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S E R V I C E
INTRODUCTION
◊ This m anual is divided into sections identified b y tw o-figure numbers. Each section has independent page
numbering.
For ease o f reference, these sections have the same numbers and nam es as the Repairs Rate Book sections.
◊ The different sections can easily be found b y consulting the table o f contents on the following pages.
◊ The docum ent num ber o f the m anual and the edition/update dates are given at the bottom o f each page.
◊ The information contained in this m anual was current on the date printed on each section. As CASE IH
constantly improves its product range, some information m ay be out o f date subsequent to modifications im
plem ented for technical o r commercial reasons o r to m eet legal requirem ents in different countries.
In the event o f conflicting information, consult the CASE IH Sales and Service Departments.
IMPORTANT WARNINGS
◊ A ll maintenance and repair work described in this m anual m ust be perform ed exclusively by CASE IH service
technicians in strict accordance with the instructions given and using any specific tools necessary.
◊ Anyone who perform s the operations described herein without strictly following the instructions is personally
responsible for resulting injury or damage to property.
◊ The M anufacturer and all organisations belonging to the M anufacturer’s distribution network, including but
not restricted to national, regional or local distributors, will accept no responsibility for personal injury or dam
age to property caused by abnorm al function o f parts and/or components not approved by the Manufacturer,
including those used for maintenance and/or repair o f the product m anufactured o r marketed b y the Manufac
turer.
In any case, the product m anufactured or m arketed by the Manufacturer is covered by no guarantee o f any
kind against personal injury or damage to property caused by abnormal function o f parts and/or components
not approved b y the Manufacturer.
PRINTED IN ?????
CONTENTS
GENERAL SECTION 00
ENGINE SECTION 10
CLUTCH SECTION 18
Clutches Chapter 1
Section Description Page
GEARBOX SECTION 21
Hydraulic d ia g ra m ............................................................................................................................ 2
STEERING SECTION 41
Steering Chapter 1
S e ctio n D e s c rip tio n Page
Equipment ........................................................................................................................................ 4
Use ............................................................................................................................................... 14
Instruments Chapter 1
Section D e s c rip tio n ............................................................................................................................. Page
Battery Chapter 5
Section D e s c rip tio n ............................................................................................................................ Page
Electrical d ia g ra m s ............................
- Direction indicator & hazard warning light circuit and connector overview . . . . 25
- Side lights,main and dipped headlights, parking light circuit and connector
overview 53
90 160 42 -4 3
90 120 10 Control levers, seat and electrical controls - disassembly and re a s s e m b ly ...........................2
90 156 52 Rear window, handle and lock - disassembly and reassembly .......................................... 10
90 154 30 Left-hand door exterior handle and lock - disassembly and re a s s e m b ly............................. 11
90 1 5 4 1 0 Left-hand door - disassembly and reassem bly...................................................................... 12
90 160 60
55 518 52 Windscreen w iper motor - disassembly and reassembly ................................................... 13
90154 24
90 156 10 - 14
90 156 28 Cab windows - re p la ce m e n t...................................................................................................... 15
SECTION 00 - GENERAL - CHAPTER 1 1
GENERAL INSTRUCTIONS
IMPORTANT NOTICE
All maintenance and repair operations described in this manual should be carried out exclusively by the CASE
IH authorised workshops. All instructions detailed should be carefully observed and special equipment indicated
should be used if necessary.
Everyone who carries out service operations described without carefully observing these prescriptions will be
directly responsible of deriving damages.
SHIMMING
At each adjustment, select adjusting shims, measure them individually using a micrometer and then sum up
recorded values. Do not rely on measuring the whole shimming set, which may be incorrect, or on rated value
indicated for each shim.
O RINGS
Lubricate the O rings before inserting them into their seats. This will prevent the O rings from rolling over and
twine during mounting which will jeopardise sealing.
SEALERS
Apply one of the following sealers: RTV SILMATE, RHODORSIL CAF 1, or LOCTITE PLASTIC GASKET over
the mating surfaces marked with an X.
Before applying the sealer, prepare the surface as follows:
- remove possible scales using a metal brush;
- thoroughly degrease the surfaces using one of the following cleaning agent: trichlorethylene, petrol or a water
and soda solution.
BEARINGS
It is advisable to heat the bearings to 80 to 90°C before mounting them on their shafts and cool them down before
inserting them into their seats with external tapping.
ROLL PINS
When fitting straight roll pins, ensure that the pin notch is oriented in the direction of the effort to stress the pin.
Coil roll pins can be installed in any position.
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2 SECTION 00 - GENERAL - CHAPTER 1
Use exclusively genuine CASE IH spare parts, the only ones bearing this logo.
CASE
Only genuine parts guarantee same quality, life, safety as original components as they are the same as mounted
in production.
Only the CASE IH genuine spare parts can offer this guarantee.
All spare parts orders should be complete with the following data:
- tractor model (commercial name) and frame number;
- engine type and number;
- part number of the ordered part, which can be found on the “Microfiches” or the “Spare Parts Catalogue”,
which is the base for order processing.
NOTICES
W ear limits indicated for some details should be intended as advised, but not binding values. The words “front”,
“rear”, “right hand”, and “left hand” referred to the different parts should be intended as seen from the operator’s
seat oriented to the normal sense of movement of the tractor.
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SECTION 00 - GENERAL - CHAPTER 1 3
SAFETY RULES
A
This warning symbol points out im portant messages involving personal safety.
Carefully read the safety rules contained herein and follow advised precautions to
avoid potential hazards and safeguard your safety and personal integrity.
In this m anual you will find this symbol together with the following key-w ords:
WARNING - it gives warning about improper repair operations and deriving potential
consequences affecting the service technician’s personal safety.
DANGER - it gives specific warning about potential dangers for personal safety o f the
operator or other persons directly o r indirectly involved.
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4 SECTION 00 - GENERAL - CHAPTER 1
0 Use exclusively specified towing points for tow 0 In case of operations outside the workshop, drive
ing the tractor. Connect parts carefully. Ensure the tractor to a flat area and block it. If working on
that foreseen pins and/or locks are steadily fixed an incline cannot be avoided, first block the trac
before applying traction. Do not stop near towing tor carefully. Move it to a flat area as soon as pos
bars, cables or chains working under load. sible with a certain extent of safety.
0 To transfer a failed tractor, use a trailer or a low 0 Ruined or plied cables and chains are unreliable.
loading platform trolley if available. Do not use them for lifting or trailing. Always han
0 To load and unload the machine from the trans dle them wearing gloves of proper thickness.
portation mean, select a flat area providing a firm
0 Chains should always be safely fastened.
support to the trailer or truck wheels. Firmly tie
Ensure that fastening device is strong enough to
the machine to the truck or trailer platform and
hold the load foreseen. No persons should stop
block wheels as required by the forwarder.
near the fastening point, trailing chains or cables.
0 For electrical heaters, battery-chargers and sim
ilar equipment use exclusive auxiliary power 0 The working area should be always kept CLEAN
supplies with a efficient ground to avoid electrical and DRY. Immediately clean any spillage of
shock hazard. water or oil.
0 Always use lifting equipment and sim ilar of 0 Do not pile up grease or oil soaked rags, as they
appropriate capacity to lift or move heavy compo constitute a great fire hazard. Always place them
nents. into a metal container.
Before starting the tractor or its attachments,
0 Pay special attention to bystanders. check, adjust and block the operator’s seat. Also
0 Never pour gasoline or diesel oil into open, wide ensure that there are no persons within the trac
and low containers. tor or attachment operating range.
0 Never use gasoline, diesel oil or other flammable 0 Do not keep into your pockets any object which
liquids as cleaning agents. Use non-flam m able might fall unobserved into the tractor’s inner
non-toxic proprietary solvents. compartments.
0 W ear protection goggles with side guards when 0 Whenever there is the possibility of being
cleaning parts using compressed air. reached by ejected metal parts or similar, use
protection eye mask or goggles with side guards,
0 Do not exceed a pressure of 2.1 bar, in accor
helmets, special footwear and heavy gloves.
dance with local regulations.
0 Do not run the engine in a closed building without 0 Wear suitable protection such as tinted eye
proper ventilation. protection, helmets, special clothing, gloves and
footwear whenever it is necessary to carry out
0 Do not smoke, use open flames, cause sparks in welding procedures. All persons standing in the
the nearby area when filling fuel or handling vicinity of the welding process should wear tinted
highly flammable liquids. eye protection. NEVER LOOK AT THE WELD
ING ARC IF YOUR EYES ARE NOT SUITABLY
0 Do not use flames as light sources when working
PROTECTED.
on a machine or checking for leaks.
0 Move with caution when working under a tractor, 0 Metal cables with the use get frayed. Always
and also on or near a tractor. Wear proper safety wear adequate protections (heavy gloves, eye
accessories: helmets, goggles and special foot protection, etc.)
wear.
0 Handle all parts with the greatest caution. Keep
0 During checks which should be carried out with your hands and fingers far from gaps, moving
the engine running, ask an assistant to seat at the gears and similar. Always use approved protec
operator’s seat and keep the service technician tive equipment, such as eye protection, heavy
under visual control at any moment. gloves and protective footwear.
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SECTION 00 - GENERAL - CHAPTER 1 5
ENGINE
0 Always take system pressure readings using the
0 Always loosen the radiator cap very slowly before appropriate gauges.
removing it to allow pressure in the system to dis
sipate. Coolant should be topped up only when WHEELS AND TYRES
the engine is stopped or idle if hot.
0 Check that the tyres are correctly inflated at the
pressure specified by the manufacturer. Periodi
cally check possible damages to the rims and
0 Do not fill up fuel tank when the engine is running,
tyres.
mainly if it is hot, to avoid ignition of fires in case
of fuel spilling.
0 Keep off and stay at the tyre side when correcting
the inflation pressure.
0 Never check or adjust the fan belt tension when
the engine is running. 0 Check the pressure only when the tractor is
Never adjust the fuel injection pump when the unloaded and tyres are cold to avoid wrong read
tractor is moving. ings due to over-pressure. Do not reuse parts of
recovered wheels as improper welding, brazing
or heating may weaken the wheel and make it fail.
0 Never lubricate the tractor when the engine is run
ning. 0 Never cut, nor weld a rim with the inflated tyre
assembled.
0 Always disconnect the batteries before perform 0 Do not twine chains or metal cables. Always wear
ing any type of service on the electrical system. protection gloves to handle cables or chains.
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6 SECTION 00 - GENERAL - CHAPTER 1
CONSUMABLES
QUANTITY CASE IH
COMPONENT TO BE FILLED OR INTERNATIONAL
RECOMMENDED
TOPPED UP litres/dm3 US gal IMP gal SPECIFICATION
PRODUCTS
Cooling system:
JX60, JX70 models 12 3.2 2.64 Water & liquid
JX80, JX90, JX95 models 14 3.7 3.08 AKCELA PREMIUM
-
with cab : ANTI-FREEZE
JX60, JX70 models 14 3.7 3.1 50% + 50%
JX80, JX90, JX95 models 16 4.2 3.5
Water & cleaning
Windscreen washer bottle .................. 2 0.53 0.44 -
liquid
Fuel tank 90 23.8 19.8 Decanted and filtered -
Additional fuel tank (Optional) ............ 27 7.1 5.94 diesel fuel -
Engine sump:
without filter :
AKCELA No.1
JX60, JX70 models 7.6 1.98 1.67 API C F-4/SG
ENGINE OIL
JX80, JX90, JX95 models 10.5 2.77 2.31 CCMC D4
with filter : API C H -4 * ACEA M IL-L-2104E
JX60, JX70 models 8.3 2.19 1.83 E5 * MB 228.3 *
CUMMINS CES
JX80, JX90, JX95 models 11.2 2.96 2.46
200072/20076/20077
AKCELA LHM
Brake control c irc u it.............................. 0.4 0.1 0.09 ISO 7308
FLUID Oil
Hydrostatic steering c ir c u it.................. 2.0 0.5 0.44
Front axle:
- axle housing : 4.5 1.2 0.99
JX60, JX70 models
7.0 1.8 1.54
JX80, JX90, JX95 models
- final drives (each) :
JX60, JX70 HP models 0.8 0.2 0.18
JX80, JX90, JX95 models 1.25 0.3 0.28
Rear transmission (bevel drive and API GL4
Oil
brakes), gearbox, hydraulic lift and
PTO AKCELA ISO 32/46
NEXPLORE SAE 10W -30
JX60, JX70, JX80, JX90, 12.15 10.12
46
JX95 models ..................................
- with synchro-reverser:
JX60, JX70, JX80, JX90, 12.15 10.12
46
JX95 models ..................................
Rear final drives (each) :
JX60, JX70 HP models 3.9 1.03 0.86
JX80, JX90, JX95 models 5.3 1.40 1.17
Grease
Front wheel h u b s .................................. - - -
AKCELA
MULTI PURPOSE NLGI 2
Grease fittings ...................................... GREASE
- - -
(251H EP)
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SECTION 10 - ENGINE - CHAPTER 1 1
SECTION 10 - ENGINE
Chapter 1 - Engine
CONTENTS
6-62720 - 09 - 2006
2 SECTION 10 - ENGINE - CHAPTER 1
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 3
(continued)
Normal oil pressure, with engine hot and at fast idling speed . 2.9 to 3.9 bar (42.06 to 56.56 psi)
Radiator on JX60, JX70, JX80 and JX90 models .................... three-row vertical pipes with copper fins
Fan, attached to coolant pump pulley ........................................ four-blade steel exhauster fan
6-62720 - 09 - 2006
4 SECTION 10 - ENGINE - CHAPTER 1
(continued)
Fuel System
A ir c le a n in g ....................................................................................... dual cartridge dry air filter, with clogged
filter indicator with centrifugal pre-filter
and automatic dust ejector.
Fuel p u m p ......................................................................................... with double diaphragm
For fixed advance (pump setting for start of delivery before refer to the data for the relevant engine
TDC) - Pressure setting - Injection order, and other type in the tables from page 6 to page
information regarding the BOSCH pump 14.
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 5
DATA
BOSCH pump:
Fuel injectors:
BOSCH ..................................................
- Nozzle t y p e ........................................
- Type ....................................................
- D im e n sio n s................................ mm
6-62720 - 09 - 2006
6 SECTION 10 - ENGINE - CHAPTER 1
1. START OF DELIVERY
Plunger pre-lift from BDC: Pump rotation (viewed from drive side): Injection o rd e r:1 -2 -3
mm - anticlockwise
10. BACKFLOW
Rev/min 500 1250
Backflow cm3/1 0 s 44.5 to 77.7 58.3 to 97.1
(continued)
Note: The values shown above in brackets must be used for checking purposes only.
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 7
(continued)
Note: The values shown above in brackets must be used for checking purposes only.
TDC fixed advance with cylinder No. 1 in compression stroke: Relative humidity 70% ± 5.
(see previous page).
Engine without fan, air filter and exhaust silencer. Ambient temperature 25 °C.
