Professional Documents
Culture Documents
Agrokid 220
->ZKDS2102V0MD20001
Agrokid 220
->ZKDS2902V0MD20001
Agrokid 230
->ZKDS2202V0MD20001
Agrokid 230
->ZKDS3002V0MD20001
Workshop manual
CONTENTS
0 - Introduction
0.1 - Introduction
0.1.1 - Safety notes
0.1.2 - General safety rules
0.1.3 - Safety precautions for removal and refitting operations
0.1.4 - Lifting instructions
0.1.5 - Tightening torques
0.1.6 - Threadlockers, adhesives, sealants and lubricants
0.1.7 - Conversion factors
0-2
0-2
0-2
0-3
0-4
0-5
0-8
0-10
10 - Technical characteristics
10.1 - Transmission
10.1.1 - Transmission
10.1.2 - Rear PTO and Mid PTO
10.2 - Rear axle
10.2.1 - Brakes and rear axle assembly
10.3 - Front axle
10.3.1 - Front axle
10.4 - Hydraulic system
10.4.1 - Gear pump
10.4.2 - Differential lock control assembly
10.4.3 - Steering circuit
10.4.4 - Power steering valve
10.4.5 - Remote control valve
10-2
10-2
10-8
10-13
10-13
10-14
10-14
10-17
10-17
10-18
10-20
10-22
10-23
20-2
20-2
20-8
30 - Method of intervention
30.1 - B0 - Engine
30.1.1 - PREPARATION FOR DISASSEMBLY
30.1.2 - Engine - Separation from the transmission
30.1.3 - Engine
30.1.4 - Compression test
30.1.5 - engine block, crankshaft, pistons and sump
30.1.6 - Inspection of the engine monobloc
30.1.7 - Inspection of the crankshaft
30.1.8 - Fan - alternator drivebelt
30.1.9 - A/C fan - compressor drivebelt
30.1.10 - Crankshaft pulley
30.1.11 - Flywheel bearing
30.1.12 - Timing gears and flywheel
30.1.13 - Inspection of the flywheel and ring gear
30.1.14 - Inspection of the pistons, piston rings and gudgeon pins
30.1.15 - Inspection of the connecting rods
30.1.16 - Inspection of the camshaft
30-2
30-2
30-3
30-10
30-11
30-13
30-23
30-23
30-26
30-29
30-32
30-33
30-33
30-44
30-45
30-47
30-48
III
CONTENTS
30.1.17 - Inspection of the camshaft
30.1.18 - Inspection of the idler gear
30.1.19 - Inspection of the valves, valve guides and valve seats
30.1.20 - Valve clearances
30.1.21 - Inspection of the rocker arms and rocker shaft
30.1.22 - Cylinder head and valve train components
30.1.23 - Inspection of the cylinder head
30.1.24 - Inspection of the valve springs
30.1.25 - Inspection of the valve pushrods
30.1.26 - Renewal of the jets
30.1.27 - Lubrication System
30.1.28 - Inspection of the lubrication system
30.1.29 - Fuel System
30.1.30 - Inspection and adjustment of the fuel system
30.1.31 - Inspection of the fuel lift pump
30.1.32 - Injection pump
30.1.33 - Inspection of the fuel injection pump camshaft
30.1.34 - Inspection of the fuel injection pump camshaft
30.1.35 - Fuel injection nozzle
30.1.36 - Maintenance of the injector nozzles
30.1.37 - Governor
30.1.38 - Cooling system
30.1.39 - Inspection of the cooling system
30.1.40 - Engine air intake pipe
30.1.41 - Intake and exhaust systems
30.1.42 - Inspection of the air intake and exhaust system
30.2 - C0 - Engine accessories
30.2.1 - Engine cooling system radiator
30.2.2 - Expansion tank
30.2.3 - Fan
30.2.4 - Air cleaner assembly
30.2.5 - Fuel filter
30.2.6 - Fuel tank - Fuel tank float switch
30.2.7 - Auxiliary fuel tank
30.2.8 - Engine stop keyswitch
30.2.9 - Exhaust pipe - tractor with cab
30.2.10 - Engine stop keyswitch
30.2.11 - Alternator
30.2.12 - Alternator
30.2.13 - Starter motor
30.2.14 - Starter motor
30.2.15 - Disassembly of the starter motor
30.3 - D0 - Transmission
30.3.1 - Clutch plate
30.3.2 - Checking clutch plate wear
30.3.3 - Clutch release bearing
30.3.4 - Clutch release forks
30.3.5 - Clutch housing
IV
30-49
30-50
30-50
30-53
30-55
30-55
30-62
30-62
30-62
30-62
30-63
30-65
30-66
30-69
30-71
30-71
30-78
30-79
30-80
30-82
30-83
30-85
30-87
30-89
30-90
30-91
30-93
30-93
30-96
30-97
30-98
30-99
30-99
30-103
30-104
30-106
30-107
30-109
30-112
30-116
30-118
30-120
30-127
30-127
30-128
30-128
30-129
30-131
CONTENTS
30.3.6 - Disassembly of the gearbox input shaft
30.3.7 - Disassembly of the main shaft
30.3.8 - Disassembly of the secondary shaft
30.3.9 - Gearbox and shuttle assembly - complete unit
30.3.10 - Gearbox and shuttle assembly - complete unit
30.3.11 - Range gearbox and differential assembly - complete unit
30.3.12 - Gearbox input shaft - oil seal renewal
30.3.13 - Bevel gear pair
30.3.14 - Disassembly of 4WD output shaft and groundspeed PTO
30.3.15 - Creeper - synchronizer renewal
30.3.16 - PTO output shaft.
30.3.17 - Disassembly of the PTO output shaft.
30.3.18 - Removal of the PTO output shaft
30.3.19 - Parking brake
30.3.20 - Adjustment of the bevel gear pair
30.4 - E0 - Rear axle
30.4.1 - Left-hand rear axle
30.4.2 - Disassembly of LH/RH rear axle
30.4.3 - Rear differential
30.4.4 - Disassembly of the rear differential
30.4.5 - Rear axle brake discs
30.5 - F0 - Front axle
30.5.1 - Front support
30.5.2 - Front axle - complete assembly
30.5.3 - Steering cylinders
30.5.4 - Steering cylinders disassembly
30.5.5 - Steering knuckle housing and axle shaft
30.5.6 - Disassembly of the bevel gear pair
30.5.7 - Propeller shaft - Front axle drive shaft
30.5.8 - Planetary reduction gear
30.5.9 - Disassembly of the planetary reduction gear
30.6 - G0 - Bodywork - Cab - Platform
30.6.1 - Cab
30.6.2 - Hood and side panels
30.6.3 - Cab access steps
30.6.4 - Adjustable front fenders
30.6.5 - Cab door lock - tie-rod
30.6.6 - Instrument panel
30.6.7 - Left-hand rear cab pillar - screenwash reservoir
30.6.8 - Right-hand console
30.6.9 - Left-hand console
30.6.10 - Instrument panel
30.6.11 - Centre console
30.6.12 - RH rear cab pillar trim
30.6.13 - A/C system air intake filters
30.6.14 - Cab roof
30.6.15 - Seat
30.6.16 - Air conditioning system - Standard roof version
30-135
30-137
30-138
30-141
30-142
30-146
30-148
30-149
30-153
30-155
30-157
30-158
30-158
30-160
30-162
30-166
30-166
30-168
30-172
30-175
30-176
30-178
30-178
30-182
30-184
30-186
30-188
30-190
30-198
30-199
30-200
30-205
30-205
30-212
30-216
30-217
30-217
30-219
30-220
30-221
30-222
30-223
30-224
30-225
30-225
30-226
30-230
30-231
V
CONTENTS
30.6.17 - Air conditioning compressor
30.6.18 - Condenser
30.6.19 - Receiver-dryer
30.6.20 - Evaporator assembly
30.6.21 - Air conditioner fan
30.6.22 - Bistable pressure switch for compressor clutch engagement/disengagement
30.6.23 - Steering wheel
30.6.24 - Adjustment of the lift control valve levers
30.6.25 - Remote valve control levers
30.7 - H0 - Hydraulic system
30.7.1 - Pump for hydraulic lift and auxiliary services and power steering system
30.7.2 - Transmission oil filter assembly
30.7.3 - Power steering valve - Complete assembly
30.7.4 - Power steering disassembly
30.7.5 - Pressure relief valve - lift control valve
30.7.6 - Lift locking shut-off valve
30.7.7 - Remote control valve
30.7.8 - Remote control valve
30.7.9 - Control rods
30.7.10 - Double/single acting conversion valve
30.8 - L0 - Electrical system
30.8.1 - Battery
30.8.2 - Fuse and relay assembly
30.8.3 - Electrostatic unit
30.8.4 - Parking brake switch
30.8.5 - Adjustment of the parking brake switch
30.8.6 - Brake lights switches
30.8.7 - Adjustment of the brake light switches
30.8.8 - Steering column switch
30.8.9 - Control buttons - RH console
30.9 - M0 - Front PTO
30.9.1 - Pump - clutch assembly - brake
30.9.2 - PTO output shaft
30.9.3 - Solenoid valve
30.10 - N0 - Front lift
30.10.1 - Front lift - version with front PTO -
30.10.2 - Cylinder
30.11 - R0 - Rear lift
30.11.1 - Rear lift - complete assembly
30.11.2 - Rear lift - complete assembly
30.11.3 - Adjustment of the rear lift
30.11.4 - Lift cylinders
30.11.5 - Lift cylinders
30.11.6 - Renewal of the rear lift bush
30.11.7 - Lift arms
30.11.8 - Hydraulic lift control valve
30.11.9 - Disassembly of the lift control valve
VI
30-233
30-235
30-236
30-237
30-238
30-239
30-240
30-241
30-243
30-244
30-244
30-245
30-246
30-248
30-260
30-261
30-262
30-262
30-264
30-265
30-267
30-267
30-268
30-269
30-270
30-271
30-272
30-273
30-273
30-273
30-276
30-276
30-279
30-281
30-283
30-283
30-285
30-287
30-287
30-289
30-294
30-296
30-297
30-298
30-299
30-301
30-302
CONTENTS
30.11.10 - Three-point linkage with mechanical adjustment
30.12 - S0 - Wheels
30.12.1 - Front wheels
30.12.2 - Rear wheels
30.13 - V0 - Ballast - towing hitches
30.13.1 - Support and towing hitch
30-307
30-309
30-309
30-309
30-310
30-310
40 - Wiring diagrams
40.1 - Introduction
40.1.1 - Structure of the unit
40.1.2 - Wiring and components index
40.1.3 - Introduction
40.1.4 - Basic electronics for mechanics (1/2)
40.1.5 - Basic electronics for mechanics (2/2)
40.1.6 - Electrical and electronic components (1/2)
40.1.7 - Electrical and electronic components (2/2)
40.2 - Components
40.2.1 - Components
40.3 - Systems
40.3.1 - Earthing points
40.3.2 - Starting
40.3.3 - Control unit - Fan
40.3.4 - Steering column lights switch
40.3.5 - Instrument panel
40.3.6 - Cab
40.3.7 - Aereo cab
40.3.8 - PTO
40.3.9 - Front axle differential lock
40.3.10 - Brakes
40.4 - Wiring harnesses
40.4.1 - Wiring harnesses
40.4.2 - Positions of front wiring connectors
40.4.3 - Front PTO wiring - 0.014.2645.4
40.4.4 - Positions of front PTO wiring connectors.
40.4.5 - Front lights wiring - 0.014.7599.4
40.4.6 - Positions of front light wiring connectors
40.4.7 - Compressor wiring - 0.014.7601.4
40.4.8 - Positions of compressor wiring connectors
40.4.9 - Front wiring with cab
40.4.10 - Positions of front wiring connectors with cab
40.4.11 - Central wiring - 0.012.6949.4
40.4.12 - Positions of central wiring connectors
40.4.13 - Solenoid valve wiring - 0.014.1482.4
40.4.14 - Positions of solenoid valve wiring connectors
40.4.15 - Rear wiring - 0.013.1452.4/10
40.4.16 - Positions of rear wiring connectors
40.4.17 - Remote valve wiring - 0.012.6955.4
40-2
40-2
40-6
40-6
40-9
40-11
40-18
40-26
40-31
40-31
40-35
40-35
40-37
40-39
40-40
40-43
40-45
40-48
40-51
40-53
40-55
40-57
40-57
40-58
40-61
40-61
40-63
40-64
40-65
40-65
40-66
40-68
40-71
40-75
40-80
40-81
40-82
40-84
40-86
VII
CONTENTS
40.4.18 - Rear lights wiring - 0.014.7602.4
40.4.19 - Positions of rear light wiring connectors
40.4.20 - Aereo cab wiring - 0.014.7593.4
40.4.21 - Positions of aereo-cab wiring connectors
40.4.22 - Cab power supply - 0.014.7594.4
40.4.23 - Positions of cab power supply wiring connectors
40.4.24 - Air conditioning system - 0.014.7596.4
40.4.25 - Position of air conditioner wiring connectors
40.4.26 - Cab earth wiring - 0.015.0031.4
40.4.27 - Positions of cab earth wiring connectors
40.4.28 - Worklights-number plate light- flashing light - 0.014.7595.4
40.4.29 - Positions of worklight, number plate and flashing light wiring connectors
40.4.30 - Flashing light wiring - 0.014.7591.4
40.4.31 - Positions of flashing light wiring connectors
40.4.32 - Windscreen wipers - 0.014.7598.4
40.4.33 - Positions of windscreen wiper wiring connectors
40.4.34 - Radio wiring - 0.014.7600.4
40.4.35 - Positions of radio-loudspeaker wiring connectors
VIII
40-86
40-87
40-89
40-91
40-92
40-93
40-94
40-95
40-96
40-97
40-98
40-99
40-101
40-101
40-102
40-103
40-104
40-105
0 - Introduction
0-1
Introduction
0.1 - Introduction
The purpose of this workshop manual is to provide instruction for repair technicians and a practical guide to improving the quality
of repairs. This manual enables repair technicians to acquire a thorough knowledge of the machine, indicating the correct methods
for fault diagnosis, for working in safety and for accurate dimensional checks and visual inspections. The instructions also indicate
the products to use, the tightening torques and the adjustment data. The technical material contained in this manual is reserved to
Authorised Dealers and Service Centres who will be duly informed of any technical changes to the machines in question through the
issue of documents regarding modifications, updates and supplements for optional equipment. All technicians and their colleagues
are expressly forbidden from reproducing any part of this manual in any form or from communicating the contents to third parties
without the express written permission of the Manufacturer, who remains the sole owner of this document with all rights reserved in
accordance with applicable laws.
To ensure that machines entrusted to Authorised Service Centres for repair or overhaul continue to function correctly, it is very important that all repair work is carried out in the prescribed manner. The procedures for checks and repairs indicated in this manual are
safe and effective. Some of the operations described require the use of special tools and equipment; these tools have been specifally
designed for the intended purpose and may be ordered directly from the Manufacturers. DO NOT USE MAKESHIFT TOOLS; not
only is there a risk of personal injury, but such tools are rarely suited to the purpose for which they are used. In potentially hazardous
situations, always give priority to personal safety and take the necessary actions to eliminate the danger
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0-2
Even if you have a thorough knowledge of the machine as regards its components, operation and controls, always take special care when carrying out the following operations; Remember that the machine you are working on is in need of repair or
overhaul and consequently may not always behave as expected.
Before starting work, clean the tractor thoroughly to remove all mud, dust and road dirt. Also clean the cab to remove all traces
of oil, snow and ice from the access steps and grab rails.
When climbing up to or down from the cab, always ensure you maintain three points of contact at a time (foot or handholds)
in order to keep your balance and prevent accidental falls.
Always take special care when carrying out fault diagnosis operations; these operations often require two persons, who must
never stand in front of the wheels when the engine is running.
When carrying out checks and repairs, wear close-fitting clothing, safety goggles and protective gloves that are suitable for
the task (cleaning, draining fluids, repairs). When working near moving parts, long hair should be gathered up and tied back
safely under a cap to prevent the risk of entanglement and severe injury.
Do not allow anyone who is not directly involved in the work to come near the tractor; ensure that they remain at a safe distance.
Keep well clear of moving parts; when the engine is running, some moving parts are not easily visible and therefore present a
risk of entanglement, even if protected by safety guards.
Ensure that the area is well ventilated before starting the engine in order to avoid the formation of dangerous concentrations
of toxic gases; always connect suitable fume extraction equipment to the exhaust pipe.
Do not start the engine with the safety guards removed under any circumstances; all repair and adjustment operations must
be carried out with the engine stopped.
Do not top up fuel, oil or coolant levels when the engine is running.
Never smoke and ensure there are no naked flames nearby when topping up fuel or oil. Always remove the battery from the
machine before recharging.
Before checking or removing the battery, stop the engine and remove the key from the starter switch.
Remove the battery and recharge in a well-ventilated area where the temperature exceeds 0C.
When checking or recharging the battery, do not smoke or allow naked flames in the vicinity as the hydrogen gas given off by
the battery is highly explosive.
The liquid (electrolyte) contained in the battery is very harmful if it comes into contact with the skin and the eyes; for this reason, always wear gloves and safety goggles with side shields when checking or topping up the battery. Should any electrolyte
accidentally come into contact with your skin, wash the affected areas immediately with plenty of fresh water; if electrolyte
comes into contact with your clothing, this should be removed as soon as possible. In case of accidental ingestion of electrolyte, drink copious amounts of water, milk or vegetable oil and take antacids such as magnesium, bicarbonate, etc. and seek
medical attention immediately.
Before working on the electrical systems, always disconnect the battery terminals.
Introduction
DANGER
Always disconnect the negative lead (--) before the positive lead (+); when re-connecting the battery on completion of
the work, first connect the positive terminal (+) and then the negative (--).
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Before carrying out any arc welding (permitted only on implements attached to the machine) always disconnect the battery
terminals and unplug all the connectors of the electronic control units and the alternator.
When topping up lubricants, always wear suitable protective gloves.
Do not wear clothing contaminated by engine or hydraulic oil; prolonged contact with the skin can be harmful and may cause
allergic reactions.
Used engine oil and hydraulic oil must be disposed of properly; recover used lubricants and dispose of them in accordance
with the applicable regulations.
Before carrying out any work on the hydraulic or pneumatic systems, discharge all residual pressure from the circuits.
Before carrying out any work on the hydraulic system or engine, allow the oil and engine coolant to cool down.
When removing and refitting certain assemblies, it will be necessary to support the tractor; use stands, jacks or blocks capable
of supporting the weight and arrange them in a triangular pattern to prevent the machine from overturning.
To lift heavy components, use a hoist or crane. Check that wire ropes, chains or fibre slings are not worn and that hooks are
not damaged.
Always use lifting equipment of suitable capacity for the weight of the components to be removed. Ensure lifting equipment is
attached correctly.
When lifting or supporting an assembly or component, manoeuvre the parts slowly and carefully to avoid swinging movements
or collision with other components.
Never work on components suspended from a hoist or crane.
When removing the retaining bolts of a component that could fall, always leave two opposing bolts in place for safety; before
removing these last two bolts, attach the component to suitable lifting equipment or position support blocks.
Any oil or fuel spilled during removal or dismantling operations should be cleaned up as soon as possible to prevent the risk
of slipping and fire.
When refitting electrical wiring looms and wires, ensure that they are properly secured with their original retaining straps or
brackets to prevent the possibility of damage caused by vibration.
Never insert your fingers or hands to check the alignment between fixing holes in components; always use a suitable dowel
of soft material.
When refitting assemblies or components, always use the specified tightening torques; the tightening torques indicated in the
paragraphs regarding assembly/refitting operations have been determined through experimentation and must be scrupulously
adhered to.
When refitting parts that are subject to vibration or that rotate at high speed, take particular care when carrying out final installation checks.
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Unless otherwise indicated, lower the lifting equipment until it the component or assembly rests on the ground.
After disconnecting hydraulic and fuel system pipes, always fit plugs to the open ends of the pipes to prevent ingress of dirt.
Before removing a cylinder, fully retract the piston and secure it in this position using a retaining strap.
Use containers of sufficient capacity when draining oil, coolant or fuel.
Before removing a part from the machine, check for alignment markings indicating the correct assembly position. If necessary,
make new markings to ensure correct assembly.
When unplugging electrical connectors, always grip the connectors firmly to avoid pulling on the wires.
Where necessary, label wires and pipes before removal to avoid confusion when reconnecting.
Check the number and thickness of any shims removed and keep them together in a safe place.
To lift the tractor or any of its main components, use lifting equipment of suitable capacity.
When using eyebolts for lifting components, first check that they are not deformed or damaged; screw them fully home and
then turn the bolt so that the eye is aligned with the lifting hook.
Before removing a part, clean the surrounding area and, after removing the part, cover it to protect it from dirt and dust.
0-3
Introduction
Precautions for refitting operations
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If coolant has been drained from the engine, refit the drain plug and pour in new coolant to the correct level. Start the engine
to circulate the coolant and then check the level again and top up.
After removing hydraulic components, top up the hydraulic oil to the specified level. Start the engine to circulate the oil in the
hydraulic circuits and then recheck the level and top up as necessary.
After having removed a variable displacement pump, connect the drain pipe and fill the pump casing with oil through the filler
hole provided.
Grease stub axle housings, cylinder pivot mountings and drive shafts thoroughly after assembly.
Use wire ropes or polyester slings of suitable capacity for the parts to be lifted, referring to the following tables:
Table 1
WIRE ROPES (standard twisted S or Z type)
rope mm Capacity (kg)
8
10
12
14
16
18
25
50
62
75
100
150
650
1000
1450
2000
2600
3300
620
1740
2500
3460
4500
5710
500
1420
2050
2820
3670
4660
500
1000
1250
1400
2000
2500
400
800
1000
1120
1600
2000
860
1730
2160
2420
3460
4330
700
1410
1760
1980
2820
3530
0-4
The lifting hook should be attached to the central part of the rope or sling; if the hook is attached near the ends of the rope/
sling, this could cause the load to slip during lifting.
Never lift a heavy load using a single rope; always use two or more symmetrically arranged ropes.
Introduction
DANGER
Suspension of a load from a single rope could cause the load to start rotating and consequently cause the rope
strands to untwist or the load to slip; this could lead to serious injury.
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Never lift a heavy load when the two legs of the ropes form a wide angle. the permitted load (kg) decreases in inverse proportion to the angle of suspension; the table below indicates how the permitted load varies according to the angle of suspension
for two 10 mm ropes each with a load capacity of 1000 kg.
Fig. 1
DANGER
The tightening torques for certain specific components and special tightening methods are indicated in the relative
assembly paragraphs.
The tightening torques indicated below refer to screws and nuts assembled without lubrication and, where applicable, with anaerobic
threadlocking compound. the values apply to tightening on steel or cast iron components; for soft materials such as aluminium, copper, plastic, sheet metal or panels, the indicated tightening torques must be reduced by 50%.
Table 2
BOLT SIZE
M6x1
M8x1.25
M10x1.5
M12x1.75
M14x2
M16x2
M18x2.5
M20x2.5
M22x2.5
M24x3
M27x3
BOLT CLASS
8.8
Nm
8.0 8.8
19.4 21.4
38.4 42.4
66.5 73.5
106 117
164 182
228 252
321 355
441 487
553 611
816 902
lb.ft.
5.9 6.5
14.3 15.8
28.3 31.2
49.0 54.2
78.1 86.2
120.9 134.1
168.0 185.7
236.6 261.6
325.0 358.9
407.6 450.3
601.4 664.8
10.9
Nm
11.8 13.0
28.5 31.5
56.4 62.4
96.9 107
156 172
241 267
334 370
472 522
647 715
812 898
1198 1324
lb.ft.
8.7 9.6
21.0 23.2
41.6 46.0
71.4 78.9
115.0 126.8
117.6 196.8
246.2 272.7
347.9 384.7
476.8 527.0
598.4 661.8
882.9 975.8
12.9
Nm
13.8 15.2
33.3 36.9
67.4 74.4
115 128
184 204
282 312
391 432
553 611
751 830
950 1050
1419 1569
lb.ft.
10.2 11.2
24.5 27.2
49.7 54.8
84.8 94.3
135.6 150.3
207.8 229.9
288.2 318.4
407.6 450.3
553.5 611.7
700.2 773.9
1045.8 1156.4
0-5
Introduction
FINE
M8x1
M10x1.25
M12x1.25
M12x1.5
M14x1.5
M16x1.5
M18x1.5
M20x1.5
M22x1.5
M24x2
20.8 23.0
40.6 44.8
72.2 79.8
69.4 76.7
114 126
175 194
256 282
355 393
482 532
602 666
15.3 17.0
29.9 33.0
53.2 58.8
51.1 56.5
84.0 92.9
129 143
188.7 207.8
261.6 289.6
355.2 392.1
443.7 490.8
30.6 33.8
59.7 65.9
106 118
102 112
168 186
257 285
375 415
523 578
708 782
884 978
22.6 24.9
44.0 48.6
78.1 87.0
75.2 82.5
123.8 137.1
189.4 210.0
276.4 305.9
385.5 426.0
521.8 576.3
651.5 720.8
35.8 39.6
71.2 78.6
126 140
121 134
199 220
301 333
439 485
611 676
821 908
1035 1143
26.4 29.2
52.5 57.9
92.9 103.2
89.2 98.8
146.7 162.1
221.8 245.4
323.5 357.4
450.3 498.2
605.1 669.2
762.8 842.4
Fittings
The tightening torques indicated below refer to fittings assembled on any material.
Table 3
METRIC
17
19
19
19
22
24
27
30
36
36
41
50
60
17
19
19
22
24
27
30
36
41
46
50
60
T end fittings
Torque Nm Wrench
10%
14
14
14
17
30
17
40
19
48
22
58
24
65
27
73
30
95
36
100
36
160
41
250
50
305
60
13
14
13
37
19
37
53
24
73
27
73
100
36
160
41
160
250
50
305
60
L end fittings
90 end fittings
Torque Nm Wrench
10%
14
14
14
17
30
17
40
19
48
22
58
24
65
27
73
30
95
36
100
36
160
41
250
50
305
60
13
14
Torque Nm Wrench
10%
14
14
14
30
17
40
19
48
22
58
24
65
27
73
30
95
36
100
36
160
41
250
50
305
60
13
14
Torque Nm
10%
14
30
40
48
58
65
73
95
100
160
250
305
13
37
19
37
19
37
53
73
24
27
53
73
24
27
53
73
100
160
36
41
100
160
36
41
100
160
250
305
50
60
250
305
50
60
250
305
Plugs
Table 4
Hex plugs
Thread size
0-6
Wrench
Torque Nm 10%
Wrench
Torque Nm 10%
Introduction
METRIC
M6x1
M8x1
M10x1
M10x1.25
M10x1.5
M12x1.25
M12x1.5
M12x1.75
M14x1.5
M14x2
M16x1.5
M16x2
M18x1.5
M18x2.5
M20x1.5
M22x1.5
M24x1.5
M24x2
M27x2
M28x1.5
M30x1.5
M32x1.5
M35x1.5
M40x1.5
G 1/8
G 1/4
G 3/8
G 1/2
G 5/8
G 3/4
G 1
10
13
13
13
13
17
17
17
19
19
22
22
17
17
19
22
22
22
22
14
19
22
19
22
22
22
10
12
14
14
14
30
30
30
40
40
48
48
58
58
65
80
80
100
130
13
37
53
73
85
100
160
10
12
12
17
19
22
24
14
30
40
48
58
73
80
110
150
180
225
Thread size
7/16 - 20
1/2 - 20
9/16 - 18
3/4 - 16
7/8 - 14
1 1/16 - 12
1 3/16 - 12
1 5/16 - 12
1 5/8 - 12
1 7/8 - 12
2 1/2 - 12
Wrench
14
16
17
22
27
32
36
36
38
50
60
75
Torque Nm 10%
13
19
28
47
76
110
110
138
155
215
290
345
0-7
Introduction
Fittings for pipes with banjo union
These tightening torques refer to tightening the fitting with new copper sealing washers.
Table 6
Unions for one-way fittings
Thread size
Wrench
M8x1
M8x1.25
M10x1
M10x1.25
M12x1.25
M12x1.5
M14x1.5
M16x1.5
M18x1.5
M20x1.5
M22x1.5
M24x1.5
M26x1.5
M28x1.5
M30x1.5
M35x2
M38x1.5
M42x2
M45x1.5
M50x2
M52x1.5
M65x2
13
13
17
19
22
22
27
32
36
41
50
60
Torque
10%
14
20
30
40
48
58
65
80
110
180
250
320
Nm Wrench
12
Torque
10%
14
14
17
19
22
24
27
32
36
46
55
60
75
20
30
40
48
58
73
95
130
200
280
320
450
Nm Wrench
Torque
10%
14
17
19
22
24
27
32
36
46
55
60
75
20
30
40
48
58
73
95
130
200
280
320
450
Nm
FUNCTION
THREADLOCKER
0-8
NAME
DESCRIPTION
Loctite 222 Colour: opaque fluorescent Anaerobic product suitable for low-strength locking of retaining,
purple
adjustment and precision fasteners. All traces of lubricant must
first be removed using the specific activator.
Loctite 242 Colour: fluorescent blue
Anaerobic product that prevents loosening of all types of nut and
bolt; used in place of conventional mechanical locking systems.
Used for medium-strength locking. All traces of lubricant must
first be removed using the specific activator.
Loctite 243 Colour: opaque fluorescent Alternative product to 242 ; oil tolerant and so can be used on
blue
lightly lubricated surfaces without prior use of activator.
Loctite 270 Colour: fluorescent green
Anaerobic product for high-strength locking of bolts and studs
that do not normally require disassembly. Parts must be heated
to approximately 80C for removal. All traces of lubricant must
first be removed using the specific activator.
Introduction
DEGREASERS
Loctite 703
AND ACTIVATORS
SEALANTS
(for
faces and fittings)
INSTANT
SIVES
ADHE-
SEALANTS
CONE
SILI-
SEALANTS
URETHANE
POL-
Product used for degreasing and cleaning parts prior to application of Loctite anaerobic products; after drying, promotes uniform
curing of threadlockers
Loctite 747
Product used specifically for treatment of passive metals prior to
use of slow-cure anaerobic threadlockers (series 5 and 6). Can
also be used to increase cure speed at low temperatures or in applications where there are large gaps between the parts.
Loctite 510 Colour: red
Super-rapid anaerobic sealant for sealing between rigid metal
faces; can eliminate the need for conventional gaskets as it can
fill gaps up to 0.4 mm. Does not shrink and therefore fasteners
do not need re-tightening to specified torque values after curing.
Loctite 542 Colour: Brown
Anaerobic product used as a liquid sealant for threaded fittings
up to 3/4 gas; rapid curing and parts may be disassembled with
ordinary tools.
Loctite 554 Colour: red
Anaerobic sealant and locking compound used for sealing cooling and industrial fluid circuits. Slow curing, also suitable for use
on non-ferrous alloys
Loctite 572 Colour: White
Anaerobic sealant and locking compound used for sealing pipes
and threaded fittings up to 2 in diameter. Very slow curing on
most metal surfaces.
