning lights indicator sending unit 44-- Interior lamps
5-- Fuse Box 45-- Wiper
6-- Low beam relay 46-- Radio
7-- High beam relay 47-- Heater
8-- Horn relay 48-- Washer
9-- Compressor 49-- Beacon lamp
10-- Flasher 50-- Fuel sedimenter
11-- Battery 51-- Brake disc
12-- Starter 52-- Front working lamp relay
13-- Alternator 53-- Rear working lamp relay
14-- Over voltage circuit breaker (DIODE) 54-- Front and rear working lamp relay
15-- Engine oil pressure switch 55-- Power relay
16-- Air cleaner restriction indicator sending unit 56-- Front left signal and parking light
17-- Water temperature gauge sending unit
18-- Thermostarter button
19-- Horn A--Main and chassis harness connector
20-- Right front parking and turn signal lights B--Main and cab harness connector
21-- Rear left parking,turn signal and stop lights C--Main and headlamp connector
22-- Working lamp D--Main and right front signal connector
23-- Fuel level sensor E--Main and left front signal connector
24-- Beacon lamp F--Chassis and rear right indicator connector
25-- Trailer plug G--Chassis and rear left indicator connector
26-- Number plate lamp

84176554 -- 03--2008
14 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 15

GENERAL DIAGRAM --CENTRE(WITHOUT CAB)

C
1,5 U/W 2,0 U/W
1,0 P/N 1,0 P/N 1,0 P/N
2,0 B 2,0 B 1,0 B 19
1,5 U/R 2,0 U/R
6
1,5 U/W 1,5 U/W
15A 1,0 B
1,5 U/R 1,5 U/R
87
1.5 P/W 1,5 U/R
85 30

10A 1,0 U/W

1,0 W/S 1,5 R 1,5 R/W
1,0 B 10A
86

1,0 R 1,0 R/B 1,0 U/R

7 1,5 Y/W
7.5A
1,5 P/Y
1.5 P/W 1,5 U/W 7.5A
30

87

1,0 W/G
1.5 Y/W 10A
1.5 G 32
1,0 B 1,5 Y/W 1,0 G
85

86

10A 1,0 U/R

3,0 Y/W 3,0 P/W 1,0 R
20A 1,0 U/W
1,0 P/W 1,0 P/N 1,5 N 1,5 P
30

86 87

15A 1,0 B
1,0 P
85

1,0 B
2,0 N 15A 1,0 P/G
8 1,5 N 1,5 P
15A

2,5 N/R 2,5 N/R

15A

1,5 Y/W 1,5 S

20A
1,5 G/O 1,5 G/O 1,5 G/O 1,5 G
15A 24
B 1,0 B
30 R 1,0 R
20
5 G/W 1,0 G/W
2,5 N/R

1,5 P
1,5 B
0,5 R

1,0 P/G
D
A

1,0 B
23
28 33 6,0 B 1,0 P/G 1,0 P/G
0,5 G/B 0,5 G/B 0,5 G/B 0,5 B
0,5 R/K 0,5 R/K
1,5 G 1,5 G
1,0 G/R 1,0 G/R 29
1,5 R 1,5 R
1,0 G/W 0,5 R/K 0,5 B
E 1,0 G/W
B 1,0 B 1,0 R/B 1,0 R/B
R/B 1,0 R/B 2,0 B 2,0 B
38 G/R 1,0 G/R 0,5 W/B 0,5 W/B

1,0 B
20 1,0 G/N 22
0,5 R/K F
19
1 1,5 U 36 0,5 B 0,5 W/B 0,5 G
18 1,5 R 1,5 R
1,0 G/W 0,5 W/B 1,0 G/W 1,0 G/W
2 17
3 1,0 G/R 0,5 N/Y
16 1,0 G/P 1,0 G/P 34
1,0 W/G 0,5 W/N 1,0 B 1,0 B
15
4 16
3 5 1,5 S
0,5 B 0,5 B/S 0,5 B/S
14
6 1,5 LG/N 13
1,0 W/S 6,0 N 0,5 G/W
7 12 G
0,5 U
8 1,0 P/B
30 0,5 G/B
11 1 1,0 R/B 1,0 R/B
9 1,0 P 1,0 R 10 1,0 G/R 1,0 G/R
1,5 U 1,5 U 57 15/542,5 N/U 0,5 U 9 1,0 G/P 1,0 G/P 21
9
6,0 Y/W

1.5 R 58/57 50 1,0 B 8 1,0 B 1,0 B

0,5 G/U
7
0,5 B
2,5 W/Y

6 1,0 B
35 0,5 LG/Y
26
16,0 N FUSE
6,0 N 2 18 0,5 LG/R
5 0,5 W/B 1,0 R/B
4
6,0 N 2,5 N/U 2,5 N/R 0,5 G/R
3 0,5 B
37
6,0 N 6,0 N 0,5 R/W
2
0,5 U/W
1
13 1,0 LN/W
B+ 1
3,0 N/P

D+0,5 N/Y 2

0,5 W/N
1,5 P/Y
0,5 G/U
12 1,5 B 3
16.0 N 1,0 LN/R
1,0 R
4 25
5
17 15 1,0 G/P
14 1,0 R/B
6
7
0,5 LG/R
1,5 LG/N

1,5 LG/N
0,5 LG/Y

1,0 G/W
3.0 B

1,0 G/R

0.5 R/B

11 31
1.5 O

1,0 G
1.5 O
1,0 B

1,0 B

1,5 P

1,5 B
27

1,0 B
2,5 W/R 2,5 W/Y
10,0 B

10 4

84176554 -- 03--2008
16 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 17

GENERAL DIAGRAM --CENTRE(WITHOUT CAB)