6-62720 - 09 - 2006
8 SECTION 10 - ENGINE - CHAPTER 1
1. START OF DELIVERY
Plunger pre -lift from B.D.C.: mm - Pump rotation (viewed from drive side): Injection o rd e r:1 -2 -3
anticlockwise
11. BACKFLOW
Rev/min 1250 500
LDA pressure kPa 100 100
Backflow for cm3/1 0 s 66.7 to 105.5 50.0 to 77.6
(continued)
Note: The values shown above in brackets must be used for checking purposes only.
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 9
(continued)
12. DELIVERY PROGRESSION
Rev/min LDA pressure kPa Delivery per 1000 shots: cm3
1390 100 0 to 3.0
1350 100 32 to 33
1250 100 66 to 71
900 100 76.5 to 76.9
600 27,5 76.2 to 77.2
400 100 91
600 0 73.8 to 74.2
Note: The values shown above in brackets must be used for checking purposes only.
TDC fixed advance with cylinder No. 1 in compression stroke: Relative humidity 70% ± 5.
(see previous page)
Engine without fan, air filter and exhaust silencer. Ambient temperature 25 °C.
Atm ospheric pressure: 990 mbar Specific gravity of diesel fuel
830 ± 10 g/litre.
Power output with engine Fuel
Throttle run-in for a total of: consumption
lever Braking load applied Engine rpm
2 hours 50 hours
position
kW (HP) kW kg/h
For maximum
Maximum 2500 - 47.5 - 50.5 11.1 - 11.8
torque
Maximum For maximum torque 1500 - 37.0 - 39.5 8.2 - 8.7
Maximum None (no-load) 2770 ± 25 - - -
Minimum None (no-load) 650 ± 25 - - -
6-62720 - 09 - 2006
10 SECTION 10 - ENGINE - CHAPTER 1
1. START OF DELIVERY
Plunger pre -lift from BDC: Pump rotation (viewed from drive side): Injection o rd e r:1 -3 -4 -2
mm - anticlockwise
10. BACKFLOW
Rev/min 400 1250
Backflow l/h 16 to 30 21 to 39
(continued)
Note: The values shown above in brackets must be used for checking purposes only.
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 11
(continued)
Note: The values shown above in brackets must be used for checking purposes only.
TDC fixed advance with cylinder No. 1 in compression stroke: Relative humidity 70% ± 5.
(see previous page)
Engine without fan, air filter and exhaust silencer. Ambient temperature 25 °C.
Atm ospheric pressure: 990 mbar Specific gravity of diesel fuel
830 ± 10 g/litre.
Power output with engine run-in for a to Fuel
Throttle tal of: consumption
lever Braking load applied Engine rpm
2 hours 50 hours
position
kW (HP) kW (HP) kg/h
For maximum
Maximum 2500 - 54.0 - 57.5 12.3 - 13.1
torque
Maximum For maximum torque 1500 - 39.5 - 42 8.5 - 9.0
Maximum None (no-load) 2725 ± 25 - - -
Minimum None (no-load) 650 ± 25 - - -
6-62720 - 09 - 2006
12 SECTION 10 - ENGINE - CHAPTER 1
1. START OF DELIVERY
Plunger pre -lift from BDC: Pump rotation (viewed from drive side): Injection o rd e r:1 -3 -4 -2
mm - anticlockwise
10. BACKFLOW
Rev/min 400 1250
Backflow l/h 15 to 29 22 to 40
(continued)
Note: The values shown above in brackets must be used for checking purposes only.
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 13
(continued)
Note: The values shown above in brackets must be used for checking purposes only.
TDC fixed advance with cylinder No. 1 in compression stroke: Relative humidity 70% ± 5.
(see previous page)
Engine without fan, air filter and exhaust silencer. Ambient temperature 25 °C.
Atm ospheric pressure: 990 mbar Specific gravity of diesel fuel
830 ± 10 g/litre.
Power output with engine run-in for a Fuel
Throttle total of: consumption
lever Braking load applied Engine rpm
2 hours 50 hours
position
kW (HP) kW (HP) kg/h
For maximum
Maximum 2500 - 60.0 - 64.0 13.7 - 14.6
torque
Maximum For maximum torque 1500 - 46.0 - 48.8 9.8 - 10.4
Maximum None (no-load) 2725 ± 25 - - -
Minimum None (no-load) 650 ± 25 - - -
6-62720 - 09 - 2006
14 SECTION 10 - ENGINE - CHAPTER 1
1. START OF DELIVERY
Plunger pre -lift from B.D.C.: mm - Pump rotation (viewed from drive side): Injection o rd e r:1 -3 -4 -2
anticlockwise
11. BACKFLOW
Rev/min 500 1250
LDA pressure kPa 100 100
Backflow for 10 sec. l/h 18 to 32 21 to 39
(continued)
Note: The values shown above in brackets must be used for checking purposes only.
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 15
(continued)
12. DELIVERY PROGRESSION
Rev/min LDA pressure kPa Delivery per 1000 shots: cm3
1405 100 0 to 3.0
1250 100 66 to 72
900 100 75.5 to 80.5
600 25 72 to 78
500 0 66 to 72
Note: The values shown above in brackets must be used for checking purposes only.
TDC fixed advance with cylinder No. 1 in compression stroke: Relative humidity 70% ± 5.
(see previous page)
Engine without fan, air filter and exhaust silencer. Ambient temperature 25 °C.
6-62720 - 09 - 2006
16 SECTION 10 - ENGINE - CHAPTER 1
Internal diam eter of installed and reamed bushings .................... 32.050 to 32.075 (1.2589 to 1.2628)
Assembly clearance between shaft and b u s h in g s ........................ 0.050 to 0.100 (0.0020 to 0.0039)
Internal diam eter of cylinder liners (4-cylinder e n g in e s ).............. 104.000 to 104.024 (4.0945 to 4.0954)
(1)
External diam eter of cylinder liners (4-cylinder engines) ............ 107,020 to 107.050 (4.2134 to 4.2146)
Diameter of cylinder bores (4-cylinder engines) .......................... 106.850 to 106.900 (4.2067 to 4.2087)
Liner internal diam eter oversizes (4-cylinder e n g in e s )................ 0.4 to 0.8 (0.0157 to 0.0315)
Liner external diam eter oversizes (4-cylinder engines) .............. 0.2 (0.0079)
Diameter of main shell bearing seats ............................................ 84.200 to 84.230 (3.3150 to 3.3161)
Diameter of standard tappet bores in crankcase .......................... 15.000 to 15.018 (0.5906 to 0.5913)
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 17
Standard journal diam eter ................................................................ 79.791 to 79.810 (3.1414 to 3.1421) (1)
Standard main bearing shell thickness .......................................... 2.168 to 2.178 (0.0854 to 0.0857)
Main bearing shell undersizes (internal diameter) ........................ 0.254 - 0.508 - 0.762 - 1.016
(0.01 - 0.02 - 0.03 - 0.04)
Big-end bearing shell undersizes (internal diameter) .................. 0.254 - 0.508 - 0.762 - 1.016
(0.01 - 0.02 - 0.03 - 0.04)
Width of main bearing including thrust w a s h e rs ............................ 31.766 to 31.918 (1.2506 to 1.2566)
(continued)
(1) Crankshafts with 0.1 mm (0.0039 in.) undersize journals and crankpins and consequently undersize bearing shells may
be fitted in factory production.
6-62720 - 09 - 2006
18 SECTION 10 - ENGINE - CHAPTER 1
(continued)
Outside diam eter of small end bushing .......................................... 41.979 to 42.017 (1.6527 to 1.6542)
Interference between small end bushing and s e a t........................ 0.095 to 0.171 (0.0037 to 0.0067)
Inside diam eter of small end bushing (measured after fitting) . . . 38.004 to 38.014 (1.4962 to 1.4966)
Diameter of big end shell bearing s e a ts .......................................... 67.407 to 67.422 (2.6538 to 2.6544)
Maximum weight difference between con rods in same engine .. 25 grams (0.0551 lb)
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 19
mm (in.)
PISTON DATA
JX60, JX80 JX70, JX90, JX95
Standard piston diameter, measured at 57 mm (2.2441 in.) from 103.852 to 103.870 (4.0886 to 4.0893)
base and perpendicularly to the gudgeon pin a x is ........................
Piston protrusion at TDC from cylinder block f a c e ........................ 0.355 to 0.761 (0.014 to 0.030)
Diameter of gudgeon pin seat in piston .......................................... 37.994 to 38.000 (1.4958 to 1.4960)
Gudgeon pin to small end bearing clearance ................................ 0.014 to 0.031 (0.0006 to 0.0012)
Maximum weight difference between pistons in same engine . . . 20 grams (0.00441 lb)
6-62720 - 09 - 2006
20 SECTION 10 - ENGINE - CHAPTER 1
Bushing interference fit in seat in intermediate g e a r .................... 0.063 to 0.140 (0.0025 to 0.0055)
Interference between bearings and seats in cylinder block 0.070 to 0.150 (0.0028 to 0.0059)
Clearance between camshaft journals and b e a rin g s .................... 0.080 to 0.160 (0.0031 to 0.0063)
Camshaft endfloat between thrust plate and seat on camshaft .. 0.070 to 0.220 (0.0028 to 0.0087)
Outside diam eter of standard tappet .............................................. 14.950 to 14.970 (0.5886 to 0.5894)
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 21
Diameter of shaft bores in rocker arms .......................................... 18.016 to 18.034 (0.7093 to 0.71)
Rocker shaft to rocker arm bore c le a ra n c e .................................... 0.016 to 0.052 (0.0006 to 0.0020)
Cam lift:
6-62720 - 09 - 2006
22 SECTION 10 - ENGINE - CHAPTER 1
Outside diam eter of standard valve g u id e s .................................... 13.993 to 14.016 (0.5509 to 0.5518)
Assembly clearance between valve stem and g u id e .................... 0.023 to 0.058 (0.0009 to 0.0023)
Maximum permissible clearance (wear limit) ................................ 0.13 (0.0051)
Valve stand-in relative to cylinder head face ................................ 0.7 to 1.0 (0.0276 to 0.0394)
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 23
mm (in.)
LUBRICATION SYSTEM DATA JX60, JX80 JX70, JX90 and
JX95
Assembly clearance between oil pump drive shaft and bushing . 0.016 to 0.055
(0.0006 to 0.0022)
Clearance between shaft and driven g e a r ...................................... 0.033 to 0.066
(0.0013 to 0.0026)
Tooth backlash between drive and driven g e a rs ............................ 0.100 (0.004)
Radial clearance between drive and driven gears and housing .. 0.060 to 0.170
(0.0024 to 0.0067)
Thickness of drive and driven g e a rs ................................................ 40.961 to 41.000
(1.6126 to 1.6142)
Height of gear seat in p u m p .............................................................. 41.025 to 41.087
(1.6152 to 1.6176)
Endfloat between gears and gear housing in p u m p ...................... 0.025 to 0.126
(0.0010 to 0.0050)
Pressure relief valve spring:
- free length ....................................................................................... 45 (1.7717) 35.9 (1.4134)
- length under load of 45 to 49 N (10.14 to 11.02 l b ) .................. 37.5 (1.4764)
- length under load of 88 to 94 N (19.84 to 21.16 l b ) .................. 30.5 (1.2008)
- length under load of 127.8 to 141.2 N (286.60 to 317.46 lb)
(2, fig. 1 8 2 )....................................................................................... 29 (1.1417)
- length under load of 233.4 - 258 N (524.70 to 579.81 lb)
(2, fig. 1 8 2 )....................................................................................... 3.2 (0.9134)
For further lubrication system d a t a .................................................. See pa ge 3
Interference fit between pump impeller and shaft ........................ 0.017 to 0.059 (0.0007 to 0.00231)
Interference fit between fan hub and shaft .................................... 0.024 to 0.058 (0.0009 to 0.0023)
Interference fit between front seal bushing and im p e lle r.............. 0.012 to 0.058 (0.0005 to 0.0023
6-62720 - 09 - 2006
24 SECTION 10 - ENGINE - CHAPTER 1
Preliminary torque
PART Thread Angle
Nm ft lb
Cylinder head bolts (2) fig. 3 or 5 .............................. M 12x1.25 70 51.6293 90° + 90°
Main bearing cap bolts (4) fig. 3 or 5 ........................ M 14x1.5 80 59.0050 90°
Tightening torque
PART Thread
Nm ft lb
Crankshaft hub retaining nut (7) fig. 3 or 5 .................................... M 30x1.5 294 216.8432
Fan and alternator pulley bolts (6) fig. 3 or 5 ................................ M 10x1.25 55 40.5659
Alternator and belt tension adjustment nut (1) fig. 54 .................. M 10x1.25 55 40.5659
Nuts for injector mounting studs (1) fig. 1 3 8 .................................. M8 25 (*) 18.4390(*)
Oil pump and pump cover retaining bolts (1) fig. 89 .................... M8 25 18.4390
Timing gear case and cover bolts (1) fig. 9 3 .................................. M8 25 18.4390
(*) Tighten the nuts in two stages: see the operation in figure 138.
6 -62 7 2 0 - 09 - 2 0 06
SECTION 10 - ENGINE - CHAPTER 1 25
X 380000236 Tractor dismantling stand. X 380000223 Puller for coolant pump impeller.
380000216 Engine lifting hook. X 380000247 Drift for installation of coolant pump
impeller seal.
380000301 Rotating engine service stand.
380000311 Wrench for injection pump delivery
380000313 Engine mounting brackets for line unions.
rotating stand 380000301.
380000254 Injector cleaning kit.
X 380000303 Compression test kit (complete with
dummy injector 380000617. 380000308 Injector splitting support.
291966 Digital rev counter. X 380000309 Wrench set for injector dismantling.
380000240 Engine oil pressure test kit. 380000215 Hand pump for injector calibration
test.
293240 Check set, turbocharger
(JX95 model). 293830 Adaptor for injector removal
(with 380000549).
293679 Filter cartridge removal tool
380000549 Slide hammer.
X 296118 Drive belt tension test tool.
In je c tio n p um p b e n ch te s t
X 291160 Piston ring pliers.
380000228 Dial gauge (1/100 mm (0.0394/
X 291048 Piston ring clamp. 3.94 in.) scale, 5 mm (0.1968 in.)
stroke, 0 40 mm (1.5748 in.) with
X 292248 Protractor for angular torque 380000229).
measurement.
380000229 Device for BOSCH injection pump
X 291504 Puller for crankshaft pulley hub. timing on engine.
X 380000232 Wrench for valve clearance X 380000322 Extractor for injection pump drive
adjustment. gear.