Loctite 573 Colour: green
Thixotropic anaerobic product used for sealing joints between
metal faces. Ensures total contact between surfaces with maximum tolerance of 0.10 mm, filling microvoids caused by flatness
errors. Very slow curing on most metal surfaces and requires
prior application of an activator.
Loctite 576 Colour: brown
Anaerobic product used as a liquid thread sealant for large diameter threaded fittings (up to 2). Very slow curing; also suitable for
non-ferrous alloys and parts requiring subsequent removal.
Loctite 401 Colour: colourless
Cyanoacrylate instant adhesive suitable for bonding a wide range
of acidic and porous materials including, ceramics, wood, rubber and plastic (excluding polyolefin). Curing takes place in a few
seconds as an effect of the condensed humidity present on the
surfaces to be bonded, and is independent of environmental conditions.
Loctite 495 Colour: colourless
Cyanoacrylate instant adhesive suitable for bonding a rubber,
plastics and metal in any combination.
Silastic 738 (Dow Corning) Colour: milky One-part silicone adhesive/sealant, non dhrinking, ready for use.
white
Cures on exposure to air to form a rubbery solid and obviates the
need for conventional seals on flexible joints, filling gaps greater
than 1 mm.
Dirko Transparent Colour: transparent
One-part silicone adhesive/sealant, shrinking, ready for use.
Cures rapidly when exposed to humidity in the air to form a rubbery solid; resistant to high temperatures.
Betaseal HV3 (Gurit Essex) Colour: black Polyurethane prepolymer based adhesive/sealant, high viscosity,
suitable for permanent, high-strength flexible bonding. Slow curing, used for bonding glass to frames, wire mesh, metal plates,
etc. surfaces must be degreased with primer.
0-9
Introduction
RETAINING COM- Loctite 601 Colour: fluorescent green
POUNDS
LUBRICANTS
Anaerobic, fast-curing, high-strength adhesive. Suitable for sealing and retaining cylindrical assemblies with gap clearances of
up to 0.10 mm; used for retaining rotors, gears, bearings, pulleys,
bushes etc. on shafts.
Loctite 638 Colour: fluorescent green
Anaerobic structural adhesive, quick-curing, very high strength;
suitable for bonding cylindrical parts in non-ferrous alloys.
Loctite 648 Colour: fluorescent green
Anaerobic structural adhesive, quick-curing, high-strength; suitable for bonding cylindrical parts, permanent retention of threaded parts, sealing of refrigeration systems, retention of bearings,
etc. Alternative to Loctite 601 in high-temperature applications.
Loctite 986/AVX Colour: Fluorescent red Anaerobic sealant/retaining compound for metal cylindrical parts.
Slow-curing, high-strength, heat-resistant and resistant to chemical attack. Parts must be first treated with an activator.
Grease (NLGI 2 EP ASTM D217: 265/295) Multi-purpose Lithium grease used for lubrication of seals, to prevent oxidization and to facilitate assembly operations.
Molikote (Dow Corning)
Anti-wear compound, contains Molybdenum bisulphate, used
neat or diluted with engine oil for assembly of main engine bearings.
Vaseline
Neutral pH compound used to protect battery terminals against
oxidization and corrosion.
Engine oil 10W - 30
Used to dilute Molikote anti-wear lubricant during assembly of
main engine bearings.
Table 8
inch x 25.40
foot x 0.305
yard x 0.914
Eng.miles x 1.609
Sq.in. x 6.452
Sq.ft. x 0.093
Sq.yard x 0.835
Cu.in. x 16.39
Cu.ft. x 28.36
Cu.yard x 0.763
Imp.gall. x 4.547
US gall. x 3.785
pint x 0.568
quart x 1.137
US.gpm x 3.785
oz. x 0.028
lb. x 0.454
lb.ft. x 0.139
lb.in. x 17.87
psi x 0.070
lb./Imp.gall x 0.100
lb./US.gall x 0.120
lb./cu.ft. x 16.21
lb.ft. x 1.356
psi x 1.379
= mm
=m
= km
= cm
= m
= cm
= m
= litres
= ,/min
= kg
= kgm
= kg/m
= kg/cm
= kg/,
= kg/m
= Nm
= bar
Table 9
mm x 0.0394
m x 3.281
m x 1,094
km x 0.622
cm x 0.155
m x 10.77
0-10
= inch
= foot
= yard
= Brit.miles
= Sq.in.
= Sq.ft.
Introduction
m x 1.197
cm x 0.061
m x 0.035
m x 1.311
litres x 0.220
litres x 0.264
litres x 1.762
litres x 0.880
,/min x 0.2642
kg x 35.25
kg x 2.203
kgm x 7.233
kg/m x 0.056
kg/cm x 14.22
kg/, x 10.00
kg/, x 8.333
kg/m x 0.062
Nm x 0.737
bar x 14.503
= Sq.yard
= Cu.in.
= Cu.ft
= Cu.yard
= Imp.gall.
= US gall.
= pint
= quart
= US.gpm
= oz.
= lb.
= lb.ft.
= lb.in.
= psi
= lb./Imp.gal.
= lb./US.gal.
= lb./cu.ft.
= lb.ft.
= psi
0-11
Introduction
0-12
10 - Technical
characteristics
10-1
Technical characteristics
10.1 - Transmission
10.1.1 - Transmission
Introduction
l
The tractor in this series are equipped with a 4-speed transmission with forward/reverse shuttle and three speed ranges. The
main gearbox and the forward/reverse shuttle are synchronised, while the 3-speed range gearbox is not synchronised.
The rear transmission casing also houses the drive train for the rear PTO, which is supplied in a single version (540-1000-groundspeed). The rear PTO is of the mechanical type with non-synchronised gears. The PTO can also be supplied with a midmounted output shaft that is only enabled when the 1000 rpm PTO speed is selected.
Clutch housing
Shuttle gearbox assembly
Range gearbox and differential assembly
Rear PTO
Mid PTO
Description
l
10-2
The transmission receives drive from the engine and transmits it through the dual clutch assembly (1) (main drive clutch (1a)
and rear PTO clutch (1b)), the main gearbox (3), the shuttle (2) and the range gearbox (4) to the bevel drive gears (5). Drive is
then transmitted to the final drive units (6) which mount the brake assemblies providing both service brake and parking brake
functions.
Technical characteristics
Drive transmission
Fig. 4 - 1st gear, forward drive and high range (H) selected
10-3
Technical characteristics
Fig. 5 - 1st gear, reverse drive and low range (L) selected
Fig. 6 - 3rd gear, forward drive and medium range (M) selected
10-4
Technical characteristics
Clutch housing
Flywheel
Rear PTO clutch plate
Main clutch plate
Rear PTO clutch sleeve
Main clutch sleeve
Sleeves support
Main clutch release fork return spring
PTO clutch release bearing
PTO clutch thrust plate
Main clutch thrust bearing
Main clutch control fork
Main clutch control shaft
PTO clutch release fork
PTO clutch control shaft
PTO clutch release forks return spring
10-5
Technical characteristics
Gearbox and shuttle assembly
10-6
Technical characteristics
4WD - Range gears assembly
Secondary shaft
Driven gear
L and M range driving shaft
Pinion
Groundspeed PTO driving gear
Groundspeed PTO drive shaft
4WD driven gear
4WD engagement sleeve
4WD output shaft
L and M range driven gear
4WD drive gear
4WD engagement control shaft
Bush
Shoe
2nd speed driven gear
1st speed driven gear
1st speed synchronizer
10-7
Technical characteristics
Pinion and differential assembly
Pinion
Nut
4WD drive gear
Pinion bearing
Differential lock sleeve
Differential carrier
Differential crown wheel
Planet gear
Side gear
Differential housing
The mid PTO rotation speed is selected via the rear PTO speed selection lever and the drive is taken directly from the rear PTO
driven gear.
10-8
Technical characteristics
540 PTO
10-9
Technical characteristics
540-750 PTO
10-10
Technical characteristics
540-750 PTO and Mid PTO dt1
10-11
Technical characteristics
540-750 PTO and Mid PTO dt2
10-12
Technical characteristics
10.2 - Rear axle
Drive shaft
Driven gear
Axle shaft
Final drive housing
Steel disc
Braking device
Friction discs
Gaiter
10-13
Technical characteristics
10.3 - Front axle
10.3.1 - Front axle
Version
Toe-in (X-Y)
55 HP
45 HP
35 HP
Standard
Standard
Standard
Narrow
1200
1050
1050
1016
+0/-2
+0/-2
+0/-2
+0/-2
10-14
Maximum steering
angle (Z)
max. 57
max 57
max 57
max 50
Technical characteristics
Steering cylinder
Axle shaft
Input bevel gear pair
Hub support
Oil seal
Axle casing
10-15
Technical characteristics
10-16
Flange
Output bevel gear pair
Steering knuckle housing
Shaft
Spacer
Differential lock engagement fork
Differential lock engagement piston
Pinion
Spacer
Differential carrier
Side gear
Planet gear
Differential crown wheel
Differential lock engagement sleeve
Lever return spring
Shoe
Technical characteristics
10.4 - Hydraulic system
10.4.1 - Gear pump
Displacement
Maximum operating pressure
Maximum flow rate
Pump A
11 cc/rev
180 bar
33.0 l/min.
Pump B
5.5 cc/rev
100 bar
16.5 l/min.
Notes
10-17
Technical characteristics
10.4.2 - Differential lock control assembly
10-18
P -Supply to assembly
L - Lubrication of gearbox/shuttle assembly
U - Differential lock control
T - Return to transmission housing
Technical characteristics
Function
The differential lock control serves to direct the oil pressure from the power steering to the front differential control piston. In order to
limit the oil pressure sent to the differential lock piston, the control assembly incorporates a pressure relief valve set to 12 bar. The
excess oil not used by the solenoid valve is used for lubrication of the gearbox/shuttle assembly.
10-19
Technical characteristics
Fig. 22 - Function
Operation
l
The pressurised oil from the power steering reaches chamber P and chamberA through passage B. If there is no demand from
the actuators, the oil stays in chamber P where the pressure starts to increase. When the force exerted on the spool (1) by
the oil pressure in chamber A exceeds the force of the spring (2), the spool shifts downwards, thereby connecting chamber
P with chamber L and regulating the pressure in chamber P1 to 12 bar. Surplus oil is thus directed through chamber L to the
gearbox/shuttle assembly where it is used for lubrication
If the solenoid valve (3) is not energised, the oil stops in chamber P1 and chamber U is connected to chamber T and the oil
is returned to tank.
If the solenoid valve (3) is energised, (as shown in the drawing), chamber P1 is connected to chamber U and oil is sent to the
control piston of the front differential lock.
10-20
Technical characteristics
Function
The steering circuit sends oil to the power steering, which in turn, according to the request from the operator, sends oil pressure to
the steering circuit.
Fig. 23 - Function
Operation
Gear pump (1) draws in oil (through filter (2)) from the transmission casing and sends it to the power steering (3). The excess oil not
used by the power steering (3) is sent to the differential lock control (5) and used to operate the front axle differential lock piston (6)
and for lubrication of the gearbox and shuttle assembly (7). When the operator turns the steering wheel, part of the oil supplied from
the pump (1) is sent to the the steering cylinder (4) which steers the tractor.
10-21
Technical characteristics
10.4.4 - Power steering valve
Operation
l
The power steering system consists of a directional control valve with a rotary spool; these components feature hydrostatic
operation.
When the steering wheel is turned, the rotary spool control valve sends the oil from the pump to one side or the other of the
steering cylinder. The rotary spool ensures that that the volume of oil delivered to the cylinder is proportional to the angle
through which the steering wheel is turned.
In the event of a malfunction of the power steering pump, the rotary spool valve automatically functions as a manual pump to
ensure emergency steering.
Characteristics
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10-22
Technical characteristics
10.4.5 - Remote control valve
10-23
Technical characteristics
10-24
Ball
Spring
Cap
Remote valve spool n2
Spool return spring
Pin
Detent device
Bush
Screw
Spool return spring
Remote valve spool n1
Technical characteristics
Hydraulic lift control valve
Cap
Rate of drop control valve spool (Valvematic)
Plunger
10-25
Technical characteristics
Function
The function of the lift control valve is to direct oil pressure to the lifting cylinder, thereby allowing the implement to be raised and
lowered. It incorporates the following valves:
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10-26
Technical characteristics
Fig. 29 - Function
Operation
l
The lift is in neutral position when the the oil pressure from pump (1) reaches line A. As all the passages are closed, the pressure increases and when the force exerted on the enabling valve (2) overcomes that of the spring (3), the valve (2) shifts to the
right to allow oil to flow in line B and on to the gearbox/shuttle assembly where it is used for lubrication (4). To prevent sudden
changes in pressure, a pressure control valve (5) is installed on line B, to limit the lubrication oil pressure.
10-27
Technical characteristics
10-28
When the spool (6) is shifted to the right, the lift lowering operation begins, which can be divided into two stages. Stage 1:
m When the spool (6) shifts, line C is connected to line line D; this allows the piston (8) to move to the right thereby connecting line F with line I (drain), thereby allowing the pressure to reduce in line F.
Technical characteristics
And in stage 2:
m When the piston (8) moves to the right, the ball (9) is also moved to the right to connect chamber M of the check valve
(10) with line F. Consequently the pressure in chamber M is decreased and the force exerted on the piston (8) by the
pressure in chamber N pushes the valve (10) to right, thereby connecting line P with line F and allowing the oil to flow
and the lift to be be lowered. Valve (11) is used to regulate the rate of drop; when moved downwards, it limits the flow
of oil between port T and line P.
10-29
Technical characteristics
10-30
When the raise control is operated, spool (6) is shifted to the left; this opens the connecting passages between lines C and E,
G and H, A and F. When the forces exerted by the pressure in line F overcome the force exerted by the pressure in chamber
M, the valve (10) is shifted to the right and oil can flow into line P and from there, through valve (11), to port T and the lifting
cylinder (12). To increase the lifting speed i.e. the flow of oil to the lifting cylinder (12), a one-way valve (13) is installed in parallel with the spool (6); this ensures that oil is only supplied during the lifting stage.
Technical characteristics
Fig. 33 - Raising
10-31
Technical characteristics
10-32
20 - Calibrations and
electronic diagnosis
20-1
Description
The Baruffaldi system is comprised of the following elements:
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Electromagnetic clutch
Sensor to measure ambient temperature sensor inside the control unit
Coolant temperature sensor
Coolant thermostat
Connection to alarm warning light on instrument
Electronic control unit
Wiring
The electronic control unit uses the following inputs/outputs to control the electromagnetic clutch:
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Below is the electrical control diagram of the electronic control unit 2.8519.035.0.
20-2
Fig. 34
1.
2.
3.
4.
5.
Table 12
Pin 17 - NC
Pin 16 - NC
Pin 9 - Diag
Pin 8 - NC
Pin 13 - NC
Pin 5 -NC
Pin 4 - NC
Below is the electrical control diagram of the electronic control unit 2.8519.056.0.
20-3
Fig. 35
1.
2.
3.
4.
5.
Table 13
A8 - Thermo- A7 - CFG1
stat
B8 - Coolant B7 - CFG2
temperature
C8 - NC
C7 - Diag
l
A6 - NC
A5 - NC
A4 - NC
A3 - NC
B6 - NC
B5 - NC
C6 - NC
C5 - NC
B4 - L indica- B3 - NC
tor light
C4 - NC
C3 - NC
A2 - NC
A1 - NC
B2 - Relay 1
B1 - V Bat +
C2 - NC
C1 - V Bat -
20-4
Fig. 36
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The following graph shows the threshold values used by the control unit.
Fig. 37
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T1 = coolant temperature
T2 = ambient temperature
T3 = winter temperature for non-intervention of control unit
T4 = winter temperature for intervention of control unit
T5 = summer temperature for non-intervention of control unit
T6 = summer temperature for intervention of control unit
T7 = low ambient temperature
T8 = high ambient temperature
The thermostat ensures safety in the event of a malfunction of the coolant tempearture sensor. If the thermostat is tripped both the
electromagnetic clutch and the alarm warning light will be activated. If the electromagnetic clutch is activated due to the coolant temperature being above the threshold value, then the alarm warning light is not activated. In this application the oil temperature sensor
is not used. As an option, the air temperature sensor located inside the control unit can be used to check that the unit is operating
within its limits. If the temperature exceeds 80C, an alarm is signalled (see diagnostics). The option can be enabled by connecting
pin 9 (DIAG) to 12V.
Tolerance limits
Below are described the maximum tolerance limits calculated for the temperature sensors used.
l
The sensor in question is an NTC decvice installed inside the control unit. The NTC sensor has a specific tolerance of 2% while the
pull-up resistor has a specific tolerance of 1%. The sum of the tolerances makes for a maximum error of 3%, which in terms of
the temperatures in consideration, is equivalent to a maximum error of 0.5C.
l
20-6
Table 14
Nominal thresholds (C)
82
87
90
95
81
85
89
93
83
88
92
96
The temperatures detected by the control unit will always between contained within the minimum and maximum threshold values
according to tolerance trends. It is necessary to add 1C to these thresholds due to the error of the microprocessors analogue/digital
converter. Consequently the maximum possible error is 3C.
The use of a microprocessor with 10-bit converter will improve sensor tolerance limits, bringing them to within -1.5C +1C. The
following table indicates the minimum and maximum threshold values in accordance with the tolerance limits obtained with an 10 bit
converter (2.8519.056.0).
Table 15
Nominal thresholds (C)
82
87
90
95
80.5
86
89
94
83
88
91
96
The error caused by the converter increases the total by 0.5C, bringing the maximum error to -2C +1.5C.
Diagnostics
The control unit monitors the coolant temperature sensor connection and its own operating temperature. If a fault is detected in the
coolant temperature sensor, the control unit activates the electromagnetic clutch.
The following table lists the various fault conditions that generate alarms.
Table 16
Error code
Notes
3
4
Short to earth of sensor/control unit connection - Sensor faulty - Control unit faulty
Sensor/control unit connection open - Sensor/earth connection open - Sensor faulty
- Control unit faulty
Temperature in engine compartment high Control unit faulty
IMPORTANT
Alarm 4 is normally disabled, and therefore must be enabled in order to be operational (see Operation).
The condition is considered a fault if it lasts for at least 0.5 seconds. If the cause of the alarm is removed the alarm code will no
longer be displayed.
Faults are signalled by flashing codes on the indicator light. The code comprises a sequence of flashes identifying the type of fault,
with a duration of 0.2 seconds repeated continuously every 1.2 seconds. Below is an example display of alarm code 2.
20-7
Fig. 38
The purpose of this document is to describe the functions of the operator seated sensor ECU p/n 2.8519.106.0.
digital or
analogue.
The digital sensor consists of a normally open contact (N.O.) which is closed when the operator sits on the seat.
The analogue sensor is practically a digital sensor with the addition of resistors enabling diagnosis of the state of the sensor itself.
This sensor is recognised as a 2 KOhm resistor when the operator is not seated and as a 500 Ohm resistor when the operator is
seated.
A 1 KOhm resistor within the ECU connected to the 5V power line enables accurate diagnosis of the state of the sensor:
Table 17
ADC reading
2-3 V dc (400mV)
1-3 V dc (400mV)
V dc
GND
Any value exceeding the values
indicated above
Condition
Notes
Alarm state
Alarm state
Alarm state
System function
The ECU is powered directly by the battery and is always on, in two possible modes:
l
l
Key OFF
In this ignition switch state, the ECU monitors the handbrake state only.
The ECU monitors the following two conditions:
l
l
In this mode, the ECU implements low power consumption strategies to keep maximum current absorption within 2mA.
Transition from key ON -> key OFF
When the ECU detects a transition in the state of the ignition switch from ON to OFF, it queries the state of the handbrake and,
if the handbrake is not engaged, indicates this condition with an audible warning signal [buzzer] and a visual warning [warning lamp
output] for 10 seconds. The warning signals are stopped if the handbrake is applied.
Key OFF mode
When the machine is switched off, the ECU monitors the state of the handbrake only, and activates the audible/visual warning signals
for 10 seconds whenever there is a transition in the handbrake state from active to deactivated. The warning signals are stopped if
the handbrake is applied.
Key ON
In this ignition switch state, the ECU monitors all input signals. The main function of the ECU in this mode is to verify whether the
operator is seated in relation to the handbrake state.
When the ECU detects that the handbrake is released without the operator seated, it activates the audible [buzzer] and visual [warning lamp] warning signals for as long as the conditions persists - specifically, until the handbrake is applied or the operator sits in
the seat.
The state of the operator seated signal is verified every 200 mS.
The operator not seated state is recognised after a period of 2 seconds.
The handbrake state is always recognised with a latency of 0.5 seconds.
Reverse input management
If the reverse input is activated, the ECU activates the buzzer with priority over any other internal request.
The ECU restores normal buzzer management one second after the signal is deactivated.
If the reverse signal is activated while the audible/visual handbrake released signals are active, the handbrake released warning
sound is stopped and superseded by the reverse warning, while the visual handbrake released warning continues.
The recognition time for the ON/OFF signal is 0.1 seconds.
20-9
Short circuit to ground [Vin < 0.5v] = 3 pulses of 0.2 seconds ON/ 0.2 seconds OFF + 1 second pause.
Short circuit to +12V or sensor not connected [Vin > 4.5v]: 2 pulses of 0.2 seconds ON / 0.2 seconds OFF + 1 second
pause.
Values not within valid range: 4 pulses of 0.2 seconds ON / 0.2 seconds OFF 1 second pause.
The diagnostic signal is stopped as soon as the seat sensor signal returns within valid ranges.
0.5 seconds ON
At the end of the sequence, the ECU starts functioning in normal operating mode, in relation to the states of the inputs.
The diagnostic signal is stopped as soon as the seat sensor signal returns within valid ranges.
20-10
K30
SELECT
Hand Brake
Light
Key K15
8
Reverse Speed (N.O.)
3
Analogic
seat sensor
N.O.
1500 ohm
Hand Brake
(N.O.)
500 ohm
5
GND
20-11
20-12
30 - Method of intervention
30-1
Method of intervention
30.1 - B0 - Engine
This section outlines basic precautions recommended by Mitsubishi that should always be observed.
Disassembly
1.
2.
3.
Always use tools that are in good condition and be sure you understand how to use them before performing any job.
Use an overhaul stand or a work bench, where necessary. Also, use bins to keep engine parts in order of removal.
Parts must be restored to their respective components from which they were removed at disassembly. This means that all
parts must be set aside separately in groups, each marked for its component, so that the same combination or set can be
reproduced at assembly.
Pay attention to marks on assemblies, components and parts for their positions or directions. Apply marks, if necessary, to
aid assembly.
Carefully check each part or component for any sign of faulty condition during removal or cleaning. Clues as to how well part
is functioning are more easily revealed during removal or cleaning operations.
When lifting or carrying a part too heavy or too awkward for one person to handle, enlist the help of another person and, if
necessary, use a jack or other lifting equipment.
4.
5.
6.
Assembly
l
l
l
l
l
Wash all parts, except for oil seals, O-rings, rubber sheets, etc., with cleaning solvent and dry them with compressed air.
Always use tools that are in good condition and be sure you understand how to use them before performing any job.
Use only good quality lubricants. Be sure to apply oil, grease or sealant to parts as specified.
Be sure to use a torque wrench to tighten parts for which torques are specified.
Each time the engine is re-assembled, new gaskets and O-rings must be installed.
DANGER
Hot oil and components can cause serious personal injury.
Do not allow hot oil or components to come into contact with
skin.
To drain the oil, remove the drain plug from the oil sump.
Table 18
Capacity (high level less 0.5 litres S3L / S3L2:
(0.13 U.S. gal) of oil in the filter), li- 5.7 (1.5) (with oversize oil sump)
3.7 (1.0) (with standard oil sump)
tres (U.S. gal)
S4L / S4L2:
7.7 (2.0) (with oversize oil sump)
5.4 (1.4) (with standard oil sump)
Fig. 40
Draining coolant
1.
Loose the drain plug on the right side of the engine block and allow the
coolant to drain.
Table 19
Capacity, litres (U.S. Gal)
Fig. 41
30-2
Method of intervention
30.1.2 - Engine - Separation from the transmission
Removal
1.
DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.
2.
Fig. 42
3.
Fig. 43
4.
Disconnect the front PTO lube pipe (4) on the left-hand side.
Fig. 44
5.
On both sides, remove silent block retaining nuts (5), remove the two lateral
fixing screws and remove footplates (6).
Fig. 45
30-3
Method of intervention
6.
Remove cable support bracket (6) and disconnect throttle cables (7).
Fig. 46
7.
On both sides, remove fixing screws (8) and remove tank frame (9).
Fig. 47
8.
Fig. 48
9.
Fig. 49
30-4
Method of intervention
10.
Fig. 50
11.
Disconnect the outer cable (13) of the positive terminal of the starter motor.
Fig. 51
12.
Remove retaining nut (14) and remove starter motor protection (15).
Fig. 52
13.
Disconnect the cable (16) connected to the positive terminal of the starter
motor.
Fig. 53
30-5
Method of intervention
14.
Remove nut (17) to release the inner cable from positive terminal (18).
Fig. 54
15.
On the left-hand side, remove retaining nut (19) of the bracket of the climate control pipe bracket.
Fig. 55
16.
Disconnect the two oil supply pipes (20) of the hydraulic services pump and
of the rear lift hydraulic pump.
m
Fig. 56
17.
Remove the two screws (21) and remove bracket (22) supporting the power
steering pipes.
Fig. 57
30-6
Method of intervention
18.
Fig. 58
19.
Fig. 59
20.
Fig. 60
21.
Loosen hose clamp (26) and disconnect fuel suction pipe (27) from the
pump.
m
Fig. 61
30-7
Method of intervention
22.
Fig. 62
23.
Fig. 63
24.
Fig. 64
25.
Fig. 65
30-8
Method of intervention
26.
On th left-hand side, unscrew nut (32), remove fixing screws (33) and remove climate control pipe bracket (34).
m
Fig. 66
27.
Remove the two retaining screws (35), disconnect pipe (36) from front lift
valve and from the strap securing it to the bracket, then remove mid-mounted hydraulic couplers (37) along with the support bracket.
Fig. 67
28.
Fig. 68
29.
Fig. 69
30-9
Method of intervention
30.
Fig. 70
Refitting
1.
30.1.3 - Engine
Removal
1.
DANGER
Disconnect the lead from the battery negative terminal (-)
and apply the parking brake.
Place one stand under the gearbox and one under the engine (1).
Fig. 71
2.
Attach two hooks (2) to the lifting brackets provided on the engine.
Fig. 72
3.
Attach a hoist to the engine and take the strain with the lifting ropes.
Fig. 73
30-10
Method of intervention
4.
Remove the seven screws (3) securing the engine to clutch housing.
Fig. 74
5.
Fig. 75
Refitting
1.
Check the engine oil level is correct, that the air cleaner is adequate, that
the starter motor and battery are in good condition and that the engine
temperature is within the normal operating range.
Fig. 76
30-11
Method of intervention
Test
1.
Move the control lever to the position to shut off the fuel supply. Remove all
the glow plugs from the engine. Install the compression test gauge on the
cylinder on which the compression pressure is to be measured. Turn the
engine over with the starter motor and read the pressure on the gauge at
the point the gauge needle stops.
m
If the gauge reading is below the limit, proceed with engine overhaul.
The compression pressure varies with the engine rpm. For this reason it is necessary to check engine rpm when testing cylinder compression.
Table 20
Item
Engine speed,
rpm
Compression
pressure, kg/cm2
(psi) [kPa]
Maximum permissible difference
between
average
compression pressure of all cylinders in one
engine,
kgf/
cm(psi) [kPa]
30-12
Standard
290
SL
SL2
3 (42.7) [294]
Limit
It is important to measure the compression pressure at regular intervals in order to obtain the data on the gradual change in value.
Fig. 77
Method of intervention
30.1.5 - engine block, crankshaft, pistons and sump
Oil sump.
Mesh filter.
Connecting rod big-end cap.
Big-end shell bearing (lower).
Connecting rod.
Gudgeon pin
Top compression ring.
Second compression ring.
Oil control ring.
Piston.
Big-end shell bearing (upper).
Main bearing cap
Main bearing shell (lower)
Crankshaft
Main bearing shell (upper)
engine block
If the engine block is to be discarded, remove from the block the components (pressure relief valve, etc) that can be reutilised.
Disassembly
1.
Do not attempt to prise the sump off the engine block using a screwdriver as this could damage the components.
Fig. 79
30-13
Method of intervention
2.
Fig. 80
3.
Table 21
Item
Standard
Limit
4.
Fig. 82
5.
Fig. 83
30-14
Method of intervention
6.
Table 22
Item
Standard
Limit
7.
Fig. 85
8.
Mark the main bearing shells so they can be refitted to their original
positions.
Fig. 86
9.
Fig. 87
30-15
Method of intervention
10.
Insert the push rod of the tool into the small-end bearing bore in the piston
and, using an arbor press, drive out the gudgeon pin. Use the same gudgeon pin tool to refit the connecting rod to the piston.
1 - Gudgeon pin.
2 - Arrow mark.
3 - Piston.
4 - Tool
5 - Connecting rod.
6 - Identification mark.
7 - Tool holder.
Fig. 88
11.
Do not attempt to drive out the gudgeon pin by hitting it. A gudgeon
pin which can only be removed using a greater force should be renewed.
Fig. 89
Inspection
30-16
Method of intervention
Force fit.
Lubricate the bearing (inside) surface with engine oil.
Coat with Three Bond 1212.
Tightening torque: 5.25 0.25 kgf x m (38 1.8 lbf x ft) [51.5 2.5 N x m].
Refitting
1.
Fig. 91
2.
Fig. 92
30-17
Method of intervention
3.
Fig. 93
4.
Install the front and rear bearing caps so their end faces are even
with the end faces of the engine block.
Tighten the main bearing cap bolts gradually to the specified torque.
m
Table 23
Tightening torque
Fig. 94
5.
Make sure the crankshaft rotates freely without binding or catching. Measure the crankshaft end float. If the end float is incorrect, loosen the main
bearing cap bolts and then tighten them again.
Fig. 95
6.
Fig. 96
30-18
Method of intervention
7.
Using a flat plate, push the seals into position, taking care not to bend them.
Fig. 97
8.
Fig. 98
9.
Position the piston on the connecting rod, making sure the identification
mark on the connecting rod is on the same side as the arrow on the piston
crown. Locate the gudgeon pin.
Fig. 99
10.
Insert the end of the tool into the small-end bore in the piston and install the
gudgeon pin with the press.
m
Observe the gauge of the press when installing the gudgeon pin. If
the force of the press exceeds 50 kgf (110 1bf) [490 N], stop installing the pin and check that the bores in the piston and connecting rod
are properly aligned.
Fig. 100
30-19
Method of intervention
11.