1-- Instrument panel 18-- Thermostarter button
1-- High beam 19-- Horn
2-- Park 20-- Right front parking and turn signal lights
3-- Left signal 21-- Rear left parking,turn signal and stop lights
4-- 2 nd trailer 22-- Working lamp
5-- 1 st trailer 23-- Fuel level sensor
6-- Earth 24-- Beacon lamp
7-- Fuel gauge 25-- Trailer plug
10-- Engine water temperature gauge 26-- Number plate lamp
12-- Right signal 27-- Engine shut off solenoid
13-- Air filter 28-- Thermostarter
15-- Oil pressure 29-- Hand brake switch
18-- Battery charge indicator 30-- Brake stop light switch
19-- Parking brake 31-- Starter inhibitor unit
32-- Headlamps
2-- Starter switch 33-- Lighter
3-- Turn signal switch 34-- Rear right parking,turn signal and stop lights
4-- Hazard warning lights indicator sending unit 35-- Main fuse
5-- Fuse Box 36-- Front brake oil unit
6-- Low beam relay 37-- Brake disc
7-- High beam relay 38-- Front left signal and parking light
8-- Horn relay
9-- Fuel sedimenter
10-- Flasher A-- Main and chassis harness connector
11-- Battery B-- Main and headlight harness
12-- Starter C-- Main and right front signal connector
13-- Alternator D-- Main and left front signal connector
14-- Over voltage circuit breaker (DIODE) E-- Chassis and rear right indicator connector
15-- Engine oil pressure switch F-- Chassis and rear left indicator connector
16-- Air cleaner restriction indicator sending unit
17-- Water temperature gauge sending unit

84176554 -- 03--2008
18 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 19

ANALOGUE INSTRUMENT CIRCUIT

1 -- Left turn indicator 9 -- Brake oil level low

2 -- Side lamps 10 -- Parking brake
3-- Headlamp main beam 11-- Riٛ ht turn indicator
4 -- Water in fuel 12-- 1st. trailer turn signal
5 -- Air filter blocked 13 -- 2nd.trailer turn signal
6 -- Unused 14 -- Unused
7-- Engine oil pressure 15 -- Unused
8 -- Battery charger

84176554 -- 03--2008
20 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

0,5 G/B
--
--
0,5 G/U
0,5 B
0,5 LG/Y
1
0,5 LG/R
0,5 G/R
0,5 R/W
0,5 U/W

0,5 U
0,5 G/W
0,5 B/S
--
0,5 W/N
0,5 N/Y
0,5 W/B
0,5 G
0,5 R/K
--

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 21

STARTING CIRCUIT

6,0 N

30

57 15/54
58/57 50

35
16.0 NFUSE
2
6,0 N
6,0 N 6,0 N
13
B+
12

3,0 N/P
D+ 0,5 N/Y 0,5N/Y
16

16.0 N

14
1

3.0 B
31
11 2,5W/R 2,5W/Y

STARTING CIRCUIT

1 -- Instrument panel
2 -- Starter switch
11 -- Battery
12 -- Starter
13 -- Alternator
14 -- Over voltage circuit breaker (DIODE)
31 -- Starter inhibitor unit
35 -- Main Fuse

84176554 -- 03--2008
22 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 23

CONNECTOR OVERVIEW

0,5 G/B
--
-- 2
0,5 G/U
0,5 B
0,5 LG/Y
1 6N
0,5 LG/R
0,5 G/R 6 Y/W
0,5 R/W 2,5 N/U
0,5 U/W 1,5 R
2,5 W/Y
1,5 U

0,5 U
0,5 G/W
0,5 B/S
--
16N
0,5 W/N 14
0,5 N/Y 12
0,5 W/B 2,5 W/R
0,5 G
0,5 R/K
--

3 N/P
3 N/P
3B 6N

18 13
0,5 N/Y

2,5 N/U

2,5 N/R 31

28
2,5 W/R

2,5 W/Y

2,5 N/R

84176554 -- 03--2008
24 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

CONNECTOR OVERVIEW

1 G/W

1,5 G

1 P/G

0,5 G/B
0,5 R/K

1 G/R
1,5 R
1 R/B

2B

0,5 W/B

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 25

-- DIRECTION INDICATOR AND HAZARD WARNING LIGHT CIRCUIT

A
6,0 B
D
B 1,0B

20 G/W 1,0G/W
1,0 G/R 1,0G/R

E
1,0 G/W 1,0G/W
B 1,0B

56 G/R 1,0G/R
2,0 B 2,0B

2 1,0 G/W
G/R
3 1,0

3 5 1,5 S F
6 1,5 LG/N 1,0 G/W 1,0 G/W
34
1,0 B 1,0 B

0,5G/W
5
12
G
1,5Y/W
20A
1,5S
1 1,0 G/R 1,0G/R

1,5 Y/W
10A
1,0G
21
1,0 B 1,0 B
1,5N 1,5P 0,5 B
15A 6
0,5 LG/Y
5
6,0 N 0,5 LG/R
4
2 30
0,5 G/R
3

6,0 Y/W
57 15/54
35
6,0 N

58/57 50 1,0 LN/W

1
16.0 NFUSE
6,0 N 1,5 B
6,0 N 6,0 N 3

16.0 N
1,0 LN/R
4 25
B+
D+
1,5LG/N
0,5LG/R
0,5LG/Y

1,5LG/N

1,0G/W
1,0G/R
1.5O

1.5O
1,5P
1,0G
1,0B
1,0B

1,0 B

1,5 B
11
10,0 B

12
13 10 4

84176554 -- 03--2008
 26 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

-- DIRECTION INDICATOR AND HAZARD WARNING LIGHT CIRCUIT

1-- Instrument panel

2-- Starter switch
3-- Turn signal switch
4-- Hazard warning lights indicator sending unit
5-- Fuse Box
10-- Flasher
11-- Battery
12-- Starter
13-- Alternator
20-- Right front parking and turn signal lights
21-- Rear left parking,turn signal and stop lights
25-- Trailer plug
34-- Rear right parking,turn signal and stop lights
35-- Main fuse20-- Right front parking and turn signal lights
56-- Front left signal and parking light