6-62720 - 09 - 2006
26 SECTION 10 - ENGINE - CHAPTER 1
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 27
6-62720 - 09 - 2006
28 SECTION 10 - ENGINE - CHAPTER 1
3
L o n g itu d in a l s e c tio n o f 3 -c y lin d e r JX60 and JX70 M odels
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 29
4
C ross -s e c tio n o f 3 -c y lin d e r JX60 and JX70 M odels
6-62720 - 09 - 2006
30 SECTION 10 - ENGINE - CHAPTER 1
MIG0493A
5
L o n g itu d in a l s e c tio n o f 4 -c y lin d e r m odel JX80, JX90 and JX95 M odels
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 31
6
C ro s s -s e c tio n o f 4 -c y lin d e r m odel JX80, JX90 and JX95
6-62720 - 09 - 2006
6-62720 - 09 - 2 0 06
CO
KJ
SECTION
10 - ENGINE
- CHAPTER
1
Lubrication system of normally aspirated 3-cylin d er engines
1. Oil filler cap 2. Filter safety valve (opens when oil pressure at filter inlet exceeds the outlet pressure by 1.5-1.7 bar/cm2 (140.355- 159.068 psi/in2)
3. Filter. 4. Switch for low engine oil pressure warning (on dashboard). 5. Dipstick.
6. Pump. 7. Oil pressure limiting valve. 8. Screen filter on pick-up pipe
SECTION
10 - ENGINE
- CHAPTER
1
6-62720 - 09 - 2 0 06
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 35
ENGINE TROUBLESHOOTING
E ngin e does n o t sta rt. 1. Batteries partially discharged. Check and recharge battery. Replace
if necessary.
(continued)
6-62720 - 09 - 2006
36 SECTION 10 - ENGINE - CHAPTER 1
ENGINE TROUBLESHOOTING
(continued)
5. Coolant pump and fan drive belt Check and adjust belt tension.
slack.
E ngin e lacks p o w e r and 1. Incorrect injection pump timing. Adjust pump timing.
ru n s unevenly.
(continued)
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 37
ENGINE TROUBLESHOOTING
(continued)
8. Piston knock due to excessive Rebore cylinder liners and fit oversize
wear. pistons.
6-62720 - 09 - 2006
38 SECTION 10 - ENGINE - CHAPTER 1
ENGINE TROUBLESHOOTING
(continued)
E ngin e p ro d u c e s excessive 1. Maximum delivery of injection Adjust injection pump on test bench to
b la ck o r dark gre y sm oke. pump too high. the values specified in calibration
chart.
3. Oil leaking past piston rings due Replace damaged parts or, if
to sticking rings or cylinder liner necessary, overhaul the engine.
wear.
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 39
ENGINE
R em oval - In s ta lla tio n (O p eratio n 10 001 10)
10
11
6-62720 - 09 - 2006
40 SECTION 10 - ENGINE - CHAPTER 1
12
6. Remove the exhaust pipe, attach lifting chains to
the bonnet (1) and attach the chain to the hoist.
13
7. Disconnect the electrical leads (1) from
headlamps (2).
14
8. Detach the gas struts (1) from the bonnet.
15
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 41
6-62720 - 09 - 2006
42 SECTION 10 - ENGINE - CHAPTER 1
20
21
22
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 43
23
24
18. Remove the hose (1) from the lift pump suction
pipe.
25
6-62720 - 09 - 2006
44 SECTION 10 - ENGINE - CHAPTER 1
26
27
28
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 45
23. Remove the circlip (2) from the front of the prop
shaft and slide the sleeve (1), in the direction
shown by the arrow, until it is free of the splines
on the front axle.
24. Remove the circlip (2) from the rear of the prop
shaft and slide the sleeve (1), in the direction
shown by the arrow, until it is free of the splines
on the crankshaft.
32
6-62720 - 09 - 2006
46 SECTION 10 - ENGINE - CHAPTER 1
33
27. Unscrew the nuts (1) and the bolts securing the
engine to the transmission. Access is through
the two slots in the cab floor.
34
35
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 47
36
30. Insert a wooden block between the stands and
the tractor.
37
31. Place a fixed stand (1) underneath the drawbar
support and apply the handbrake.
25052
38
39
6-62720 - 09 - 2006
48 SECTION 10 - ENGINE - CHAPTER 1
40
41
42
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 49
43
39. Remove the lift pump (1) complete with its filter
by unscrewing the four retaining bolts.
44
45
6-62720 - 09 - 2006
50 SECTION 10 - ENGINE - CHAPTER 1
46
47
43. Unscrew the bolts (1) securing the silencer to its
bracket.
48
44. Undo the hose clamp and disconnect the top
radiator hose (1).
45. Unscrew the three nuts securing the silencer to
the manifold and lift off the entire silencer assem
bly.
— r—
TRE0613B W \
49
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 51
50
51
To re--install the engine, proceed as follows: — Reconnect all electrical leads: thermostart
— Attach the three hooks of an adjustable lifting glow plug, coolant temperature sensor, ‘air
chain to the three eye bolts on the engine. Raise filter blocked’ sensor, horn, front axle support
the engine from the platform and position it in earth, engine stop on injection pump, leads to
front of the front axle support. Join the two units the alternator and relay, oil pressure sensor,
using the four securing bolts. starter motor, fuel dryer filter. Secure all leads
with plastic ties.
— Reposition the moveable stand from under the
front axle differential housing to underthe engine — Fit the clutch back on with the aid of kit
sump, inserting a suitably shaped block of wood 380000612 (11711” clutch) or pin 380000292
between the stand and the sump pan. (12”/12” clutch). Fix clutch to the engine fly
wheel using the six retaining bolts.
— Attach the top radiator hose to the thermostat
housing and secure with an adjustable hose — Reconnect the oil delivery pipe to the 4WD
clamp. control valve. Tighten the pipe union on the
anti-cavitation accumulator; fix the bracket on
— Connect the bottom radiator hose to the coolant the left-hand side near the engine oil filter.
pump and secure at both ends with adjustable
hose clamps. — Clean the distance collar and the mating surfa
ces of the overdrive clutch housing; scrape
— Refit the fuel pump. away all traces of old sealing compound.
— Detach the lifting chain from the engine. — Apply LOCTITE sealing compound to the
— Connect the rigid pipe from the air cleaner to the mating surfaces of engine and distance collar.
inlet manifold and secure with the relative clamp. Fit the distance ring on the engine studs.
6-62720 - 09 - 2006
52 SECTION 10 - ENGINE - CHAPTER 1
Apply LOCTITE sealing compound to the mating — Connect the two flexible power steering pipes to
surfaces of the overdrive clutch housing. the union on the left-hand side of the front axle.
Secure the two pipes with the special clamp and
Remove the fixed stand from under the front screw the clamp to the tractor.
weight support. Remove the wooden wedges from
under the front wheels. — Fit the tachom eter cable and secure the sleeve
with the retaining ring.
Attach the adjustable lifting chain to the eyebolts
on the engine. — Fit the silencer onto the exhaust manifold,
remembering to replace the gas seal. Fix the
Place wooden wedges under the rear wheels, front of the silencer to the vertical support
check that the handbrake is fully on and that the bracket. Attach the flexible DONASPIN pipe.
fixed and moveable stands are firmly in place.
— Attach the bonnet stay bracket to the radiator
Detach the lifting chain from the engine. Connect bracket.
the two wires still attached to the cab handrail to
the hook of the hoist. Raise the front part of the — Refit the 4WD propeller shaft and the guard.
cab about 6 cm.
— R e-connect the throttle cable to the accelerator
Replace and tighten all the bolts securing the pedal. It may be necessary to adjust the cable at
engine to the overdrive clutch housing. the injection pump lever end.
Bolt the brake pipe support bracket to the right- — Refit the clutch cable to the clutch pedal. Fix the
hand side of the engine. Lower the hoist and de sleeve to the travel stop.
tach the cables from the cab handrail.
— Replace the plastic plugs in the holes in the cab
floor. Replace the mat.
Lowerthe stands underthe engine sump and the
clutch housing. Remove tool 380000236 and the — Refit the steering column cover panels.
stand from underthe drawbar support.
— Replace the wire mesh fan guards.
Fix the cab in place with the two front securing
bolts. — Attach slings to the bonnet in the manner descri
bed previously in the engine removal instruc
Connect the injector lea k-o ff pipe. Connect the tions. Screw the bonnet hinge to its bracket. A t
pipes to the glowplug and to the fuel dryer filter. tach the gas strut, the electrical leads to the
headlamps and then remove the slings.
Refit the fuel filter mounting to the engine. Connect
the two semi--rigid pipes to the mounting. — Refit the secondary bracket (battery support) to
the overdrive clutch housing. Fit the rotating
Connect the oil suction pipes to the pumps; bracket with the battery to the fixed support.
secure the rubber hoses with hose clamps.
— Refit the front weights and secure with the lock
Connect the rigid lift control valve supply pipe to the pin.
relative pump, remembering to first fit the O--ring.
— Refit the tool box support bracket and then the
Secure the three pipes with the adjustable hose tool box.
clamp.
— Fill the transmission/gearbox and power steer
Connect up all the electrical leads to the ing unit with oil.
connectors on the vertical support bracket.
— Fill the radiator with coolant.
Fit the cab heater pipe union on the engine/
clutch distance collar. Connect the rubber heater — Connect the battery positive and negative leads.
hoses to the union and, if necessary, restore the Replace the plastic battery cover.
gas in the air-conditioning system with tool
294030.
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 53
ENGINE
R em oval - In s ta lla tio n (O p eratio n 10 001 54)
A WARNING A -----------
Handle all parts carefully. Do not put your hands or
fingers between parts.
W ear suitable safety clothing, safety goggles, gloves
and footwear.
53
54
7. Unscrew the bolts securing the fan (1) and pulley
to the coolant pump. Remove the fan and pulley.
55
6-62720 - 09 - 2006
54 SECTION 10 - ENGINE - CHAPTER 1
56
57
58
11. Unscrew the coolant pump retaining bolts (1)
and remove the pump.
59
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 55
60
61
62
16. Undo the alternator support retaining bolts (1)
and remove the complete alternator assembly.
63
6-62720 - 09 - 2006
56 SECTION 10 - ENGINE - CHAPTER 1
64
65
66
20. Unscrew the high pressure fuel line unions (1) on
the injection pump and remove the fuel lines.
67
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 57
68
69
70
24. Undo screws (1) and remove the injection pump
drive gear cover.
71
6-62720 - 09 - 2006
58 SECTION 10 - ENGINE - CHAPTER 1
72
73
74
28. Unscrew the bolts securing the sedimentation
filter support to the engine block and recover the
complete filter assembly.
75
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 59
76
77
78
32. Unscrew the starter motor retaining bolts (1) and
remove starter motor.
79
6-62720 - 09 - 2006
60 SECTION 10 - ENGINE - CHAPTER 1
80
81
82
83
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 61
NOTE: When fitting the gaskets (1) and (3) (fig. 86),
apply RHODORSIL CAF1 silicone sealing
compound to the mating surfaces.
6-62720 - 09 - 2006
62 SECTION 10 - ENGINE - CHAPTER 1
88
89
90
48. Straighten the lock tab, preventing rotation ofthe
crankshaft and unscrew nut (1).
91
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 63
49. Pull the pulley hub off the crankshaft using tool
380000226 (1) and retain the woodruff key for
re-use.
92
93
51. Unscrew the retaining bolts and remove the lift
pump drive gear carrier (1).
94
52. Remove the circlip (1) and remove the thrust
washer and the intermediate gear (2).
95
6-62720 - 09 - 2006
64 SECTION 10 - ENGINE - CHAPTER 1
96
97
55. Remove the circlip (1) and the thrust washer.
W ithdraw the gear with fuel supply pump
camshaft (2) from the opposite side.
98
56. Unscrew the bolts (1) and remove the timing
gear case.
99
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 65
100
101
102
103
6-62720 - 09 - 2006
66 SECTION 10 - ENGINE - CHAPTER 1
104
105
NOTE: The figure shows the oil pump for the JX90
and JX95 models
26106
106
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 67
S e c tio n a l v ie w o f d yn a m ic ba la n ce r 108
6-62720 - 09 - 2006
68 SECTION 10 - ENGINE - CHAPTER 1
Proceed as follows:
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 69
Proceed as follows:
— Install the tappets in their crankcase bores.
— Lubricate the main bearing seats (2) with engine
oil and install the half shell bearings (1).
— Stick the sem i-circularthrust washers (3) to both
sides of the penultimate main bearing with
grease.
111
112
113
6-62720 - 09 - 2006
70 SECTION 10 - ENGINE - CHAPTER 1
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 71
Proceed as follows:
— Fit the rear oil seal carrier (3) with the outer seal.
Tighten retaining bolts (2) to the torque specified
on page 24. Using a feeler gauge (1), check that
the crankshaft flange is coaxial with the carrier.
117
— Fit the inner rear oil seal using installer and hand
grip 50139 (1).
118
— Fit the flywheel and tighten the retaining bolts (1)
to a torque of 40 Nm (4.1 kgm).
119
120
6-62720 - 09 - 2006
72 SECTION 10 - ENGINE - CHAPTER 1
124
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 73
Proceed as follows:
125
The flywheel is marked in degrees BTDC. Rotate
the crankshaft to bring cylinder no. 1 to TDC of
the compression stroke. Look through the in
spection window and check that the notch aligns
with the appropriate index mark, according to the
type of BOSCH pump installed on the tractor
(see from page 6 to page 14).
126
— Fit the timing gears making sure that the various
reference marks on the mating gears (indicated
by the arrows in the figure) are aligned.
25169
127
6-62720 - 09 - 2006
74 SECTION 10 - ENGINE - CHAPTER 1
128
129
— Slide the coupling sleeve (1) over the splines of
the counterweight drive gear as shown in figure
85.
— Slide the other end of the coupling sleeve (1)
over the splined shaft of the counterweight drive
gear, so that the master spline in the sleeve
coincides with the master spline (3) on the shaft
(2).
— Tighten the dynamic balancer housing retaining
bolts (1) fig. 129 to the torque specified on
page 24.
130
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 75
131
Proceed as follows:
132
6-62720 - 09 - 2006
76 SECTION 10 - ENGINE - CHAPTER 1
Proceed as follows:
— Lower the cylinder head onto the block and
screw in the cylinder head bolts (1) fig. 135,
finger tight.
— fig. 133 - Tightening sequence for cylinder head
bolts on 3-cylinder engines to be followed for
each of the four tightening stages (A = fan end).
133
134
— First phase - Tighten the bolts (1) to a torque of
70 Nm (7.1 kgm) in the sequence shown in the
above figures (fig. 133/134).
— Second phase - Recheck the torque of all the
bolts in the sequence indicated above (fig.
133/134).
135
99. Using the angular tightening tool 380000304
(1), tighten each bolt (2) in sequence through
90° (third phase) and then through a further 90°
(fourth phase) in the sequence indicated above
(figures 133/134).
136
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 77
137
Proceed as follows:
6-62720 - 09 - 2006
78 SECTION 10 - ENGINE - CHAPTER 1
25307
139
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 79
140
25310
141
a,b. Position of dial gauge to measure liner inside X. Area for measurement of inside diam eter of
diameter. worn liner (area swept by piston rings) to
c. JX70, JX90 and JX95 Models. determine ovality and taper (measure along
C. Dimension to achieve after press--fitting and axes a and b, respectively parallel and at right
reaming of liner. angles to crankshaft).