After assembling the piston and connecting rod, make sure the connecting
rod moves freely.
Fig. 101
12.
Fig. 102
13.
The oil control ring must be installed with the ring gap positioned
180 to the expander spring joint.
A - Expander spring joint.
B - Oil control ring end gap.
m
Fig. 103
14.
30-20
Fig. 104
Method of intervention
15.
Using a piston guide (commercially available), insert the piston and connecting rod in the cylinder from the top of the engine block.
m
Do not hit the piston with a mallet to install the piston and connecting
rod. This will put force on the piston and connecting rod and cause
damage to the piston rings and crankpin.
Fig. 105
16.
Check that the identification number on the bearing cap matches the
number on the connecting rod.
Check that the identification number on the bearing cap matches the
number on the connecting rod.
A - Notches.
B - Cylinder number.
m
17.
Fig. 106
Tighten the big-end bearing cap nuts gradually to the specified torque.
Table 24
Tightening torque
Check the thrust clearance for the connecting rod big end.
Fig. 107
18.
The gauze oil filter must be positioned so that remains below the oil
level and clear of the sump.
Fig. 108
30-21
Method of intervention
19.
Fig. 109
20.
Squeeze out a 4 mm (0.2 in.) bead bar of sealant (Three Bond) from
the tube and apply to the flange of the oil sump as shown.
Fig. 110
21.
To obtain a 4 mm (0.2 in.) bead of sealant, cut the nozzle of the tube (A) as
shown in the figure.
Fig. 111
22.
Tighten the bolts securing the sump to the engine block in a crisscross pattern to the specified torque.
Table 25
Tightening torque
30-22
Cast sump:
2.8 0.3 kgf x m
(20.3 2.2 lbf x ft)
[27.5 3 N x m]
Pressed steel sump:
1.15 0.15 kgf x m
(8.3 1.1 lbf x ft)
[11.3 1.5 N x m]
Fig. 112
Method of intervention
30.1.6 - Inspection of the engine monobloc
Check
1.
Measure the bore at the top, middle and bottom points on axes A and B with
a cylinder bore gauge as shown in the figure.
m
If the measured values are outside the specified limit, hone the cylinder bores for oversize pistons.
Table 26
Piston and piston ring
Dimensions
Standard
Size code
STD
0.25 mm (0.0098 25
in.) oversize
0.50 mm (0.0197 50
in.) oversize
Taper and out of round
2.
Bore
Standard
78 (from 0 to
0.03) mm (3.07
(from 0 to 0.0012)
in
78.25 (from 0
to 0.03) mm
(3.0807 (from 0
to 0.0012 in)
78.50
(from
0 a 0,03) mm
(3.0905 (from 0
to 0.0012 in)
0.01 mm (0.0004
in) maximum
Limit
Standard +0.2
mm (+0.008 in)
Fig. 113
Using a heavy and accurate straight edge and a feeler gauge, check the
top face for warpage in two positions lengthwise, two crosswise and two
widthwise, as shown in the figure. If warpage exceeds the limit, reface the
top face with a surface grinder.
m
Table 27
Item
Warpage of
block top face
Standard
Limit
Fig. 114
Install the bearing shells (upper and lower halves) and cap to the big end
of the connecting rod and tighten the cap nuts to the specified torque. Measure the bore in the bearing for crankpin as shown in the figure (A).
Table 28
Tightening torque
Fig. 115
30-23
Method of intervention
2.
Measure the diameter of the crankpin as shown in the figure to obtain the
clearance between the crankpin and big-end bearing.
Table 29
Item
3.
If the clearance still exceeds the limit, grind the crankpin to 0.25 mm
(0.0098 in.), 0.50 mm (0.0197 in.) or 0.75 mm (0.0295 in.) undersize
and use an undersize big-end bearing.
Fig. 116
Table 30
Item
Crankpin
Undersize
4.
Limit
Finish
Fig. 117
Install the main bearing (upper and lower halves) and cap to the cylinder
block and tighten the cap bolts to the specified torque. measure the bore of
the main bearings. as shown in the figure.
Table 31
Tightening torque
Fig. 118
30-24
Method of intervention
5.
Measure the diameter of the main bearing journal as shown in the figure (A)
to find the clearance between the journal and main bearing.
m
If the clearance exceeds the limit, install a new bearing and check
the clearance again.
If the clearance still exceeds the limit, grind the journal to 0.25 mm
(0.0098 in.), 0.50 mm (0.0197 in.) or 0.75 mm (0.0295 in.) undersize
and use an undersize main bearing.
Table 32
Item
Limit
Fig. 119
Grind all the main bearing journals of one crankshaft to the same
undersize.
Table 33
Item
Undersize
7.
Finish
Fig. 120
Support the crankshaft on its front and rear journals in V-blocks or in a lathe
and check runout at the centre journal with a dial gauge, as shown in the
figure. Depending on the amount of runout, repair the crankshaft by grinding or by straightening with a press.
m
Table 34
Item
Crankshaft runout
Standard
Limit
30-25
Method of intervention
8.
Fig. 122
9.
Locate the Woodruff key in its seat in the crankshaft, then locate the gear,
aligning the slot with the key as shown in the figure (A).
Fig. 123
DANGER
Disconnect the lead from the battery negative terminal (-).
2.
Fig. 124
3.
4.
Fig. 125
30-26
Method of intervention
Refitting - version without front PTO
Refitting is the reverse of removal.
DANGER
Disconnect the lead from the battery negative terminal (-).
2.
Fig. 126
3.
Fig. 127
4.
Fig. 128
5.
Fig. 129
30-27
Method of intervention
6.
Move flange (6) forwards to create the necessary space to remove the
drivebelt.
Fig. 130
7.
Fig. 131
Tension adjustment
1.
DANGER
Disconnect the lead from the battery negative terminal (-).
m
2.
Fig. 132
30-28
Method of intervention
3.
Fig. 133
DANGER
Disconnect the lead from the battery negative terminal (-).
2.
Fig. 134
3.
Fig. 135
DANGER
Disconnect the lead from the battery negative terminal (-).
30-29
Method of intervention
2.
Fig. 136
3.
Fig. 137
4.
Move flange (5) forwards to create the necessary space to remove the
drivebelt.
Fig. 138
5.
Fig. 139
30-30
Method of intervention
6.
Fig. 140
Tension adjustment
1.
DANGER
Disconnect the lead from the battery negative terminal (-).
m
2.
Fig. 141
3.
Fig. 142
30-31
Method of intervention
30.1.10 - Crankshaft pulley
Removal
1.
Fig. 143
2.
Remove the crankshaft pulley nut before removing the alternatorfan drivebelt and the A/C drivebelt as the tension of the drivebelts
helps oppose rotation of the crankshaft.
Fig. 144
3.
Fig. 145
30-32
Method of intervention
Refitting
Refitting is the reverse of removal.
Fig. 146
2.
Tap the punch with a hammer to drive bearing (2) out of the flywheel.
Fig. 147
Refitting
Refitting is the reverse of removal.
30-33
Method of intervention
Flywheel.
Rear cover.
Oil seal carrier; oil seal.
Tappets.
Speedometer drive gear.
Power take-off Gear.
Crankshaft pulley.
Timing cover.
Idler gear.
Camshaft gear
Thrust washer.
Camshaft.
Fuel injection pump camshaft gear.
Bearing.
Fuel injection pump camshaft.
Oil pump.
Front cover.
Measure the backlash before removing gears (A).
Disassembly
1.
Fig. 149
30-34
Method of intervention
2.
DANGER
When removing the flywheel, wear heavy gloves to avoid
hand injury.
Insert a safety rod (M12 x 1.25) in the threaded hole in the flywheel from
which the screw was removed, then remove the remaining screws.
Grasp the flywheel in both hands and pull it off the crankshaft. Joggling the
flywheel back and forth will facilitate removal.
Fig. 150
3.
Fig. 151
4.
Fig. 152
5.
If the camshaft is removed before the tappets, the tappets will fall
into the sump.
Fig. 153
30-35
Method of intervention
6.
Unless the speedometer drive gear is removed, the camshaft cannot be removed.
Fig. 154
7.
8.
The front plate is fixed to the inside the timing cover with screws.
Do not attempt to remove this plate along with the timing cover by
tapping.
Fig. 156
30-36
Method of intervention
9.
Table 35
Item
Gear backlash
Crankshaft gear
and idler gear
Idler gear and
camshaft gear
Idler gear and
fuel
injection
pump camshaft
gear
Camshaft gear
and PTO gear
Standard
Limit
Fig. 157
From 0.08 mm to
0.19 mm (from
0.0031 in to
0.0075 in)
Fuel
injection From 0.07 mm to
pump camshaft 0.20 mm (from
gear and oil 0.0028 in to
pump gear
0.0079 in)
10.
Fig. 158
11.
Take care not to damage the lobes or the bearing journals when
removing the camshaft.
Fig. 159
30-37
Method of intervention
12.
Fig. 160
13.
Tap the rear end of the camshaft gently with a copper bar in order to drive
it out from the front end of the engine block.
Fig. 161
14.
15.
Fig. 162
16.
Fig. 163
30-38
Method of intervention
Inspection
Tightening torque: 17.5 2.5 kgf x m (12718 lbf x ft) [172 25 N x m].
Tightening torque: 1.1 0,1 kgf x m( 8 0.7 lbf x ft) [10.8 25 N x m].
Use a new gasket.
Lubricate with engine oil.
Lubricate lip of oil seal with engine oil.
Lubricate bearing journals and lobes with engine oil.
Tightening torque: 6.5 1 kgf x m (47 7 lbf x ft) [64 10 N x m].
Tightening torque: 13.5 0.5 kgf x m (98 4 lbf x ft) [132 5 N x m].
Refitting
1.
Fig. 165
30-39
Method of intervention
2.
Fig. 166
3.
Fig. 167
4.
Fig. 168
5.
Take care not to damage the lobes or the bearing journals when
inserting the camshaft.
Fig. 169
30-40
Method of intervention
6.
Tighten the screws securing the thrust plate to the specified torque.
Table 36
Tightening torque
Make sure the camshaft rotates freely and check the camshaft end float.
Fig. 170
7.
Fig. 171
8.
Fig. 172
9.
Table 37
Tightening torque
Ensure that the screws and bar used to counterhold the crankshaft
are strong enough.
Fig. 173
30-41
Method of intervention
10.
Fig. 174
11.
Fig. 175
12.
Fig. 176
13.
Fig. 177
30-42
Method of intervention
14.
Table 38
Tightening torque
15.
6.5 1 kgf x m
(47 7 lbf x ft)
[64 10 N x m]
Fig. 178
Fig. 179
16.
Have an assistant hold the crankshaft pulley with a wrench to prevent the
flywheel from rotating; then tighten the four flywheel screws to the specified
torque.
Table 39
Tightening torque
DANGER
When working with other persons, use appropriate signals
to avoid possible accidents or injuries.
Fig. 180
30-43
Method of intervention
30.1.13 - Inspection of the flywheel and ring gear
Inspection
1.
Place the flywheel on the flat plate. Set a dial gauge at one side of the friction (clutch contact) face and move it over to the opposite side of the face
as shown in the figure to find the flatness error.
m
Table 40
Item
Standard
Limit
2.
Fig. 182
30-44
Method of intervention
30.1.14 - Inspection of the pistons, piston rings and gudgeon pins
Inspection
1.
Using a micrometer, measure the diameter of the piston at its skirt in a direction perpendicular to the gudgeon pin (1), as shown in the figure.
If the diameter exceeds the specified limit, renew the piston.
Select a new piston so that the difference between average weight of all
pistons in one engine does not exceed the standard.
m
Table 41
Item
Diameter
piston
Standard
78.00
mm From 77.93
(3.0709 in)
mm to 77.95
mm
(From
3.0681 in to
3.0689 in)
0.25
mm 78.25
mm from 78.18
(0.0098 in.) (3.0807 in)
mm to 78.20
oversize
mm
(from
3.0779 in to
3.0787 in)
0.50
mm 78.50
mm from 78.43
(0.0197 in.) (3.0905 in)
mm to 87.45
oversize
mm
(from
3.0878 in to
3.0886 in)
Maximum permissible difference between 5 mm (0.18
average weight of all pistons in the same in)
engine, g (oz)
2.
of Standard
Nominal
size
Limit
77.80
mm
(3.0630 in)
Fig. 183
78.05
mm
(3.0728 in)
78.30
mm
(3.0827 in)
Measure the piston ring side clearance using a straight edge and a feeler
gauge as shown in the figure.
m
If the clearance still exceeds the limit after fitting new piston rings,
renew the piston
Table 42
Item
Standard
from 0.06
mm (from
0.0039 in)
Second compression from 0.06
ring
mm (from
0.0039 in)
Oil control ring
from 0.06
mm (from
0.0039 in)
Limit
Fig. 184
30-45
Method of intervention
3.
Put the piston ring in a gauge or in the bore in a new engine block and measure the gap between the ends of the ring with a feeler gauge as shown in
the figure.
If the end gap exceeds the limit, renew all the rings.
Inside diameter of gauge.
Standards:
78 (from 0 to 0.03) mm; 3.07 (from 0 to 0.0012) in
0.25 (from 0 to 0.03) mm; 0.0098 (from 0 to 0.0012) in
oversize: 78.25 (from 0 to 0.03) mm; 3.08 (from 0 to 0.0012) in
0.50 (from 0 to 0.03) mm; 0.0197 (from 0 to 0.0012) in
oversize: 78.50 (from 0 to 0.03) mm; 3.09 (from 0 to 0.0012) in
m
Fig. 185
Put the piston ring in the gauge or cylinder square with the piston.
Table 43
Item
Standard
Limit
Measure the diameter of the gudgeon pin and the small-end bore in the
piston as shown in the figure to find the clearance.
m
If the clearance exceeds the specified limit, renew either the piston
or the gudgeon pin, whichever is most worn.
Table 44
Item
30-46
Limit
Fig. 186
Method of intervention
30.1.15 - Inspection of the connecting rods
Inspection
1.
Units: mm (in)
Table 45
Item
Fig. 187
Standard
Limit
mm
Measure the piston ring side clearance using a straight edge and a feeler
gauge as shown in the figure.
m
If the clearance still exceeds the limit after fitting new piston rings,
renew the piston
Table 46
Item
Standard
from 0.06
mm (from
0.0039 in)
Second compression from 0.06
ring
mm (from
0.0039 in)
Oil control ring
from 0.06
mm (from
0.0039 in)
3.
Limit
Fig. 187
Check the connecting rod for bending or twisting using a connecting rod
aligner.
m
To check the straightness of the connecting rod, fit the big-end cap
and tighten the cap nuts to the specified torque.
Fig. 188
30-47
Method of intervention
4.
To check the straightness of the connecting rod fitted to the piston, put the
connecting rod and piston on the surface plate as shown in the figure, insert
a round bar of diameter equal to that of the crankpin into the big end bore
and measure (A) and (B) with a dial gauge. Subtract (A) from (B) to obtain
curvature (C).
Fig. 189
Measure the diameter of the bearing journal and the bore in the camshaft
bearing to find the clearance, as shown in the figure. If the clearance exceeds the limit, replace the bearing.
Table 47
Item
Standard
Fig. 190
2.
Fig. 191
3.
Remove the sump. Using the remover end of the tool, force the bearing
out of the engine block. Crush and remove the bearing from the block.
3.1. Front end of engine block
3.2. Camshaft bearing
3.3. Bearing installer
Fig. 192
30-48
Method of intervention
4.
Install a new bearing, aligning the oil holes with those of the oil gallery.
4.1. Oil holes
4.2. Notch in bearing
4.3. End of bearing
Fig. 193
5.
Measure the cam lobe height and base circle as shown in the figure. Subtract the base circle from the lobe height to find the cam lift. If the cam lift
exceeds the specified limit, renew the camshaft.
Table 48
Item
Standard
Limit
Fig. 194
The correct contact surfaces of the tappets are shown in (A). Check for
abnormal wear patterns on the individual tappets (B).
m
Fig. 195
2.
Measure the diameter of the tappet and of the corresponding bore in the
engine block to find the clearance.
m
Table 49
Item
Standard
30-49
Method of intervention
30.1.18 - Inspection of the idler gear
Inspection
1.
Measure the bore in the idler gear for the shaft and the diameter of the shaft
to find the clearance.
m
If the clearance exceeds the specified limit, replace either the gear
or the shaft, whichever is most worn.
Table 50
Item
Standard
Limit
Clearance
between From 0.03 mm to 0.07 0.20 mm (0.0079 in)
idler gear and shaft
mm (From 0.0012 in to
0.0028 in)
2.
Fig. 197
The new idler shaft should be installed so that it protrudes 26.5 0.5 mm
(1.043 0.020 in.) from the face of the engine block.
Fig. 198
If the stem is worn beyond the limit, or if it is abnormally worn, replace the valve.
Table 51
Item
Exhaust
valve
30-50
Nominal
Standard
dimensions
Limit
6.6
mm From 6.565 6.500
mm
(0.260 in)
mm to 6.580 (0.25591 in)
mm
(from
0.25846 in to
0.25905 in)
6.6
mm From 6.530
(0.260 in)
mm to 6.550
mm
(from
0.25709 in to
0.25787 in)
Fig. 199
Method of intervention
2.
Valve guides wear more rapidly at their ends than at any other part.
Using a bore gauge (A), measure the inside diameter of the valve guides at
both ends to find the clearance between valve stem and valve guide,
m
If the clearance exceeds the specified limit, renew the valve guide or
valve, whichever is most worn.
Table 52
Item
Clearance
Intake valve
between
valve stem
and
valve
guide
Exhaust
valve
Nominal
size
From
0.02
mm to 0.05
mm
(from
0.0008 in to
0.0020 in)
From
0.05
mm to 0.085
mm
(from
0.0020 in to
0.00335 in)
Height to top of valve guide 10 mm (0.39 From 9.5 mm
in)
to 10.5 mm
(From 0.374
in to 0.413 in)
3.
Standard
0.10
mm
(0.0039 in)
Fig. 200
0.15
mm
(0.0059 in)
Before measuring the valve guides, remove all traces of paint and
carbon deposits.
Force old valve guide (1) from cylinder head (2) using a suitable tool and an
arbor press from the underside of the head.
Install the new valve guide (1) in the cylinder head (2) by inserting it with an
arbor press from the upper side of the cylinder head to obtain the specified
stand-out (10 mm 0.5 mm; 0.93 in 0.020 in).
m
Fig. 201
4.
Insert a new valve (3) in the guide (1); make sure the valve slides in the
guide freely.
After renewing the valve guide (1), check the contact between the valve (3)
and its seat (4)
Put a small amount of Prussian blue or read lead on the valve face (5).
Hold valve (3) with a valve lapping tool (6) and press it against seat (4) to
check the contact.
Fig. 202
30-51
Method of intervention
5.
The width of contact (7) must be uniform all the way around both the seat
and the valve (C).
m
Fig. 203
6.
If the valve margin (8) exceeds the specified limit, renew the valve
(3).
If the valve sinkage (9) exceeds the specified limit, recondition the
valve seat or renew the cylinder head assembly
Table 53
Item
Standard
Limit
Table 54
Item
Standard
Limit
If the margin (8) is below the limit when the valve is refaced, renew
the valve (3).
Fig. 205
8.
Check the clearance between the valve (3) and valve guide (1) before
refacing the valve seat (4).
Renew the valve guide (1) if necessary.
Finish the valve seat (4) using a finishing tool or a valve seat grinder (E).
m
Fig. 206
30-52
Method of intervention
9.
Check the valve face angle (F) and valve seat width (G).
Table 55
Item
Standard
Limit
45
From 1.3 mm to 1.8 mm 2.5 mm (0.098 in)
(from 0.051 in to 0.071
in)
Fig. 207
10.
Be sure to lap the valves (3) in their seats after refacing or renewal of the
valves or valve seats (4).
Put a small amount of lapping compound on the valve face.
m
Use a 120 - 150 grit lapping compound (H) for initial lapping and a
compound finer than 200 grit for finish lapping.
Mixing the compound with a small amount of engine oil will help
distribute the compound on the valve face uniformly.
Using a lapping tool, hold the valve (3) in its seat (4) and rotate it only a part
of a turn, then raise the valve off its sealing surface to reposition it. Press
the valve against the sealing surface and rotate through another part turn.
Repeat this operation until the compound wears and loses its cutting property.
Wash the valve (3) and valve seat (4) with dry cleaning solvent.
Apply engine oil to the valve (3) and lap it in the seat (4).
Check the valve face contact (7).
m
Fig. 208
Table 56
Tightening torque
9 0.5 kgf x m
(65 4 Ibf x ft)
[88 5 N x m]
A - Front of engine
Fig. 209
30-53
Method of intervention
2.
Find TDC on the compression stroke for No. 1 piston using the following
procedure:
- rotate the crankshaft to bring the TDC mark on the crankshaft pulley into
alignment with the mark on the timing cover;
- with No. 1 piston at TDC on the compression stroke, the rocker arms
should not move when the crankshaft is turned approximately 20 in both
directions;
- if the rocker arms move, No. 1 piston is at top dead center on the intake
or exhaust stroke; in this case, rotate the crankshaft through 360 in the
normal direction of engine rotation. No. 1 piston is now at top dead centre
on the compression stroke.
Loosen the lock nut of the adjusting screw. With a feeler gauge inserted
between the rocker arm and valve cap, adjust the valve clearance by turning the adjusting screw.
Fig. 210
Table 57
Item
Standard
3.
A - TDC (top dead center) mark for pistons No. 1 and No. 4
B - Mark on timing cover.
C - Injection timing mark.
D - TDC mark for pistons No. 2 and No. 3.
Hold the adjusting screw and tighten the lock nut. After adjusting the valve
clearance on the valves for No. 1 cylinder, rotate crankshaft 180 in the
direction of engine rotation and adjust the valve clearance on the valves for
the remainder of the cylinders in firing order (injection sequence).
Table 58
Firing order (injection sequence)
S3L
S4L
m
30-54
132
1342
240
180
After adjusting the valve clearance on the valves for all cylinders,
rotate the crankshaft two or three times and check that the valve
clearances are still correct.
Fig. 211
Method of intervention
30.1.21 - Inspection of the rocker arms and rocker shaft
Inspection
1.
Measure the inside diameter of the bore in the rocker arm for the rocker
shaft and the diameter of the rocker shaft to find the clearance between
the arm and shaft.
m
If it exceeds the limit, renew both the rocker arm and the shaft.
Table 59
Item
Nominal size
Standard
Limit
Fig. 212
0.200
mm
(0.00787 in)
Rocker cover.
Rocker assembly.
Pushrod.
Cylinder head screw.
Cylinder head.
30-55
Method of intervention
Disassembly
1.
Fig. 214
30-56
Method of intervention
2.
Fig. 215
3.
If any parts of the cylinder head are faulty, check the tightness of the
cylinder head screws with a torque wrench before loosening them.
Fig. 216
4.
If the gasket is stuck fast and the cylinder head cannot be separated
from the cylinder block, tap around the side of the cylinder head with
a rubber mallet
Fig. 217
5.
The valves, spring retainers, springs and collets must be set aside
separately in groups, each labelled with the cylinder number, to ensure subsequent installation in the original position.
Fig. 218
30-57
Method of intervention
6.
Fig. 219
Inspection
30-58
Tightening torque: 1.15 0.15 kgf x m (8.3 1.1 lbf x ft) [11.3 1.5 N x m].
Tightening torque: 1.50 0.50 kgf x m (11 4.0 lbf x ft) [14.7 5.0 N x m].
Tightening torque: 9.50 0.50 kgf x m (65 4 lbf x ft) [88 5 N x m].
Use a new part.
Use a new gasket.
Lubricate stem with engine oil.
Method of intervention
Refitting
1.
After scraping off the gasket, remove all residue using an oilstone
smeared with engine oil and thoroughly clean the face.
Fig. 221
2.
Fig. 222
3.
Fig. 223
4.
Fig. 224
30-59
Method of intervention
5.
Do not use any gasket adhesive or other substances on the top face
of the engine block.
Fig. 225
6.
Fig. 226
7.
Table 60
Tightening torque
9 0.5 kgf x m
(65 4 lbf x ft)
[88 5 N x m]
Fig. 227
8.
Fig. 228
30-60
Method of intervention
9.
Fig. 229
10.
Table 61
Tightening torque
11.
Fig. 231
12.
Table 62
Tightening torque
Fig. 232
30-61
Method of intervention
30.1.23 - Inspection of the cylinder head
Using an accurate straight edge and a feeler gauge, check the gasket face
for warpage in three positions lengthwise, two crosswise and two widthwise
as shown in the figure.
m
Table 63
Part
Standard
Limit
Fig. 233
If the squareness and/or free length exceeds the limit, replace the
spring.
Table 64
Item
Standard
Limit
Fig. 234
Table 65
Item
Limit
Fig. 235
30-62
Method of intervention
Renewal
1.
Fig. 236
2.
To install new jet (3), locate it in the cylinder head with its tangential orifice
aligned with the centre of the main chamber and tap it gently with a rubber
mallet.
Fig. 237
Fig. 238
2.
Fig. 239
30-63
Method of intervention
3.
Fig. 240
Refitting
1.
Table 66
Tightening torque
5 0.5 kgf x m
(36 4 lbf x ft)
[49 5 N x m]
Fig. 241
2.
Fig. 242
3.
Fig. 243
30-64
Method of intervention
30.1.28 - Inspection of the lubrication system
Inspection
1.
Oil pump.
Visually check the pump for rough rotation or other defects.
m
Fig. 244
2.
Fig. 245
3.
Insert a small diameter rod into the oil hole in the switch and lightly push it
in to test for electrical continuity, as shown in the figure.
If there is no electrical continuity, renew the pressure switch.
Apply air pressure of 0.5 kgf/cm (7 psi) [49 kPa] to the switch through the
oil hole and test for continuity.
m
4.
If the pressure is not correct, remove the cap nut and either increase
or reduce the shim thickness accordingly.
Table 67
Relief valve opening pressure
Fig. 247
1 - Cap nut.
2 - Shims.
30-65
Method of intervention
30.1.29 - Fuel System
Disassembly
1.
Put plugs or caps on the openings of the injection pump and nozzle
connectors.
Fig. 248
2.
Remove the seals from the cylinder head with a screwdriver or similar tool. Discard any defective seals.
Fig. 249
3.
Fig. 250
4.
Fig. 251
30-66
Method of intervention
5.
Fig. 252
6.
Fig. 253
Refitting
1.
Table 68
Tightening torque
Fig. 254
2.
Fig. 255
30-67
Method of intervention
3.
Table 69
Tightening torque
Fig. 256
4.
Fig. 257
5.
Fig. 258
6.
Fig. 259
30-68
Method of intervention
30.1.30 - Inspection and adjustment of the fuel system
Maintenance
Preparation
1.
Close the fuel filter valve. Disconnect the fuel injection pipe from the cylinder head and from the injection pump. Remove the delivery valve holder
from the injection pump. Remove the delivery valve and spring from the
holder. Refit the delivery valve holder to the injection pump only. Connect
the pipe to the injection pump. Hold the speed control lever in the low revs
position.
Fig. 260
Inspection
1.
Fuel system.
Open the fuel filter valve. Turn the starter switch key to ON position.
m
Fuel will flow from the injection pipe at high pressure when the starter switch key is turned to the ON position if the engine is equipped
with an electric lift pump. Direct the fuel flow into a container.
Fig. 261
2.
Slowly turn the crankshaft clockwise, while watching the free end of the
injection pipe. The instant the fuel stops flowing represents the fuel injection timing.
m
Rotate the crankshaft in reverse direction just a little and repeat the
operation described above again to recheck the injection timing.
Fig. 262
3.
The fuel injection timing is correct if the timing mark on the crankshaft pulley
is aligned with the mark on the timing cover when fuel stops flowing from
the injection pipe.
Table 70
Fuel injection timing (BTDC)
17 (standard)
A - TDC (top dead center) mark for pistons No. 1 and No. 4
B - Timing mark on timing cover.
C - IT (injection timing) mark.
D - TDC mark for pistons No. 2 and No. 3.
Fig. 263
30-69
Method of intervention
4.
Alternative method.
In the fuel flow method, the delivery valve has to be removed. As a result,
there is a good chance for dirt particles to get inside the fuel injection pump.
In this alternate method, however, it is not necessary to remove the delivery
valve.
Disconnect No. 1 fuel injection pipe at the fuel injection nozzle (cylinder
head). Prime the fuel lift pump. Slowly turn the crankshaft clockwise until
the point where fuel flows freely from the open end of the injection pipe and
then check the position of the timing mark relative to the mark on the timing
cover. The timing is retarded by approximately 1. Take this retard angle of
1 into account when adjusting the shims.
Fig. 264
Adjustment
1.
If the fuel injection timing is incorrect, alter the thickness of shims under the
fuel injection pump. An increase or decrease in shim thickness of 0.1 mm
(0.004 in.) will result in a 1 change in the timing. Increase the thickness of
the shims to retard the timing or decrease it to advance the timing.
Table 71
Adjustment range
2.
standard 1.5
Fig. 265
Fig. 266
30-70
Method of intervention
30.1.31 - Inspection of the fuel lift pump
Inspection
1.
Examine the exterior of the pump for defects and test its performance.
Do not attempt to disassemble the pump.
Plunger-type fuel lift pump.
m
Fig. 267
2.
Fig. 268
Test the operation injection pump using the methods suggested in the table below. Renew defective parts as necessary.
m Do not attempt to repair by disassembling.
Table 72
Characteristic to be
tested
Idle speed
Exhaust smoke
Spray pattern
Test method
Criteria
Use a tachometer.
30-71
Method of intervention
Disassembly
Method of intervention
10.
11.
12.
13.
14.
15.
16.
17.
Control rack
Delivery valve holder
O-ring
Delivery valve spring
Delivery valve gasket
Delivery valve
Plunger barrel
Pump housing
Hold the injection pump in a vice with the tappet side (3) facing upwards.
Using a screwdriver, separate the lock plate from the tappet guide pin.
Rotate the tappet guide pin 180 to release it.
Fig. 270
2.
Remove tappet guide pin (1) with long-nose pliers while pushing down on
tappet (3), then remove the tappet.
Repeat the above procedure to remove all the remaining tappets.
m
The tappet may be expelled from its bore when the tappet guide pin
is removed. Hold the tappet to prevent it from falling Hold the tappet
to prevent it from falling.
Fig. 271
Fig. 272
30-73
Method of intervention
Removal of the delivery valves
1.
Fig. 273
2.
Fig. 274
The plungers and barrels are are delicate components. Keep them
as clean as possible.
Keep the plungers with their respective barrels for subsequent installation. Do not use barrels with other plungers.
Fig. 275
2.
Fig. 276
30-74
Method of intervention
Inspection
1.
1.
1.
30-75
Method of intervention
Assembly
To assemble, follow the disassembly steps in reverse order.
Use the following procedure:
Tightening torque: 4.5 0.5 kgf xm (32.5 4 lbf x ft) [44 5Nxm]
1.
1.