A-- Main and chassis harness connector

D-- Main and right front signal connector
E-- Main and left connector
F-- Chassis and rear right indicator connector
G--Chassis and rear left indicator connector

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 27

CONNECTOR OVERVIEW

0,5 G/B
--
--
0,5 G/U
0,5 B
2
0,5 LG/Y
1
0,5 LG/R
0,5 G/R 6N
0,5 R/W 6 Y/W
0,5 U/W
2,5 N/U
1,5 R
2,5 W/Y
1,5 U

0,5 U
0,5 G/W
0,5 B/S
--
0,5 W/N
0,5 N/Y
0,5 W/B
0,5 G
0,5 R/K
--

1 G/R
1 G/W
3
1,5 U

1 S/B
1 P/B
1,5 G/B
1,5 S
1Y
1 TQ

1 W/G

1 W/S
1 TQ/B
1 W/B
1P 1,5 S

1 P/B

1,5 LG/N

1P

84176554 -- 03--2008
 28 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

CONNECTOR OVERVIEW

--
4
0,5 LG/R 0,5 LG/Y 1B

10
1,5 O
1G
1,5 P 1,5 O 1,5 LG/N
0,5 R/B
1B
1,5 LG/N
1 G/R
1 G/W
20

1 G/W

16 N
1R

2,5 W/R 12
1B

21 25 1,5 B
1 LN/R
1 R/B
1 R/B 1R

1 G/R
1B

1 G/P

1 G/P
1 LN/W
--

84176554 -- 03--2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 29

CONNECTOR OVERVIEW

38

34

1,5 R
1 G/N
1R 1 G/R

1 G/W 1 R/B

1B
1 G/P 1B

1,5 R
1 G/W
1 G/P
1 B

1 R/B
1 G/R
1 G/P
1 B

84176554 -- 03--2008
30 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

CONNECTOR OVERVIEW

1 G/W

1,5 G

1 P/G

0,5 G/B

0,5 R/K

1 G/R

1,5 R
1 R/B

2B

0,5 W/B

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 31

-- WINDSCREEN AND REAR WINDOW WIPER/WASHER CIRCUIT

40
37

1,0 LG/B

1,0 LG

1,0 LG/B
1,0 LG
1,0 B

1,0 B
1,5 B

1,0 G

1,0 G
1,5 U/LG

1,0 B
1,0 B
55

1,5 U/LG
1,5 U/LG
30
5,0 Y/W 5,0 Y/W

87
1,0 R 1,0 W/B

86
85
38 48
1,5 Y/W7.5 A 1,5 U/LG

1,0 Y/W
7,5 A
1,5 Y/W
5
10 A
B

5,0N 5,0 Y/W 5,0 Y/W

30A 5,0Y/W

5,0 B 5,0 B

1,5 W/LG
1,5 R/LG
1,5 U/LG
1,5 R/G
1.5Y/W G 1,5 R
10A 1.5 1,5 R

6,0 B
6,0 N

2 30 6,0B 6,0 B
6,0 Y/W
57 15/54
35 6,0 B
6,0 N

58/57 50
6,0 B
16.0 NFUSE
6,0 N
6,0 N
B+
45
16.0 N
D+

12
11 13

84176554 -- 03--2008
 32 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

-- WINDSCREEN AND REAR WINDOW WIPER/WASHER CIRCUIT

2-- Starter switch

5-- Fuse Box
11-- Battery
12-- Starter
13-- Alternator
35-- Main Fuse
37-- Rear wiper
38-- Cabin fuse box
40-- Switches
45-- Wiper
48-- Washer

55-- Power relay

B-- Main and cabin harness connector

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 33

CONNECTOR OVERVIEW

6N 16 N
6 Y/W
2,5 W/R 12
2,5 N/U
1,5 R
2,5 W/Y
1,5 U

45

40
1.5 R/LG 1.5 R/G
1 R/W

1 R/W
1.5 W/LG
1.5 U/LG

1R

1R

48--1

1,5 P/G

1,5 P/R 1B

1 LG/B 48--2

1G

1G 1B

1 LG

1 LG/B 37

1 LG

1,5 U/LG

1,5 B

84176554 -- 03--2008
34 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

CONNECTOR OVERVIEW

B B

5 Y/W
1 LG/W

5B 1,5 R

5 Y/W 2,5 Y/W

40

1,5 UL/G
1,5 UL/G
1,5 W/LG

1,5 R/LG

1,5 R/G

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 35

-- BRAKE LIGHT CIRCUIT

1,5G/O G/O 1,5G/O 1,5G 1,5 G

15A 1,5 1,5 G

F
30
6,0N
1,0 G/P 1,0 G/P 34
2 30 2,0 B 2,0B 1,0 B 1,0 B
6,0 Y/W
57 15/54 2,5 N/U

10,0 B
58/57 50 G

35 1,0 G/P 1,0 G/P 21

1,0 B 1,0 B
16.0 N FUSE 6,0 N

1,0 B
6,0 N 1
B+ 2
1,5 B
D+ 3
12 4 25
5
16.0 N 1,0 G/P
6

13 7

11

84176554 -- 03--2008
 36 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

-- BRAKE LIGHT CIRCUIT

2-- Starter switch

11-- Battery
12-- Starter
13-- Alternator
21-- Rear left parking,turn signal and stop lights
25-- Trailer plug
30-- Stop light switch
34-- Rear right parking turn signal and stop light
35-- Main Fuse
A-- Main and chassis harness connector
F-- Chassis and rear right indicator connector
G-- Chassis and rear left indicator connector