Z. Area for measurement of inside diam eter of 1,2,3. Points at which to measure inside diameter
used liner to determine piston running of new or rebored liners along axes a and b.
clearance (measured along axis b at right
angles to crankshaft).
6-62720 - 09 - 2006
80 SECTION 10 - ENGINE - CHAPTER 1
C ra n ksh a ft
Clean parts carefully before proceeding with
operations described below.
Carefully inspect the crankshaft. Any cracks, even
minor ones, will necessitate replacement of the
crankshaft.
Inspect the crankshaft journals and crankpins;
slight scoring or seizure marks can be removed with
very fine grade emery cloth.
If scoring, ovality or taper exceeds 0.05 mm
(0.002 in.), the crankshaft will have to be reground.
Measure journal diameter, fig. 142 to determine the
nearest undersize (see page 17).
A fter regrinding, restore the journal and crankpin
radii and fillets as shown in the details in fig. 143 and
check that:
— main bearing journal and crankpin ovality does
not exceed 0.008 mm (0.0003 in.);
— main bearing journal and crankpin taper does
not exceed 0.01 mm (0.0004 in.);
142
rZM
rZB
m e
25312 25313
143
S ta nd ard d im e n s io n s (m m ) o f m ain bearing jo u rn a ls and cra n k p in s , m ain b e arings
and s e m i- c irc u la r th ru s t w ashers.
a. JX60 and JX70 models. d. Normal crankshaft journal radii and fillets.
b. JX80, JX90 and JX95 models. e. Radii and fillets of crankshaft journal with
c. Crankpin radii and fillets. thrust washers.
6-62720 - 0 9 - 2006
SECTION 10 - ENGINE - CHAPTER 1 81
with the crankshaft resting on parallel gauge — the run--out measured with the dial gauge
blocks, the maximum misalignment of the main contact point resting on surface (A) or (B),
bearing journals does not exceed 0.10 mm fig. 144, does not exceed the measurement
(0.004 in.) (D) fig. 161; given in the chart on page 18;
the centrelines of the crankpins (mod. JX70) or
of each pair of crankpins (JX70, JX80, JX90
— the oil plugs seal against an oil pressure of 14.7
and JX95 models) lie in the same plane as the
bar (213.2 psi);
main journal centrelines, with a maximum
deviation of ± 0 .2 5 mm (0.0098 in.) as
measured perpendicularly to the same plane
(see fig. 143); — if new plugs are fitted, punch--lock in position
the distances between the outersurfaces ofthe and re--check oil tightness with the system
crankpins and the crankshaft centreline are pressurised.
equal with a tolerance of ± 0.10 mm
(0.004 in.);
144
6-62720 - 09 - 2006
82 SECTION 10 - ENGINE - CHAPTER 1
B ea rin g s
Check the clearance between the crankshaft
journals and bearing shells using a calibrated wire
gauge as follows:
— make sure that all parts are perfectly clean and
remove all traces of oil;
— locate the half--shells in their respective seats (5);
— install the crankshaft;
— position lengths of calibrating wire (6) on the
crankshaft journals (4) corresponding with the
crankshaft centreline.
— fit the caps (1) complete with half-shells (2) to
the respective journals; 145
25318
146
147
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 83
F lyw heel
149
6-62720 - 09 - 2006
84 SECTION 10 - ENGINE - CHAPTER 1
D im e n s io n s (m m ) o f s ta n d a rd c o n n e c tin g rods,
bea ring s h e lls , b u s h in g s and g u d g e o n pins.
A = Dimension required by reaming after fitting
bushings - L, M = Oil ports.
150
Also check that the oil ways (L and M) fig. 150 are
not obstructed by scale or impurities.
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 85
If th e p isto n ru n n in g c le a ra n c e e x c e e d s 0 .3 0 m m
(0 .011 8 in.), re b o re and re a m th e lin e rs and fit
o v e rs iz e p is to n s and rin g s (se e p a g e s 16 and 19).
In c a s e o f p isto n re p la c e m e n t, c h e c k th a t th e w e ig h t
d iffe re n c e b e tw e e n p is to n s in th e s a m e e n g in e d o e s
no t e xc e e d 2 0 g ra m s (0.0441 lb).
6-62720 - 09 - 2006
86 SECTION 10 - ENGINE - CHAPTER 1
a3o
®T 0,55
2,478
2,490
t a3o
rll< 1 0,55
3,975 I*
m m w
37,983
37,990
a
WWWWWWWN
2,575 m
2,595 0 - Si” ®r 0,85
2,478
2,490
a30
rll< 1 ass
3,975
m m w
37,983
37,990 b
WWWWWWWN
153
D im e n s io n s (m m ) o f s ta n d a rd p is to n s , g u d g e o n p in s and rin g s.
154
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 87
155
NOTES:
156
157
6-62720 - 09 - 2006
88 SECTION 10 - ENGINE - CHAPTER 1
Valves
Use tool 380000302 for valve removal and installa
tion.
In the case of minor sealing faults, the valves and
their seats in the cylinder head may be re-faced
using a pneumatic grinder or universal grinder. In
case of more serious defects, re--face the seats and
grind the valves as shown in the relative chapter.
After grinding, check that the step below the valve
contact band is no less than 0.5 mm (0.02 in.).
158
Tappets
Check that the tappets slide freely in their bores
without excessive play.
In the case of excessive tappet--to--bore clearance,
rebore the seats and fit oversize tappets
(see page 20).
Pushrods must be perfectly straight, and the
concave contact surface with the rocker arm ad
juster screw must not show signs of seizure or
excessive wear, otherwise the rod must be replaced.
In case of refacing of the contact surfaces, remove
as little material as possible.
159
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 89
C am shaft
25331
161
D im e n s io n s (m m ) o f c a m sh a ft jo u rn a ls and relative seats in c y lin d e r blo ck.
N O TE : The value indicated for the bushing inside diameter is for an installed bush.
6-62720 - 09 - 2006
90 SECTION 10 - ENGINE - CHAPTER 1
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 91
6-62720 - 09 - 2006
92 SECTION 10 - ENGINE - CHAPTER 1
VALVE GUIDES
R eplacem ent (O p e ra tio n 10 101 53)
165
3. Turn the head upside down, and force fit the new
valve guide with the enlarged bore using drift
380000219 (1) and bush 380000242 (2).
166
167
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 93
B - L = C
where:
170
6-62720 - 09 - 2006
94 SECTION 10 - ENGINE - CHAPTER 1
171
9. Position the depth stop (1) at a distance
(D) = 35.9 to 336.4 mm (1.4134 to 13.2441 in.)
from the end of the cutter shank and fix in place
with its set screw.
D=A - C
where:
Exam ple
10. Turn the cutting tool (2) until the plate (3) is
brought up to the cylinder head face by the depth
stop (1).
173
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SECTION 10 - ENGINE - CHAPTER 1 95
175
6-62720 - 09 - 2006
96 SECTION 10 - ENGINE - CHAPTER 1
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 97
10. Press by hand on the ring nut (or tap gently with
a rubber mallet) to release the inside of the guide
bush 380000830 (10) fig. 179.
11. Remove the guide bush, and fit the milling cutter
380000833 (8) fig. 179 in the bush. Install the
bush in the sleeve (12) and fix in position by turn
ing the ring nut (9) clockwise.
12. W ork with the cutter to remove material until the
seating is perfectly smooth and free from all
marks.
13. This done, remove the cutter, fit the injector and
check that stand-out is as specified on page 22.
178
D isassem bly, rem oval o f residue, in s ta lla tio n and ream ing 179
o f in je c to r sleeve in c y lin d e r head u s in g to o l k it 380000246.
1, 2, and 11. Injector sleeve extractor 380000832. 6. O -ring seals.
3. M8 x 1.25 retaining nuts. 7. Reamer 380000831 .
4. Waste removal tool 380000370. 8. C utter 380000833.
5. Injector sleeve dressing tool 380000834. 9. Ring nut.
10. Guide bush 380000830.
12. Injector sleeve.
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O IL PUMP - O verhaul
182
183
6-62720 - 09 - 2006
100 SECTION 10 - ENGINE - CHAPTER 1
If m a lfu n c tio n is s u s p e c te d , im m e rs e th e b u lb o f th e
th e rm o m e te r in w a te r and c h e c k th e re a d in g s
a g a in s t a te s t th e rm o m e te r (re p e a t th e te s t a n u m b e r
o f tim e s w ith d iffe re n t w a te r te m p e ra tu re s to be
su re ).
T h e fa n /c o o la n t p u m p /a lte rn a to r d riv e b e lt is
te n s io n e d c o rre c tly w h e n it d e fle c ts 10 to 11 m m
(0 .3 9 3 7 to 0.4331 in.) w h e n a fo rc e o f 78 to 98 N
(1 7 .6 4 to 2 2 .0 5 lb) is a p p lie d a t th e m id -p o in t o f th e
run b e tw e e n th e a lte rn a to r and c o o la n t p u m p
pulle ys.
1. C h e c k th e te n s io n u sin g th e b e lt te n s io n te s te r
296118 . A d ju s t te n s io n if n e c e s s a ry as fo llo w s :
3. M o ve th e a lte rn a to r to a c h ie v e th e re q u ire d be lt
te n s io n and lo c k th e n u t ( 1 ).
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102 SECTION 10 - ENGINE - CHAPTER 1
RADIATOR
R em oval - In s ta lla tio n (O p eratio n 10 406 10)
1. R e m o v e th e e x h a u s t p ipe and o p e n th e b o n n e t.
2. D is c o n n e c t th e b a tte ry n e g a tiv e ca b le .
3. R e m o v e th e le ft and rig h t-h a n d s a fe ty g u a rd s
( 1 ) fro m a ro u n d th e fan.
185
4. R e m o v e th e h o se c la m p , d e ta c h th e b o tto m radi
a to r h o se ( 1 ) and d ra in o ff th e co o la n t.
186
5. U n s c re w th e fro n t a xle e a rth c a b le fix in g b o lt (1)
6. D is c o n n e c t e le c tric a l le a d s fro m th e horn.
187
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SECTION 10 - ENGINE - CHAPTER 1 103
188
8. R e m o v e th e c la m p (1) on th e in le t m a n ifo ld hose.
189
9. R e m o v e th e c la m p (1) on th e a ir filte r hose.
190
10. R e m o v e th e a ir filte r re s tric tio n s e n s o r (1) and re
c o v e r th e pipe.
191
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104 SECTION 10 - ENGINE - CHAPTER 1
192
193
13. U n s c re w th e c la m p and re m o v e th e pip e (1) fro m
th e ra d ia to r cap.
194
14. U n s c re w th e tw o b o lts (1) s e c u rin g th e ra d ia to r
to th e fro n t a x le s u p p o rt and re m o v e th e b olts,
ru b b e r m o u n tin g s and s p a c e rs .
195
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SECTION 10 - ENGINE - CHAPTER 1 105
To re fit th e ra d ia to r p ro c e e d as fo llo w s :
— R e p la c e th e ra d ia to r and s e c u re w ith th e tw o
b olts.
— R e fit th e tw o ru b b e r h o s e s to th e c o o la n t p u m p 196
and th e th e rm o s ta t h o u s in g . R e c o n n e c t th e
p ipe to th e ra d ia to r cap.
— R e c o n n e c t th e b o n n e t s ta y b ra c k e t to th e b ra c
k e t m o u n te d on th e ra d ia to r and re p la c e th e re
ta in in g b olts.
— R e fit th e h o se to th e e x h a u s t a s p ira to r.
— R e fit th e h o se c o n n e c tin g th e a ir c le a n e r to th e
in le t m a n ifo ld . R e fit th e a irfilte rc lo g g in g s e n so r.
— R e c o n n e c t th e e le c tric a l le a d s to th e ho rn , a ir
filte r re s tric tio n s e n s o r and th e fro n t a x le e a rth
lead.
— R e fit th e tw o w ire m e sh g u a rd s a ro u n d th e fan.
— Fill th e ra d ia to r w ith co o la n t.
— R e c o n n e c t th e b a tte ry n e g a tiv e lead; c lo se th e
b o n n e t.
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106 SECTION 10 - ENGINE - CHAPTER 1
1. R e m o v e th e e x h a u s t p ipe and o p e n th e b o n n e t.
2. D is c o n n e c t th e b a tte ry n e g a tiv e ca b le .
3. R e m o v e th e le ft and rig h t--h a n d w ire m e sh
g u a rd s ( 1 ) fro m a ro u n d th e fan.
197
4. R e m o v e th e h o se c la m p , d e ta c h th e b o tto m
h o se ( 1 ) and d ra in o ff th e co o la n t.
198
5. U n s c re w th e fro n t a xle e a rth c a b le fix in g b o lt (1).
6. D is c o n n e c t e le c tric a l le a d s fro m th e horn.
199
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108 SECTION 10 - ENGINE - CHAPTER 1
20 4
12. U n s c re w th e h o se c la m p re m o v e th e to p ra d ia to r
h o se ( 1 ).
20 5
13. U n s c re w th e c la m p and re m o v e th e pip e (1) fro m
th e ra d ia to r cap.
20 6
14. U n s c re w th e tw o b o lts (1) s e c u rin g th e ra d ia to r
to th e fro n t a x le s u p p o rt and re m o v e th e b olts,
ru b b e r m o u n tin g s and s p a c e rs .
20 7
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SECTION 10 - ENGINE - CHAPTER 1 109
18. R e m o v e th e ra d ia to r fa n (1).
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110 SECTION 10 - ENGINE - CHAPTER 1
212
21 3
21 4
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6-62720 - 09 - 2006
112 SECTION 10 - ENGINE - CHAPTER 1
C O O LAN T PUMP
R e m o v a l-In s ta lla tio n (O p eratio n 10 402 10)
1. R e m o v e th e e x h a u s t pip e and o p e n th e b o n n e t.
2. D is c o n n e c t th e b a tte ry n e g a tiv e ca b le .
3. R e m o v e th e w ire m e sh g u a rd s (1) fro m th e left
and rig h t-h a n d s id e s o f th e fan.
21 6
4. R e m o v e th e h o se c la m p , d e ta c h th e b o tto m
ra d ia to r h o se ( 1 ) and d ra in o ff th e co o la n t.
21 7
5. R e m o v e th e fa n s h ro u d (1) re ta in in g b olts.
21 8
21 9
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SECTION 10 - ENGINE - CHAPTER 1 113
221
11. Remove the coolant pump pulley (1).
12. Loosen the hose clamp (1) and detach the hose
from the coolant pump.
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114 SECTION 10 - ENGINE - CHAPTER 1
13. U n s c re w th e b e lt te n s io n a d ju s tm e n t a rm
re ta in in g n u t ( 1 ) and m o v e th e a lte rn a to r
o u tw a rd .
16. D is c o n n e c t th e h o se fro m th e c o o la n t p u m p to
th e th e rm o s ta t h o u s in g , th e n re m o v e th e p u m p
(1) fig. 2 27.