30-76
Method of intervention
Refitting the barrels
1.
Locate each barrel (16), aligning the groove with locating dowel (A) and
inserting it squarely into its bore.
m
If the groove in the barrel is not aligned with the locating dowel, the
O -ring will not seat correctly (it will still be visible) after the delivery
valve holder has been installed.
Fig. 279
Install delivery valve (15), gasket, spring and O-ring in the barrel (16) and
then tighten the delivery valve holder by hand.
Repeat this procedure to refit all the remaining delivery valves.
m
Take care not to damage O-rings (12) with the threads of delivery
valve holder (11).
Fig. 280
Install each control sleeve with the center tooth (C) aligned with the reference mark on the control rack (D).
Fig. 281
2.
Make sure the notch in the plunger is pointing toward the adjustment
plate.
Fig. 282
30-77
Method of intervention
Refitting the tappets
1.
Move the control rack back and forth while pushing down on each tappet
(3) to align the slot in the tappet with the hole in the housing for the tappet
guide pin. Locate lock plates (2) and tappet guide pins (1).
m
Every time the fuel injection pump is disassembled, new lock plates
must installed.
Fig. 283
Locate the delivery valve holders and tighten them to the specified torque.
m
Do not over tighten the delivery valve holders to avoid applying excessive force on the barrels and preventing free movement of the
plunger. If the holders are not tightened to the specified torque, engine oil leaks may develop in the fuel injection pump.
Delivery valve holders 4.5 0.5 kgf x m (32.5 4 lbf ft) [44 5 N x m]
Fig. 284
Post-assembly inspection
1.
Immediately after reassembling the fuel injection pump, check that the control rack moves freely without any binding or catching.
If the control rack fails to move freely, the possible causes are Pumping
element(s) sticking; Foreign particles lodged between control rack and
sleeves; Over-tightening of delivery valve holder(s).
Disassemble and check the injection pump to locate the cause of the problem.
After reassembly of the fuel injection pump, check the injection timing.
Fig. 285
Measure the lobe height and base circle as shown in the figure. Subtract
the base circle from the lobe height to find the cam lift. If the cam lift exceeds the prescribed limit, renew the camshaft.
Table 73
Item
Standard
Limit
43 mm (1.69 in)
Fig. 285
30-78
Method of intervention
30.1.34 - Inspection of the fuel injection pump camshaft
Test
1.
Measure the lobe height and base circle as shown in the figure. Subtract
the base circle from the lobe height to find the cam lift. If the cam lift exceeds the prescribed limit, renew the camshaft.
Table 74
Item
Standard
Limit
43 mm (1.69 in)
Fig. 285
30-79
Method of intervention
30.1.35 - Fuel injection nozzle
Disassembly
Lock nut. Tightening torque: 3.75 0.25 kgf x m (27 1.8lbf x ft) [36.8 N x m].
Fuel injector nozzle assembly. Check for excess carbon deposits on the nozzle or in the nozzle holes.
Item.
Pin. Examine for signs of wear or damage.
Spring. Check the applied force and straightness
Washer. Examine for signs of wear
Body. Tightening torque: 5.5 0.5 kgf x m (40 4 lbf x ft) [54 5 N x m].
Method of intervention
Inspection
1.
DANGER
Wear safety goggles when testing the nozzles. Fuel spraying out from the nozzles under high pressure can perforate
the skin and cause serious lesions. Never direct the nozzle
towards yourself or other persons, always point it in the direction of the collector.
Injection pressure (valve opening pressure) test.
Install the injection nozzle on the tester. Operate the tester handle slowly at
a speed of one stroke per second to make gradually increase the pressure
to the point where the valve in the injection nozzle starts to open.
Read the maximum pressure reading at the instant fluid flows from the tip.
2.
Fig. 287
3.
Fig. 289
30-81
Method of intervention
4.
When removing the tip from the injection nozzle, be careful not to
damage it.
Keep the needle valves together with their respective bodies. Do not
use needle valves with bodies of a different type.
After cleaning tip (2), install it in the nozzle and tighten lock nut (1) to the
specified torque.
m
Tightening torque: 3.75 0.25 kgf x m (27 1.8 Ibf x ft) [36.8 2.5
N x m].
If the injection nozzle is still faulty after the tip has been washed, renew tip
(2).
Fig. 290
When installing the new nozzle tip, remove the synthetic resin film
from the tip and slide the needle valve in the body with clean diesel
fuel to wash off all traces of the protective film.
Assembly
1.
Table 75
Tightening torque
Fig. 291
30-82
Method of intervention
30.1.37 - Governor
Disassembly
Spring
Tie-rod
Speed control lever
Spring pin
Grooved pin
Governor shaft
Governor lever
Starting spring
Tension lever
Governor spring
Governor spring lever
Governor housing
Inspection
1.
Check sliding sleeve for wear or damage. Make sure the sleeve moves freely.
30-83
Method of intervention
Assembly
1.
Fig. 293
2.
Install grooved pin (5) and spring pin (4) using a hammer.
Locate tie-rod (2) and spring (1).
Fig. 294
3.
In this position, tie-rod (2) does exert force on governor spring (10).
Torque spring assembly (A) is to be installed and adjusted after having first adjusted the low idle speed and high idle speed, with the
engine not running.
Fig. 295
4.
Rotate torque spring assembly (A), while slightly moving tie-rod (2) until the
reference mark on control rack (B) is aligned with the mark on the pump
body (C).
With these reference marks aligned, secure torque spring assembly (A) in
position by tightening nut (D).
Install sealing cap (E) over the torque spring assembly (A) and stake the
cap in position.
Fig. 296
30-84
Method of intervention
30.1.38 - Cooling system
Disassembly
1.
Fig. 297
2.
Fig. 298
3.
Fig. 299
Refitting
1.
Fig. 300
30-85
Method of intervention
2.
Fig. 301
3.
Fig. 302
4.
Table 76
Tightening torque
30-86
Method of intervention
30.1.39 - Inspection of the cooling system
Inspection points
Test the thermoswitch and preheating control unit using the following procedure.
Test the thermostat using the following procedure.
Check for signs of aging or damage.
Use new gaskets.
Check for cracks or distortion.
Check for cracks or leaks.
Check for elongation, aging or wear.
Inspection
1.
Water pump
Check rotation of the impeller and shaft.
m
If they do not rotate freely or are abnormally noisy, renew the water
pump assembly.
Fig. 305
30-87
Method of intervention
2.
Standard thermostat.
DANGER
Contact with the water in the radiator can cause severe
burns.
Hang the thermostat in a pan of water as shown in the figure. The thermostat must be below the surface of the water and it must not touch the sides
of the pan. Heat the water uniformly in the pan and read the temperature at
which the thermostat valve starts opening and the temperature at which the
valve lift (distance) is 8 mm (0.3 in).
Table 77
Fig. 306
3.
Thermoswitch (standard).
DANGER
The oil in the pan is hot. Any contact can cause severe
burns.
Hang the thermoswitch in a pan of oil with its temperature sensor below the
surface of oil and measure the resistance while heating the oil as shown
in the figure.
Table 78
Resistance at 120 C (248F)
30 m Ohm
Temperature at which switch is 111 3.5 C (232 6.3 F)
turned ON
m
4.
Fig. 307
Table 79
Standards
30-88
50 C (122 F): 80 10 W
80 C (176 F): 29.5 2.5 W
120 C (248 F): 10 0.3 W
Fig. 308
Method of intervention
30.1.40 - Engine air intake pipe
Removal
1.
Fig. 309
2.
Fig. 310
3.
Fig. 311
4.
Fig. 312
30-89
Method of intervention
Refitting
1.
Fig. 313
2.
Fig. 314
Refitting
1.
Table 80
Tightening torque
2.
Table 81
Tightening torque
30-90
Method of intervention
30.1.42 - Inspection of the air intake and exhaust system
Inspection
Inspection
30-91
Method of intervention
Inspection procedure
1.
Using a straight edge and a feeler gauge, check the flange faces of the
manifold for warpage and compare with the values given in the table below.
Table 82
Item
Warpage of manifold
m
Standards
Fig. 319
30-92
Method of intervention
30.2 - C0 - Engine accessories
Open radiator cap (1) to allow the coolant to flow and then open drain valve
(2).
Fig. 320
2.
Fig. 321
3.
Remove the four upper screws and two lateral screws (4) and remove RH
fan guard (5).
Fig. 322
4.
Remove the three retaining screws (6) and remove LH fan guard (7).
Fig. 323
30-93
Method of intervention
5.
Remove the three retaining screws (8) of the top hose shroud.
Fig. 324
6.
Fig. 325
7.
Fig. 326
8.
Remove the six hex socket screws (12) securing the fan cowling.
Fig. 327
30-94
Method of intervention
9.
Remove the two lower radiator retaining screws (13) on either side.
m
Fig. 328
10.
Tilt the radiator forwards and loosen clamp (14) to disconnect the bottom
hose.
Fig. 329
11.
Tilt the radiator forwards and loosen clamp (15) to disconnect the water
drain hose.
Fig. 330
12.
Fig. 331
30-95
Method of intervention
Refitting
1.
Start the engine and run for a few minutes to allow the coolant to circulate; check the system for leaks.
Remove the two screws (1) securing the expansion tank to the hood support bracket.
Fig. 332
2.
Fig. 333
3.
Fig. 334
Refitting
1.
30-96
Method of intervention
30.2.3 - Fan
Removal
1.
Fig. 335
2.
Remove the centre nut (2) of the fan by turning it clockwise (LH thread),
while holding the back of the fan against rotation.
m
Fig. 336
3.
Fig. 337
Refitting
1.
30-97
Method of intervention
30.2.4 - Air cleaner assembly
Removal
1.
Fig. 338
2.
Fig. 339
3.
Fig. 340
30-98
Method of intervention
Refitting
Refitting is the reverse of removal.
Fig. 341
To remove the fuel tank float switch it is not necessary to carry out
all the removal operations described above.
Remove the upper retaining screws of shroud (1) and the retaining screw
of upper panel (2), and unscrew fuel tank filler cap (3).
m
Fig. 342
2.
Fig. 343
30-99
Method of intervention
3.
Fig. 344
4.
Fig. 345
Refitting
Refitting is the reverse of removal.
Fuel tank
Removal
1.
Fig. 346
2.
Remove upper panel (4) and fuel tank filler cap (3), if the fuel tank float
switch has not already been removed.
Fig. 347
30-100
Method of intervention
3.
Remove relay (8) and preheating control unit (9) from the fuel tank.
Fig. 348
4.
Loosen clip (10) and remove preheating control unit wiring (11).
Fig. 349
5.
Fig. 350
6.
Remove retaining screws (14) and remove side panel (13) on either side.
Fig. 351
30-101
Method of intervention
7.
Remove the lateral fuel tank retaining screws (15) on both sides.
Fig. 352
8.
Fig. 353
9.
Remove the three screws (18) and remove upper heat shield (17).
Fig. 354
10.
Note the position of the pipe connecting the main fuel tank to auxiliary tank (20).
Fig. 355
30-102
Method of intervention
11.
Take care not to lose the spacers and the damper located on the two
guides (21) of the fuel tank subframe.
Fig. 356
Refitting
Refitting is the reverse of removal.
First drain the main fuel tank and then the auxiliary tank.
m Do not remove the drain plug of the auxiliary tank without having first removed the drain plug of the main tank.
Remove cover (1) of the A/C valve.
Fig. 357
3.
Fig. 358
4.
Remove the auxiliary electrical connector support bracket (3) from the tank.
Fig. 359
30-103
Method of intervention
5.
Fig. 360
6.
Fig. 361
7.
Refitting
1.
Turning the starter switch to ON position activates the glow plugs to heat
the engine and causes the glow plug indicator to come on.
Table 83
Heating time
30-104
Method of intervention
Glow plug timer specifications
1.
The following table contains the standard technical data for the glow plug timer.
Table 84
Model
QGS
Type
Voltage rating
Operating voltage range
Operating temperature range
Storage temperature range
Glow plug activation time
Quick heating
12 Vdc
7 to 15 V
from -30 C to +70 C (from -22 F to +158 F)
from -40 C to +80 C (from -40 F to +176 F)
6.2 0.7 seconds
The following table contains the standard technical data for the glow plug
relay.
Table 85
Model
Voltage rating
Continuous rating
Coil resistance
Inductance
Operating temperature range
G71SP
12 Vdc
1 minute
13 Ohm
24 mH (at 1 kHz)
from -40 C to +100 C (From -40 F
to +212 F)
Fig. 363
Test for continuity between the terminal and body as shown in the figure.
Table 86
Item
Resistor
Standard
0.55 Ohm
Fig. 364
30-105
Method of intervention
30.2.9 - Exhaust pipe - tractor with cab
Removal
1.
Fig. 365
2.
Fig. 366
3.
Fig. 367
30-106
Method of intervention
Refitting
1.
Fig. 368
Table 87
No
Wire colour
1
2
3
Dark blue
Dark blue
Red
Green
Red/white
7
8
Yellow
Black
Connected to:
Solenoid
Solenoid
Battery (starter switch B
terminal)
Starter switch ON terminal
Starter (starter switch
and starter)
Oil pressure switch
Earth
Fig. 369
30-107
Method of intervention
Refitting the engine stop solenoid
1.
Remove the control rod cover. Apply thread sealant (Three Bond 1212) to
the threads of the engine stop solenoid.
Apply sealant to the entire length of thread to be screwed into the
governor housing.
Temporarily install the engine stop solenoid and the relative nut in the governor housing; then move the injection pump control rack to the injection
shutoff position
Insert the engine stop solenoid in the governor housing while pushing the
plunger towards the control rack to bring the shaft in contact with the control
rod. At this point, clearance C should be 0 mm. (the plunger will be rotated
as a result of the engine stop solenoid being screwed in).
Back off the engine stop solenoid by 30 - 45 (the clearance between the
control rack and plunger will be 0.15 to 0.20 mm (0.6059 to 0.0079 in.), then
tighten the nut to the specified torque. Start the engine and make sure the
engine stops when the plunger reaches the end of its stroke.
1 - Tightening torque: 4.5 0.5 kgf x m(32.5 3.6 lbf x ft) [44 N x m].
2 - Threads to be coated with thread sealant.
3 - Shaft.
4 - Plunger.
5 - From 0.15 mm to 0.20 mm (from 0.0059 to 0.0079 in).
m
2.
Fig. 370
Do not allow thread sealant to contact (A) and do not allow cleaning
solvent to enter the solenoid through aperture (B).
Install the rubber cap in position with the arrow pointing upwards (with the
side with the water drain hole down) as shown in the figure.
Do not allow cleaning solvent to come into contact with any part of
the solenoid.
1 - Rubber cap.
2 - Water drain hole.
m
Fig. 371
30-108
Method of intervention
Inspection after installation.
1.
Start the engine and make sure the engine stops when the starter switch key is turned to OFF position. Start the engine and
make sure the engine stops when the oil pressure switch terminal is shorted to the switch body.
30.2.11 - Alternator
Table 88
Excessive charge from alternator
2.
Fig. 372
Fig. 373
30-109
Method of intervention
3.
Table 89
Item
4.
Fig. 374
Standard
14.7 V 0.3 V
1 - Ammeter.
2 - Switch.
3 - Voltmeter.
4 - Battery (12 volts).
Testing output characteristics.
Disconnect the earth lead from the negative terminal of the battery. Connect one ammeter lead to the B terminal of the alternator and the other lead
to the positive terminal of the battery. Connect one voltmeter lead to the
B terminal and the other lead to earth; then connect the earth (negative)
lead of the battery. Start the engine and switch on all the electrical loads.
Increase the engine revs and measure the maximum output current at the
specified alternator speed, when the voltmeter reading is 13.5 volts.
Table 90
Item
Model
30-110
Standards
Fig. 375
Method of intervention
Disassembly
1.
Disconnect the battery leads, disconnect the lead from terminal B of the
alternator, then disconnect the wiring connector from the alternator.
Loosen the mounting screws, move the alternator towards the engine and
remove the drivebelt.
Remove the alternator.
Fig. 376
Refitting
1.
Locate the alternator. Fit the adjustment screw to hold the alternator in
position.
Locate the drivebelt on the pulley. Move the alternator away from the engine to tension the drivebelt.
Tighten the screws.
Fig. 377
2.
Table 91
Deflection under applied force of from 10 mm to 12 mm (from 0.4 in
less then 10 kgf (22 lbf) [98 N]
to 0.5 in)
A - Apply a force of 10 kgf (22 1bf) [98 N] midway between the crankshaft
pulley and the alternator pulley.
B - Adjustment screw.
Fig. 378
30-111
Method of intervention
30.2.12 - Alternator
Disassembly
Screw.
Pulley.
Rotor.
Rear bearing.
Bearing retainer plate.
Front bearing.
Front bracket.
Stator core.
Brush older.
Rectifier.
Rear bracket.
Disassembly procedure
1.
Fig. 380
30-112
Method of intervention
2.
Fig. 381
3.
Fig. 382
Inspection
30-113
Method of intervention
Inspection procedure
1.
Diodes.
Test the resistance between the diode and heat sink. Using an ohmmeter,
first touch the diode with the positive (+) probe, then with the negative ( )
probe. If the resistance is infinite in both cases, the diode circuit is open. If
it is nearly zero in both cases, the diode is shorted. Repeat this test on all
the remaining diodes.
m
Fig. 384
2.
Field coil.
Test for continuity between the slip rings as shown in the figure.
m
Fig. 385
3.
Test for electrical continuity between the slip ring and shaft (or core), as
shown in the figure.
m
Fig. 386
4.
Stator core.
Test for continuity between the leads, as shown in the figure.
m
Fig. 387
30-114
Method of intervention
5.
Test for continuity between each wire and the stator core, as shown in the
figure.
m
Fig. 388
6.
Brushes.
Renew the brushes if they are worn down to or beyond the wear limit.
A - Wear limit.
Fig. 389
7.
To remove the brushes from the brush holder for replacement, unsolder the
wires from the brushes, then remove the brushes and springs.
1 - Unsolder.
2 - Brush holder.
Fig. 390
8.
Fit the new brushes in the brush holder and solder the wires to the brushes.
Fig. 391
30-115
Method of intervention
Assembly
1.
To assemble, reverse the disassembly steps and use the following procedure:
the rear bearing has a groove for slip ring. Install the slip ring in this groove,
making sure the tab locates the deepest part of the groove.
to install a new rear bearing, position it with the grooved side facing the slip
rings of the rotor;
before installing the bearing in the rear bracket, heat the bracket;
before installing the rotor in the rear bracket, insert a bent wire tool into the
hole in the rear bracket to lift the brushes clear of the slip rings. Remove the
tool after the rotor has been installed in position.
1 - Bent wire tool.
2 - Brushes.
3 - Rear bracket.
Fig. 392
DANGER
Disconnect the lead from the battery negative terminal (-).
2.
Fig. 393
3.
Fig. 394
30-116
Method of intervention
4.
Fig. 395
5.
Fig. 396
6.
Fig. 397
7.
Fig. 398
30-117
Method of intervention
Refitting
1.
2.
Fig. 399
No-load characteristics.
Connect the starter motor to a 12 volt battery, as shown in the figure. Close
the switch to shift the pinion into cranking position, and run the starter at
a speed higher than that specified. If the current draw and/or operating
speed is out of the normal range, disassemble the starter for inspection
and repairs.
1- Switch.
2 - Ammeter.
3 - Starter motor.
4- Speedometer.
5 - Battery (12 volts).
3.
Fig. 400
For this test, use wires of the largest permitted size. Tighten the terminals securely.
The starter motor has a reduction gear Do not confuse gear noise with abnormal noise.
When measuring the starter motor speed at the end face of the pinion, be ready for sudden movement of the pinion.
Table 92
Item
Model
Nominal output, V - kW
No-load characteristics
30-118
Standard
M2T56272
12 - 2.0
11
130 maximum
3850 minimum
M2T50381
12 - 1.6
11.5
100 maximum
3000 minimum
Method of intervention
4.
Solenoid
Disconnect the wiring connector from the M terminal of the solenoid. Connect the solenoid to a 12 volt battery with a switch, as shown in the figure,
to test the pull-in coil. Close the switch to see if the pinion shifts.
m
Fig. 401
5.
Fig. 402
6.
Fig. 403
7.
Removal.
Disconnect the battery leads. Disconnect the negative ( ) lead first. Disconnect lead (1) from the starter motor. Loosen the two retaining screws (2)
and remove the starter motor (3).
Fig. 404
30-119
Method of intervention
Refitting
1.
Pinion assembly.
Field magnet
Support bracket.
Brush gear.
Yoke.
Armature.
Bearing.
Ball.
Seal.
Gear.
Lever assembly.
Gasket kit.
Gear carrier shaft.
Internal gear.
Overrunning clutch.
Front support bracket.
l
The pinion must be removed prior to removing or renewing bracket (16), gears (10) and the overrunning clutch (15).
Disassembly procedure
1.
Pinion.
It is possible to remove the pinion when in the forward position as a result of excitation of the field magnet. Disconnect the
connector of the M terminal and create a circuit that connects the starter motor and the battery as illustrated in the figure. Close
the switches S1 and S2 so that the pinion is moved forward and rotates. Then open switch S2. The pinion will stop rotating but
will remain in the forward position. Apply a tubular tool to the pinion stop and tap it gently with a mallet to remove the pinion.
m If, when tapped, the pinion returns to its back position before the stop is detached, repeat the operation from the beginning.
30-120
Method of intervention
2.
Ball.
The ball at the end of the armature serves as a thrust bearing. When the
armature is removed, the ball may remain attached to the end with grease.
m
Fig. 406
Test
Armature
1.
Fig. 407
2.
Fig. 408
3.
Commutator test.
Measure the commutator run-out using a dial gauge.
Table 93
Commutator run-out
m
Limit
If the run-out exceeds the indicated tolerance limit, lightly skim the
commutator on a lathe so that the outside diameter is within the
specifications.
Fig. 409
If the surface of the commutator is rough or has steps worn into it,
smooth using fine grade glasspaper (# 300 500).
30-121
Method of intervention
4.
Table 94
Normal value
Limit
5.
Table 95
Commutator run-out
m
Limit
If the depth is less that the specified tolerance limit, recut the slots to
depth of 0.4 0.6 mm. (0.016-0.024 inches).
Fig. 411
Field coil
1.
Fig. 412
2.
Fig. 413
30-122
Method of intervention
Brushes and brush gear
1.
Brushes worn.
Measure the length of the brushes. If the length is below the specified tolerance limit, renew the brush.
Table 96
Brush length
m
2.
Normal value
18 mm (0.71 in)
Limit
11 mm (0.43 in)
If the brush is worn unevenly or has rough contact face, repair using
fine grade glasspaper (#300-500).
Fig. 414
Table 97
Brush spring force
3.
Normal value
Limit
Renew the spring if the force is less than the specified limit.
Fig. 415
Fig. 416
30-123
Method of intervention
Overrunning clutch
1.
Check that the pinion shaft runs smoothly when turned clockwise (normal
direction of rotation) and that it locks up when turned anticlockwise.
m
If the pinion shaft does not function correctly, renew the overrunning
clutch.
Fig. 417
It is not necessary to adjust the end float of the gear carrier shaft.
Assembly
16 > 12 > 13 > 14 > 15 > 1 > 10 > 11 > 9 > 8 > 5 > 6 > 7 > 4 > 3 > 2
After assembling the starter motor, carry out the following tests and checks.
30-124
Method of intervention
Checking and adjustment of the pinion clearance
1.
Connect the starter motor to the battery as shown in the figure. The pinion
will move outwards and rotate slowly. Then remove the connector of terminal M to stop the starter motor.
Fig. 419
2.
Push the pinion shaft gently towards the armature and measure the axial
movement, which corresponds to the pinion clearance.
If the pinion clearance is not within the prescribed tolerance limits of 0.52.0 mm (0.02 0.08 in.), adjust by increasing or decreasing the number of
gaskets on the field magnet (adding gaskets reduces the pinion clearance).
It may be necessary to renew the lever in order to obtain the correct pinion
clearance.
Table 98
Limit
Pinion clearance
m
Fig. 420
Do not excite the field magnet for more than 10 seconds to avoid
overheating.
No-load test
1.
When the pinion clearance has been correctly adjusted, connect an ammeter and a voltmeter between the starter motor and the battery as shown
in the figure, then check the no-load characteristics of the starter motor.
Table 99
Voltage
No-load charac- 11 V
teristics
m
Current
Use the thickest possible cables. Tighten all the terminals securely.
1. Ammeter.
2. Switch.
3. Starter motor.
4. Voltmeter.
5. Battery.
Fig. 421
30-125
Method of intervention
Field magnet
1.
Carry out the following continuity tests. If the field magnet fails any of these
tests, it should be renewed.
Check for interruptions in the coil circuit. There should be continuity between terminals S and M and between terminal S and earth (casing).
Check for poor contacts. There should be not be continuity between terminals B and M.
Fig. 422
30-126
Method of intervention
30.3 - D0 - Transmission
30.3.1 - Clutch plate
Removal
1.
Insert a suitable dowel (1) in the centre hole of the clutch assembly, then
attach the clutch assembly to a hoist (2).
Fig. 423
2.
Fig. 424
3.
Fig. 425
4.
Fig. 426
Refitting
Refitting is the reverse of removal.
30-127
Method of intervention
30.3.2 - Checking clutch plate wear
1.
Check that the thickness of clutch plate (1) is within the prescribed tolerance limits and there is no sign of burning.
Clutch plate thickness:
- standard measurement: 10 0.3 mm
- limit measurement: 7.5 mm
Fig. 427
Detach the two springs (2) from the clutch housing (1).
Fig. 428
2.
Remove screws (3) securing the clutch release forks, then remove the
clutch release bearing assembly (4).
Fig. 429
3.
Using a suitable drift, separate main clutch release bearing (5) from sleeve
(6).
Fig. 430
30-128
Method of intervention
4.
Using a suitable drift, remove ring (7) from bearing (8) and bearing (8) from
sleeve (9).
Fig. 431
5.
Remove the two thrust pins (10) from each of the two release forks.
m
Check that the pins are not excessively worn or deformed and renew them if necessary.
Fig. 432
Refitting
1.
Remove cotter pin (1) from the external tie-rod of the release fork control
lever.
Fig. 434
30-129
Method of intervention
2.
Fig. 435
3.
Remove lock pin (4) securing the tie-rod of the main clutch release fork.
Fig. 436
4.
Fig. 437
5.
Looking at the clutch housing from the front end, main clutch release fork
(6) is the smaller of the two forks and is located to the rear of PTO clutch
release fork (3).
Fig. 438
30-130
Method of intervention
Refitting
Refitting is the reverse of removal.
Fig. 439
2.
Fig. 440
3.
Remove the four screws (3) and remove footplate support brackets (4).
Fig. 441
4.
Fig. 442
30-131
Method of intervention
5.
Fig. 443
6.
Remove retaining screw (7), cotter pin (8) and remove gearshift linkage (9).
m
Mark the relative positions of gear lever (10) and the gearshift linkage.
Fig. 444
7.
Remove the two screws (11) and remove the support complete with shuttle
lever (12).
Fig. 445
8.
Fig. 446
30-132
Method of intervention
9.
Remove the two cotter pins (15) and PTO tie-rod (16).
Fig. 447
10.
Remove the two screws (17) and remove main gear lever (18).
Fig. 448
11.
Remove the two cotter pins (19) and remove gearshift tie-rod (20).
Fig. 449
12.
Unscrew fork retaining screw (21) but leave the fork in position.
Fig. 450
30-133
Method of intervention
13.
Fig. 451
14.
Fig. 452
15.
Remove the four screws (24) and lift the clutch housing clear so as to withdraw the fork.
Fig. 453
16.
Fig. 454
30-134
Method of intervention
Refitting
1.
Fig. 455
Disassembly
1.
DANGER
Disconnect the lead from the negative () terminal of the battery.
2.
Fig. 457
30-135
Method of intervention
3.
Fig. 458
4.
Fig. 459
5.
Fig. 460
6.
Only if necessary:
Remove inner race (8) of roller cage (9), the remove circlip (10) and remove
roller cage (9).
Fig. 461
30-136
Method of intervention
Assembly
1.
Disassembly
1.
Remove circlip (1) and, using a suitable puller, remove bearing (2).
Fig. 463
Assembly
1.
30-137
Method of intervention
30.3.8 - Disassembly of the secondary shaft
Disassembly
1.
Fig. 465
2.
Remove 1st speed driven gear (2), then remove driver ring (3) from gear
(2).
Fig. 466
30-138
Method of intervention
3.
Fig. 467
4.
Fig. 468
5.
Fig. 469
6.
Fig. 470
7.
Remove the thrust plate (12) and the 3rd speed driven gear (13).
m
Fig. 471
30-139
Method of intervention
8.
Remove circlip (14) and remove synchronizer (15) complete with driver ring
(16).
Fig. 472
9.
Fig. 473
10.
Remove 4th speed driven gear (19) and remove circlip (20).
Fig. 474
11.
Fig. 475
12.
Position output shaft (23) under a press and remove bearing (24).
Fig. 476
30-140
Method of intervention
Assembly
1.
DANGER
Disconnect the lead from the negative () terminal of the battery.
2.
Separate the clutch housing from the transmission and remove union (1).
m
Fig. 477
3.
Remove the two screws (2) and remove bracket (3), then remove pivot pin
(4) and rotate 4WD control lever (5).
Fig. 478
4.
Remove screws (6), attach the gearbox/shuttle (7) assembly to a hoist and
remove it.
Fig. 479
5.
Remove the two seals (8) of the range gear selector rod and the PTO
speed selector rod.
m
Remove all traces of paint from the selector rods to prevent damage
to the seals during reassembly.
Fig. 480
30-141
Method of intervention
Refitting
Refitting is the reverse of removal.
Carry out the following procedures:
Procedure 3
l
Apply a continuous bead of sealant to the contact surfaces of the transmission casing and the gearbox/shuttle assembly.
Surfaces: Loctite 510
Fig. 481
Procedure 3
l
l
Fig. 482
Procedure 4
l
Using the installation tool T3, fit previously removed seals (8).
Fig. 483
DANGER
Disconnect the lead from the negative () terminal of the battery.
2.
Fig. 484
30-142
Method of intervention
3.
Remove screws (4) and plate (5), then remove pin (6), springs (7) and balls
(8).
Fig. 485
4.
Fig. 486
5.
Fig. 487
6.
Remove circlips (11) and (12) securing the main shaft and secondary shaft.
Fig. 488
7.
Fig. 489
30-143
Method of intervention
8.
Fig. 490
9.
Using a copper bar and a soft-faced mallet, simultaneously drive out the
input, primary and secondary shafts, tapping each in turn alternately.
Fig. 491
10.
Fig. 492
11.
Fig. 493
30-144
Method of intervention
Assembly
To assemble, follow the disassembly steps in reverse order.