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 37

CONNECTOR OVERVIEW

0,5 G/B
-- 2
--
0,5 G/U
0,5 B 6N
0,5 LG/Y
1 6 Y/W
0,5 LG/R
0,5 G/R 2,5 N/U
0,5 R/W 1,5 R
0,5 U/W
2,5 W/Y
1,5 U

0,5 U
0,5 G/W
0,5 B/S
-- 16N
0,5 W/N
0,5 N/Y 12
2,5 W/R
0,5 W/B
0,5 G
0,5 R/K
--

25
1,5 B
1 LN/R
21 1 R/B
1R

1 R/B
1 RB

1 G/R 1 G/P
1B 1 LN/W

1 G/P --

84176554 -- 03--2008
38 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

CONNECTOR OVERVIEW

34
30
1,5 R
1 G/N
1,5 G 1R
1,5 G/O

1 G/W

1B
1 G/P

1,5 R
1 G/W
1 G/P
1 B

1 R/B
1 G/R
1 G/P
1 B

3 -- Turn signal switch

84176554 -- 03--2008
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 39

CONNECTOR OVERVIEW

1 G/W

1,5 G

1 P/G

0,5 G/B

0,5 R/K

1 G/R
1,5 R
1 R/B

2B

0,5 W/B

84176554 -- 03--2008
40 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 41

-- HEATING AND AIR--CONDITIONING SYSTEM CIRCUIT

I VI

II

III
MAX

1,0 LG/W

1,0 G/P
1,0 G/Y
1,0 P/G
1,0 B

1,0 B
1,0 N/U

1,0 N/U
1,0 P/K
1,0 P/U
VII

1,0 LG/W
M

2.5 G

2.5 B
IV H
C
9 V
47
38

1,0 LG/W
B
KOMPRESOR
1,0 LG/W
55

2,5 G

2,5 B
COMPRESSOR

5,0 Y/W 2,5 Y/W 20 A 2,5 G

85 30

86 87
5,0 Y/W
1,0 R 1,0 W/B
5 B

1,0LG/W 1,0 LG/W

5,0N 30A 5,0Y/W 5,0 Y/W 5,0 Y/W

5,0 B 5,0 B

Y/W 10A 1.5G

1.5 1,5 R 1,5 R

6,0N
2 30 6,0B 6,0 B

6,0 B
6,0 Y/W
57
35
15/54
6,0 B
6,0 N

58/57 50
6,0 B
16.0 N
FUSE
6,0 N
6,0 N
B+
16.0 N
D+

12
11 13

84176554 -- 03--2008
 42 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

-- HEATING AND AIR--CONDITIONING SYSTEM CIRCUIT

2-- Starter switch

5-- Fuse Box
9-- Compressor
11-- Battery
12-- Starter
13-- Alternator
35-- Main Fuse
38-- Cab fuse box
47-- Heater
54-- Compressor
55-- Power relay
B-- Main and cab harness connector

I-- Electrical fans

II-- Air conditioning--thermostat
III--.Air--conditioning pressure switch
IV-- Electric fan control switch
V-- Air--conditioning control switch
VI-- Heating control
VII-- Air--conditioning control switch connection

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 43

CONNECTOR OVERVIEW

16N
6N
12
6 Y/W 2,5 W/R

2,5 N/U
1,5 R
2,5 W/Y
1,5 U

9
47

1 LG/W

1 LG/W
2,5 B
2,5 G
B
1,5 G

5 Y/W
1 LG/W

5B
5 Y/W

1,5 R
2,5 Y/W

84176554 -- 03--2008
44 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 45

-- WORK LAMP (WITHOUT CAB) CIRCUIT

5
1,5 R 1,5 R 1,5R
10A 1,5 R/W

1,5Y/W 1,5S
20A
2,0 B 2,0B

1,5 U
1

3 1,5 S 1,0 B
5
1,5G/N 22
F

2 6,0 N
1,5 R 1,5R

34
6,0 Y/W

30
1,0 B 1,0 B
1,5 U 1,5 U
57 15/54
1.5 R 58/57 50

16.0 NFUSE 6,0 N

6,0 N

35
12 B+
D+
16.0 N

13
10,0 B

11

1,0 B

84176554 -- 03--2008
 46 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

-- WORK LAMP (WITHOUT CAB) CIRCUIT

2-- Starter switch
3-- Turn signal switch
5-- Fuse Box
11-- Battery
12-- Starter
13-- Alternator
22-- Work lamp