To re fit th e c o o la n t p u m p p ro c e e d as fo llo w s :
— R e fit th e c o o la n t p u m p . T a ke c a re n o t to lose th e
se a ls on th e u p rig h t h o se c o n n e c tin g th e p u m p
to th e th e rm o s ta t body.
— R e fit th e c o n n e c tio n p ipe to th e p u m p , and re p la
ce th e tw o re ta in in g b olts.
— R e fit th e c o o la n t p u m p p u lle y and th e fa n . R e fit
th e fa n s h ro u d and th e tw o v e rtic a l s id e s trip s to
th e rad ia to r. F ix th e b e lt te n s io n a d ju s tm e n t arm .
T ig h te n th e a lte rn a to r p iv o t bolt.
— R e fit th e b o tto m ra d ia to r h o se to th e c o n n e c tio n
pipe on th e c o o la n t p u m p and th e ra d ia to r.
— R e fit th e rig h t-h a n d w ire m e sh g u a rd .
— R e fit th e le ft-h a n d w ire m e sh g u a rd .
— Fill th e c o o lin g s y s te m fro m th e ra d ia to r cap.
— R e c o n n e c t th e n e g a tiv e b a tte ry lead and re fit th e
e x h a u s t pipe.
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SECTION 10 - ENGINE - CHAPTER 1 115
1. D is c o n n e c t th e b a tte ry n e g a tiv e ca b le .
2. R e m o v e th e e x h a u s t pipe, a tta c h liftin g c h a in s to
th e b o n n e t ( 1 ) and a tta c h th e c h a in s to th e h oist.
230
231
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116 SECTION 10 - ENGINE - CHAPTER 1
8. U n s c re w th e h o se c la m p and d is c o n n e c t th e
h o se ( 1 ) c o n n e c tin g th e ra d ia to r to th e
th e rm o s ta t h o u sin g .
9. R e m o v e th e th e rm o s ta t h o u s in g c o v e r s c re w s
( 1 ).
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SECTION 10 - ENGINE - CHAPTER 1 117
23 6
11. R e m o v e th e th e rm o s ta t v a lv e (1).
23 7
To re fit th e th e rm o s ta t p ro c e e d as fo llo w s :
— F it th e th e rm o s ta t in its h o u s in g and lo c a te th e
g a s k e t. R e fit th e c o v e r to th e h o u sin g .
— C o n n e c t th e to p ra d ia to r h o se to th e th e rm o s ta t
ho u sin g and s e c u re w ith a h o se c la m p .
— R e fit th e b o n n e t stay.
— R e fit th e rig h t-h a n d w ire g u a rd to th e fan.
— R e fit th e b o n n e t.
— Fill th e c o o lin g s y s te m . Top up as n e ce ssa ry.
— R e c o n n e c t th e b a tte ry n e g a tiv e lead. C lo s e th e
b o n n e t and re fit th e e x h a u s t pipe.
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118 SECTION 10 - ENGINE - CHAPTER 1
Op. 10 246 14
BOSCH INJECTION PUMP Removal-Instal
lation, timing and air bleeding
A CAUTION A ----------
H a n d le all p a rts c a re fu lly. D o n o t p u t y o u r h a n d s o r
fin g e rs b e tw e e n p a rts. W e a r th e p re s c rib e d s a fe ty
clo th in g , in clu d in g g o g g le s , g lo v e s and s a fe ty fo o t
w ea r.
A CAUTION A ----------
A lw a y s use a p p ro p ria te to o ls to a lig n fix in g holes.
N E V E R U S E F IN G E R S O R H A N D S .
P ro c e e d as fo llo w s :
1. R a ise th e b o n n e t.
2. U n s c re w th e re ta in in g b o lts and ta k e o ff th e in je c
tio n p u m p g e a rb o x c o v e r (2 ); if th e re is an air-
c o n d itio n in g s y s te m c o m p re s s o r, re m o v e th e
b ra c k e t ( 1 ) s u p p o rtin g th e c o m p re s s o r.
3. U n s c re w and re m o v e th e fu e l filter. 23 8
4. R e m o v e th e fly w h e e l in s p e c tio n w in d o w c o v e r
( 1 ) and th e ta p p e t cover.
5. R o ta te th e c ra n k s h a ft to brin g c y lin d e r no. 1 to
T .D .C . and m a k e s u re th e v a lv e s a re c lo se d
(c o m p re s s io n s tro k e ).
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SECTION 10 - ENGINE - CHAPTER 1 119
7. U n s c re w th e u n io n s o f th e fu e l s u p p ly lin e s (1)
fro m th e in je c tio n p u m p , fro m th e fu e l re tu rn pipe
(2) and fro m th e p u m p fu e l s u p p ly line (3).
8 . D is c o n n e c t th e L .D .A . d e v ic e c o n n e c tin g p ipe to
th e in le t m a n ifo ld (o n ly J X 7 0 and J X 9 5 m o d e ls ).
241
9. U n s c re w th e in je c tio n p u m p lo c k n u t on th e re la ti
ve g e a rin g ( 1 ).
24 3
11. U n s c re w th e b o lts (1) s e c u rin g th e in je ctio n
pum p .
24 4
6-62720 - 09 - 2006
120 SECTION 10 - ENGINE - CHAPTER 1
A CAUTION A ----------
A lw a y s use a p p ro p ria te to o ls to a lig n fix in g holes.
N E V E R U S E F IN G E R S O R H A N D S .
-- R e s p e c t th e tig h te n in g to rq u e s p re s c rib e d on
pa g e 24.
- C h e c k th a t c y lin d e r no. 1 is a t T .D .C . and th e
v a lv e s a re c lo s e d (c o m p re s s io n s tro k e ).
-- P o s itio n th e in je c tio n p u m p in its s e a t and s e c u re
it w ith th e bo lts, c h e c k in g th e y a re in th e m id d le
o f th e slo t.
-- L o c k th e in je c tio n p u m p d riv e g e a r w ith th e nut
tig h te n e d to a to rq u e o f 90 N m , m a k in g s u re th e
c ra n k s h a ft d o e s n o t tu rn .
- L o o se n th e s c re w s to p p in g th e in je c tio n p u m p
fro m tu rn in g . In s e rt th e re le v a n t s p a c e r and
tig h te n th e s c re w b a ck. In th e s e c o n d itio n s , th e
p u m p s p in d le ca n tu rn freely.
-- R e fit th e in je c tio n p u m p d riv e g e a r b o x a c c e s s
cover.
- A s s e m b le th e L D A d e v ic e c o n n e c tio n p ipe to th e
in le t m a n ifo ld (J X 7 0 and J X 9 5 m o d e ls o n ly).
- C o n n e c t th e fu e l s u p p ly and re tu rn lin e s to th e in
je c tio n pum p .
- C o n n e c t th e e n g in e c u t- o u t e le c tro m a g n e t ca b le
and th e c a b le o f th e th e rm o m e tric c irc u it b re a k e r
cu ttin g o u t s ta rtin g a d v a n c e a c c o rd in g to te m
p e ra tu re (K S B ).
- C o n n e c t th e d e liv e ry p ip e s to th e in je c to rs , to th e
in je ctio n pum p .
- C o n n e c t th e th ro ttle lead to th e in je c tio n p u m p .
- F it th e fu e l filter.
-- C lo s e th e b o n n e t.
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SECTION 10 - ENGINE - CHAPTER 1 121
24 5
2. M a ke s u re th a t th e K S B fo rk (1) is fre e to m o ve .
24 6
3. U n s c re w th e u n io n s o f th e fu e l s u p p ly lin e s (1),
d e ta c h in g th e m fro m th e in je c tio n pu m p .
If n e ce ssa ry, d is c o n n e c t th e in je c tio n p u m p s u p
ply and re tu rn lin e s (2 and 3) and th e L D A /in ta k e
m a n ifo ld c o n n e c tin g pipe.
24 7
4. R e m o v e th e fly w h e e l in s p e c tio n w in d o w c o v e r
( 1 ) and th e ta p p e t cover.
5. R o ta te th e c ra n k s h a ft to brin g c y lin d e r no. 1 at
T .D .C . and m a k e s u re th e v a lv e s a re c lo se d
(c o m p re s s io n s tro k e ).
24 8
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122 SECTION 10 - ENGINE - CHAPTER 1
6 . C h e c k th ro u g h th e in s p e c tio n w in d o w th a t th e
p o in te r is a lig n e d w ith re fe re n c e m a rk s 4 ° fo r
m od . JX60, 0 ° fo r m o d . JX70 and JX 95 , o r 1 °
fo r m o d. JX80 a nd JX 90 .
250
10. Z e r o - s e t th e d ia l g a u g e and s lo w ly tu rn th e
fly w h e e l c lo c k w is e (as v ie w e d fro m th e fa n end
o f th e e n g in e ) u ntil th e p o in te r lin e s up w ith
re fe re n c e m a rk s 4 ° fo r JX60 m o d e ls , 0 ° fo r JX70
and JX95 m o d e ls , o r 1 ° fo r JX80 and JX90
m o d e ls.
11. C h e c k on th e d ia l g a u g e th a t th e p lu n g e r has
co m p le te d a s tro k e o f 1 m m (0 .0 3 9 4 in.) up to th is
po int, if not, s la c k e n o ff th e p u m p m o u n tin g b olts.
I f th e p lu n g e r s tro k e is c h e c k e d w ith th e p o in te r
at th e T .D .C . th e re m u s t be a s tro k e of: 1.47 mm
( 0.0578 in . ) fo r m o d . JX60 o r 1.00 m m ( 0.0394
in . ) fo r m od . JX70 and JX 95 , o r 1.12 mm
( 0.0440 in . ) fo r m o d . JX80 and JX 90 .
12. T u rn th e p u m p a n ti-c lo c k w is e if th e p lu n g e r has
c o m p le te d a s h o rte r s tro k e and c lo c k w is e if th e
s tro k e is longer, re p e a tin g th e te s t u n til th e c o r
re c t s tro k e is o b ta in e d .
13. H a vin g o b ta in e d th e c o rre c t p lu n g e r s tro k e , fix
th e p u m p in p o s itio n by tig h te n in g th e m o u n tin g
n u ts to th e to rq u e s p e c ifie d on p a g e 24.
14. R e m o v e th e dia l g a u g e 380000228 (1) and re la ti
ve to o l 380000229 (2) and re p la c e th e plug and
tig h te n to a to rq u e o f 8 - 10 N m (5 .9 0 0 5 - 7 .3 7 5 6
ft lb).
15. D is c o n n e c t th e K S B e x te rn a l p o w e r s u p p ly unit.
16. R e fit o th e r p a rts in th e re v e rs e o f th e d is m a n tlin g
order.
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SECTION 10 - ENGINE - CHAPTER 1 123
252
253
3. Slacken the fuel line unions (1) on the injectors,
start the engine and then re-tightenthe union (1)
when the fuel flows out free of bubbles.
254
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124 SECTION 10 - ENGINE - CHAPTER 1
FUEL INJECTORS
R e m o v a l-In s ta lla tio n (O p eratio n 10 218 30)
1. D is c o n n e c t th e b a tte ry n e g a tiv e ca b le .
2. A tta c h lifting c h a in s to th e b o n n e t (1) and th e n
a tta c h th e c h a in s to th e h oist.
25 5
25 6
4. D e ta ch th e g a s s tru ts (1) fro m th e b o n n e t.
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 125
259
7. Unscrew the union (1) of the high-pressure fuel
line on the injector.
260
8. Unscrew the two retaining nuts (1) and withdraw
the injector.
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126 SECTION 10 - ENGINE - CHAPTER 1
1. D is c o n n e c t th e b a tte ry n e g a tiv e ca b le .
2. A tta c h lifting c h a in s to th e b o n n e t (1) and th e n a t
ta c h th e m to th e h oist.
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SECTION 10 - ENGINE - CHAPTER 1 127
6. U n d o th e h o se c la m p and d e ta c h th e h o se fro m
th e s ile n c e r eje cto r.
7. U n s c re w th e tw o s c re w s s e c u rin g th e s ile n c e r
fro n t s u p p o rt.
8. U n s c re w th e re ta in in g n u ts s e c u rin g th e s ile n c e r
to th e e x h a u s t m a n ifo ld and re m o v e th e s ile n ce r.
26 6
9. U n s c re w th e fo u r ro c k e r c o v e r n u ts (1) and
re m o v e cover.
11. A d ju s t th e c le a ra n c e b e tw e e n th e v a lv e s and th e
ro c k e ra rm s u sin g a fe e le rg a u g e , w re n c h ( 1 ) and
th e s p e c ia l to o l 291883 (2).
NOTE: Before proceeding with adjustment
operations, position the valves as described on the
following page.
26 9
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128 SECTION 10 - ENGINE - CHAPTER 1
To a d ju s t v a lv e c le a ra n c e s on th e 3 --c y lin d e r J X 6 0
and J X 7 0 e n g in e s , p ro c e e d as fo llo w s :
— T urn th e c ra n k s h a ft so th a t th e in le t and e x h a u s t
v a lv e s o f c y lin d e r no. 1 a re b a la n c e d (s ta rt o f
in d u c tio n s tro k e ). In th is p o s itio n th e p o in te r w ill
be a lig n e d w ith th e re fe re n c e m a rk P M S 1
(T D C 1) on th e fly w h e e l.
— R o ta te th e c ra n k s h a ft th ro u g h a fu ll re v o lu tio n ,
re tu rn in g to T D C 1, th e n c h e c k th a t th e v a lv e
c le a ra n c e s c o rre s p o n d w ith th e v a lu e s s p e c ifie d
in th e ta b le on p a g e 4.
— R e p e a t th is o p e ra tio n fo r th e o th e r v a lv e pairs.
N o te th a t th e T D C p o s itio n s o f c y lin d e rs 2 and 3
are n o t m a rk e d on th e fly w h e e l.
To c h e c k v a lv e c le a ra n c e s on 4 - c y lin d e r J X 8 0 , J X 9 0
and J X 9 5 m o d e ls , p ro c e e d as fo llo w s :
— T urn th e c ra n k s h a ft so th a t th e in le t and e x h a u s t
v a lv e s o f c y lin d e r no. 1 a re b a la n c e d (s ta rt o f in
d u c tio n s tro k e ). In th is p o s itio n th e p o in te r w ill be
a lig n e d w ith th e re fe re n c e m a rk P M S 1 (T D C 1)
on th e fly w h e e l.
— C h e c k th a t th e c le a ra n c e b e tw e e n v a lv e s and
ro c k e r a rm s on c y lin d e r no. 4 c o rre s p o n d s w ith
th e v a lu e s s p e c ifie d in th e ta b le on p a g e 4.
R o ta te th e c ra n k s h a ft th ro u g h 3 6 0 ° and c h e c k
v a lv e c le a ra n c e s on th e o p p o s in g c y lin d e r
(N o. 1).
— R e p e a t th is o p e ra tio n fo r th e o th e r v a lv e pairs.
N o te th a t th e o p p o s in g c y lin d e rs a re 1 - 4 and
2 -3 .