Carry out the following procedures:
Procedure 3
l
l
Fig. 494
Procedure 4
l
l
l
Fig. 495
Procedure 8
l
Insert all the shafts and forks simultaneously and, using a soft-faced mallet,
tap each shaft in succession to gradually drive them up against the bearings in the gearbox casing.
Fig. 496
Procedure 8
l
l
l
l
Adjust the position of the gear selector forks so that they positioned centrally relative to the synchronizer ring and secure them by tightening nuts (20).
Nuts: Loctite 270
Nuts: 90 to 105 Nm (66 to 77lb.ft.)
Fit the nuts so that the flat sides face the forks.
Fig. 497
30-145
Method of intervention
Procedure 10
l
Take care that the friction ring (21) of the 1st speed synchronizer does not
move out of position.
Do not install the oil seals at this stage.
Fig. 498
30-146
Method of intervention
Removal
1.
Fig. 500
2.
Move circlip (3) towards the rear of the transmission and drive shaft (4)
towards the front using a copper punch.
Fig. 501
3.
Remove bearing (5) and remove shaft (4) complete with gear (6), circlip (3)
and bearing (7).
m
Fig. 502
4.
Fig. 503
30-147
Method of intervention
Refitting
Refitting is the reverse of removal.
l
l
Fig. 504
2.
Fig. 505
3.
Fig. 506
4.
Fig. 507
30-148
Method of intervention
5.
The oil seal must always be renewed using installer (6) whenever it
is removed.
Fig. 508
Refitting
Refitting is the reverse of removal.
30-149
Method of intervention
Removal
1.
Remove screw (1) and remove spring (2) and ball (3).
Fig. 510
2.
Fig. 511
3.
Remove bearing (8) on the opposite side to crown wheel (9) from differential housing (7). Then remove screws (10) and remove crown wheel (9)
complete with bearing (11).
Fig. 512
4.
Remove the outer races of bearings (8) and (11) from differential supports
(12) and (13), while leaving in position the relative shims (14) and (15).
Fig. 513
5.
Using a C spanner and a soft metal bar inserted between the driven gear
and the transmission casing, fully loosen nut (16).
m
Fig. 514
30-150
Method of intervention
6.
Fig. 515
7.
Move 4WD driving gear (18) towards the front of the transmission and remove key (19); then remove pinion (20).
Fig. 516
8.
Remove the outer race of pinion bearing (21) and spacers (22) from the
transmission casing.
m
Fig. 517
9.
Using a press, remove the remaining components of bearing (21) from pinion (20).
Fig. 518
30-151
Method of intervention
Preparation for refitting
1.
Mount new crown wheel (9) on differential housing (7) and secure it with
screws (10).
m
Fig. 519
2.
Using a suitable drift, install the inner races of bearings (8) and (11).
Fig. 520
3.
Remove shims to the value of 0.2 mm from each of the two shim packs (14)
and (15) of differential supports (12) and (13) and refit them in their respective supports along with the outer races of bearings (11) and (8).
m
If it is not possible to identify the shim packs of the two sides, form
two shim packs: one 1.3 mm thick for the crown wheel side and the
other 1.8 mm thick for the opposite side.
Fig. 521
Refitting
1.
Before refitting, see the various bevel gear pair adjustment procedures:
See para. 30.3.20 - Adjustment of the beve... - page 30-162
Fig. 522
30-152
Method of intervention
2.
Fig. 523
3.
Adjust the position of fork (5) so that the selector gear is positioned centrally relative to the corresponding gear when the selector rod is in the L
range position. Tighten nuts (4) to secure in position.
m
m
Fig. 524
When removing the differential, mark the crown wheel side support
to avoid confusion on reassembly.
m If the bevel gear pair is to be renewed, do not remove the shims from
the differential support.
Remove oil seal (1) and remove circlip (2).
m
Fig. 525
2.
Using a soft metal bar as a punch, drive out shaft (3) complete with the
bearing and remove sleeve (4) from the transmission casing; then remove
bearing (5) from shaft (3).
Fig. 526
30-153
Method of intervention
3.
Remove circlip (6) and remove 4WD driven gear (8) and spacer (7).
Fig. 527
4.
Remove circlip (9) and move shaft (10) towards the rear of the transmission
casing. Remove circlip (11) and withdraw the complete shaft assembly (10)
towards the front of the transmission.
Fig. 528
5.
Remove circlip (12) and gear (13), then remove bearing (14).
Fig. 529
6.
Fig. 530
30-154
Method of intervention
Assembly
1.
Fig. 531
Fig. 532
2.
Fig. 533
3.
Fig. 534
30-155
Method of intervention
4.
Remove set screw (4), then remove the selector fork-synchronizer assembly (5) and bronze crown (6).
Fig. 535
5.
Remove cover (7 ) and remove the spring and ball (8) from the relative gear
selector rod.
Fig. 536
6.
Remove creeper interlock plunger (9) after removing the relative plug.
Fig. 537
7.
Fig. 538
30-156
Method of intervention
8.
Loosen the nut and locknut of selector fork (11), so that the fork may be
shifted forwards to allow removal of the synchronizer gear.
Fig. 539
9.
Fig. 540
Refitting
1.
Fig. 541
2.
Fig. 542
30-157
Method of intervention
3.
Fig. 543
Refitting
Refitting is the reverse of removal.
Remove circlip (2) from shaft (1) and remove bearing (3).
Fig. 544
Assembly
To assemble, follow the disassembly steps in reverse order. Carry out the following procedures:
Remove screw (1) and remove spring (2) and ball (3).
Fig. 545
2.
Fig. 546
30-158
Method of intervention
3.
Fig. 547
4.
Move circlip (8) towards the front of the transmission. Using a suitable tool,
partially withdraw PTO shaft (9).
Fig. 548
5.
In some cases bearing (10) may remain on shaft (9). Remove it using gear (11).
Recover shims (12), spacer (13) and gear (14).
Fig. 549
6.
Fig. 550
30-159
Method of intervention
Refitting
1.
If PTO shaft (9), bearings (10) and (15) or transmission casing (16)
are to be renewed, form a shim pack to be installed between PTO
shaft (9) and the front bearing (10) to obtain play of 0.05 to 0.15 mm.
Fig. 551
2.
Adjust the position of the PTO speed selector fork so that, when selector
rod (17) is in the 1000 rpm position, selector gear (11) is positioned centrally relative to the gear (18).
m
m
m
m
Fig. 552
To disconnect the parking brake cable, remove cotter pin (1) and loosen the
clamp securing gaiter (2) to remove the outer cable.
Fig. 553
30-160
Method of intervention
2.
Fig. 554
3.
Remove the four retaining screws (6) and remove parking brake lever (7).
Fig. 555
4.
Fig. 556
5.
Remove the pin securing the cable to lever (9) and relative circlip (10).
Fig. 557
30-161
Method of intervention
6.
Fig. 558
Refitting
1.
Fig. 559
2.
Position a dial gauge with magnetic stand A on the differential support (2)
of the crown wheel side and set it to zero on the head of the differential,
while using a lever to force the differential towards the opposite side to the
crown wheel.
Fig. 560
3.
Force the differential towards the crown wheel side and measure the end
float. Add 0.1 mm to the measured end float to determine the thickness of
the shims to be installed under the bearing (4) on the opposite side to the
crown wheel.
m
Fig. 561
30-162
Method of intervention
4.
Remove flange (3) on the opposite to the crown wheel and install a shim
pack (5) of the thickness calculated in the previous step. Refit differential
support (3) to the transmission casing.
Fig. 562
5.
Wind a cord around the 122 mm section of the differential housing and,
using a spring dynamometer T5 (code 5.9030.529.0), measure the rolling
resistance torque of differential (1) to check the correct preloading of the
differential bearings.
m
Fig. 563
Take care not to confuse the right and left differential supports.
Fig. 564
2.
Install pinion (6) complete with the bearing in the transmission casing and
drive it into its seating.
Make a note of the value E stamped on a tooth of pinion (6) (in this
example + 0.3 mm).
Temporarily fit 4WD gear (7) and nut (8).
m
Fig. 565
3.
Install differential (1) complete with supports (2) and (3), and then fix the
supports.
m
Fig. 566
30-163
Method of intervention
4.
5.
Use a feeler gauge to measure the distance D between the end face of
pinion (20) and the 122 mm section of the differential housing (in this
example 2.95 mm).
Calculate the value R by adding value E stamped on the tooth of pinion
(20) to the theoretical value of 2.00 mm.
If E is positive, as in the example shown in figure, add it to the theoretical
value of 2.00 mm.
R = 2.00 + E
i.e.
R = 2.00 + 0.30 = 2.30
If E is negative, subtract it from the theoretical value of 2.00 mm.
R = 2.00 - E
i.e
R = 2.00 - 0.30 = 1.70
If the measured value D differs from the calculated value R, calculate the
difference between D and R.
The resulting value S is the shim thickness to be installed under the bearing of pinion (6).
Formula: S = D - R
which in our example gives: S = 2.95 2.30 = 0.65 mm
Fig. 567
Remove differential (1) and pinion (6) complete with the bearing. Fit the
calculated shim pack S (10) on bearing (9) and install in the transmission
casing.
m
Fit 4WD driving gear (7), nut (8) and the driven range gear (11) on
pinion shaft (6).
Fig. 568
6.
Secure bearing (9) in position with circlip (12) selected from the available
sizes.
Select the circlip by applying the following formula:
Circlip thickness = A
Fixed dimension = R
Shim thickness = S
A=RS
which in our example gives: A = 3.50 0.65 = 2.85 mm
A 2.80 mm thick circlip is therefore required.
Fig. 569
7.
Insert key (13) and, using wrench T6 (code 5.9030.964.0), tighten nut (8).
m
m
Fig. 570
30-164
Method of intervention
8.
Fig. 571
Install complete differential assembly (1) and supports (12) and (13). Fix
supports (12) and (13) by tightening screws (24).
m
While tightening the screws, rotate the pinion in both directions and
lightly tap the differential housing to help seat the bearings.
Fig. 572
2.
Position a dial gauge B on a magnetic stand with the contact point perpendicular to the side of a tooth on the external diameter of the crown
wheel. Preload the gauge by approx. 3 mm and measure the backlash Z
between the pinion and crown wheel by turning crown wheel (15) in both
directions.
m
m
Fig. 573
3.
If the backlash Z is less than 0.10 mm, transfer shims from pack S1
(crown wheel side) to pack S2 (opposite side to the crown wheel). If the
backlash Z is greater than 0.15 mm, transfer shims from shim pack S1
(crown wheel side) to shim pack S2 (opposite side to crown wheel).
The sum total thickness of shim packs S1 and S2 should not be
altered from the value determined by testing the rolling resistance
of the differential.
Recheck backlash Z and, if necessary, continue to adjust the shims until
the backlash is within the specified tolerance limits.
m
Fig. 574
4.
Finally tighten down screws (14) securing differential supports (2) and (3).
m Screws: 211 Nm (15.50.7 lb.ft.)
m Screws: Loctite 242
30-165
Method of intervention
30.4 - E0 - Rear axle
DANGER
Disconnect the lead from the battery negative terminal (-) and apply the parking brake.
2.
Loosen clamps (1) and disconnect sleeve (2) from one of the pipes (3).
Fig. 575
3.
Remove nuts (4) and disconnect plate (5) from the transmission.
Move the stand (A) positioned under the rear axle under the bar (B).
Fig. 576
4.
Fig. 577
5.
Remove the two screws (8), nut (9) and remove oil suction pipe (10).
m
Fig. 578
30-166
Method of intervention
6.
Remove all the nuts (12), remove bracket (13) and spring (14), then remove
parking brake cable retaining plate (15).
Fig. 579
7.
Attach rear axle (16) to a hoist and take up the slack in the lifting slings/
ropes, then remove axle assembly (16).
Fig. 580
Refitting
Refitting is the reverse of removal.
l
Fig. 581
Procedure 6
l
Procedure 5
l
l
30-167
Method of intervention
30.4.2 - Disassembly of LH/RH rear axle
Disassembly
1.
Relieve the staking and remove the ringnut (1) using the special wrench T4
(code 5.9030.601.0).
m
Fig. 583
2.
Fig. 584
30-168
Method of intervention
3.
Remove bearing (3) and ring (4) complete with oil seal (5).
Fig. 585
4.
Fig. 586
5.
Fig. 587
6.
Fig. 588
7.
To withdraw the shaft, pull it towards you while tapping it with a softfaced mallet.
Fig. 589
30-169
Method of intervention
8.
Fig. 590
9.
Fig. 591
Assembly
1.
Using a press, install bearing (16) on shaft (11), then fit spacer (15) and
secure with circlip (14).
Fig. 592
2.
Install bearing (3) in axle housing (6) then fit oil seal (5) to ring (4).
m
Take care to install the oil seal the right way round.
Fig. 593
3.
Position complete ring assembly (4) in the axle housing and, using a suitable tool, drive it into its seating.
m
m
m
m
Fig. 594
30-170
Method of intervention
4.
Fit shaft (11) in axle housing(6) and secure it in position with circlip (10).
Fig. 595
5.
Fig. 596
6.
Fig. 597
7.
Position axle housing (6) under a press and install hub (2), driving it up
against bearing (9).
m
Fig. 598
8.
Using a suitable drift, install bearing (13) and secure in position with circlip
(12).
Fig. 599
30-171
Method of intervention
9.
Fig. 600
10.
Fig. 601
30-172
Method of intervention
Removal
1.
Remove the rear axles and braking devices, and remove the lift assembly.
Remove screws (1) and remove LH differential support (2).
m
Fig. 603
30-173
Method of intervention
2.
Fig. 604
3.
Fig. 605
4.
Fig. 606
30-174
Method of intervention
Refitting
1.
Fig. 607
2.
Fig. 608
3.
Fig. 609
4.
Withdraw the pin (6), planet pinions (7), thrust washers (8) and the second
side gear (9) with its thrust washer (10).
Fig. 610
30-175
Method of intervention
Assembly
1.
Fig. 611
2.
Insert the spring pin (5) so that the end lies approx. 1 mm below
the the face of the differential housing to which the crown wheel is
mounted.
Fig. 612
Fig. 613
2.
Fig. 614
30-176
Method of intervention
3.
Loosen off fully brake operating tie-rod (4) and remove nut (5) and spring
(6).
Fig. 615
4.
Remove braking device (7) and the last friction disc (8).
Fig. 616
Only if necessary
1.
Fig. 617
Refitting
1.
30-177
Method of intervention
30.5 - F0 - Front axle
30.5.1 - Front support
Removal
1.
Fig. 618
2.
Disconnect differential lock pipe (2) and the two power steering pipes (3).
Fig. 619
3.
Fig. 620
4.
Fig. 621
30-178
Method of intervention
5.
Disconnect the lower connection pipe of front lift control valve (6).
Fig. 622
6.
Remove the two metal straps (7) and move the pipe to one side.
Fig. 623
7.
Fig. 624
8.
Disconnect oil supply pipe (9) from the holding valve and oil return pipe (10)
from the PTO clutch.
Fig. 625
30-179
Method of intervention
9.
Fig. 626
10.
Remove on the RH side the two screws and the two nuts (12) connecting
the front engine support.
Fig. 627
11.
Remove on the RH side the three screws and two nuts (13) connecting the
front engine support.
Fig. 628
12.
Fig. 629
30-180
Method of intervention
13.
Fig. 630
14.
Fig. 631
15.
Attach the front support to an overhead crane and remove front support
complete with axle (17).
m
Fig. 632
30-181
Method of intervention
Refitting
1.
DANGER
Apply the parking brake and remove the key from the starter switch.
2.
Remove the two screws (1) securing the clamps, remove the five screws
(2) and remove the 4WD shaft shield (3).
Fig. 633
3.
Fig. 634
4.
Fig. 635
5.
Fig. 636
30-182
Method of intervention
6.
Move sleeve (9) towards pinion (8) in order to release 4WD shaft (10).
Repeat the above procedure for the front sleeve.
m
Take care not to get sleeve (9) stuck on the pinion teeth (8).
Fig. 637
7.
Remove screws (11) and remove 4WD shaft (10) complete with centre support (12).
Fig. 638
8.
Raise the front end of the tractor and position a stand A under the sump,
then remove the front wheels (13).
Fig. 639
9.
Position a jack under the front axle; remove nuts (14) and washers (15) and
remove axle (16).
Fig. 640
30-183
Method of intervention
Refitting
1.
Start the engine and repeatedly turn the steering to full lock in both directions to expel any air from the steering circuit.
Supports: Grease
Removal
1.
Remove the left and right plugs (1) and plug (2) and drain off all the oil.
m
Fig. 642
30-184
Method of intervention
2.
Fig. 643
3.
Using a soft mallet and nut (4) as a driving tool, disconnect pin (5) from
steering knuckle housing (6), then remove nut (4) and remove pin (5) from
the steering knuckle housing.
m
Repeat the above operations to remove the pin on the opposite side.
Fig. 644
4.
Fig. 645
5.
Using a hot air blower, heat one side of the piston to approx. 65 C and
removing steering arm (8).
Fig. 646
6.
On both sides remove the two screws (9), remove end fitting (10), then
withdraw piston (11) complete with end fitting (12).
Fig. 647
30-185
Method of intervention
Refitting
1.
Take care to position ring (A) and ring (B) as shown in the figure.
Fig. 648
Disassembly
1.
Grip the piston in a vice (with soft-faced jaws) and, using a hot air gun, heat
the end to approx. 65C and remove steering arm (1).
Fig. 650
30-186
Method of intervention
2.
Remove spacers (3), the shims (4) and the steering cylinder (5) from axle
housing (2).
Fig. 651
3.
Remove O-ring (6), seal (7) and dust seal (8) from the end caps (9).
m
Fig. 652
4.
Remove seal (11) and guide ring (12) from piston (10).
Fig. 653
30-187
Method of intervention
Assembly
1.
2.
Narrow version.
On both ends of the steering cylinder, install piston (10), spacer (3) and end
cap (9) and tighten screws (13).
m
Fig. 655
Raise the front of the tractor and position a stand (A) under the sump.
Fig. 656
2.
Position a jack under the front axle and remove nuts (1) and the two washers (2); apply a lever between front support (3) and front and rear axle supports (4) and remove the complete axle.
Fig. 657
30-188
Method of intervention
3.
Fig. 658
4.
Remove screw (6) and unions (7) and remove steering control pipes (8).
Fig. 659
5.
Remove rear axle support (9) and spacer (10), then remove union (11) and
differential lock pipe (12).
m
Fig. 660
6.
Remove screws (13) and remove the complete differential assembly (14).
m
Fig. 661
30-189
Method of intervention
Refitting
1.
Disassembly
1.
Remove screws (1) and remove the complete differential assembly (2).
m
Fig. 663
30-190
Method of intervention
2.
Detach spring (4) from fork (5) and remove sleeve (6) and shoes (7).
Fig. 664
3.
Drive out spring pin (8) and remove, in order: washer (9), pin (10), complete
with washer (11), spring (12), fork (13) and spacer (14).
m
Fig. 665
4.
Force out the differential lock piston (15) using a low pressure compressed
air jet.
m
Fig. 666
5.
Remove circlip (17) on the crown wheel side and recover shims (18).
m
Fig. 667
6.
Remove circlip (19) from the opposite side to the crown wheel and recover
shims (20).
m
Fig. 668
30-191
Method of intervention
7.
Withdraw bearings (21) and (22) and remove the complete differential assembly (23).
Fig. 669
8.
Fig. 670
9.
Remove the sun gear (28) and thrust washer (27) from differential housing
(26).
Fig. 671
10.
Drive out spring pin (29) sufficiently to release pin (30) and withdraw pin
(30); then withdraw planet pinions (31) and relative washers (32).
Fig. 672
11.
Remove side gear (33) and thrust washer (34) from differential housing
(26).
Fig. 673
30-192
Method of intervention
12.
Fig. 674
13.
Fig. 675
14.
Remove the inner race of bearing (41) from differential support (40) and
withdraw the inner race of the bearing (42) from pinion shaft (39).
Fig. 676
15.
Withdraw the outer races of bearings (41) and (42) from the differential
support (40).
m
Recover shims (43) installed under the outer race of bearing (42).
Fig. 677
30-193
Method of intervention
Assembly
1.
Install bearing (42) without shims (43) in differential support (40), and use a
depth gauge (A) to measure dimension X.
m
Fig. 678
2.
Calculate the distance D of the axis of rotation of the differential from the
face of bearing (42) using the following formula:
D = X + B radius of crown wheel bearing (R)
Example:
- dimension X = 128.9 mm
- pin diameter B = 8.00
- radius of crown wheel bearing = 40.0 mm
D = 128.9 + 8.00 40.0 = 76.9 mm
Fig. 679
3.
4.
Note the dimension E stamped on the tooth tip. Remove outer race of
bearing (42) and differential support bearings (21) and (22); form a shim
pack S using the following formula:
S = D theoretical value E
where:
S =shim pack thickness
D = distance calculated in point 2.
theoretical value = 76.00
E = value stamped on tooth
Example 1 (positive E value): D = 76.90 mm E = 0.30 mm theoretical
value = 76.00 S = 76.90 76.00 0.30 = 0.60 mm Example 2 (negative E
value): D = 76.90 mm E = 0.30 mm theoretical value = 76.00 S = 76.90
76.00 + 0.30 = 1.20 mm
Fig. 680
Install in differential support (40) shim pack (43), the outer race of bearing
(42) and the outer race of bearing (41).
Fig. 681
30-194
Method of intervention
5.
Insert pinion (39) complete with the inner races of bearing (42) and bearing
(41).
Fig. 682
6.
Fig. 683
7.
Using tool (T), screw in nut (35) to seat the bearings, then back off by about
1/4 turn.
Nut: Loctite 270
While tightening the nut, rotate pinion (39) in both directions and tap it lightly to help seat the bearings.
m
Tighten nut (35) gradually until all pinion end float is eliminated, but
without preloading the bearings.
Fig. 684
8.
Position thrust washer (34) and the side gear (33) in differential housing
(26).
m
Fig. 685
9.
Insert the spring pin so that the end lies approx. 0.5 mm below the
face of the differential housing to which the crown wheel is mounted.
Fig. 686
30-195
Method of intervention
10.
Fig. 687
11.
Position the complete differential assembly (23) in support (40) and fit bearing (22) on the opposite side to the crown wheel.
Fig. 688
12.
Form shim pack (20) on the opposite side to the crown wheel by adding 0.2
mm to the thickness measured during disassembly.
Example:
measured thickness = 1.5 mm
new shim pack = 1.7 mm
Fit new shim pack (20) and secure with circlip (19).
Fig. 689
13.
Fit crown wheel side bearing (21) in its seat in the differential housing.
m
Check that both bearings are fully seated in the differential housing.
Fig. 690
14.
m
m
Check that bearing (22) on the opposite side to the crown wheel is
seated against the circlip.
Normal backlash Z: 0.14 to 0.19 mm
Take four measurements 90 apart and calculate the average.
Fig. 691
30-196
Method of intervention
15.
Temporarily fit circlip (17) and, with a feeler gauge, measure the clearance
between circlip (17) and bearing (21) to determine the thickness of the shim
pack (18) to be installed under the circlip on the crown wheel side.
Shim pack (18) should be thick enough to eliminate the end float of
differential (23).
Fit shim pack (18) and secure it with circlip (17).
m
Fig. 692
16.
Fig. 693
17.
Install the following components in the differential support in the order given: spacer (14), fork (13), spring (12), pin (10), washer (9) and secure with
spring pin (8).
m
Fig. 694
18.
Insert shoes (7) in fork (13) and insert the end of spring (12) in hole (A),
then fit sleeve (6).
Fig. 695
19.
Using a suitable tool, fit oil seal (38) on differential support (40) and install
O-ring (3).
m
O-ring: grease
Fig. 696
30-197
Method of intervention
30.5.7 - Propeller shaft - Front axle drive shaft
Removal
1.
Remove the two front screws (1) and central screw (2) securing the cover.
Fig. 697
2.
Remove the two rear screws (3) and remove cover (4).
Fig. 698
3.
Unseat circlip (5) and drive out spring pin (6) from the front and rear ends
of the shaft.
Fig. 699
4.
Move the sleeve towards pinion (7) and remove front axle drive shaft (8).
m
Take care not to get the sleeve stuck on the pinion teeth.
Fig. 700
30-198
Method of intervention
Refitting
1.
Remove the front wheels, remove left and right plugs (1) and (2) and drain
off all the oil.
m
Fig. 701
2.
Fig. 702
3.
Using a soft faced mallet and nut (4) as a drift, detach pin (5) from steering
knuckle housing (6); remove nut (4) and remove pin (5) from the steering
knuckle housing. Remove screws (7) and finally remove complete planetary reduction gear assembly (8).
Fig. 703
Refitting
1.
30-199
Method of intervention
30.5.9 - Disassembly of the planetary reduction gear
Disassembly
1.
Fig. 705
2.
Fig. 706
30-200
Method of intervention
3.
Fig. 707
4.
Fig. 708
5.
Fig. 709
6.
Fig. 710
7.
Fig. 711
30-201
Method of intervention
8.
Remove from stub axle housing (13) bearing (14) complete with gear (15)
and shaft (16); remove circlip (17).
m
Fig. 712
9.
Using a soft metal punch and a mallet, separate steering joint support (18)
from stub axle housing (13).
Fig. 713
10.
Using a soft metal punch and a mallet, drive bearing (19) from stub axle
housing (13).
Fig. 714
11.
Using a lever, prise out oil seal (20) then remove spacer (21) and bearing
(22).
Fig. 715
12.
Fig. 716
30-202
Method of intervention
13.
Remove from steering joint support (18) bearings (24) and (25) complete
with gears (26) and (27).
Fig. 717
14.
Separate bearings (14), (24) and (25) from the respective gears (15), (26)
and (27) , then recover spacers (28) from gear (27).
Fig. 718
Assembly
1.
Fit gear (27) without shims (28) on bearing (25) and fit gears (15) and (26)
on the corresponding bearings (14) and (24).
Fig. 719
2.
Fit complete gear assembly (26) and carefully drive it into its seating in
steering joint support (18); then fit gear (27) previously assembled without
the shims and seat it against gear (26).
Fig. 720
3.
Using a depth gauge (A), measure distance (B) between the face of steering joint support (18) and the outer race of bearing (25). Calculate the thickness of the spacers S to be inserted by applying the following formula: S
= B 0.3 mm.
Fig. 721
30-203
Method of intervention
4.
Form shim pack (28) with thickness equal to calculated value S 0.04
mm; then install shim pack (28) under gear (27).
Fig. 722
5.
Install bearing (22) and spacer (21) in stub axle housing (13).
Fig. 723
6.
Using service tool T8, install oil seal (20) in stub axle housing (13).
m
Before installing the oil seal, carefully clean and degrease the seat
of the seal in the stub axle housing and on the steering joint support.
Fig. 724
7.
After carrying out the above steps, reassemble following the disassembly
procedure in reverse order.
30-204
O-ring: grease.
O-ring: grease.
Fig. 725
Method of intervention
30.6 - G0 - Bodywork - Cab - Platform
30.6.1 - Cab
Removal
1.
Fig. 726
2.
Fig. 727
3.
Fig. 728
4.
Remove the two screws (4) securing the floor mat moulding.
Fig. 729
30-205
Method of intervention
5.
Fig. 730
6.
Remove A/C valve assembly cover (6) secure with two screws on the LH
side.
Fig. 731
7.
Remove the four screws (7) and remove oil filter bracket (8).
Fig. 732
8.
Loosen clamp (9) and remove cab heating water pipe (10).
Fig. 733
30-206
Method of intervention
9.
Fig. 734
10.
Fig. 735
11.
Disconnect the two wiring connectors (13) on the LH side and remove cab
wiring fuses (14).
Fig. 736
12.
Disconnect the parking brake cable by removing the cotter pin, pin (15) and
loosening the clamp securing gaiter (16) to release the outer cable.
Fig. 737
30-207
Method of intervention
13.
Fig. 738
14.
Disconnect the two wiring harnesses (18) for the rear lights.
m
Do not remove the connector for the rear trailer lights from the bracket.
Fig. 739
15.
Fig. 740
16.
Fig. 741
30-208
Method of intervention
17.
Remove lower cover (21) secured with two screws and side panels (22)
secured with four screws.
Fig. 742
18.
Remove on both sides the four screws (23) securing the inside of the cab
to the footplate.
Fig. 743
19.
Fig. 744
20.
On both sides remove the two screws (25) to release the cab from the metal
guards.
Fig. 745
30-209
Method of intervention
21.
Fig. 746
22.
Disconnect the pipe from the A/C valve (27) on the RH side.
Fig. 747
23.
Remove the three retaining screws and remove A/C pipe cover (28).
Fig. 748
24.
Fig. 749
30-210
Method of intervention
25.
Sling the top of the cab to a hoist and raise it about by 10 cm.
Fig. 750
26.
On the LH side disconnect parking brake warning light connector (31) and
on the RH side disconnect front PTO pushbutton wiring connector (32).
Fig. 751
27.
Raise the cab slowly and carefully remove it from the tractor.
m
Help separate the lower part of the cab from the tractor with little
jolts.
Fig. 752
30-211
Method of intervention
Refitting
1.
Fig. 753
2.
Fig. 754
3.
Fig. 755
4.
Disconnect the three-wire connector of LF front worklight (4) and the fourwire connector of RH front worklight and horn (5).
Fig. 756
30-212
Method of intervention
5.
Fig. 757
6.
Remove the two screws and washers (7) on the RH and LH sides to release
the hood.
Fig. 758
7.
Fig. 759
30-213
Method of intervention
Refitting
Refitting is the reverse of removal.
Fig. 760
2.
Fig. 761
3.
Fig. 762
4.
Fig. 763
30-214
Method of intervention
5.
Fig. 764
Refitting
1.
Fig. 765
2.
Refit the two front screws by positioning in the correct sequence: screw
(11), washer (13), asbestos washer (14), washer (13), bracket (12), washer
(13), asbestos washer (14).
Fig. 766
Lower hood
Removal
1.
2.
3.
Fig. 767
30-215
Method of intervention
4.
Fig. 768
Refitting
1.
Fig. 769
2.
Fig. 770
3.
Remove the two hex socket screws (3) located on the underside of the
steps.
DANGER
Support the auxiliary fuel tank to prevent it from falling.
Fig. 771
4.
Remove the steps assembly, leaving the auxiliary fuel tank attached to the tractor.
30-216
Method of intervention
Refitting
1.
Fig. 772
2.
Fig. 773
Refitting
1.
Fig. 774
30-217
Method of intervention
2.
Remove the two screws, disconnect the internal tie-rod (2) and remove
door lock (3).
Fig. 775
3.
Remove one screw, disconnect tie-rod (4) and remove the manual door
opening control (5).
Fig. 776
4.
Fig. 777
5.
Fig. 778
30-218
Method of intervention
6.
Fig. 779
Refitting
1.
Withdraw the instrument panel from its shroud by pushing in side clip (1).
Fig. 780
2.
Fig. 781
3.
Fig. 782
30-219
Method of intervention
Refitting
1.
Fig. 783
2.