34-- Rear right parking,turn signal and stop lights

35-- Main Fuse
57-- Work lamp
A-- Main and chassis harness connector

F-- Chassis and rear right indicator connector

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 47

CONNECTOR OVERVIEW

6N 16N

6 Y/W 12
2,5 W/R
2,5 N/U
1,5 R
2,5 W/Y
1,5 U

22

1 G/N

1B

34

1,5 R
1 G/N

1R

1 G/W

1B
1 G/P

84176554 -- 03--2008
48 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

CONNECTOR OVERVIEW

1,5 R
1 G/W
1 G/P
1 B

1 G/W

1,5 G

1 P/G

0,5 G/B

0,5 R/K

1 G/R

1,5 R
1 R/B

2B

0,5 W/B

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 49

-- WORK LAMP (WITH CAB) CIRCUIT

1,0 R/W

1,0 R
55
5,0 Y/W 5,0 Y/W

30

87

1,0 R/W
40

1,0 R
1,0 R 1,0 W/B

85

86
38
54
5,0 Y/W 4,0 Y/W
25 A 4,0 P/U

30

87
5,0 Y/W
1,0 R 1,0 W/B 3,0 Y/W 15 A 3,0 P/U 1,0 R/W

86
85
1,0 Y/W 1,0 R
10 A
53
4,0 G/N

30

87
4,0 P/U
1,0 R 1,0 W/B

85

86
52
2,5 P

30

87
B 3,0 P/U
5 1,0 R/W 1,0 W/B

86
85
5,0N 5,0 Y/W 5,0 Y/W 1,0 G/N
30A 5,0Y/W
5,0 Y/W 5,0 Y/W 1,0 B

5,0N 5,0 B 5,0 B

30A 5,0Y/W
1.5Y/W G 1,5 R
10A 1.5 1,5 R
1,0 G/N
6,0 N 1,0 B

2
30
6,0B 6,0 B 41
6,0 Y/W
57 15/54
1,0 G/N
6,0 N

35 58/57 50 6,0 B 1,0 B

16.0 NFUSE 6,0 B
6,0 N
6,0 N

1,0 B
1,0 P

1,0 B
1,0 P
B+
16.0 N 1,0 G/N
D+

6,0 B
1,0 B

12

13
11

42

84176554 -- 03--2008
 50 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

-- WORK LAMP (WITH CAB) CIRCUIT

2-- Starter switch
5-- Fuse Box
11-- Battery
12-- Starter
13-- Alternator
35-- Main Fuse
38-- Cab fuse box
40-- Switches
41-- Rear work lamps
42-- Front work lamps
52-- Front work lamps relay
53--Rear work lamps relay
54--Fronrt and rear work lamps relay
55--Power relay
B--Main and cab harness connector

84176554 -- 03--2008
51 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

CONNECTOR OVERVIEW

6N 16N

6 Y/W 12
2,5 W/R
2,5 N/U
1,5 R
2,5 W/Y
1,5 U

40

1 R/W

1 R/W

41

1R
1 G/N

1R

1,5 P/G 1B

1,5 P/R

1G
42
1G

1P

1 LG/B

1 LG 1B

84176554 -- 03--2008
52 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

5 Y/W
1 LG/W

5B
5 Y/W

1,5 R
2,5 Y/W

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 53

-- SIDE LIGHTS, MAIN AND DIPPED HEADLIGHTS, PARKING LIGHT CIRCUIT

C
1,0 B
1,5U/W 2,0 U/W 1,0 U/W
5 1,5B 2,0 B 1,0 U/R

32
30
6 1,5 U/W 15A 1,5U/W
1,5U/R U/R 1,5U/R 2,0 U/R 1,0 U/R

87
1.5
P/W 1,5U/R 10A 1,5
1,5R R/W 1,0 U/W
B
1,0 1,0
W/S 10A 1,5
86
85

1,0R 1,0R/B 1,0 B

7 3,0Y/W
7.5A
20A
3,0P/W
30

87

1.5
P/W 1,5U/W
1,5Y/W
B
1,0 1,0W/G 20A 1,5S
85

86

B 1,0B

20 R 1,0R

D
1,5B A
0,5 R
6,0 B

33

1,5 R 1,5R
56 E
1,0R/B 1,0R/B
B 1,0B
2,0B 2,0B
R/B 1,0R/B

1 1,5U
6,0 Y/W

3 4 1,0
5 1,5S 2 6,0N 1,5 R 1,5R

30 34
7 1,0 1,5 U 1,0 B 1,0 B
1,5 U 57 15/54
1.5 R 58/57 50 G

1 1,0 R/B 1,0R/B

16.0 N
FUSE 6,0 N
6,0 N 21
35 1,0 B 1,0 B
0.5R/B
1,0B

12 B+
D+
1,0B
1,0R/B 26
16.0 N
0,5R/W 2
13 4
10,0 B

1,5 B
3

11 25

1,0 B
1,5 B
1,0 R
5
1,0 R/B
7

84176554 -- 03--2008
 54 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

-- SIDE LIGHTS, MAIN AND DIPPED HEADLIGHTS, PARKING LIGHT CIRCUIT

1-- Instrument panel
2-- Starter switch
3-- Turn signal switch
4-- Hazard warning lights indicator sending unit
5-- Fuse Box
6-- Low Beam Relay
7-- High beam relay
11-- Battery
12-- Starter
13-- Alternator
20-- Right front parking and turn signal lights
21-- Rear left parking,turn signal and stop lights
25-- Trailer plug
26-- Number plate lamp
33-- Lighter
34-- Rear right parking,turn signal and stop lights
35-- Main Fuse
56-- Front left signal and park lights
A-- Main and chassis harness connector
C-- Main and headlamp connector
D-- Main and right front signal connector
E-- Main and left connector
F-- Chassis and rear right indicator connector
G-- Chassis and rear left indicator connector

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 55

CONNECTOR OVERVIEW
0,5 G/B
--
-- 2
0,5 G/U
0,5 B
0,5 LG/Y
1 6N
0,5 LG/R
0,5 G/R 6 Y/W
0,5 R/W 2,5 N/U
0,5 U/W 1,5 R
2,5 W/Y
1,5 U