To re a s s e m b le p ro c e e d as fo llo w s :
— R e fit th e ro c k e r cover.
— R e fit th e fly w h e e l in s p e c tio n w in d o w cover.
— R e fit th e e x h a u s t s ile n ce r.
— R e fit th e b o n n e t.
— R e c o n n e c t th e b a tte ry n e g a tiv e lead.
6-62720 - 09 - 2006
SECTION 10 - ENGINE - CHAPTER 1 129
O v e rh a u l th e p u m p as fo llo w s :
27 0
— R e m o v e th e c o v e r (4) fig. 2 7 0 , and th e s h a ft
s c re w (2) re ta in in g th e s h a ft (10) and b e a rin g (9).
C h e c k c o m p o n e n ts fo r w e a r, and c h a n g e a n y th a t
a re in p o o r c o n d itio n .
— P la ce th e ro to r (1) on th e s h a ft (2), e a s in g it o n to
th e end so as n o t to d a m a g e th e b e a rin g , until
yo u o b ta in th e o p e ra tin g c le a ra n c e of
G = 0 .5 - 0 .7 m m (se e fig. 2 7 0 ).
6-62720 - 09 - 2006
130 SECTION 10 - ENGINE - CHAPTER 1
8) T est th e c o m p re s s io n on th e o th e r c y lin d e rs ,
re p e a tin g s te p s 4, 5, 6 and 7, b e a rin g in m in d th a t:
C o m p re s s io n ratio
T h e m in im u m p e rm is s ib le c o m p re s s io n on a used
T h e c o m p re s s io n ra tio is a m e a s u re o f th e q u a n tity
e n g in e is 2 1 .6 b a r (22 k g /c m 2).
o f a ir d ra w n into th e c y lin d e r and p ro v id e s an
in d ic a tio n o f th e e ffic ie n c y o f th e s e a lin g e le m e n ts in
T h e m a x im u m p e rm is s ib le c o m p re s s io n d iffe re n c e
th e c y lin d e r (p isto n rin g s and v a lv e s ).
b e tw e e n c y lin d e rs is 3 b a r (3 k g /c m 2).
U n ifo rm c o m p re s s io n in all th e c y lin d e rs e n s u re s th a t
E v e ry 100 m e tre s a b o v e s e a le ve l c o rre s p o n d s to a
th e y all p e rfo rm an e q u a l a m o u n t o f w o rk , p ro v id e d
re d u c tio n in c o m p re s s io n by a b o u t 1% .
o f c o u rs e th a t ea ch c y lin d e r is in je c te d w ith th e s a m e
q u a n tity o f fu e l a t th e rig h t tim e .
CONSIDERATIONS:
Low c o m p re s s io n n o t o n ly re d u c e s e n g in e
p e rfo rm a n c e , it a lso c a u s e s in c o m p le te fu e l
c o m b u s tio n d u e to th e la c k o f a v a ila b le c o m b u s tio n
U n ifo rm c o m p re ssio n
air.
A lth o u g h high c o m p re s s io n is im p o rta n t, it is m o re
T h e e n g in e th e re fo re g iv e s p o o r p e rfo rm a n c e w ith
im p o rta n t as re g a rd s s m o o th ru n n in g th a t th e
e x c e s s iv e fu e l c o n s u m p tio n , and c o n s e q u e n tly
c o m p re s s io n is th e s a m e in all cy lin d e rs .
e x h a u s t s m o k e and re s tric tio n o f th e e x h a u s t
p a s sa g e s.
L o w c o m p re s s io n re adings
A s th e c o m p re s s io n ra tio a lso varies w ith the
If v e ry lo w c o m p re s s io n re a d in g s a re o b ta in e d on
te m p e ra tu re o f th e e n g in e (co ld e n g in e s p ro d u c e
o n e c y lin d e r it is a d v is a b le to re p e a t th e te s t.
lo w e r c o m p re s s io n v a lu e s th a n h o t e n g in e s ) th e
c o m p re s s io n sh o u ld o n ly be te s te d w h e n th e e n g in e
B e fo re te s tin g th is tim e , p o u r a b o u t a s p o o n fu l o f
is a t n o rm a l o p e ra tin g te m p e ra tu re .
e n g in e oil in to th e c y lin d e r th ro u g h th e in je c to r bore.
C o m p re s s io n s h o u ld be te s te d u sin g th e
T u rn th e e n g in e o v e r a fe w tim e s to d is trib u te th e oil
c o m p re s s io n te s t kit 291309 as fo llo w s :
e v e n ly o v e r th e c y lin d e r w a lls , and th e n re p e a t th e
te s t.
1) R un th e e n g in e u ntil it re a c h e s n o rm a l o p e ra tin g
te m p e ra tu re . If th e s e c o n d te s t re a d in g s a re s ig n ific a n tly higher,
s u s p e c t w o rn p isto n rin g s, o u t- o f- r o u n d o rd a m a g e d
2) S w itc h o ff th e e n g in e . p is to n s o r liners.
6-62720 - 09 - 2006
SECTION 18 - CLUTCH - CHAPTER 1 1
SECTION 18 - CLUTCH
Chapter 1 - Clutch
CONTENTS
6-62720 - 09 - 2006
2 SECTION 18 - CLUTCH - CHAPTER 1
(Model JX95)
TIGHTENING TORQUES
Tightening torque
PART Thread
Nm ft lb
Release command fork securing bolt (C3, page 4) ...................... M 16 x 1.5 157 115.7972
Retaining bolts securing clutch casing to engine (C2, page 4) . . . M 12 x 1.25 98 72.2811
Clutch casing/engine retaining nuts (3, fig. 1 page 4) .................. M 12 x 1.25 98 72.2811
Nut for sleeve cover fixing stud (C6 page 4 ) .................................. M 8 x 1.25 17 12.8355
6-62720 - 09 - 2006
SECTION 18 - CLUTCH - CHAPTER 1 3
6-62720 - 09 - 2006
4 SECTION 18 - CLUTCH - CHAPTER 1
1
a . Main clutch with driven disc made of organic material. 4. Main clutch release sleeve, complete with thrust
b . Main clutch with driven disc made of cerametallic. bearings.
C2 Bolts securing clutch casing to the engine. 5. PTO clutch release sleeve, complete with thrust
bearings.
C3 Fork lever retaining bolts.
6. Power ta k e -o ff clutch release lever adjustment tie
C 6 Nuts for sleeve studs.
rod.
D . Nominal distance of lever (3) from clutch contact sur
7. Power ta k e -o ff clutch release lever stop nut.
face on flywheel (mod. JX60, JX70, JX80 and JX90,
11”/11” clutch 98 m m (3.8583 in.) - mod. JX95 12”/12”
8. Power ta k e -o ff clutch plate.
clutch 103 m m (4.0551 in.)). 9. Main transmission clutch plate.
D 1 Nominal distance of lever (2) from clutch contact sur 10. Bearing on flywheel.
face on flywheel (mod. JX60, JX70, JX80 and JX90, 11. PTO clutch release sleeve control fork.
11”/11” clutch 123 m m (4.8425 in.) - mod. JX95 12. Main clutch release sleeve control fork.
12”/12” clutch 137 m m (5.3937 in.)). 13. Main clutch release lever adjuster lever.
L 1 Clearance between PTO release lever and related 14. Main clutch release lever adjuster screw.
thrust bearing 2 m m (0.0787 in.). 15. Main clutch release lever adjuster nut.
L 2 Clearance between main clutch release lever and re
lated thrust bearing 2.5 m m (0.0984 in.). WARNING: When refitting the clutch, check that the
clutch plates are positioned as in the drawing.
1. Belleville spring.
2. PTO clutch release lever. NOTE: When refitting, carefully clean and degrease
3. Main clutch release lever. the mating surfaces X and apply sealing compound.
6-62720 - 09 - 2006
SECTION 18 - CLUTCH - CHAPTER 1 5
CLUTCH TROUBLESHOOTING
Clutch slips 1. Worn clutch plates (8 and 9, Check and compare the data given on
page 4) and/or worn pres the pages indicated; replace any
sure plate and flywheel. parts which are worn up to or over the
limit and adjust levers and clutch
control linkage.
2. Belleville spring (1, page 4) Replace the Belleville spring.
distorted or otherwise
damaged.
3. Friction linings of discs (8 and Replace discs; identify and eliminate
9, page 4) contaminated with the source of lubricant inside the
oil and grease. clutch housing and thoroughly clean
the friction surfaces.
Fierce clutch 1. Partial seizure of the external Check linkage pivots and lubricate.
control linkage.
2. Friction disc (9, page 4) Replace disc and adjust clutch control
distorted. lever.
3. Friction disc (9, page 4) with Replace friction disc.
damaged hub springs or loose
hub rivets.
4. Oil or grease contaminating Replace the discs, identify and
the friction lining of discs eliminate the source of lubricant
(8 and 9, page 4). inside the clutch housing and
thoroughly clean the friction surfaces.
Clutch sticks and drags 1. Disc friction linings (8 and 9, Replace and adjust the discs.
page 4) or discs deformed.
2. Seizure of the external control Check, replace defective parts and
linkage. lubricate.
3. Controls badly adjusted. Adjust controls (see page 21).
Clutch pedal too stiff 1. Partial seizure of external Check linkage pivots and lubricate.
control linkages.
2. Stiffening of pedal pivot. Check pivot and lubricate.
6-62720 - 09 - 2006
6 SECTION 18 - CLUTCH - CHAPTER 1
CLUTCH
Rem oval-Refitting (Operation 18 110 10)
Proceed as follows:
1. Disconnect the negative battery lead.
2. Drain off the oil from the gearbox/transmission
casing.
6-62720 - 09 - 2006
SECTION 18 - CLUTCH - CHAPTER 1 7
5
8. After draining off the oil from the power steering
tank, disconnect the oil pipes (1) from the
hydrostatic steering control valve unit.
6-62720 - 09 - 2006
8 SECTION 18 - CLUTCH - CHAPTER 1
9
12. Slacken the clamps (1) and disconnect the cab
heating pipes (2), being sure to mark them first.
6-62720 - 09 - 2006
SECTION 18 - CLUTCH - CHAPTER 1 9
12
13
16. Disconnect the fuel line (1) from the glow plug.
14
15
6-62720 - 09 - 2006
10 SECTION 18 - CLUTCH - CHAPTER 1
17
20. Remove the retaining bolts of the central support
(1) of the prop shaft and recover the shaft
complete with support.
6-62720 - 09 - 2006
SECTION 18 - CLUTCH - CHAPTER 1 11
22. Unscrew the two nuts (1) and bolts securing the
engine to the transmission, working through the
two access slots.
20
23. Unscrew the four lower bolts (1) securing the
engine to the transmission.
21
24. Position two wedges (3) on the front axle to
prevent any movement o f the engine about the
axle pivot. Position the tractor dismantling stand
380000236, so that the fixed support (1) is under
the rear transmission housing in the area of the
engine coupling flange and the mobile support
(2) under the engine in the area of the flange
attached to the transmission housing, as shown
in fig. 23.
22
25. Place another mobile stand 380000236 under
the front ballast carrier to prevent any possibility
of the engine turning and tipping forwards when
the gearbox case is removed.
23
6-62720 - 09 - 2006
12 SECTION 18 - CLUTCH - CHAPTER 1
24
25
26
6-62720 - 09 - 2006
SECTION 18 - CLUTCH - CHAPTER 1 13
To re-install the engine, proceed as follows: Remove the stands of tool 380000236 from under
the engine and the gearbox/transmission and the
Check condition of ball bearings pressed in flywheel; stand under the draw bar.
replace in the event of excessive noise or binding.
To install a new bearing pack, lubricate with grease. Refit the cab heater pipe union on the clutch/engine
spacer collar. Connect the flexible rubber hoses to
the union.
Position the clutch using tool 380000612 (mod.
JX60, JX70, JX80 and JX90) or with tool 380000292
(mod. JX95). Fix the clutch to the flywheel with the Connect the flexible power steering pipes of the
six bolts. front axle and add oil to the system.
Spread LOCTITE compound on the mating surfaces Connect all the electrical connections.
of the engine and spacer collar. Install the spacer col
lar on the stud bolts screwed on the engine.
Connect the throttle cable to the injection pump.
Before connecting the transmission casing to the en Refit the 4WD propeller shaft and the relative guard.
gine - front axle assembly, grease the discs hubs.
Refit the front ballast and secure with the vertical
lock pin.
Chock up the rear wheels with wooden wedges,
check that the hand brake is fully on and that the fi
xed and mobile stands are well positioned.
Fill the gearbox/transmission with oil.
Fit and tighten the bolts securing the clutch housing Fill the engine cooling system with coolant.
to the engine.
6-62720 - 09 - 2006
14 SECTION 18 - CLUTCH - CHAPTER 1
OVERHAUL
The clutch is removed, refitted and adjusted with the
universal outfit 293650.
A. Plate 293332.
B. Central spacer
293728. 0 35mm (1.3779 in.) for 11”/11” clutch
293729. 0 40mm (1.5748 in.) for 12”/12” clutch
C. Gauge 293731.
D. Locknut 293730 for central spacer.
E. Side spacers 293726.
F. Studs 293725.
I. Blocks.
L. Handwheel 293739 securing the gauge.
M. Handwheels 293740 securing the side spacers
N. Spacers for studs.
27
MDH1884A_______________________________________________ l_ _ l___________
28
6-62720 - 09 - 2006
SECTION 18 - CLUTCH - CHAPTER 1 15
29
6-62720 - 09 - 2006
16 SECTION 18 - CLUTCH - CHAPTER 1
Remove the nuts (7; page 4) for the PTO clutch re
lease lever adjuster tie rods and gradually unscrew
the studs (F, page 14) thereby making it possible to
extend the Belleville spring and break down the
clutch into its parts.
30
Remove the three bolts retaining the flexible tabs
driving the main clutch pressure plate from the clutch
carrier housing and retrieve the pressure plate.
31
A ATTENTION A ----------
When removing, overhauling and then refitting the
clutch, pay special attention not to move the main
clutch and PTO clutch pressure plate ring driving
tables from their original assembly position on the
pressure plate rings.
6-62720 - 09 - 2006
SECTION 18 - CLUTCH - CHAPTER 1 17
where:
A and B = distances measured of the two
pressure plates after refacing;
S 1 and S2 = measurements of the PTO and main
clutch plates:
L = 2 mm (0.0784 in.) for 11”/11” clutches
mod. JX60, JX70, JX80 and JX90
= 0.5 mm (0.0197 in.) for 12”/12” clutch
mod. JX95
Lowering on the flywheel;
P = 4.20 * 4.30 mm (0.1653 * 0.1693 in.)
for 11”/11” clutch
mod. JX60, JX70, JX80 and JX90
= 4.30 * 4.40 mm (0.1693 * 0.1732 in.)
for 12”/12” clutch
mod. JX95 The dimension the spring
must have to restore the original load.