Fig. 784
3.
Disconnect front and rear wiring connectors (3) and front and rear water
pipes (4).
Fig. 785
4.
Fig. 786
30-220
Method of intervention
Refitting
1.
Remove screw (1) and remove knob (2) of the rear PTO control lever.
m
Fig. 787
2.
Fig. 788
3.
Remove the two screws (6) and remove RH side panel (7).
Fig. 789
Refitting
1.
30-221
Method of intervention
30.6.9 - Left-hand console
Removal
1.
Remove screw (1) and remove knob (2) of the rear PTO control lever.
m
Fig. 790
2.
Fig. 791
3.
Remove the two screws (6) and remove LH side panel (7).
Fig. 792
30-222
Method of intervention
Refitting
1.
Remove the six screws (1) and move the dashboard towards the rear.
Fig. 793
2.
Fig. 794
3.
Fig. 795
4.
Fig. 796
30-223
Method of intervention
5.
Fig. 797
Refitting
1.
Fig. 798
2.
Remove the four screws (2) and then remove centre console (3).
Fig. 799
Refitting
1.
30-224
Method of intervention
30.6.12 - RH rear cab pillar trim
Removal
1.
Fig. 800
2.
Fig. 801
Refitting
1.
Undo the two knobs (1) and remove filter cover (2).
Fig. 802
30-225
Method of intervention
2.
Fig. 803
Refitting
Refitting is the reverse of removal.
Fig. 804
2.
Unscrew the two retaining screws and remove pipe cover (2).
Fig. 805
3.
Remove the two retaining screws for each and remove covers (3) on both
sides.
Fig. 806
30-226
Method of intervention
4.
Fig. 807
5.
Remove the six retaining screws and remove cab roof lining (5) from rear
of cab.
Fig. 808
6.
Remove the three retaining screws and remove fuse assembly support (6).
Fig. 809
7.
Fig. 810
30-227
Method of intervention
8.
Fig. 811
9.
Fig. 812
10.
Fig. 813
11.
Fig. 814
30-228
Method of intervention
12.
Fig. 815
13.
Remove the four roof retaining screws (13) located in the four corners of
the cab roof.
Fig. 816
14.
Fig. 817
30-229
Method of intervention
Refitting
1.
30.6.15 - Seat
Removal
1.
Fig. 818
2.
Fig. 819
Refitting
1.
30-230
Method of intervention
30.6.16 - Air conditioning system - Standard roof version
TECHNICAL DATA
30-231
Method of intervention
l
Operation
The compressor (1) is driven from the crankshaft via a drivebelt and pulley with an electromagnetic clutch (1a), which is controlled by
a switch on the control panel. The system is protected by a safety pressure switch, which performs the following functions:
l
Inhibits engagement of the electromagnetic clutch (1a) when the system pressure falls below 2.45 bar as a result of incomplete charging or refrigerant leakage.
Disengages the clutch (1a) and thereby stops the compressor when the pressure exceeds the permitted maximum of 28 bar
(406 psi) (generally as a result of overheating).
A further contact controls the operation of fan (10) of condenser (2) in order to maintain normal operating pressure within the range
of 11 to 15 bar. The refrigerant (in vapour form) is drawn in by the compressor where it is compressed. This compression causes the
temperature of the vapour to rise; the refrigerant flows to the condenser (2) where its heat is radiated to the air flow generated by
the cooling fans (10). The refrigerant vapour is thus cooled to the point where it condenses to high-pressure liquid. On leaving the
condenser, the liquefied refrigerant flows to the receiver-drier (3) which performs three functions: to filter out any impurities, absorb
any moisture in the circuit, and finally, act as a storage reservoir. The liquid refrigerant is then transferred to the evaporator (6) through
the expansion valve (5), which meters the flow of refrigerant into the evaporator to ensure optimum evaporation. In the evaporator,
the refrigerant expands to the critical evaporation point with an ambient temperature of around -- 8C (17.6F). The temperature of
the air flow over the evaporator (6) generated by the fans (8) is significantly higher than -- 8C (17.6F), and therefore it gives up its
heat to the refrigerant, causing it to boil and evaporate. On leaving evaporator (6), the refrigerant returns to compressor (1) to repeat
the cycle. The removal of heat from the ambient air flowing over the evaporator causes the moisture in the air to condense, and the
air is thus dehumidified; the moisture condenses on the fins of the evaporator, where, if it is not maintained at temperature above 0C
(32F), it will freeze and impair the efficiency of the evaporator. The task of maintaining the evaporator at a temperature above 0C
(32F) (and within the optimum temperature for efficient heat exchange), is performed by an electronic temperature sensor (7); this
sensor disengages the clutch (1a) of the compressor (1) when the temperature falls to the lower limit and engages the clutch (1a)
when the evaporator temperature reaches the upper limit. The condensate that forms on the evaporator fins (6) contains dust, pollen
and other airborne particulates; continuous condensation thus has the effect of purifying the air, and the droplets of condensate are
conveyed out of the vehicle via two ducts. A fixed quantity of moisture-free oil is added to the circuit in order to lubricate all the mechanical components of the system; a certain percentage of this oil continuously circulates in the form of an oil mist, thereby lubricating
the compressor (pistons and bearings) and the expansion valve.
DANGER
Before discharging, flushing and recharging the air conditioning system, check the system for leaks using a
leak detector.
2.
In order to carry out the system servicing operations you will require a dedicated A/C servicing station capable of performing
the following tasks:
m Aspiration of the refrigerant fluid.
m Creation of a high vacuum to purge the system of contaminants.
m Filtration of the recovered refrigerant.
m Separation of the antifreeze and lubricating oil from the liquid refrigerant and determination of its quantity by weight.
m Recharging system with the exactly the same amounts of refrigerant and oil as those recovered.
m Measuring the system high side pressure and low side pressure.
DANGER
Remove the key from the starter switch.
2.
3.
Connect the service machine to high pressure service valve (1) and follow the specific instructions for the service machine to
discharge the system.
Disconnect the system component to be renewed or overhauled immediately after the service machine stops; plug the open
ends of the system pipes as quickly as possible.
30-232
Method of intervention
Flushing and recharging the system
1.
Before each recharging, the system must be purged of all air, moisture and contaminants (oxides, deposits). This entails
creating a high vacuum within the system to evaporate any moisture present. The vapour, when extracted, draws with it any
contaminants present in the system.
m For the flushing and recharging operations, the service station must be connected to the high (1) and low (2) pressure
service valves.
DANGER
Maximum vacuum must be maintained for at least 10 minutes.
2.
After flushing, the moisture-free oil recovered during the discharging operation must be returned into the system, followed by
the refrigerant.
m Quantity of refrigerant (R134a): 1100 g Oil quantity: the quantity recovered.
DANGER
If the system must be discharged and flushed in order to renew a system component, the quantity of oil in the
replaced component must be measured and the same amount of new oil must added as that recovered with
the refrigerant.
DANGER
For details of the oil and refrigerant recharging procedure, refer to the instructions supplied with the service
machine.
Fig. 821
2.
Undo locknut (3) and loosen the tensioner so as to remove the drivebelt.
Fig. 822
30-233
Method of intervention
3.
Fig. 823
4.
Remove the screw from clamp (5) securing the front and rear pipes.
Fig. 824
5.
Remove the two retaining screws in order to remove front pipe (6) and
remove the retaining screw to remove rear pipe (7).
Fig. 825
6.
Remove the two upper screws (8) and the two lower screws (9), moving the
compressor away from the support bracket.
Fig. 826
30-234
Method of intervention
7.
Fig. 827
Refitting
1.
30.6.18 - Condenser
Removal
1.
Fig. 828
2.
Fig. 829
3.
Fig. 830
30-235
Method of intervention
Refitting
1.
30.6.19 - Receiver-dryer
Removal
1.
Fig. 831
2.
Fig. 832
3.
Fig. 833
4.
Fig. 834
30-236
Method of intervention
5.
Fig. 835
Refitting
1.
Fig. 836
2.
Fig. 837
3.
Fig. 838
30-237
Method of intervention
4.
Fig. 839
5.
Fig. 840
Refitting
1.
Fig. 841
2.
Disconnect fan wiring connector (2) and remove relative bracket (3).
Fig. 842
30-238
Method of intervention
3.
Remove the four retaining screws and remove fan assembly (4).
Fig. 843
Refitting
Refitting is the reverse of removal.
It is not necessary to drain the system as it is equipped with a specific check valve (1).
Fig. 844
2.
Fig. 845
3.
Fig. 846
30-239
Method of intervention
Refitting
Refitting is the reverse of removal.
Fig. 847
2.
Fig. 848
3.
Fig. 849
Refitting
1.
30-240
Method of intervention
30.6.24 - Adjustment of the lift control valve levers
Position control lever
Adjustment
1.
Fig. 850
2.
Fig. 851
3.
Adjust end fitting (4) to bring screw (5) into contact with stop (6), then tighten nut (3).
Fig. 852
30-241
Method of intervention
Draft control lever
Adjustment
1.
Fig. 853
2.
Fig. 854
3.
Fig. 855
4.
Fig. 856
Balance check
1.
With position control lever (1) in the CONTR position (7) and draft control lever (10) in position 4 (11), check that the linkage
is raised when the test implement is pulled upwards and is lowered when the test implement is pulled downwards.
m Test implement: 200 kg counterweight.
30-242
Method of intervention
30.6.25 - Remote valve control levers
Removal
1.
Fig. 857
2.
Disconnect the two tie-rods (2) of the rear remote valve control linkage.
Fig. 858
3.
Fig. 859
Refitting
1.
30-243
Method of intervention
30.7 - H0 - Hydraulic system
30.7.1 - Pump for hydraulic lift and auxiliary services and power steering system
Removal
1.
DANGER
Disconnect the lead from the battery negative terminal (-).
2.
Fig. 860
3.
Remove the two screws (2) the remove the pumps assembly (3).
Fig. 861
Refitting
1.
Fig. 862
30-244
Method of intervention
30.7.2 - Transmission oil filter assembly
Removal
1.
Loosen the two hose clamps (1) and collect the transmission oil.
Fig. 863
2.
Fig. 864
3.
Fig. 865
4.
Fig. 866
30-245
Method of intervention
Refitting
Refitting is the reverse of removal.
l
After refitting the filter, fill the transmission with 30 litres of oil.
DANGER
Disconnect the negative battery lead () and apply the parking brake.
2.
Remove the two screws (1), remove cover (2) and disconnect the two
steering control pipes (3).
m
Fig. 867
3.
Disconnect supply pipe (4) to the power steering valve and fully loosen nut
(5) but do not remove it.
Fig. 868
4.
Remove screw (6) to release pipe (7) from the controls support and disconnect return pipe (8).
Fig. 869
5.
Fig. 870
30-246
Method of intervention
6.
Remove the four screws (10), remove steering tube (11) and remove the
power steering valve (12).
Fig. 871
Refitting
1.
30-247
Method of intervention
30.7.4 - Power steering disassembly
26
27
24
28
15
18
13
25
25b
25a
29
19
21
20
22
16
17a
12
17b
10
17
23a
23b
5a
8
7
23
23a
6
11
9
2
5
4
2
3
30-248
Method of intervention
Disassembly
1.
Unscrew and remove screws (1) and (3) and washers (2) securing cover (4)
(6 screws plus one special screw).
1 2
F0009470
Fig. 873
2.
F0009480
Fig. 874
3.
Lift rotary spool unit (5) complete with O-rings (6) and spacer (7).
F0009490
Fig. 875
4.
F0009500
Fig. 876
5.
F0009510
Fig. 877
30-249
Method of intervention
6.
F0009520
Fig. 878
7.
11
F0009530
Fig. 879
8.
Remove ball (12) of the check valve and pins (13) and balls (15) of the
suction valves.
15
13
12
F0009541
Fig. 880
9.
Checking through the central hole of the spool, position spool-bush assembly cross pin (16) horizontally. Push assembly (17) and the bearing
assembly out of power steering housing (18).
17
18
F0009550
Fig. 881
10.
Remove outer ring (19), inner ring (20) and roller bearing (21) from the
spool; remove also ring (22).
m
It may occur that inner ring (20) (thin) remains in the steering valve
housing; ensure that it is actually removed.
20
22
19
21
F0009560
Fig. 882
30-250
Method of intervention
11.
16
17a
F0009570
Fig. 883
12.
F0009580
Fig. 884
13.
Press neutral position springs (23) and remove them from spool (17a).
23
17a
F0009590
Fig. 885
14.
Remove dust seal (24) and composite seal (25) (O-ring + seal).
25
24
F0129940
Fig. 886
15.
26
F0129930
Fig. 887
30-251
Method of intervention
16.
27
F0129950
Fig. 888
17.
Turn over the steering valve housing and remove spring (28) and relief
valve (29).
IMPORTANT
29
The seat of the relief valve is a force fit in the housing and
cannot be removed.
28
F0009681
Fig. 889
Installation
1.
IMPORTANT
Prior to reassembly, lubricate all components with gearbox
oil.
Insert the two flat washers (23a) in the seat and centre them relative to
the diameter of spool (17a). Insert the four curved washers (23b) in pairs
between the two flat washers (23a) and push them fully home.
23b
23b
23a
23a
17a
F0009690
Fig. 890
2.
23
F0009700
Fig. 891
3.
17b
17a
F0009580
Fig. 891
30-252
Method of intervention
4.
Simultaneously push springs (23) and spool (17a) until the springs are
seated in the slots in bush (17b).
23
17a
17b
F0009710
Fig. 892
5.
Align springs (23) and make sure they are positioned centrally in relation to
the diameter of bush (17b).
23
17b
F0009720
Fig. 893
6.
22
17b
F0009730
Fig. 894
7.
16
F0009740
Fig. 895
8.
20
22
21
F0009751
Fig. 896
30-253
Method of intervention
9.
17a - Spool
17b - Bush
21- Needle roller bearing
20 - Inner ring
22 - Outer ring
20
21
22
17
DANGER
The outer ring must be installed with chamfer X facing the
shoulder of the spool.
10.
17
Fig. 897
Position steering valve housing (18) so the hole is horizontal. Insert into the
bush/spool assembly bore the guide of special tool T9 (P/N. 5.9030.480.0).
Fig. 898
11.
Lubricate oil seal (25a) and O-ring (25b) and fit them on the push rod of tool
T9 (P/N. 5.9030.480.0).
Fig. 899
12.
Fit tool T9 (P/N. 5.9030.480.0). and insert it in the guide previously inserted
in the steering valve bore.
Fig. 899
13.
Push seal (25) into its seat in steering valve housing (18) while rotating it
to ease it into position.
18
F0009790
Fig. 900
30-254
Method of intervention
14.
Withdraw tool T9 (P/N 5.9030.480.0). from valve housing (18) and removal
also the guide, leaving the tool push rod in the housing.
Fig. 901
15.
Insert bush/spool assembly (17) in steering valve bore (18). Rotate the
valve slightly while inserting it to ease it into position.
17
IMPORTANT
Keep the cross pin horizontal while inserting the assembly.
18
F0009810
Fig. 902
16.
Push in assembly (17) until fully seated so that it forces out the tool push
rod left in the housing in step 14.
18
17
F0009820
Fig. 903
17.
Rotate steering valve housing (18) until the centre hole is vertical. Insert
ball (12) of the relief valve in the hole indicated by the arrow.
12
18
F0009830
Fig. 904
18.
Screw valve retaining bush (10) into the bore of the relief valve.
IMPORTANT
10
The top of the retaining bush should be set below the face of
steering valve housing (18).
18
F0009521
Fig. 905
30-255
Method of intervention
19.
Insert the two balls (15) in the holes indicated by the arrows.
15
F0010310
Fig. 906
20.
F0009841
Fig. 907
21.
11
F0009850
Fig. 908
22.
Locate distributor plate (9) so that its holes are aligned with the holes in
steering valve housing (18).
18
F0009860
Fig. 909
23.
Insert drive shaft (8) in the hole so that it engages the cross pin; check
that the engagement with the cross pin is parallel to the steering column
mounting face.
F0009870
Fig. 910
30-256
Method of intervention
24.
Position the drive shaft so that it is vertical and hold it in this position using
a suitable tool.
F0009880
Fig. 911
25.
Lubricate the two O-rings (6) and fit them in the two grooves in rotary spool
unit (5). Fit rotary spool unit (5) to drive shaft (8).
m
8
5
F0009890
Fig. 912
26.
DANGER
Install rotor (5a) on drive shaft (8) so that the valley between
two lobes is aligned with the groove in the end of the drive
shaft. Then turn outer ring (5b) to align the fixing holes.
5a
F0009900
Fig. 913
27.
5
F0009910
Fig. 914
28.
F0009920
Fig. 915
30-257
Method of intervention
29.
Insert special screw (3) complete with washer (2) in the hole indicated in
the photo.
3
F0009930
Fig. 916
30.
Insert the six screws (1) complete with washers (2). Tighten screws (1) and
(3) in a crosswise sequence to a torque of 306 Nm (22.14.4 lb.ft.).
1 2
F0009471
Fig. 917
31.
29
F0129960
Fig. 918
32.
28
F0129970
Fig. 919
33.
27
F0129950
Fig. 919
30-258
Method of intervention
34.
26
F0129930
Fig. 919
35.
24
18
F0009970
Fig. 920
36.
Install dust seal (24) in the steering valve housing using a suitable drift and
a soft faced mallet.
F0009980
Fig. 921
37.
Close off the oil ports with plastic plugs to prevent impurities getting in.
IMPORTANT
Fit the plugs by hand pressure alone; do not hammer.
F0009990
Fig. 922
38.
On completion of the assembly operation, test the operating pressure of the relief valve and calibrate as necessary.
30-259
Method of intervention
30.7.5 - Pressure relief valve - lift control valve
Removal
1.
Fig. 923
2.
Fig. 924
3.
Fig. 925
Refitting
1.
Fig. 926
30-260
Method of intervention
Calibration
1.
Interpose one or more shims (6) between the spring and the plug to increase the spring preload and thereby return the operating pressure in the
circuit to 30 bar.
Fig. 927
Fig. 928
2.
Fig. 929
Refitting
1.
Fig. 930
30-261
Method of intervention
30.7.7 - Remote control valve
Removal
1.
Fig. 931
2.
Remove the four screws (3) and remove remote control valve assembly (4).
m
Fig. 932
Refitting
1.
Fig. 933
Fig. 934
30-262
Method of intervention
2.
Fig. 935
3.
Remove the spool of control valve n 1 (4) and the spool of control valve
n 2 (5).
Fig. 936
4.
Remove plug (6) and remove the spring and ball (7).
Fig. 937
5.
Fig. 938
6.
Remove screw (9) then remove disc (10), spring (11) and disc (12).
Fig. 939
30-263
Method of intervention
Assembly
1.
Fig. 940
2.
Remove the two Woodruff keys (4), then remove Woodruff key (5), ring (6)
and O-ring (7).
Fig. 941
3.
Withdraw the two rods (8) and (9) then remove O-ring (10).
Fig. 942
Assembly
1.
30-264
Method of intervention
30.7.10 - Double/single acting conversion valve
Removal
1.
Fig. 943
2.
Fig. 944
3.
Remove circlip (4) and separate nut (5) from pin (1).
Fig. 945
4.
Fig. 946
30-265
Method of intervention
Refitting
1.
Fig. 947
30-266
Method of intervention
30.8 - L0 - Electrical system
30.8.1 - Battery
Removal
1.
DANGER
Disconnect the lead from the battery negative terminal (-).
2.
Fig. 948
3.
Fig. 949
4.
Detach fan control unit (3) an move it out of the way of the battery.
Fig. 950
5.
Remove positive terminal cover (4) and loosen clamp screw (5) securing
positive lead (6).
Fig. 951
30-267
Method of intervention
6.
Remove battery (7) raising the front and withdrawing it a forward direction.
Fig. 952
Refitting
Refitting is the reverse of removal.
Remove on both sides the retaining screws (two per cover) and side covers (1).
Fig. 953
2.
Remove the six retaining screws and remove upper panel (2).
Fig. 954
3.
Remove the six retaining screws and remove cab roof lining (3) from the
rear of the cab.
Fig. 955
30-268
Method of intervention
4.
Remove the three screws and remove fuse unit support (4).
Fig. 956
5.
Remove the two screws (5) and remove relay support bracket (6).
Fig. 957
Refitting
1.
Fig. 958
2.
Fig. 959
30-269
Method of intervention
3.
Fig. 960
4.
Fig. 961
Refitting
1.
Remove the two retaining screws (1) and remove parking brake cover (2).
Fig. 962
2.
Fig. 963
30-270
Method of intervention
3.
Fig. 964
4.
Fig. 965
Refitting
1.
The height of the microswitch can be adjusted by way of the lateral slots (1).
Fig. 966
30-271
Method of intervention
30.8.6 - Brake lights switches
Removal
1.
Fig. 967
2.
Fig. 968
3.
Fig. 969
30-272
Method of intervention
Refitting
1.
Fig. 970
Remove the four screws (1) securing the steering column switch support.
Fig. 971
2.
Fig. 972
Refitting
1.
30-273
Method of intervention
Removal
1.
Remove the two rear lift control knobs (1) and the two remote valve control
knobs (2).
Fig. 973
2.
Fig. 974
3.
Fig. 975
4.
Move the console aside and disconnect front PTO wiring connector (5).
Fig. 976
30-274
Method of intervention
5.
Fig. 977
Refitting
1.
30-275
Method of intervention
30.9 - M0 - Front PTO
Remove the eight fixing screws (1) of the upper cover of the front PTO.
Fig. 978
2.
Fig. 979
3.
Loosen the plug on the underside of the sump (4) to allow the oil to drain
out of the PTO.
Fig. 980
4.
Fig. 981
30-276
Method of intervention
5.
Fig. 982
6.
Remove the three retaining screws (8) of the front bearing cover.
Fig. 983
7.
Fig. 984
8.
Fig. 985
30-277
Method of intervention
9.
Fig. 986
10.
Fig. 987
11.
Remove the second PTO drive shaft (13) from the front end .
Fig. 988
12.
Fig. 989
30-278
Method of intervention
Refitting
1.
Remove set screw (1) securing the front PTO input shaft.
Fig. 990
2.
Remove the three retaining screws (2) of the PTO input shaft flange.
Fig. 991
3.
Fig. 992
4.
Remove the two lower screws (4) and four front screws (5) of the front lift
support.
Fig. 993
30-279
Method of intervention
5.
Fig. 994
6.
Fig. 995
7.
To remove the oil seal, make a hole in it and use a slide hammer
puller.
Fig. 996
8.
Fig. 997
30-280
Method of intervention
9.
Remove PTO output shaft (10) with gear (11) and bearing (12).
Fig. 998
Refitting
1.
Fig. 999
2.
Fig. 1000
3.
Fig. 1001
30-281
Method of intervention
4.
Check the condition of the mesh filter (5) on the solenoid valve.
Fig. 1002
Refitting
1.
30-282
Method of intervention
30.10 - N0 - Front lift
Remove the two cotter pins (1) and the two relative pivot pins (2).
Fig. 1003
2.
Fig. 1004
3.
Remove the two hydraulic service couplers (4) with their copper washers
and circlips (5).
m
Fig. 1005
4.
Fig. 1006
30-283
Method of intervention
5.
Remove on both sides the two screws (7) securing the front lift assembly on
the underside of the support.
Fig. 1007
6.
Remove the four screws (8) securing the front part of the front lift assembly.
Fig. 1008
7.
Fig. 1009
30-284
Method of intervention
Refitting
1.
30.10.2 - Cylinder
Removal
1.
Fig. 1010
2.
Fig. 1011
3.
Fig. 1012
4.
Fig. 1013
30-285
Method of intervention
Refitting
1.
30-286
Method of intervention
30.11 - R0 - Rear lift
Fig. 1014
2.
Disconnect the four pipes (2) of the rear hydraulic service couplers.
Fig. 1015
3.
Fig. 1016
4.
Remove the two centre screws (4) and remove service coupler support
frame (5).
Fig. 1017
30-287
Method of intervention
5.
Remove screw (6) securing the holding valve to the lift cover.
Fig. 1018
6.
Remove the two locking pins (7) and two pivot pins (8) from the link arms.
Fig. 1019
7.
Remove the nine screws (9) securing the lift assembly to the transmission.
Fig. 1020
8.
Fig. 1021
30-288
Method of intervention
Refitting
1.
Fig. 1022
2.
Turn the lift assembly over, remove the three screws (3) and loosen screw
(4).
Fig. 1023
3.
Turn the lift assembly over again, remove the screw (4) previously left in
place and remove cylinder assembly (5).
Fig. 1024
Refitting
1.
Fig. 1025
30-289
Method of intervention
Lift cylinders
Disassembly
1.
Fig. 1026
2.
Using a bar made of soft material, withdraw piston (7) from cylinder (5).
Fig. 1027
3.
Fig. 1028
Assembly
1.
Fig. 1029
30-290
Method of intervention
Lift arms
Removal
1.
Fig. 1030
2.
Fig. 1031
3.
On both sides, remove circlip (13), remove lift arm (14) and then remove
thrust washer (15).
Fig. 1032
4.
Fig. 1033
5.
Fig. 1034
30-291
Method of intervention
6.
Renew the oil seal on the opposite side to the controls on reassembly.
Fig. 1035
7.
Fig. 1036
8.
Check that bushes (25) are not worn out-of-round and renew them if necessary.
Fig. 1037
30-292
Method of intervention
Refitting
1.
2.
3.
Bush
Renewal
1.
Position the lift cover under a press and, using a suitable tool, remove bush
(26).
Fig. 1038
2.
Fit the new bush (26) in the lift cover, taking care to align it with the hole
Fig. 1039
3.
Fit the bush with the split rotated 45 relative to the rear of the lift cover
Fig. 1040
30-293
Method of intervention
30.11.3 - Adjustment of the rear lift
Internal adjustment
Safety stop
1.
Fig. 1041
2.
Fig. 1042
3.
Fig. 1043
30-294
Method of intervention
External adjustment
Maximum lift height
1.
Fig. 1044
2.
Fig. 1045
3.
Move RH lever (11) to bring the notch on the lever into alignment (12) with
the notch on the hub of the casing (13).
Fig. 1046
4.
Adjust screw (14) to bring it up against stop (15) then tighten nut (16).
Fig. 1047
30-295
Method of intervention
Adjustment of the sensor tie-rod
Adjustment
1.
Install the various components of the sensor tie-rod as shown in the figure.
Fig. 1048
2.
Fig. 1049
Fig. 1050
2.
Turn the lift assembly over, remove the three screws (3) and loosen screw
(4).
Fig. 1051
30-296
Method of intervention
3.
Turn the lift assembly over again, remove the screw (4) previously left in
place and remove cylinder assembly (5).
Fig. 1052
Refitting
1.
Fig. 1053
Fig. 1054
2.
Using a bar made of soft material, drive piston (3) out from cylinder (2).
Fig. 1055
30-297
Method of intervention
3.
Fig. 1056
Assembly
1.
Fig. 1057
Position the lift cover under a press and, using a suitable tool, remove bush
(1).
Fig. 1058
2.
Install new bush (1) making sure that it is inserted flush with the bore in the
lift cover.
Fig. 1059
30-298
Method of intervention
3.
Fit the bush with the split rotated 45 relative to the rear (A) of the lift cover.
Fig. 1060
Fig. 1061
2.
Fig. 1062
3.
On both sides, remove circlip (5), remove lift arm (6) and then remove
thrust washer (7).
Fig. 1063
30-299
Method of intervention
4.
Fig. 1064
5.
Fig. 1065
6.
Renew the oil seal on the opposite side to the controls on reassembly.
Fig. 1066
7.
Fig. 1067
8.
Check that the bushes (17) are not worn out-of-round and renew them if
necessary.
Fig. 1068
30-300
Method of intervention
Refitting
1.
2.
3.
DANGER
Disconnect the lead from the battery negative terminal (-).
2.
Fig. 1069
3.
Fig. 1070
4.
Fig. 1071
30-301
Method of intervention
5.
Fig. 1072
6.
Fig. 1073
Refitting
1.
Fig. 1074
Remove the two screws (1) and remove the complete bracket (2).
Fig. 1075
30-302
Method of intervention
2.
Remove screw (3) and separate control valve bodies (4) and (5).
Fig. 1076
3.
Remove spring (6) and spacer (7) from valve body (4).
Fig. 1077
4.
Fig. 1078
5.
Fig. 1079
6.
Remove plug (12) and remove valve (13), pin (14) and spring (15).
m
Fig. 1080
30-303
Method of intervention
7.
Fig. 1081
8.
Fig. 1082
9.
Withdraw spool (18) from valve body (5) and remove piston (19) and spring
(20).
Fig. 1083
10.
Remove plug (21) and withdraw spring (22), spacer (23) and valve (24).
m
Fig. 1084
11.
Fig. 1085
30-304
Method of intervention
12.
Remove plug (27) and remove spring (28) and valve (29).
m
Fig. 1086
13.
Fig. 1087
Assembly
1.
2.
Fig. 1088
3.
Fig. 1089
30-305
Method of intervention
4.
Fig. 1090
5.
Fig. 1091
6.
Fig. 1092
7.
While holding ball (A) in valve (29) tight up against rod (26), that the standout of rod (26) relative to the face of valve body (5) is within the prescribed
tolerance limits: 15.8 0.05 mm (B).
Fig. 1093
30-306
Method of intervention
30.11.10 - Three-point linkage with mechanical adjustment
Removal
1.
Remove the two screws (1) and remove rear PTO output shaft shield (2).
Fig. 1094
2.
Remove the two pins (3) and towing hitch support pins (4).
Fig. 1095
3.
Fig. 1096
4.
Remove the six screws (6) and remove the two brackets (7) for lateral adjustment of the towing hitch.
Fig. 1097
30-307
Method of intervention
Refitting
1.
30-308
Method of intervention
30.12 - S0 - Wheels
30.12.1 - Front wheels
Removal
1.
DANGER
Remove the key from the starter switch and apply the parking brake.
2.
Raise the tractor and position two stands A under the front axle.
Remove all the screws (1) except one, which should be left in position for
safety.
Remove the wheel. Repeat the above operations for the other wheel.
Fig. 1098
Refitting
1.
Fig. 1099
2.
Position a stand B under the rear axle housing and lower the jack until the
axle housing is resting on the stand.
Check that the stand is in exactly the correct position and then remove the
trolley jack.
Repeat the above operations to remove the other wheel.
Fig. 1100
Refitting
1.
30-309
Method of intervention
30.13 - V0 - Ballast - towing hitches
30.13.1 - Support and towing hitch
Removal
1.
Fig. 1101
2.
Fig. 1102
3.
Fig. 1103
Refitting
1.
30-310
40 - Wiring diagrams
40-1
Wiring diagrams
40.1 - Introduction
For easier consultation, this unit has been divided into the following chapters:
l
introduction
m Contains a brief description of the terminology used, the procedures to follow for troubleshooting and repairs, and the
instruments required for troubleshooting.