0,5 U
0,5 G/W
0,5 B/S
--
0,5 W/N
0,5 N/Y
0,5 W/B
0,5 G
0,5 R/K
--

1 G/R
1 G/W
3
1,5 U

1 S/B
1 P/B
1,5 G/B
1,5 S
1Y
1 TQ

1 W/G

1 W/S
1 TQ/B
1 W/B
1P 1,5 S

1 P/B

1,5 LG/N

1P

84176554 -- 03--2008
 56 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

CONNECTOR OVERVIEW

-- 4

16 N

2,5 W/R 12
1,5 O
1G
1,5 P
0,5 R/B
1B
1,5 LG/N
1 G/R
1 G/W

21

1 G/W 1 R/B

1 G/R
1R
1B

1B 1 G/P

25 1,5 B 32
1 LN/R
1 R/B
1R

1U/R

1 G/P
1 LN/W 1U/W 1B
--

84176554 -- 03--2008
 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 57

CONNECTOR OVERVIEW

33

34
1.5 P
1,5 R
0,5 R 1 G/N
1.5 B
1R

1 G/W

E 1B
1 G/P

1 G/W

1 R/B

1B

1 G/W

1,5 G

1 P/G

0,5 G/B

0,5 R/K

1 G/R

1,5 R
1 R/B

2B

0,5 W/B

84176554 -- 03--2008
58 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

CONNECTOR OVERVIEW

1,5 R
1 G/W
1 G/P
1 B

1 R/B
1 G/R
1 G/P
1 B

1,5 U/W 2,0 U/W

1,0 P/N
2 B
1,5 U/R 2,0 U/R

84176554 -- 03--2008
 SECTION 90 -- CAB -- CHAPTER 1 1

SECTION 90 -- CAB

Chapter 1 -- Removing parts

CONTENTS
Section Description Page

90 000 Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CONTROL LEVERS, SEAT,

ELECTRICAL CONTROLS
Disassembly--Assembly
(Op. 90 160 43--90 160 42--90 120 10) 1

1. Disconnect the negative cable from the battery.

TRE0247A

2. Take out the four securing screws (1) and re-

1
move the covering of the control panel (2). 3
3. Disconnect the electrical connector from the cab
interior light switches (3) and remove the cover.

4. Remove the LH panel retaining screws (1).

84176554 -- 03--2008
2 SECTION 90 -- CAB -- CHAPTER 1

5. Remove the three LH panel retaining screws (1).

TRE0146A

6. Remove the screws (1) on rear panel

5
7. Remove the LH panel (1).

TRE0145A

6
8. Remove the screws (1) of the RH panel retaining
elements.
1

TRE0048A

84176554 -- 03--2008
 SECTION 90 -- CAB -- CHAPTER 1 3

9. Remove the screws (1) from the RH fenders.

TRE0147A

8
10. Remove the screws (1) from the rear panel

TRE0230A

9
11. Remove the LH panel (1).
1

TRE0145A

10
12. Remove the the hand throttle lever (1).
2265
1
3

TRE0141A

11

84176554 -- 03--2008
4 SECTION 90 -- CAB -- CHAPTER 1

13. Remove the retaining nut (1) and take out the
steering wheel.

TRE0141A

12
14. Remove the retaining bolts on the control panel
and detach the electrical connector. Remove the
tachometer and the control panel (1) 1

2
TRE0026A

13
15. Unscrew the retaining screw (2) on the side of
the instrument console (rear hood) (1).
1

TRE0150A

14
16. Remove the retaining screws (1) on top of instru-
ment console (rear hood) (2). 2

TRE0149A

15

84176554 -- 03--2008
 SECTION 90 -- CAB -- CHAPTER 1 5

17. Remove the instrument console (rear hood) (1).

TRE0148A

16
18. Remove the screws (1) securing the knobs to the
control levers and remove the knobs.

17
19. Unscrew the four screws (1) securing the lever
panel.

18
20. Unscrew the lift--o--matic switch retaining screws
(1).

19

84176554 -- 03--2008
6 SECTION 90 -- CAB -- CHAPTER 1

21. Remove remove the protective cover and the

screws (1) securing the hydraulic control lever
support (2) to the platform.

TRE0154A

20
22. Remove the screws (1) holding the auxiliary
control valve levers in place.

TRE0041A

21
23. Remove the screws securing the parking brake
support (1) to the platform. Disconnect the 2
parking brake relay and the control lever from
vertical rod.

22
24. Unscrew the screws (1) securing the shuttle
lever (2).

TRE0180A

23

84176554 -- 03--2008
 SECTION 90 -- CAB -- CHAPTER 1 7

25. Unscrew the control lever retaining screws (1)

and remove the control levers.

TRE0179A

24

26. Remove the PTO clutch lever support securing

screws (1). Disconnect the PTO control lever
from the patform.

25

27. Unscrew the retaining screws (1) from the PTO

synchronised control lever support (2).

TRE0043A

26

84176554 -- 03--2008
8 SECTION 90 -- CAB -- CHAPTER 1

28. Remove the four seat securing screws (1).

Remove the seat and the covering beneath it.

To refit, proceed as follows:

— Refit the PTO clutch lever and PTO
synchronised control lever support.
— Refit the transmission control levers.
— Refit the lift--o--matic cover, securing it to the RH
panel with the three screws.
1
— Refit the RH side panel, securing it to the cab 24838
body with the five screws.
27
— Refit the rectangular PTO cover, the yellow
pushbutton and plastic plug. Secure the cover
with the two screws.
— Refit the the lift--o--matic switch , the protective
cover and the control levers.

— Refit the instrument panel and plug in the

electrical connector.

— Secure the LH side panel with the screws

previously removed.

— Fix the RH side panel and cab light control unit

and with the securing screws. Reconnect the
electrical connector to the plug on the control
panel.

— Reinstall the driver’s seat.

— Reconnect the negative cable to the battery.

84176554 -- 03--2008
 SECTION 90 -- CAB -- CHAPTER 1 9

REAR WINDOW, HANDLE AND LOCK

Disassembly--Assembly (Op. 90 156 52)

1. Disconnect the negative cable from the battery.

2. Remove the handle (2), the seals and the

threaded pin (1).

TRE0151A

28
3. Disconnect the two gas struts at the ball and
socket joints (1).

3
2

TRE0021A

29
4. Remove the securing screws (1) fig. 30 from
the hinges and take out the cab rear
windscreen complete with frame (2) fig. 29.

5. With the cab rear windscreen removed, remove

the securing screws and the frame (2) fig. 29.