- check that the value obtained (D) is greater than
or equal to the measurement made on the clutch
to overhaul and that, in order to be able to restore
it, the distance (C, fig. 34 and 36) of the housing
must not decrease under the stated value. If this
is not so, replace one or both o f the pressure
plates.
6-62720 - 09 - 2006
18 SECTION 18 - CLUTCH - CHAPTER 1
1. Engine flywheel.
2. PTO clutch pressure plate.
3. Main transmission clutch pressure plate
4. Supporting housing. 34
A. = 352 E 8 mm (1 3 .8 5 8 2 in.)
B. = 313 mm (1 2 .3 2 2 8 in.)
C. = 73.5 mm (2 .8 9 3 7 in.) 35
- 1 2 ”/ 1 2 ” d u a l c lu tc h
m od. JX 9 5
A. > 1 5 .5 0 m m (0 .6 1 0 2 in.)
B. > 2 1 .5 0 m m (0 .8 4 6 4 in.)
1. Engine flywheel.
2. PTO clutch pressure plate.
4. Supporting housing. 36
6-62720 - 09 - 2006
SECTION 18 - CLUTCH - CHAPTER 1 19
C. Gauge.
L. Handwheel 293739.
V 1 = 0.1 m m (0.0039 in.) Clearance to obtain between
the ends of the gauge pins (C) and release levers (1)
for 11711” clutch (mod. JX60, JX70, JX80, JX90) or:
= 0.1 m m (0.0039 in.) for 12712” clutch (mod. JX95).
1. Release levers.
2. Hex wrench.
3. Adjuster screw and locknut. 37
C. Gauge.
L. Handwheel 293739.
V 2 = 0.1 m m (0.0039 in.) Clearance to obtain between
the gauge face (C) and release levers (1) for 11711”
clutch ( mod. JX60, JX70, JX80, JX90 ) or:
0.1 m m (0.0039 in.) for 12 ”/ 12 ” clutch ( mod. JX95).
1. Release levers.
2. Adjuster nut. 38
6-62720 - 09 - 2006
20 SECTION 18 - CLUTCH - CHAPTER 1
39
40
mod. JX95 41
6-62720 - 09 - 2006
SECTION 18 - CLUTCH - CHAPTER 1 21
42
ADJUSTMENT OF THE MAIN CLUTCH
CONTROL LINKAGE (Op. 18.100.40)
Check that pedal free travel before clutch release is
approximately 40 mm . When free travel is down to
25 mm , adjust clutch as follows:
43
44
45
6-62720 - 09 - 2006
22 SECTION 18 - CLUTCH - CHAPTER 1
- Loosen the locknut (1) and remove the split pin (2).
46
6-62720 - 09 - 2006
SECTION 21 - TRANSMISSIONS - CHAPTER 1 1
SECTION 21 - TRANSMISSIONS
CONTENTS
21 000 M a in d a t a .......................................................................................................................................................... 1
T ig h te n in g to rq u e s ....................................................................................................................................... 2
T ools ................................................................................................................................................................... 3
S e c tio n v i e w s ................................................................................................................................................. 3& 5
D e s c rip tio n and o p e ra tio n ......................................................................................................................... 8
F a u lt d ia g n o s is .............................................................................................................................................. 8
2 1110 R e m o v a l - R e fittin g ................................................................................................................ s e e s e c t 27
- G e a rin g t y p e ..................................................................................... s p u r g e a rs
- R e d u c tio n ra tio s :
• S lo w ................................................................................................ 23x17
— r-T T - = 1 :(5 .4 9 )
43x50 v ’
• N o rm a l ............................................................................................ 23x27
-rz -rr = 1 :(2 .3 5 )
43x34
• F a s t .................................................................................................. 1
(continued overleaf)
6-62720 - 09 - 2006
2 SECTION 21 - TRANSMISSIONS - CHAPTER 1
D ia m e te r o f p o w e r ta k e o ff (P T O ) c lu tc h s h a ft (4, p a g e 5 ) ........... mm 2 4 .9 7 9 - 2 5 .0 0 0
(in.) (0 .9 8 3 4 - 0 .9 8 4 3 )
TORQUE VALUES
Torque s e ttin g s
PARTS Thread
Nm ft lb
B e ve l g e a r p a ir s u p p o rt re ta in in g b o lts (C g) .................................................... M 1 0 x 1 .2 5 59 4 3 .5 1 6 2
6-62720 - 09 - 2006
SECTION 21 - TRANSMISSIONS - CHAPTER 1 3
1
TOOLS L ist o f s p e c ia l to o ls re q u ire d fo r th e v a rio u s
o p e ra tio n s d e s c rib e d in th is S e c tio n :
6-62720 - 09 - 2006
4 SECTION 21 - TRANSMISSIONS - CHAPTER 1
D rift to be m a d e fo r re m o v a l o f g e a rb o x d riv in g s h a ft
(to o l to be s ta m p e d no. 50006 -- m e a s u re m e n t in
m m ).
M a ke in m a te ria l U N I C 40.
Tool to be m a d e fo r a d ju s tm e n t o f g e a rb o x d riv in g
s h a ft b e a rin g s (to o l be s ta m p e d no. 50007 -
m e a s u re m e n t in m m ).
M a ke in m a te ria l A q 45.
6-62720 - 09 - 2006
SECTION 21 - TRANSMISSIONS - CHAPTER 1 5
©©© ©
26218
6-62720 - 09 - 2006
6 SECTION 21 - TRANSMISSIONS - CHAPTER 1
S ealing c o m p o u n d a p p lic a tio n dia g ra m fo r m a tin g su rfa ce s betw een e n g in e , c lu tc h ca sin g and rear
tra n s m is s io n -g e a rb o x.
T h e ty p e s o f s e a lin g c o m p o u n d to use a re in d ic a te d on p a g e 1, S e c t. 00.
6-62 7 2 0 - 09 - 2 0 06
SECTION 21 - TRANSMISSIONS - CHAPTER 1 7
6-62720 - 09 - 2006
8 SECTION 21 - TRANSMISSIONS - CHAPTER 1
3. D e fe c tiv e te e th on s y n c h ro R e m o v e th e tra n s m is s io n /g e a rb o x
n is e r o r e n g a g e m e n t s le e v e . and re p la c e th e s y n c h ro n is e rs o r th e
e n g a g e m e n t s le e v e s .
3. M a in c lu tc h d ra g . S e e p a g e 5, S e c t. 18.
4. S y n c h ro n is e rs or engage R e m o v e th e tra n s m is s io n / g e a rb o x
m e n t s le e v e s d e fe c tiv e . and re p la c e th e s y n c h ro n is e rs o r
e n g a g e m e n t s le e v e s .
G e a rb o x o r ra n g e g e a r u n d u ly 1. In te rn a l c o m p o n e n t/s w o rn o r R e m o v e th e tra n s m is s io n / g e a rb o x
noisy. d e fe c tiv e . and re p la c e th e w o rn / d e fe c tiv e
pa rts.
6-62720 - 09 - 2006
SECTION 21 - TRANSMISSIONS - CHAPTER 2 1
SECTION 21 - TRANSMISSIONS
Chapter 2 - Reverser
CONTENTS
Gearbox and reduction unit controls .............................................. Independent, with two hand levers
located on right-hand side of the
operator
6-62720 - 09 -2006
2 SECTION 21 - TRANSMISSIONS - CHAPTER 2
TORQUE VALUES
Torque Settings
PARTS Thread
Nm ft lb
Bolt or nut securing clutch / reverser casing to engine (C-0 M 12 x 1.25 98 72.2811
Reverser driven shaft cover retaining bolts (C3) ............................ M 8 x 1.25 28 20.6517
Reverser driven shaft plate retaining bolts (C4) ............................ M 10 x 1.25 64 47.2040
C 98 Nm
C3 28 Nm
C4 6 Nm
C 5 98 Nm
TRE0558A
6-62720 - 09 - 2006
SECTION 21 - TRANSMISSIONS - CHAPTER 2 3
6-62720 - 09 -2006
4 SECTION 21 - TRANSMISSIONS - CHAPTER 2
4. Seal. 14.
5. Circlip. 15.
6-62720 - 09 - 2006
SECTION 21 - TRANSMISSIONS - CHAPTER 2 5
5. Internal controls do not slide Perform the checks and overhaul for
freely: rods, forks and needed parts.
sleeves.
Synchroniser reverser unduly 1. Worn or damaged internal Remove the clutch casing and
noisy. part/s. replace damaged part/s.
6-62720 - 09 -2006
6 SECTION 21 - TRANSMISSIONS - CHAPTER 2
CLUTCH/REVERSER CASING
Replacement (Op. 21 110 85)
11
13
6-62720 - 09 - 2006
SECTION 21 - TRANSMISSIONS - CHAPTER 2 7
14
5. Remove the reverser driving gear (1) complete
with roller bearings.
15
16
17
6-62720 - 09 -2006
8 SECTION 21 - TRANSMISSIONS - CHAPTER 2
18
19
20
11. Withdraw the external clutch control levers (1)
and remove the forks (2).
21
6-62720 - 09 - 2006
SECTION 21 - TRANSMISSIONS - CHAPTER 2 9
6-62720 - 09 -2006
10 SECTION 21 - TRANSMISSIONS - CHAPTER 2
6-62720 - 09 - 2006
SECTION 21 - TRANSMISSIONS - CHAPTER 3 1
SECTION 21 - TRANSMISSIONS
CONTENTS
21 000 M a in d a t a ............................................................................................................................................................ 1
T ig h te n in g to rq u e s ....................................................................................................................................... 2
T ools ................................................................................................................................................................... 3
S e c tio n v i e w s ................................................................................................................................................... 4
D e s c rip tio n and o p e ra tio n ......................................................................................................................... 6
F a u lt d ia g n o s is .............................................................................................................................................. 6
21 110 R e m o v a l- R e fittin g ........................................................................................................................................... 7
21 000 - MAIN DATA - TIGHTENING TORQUES - SECTION VIEWS - TOOLS - DESCRIPTION AND
OPERATION - FAULT DIAGNOSIS
T y p e ..................................................................................................................... M e c h a n ic a l, s p u r g e a rs , lo ca te d
b e tw e e n e n g in e and g e a rb o x .
C o m p ris in g 1 d riv in g g ear, 1
in te rm e d ia te g e a r and 1 idle
gear.
C o n t r o l................................................................................................................ b y han d le v e r lo c a te d on
le ft-h a n d s id e o f o p e ra to r
R e d u c tio n r a t i o ................................................................................................ 1 8 x2 6
----------- = 1 5 524
55x47
C o n t r o l................................................................................................................ b y han d le v e r lo c a te d on
le ft-h a n d s id e o f o p e ra to r
G e a r b o x ............................................................................................... 4 -s p e e d c o n s ta n t m e sh ,
s y n c h ro n is e d on all g e a rs
G e a rin g t y p e ..................................................................................................... s p u r g e a rs
F o r fu rth e r d a ta s e e c h a p te r 1.
6-62720 - 09 - 2006
2 SECTION 21 - TRANSMISSIONS - CHAPTER 3
TORQUE VALUES 2.
Torque S e ttin g s
PARTS Thread
Nm ft lb
B o lt o r n u t s e c u rin g c lu tc h c a s in g - re v e rs e r and c re e p e r u n it to th e
e n g in e ( C - i ) ....................................................................................................... M 1 2 x 1 .2 5 98 72.2811
S le e v e c o v e r n u ts (C 2) ................................................................................ M 8 x 1 .2 5 17 1 2 .5 3 8 5
S y n c h ro n is e r re v e rs e r - c re e p e r u n it d riv e n s h a ft c o v e r n u ts (C 3) M 8 x 1 .2 5 17 1 2 .5 3 8 5
B o lt s e c u rin g c lu tc h c a s in g - re v e rs e and c re e p e r u n it to th e re a r
tra n s m is s io n -g e a rb o x ................................................................................ M 1 2 x 1 .2 5 98 7 2 .2 8 1 117
TRE0561A
6-62720 - 09 - 2006
SECTION 21 - TRANSMISSIONS - CHAPTER 3 3
6-62720 - 09 - 2006
4 SECTION 21 - TRANSMISSIONS - CHAPTER 3
3. C irclip . 8. T h ru s t w a s h e r.
6-62720 - 09 - 2006
SECTION 21 - TRANSMISSIONS - CHAPTER 3 5
---------
X J
l: ^ --------- H
6-62720 - 09 - 2006
6 SECTION 21 - TRANSMISSIONS - CHAPTER 3
15. S y n c h ro n is e r te e th d a m a g e d . R e m o v e th e c lu tc h c a s in g and
re p la c e th e s y n c h ro n is e r.
3. M a in c lu tc h d ra g . S e e p a g e 5, S e c t. 18.
4. S y n c h ro n is e r d e fe c tiv e . R e m o v e th e c lu tc h c a s in g -g e a rb o x
and re p la c e th e s y n c h ro n is e r.
6-62720 - 09 - 2006
SECTION 21 - TRANSMISSIONS - CHAPTER 3 7
To ga in a c c e s s to th e s y n c h ro n is e r re v e rs e r-c re e p e r
unit, firs t re m o v e th e c a b o r p la tfo rm fo llo w in g th e
in s tru c tio n s g ive n in S e c t. 2 7 and re m o v e th e clu tc h
c a sin g as d e s c rib e d in S e c t. 18, and th e n p ro c e e d as
fo llo w s :
6
3. R e m o v e c irc lip (1) o f re v e rs e r tra n s m is s io n
d riv in g sh a ft.
6-62720 - 09 - 2006
8 SECTION 21 - TRANSMISSIONS - CHAPTER 3
5. R e m o v e th e re v e rs e r s y n c h ro n is e r a s s e m b ly (1)
to g e th e r w ith c o n tro l fo rk s and g e a rs .
10
11
6-62720 - 09 - 2006
SECTION 21 - TRANSMISSIONS - CHAPTER 3 9
8. U n s c re w th e re ta in in g s c re w s (2) and re m o v e
th e c o n tro l fo rk s (1).
12
9. U n s c re w th e re ta in in g s c re w (15, p a g e 5) and
w ith d ra w th e re v e rs e r in te rm e d ia te gear
a s s e m b ly (1).
13
14
11. F ro m th e re a r o f th e c a s in g , w ith d ra w th e s h a ft
(1) c o m p le te w ith th e re la tiv e b e a rin g .
15
6-62720 - 09 - 2006
10 SECTION 21 - TRANSMISSIONS - CHAPTER 3
16
17
18
19
6-62720 - 09 - 2006
SECTION 21 - TRANSMISSIONS - CHAPTER 3 11
-WARWn A A --------
A lw a y s use s u ita b le to o ls to a lig n h o le s. N E V E R
U S E Y O U R F IN G E R S O R H A N D S .