Indices
m Contains the indices arranged by connector name, by component code and by component description.
Components
m Contains the layouts of the connectors used in the electrical system, descriptions of the components installed on the
tractor,the technical data necessary for functional testing and the pinouts of the electronic control units.
Systems
m Contains the electrical diagrams of the tractors systems.
Wiring looms
m Contains the layouts, the wiring diagrams and the positioning of connectors on the tractor.
Fig. 1104
40-2
Find the starter motor in heading Index by part description and identify the system in which the component is incorporated.
The system is indicated in the System column and in this case is 2 (figure A).
Wiring diagrams
l
l
l
Consult heading Starting (figure B), where all system components are shown in the electrical diagram; these components
are accompanied by numbers that correspond to the key on the same page.
Check all the components in the system, starting for example with switch 1.
In heading Index by part description (figure A) find the item Start switch and check in the column Technical Descrn to see
if there is a technical description of the component (in this case it appears at no. 42 in the heading component technical data)
(figure C). Take note also of the name of the connector to which the component is connected (in this case X4).
l
l
In heading Connector index (figure D) find the name of the connector to which the component is connected (in this case
X4) and note down the wiring loom in which it is incorporated (in this case 0.012.5957.4) and the type of connector (in this
case 19).
Find the wiring loom in chapter Plans, wiring diagrams, connector positions using the index at the beginning of the chapter.
Find the name of the connector in the photos attached to the electrical diagrams and establish its position on the tractor using
the drawing (figure E)
Using the data contained in the paragraph Component technical data (figure C) in position no. 42, check the operation of
the switch.
DANGER
In the electrical diagrams (figure F) are indicated the names of the connectors and the descriptions that are used in
all the tables of chapter 2.
DANGER
If the pinout of the connector is not known, look in paragraph Connector layouts (figure G) for the number found in
the column Type of paragraph Connector index.
introduction
This section of the workshop manual is intended as a practical guide to troubleshooting the tractors electrical and electronic systems.
The following pages provide the technician with all the necessary information regarding the tractors systems and components. Due
to the possible time difference between the introduction of technical modifications (in line with our policy of continuous product improvement) and the corresponding amendment of our printed documentation, we are obliged to state that the data contained in this
document are subject to modification and as such are not binding.
Definition of components and symbols
To prevent any misunderstanding or ambiguity, listed below are definitions for some of the key terms used in this unit.
Table 100
TERM
Connector
Transmission oil
Main clutch
Accelerator pedal
Pressure switch
Thermostat
Lights switch
HML control
DESCRIPTION
Chapter Components shows the wiring diagrams for certain switches and buttons. The following symbols are used for ease of
interpretation:
Table 101
SYMBOL
DESCRIPTION
40-3
Wiring diagrams
SYMBOL
DESCRIPTION
Indicator lamp
Diode
General rules
The inspection, maintenance, troubleshooting and repair operations are essential to ensure that the tractor continues to operate
correctly over time and to prevent malfunctions and breakdowns. The scope of this paragraph is to describe repair procedures and
to help improve the quality of repairs.
Modification of the tractors electrical/electronic circuits
The manufacturer prohibits any modification or alteration of the electrical wiring for the connection of any non-approved electrical
applicances or components. In particular, if it is discovered that the electrical system or a component has been modified without authorisation, the Manufacturer will accept no liability for any damage to the vehicle and the vehicle warranty will be invalidated.
Main wiring faults
Bad contact between connectors
l
The main causes of poor contact between connectors are incorrect insertion of the male into the female connector, deformation of one or both connectiors, and corrosion or oxidisation of the pin contact surfaces.
The pins of the male and female connectors make good contact in the crimped or soldered area, but the wires are subjected
to excessive tension, leading to breakage of the insulation or the wire itself and a poor connection.
Disconnecting wiring
l
If components are disconnected by pulling on the wires, or if components are removed with the wires still connected, or if the
wiring is subject to a heavy impact this could damage the connections at the pins, breaking strands of wire.
The connectors are designed to prevent penetration of liquids (water, oil etc.); however, it is possible that when the tractor is
cleaned using high-pressure water or steam, water could penetrate or condense in the connectors.
As the connectors
are designed to prevent liquid penetration, any water that does get in will not be able to drain out, and thus may cause shortcircuits across the pins. For this reason it is good practice to dry the connectors with a low pressure jet of compressed air after
washing the tractor.
If the connectors or pin contact surfaces show signs of oil or grease contamination, this will prevent the passage of current
(oil and grease are electrical insulators) creating a poor contact. Clean the connectors thoroughly using a dry cloth or a low
pressure jet of compressed air and use specific products (deoxidising sprays, etc.) to degrease the contacts.
Important
Take care not to bend the pins when cleaning them. Use dry oil-free compressed air.
Wiring diagrams
clip then pull the connector apart. After disconnecting connectors, seal them in waterproof material to prevent contamination of the
contacts with dirt or moisture.
Connecting the connectors. Check the condition of the connectors:
l
l
l
l
l
Make sure the pin contact surfaces are free of water, dirt or oil.
Check that the connectors are not deformed and that the pins are not corroded or oxidised.
Check that the connector casings are not damaged or split.
If a connector is contaminated with oil or grease, or if moisture has penetrated the casing, clean it thoroughly.
If a connector is damaged, deformed or broken, replace it with a new one.
When connecting connectors, make sure they are properly aligned before applying force. For connectors with clips, insert the two
halves until they clip together.
Cleaning and drying wiring
l
l
l
When wiring is dirty or contaminated with oil or grease, clean it with a dry cloth, or, if necessary, with water or steam. If the
wiring must be cleaned with water, avoid directing the water or steam jet on the connectors; if water penetrates the connector,
clean it thoroughly.
Check that the connector is not short circuited due to the presence of water by testing for continuity across the pins.
After checking that the connector is good condition, degrease the contacts using a deoxidising product.
When replacing electrical components (fuses, relays, etc.), use only original parts supplied by the manufacturer.
When replacing fuses, check that the new fuse conforms to DIN 72581 or ISO 8820 standards and in particular:
m fuse F1 (100A) DIN 72581/2
m bayonet fuse (F2, F3, etc.) DIN 72581/3C
m fuse F51 (100A) and F52 (200A) ISO 8820.
The fitting of replacement fuses that do not comply with these standards will invalidate the warranty with immediate effect and
release the manufacturer from any liability.
When replacing relays, make sure that the new relay conforms to the standards marked on the original relay.
Diagnostic instruments
For the correct diagnosis of any faults in the tractors electrical system, the following instruments are required:
l
COLOUR CODES
A
B
C
G
H
L
M
N
R
S
V
Z
Light blue
White
Orange
Yellow
Grey
Dark blue
Brown
black
Red
Pink
green
Purple
40-5
Wiring diagrams
40.1.2 - Wiring and components index
List of wiring harnesses
Table 103
Description
Code
Wiring diagram
Aereo cab
Front
Front with cab
Cab power supply
Compressor wiring
Remote valve wiring
Solenoid valve wiring
Rear lights wiring
Flashing light wiring
Cab earth wiring
Radio wiring
Central wiring
Front lights
Rear
0.014.7593.4
0.012.6951.4
0.015.0032.4
0.014.7594.4
0.014.7601.4
0.012.6955.4
0.014.1482.4
0.014.7602.4
0.014.7597.4
0.015.0031.4
0.014.7600.4
0.012.6949.4
.014.7599.4
0.013.1452.4/10
40-89
40-57
40-66
40-92
40-65
40-86
40-80
40-86
40-100
40-96
40-104
40-71
40-62
40-82
Connector positions
40-90
40-58
40-68
40-93
40-65
40-81
40-87
40-101
40-96
40-104
40-74
40-63
40-84
Component description
Check panel
Component code
LH light
2.8339.230.0
2.8339.230.40
2.8519.035.4
0.013.3337.3
0.013.9053.2
2.8039.293.0
2.8039.293.0
2.8039.294.0
Front lights
2.8039.230.0
Worklights d. 80
Rear lights
2.8039.001.0
2.8059.230.0 (LH)
2.8059.240.0 (RH)
Receiver-dryer
0.008.9604.0
Flasher
Bosch emergency pushbutton
PTO switch
Windscreen wiper timer relay
Windscreen wiper
Rear wiper
Air conditioning fan
0.009.6758.4/10
2.7659.110.0
2.7659.262.0
2.8639.008.0
2.9019.200.0
2.9019.190.0
0.010.0618.4
Connector
A18
A20
U1
A25
N1
P2
P3
P5
P6
Z5
Z8
G14
S2
S3
S4
S6
S7
S8
M3
M4
A26
A7
V4
G9
G19
L4
M5
System
40-71
40-71
40-80
40-71
40-100
40-62
40-62
40-62
40-62
40-66
40-66
40-89
40-86
40-86
40-86
40-86
40-86
40-86
40-94
40-94
40-71
40-71
40-61
40-89
40-89
40-98
40-94
40.1.3 - Introduction
For easier consultation, this unit has been divided into the following chapters:
l
40-6
Introduction
m Contains a brief description of the terminology used, the procedures to follow for troubleshooting and repairs, and the
instruments required for fault diagnosis.
Components list
m Contains the components of the electrical systems, organised by type.
m Indicates the system code, the component code and description, the technical data required for functional testing and
a description of the pin-outs of the ECUs.
Wiring diagrams
l
Systems
m Contains the wiring diagrams of the tractors systems.
Wiring harnesses
m Contains the layouts, the wiring diagrams and the positions of connectors on the tractor.
Introduction
This section of the workshop manual is intended as a practical guide to fault diagnosis of the tractors electrical and electronic
systems. The following pages provide the technician with all the necessary information regarding the tractors systems and components. Due to the possible time difference between the introduction of technical modifications (in line with our policy of continuous
product improvement) and the corresponding amendment of our printed documentation, the data contained in this document are
subject to modification and as such are not binding.
Definition of components and symbols
To prevent any misunderstanding or ambiguity, definitions for some of the key terms used in this unit are listed below.
Table 105
TERM
DESCRIPTION
Connector
Temperature sensor
Pressure sensor
Position sensor
Pressure switch
Thermostat
Switch
Solenoid valve
Chapter Components shows the wiring diagrams for certain switches and buttons. The following symbols are used for ease of
interpretation:
Contact between pins CLOSED (stable switch position)
Contact between pins CLOSED (unstable switch position)
Indicator LED
Indicator light
Diode
General rules
The inspection, maintenance, fault diagnosis and repair operations are essential to ensure that the tractor continues to operate correctly over time and to prevent malfunctions and breakdowns. This paragraph describes repair procedures and aims to help improve
the quality of repairs.
Modification of the tractors electrical/electronic circuits
The manufacturer prohibits any modification or alteration of the electrical wiring for the connection of any non-approved electrical
appliances or components. In particular, if the electrical system or a component is altered without the Manufacturers authorisation,
the Manufacturer will accept no liability for any damage to the vehicle and the vehicle warranty will be invalidated.
40-7
Wiring diagrams
Main wiring faults
Bad contact between connectors
l
The main causes of poor contact between connectors are incorrect insertion of the male into the female connector, deformation of one or both connectors, and corrosion or oxidisation of the pin contact surfaces.
The pins of the male and female connectors make good contact in the crimped or soldered area, but the wires are subjected
to excessive strain, leading to breakage of the insulation and a poor connection or breakage of the wire.
Disconnecting wiring
l
If connectors are disconnected by pulling on the cables, or if components are removed with the wires still connected, or if the
wiring is subject to impact by a heavy object this could damage the soldering or crimping of wires on the pins and some wires
may break.
The connectors are designed to prevent penetration of liquids (water, oil etc.); however, when cleaning the tractor with pressure washers or steam washers water could penetrate or condense in the connectors. As the connectors are designed to
prevent liquid penetration, any water that does get in will be unable to drain out, and thus may cause short circuits across the
pins. It is therefore good practice to dry the connectors with a low pressure jet of compressed air after washing the tractor.
If the connectors or pin contact surfaces show signs of oil or grease contamination, this will prevent the passage of current
(oil and grease are electrical insulators) creating a poor contact. Clean the connectors thoroughly using a dry cloth or a low
pressure jet of compressed air and use specific products (deoxidising sprays, etc.) to degrease the contacts.
Important
Take care not to bend the pins when cleaning them. Use dry oil-free compressed air.
Make sure the pin contact surfaces are free of water, dirt or oil.
Check that the connectors are not deformed and that the pins are not corroded or oxidised.
Check that the connector casings are not damaged or split.
If a connector is contaminated with oil or grease, or if moisture has penetrated the casing, clean it thoroughly.
If a connector is damaged, deformed or broken, replace it with a new one.
When connecting connectors, make sure they are properly aligned before applying force. For connectors with clips, insert the two
halves until they clip together.
Cleaning and drying wiring
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When wiring is dirty or contaminated with oil or grease, clean it with a dry cloth, or, if necessary, with water or steam. If the
wiring must be cleaned with water, avoid directing the water or steam jet on the connectors; if water penetrates the connector,
clean it thoroughly.
Check that the connector is not short circuited due to the presence of water by testing for continuity across the pins.
After checking that the connector is good condition, degrease the contacts using a deoxidising product.
40-8
When replacing electrical components (fuses, relays, etc.), use only original parts supplied by the manufacturer.
When replacing fuses, check that the new fuse conforms to DIN 72581 or ISO 8820 standards, and in particular:
m fuse F1 (100A) DIN 72581/2
m bayonet fuse (F2, F3, etc.) DIN 72581/3C
m fuse F51 (100A) and F52 (200A) ISO 8820.
Wiring diagrams
l
The fitting of replacement fuses that do not comply with these standards will invalidate the warranty with immediate effect and
release the manufacturer from all liability.
When replacing relays, make sure that the new relay conforms to the standards marked on the original relay.
Diagnostic instruments
For the correct diagnosis of any faults in the tractors electrical system, the following instruments are required:
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COLOUR CODES
A
B
S
G
H
L
M
N
R
S
V
Z
Light blue
White
Orange
Yellow
Grey
Blue
Brown
Black
Red
Pink
Green
Purple
The name of this branch of electrical science is derived from the word ELECTRON, the name given to a small electrically charged
particle.
The movement of electrons produces electrical current, which we know more about for its effects - heat, light, magnetism, electrolysis, etc. - than for its actual nature.
While electrical engineering is concerned with these external effects of electrical current, electronics deals with way materials react
to the gain or loss of electrons.
Electrons in fact move from (-) to (+), but according to a convention that was established before the emergence of modern atomic
theory, electric current flows in the opposite direction from (+) to (-).
Using electronics it is possible to program complex logical processes, which could not be achieved in other ways.
The various applications of electronics on our tractors can be divided into two groups:
l
Invisible electronics, which operate without requiring any intervention of the driver, (voltage regulation, rectification of the current produced by the alternator, timing, etc.);
Visible electronics, ranging from the visible and audible information to made available to the driver via the vehicles instruments and signalling systems, to the control systems that serve to optimise work processes (Performance Monitor, SBA
System, I-Monitor, etc.).
Wiring diagrams
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Conductors,
Insulators,
Semiconductors
Fig. 1105
Under certain conditions, electrons can move from one atom to another.
If the number of electrons in an atom is the same as the number of protons, the atom is neutral (it has no charge).
If the number of electrons exceeds the number of protons, the atom is negatively charged, while if it loses electrons it will become
positively charged.
Fig. 1106
40-10
Wiring diagrams
The composition of the nucleus and the number of electrons present in an atom
determine which element it belongs to.
Fig. 1107
Electron (Planet)
Nucleus (Sun)
Fig. 1108
Electrical charges of the same sign (1) repel each other while charges of opposite
signs (2) attract.
Fig. 1109
The behaviour exhibited by different materials in response to electricity derives from their atomic structure:
1.
2.
3.
In conductors (generally metals), electrons are able to move freely from one atom to another;
In insulators (generally metalloids) electron movement is restricted to varying degrees, depending on the type of material.
Their atoms are not able to acquire electrons.
Semiconductors (germanium, silicon, selenium, etc.), are materials which in their pure state may act as insulators, but with
the addition of precisely calibrated amounts certain impurities, they can become conductors. Their electrical properties thus
lie somewhere in the range between insulators and conductors. If these materials in their pure state are subjected to a technical process known as doping (the addition of impurities with a certain number of atoms with free electrical charges), they
become positively or negatively charged, depending on the specific process.
Electrical voltage
We have talked about external causes that can provoke the movement of electrons in atoms.
One of these external causes is voltage or potential difference, which exerts a force on electrical charges, causing them to start
moving.
This force is known as electromotive force; the force supplied by electrical sources (battery, dynamo, alternator).
40-11
Wiring diagrams
The concept of voltage or potential difference is illustrated by the example shown
here.
l
Fig. 1110
For water to flow from A to B, there must a difference in level h when the
valve closed.
The difference between the height of water in A and that in B creates a difference in pressure.
Fig. 1111
When the valve is opened, water flows from A to B until the point where the two
pressures are equalised.
The same happens with electrical current:
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Fig. 1112
Resistance
The water model can also be used to explain the concept of electrical resistance. If water encounters obstacles when flowing through
a pipe the the flow rate will slow or the direction of flow will change .
The same applies to electrical current; obstacles of an electrical nature reduce the flow of electrons. Every material offers some degree resistance to the flow of electrons; the level of this resistance will depend on its atomic structure and its dimensions. Obstacles
in a water course will slow down or change the direction of the water flow.
Electrical resistance can be compared to a restriction in the conductor or scaling
on the inside of a water pipe.
Fig. 1113
40-12
Wiring diagrams
The electrical resistance of a material can be defined as the opposition it presents to the flow of electrons and varies according to the
nature of the material and its dimensions.
Electrical continuity
Staying with the water analogy, lets examine how to obtain a continuous flow of water in a circuit. 424For the flow to be continuous,
the water must be returned to basin 1.
In this hydraulic circuit, the function of the pump (2) is to return the water to basin
or tank (1).
Fig. 1114
Similarly, for current to flow continuously in an electrical circuit, the electrons must return from the positively charged terminal to the
negatively charged terminal, in order to maintain a potential difference between the two terminals. This is the job of the electrical
power source.
Fig. 1115
40-13
Wiring diagrams
Electromotive force (e.m.f.)
Taking a simple electrical circuit , lets see what happens to the voltage at the terminals of the power source when the circuit is closed
(in this example, the power source is a battery, but the same result would be obtained with a different source of power, such as an
alternator).
Simple circuit with switch I open: no current flow.
The same situation occurs if we replace the battery with an alternator in rotation.
A voltage (e.g. 12V) is present at the terminals of the power source, which can be
measured with a voltmeter. This no-load voltage is known as the electromotive
force.
R = resistance of a load.
Fig. 1116
Simple circuit with switch I closed. The battery powers the resistance R. A voltage drop occurs between the terminals of the power source, caused by the circulation of current in the source itself, which has its own internal resistance.
Vd = r A
r = internal resistance of the power source in series with the other elements of the
circuit
A = current flowing through the circuit
Fig. 1117
40-14
Wiring diagrams
The alternating current wave form illustrated in the graph is called sinusoidal.
T = 1 period
A = Amplitude
B = Positive voltage
C = Negative voltage
Fig. 1118
The number of cycles per second is the FREQUENCY and is expressed in Hertz and denoted with the letter f.
f=1T
T=1f
An AC current with a frequency of 50 Hertz therefore has a period of 1 50 = 0.02 seconds.
Fig. 1119
Fig. 1120
VOLTAGE Symbol V
Voltage: Difference in potential; (emf); force that causes electrons to flow
Units: Volts
Measuring instrument: Voltmeter.
Connection to circuit: in parallel.
40-15
Wiring diagrams
Resistance
In an electrical circuit, voltage and current are both dependent on RESISTANCE, i.e. the opposition to the flow of electrons in a
material.
We have already mentioned how the motion of electrons occurs as a result of forces produced by the collision of these minute particles.
This phenomenon generates heat and is this reason why materials heat up when current passes through them.
The greater the current (the greater the number of electrons in motion) the more heat is produced.
As the temperature increases, the movement of the electrons also increases, and the electrons find it more difficult to move under
the influence of the voltage.
In some materials, this resistance is minimal; these materials are good conductors of current (conductors: copper, aluminium, silver,
etc.). In others, the resistance is so high that it is difficult for electrons to move (insulators: mica, porcelain, glass, paper, etc.)
In addition to the nature of the material, resistance is also affected by its dimensions:
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LENGTH: the greater the length of the conductor the greater the number of collisions between atoms and free electrons.
CROSS-SECTIONAL AREA; the greater the cross-sectional area, the greater the number of free electrons. Resistance is
inversely proportional to cross-sectional area.
TEMPERATURE, the motion of atoms and consequently the probability of collision with free atoms increases proportionally
with the temperature, thus increasing also the resistance.
The electrical circuits on the tractor are generally comprised of wire conductors with a cross-sectional area that is negligible in comparison with their length.
Single colour.
Spiral striping with max. pitch 50 mm
Horizontal striping.
With narrow-spaced coloured rings.
With wide spaced rings.
With rings in groups of 2 of same or different colours, depending on use.
With coloured rings in groups of 3
40-16
Wiring diagrams
The resistance of different materials - Resistivity
It has been determined experimentally that the resistance of a wire conductor is given by:
R = p ( l S ) = ohms
in which:
p = (Greek letter pronounced rho) is a proportional coefficient that varies according to the nature of the material and is known as
resistivity or specific resistance.
l = length, expressed in metres
S = sectional area, expressed in mm
This formula can also be written:
p=(RS)l
so we can state that the unit of measurement of resistivity (p) represents a resistance of 1 ohm of a conductor of the material in question, with a length 1 metre, and sectional area of 1 mm, at a temperature of 0C.
While for conductors resistivity is measured in ohms per mm/m, for insulators it is almost always expressed in mega ohms/mm,
which is the resistance in millions of ohms of a cube with a side length of 1 m.
Variation of resistance with temperature (temperature coefficient)
For most metals, resistivity increases with the temperature (positive temperature coefficient); this is why when talking about resistivity
there must always be a reference to temperature.
There are exceptions to this rule, such as, for example, chromium and carbon, in which resistivity decreases with the temperature
(negative temperature coefficient) and some alloys in which resistivity does not vary, which have temperature coefficient of 0.
This increase or decrease in the resistance per degree of temperature and per ohm of resistance is termed the temperature coefficient , and is denoted with the Greek letter a (alpha).
If the initial resistance is R0, at a temperature t0 (ambient temperature), and the temperature difference is t = t1 - t0, the variation in
resistance will be:
Rta
and the final resistance is:
Rt = R0 + R0 t a
Rt = R0 (1 + a t0)
This formula is of great practical importance as it allows us to calculate the final temperature of a coil or resistor using the resistance
variation method.
The temperature coefficient is used (positive or negative) to characterise thermistors (PTC = Positive Temperature Coefficient and
NTC = Negative Temperature Coefficient)
Power
The power developed or dissipated is given by the formula:
Power = Voltage x Current
Watt (W) = Volts x Amps
In mechanical engineering, power is still commonly expressed in terms of horsepower: hp
The relationship between horsepower and Watts is given in the following equation:
1 hp = 736 W = 0.736 kW
1 kW = 1.36 hp
40-17
Wiring diagrams
Dissipated power, in electrical terms, is power transformed into heat and is given by:
Power = Voltage x Current = Resistance x Current x Current
given that:
W=VI
V=RI
then:
W = R I I = R I
megakilohectodecadecicentimillimicronanopico-
M
k
h
da
D
S
M
N
P
Multiply by
Divide by
1,000,000
1000
100
10
-
10
100
1.000
1,000,000
1,000,000,000
1,000,000,000,000
Electronic components are used in circuits to modulate (vary, modify), control and regulate electrical values or to protect other devices.
In particular, electronic semiconductor components exploit the various reactions of electrons to heat, magnetism, and light in order
to generate small electrical signals. These electrical signals, when suitably modified, can be used by signalling devices or to control
other components.
Components can be classified on the basis of the functions they perform; components used to control or amplify power signals are
deemed ACTIVE; components which neither control nor amplify power are deemed PASSIVE.
Resistors*
Components of various design comprised of a conductor with a known resistivity that when included in a circuit causes a voltage
drop.
They are therefore used to change voltage and current; they come in different shapes and sizes, depending on their type, ohmic
resistance value, tolerance and heat dispersion characteristics.
Table 108
TYPES OF RESISTORS
FIXED
VARIABLE
wirewound
film
-
wirewound
film
Linear or non-linear variation
SENSITIVE
RESIS-
All resistors are defined by their dimensions and characteristics: ohmic value, and maximum operating temperature.
* N.B. To avoid confusion, in this manual the term RESISTANCE is used for the value expressed in ohms which represents the opposition to the flow of electrical current.
The term RESISTOR is used for the component used to introduce resistance into an electrical circuit.
Resistors are of two types: fixed or variable.
(the term resistance is also often used for the component).
40-18
Wiring diagrams
Fixed resistors
How to determine the ohmic value of a resistor
In wirewound resistors, the value is printed with decimal point (or comma) and the
omega symbol.
If the value of the resistor is 10.5 ohms, the marking will be: 10.5 ohms
sometimes the letter R is used in place of the decimal separator (point or comma):
10 R5
On resistors with values measured in thousand of ohms, the printed value will
include the letter k, which stands for thousand (1000): 10.5 kohms (10,500 ohms)
Fig. 1122
Fig. 1123
Fig. 1124
Fig. 1125
40-19
Wiring diagrams
Preventing arcing between the resistor and sliding contact.
The figure shows a way to prevent the arcing between the resistor and the sliding
contact that may occur in the case of poor contact.
This connection allows some of the current to flow through the full length of the
resistor. The voltage drop between the sliding contact and the resistor is less than
V1, thus reducing the possibility of arcing.
The resistor of the rheostat can be sized so that the resistance can be varied in
both a linear and a non-linear way.
Fig. 1126
Voltage divider
Voltage dividers with fixed resistors or potentiometers are used whenever circuits require electrical power below the standard voltages available on the tractor (12 Volts with engine off and 14.5 Volts with engine running).
Voltage dividers are found in the voltage regulator of the alternator and in the electronic control units.
Thermistors (Thermally Sensitive Resistors)
These are semiconductor resistors in which the resistance decreases as the temperature rises, ranging from just a few ohms at 0 C
to tens of thousands of ohms at 100 C; they are used to detect changes in temperature.
They may be either self-heating, if the heat is produced by the current flowing through them, or externally heated, if sensitive to the
temperature of the environment or the component on which they are mounted.
There are two types: PTC (Positive Temperature Coefficient) and NTC (Negative Temperature Coefficient)
With PTC thermistors, resistance increases with the temperature, while with the NTC type, resistance decreases as the temperature
rises.
NTC types are available with resistance values ranging from just a few ohms to several hundred kohms.
Operating characteristics of NTC thermistors
Fig. 1127
Fig. 1128
40-20
Wiring diagrams
Capacitor
This component consists of a pair of conductors, generally in the form of flat plates, separated by an insulator (dielectric). Its function
to store electrical charge from a power supply.
This charge can then be given as and when required.
Symbol
Fig. 1129
Fig. 1130
The amount of electrical charge that a capacitor can store is referred to as its capacitance (C), and is measured in farads (F). In
practice, however, the farad is too large for general use so the following units are used instead:
mF = millifarad = 1/1,000 F
F = microfarad = 1/1,000,000 F
nF = nanofarad = 1/1,000,000,000 F
On closing the switch, the electrons start moving but their flow is impeded by the dielectric. Electrons will therefore accumulate in the
plate connected to the negative terminal (-) of the generator, causing negative charge to build up. In the meantime the positive plate
loses electrons, thereby becoming positively charged. A potential difference is thus created across the plates of the capacitor, and
this increases until it equals the potential difference of the generator.
The capacitance of the capacitor is therefore proportional to the applied voltage and to the surface area of the plates and is inversely
proportional to the distance d between the plates. It also depends on the type of dielectric used.
The process described above is known as charging the capacitor, and is complete when the capacitor is fully charged. If a resistor
or a load of another type is connected to the capacitor, the latter discharges as electrons flow in opposite direction and the potential
difference between the plates decreases to zero.
Diodes
A diode can be defined simply as a junction between two semiconductors, one made of P-type material and the other made of N-type
material.
40-21
Wiring diagrams
A diode is a junction between two semiconductors, one made of P type material
and the other made of N type material.
Fig. 1131
The contact between the two semiconductors in different situations of electrical charge forms a barrier to electrical current flow at
the junction.
This barrier prevents the current from flowing through the diode.
Fig. 1132
Fig. 1133
Fig. 1134
The situation at the junction between the two semiconductors changes when a voltage is applied across the anode and cathode; the
diode is polarised, as shown in the figure.
When a voltage is applied to the diode, it polarises in the two ways indicated.
40-22
Wiring diagrams
(A) = Direct polarisation (forward biasing)
( - ) = Cathode
( + ) = Anode
Fig. 1135
Fig. 1136
With forward biasing (positive connected to the anode and negative to the cathode) the resistance to current flow is significantly
reduced and the diode allows current to flow, providing that the applied voltage exceeds the threshold value, i.e. the voltage required
to initiate the process by which the barrier is reduced.
If the polarity of the diode is reversed, there is no electron flow except for the very weak current that crosses the junction. If the reverse voltage applied to the diode exceeds a certain value (thousand of Volts) the reverse current flowing through the diode will increase
rapidly to the point where the junction is damaged.
The function of the diode is therefore to allow current flow in one direction only, from the anode (+) to the cathode ( - ).
It this way it acts as an electrical one-way valve.
Forward biased diode allows current flow.
The lamp illuminates,
Fig. 1137
40-23
Wiring diagrams
Reverse biased diode blocks current flow.
The lamp does not illuminate.
Fig. 1138
Fig. 1139
Zener diode
We have already mentioned how diodes do not tolerate reverse voltage, as when this reaches a certain level, the reverse current flow
will increase significantly to the point where the diode itself is damaged.
The Zener diode is specifically designed to allow a certain amount of reverse current flow without damage to the junction.
It is also possible to make this reverse current flow occurs at a certain reverse voltage, known as zener voltage.
A zener diode can therefore be defined as semiconductor with a special PN junction with controlled reverse bias properties.
If forward biased, the Zener diode behaves just like a normal diode, while if reverse biased, it prevents current flow until the voltage
reaches the critical level, which is defined as the Zener point.
At this point the current increases rapidly.
40-24
Wiring diagrams
Fig. 1140
The behaviour of the Zener diode can thus be compared to that of a pressure relief valve in a hydraulic circuit.
a) current and water flow
b) no current or water flow,
c) the water flows when it overcomes the opposing force of the valve spring. Likewise, the current flows when the voltage reaches
the zener point.
Fig. 1141
40-25
Wiring diagrams
LED
1.
2.
3.
4.
Fig. 1142
LEDs are often used for signal lamps as their power consumption is very low, they require only low levels of reverse current and they
are impact resistant.
A typical application is as an indicator lamp, which, unlike a conventional bulb, can be flashed on and off repeatedly without failing.