6. To refit, proceed as follows:

— Refit the complete handle unit. 1
— Refit the locating pin.
— Renew the rear window rubber seal.
24852
— Reconnect the negative cable to the battery.
30

84176554 -- 03--2008
10 SECTION 90 -- CAB -- CHAPTER 1

LOCK AND EXTERIOR HANDLE

LH DOOR
Disassembly--Assembly (Op. 90 154 30)

1. Disconnect the negative cable from the battery.

2. Unscrew the three screws (1) securing the interior

lock cover (2).

TRE0239A

31
3. Remove two screws (1) securing the interior lock
(2).

24897

32
4. Remove the exterior handle by unscrewing the
two retaining screws (1) from the inside.
1
To refit, proceed as follows:
— Refit the exterior handle.
— Fit the lock.
— Reconnect the negative cable to the battery.

24898

33

84176554 -- 03--2008
 SECTION 90 -- CAB -- CHAPTER 1 11

LH DOOR
Disassembly--Assembly (Op. 90 154 10)

1. Disconnect the negative cable from the battery. 1

TRE0247A

34

2. Remove the door closure (gas strut).

1
TRE0238A

35
3. From inside the cab, unscrew the two top screws
(1) securing the door hinge.

TRE0238B

36
4. Remove the door.

To refit, proceed as follows:

— Refit the left hand door.

— Refit the left hand pillar seal.

— Reconnect the negative cable to the battery.

TRE0001A

37

84176554 -- 03--2008
12 SECTION 90 -- CAB -- CHAPTER 1

FRONT WIPER MOTOR

Disassembly--Assembly
(Op. 90 160 60 e 55 518 52)
1
1. Disconnect the negative cable from the battery.

TRE0247A

38
2. Remove the roof securing screws.

TRE0124A

39
3. Remove the cap top cover (1) and disconnect
the electrical connection from the front wiper
1
motor.

TRE0152A

40
4. Unscrew the wiper blade retaining screw (1).
1

24917

41

84176554 -- 03--2008
 SECTION 90 -- CAB -- CHAPTER 1 13

5. Unscrew the small nut (1) securing the wiper mo-

tor unit.

24918

42
6. Unscrew the large nut and remove the wiper
motor unit (1) from top the cab.

1
To reinstall, proceed as follows:
— Refit the motor unit and secure it with the two
nuts
— Refit the wiper blade
— Reconnect the electrical connector to the motor
— Refit the cab roof lining and all the parts
previously removed.
— Reconnect the negative cable to the battery. TRE0225A

43

84176554 -- 03--2008
14 SECTION 90 -- CAB -- CHAPTER 1

CAB WINDOWS
Replacing bonded cab windows
(Op.90 154 24 -- 90 156 10 -- 90 156 14 -- 90 156 28)
Removing window

Proceed as follows.

WARNING
Handle all parts with great caution. TA6090018
Do not insert your hands or fingers between one part 44
and another.
Wear the prescribed safety clothing, including
glasses, gloves and safety footwear.

1. If possible, remove any window support blocks

present as they can restrict the action of the
cutting wire.
2. From inside the cab use a pair of pliers to push
the cutting wire (1) fig. 44 through the adhesive
(2) between the glass and the frame.
3. Thread the cutting wire (1) fig. 45 into the handle
and lock it with the screw (2). 45

4. Anchor the pointed end of the the tool into the

adhesive (see figure A). Keep the wire close to
the glass and pull on the handgrip (2) fig. 46.
5. Pull the pointed tool from the adhesive and
reposition it further along, as shown at (2). Again,
pull on the wire, making long cuts on straight
sections and short cuts around corners to avoid
breaking the glass. Repeat this operation until
the window is completely detached.
6. Use a tool with suction cups to remove the
window and place it on a suitable surface to avoid
damaging it.
46
7. Completely remove the adhesive from the
window surround, taking care not to damage the
surround.
8. Remove the adhesive from the glass using a
suitable solvent.

NOTE: When replacing a broken window, remove

the glass fragments still attached to the cab and use
a knife blade to cut the adhesive (1) fig. 47, away
from the frame. Take care not to damage the frame.

9. Clean the frame, as described in operation 7. 47

84176554 -- 03--2008
 SECTION 90 -- CAB -- CHAPTER 1 15

Refitting the window

Proceed as follows.

1. Make sure that the contact area between the

glass and the metal frame in the cab is perfectly
clean.
2. Using a clean tissue, apply the activator (VP
04604 GURIT ESSEX) around the edge of the
glass, where contact will be made with the metal
frame. Allow to dry.
3. Shake the bottle of glass primer (Betaprime 5100
GURIT ESSEX) for 60 seconds. Using the
applicator provided (1) fig. 48, apply the primer
(2) around the edge of the glass, over the top of
the dried activator. Allow to dry thoroughly.
4. Shake the bottle of metal plate primer
(Betaprime 5402 GURIT ESSEX) for 60
seconds. Using the applicator provided apply
around the metal frame, where contact will be 48
made with the glass. Allow to dry thoroughly.
5. Cut the spout of the adhesive dispenser as 60
shown in fig. 49 to obtain a bead of triangular
cross--section.
6. Apply a smooth, continuous bead of
polyurethane adhesive (Betaseal 1703 GURIT 65
ESSEX) around the edge of the glass over the
previously primed area (the cross--section of this
bead must be triangular, with a base width of 10 7.0
mm and a height of 10 mm).
3.0

NOTE: Make sure that the adhesive bead is

continuous, i.e., there are no areas where adhesive 49
is missing, otherwise water may penetrate.

7. Insert the window support blocks, if present.

8. Using a tool with suction cups, position the
window in its surround and use suitable clamps
to apply a uniform pressure to obtain a 4 mm
thickness of adhesive and ensure perfect
adhesion.

NOTE: Leave the clamps in place for 4 hours until the

adhesive has completely polymerised. To promote a
good bond, do not move the cab or the tractor during
this time.

84176554 -- 03--2008
16 SECTION 90 -- CAB -- CHAPTER 1

CAB
Disassembly--Assembly (Op. 90 150 10 )

1. Disconnect the negative cable from the battery. 1

50

2. Remove the exhaust pipe, attach lifting chains

(2) to the bonnet (1) and attach the chain to the
hoist. 2

51
3. Disconnect the electrical connection (1) of
bonnet.

52
4. Detach the gas struts (1) from the bonnet.

53

84176554 -- 03--2008
 SECTION 90 -- CAB -- CHAPTER 1 17

5. Remove the four bonnet hinge bolts (1) and lift

the bonnet clear.

54
6. Remove cab heating system hoses (1) be-
tween engine and cab. 1

55
7. Remove both control wires from fuel injection
pump by removing retaining circilip.

56
8. Drain air condition system gas and remove air con-
dition pipes (1) which are between cab and air con-
dition compressor.
1

57

84176554 -- 03--2008
18 SECTION 90 -- CAB -- CHAPTER 1

9. Drain brake fluid and remove hoses (1) which are

between main brake center and fluid tank by re-
moving clamps.

58
10. Remove steering hoses (1) from steering valve.

59
11. Remove harnes (1) which is between cab and
engine.

60
12. Remove fuel tank by loosening retaining bolts (1)
which are under the tank after drain the fuel.

NOT: If there is an expansion tank also remove the

expansion fuel tank.
1

61

84176554 -- 03--2008
 SECTION 90 -- CAB -- CHAPTER 1 19

13. Detach auxilary valves control levers (1) from the

back side of the tractor by removing retaining
pins.

62
14. Detach external lift lever connection (1) by
removing retaining pin from backside of the
tractor. 1

63
15. Detach connections of draft control (1) and posi-
tion control (2) levers.

1 2

64
16. Detach 4WD engagement lever connection (1)
which is under platform.

65

84176554 -- 03--2008
20 SECTION 90 -- CAB -- CHAPTER 1

17. Detach creeper engagement lever connection

(1) under platform.

66
18. Remove differantial lock knob (1) from platform
by removing retaining pin.

67
19. Remove transmission control levers (1) from
above the platform by loosening retaining bolts.

68
20. Remove fuel tank and transmission breather
hoses (1) from back of the cab.

69

84176554 -- 03--2008
 SECTION 90 -- CAB -- CHAPTER 1 21

21. Detach ground/engine selection lever connec-

tion (2) of PTO and electrical connections (1)
park brake lever from left back side of the cab.
1

70
22. Detach PTO cluch control wire connection (1)
from under platform left--hand side of the tractor.

71
23. Detach main cluch wire.

72
24. Detach shutle lever connection (1).

73

84176554 -- 03--2008
22 SECTION 90 -- CAB -- CHAPTER 1

25. Detach park brake wire (1) under platform.

74
26. Remove electrical connectors (1) which are con-
necting wires of lights on mudguards. Remove
plastic clamps holding electrical wires on cab
frame.

75
27. Detach brake hoses (1) which are under platform
front right--hand side.

76
28. Remove platform covering plastic retainer plate
(1) by loosening secrews.

77

84176554 -- 03--2008
 SECTION 90 -- CAB -- CHAPTER 1 23

29. Open front side of platform covering plastic (1)

by pulling it up. Remove cab front retaining nuts
(2) from both side.

1
2

78

30. Remove cab retaining studs (1) from both back

side of cab.

1
79

31. Connect a crane (1) on cab by using lifting eye

bolts and slowly rise the cab. While rising the
cab, be sure that there isn’t any connection pre-
1
venting cab to rise.

80

84176554 -- 03--2008
24 SECTION 90 -- CAB -- CHAPTER 1

To refit proceed as follows.

— Pick up the cab from the wooden base, transfer — Reconnect auxilary valves control levers from
and lower it slowly onto the tractor body, carefully the back side of the tractor by using retaining
checking there are no cables or pipes that get in pins.
the way of the engine or transmission to prevent
them getting damaged. — Mount fuel tank by tightening retaining bolts
which are under the tank. Than fill the fuel.
— Fit cab retaining studs to both back side of cab.
NOT: If there is an expansion tank also mount the ex-
— Open front side of platform covering plastic by pansion fuel tank.
pulling it up. Fit cab front retaining nuts to both
side. — Fit and reconnect harnes which is between cab
and engine.
— Fit platform covering plastic retainer plate by
tightening secrews. — Fit the steering hoses to steering valve.
— Fit brake hoses which are between main brake
— Reconnect brake hoses which are under plat- center and fluid tank by tightening clamps. Than
form front right--hand side. fill brake fluid.
— Reconnect electrical connectors which are con-
necting wires of lights on mudguards. Fit plastic — Fit the air condition pipes which are between cab
clamps holding electrical wires on cab frame. and air condition compressor. Than fill the air
condition system gas.
— Reconnect park brake wire under platform.
— Reconnect both control wires to fuel injection
— Reconnect shutle lever connection . pump by refitting retaining circilip.
— Reconnect main cluch wire. — Fit cab heating system hoses between engine
and cab.
— Reconnect PTO cluch control wire connection
from under platform left--hand side of the tractor. — Fit bonnet to tractor.
— Reconnect ground/engine selection lever con-
nection of PTO and electrical connections park — Reconnect the negative cable to the battery.
brake lever from left back side of the cab.
— Fit fuel tank and transmission breather hoses to
back of the cab.
— Fit transmission control levers to above the plat-
form by tightening retaining bolts.
— Fit differantial lock knob to platform by using re-
taining pin.
— Reconnect creeper engagement lever connec-
tion under platform.

— Reconnect 4WD engagement lever connection

which is under platform.
— Reconnect connections of draft control and posi-
tion control levers.
— Reconnect external lift lever connection and fix
it by using retaining pin from backside of the
tractor.

84176554 -- 03--2008