They are also used to display segmented symbols and alphanumeric digits.
40-26
Wiring diagrams
When voltage is applied across terminals (E) and (C), no current flows through
the transistor.
Fig. 1144
If a weak voltage is applied simultaneously to the base terminal, the transistor becomes a conductor and current flows between the
emitter and collector.
When voltage is also applied to the base terminal, the transistor allows current
flow.
Fig. 1145
When the voltage applied to the base terminal is modified, the current flow between the emitter and collector will also vary proportionally. From this behaviour are derived the two main characteristics of the transistor:
1.
Current does not flow through the transistor if the circuit between the emitter and collector is interrupted, i.e. no voltage applied.
The current flowing through the transistor is directly proportional to current that flows through the emitter-base circuit, within
the operating limits of the transistor. This means that the base current (the current that flows between the emitter and base) is
proportional to the collector current (the current flow between the emitter and the collector) and therefore the latter increases.
2.
Given these two characteristics, a transistor can function as a switch (by removing the voltage at the base) or as an amplifier.
With a transistor, a weak current flowing from the emitter E to the base B (PNP transistor) or from the base to the emitter (NPN
transistor), can be used to control a strong current flow from the emitter to the collector (PNP) or from the collector to emitter (NPN).
This is the most useful characteristic of the transistor, which can be summarised in the equation:
a = ( Ic ) ( Ib )
This parameter, however, varies according to the collector current and voltage, as well as the temperature of the transistor.
The difference between NPN-type and PNP-type transistors lies solely in the direction of the current flow. The operating limits of
transistors are:
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40-27
Wiring diagrams
Fig. 1147
Typical connection of a transistor. The resistor R limits the current and protects the transistor.
40-28
Wiring diagrams
Fig. 1148
Typical connection of a transistor. The resistor R limits the current and protects the transistor.
Fig. 1149
40-29
Wiring diagrams
Fig. 1150
Circuit diagrams show use of an electromagnetic relay (B) and use of a transistor as a relay (A). U = Load in main circuit.
40-30
Wiring diagrams
40.2 - Components
40.2.1 - Components
This chapter contains:
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Description
Code
2.7659.110.0
2.8339.230.0
2.8339.230.4
0.013.3337.3
0.009.6758.4/10
2.8639.008.0
Worklights d.80
2.8039.001.0
Windscreen wiper
2.9019.200.0
Characteristics
Connector
A7
A18
A20
A25
A26
G9
Fig. 1151
Fig. 1152
G14
G19
Fig. 1153
40-31
Wiring diagrams
Description
Code
Characteristics
Receiver-dryer
0.008.9604.0
0.010.0618.4
0.013.9053.2
RH light
2.8039.293.0
2.8039.293.0
2.8039.294.0
2.8039.294.0
2.8059.230.0
(LH)
2.8059.240.0
(RH)
Rear wiper
LH light
Rear lights
Rear lights
40-32
2.9019.200.0
Connector
L4
Fig. 1154
Fig. 1155
M3
M4
M5
N1
P2
P3
P5
P6
S2
S3
S4
S6
S7
S8
Wiring diagrams
Description
Code
PTO switch
2.7659.262.0
Front lights
2.8039.230.0
2.8519.035.4
Characteristics
Connector
U1
Fig. 1156
Fig. 1157
V4
Z5
Z8
Table 110
PIN
VOLTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
+12V
-
SYMBOL
GND
-
Positive (+12V)
N.C.
Triangle warning light
N.C.
N.C.
N.C.
N.C.
N.C.
N.C.
Earth
Sensor on/off
Temperature sensor
N.C.
N.C.
Fan control
N.C.
N.C.
Table 111
PIN
1
2
3
4
5
6
7
8
VOLTS
SYMBOL
B
L1A
L2A
L2A
L3A
L4A
L5A
L6A
DESCRIPTION
Wiring diagrams
PIN
9
10
11
12
VOLTS
+12V
SYMBOL
L7A
L8A
L9A
+
DESCRIPTION
Table 112
PIN
1
2
3
4
5
6
VOLTS
+12V
-
SYMBOL
+
S
+L
GND
DESCRIPTION
Positive (+12V)
N.C.
N.C.
ILC instrument signal
Lighting (+lights)
Earth
Table 113
PIN
1
2
3
4
5
6
7
8
9
10
11
12
VOLTS
+12V
SYMBOL
GND
L1B
L2B
L3B
L4B
L5B
L6B
L7B
L8B
L9B
L1B
+
DESCRIPTION
Earth
Differential lock indicator light (amber)
Front wheel drive engaged (yellow)
Low fuel warning light (yellow)
Trailer brakes alarm warning light (red)
Direction indicators warning light (green)
Trailer direction indicators warning light (green)
Sidelights warning light (green)
Full beam headlights warning light (blue)
PTO clutch indicator light (red)
N.C.
Positive (+12V)
Table 114
PIN
1
2
3
4
5
VOLTS
+12V
-
SYMBOL
GND
+L
S2
+12
+24
DESCRIPTION
Earth
Lighting (+lights)
TA instrument signal
Positive (+12V)
N.C.
Table 115
PIN
1
2
3
4
5
6
40-34
VOLTS
+12V
SYMBOL
GND
+L
5
+
DESCRIPTION
Earth
Lighting (+lights)
Temperature gauge signal
N.C,
N.C.
Positive (+12V)
Wiring diagrams
40.3 - Systems
Connector positions
Table 116
A28
A34
GND6
Fig. 1159
Fig. 1160
40-35
Wiring diagrams
Connec- Connector positions
tor/System
U8
G13
J1
L5
C2
Fig. 1161
Fig. 1163
Fig. 1165
Fig. 1167
40-36
Fig. 1162
H3
Fig. 1164
J2
Fig. 1166
Wiring diagrams
40.3.2 - Starting
Wiring diagrams
A32 Glowplugs
A33 Front PTO
A34 Earth
A39 Starter motor
A40 Starter motor
V1 To central wiring
Z9 To central wiring
Z10 Engine stop solenoid
Z11 Engine stop solenoid
40-38
Wiring diagrams
40.3.3 - Control unit - Fan
Fig. 1169
Key
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l
l
l
l
l
l
l
U1 Control unit
U2 Fan
U3 Indicator light
U4 Temperature
U5 Temp
U6 Female connector terminal
U7 Male connector terminal
U8 Earth
Z13 Fuel lift pump
Z15 Engine coolant temperature sensor for warning light
40-39
Wiring diagrams
40.3.4 - Steering column lights switch
40-40
Wiring diagrams
Wiring diagrams
40-42
Wiring diagrams
l
Wiring diagrams
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
40-44
A11 Clutch
A15 To front wiring
A18 Instrument panel
A19 Coolant temperature gauge
A20 Instrument panel
A21 Rev counter
A22 Fuel gauge
A23 Fuel level float switch
A24 Pre-heating relay
A26 Flasher
A31 To front wiring
A34 Earth
A36 To rear wiring
A37 Alternator
A38 Alternator
A41 Oil filter
Z2 To central wiring
Z3 Air cleaner clogging sensor
Z4 Air cleaner clogging sensor
Z9 To central wiring
Z12 Engine oil pressure switch
Z13 Fuel lift pump
Z14 Coolant temperature sensor
Z15 Engine coolant temperature sensor for warning light
Wiring diagrams
Wiring and connectors list
l
40.3.6 - Cab
Wiring diagrams
40-46
L3 To front worklights
L4 To rear wiper
L5 Earth
L6 To front worklights
L7 To front worklights
L8 To rotating beacon
L9 To LH rear worklight
L10 To number plate light
L11 To number plate light
L12 To RH rear worklight
M1 Relay
M2 Aereo-cab system
M3 To receiver-drier
M4 To receiver-drier
M5 To fan
N1 Worklight connection
Q1 Provision for radio
Q2 Provision for radio
Q3 Interior roof light
Q4 RH loudspeaker
Q5 LH loudspeaker
Q6 To aereo-cab wiring
X1 Fan speed selector switch
X2 Fan speed resistor
X3 Electric fan
Wiring diagrams
40-47
Wiring diagrams
l
40-48
G1 Clock
G2 Rear wiper switch
G3 Rear worklights switch
G4 Windscreen wiper switch
G5 Screenwash pump
G6 Front lights switch
G7 Flashing light switch
G8 Relay
Wiring diagrams
G9 Timer
G10 Power
G11 Power
G12 To door switch
G13 Earth
G14 To worklights wiring
G15 To radio/interior light wiring
G16 To A/C wiring
G17 To Borletti heater - air conditioning unit
G18 To Borletti heater - air conditioning unit
G19 To windscreen wiper
G20 Fusebox
H5 To aereo-cab wiring
H6 To relay
L1 To aereo-cab wiring
M2 Aereo-cab system
O2 To aereo-cab wiring
Q6 To aereo-cab wiring
40-49
Wiring diagrams
Wiring and connectors list
l
40-50
Wiring diagrams
40.3.8 - PTO
Wiring diagrams
l
l
l
l
l
l
l
l
l
l
l
l
l
l
40-52
Wiring diagrams
40.3.9 - Front axle differential lock
Wiring diagrams
A34 Earth
A36 To rear wiring
C1 To central wiring
C2 Earth
C3 4WD engagement light switch
C10 Diff. lock engagement control solenoid
Z9 To central wiring
Z10 Engine stop solenoid
40-54
Wiring diagrams
40.3.10 - Brakes
Wiring diagrams
l
l
l
l
S1 To rear wiring
S2 To LH rear lights
S5 To rear wiring
S6 To RH rear lights
40-56
Wiring diagrams
40.4 - Wiring harnesses
40.4.1 - Wiring harnesses
B1 - To central wiring
B2 - To central wiring
B3 - Air cleaner clogging sensor
B4 - Air cleaner clogging sensor
B5 - RH front light
B6 - Horn
B7 - Horn
B8 - LH front light
B9 - To central wiring
B10 - Engine stop solenoid
B11 - Engine stop solenoid
B12 - Engine oil pressure switch
B13 - Fuel lift pump
B14 - Coolant temperature sensor
B15 - Coolant temperature sensor for warning light
B16 - Earth
B17 - Battery negative
B18 - Battery positive
B19 - Heatshrink sheath
B20 - Earth
40-57
Wiring diagrams
40-58
Wiring diagrams
View of wiring
Connector positions
Table 117
Z1
40-40
Z2
40-40
40-43
Z3
40-43
Z4
40-40
40-43
Fig. 1181
Fig. 1182
40-59
Wiring diagrams
Connec- Connector positions
tor/System
Z5
40-40
Z8
40-40
Z10
40-52
40-37
Z11
40-37
Z13
40-39
40-40
40-43
Z6
40-40
Z7
40-40
Fig. 1183
Fig. 1185
Fig. 1187
Fig. 1189
40-60
Z9
40-37
40-40
40-52
40-43
Z12
40-43
Z14
40-43
Fig. 1184
Fig. 1186
Fig. 1188
Fig. 1190
Wiring diagrams
Connec- Connector positions
tor/System
Z15
40-39
40-43
Fig. 1191
V1 - To central wiring
V2 - PTO brake
V3 - PTO
V4 - PTO switch
40-61
Wiring diagrams
Connector positions
Table 118
V1
40-43
40-50
V4
40-50
V2
40-50
V3
40-50
Fig. 1193
Fig. 1195
40-62
Fig. 1194
Wiring diagrams
40.4.5 - Front lights wiring - 0.014.7599.4
P1 - To front wiring
P2 - To RH front lights
P3 - To RH front lights
P4 - To front wiring
P5 - To LH front lights
P6 - To LH front lights
40-63
Wiring diagrams
40.4.6 - Positions of front light wiring connectors
View of wiring
Connector positions
Table 119
P1
40-40
P2
P3
P4
40-40
P5
P6
Fig. 1198
40-64
Fig. 1199
Wiring diagrams
40.4.7 - Compressor wiring - 0.014.7601.4
R1 - Connector
R2 - Connector
40-65
Wiring diagrams
Connector positions
Table 120
R1
R2
Fig. 1202
40-66
Z1 - To central wiring
Z2 - To central wiring
Z3 - Air cleaner clogging sensor
Z4 - RH front light
Z5 - Horn
Z6 - LH headlight
Z7 - To central wiring
Fig. 1203
Wiring diagrams
40-67
Wiring diagrams
40-68
Wiring diagrams
View of wiring
Connector positions
Table 121
Z1
40-40
Z2
40-40
40-43
Z3
40-43
Z4
40-40
40-43
Fig. 1208
Fig. 1209
40-69
Wiring diagrams
Connec- Connector positions
tor/System
Z5
40-40
Z8
40-40
Z10
40-52
40-37
Z11
40-37
Z13
40-39
40-40
40-43
Z6
40-40
Z7
40-40
Fig. 1210
Fig. 1212
Fig. 1214
Fig. 1216
40-70
Z9
40-37
40-40
40-52
40-43
Z12
40-43
Z14
40-43
Fig. 1211
Fig. 1213
Fig. 1215
Fig. 1217
Wiring diagrams
Connec- Connector positions
tor/System
Z15
40-39
40-43
Fig. 1218
Wiring diagrams
40-72
Wiring diagrams
A38 - Alternator
A39 - Starter motor
A40 - Starter motor
A41- Oil filter
40-73
Wiring diagrams
40-74
Wiring diagrams
40.4.12 - Positions of central wiring connectors
View of wiring
40-75
Wiring diagrams
Connector positions
Table 122
A1
40-37
40-52
40-40
A4
40-37
40-40
A6
40-37
40-40
40-43
40-52
A3
40-37
40-52
40-40
Fig. 1222
Fig. 1224
Fig. 1226
40-76
A5
40-40
A7
40-40
Fig. 1223
Fig. 1225
Fig. 1227
Wiring diagrams
Connec- Connector positions
tor/System
A10
40-52
40-50
40-37
40-43
A12
A14
40-37
40-40
40-52
A15
40-52
40-40
40-43
A16
40-40
A11
40-50
40-52
40-43
40-43
Fig. 1228
Fig. 1230
Fig. 1232
A13
40-37
40-52
40-40
A17
40-37
40-40
40-52
Fig. 1229
Fig. 1231
Fig. 1233
40-77
Wiring diagrams
Connec- Connector positions
tor/System
A18
40-37
40-40
40-43
40-50
40-52
40-55
A19
40-37
40-40
40-43
40-52
40-50
40-55
A20
40-37
40-40
40-43
40-50
40-52
A21
40-37
40-40
40-43
40-52
A22
A24
40-37
40-37
40-43
40-52
A26
40-37
40-40
40-43
40-52
A23
40-37
40-43
40-52
Fig. 1234
A25
40-40
Fig. 1236
Fig. 1238
40-78
Fig. 1235
A27
40-37
A28
40-37
40-52
A29
40-52
40-37
Fig. 1237
Fig. 1239
Wiring diagrams
Connec- Connector positions
tor/System
A30
40-37
40-40
40-52
A32
40-37
A34
40-37
40-40
40-43
40-50
40-52
A36
40-40
40-43
40-50
40-52
40-55
A31
40-37
40-40
40-43
40-52
Fig. 1240
Fig. 1242
Fig. 1244
Fig. 1246
A33
40-50
40-37
40-52
A35
A37
40-43
A38
40-43
Fig. 1241
Fig. 1243
Fig. 1245
Fig. 1247
40-79
Wiring diagrams
Connec- Connector positions
tor/System
A39
40-37
A40
40-37
40-50
A41
40-43
Fig. 1248
40-80
U1 - Control unit
U2 - Fan
U3 - Indicator light
U4 - Temperature
U5 - Temp
U6 - Female connector terminal
U7 - Male connector terminal
U8 - Earth
Fig. 1249
Wiring diagrams
40.4.14 - Positions of solenoid valve wiring connectors
View of wiring
Connector positions
Table 123
U1
40-39
U2
40-39
U3
40-39
Fig. 1252
Fig. 1253
40-81
Wiring diagrams
Connec- Connector positions
tor/System
U4
40-39
U5
40-39
Fig. 1254
U6
40-39
U7
40-39
Fig. 1256
40-82
C1 - To central wiring
C2 - Earth
U8
40-39
Fig. 1255
Fig. 1257
Wiring diagrams
Fig. 1259
40-83
Wiring diagrams
40.4.16 - Positions of rear wiring connectors
View of wiring
Connector positions
Table 124
C1
40-40
40-50
40-52
40-55
C2
40-50
40-52
40-55
Fig. 1261
40-84
Fig. 1262
Wiring diagrams
Connec- Connector positions
tor/System
C3
40-52
C4
40-55
Fig. 1264
C5
40-40
40-55
C7
40-40
40-55
C8
C9
40-40
C10
40-52
Fig. 1263
Fig. 1265
Fig. 1267
C6
40-40
C11
40-50
C12
40-50
Fig. 1266
Fig. 1267
40-85
Wiring diagrams
40.4.17 - Remote valve wiring - 0.012.6955.4
D1 - To central wiring
D2 - PTO wiring
D3 - Flow control switch
D4 - To platform wiring
40-86
To rear wiring
To LH worklights
To LH worklights
To LH worklights
To rear wiring
To RH worklights
To RH worklights
To RH worklights
Wiring diagrams
40.4.19 - Positions of rear light wiring connectors
View of wiring
40-87
Wiring diagrams
View of wiring
Connector positions
Table 125
S1
40-40
40-55
S2
40-40
40-55
S3
40-40
S4
40-40
S5
40-40
40-55
S6
40-40
40-55
S7
40-40
S8
40-40
Fig. 1272
40-88
Fig. 1273
Wiring diagrams
40.4.20 - Aereo cab wiring - 0.014.7593.4
G1 - Clock
G2 - Rear wiper switch
G3 - Rear worklights switch
G4 - Windscreen wiper switch
G5 - Screenwash pump
G6 - Front lights switch
G7 - Flashing light switch
G8 - Relay
G9 - Timer
G10 - Power supply
G11 - Power supply
G12 - To door switch
G13 - Earth
G14 - To worklights wiring
G15 - To radio/interior light wiring
G16 - To A/C wiring
G17 - To Borletti heater - air conditioning unit
G18 - To Borletti heater - air conditioning unit
G19 - To windscreen wiper
G20 - Fusebox
40-89
Wiring diagrams
40-90
Wiring diagrams
40.4.21 - Positions of aereo-cab wiring connectors
View of wiring
Connector positions
Table 126
G1
40-48
G2
40-48
G3
40-48
G4
40-48
G5
40-48
G6
40-48
G7
40-48
G13
40-48
G19
40-48
Fig. 1277
Fig. 1278
40-91
Wiring diagrams
Connec- Connector positions
tor/System
G14
40-45
40-48
G15
40-45
40-48
Fig. 1279
40-92
H1 - To compressor
H2 - To central wiring
H3 - Earth
H4 - Fuses (20 A - 40 A)
H5 - To cab wiring
H6 - To relay
G8
40-48
G9
40-48
G10
40-48
40-45
G11
40-48
40-45
G12
40-48
G13
40-48
G16
40-45
40-48
G17
40-48
G18
40-48
Fig. 1280
Wiring diagrams
40.4.23 - Positions of cab power supply wiring connectors
View of wiring
Connector positions
Table 127
H1
40-45
H2
40-45
H4
H3
Fig. 1283
Fig. 1284
40-93
Wiring diagrams
40.4.24 - Air conditioning system - 0.014.7596.4
40-94
M1 - Relay
M2 - Aereo cab system
M3 - To receiver-drier
M4 - To receiver-drier
M5 - To fan
Wiring diagrams
40.4.25 - Position of air conditioner wiring connectors
View of wiring
Connector positions
Table 128
M1
40-45
M2
40-45
40-48
Fig. 1287
Fig. 1288
40-95
Wiring diagrams
Connec- Connector positions
tor/System
M3
40-48
M4
40-45
M5
40-45
Fig. 1289
40-96
J1 - Earth 1
J2 - Earth 2
Fig. 1290
Wiring diagrams
40.4.27 - Positions of cab earth wiring connectors
View of wiring
Connector positions
Table 129
J1
J2
Fig. 1293
Fig. 1294
40-97
Wiring diagrams
40.4.28 - Worklights-number plate light- flashing light - 0.014.7595.4
40-98
Wiring diagrams
40.4.29 - Positions of worklight, number plate and flashing light wiring connectors
View of wiring
Fig. 1297 - Positions of worklight, number plate and flashing light wiring connectors
0.014.7595.4
l
40-99
Wiring diagrams
Connector positions
Table 130
L1
40-45
40-48
L4
40-45
L8
40-45
L9
40-45
L10
L2
40-40
40-45
T3
40-45
Fig. 1298
Fig. 1300
Fig. 1302
40-100
L6
40-45
L7
40-45
L11
L12
Fig. 1299
Fig. 1301
Fig. 1303
Wiring diagrams
40.4.30 - Flashing light wiring - 0.014.7591.4
40-101
Wiring diagrams
Connector positions
Table 131
N1
40-45
N2
N3
Fig. 1306
O1 - To windscreen wipers
O2 - To aereo wiring
40-102
Wiring diagrams
40.4.33 - Positions of windscreen wiper wiring connectors
View of wiring
Connector positions
Table 132
O1
O2
40-48
Fig. 1309
Fig. 1310
40-103
Wiring diagrams
40.4.34 - Radio wiring - 0.014.7600.4
40-104
Wiring diagrams
40.4.35 - Positions of radio-loudspeaker wiring connectors
View of wiring
40-105
Wiring diagrams
Connector positions
Table 133
Q1
40-45
Q2
40-45
Q6
40-45
40-48
Q3
40-45
Fig. 1313
Fig. 1315
40-106
Q5
Fig. 1314
INDEX
A
A/C fan - compressor drivebelt
A/C system air intake filters
Adjustable front fenders
Adjustment of the bevel gear pair
Adjustment of the brake light switches
Adjustment of the lift control valve levers
Adjustment of the parking brake switch
Adjustment of the rear lift
Aereo cab
Aereo cab wiring - 0.014.7593.4
Air cleaner assembly
Air conditioner fan
Air conditioning compressor
Air conditioning system - 0.014.7596.4
Air conditioning system - Standard roof version
Alternator
Auxiliary fuel tank
30-29
30-225
30-217
30-162
30-273
30-240
30-271
30-293
40-48
40-89
30-97
30-238
30-233
40-94
30-230
30-109, 30-111
30-103
B
B0 - Engine
Baruffaldi electromagnetic clutch
Basic electronics for mechanics (1/2)
Basic electronics for mechanics (2/2)
Battery
Bevel gear pair
Bistable pressure switch for compressor clutch engagement/disengagement
Brake lights switches
Brakes
Brakes and rear axle assembly
30-2
20-2
40-9
40-11
30-267
30-149
30-239
30-271
40-55
10-13
C
C0 - Engine accessories
Cab
Cab access steps
Cab door lock - tie-rod
Cab earth wiring - 0.015.0031.4
Cab power supply - 0.014.7594.4
Cab roof
Central wiring - 0.012.6949.4
Centre console
Checking clutch plate wear
Clutch housing
Clutch plate
Clutch release bearing
Clutch release forks
Components
Compression test
Compressor wiring - 0.014.7601.4
Condenser
Control buttons - RH console
Control rods
Control unit - Fan
Conversion factors
Cooling system
Crankshaft pulley
Creeper - synchronizer renewal
Cylinder
Cylinder head and valve train components
30-93
30-205, 40-45
30-216
30-217
40-96
40-92
30-226
40-71
30-224
30-128
30-131
30-127
30-128
30-129
40-31, 40-31
30-11
40-65
30-235
30-273
30-264
40-39
0-10
30-85
30-31
30-155
30-285
30-55
D
D0 - Transmission
Diagnostic tool screens
Differential lock control assembly
30-127
20-2
10-17
INDEX
Disassembly of 4WD output shaft and groundspeed PTO
Disassembly of LH/RH rear axle
Disassembly of the bevel gear pair
Disassembly of the gearbox input shaft
Disassembly of the lift control valve
Disassembly of the main shaft
Disassembly of the planetary reduction gear
Disassembly of the PTO output shaft.
Disassembly of the rear differential
Disassembly of the secondary shaft
Disassembly of the starter motor
Double/single acting conversion valve
30-153
30-167
30-190
30-135
30-302
30-137
30-199
30-158
30-175
30-137
30-120
30-264
E
E0 - Rear axle
Earthing points
Electrical and electronic components (1/2)
Electrical and electronic components (2/2)
Electrostatic unit
Engine
Engine - Separation from the transmission
Engine air intake pipe
30-166
40-35
40-18
40-26
30-269
30-10
30-3
30-89
e
engine block, crankshaft, pistons and sump
30-13
E
Engine cooling system radiator
Engine stop keyswitch
Evaporator assembly
Exhaust pipe - tractor with cab
Expansion tank
30-93
30-104, 30-107
30-237
30-105
30-96
F
F0 - Front axle
Fan
Fan - alternator drivebelt
Flashing light wiring - 0.014.7591.4
Flywheel bearing
Front axle
Front axle - complete assembly
Front axle differential lock
Front lift - version with front PTO Front lights wiring - 0.014.7599.4
Front PTO wiring - 0.014.2645.4
Front support
Front wheels
Front wiring with cab
Fuel filter
Fuel injection nozzle
Fuel System
Fuel tank - Fuel tank float switch
Fuse and relay assembly
30-178
30-97
30-26
40-100
30-33
10-14, 10-14
30-182
40-52
30-283
40-62
40-61
30-178
30-309
40-66
30-99
30-79
30-66
30-99
30-268
G
G0 - Bodywork - Cab - Platform
Gear pump
Gearbox and shuttle assembly - complete unit
Gearbox input shaft - oil seal renewal
General safety rules
Governor
II
30-205
10-17
30-141, 30-142
30-148
0-2
30-82
INDEX
H
H0 - Hydraulic system
Hood and side panels
Hydraulic lift control valve
Hydraulic system
30-244
30-212
30-301
10-17
I
Injection pump
Inspection and adjustment of the fuel system
Inspection of the air intake and exhaust system
Inspection of the camshaft
Inspection of the connecting rods
Inspection of the cooling system
Inspection of the crankshaft
Inspection of the cylinder head
Inspection of the engine monobloc
Inspection of the flywheel and ring gear
Inspection of the fuel injection pump camshaft
Inspection of the fuel lift pump
Inspection of the idler gear
Inspection of the lubrication system
Inspection of the pistons, piston rings and gudgeon pins
Inspection of the rocker arms and rocker shaft
Inspection of the valve pushrods
Inspection of the valve springs
Inspection of the valves, valve guides and valve seats
Instrument panel
Intake and exhaust systems
Introduction
30-71
30-69
30-91
30-48, 30-49
30-47
30-87
30-23
30-62
30-23
30-44
30-78, 30-79
30-70
30-50
30-65
30-44
30-55
30-62
30-62
30-50
30-219, 30-223, 40-43
30-90
0-2, 40-2, 40-6
L
L0 - Electrical system
Left-hand console
Left-hand rear axle
Left-hand rear cab pillar - screenwash reservoir
Lift arms
Lift cylinders
Lift locking shut-off valve
Lifting instructions
Lubrication System
30-267
30-221
30-166
30-220
30-299
30-296, 30-297
30-261
0-4
30-63
M
M0 - Front PTO
Maintenance of the injector nozzles
30-276
30-82
N
N0 - Front lift
30-283
O
Operator seated sensor ECU (p/n 2.8519.106.0)
20-8
P
Parking brake
Parking brake switch
30-160
30-270
III
INDEX
Planetary reduction gear
Position of air conditioner wiring connectors
Positions of aereo-cab wiring connectors
Positions of cab earth wiring connectors
Positions of cab power supply wiring connectors
Positions of central wiring connectors
Positions of compressor wiring connectors
Positions of flashing light wiring connectors
Positions of front light wiring connectors
Positions of front PTO wiring connectors.
Positions of front wiring connectors
Positions of front wiring connectors with cab
Positions of radio-loudspeaker wiring connectors
Positions of rear light wiring connectors
Positions of rear wiring connectors
Positions of solenoid valve wiring connectors
Positions of windscreen wiper wiring connectors
Positions of worklight, number plate and flashing light wiring connectors
Power steering disassembly
Power steering valve
Power steering valve - Complete assembly
PREPARATION FOR DISASSEMBLY
Pressure relief valve - lift control valve
Propeller shaft - Front axle drive shaft
PTO
PTO output shaft
PTO output shaft.
Pump - clutch assembly - brake
Pump for hydraulic lift and auxiliary services and power steering system
30-199
40-94
40-90
40-96
40-93
40-74
40-65
40-101
40-63
40-61
40-58
40-68
40-104
40-87
40-84
40-81
40-102
40-99
30-247
10-22
30-246
30-2
30-260
30-198
40-50
30-279
30-157
30-276
30-244
R
R0 - Rear lift
Radio wiring - 0.014.7600.4
Range gearbox and differential assembly - complete unit
Rear axle
Rear axle brake discs
Rear differential
Rear lift - complete assembly
Rear lights wiring - 0.014.7602.4
Rear PTO and Mid PTO
Rear wheels
Rear wiring - 0.013.1452.4/10
Receiver-dryer
Remote control valve
Remote valve control levers
Remote valve wiring - 0.012.6955.4
Removal of the PTO output shaft
Renewal of the jets
Renewal of the rear lift bush
RH rear cab pillar trim
Right-hand console
30-287
40-104
30-146
10-13
30-176
30-172
30-287, 30-289
40-86
10-8
30-309
40-82
30-236
10-22, 30-262, 30-262
30-243
40-86
30-158
30-62
30-298
30-224
30-221
S
S0 - Wheels
Safety notes
Safety precautions for removal and refitting operations
Seat
Solenoid valve
Solenoid valve wiring - 0.014.1482.4
Starter motor
Starting
Steering circuit
Steering column lights switch
Steering column switch
Steering cylinders
Steering cylinders disassembly
Steering knuckle housing and axle shaft
Steering wheel
Structure of the unit
Support and towing hitch
Systems
IV
30-309
0-2
0-3
30-230
30-281
40-80
30-116, 30-118
40-37
10-20
40-40
30-273
30-184
30-186
30-188
30-240
40-2
30-310
40-35
INDEX
T
Threadlockers, adhesives, sealants and lubricants
Three-point linkage with mechanical adjustment
Tightening torques
Timing gears and flywheel
Transmission
Transmission oil filter assembly
0-8
30-307
0-5
30-33
10-2, 10-2
30-244
V
V0 - Ballast - towing hitches
Valve clearances
30-310
30-53
W
Windscreen wipers - 0.014.7598.4
Wiring and components index
Wiring harnesses
Worklights-number plate light- flashing light - 0.014.7595.4
40-102
40-6
40-57, 40-57
40-98
VI
20-8
*307.W.0430.en.6.02*
04/2015
SAME DEUTZ-FAHR ITALIA S.p.A.
Viale F. Cassani, 15 - 24047 Treviglio (BG) Italy
T + 39.0363.4211 F + 39.0363.421638
www.samedeutz-fahr.com
Deutz-Fahr is a
www.deutz-fahr.com
trademark