20
6-62720 - 09 - 2006
12 SECTION 21 - TRANSMISSIONS - CHAPTER 3
6-62720 - 09 - 2006
SECTION 23 - DRIVE LINES - CHAPTER 1 1
CONTENTS
23 000 M a in s p e c if ic a t io n ........................................................................................................................................... 1
T o rq u e s e ttin g s and T ools ......................................................................................................................... 2
C ro s s -S e c tio n a l v i e w s ................................................................................................................................ 3
23 101 26 T ra n s m is s io n s h a fts and g u a rd (D is a s s e m b ly - A s s e m b ly ) ........................................................... 4
23 101 40 D riv e g e a r h o u s in g (R e m o v a l - In s ta lla tio n ) ........................................................................................ 5
23 101 42 D riv e g e a r h o u s in g re m o v e d (D is a s s e m b ly - A s s e m b ly ) ............................................................... 7
MAIN SPECIFICATION
P ad c le a ra n c e in s e a t ............................................................ ..................... mm 0 .2 8 0 - 0 .4 6 0
(in.) (0 .0 1 1 0 - 0 .3 1 5 )
R e la y le v e r p iv o t d i a m e t e r .................................................. ..................... mm 1 5 .9 7 3 - 1 6 .0 0 0
(in.) (0 .6 2 8 9 - 0 .6 2 9 9 )
P iv o t c le a ra n c e in h o u s in g .................................................. ..................... mm 0 .0 1 6 - 0 .0 8 6
(in.) (0 .0 0 0 6 - 0 .0 1 2 4 )
R e la y le v e r d e te n t s p rin g le n g th
6-62720 - 09 - 2006
2 SECTION 23 - DRIVE LINES - CHAPTER 1
TORQUE SETTINGS
TRE0400A
T o rq u e s e ttin g
PART TO BE TO R Q U E D T h re a d
Nm ft lb
TOOLS
380000821 D riv e s h a ft s e a l k e y
6-62720 - 09 - 2006
SECTION 23 - DRIVE LINES - CHAPTER 1 3
6-62720 - 09 - 2006
4 SECTION 23 - DRIVE LINES - CHAPTER 1
Op. 23 101 26
TRANSMISSION SHAFTS AND GUARD
D isa sse m b ly - A s s e m b ly
To re m o v e , p ro c e e d a s fo llo w s :
1 .D is c o n n e c t th e n e g a tiv e b a tte ry le a d .
2 .R e m o v e th e fro n t, c e n tre a n d r e a r s c r e w s s e c u r in g
th e fr o n t a x le p ro p s h a ft g u a rd a n d re m o v e th e
g u a rd (1 ).
3 .R e m o v e c irc lip (2 ) fig . 5 a n d m o v e s le e v e (1 ) in th e
d ire c tio n s h o w n b y th e a rr o w to d is e n g a g e it fr o m
th e s p lin e d s h a ft o f t h e fr o n t a x le .
4 .T o r e - f it th e tr a n s m is s io n s h a ft a n d g u a rd , p ro c e e d
a s fo llo w s :
- F i t a n d s e c u r e th e tr a n s m is s io n s h a ft in p o s itio n
NOTE:
M o v e t h e f r o n t s p lin e d s le e v e (2 7 ) a g a in s t
r e t a in in g rin g ( 2 8 ). U s in g a f e e le r g a u g e ,
m e a s u re g a p b e tw e e n t h e s le e v e a n d t h e
r e t a in in g rin g (2 6 ) a n d in s ta ll s h im (S 5 ) to
o b ta in s le e v e e n d p la y (L ) o f 1 to 1 .5 m m
( 0 . 0 3 9 4 to 0 .0 5 9 1 in .) (s e e S e c t io n 2 5 p a g e 9 ).
- F it a n d s e c u r e th e g u a rd .
6-62720 - 09 - 2006
SECTION 23 - DRIVE LINES - CHAPTER 1 5
Op. 23 101 40
DRIVE GEAR HOUSING ASSEM BLY
R em oval - In s ta lla tio n
To re m o ve , p ro c e e d as fo llo w s :
7
4 .R e m o v e th e s c re w s (1) th a t hold th e d riv e g e a r
h o u sin g (tra n s fe r b ox) to th e tra n s m is s io n h o u sin g .
5 .R e m o v e th e d riv e g e a r h o u s in g fro m th e
tra n s m is s io n h o u sin g .
6-62720 - 09 - 2006
6 SECTION 23 - DRIVE LINES - CHAPTER 1
R e fe r to th e tig h te n in g to rq u e s s h o w n on p a g e 2.
A p p ly se a lin g c o m p o u n d (a p p ro x . 2 m m (0 .0 7 8 7 in.)
w id e strip ) to th e c o n ta c t s u rfa c e o f th e d riv e g e a r
h o u sin g .
F it th e d riv e g e a r h o u s in g to th e tra n s m is s io n
h o u sin g .
C o n n e c t th e d riv e g e a r e n g a g e m e n t c o n tro l le v e r
F it th e d riv e s h a ft g u a rd .
6-62720 - 09 - 2006
SECTION 23 - DRIVE LINES - CHAPTER 1 7
W ith th e tra n s fe r b o x on th e b e n ch , p ro c e e d as
fo llo w s :
10
3 .U s e th e s p e c ia l p u n ch to w ith d ra w th e s n a p ring
(1), th e n th e pin (2). R e m o v e th e ro lle r b e a rin g , th e
sp a ce r, th e th ru s t w a s h e rs and th e in te rm e d ia te
g e a r (3).
4 .R e m o v e th e p a rk in g b ra k e c o n tro l lever.
11
5 .U s e a s c re w d riv e r to re m o v e th e d u s t ring (1).
6 .R e m o v e th e s p lin e d d riv e n s h a ft, c o m p le te w ith
p a rts, p a rkin g b ra k e d is c s and th e d riv e n gear.
12
6-62720 - 09 - 2006
8 SECTION 23 - DRIVE LINES - CHAPTER 1
In s e rt th e s h a ft in th e h o u s in g , th e n a s s e m b le th e
g e a r unit, w a s h e r and circlip .
F it th e in te rn a l le v e r ,the e x te rn a l lever, th e
c o u p lin g pad and s e c u re in p o s itio n by m e a n s o f
th e w a s h e r and re la tiv e circlip .
F it th e b e a rin g and re la tiv e c irc lip s
6-62720 - 09 - 2006
SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 1
CONTENTS
25 000 M a in d a t a ........................................................................................................................................................... 1
T ig h te n in g to rq u e s ....................................................................................................................................... 4
T ools ................................................................................................................................................................... 6
C ro s s -s e c tio n a l v ie w s ................................................................................................................................ 7
D e s c rip tio n and o p e ra tio n ......................................................................................................................... 9
25 100 30 C o m p le te fro n t a xle . R e m o v a l - In s ta lla tio n ................................................................................... 10
25 100 38 F ro n t a xle . R e m o v a l - In s ta lla tio n ........................................................................................................ 14
25 108 46 -4 7 S te e rin g k n u c k le b e a rin g pins. R e p la c e m e n t ................................................................................ 24
S tu b a xle a d ju s tm e n t ................................................................................................................................ 25
W h e e l h u b b e a rin g a d ju s tm e n t.............................................................................................................. 27
B e v e l d riv e a d ju s tm e n t.............................................................................................................................. 29
25 102 24 F ro n t a x le d iffe re n tia l. O v e r h a u l............................................................................................................. 36
25 100 27 F ro n t a x le d iffe re n tia l w ith L IM -S L IP . O v e r h a u l............................................................................... 37
F ro n t a x le d iffe re n tia l w ith N O S P IN . O v e rh a u l .............................................................................. 39
44 511 80 L e a d in g d riv e w h e e ls to e - in c h e c k ...................................................................................................... 42
MAIN DATA
P in io n -c ro w n g e a r ra tio : 30 km /h :
- J X 6 0 and J X 7 0 M o d e ls 9 /3 8 = 1 :4.2
- J X 8 0 , J X 9 0 and J X 9 5 M o d e ls 9 /3 9 = 1:4.3
P in io n -c ro w n g e a r ra tio : 4 0 km /h :
- J X 6 0 and J X 7 0 M o d e ls 11/38 = 1 :3 .4 5
- J X 8 0 , J X 9 0 and J X 9 5 M o d e ls 11/39 = 1 :3 .5 4
B a c k la s h b e tw e e n b e ve l g e a r pair:
- J X 6 0 and J X 7 0 M o d e ls mm 0 .1 8 - 0 .2 3
(in.) (0.0071 - 0 .0 0 9 1 )
- J X 8 0 , J X 9 0 and J X 9 5 M o d e ls mm 0 .1 5 - 0 .2 0
(in.) (0 .0 0 5 9 - 0 .0 0 7 9 )
- J X 6 0 and J X 7 0 M o d e ls mm 1.3 8 6
(in.) (0 .5 4 5 )
- J X 8 0 , J X 9 0 and J X 9 5 M o d e ls mm 1.3 7 8
(in.) (0 .5 4 2 )
- JX 95 M odel 1.3 9 8
(0 .5 5 0 )
(continued overleaf)
6-62720 - 09 - 2006
2 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
MAIN DATA
Bevel D rive and D iffe re n tia l
- T h ic k n e s s o f p in io n b e a rin g a d ju s tm e n t s p a c e r
J X 6 0 and J X 7 0 M o d e ls ......................................................... mm 2 .5 - 2 .5 5 - 2 . 6 - 2 . 6 5 - 2 . 7 - 2 . 7 5 - 2 . 8 - 2
.8 5 - 2 .9 - 2 . 9 5 - 3 . 0 0 - 3 .0 5 - 3 . 1 0
3 .1 5 - 3 .2 - 3 . 2 5 - 3 . 3 - 3 .3 5 - 3 . 4 - 3 . 4 5
- 3 . 5 - 3 . 5 5 - 3 . 6 - 3 . 6 5 - 3.7
(in.) ( 0 .0 9 8 4 -0 .1 0 0 4 - 0 .1 0 2 4 -0 .1 0 4 3
0 .1 0 6 3 - 0 .1 0 8 3 -0 .1 1 0 2 -0 .1 1 2 2
0 .1 1 4 2 -0 .1 1 6 1 -0 .1 1 8 1 -0 .1 2 0 1
0 .1 2 2 0 - 0 .1 2 4 0 -0 .1 2 6 0 -0 .1 2 8 0
0 .1 2 9 9 - 0 .1 3 1 9 -0 .1 3 3 9 -0 .1 3 5 8
0 .1 3 7 8 - 0 .1 3 9 8 -0 .1 4 1 7 -0 .1 4 3 7
0 .1 4 5 7 )
J X 8 0 , J X 9 0 and J X 9 5 M o d e ls ........................................... mm 2 .2 - 2 .2 5 - 2 . 3 0 - 2 . 3 5 - 2 .4 0 - 2 . 4 5 - 2 . 5
-2 .5 5 -2 .6 -2 .6 5 -2 .7 -2 .7 5 -2 .8 -2 .8 5
-2 .9 -2 .9 5 -3 .0 0 -3 .0 5 -3 .1 -3 .1 5 -3 .2
- 3 . 2 5 - 3 .3 - 3 .3 5 - 3 . 4
(in.) ( 0 .0 8 6 6 -0 .0 8 8 6 - 0 .0 9 0 6 -0 .0 9 2 5
0 .0 9 4 5 - 0 .0 9 6 5 -0 .0 9 8 4 -0 .1 0 0 4
0 .1 0 2 4 - 0 .1 0 4 3 -0 .1 0 6 3 -0 .1 0 8 3
0 .1 1 0 2 -0 .1 1 2 2 -0 .1 1 4 2 -0 .1 1 6 1
0 .1 1 8 1 - 0 .1 2 0 1 -0 .1 2 2 0 -0 .1 2 4 0
0 .1 2 6 0 - 0 .1 2 8 0 -0 .1 2 9 9 -0 .1 3 1 9
0 .1 3 3 9 )
- T h ic k n e s s o f c ro w n w h e e l p o s itio n a d ju s tm e n t s p a c e r
J X 6 0 and J X 7 0 M o d e ls ......................................................... mm 2 .5 - 2 .6 -2 .7 -2 .8 -2 .9 - 3 .0 0 -3 .1
3 .2 - 3 .3 - 3 . 4 - 3 . 5 - 3 . 6 - 3 . 7
(in.) (0 .0 9 8 4 -0 .1 0 2 4 - 0 .1 0 6 3 -0 .1 1 0 2
0 .1 1 4 2 - 0 .1 1 8 1 1 -0 .1 2 2 0 -0 .1 2 6 0
0 .1 2 9 9 - 0 .1 3 3 9 -0 .1 3 7 8 -0 .1 4 1 7
0 .1 4 5 7 )
J X 8 0 , J X 9 0 and J X 9 5 M o d e ls ........................................... mm 2 .2 - 2 .3 -2 .4 -2 .5 -2 .6 - 2 .7 -2 .8 -2 .9
3 .0 - 3 .1 - 3 . 2 - 3 . 3 - 3 . 4 - 3 . 5
(in.) (0 .0 9 8 4 -0 .1 0 2 4 - 0 .1 0 6 3 -0 .1 1 0 2
0 .1 1 4 2 - 0 .1 1 8 1 1 -0 .1 2 2 0 -0 .1 2 6 0
0 .1 2 9 9 - 0 .1 3 3 9 -0 .1 3 7 8 -0 .1 4 1 7
0 .1 4 5 7 )
- C le a ra n c e b e tw e e n s id e s o f p la n e t and s id e p in io n te e th . m m (in.) 0 .1 5 (0 .0 0 5 9 )
- T h ic k n e s s o f p la n e t p in io n th ru s t w a s h e rs ........................... m m (in.) 1 .4 7 0 - 1 .5 3 0 (0 .0 5 7 9 - 0 .0 6 0 2
- T h ic k n e s s o f s id e g e a r th ru s t w a s h e rs .................................. m m (in.) 1.50 to 1 .60 (0.0591 to 0 .0 6 3 0 )
- D ia m e te r o f c ro s s pin fo r p la n e t p in io n s
J X 6 0 and J X 7 0 M o d e ls ......................................................... m m (in.) 2 1 .9 3 9 - 2 1 .9 6 0 (0 .8 6 3 7 - 0 .8 6 4 6 )
J X 8 0 , J X 9 0 and J X 9 5 M o d e ls ........................................... m m (in.) 2 3 .9 3 9 - 2 3 .9 6 0 (0 .9 4 2 5 - 0 .9 4 3 3 )
- S id e d ia m e te r c ro s s pin b o re d ia m e te r
J X 6 0 and J X 7 0 M o d e ls ......................................................... m m (in.) 2 2 .0 4 0 - 22.961 (0 .8 6 7 7 - 0 .9 0 4 0 )
J X 8 0 , J X 9 0 and J X 9 5 M o d e ls ........................................... m m (in.) 2 3 .9 4 0 - 23.961 (0 .9 4 2 5 - 0 .9 4 3 3 )
- C le a ra n c e b e tw e e n c ro s s pin and b o re s ................................ 0 .0 8 0 - 0 .1 2 2 (0.0031 - 0 .0 0 4 8 )
- D ia m e te r o f o u te r a x le s h a fts and c o rre s p o n d in g b u s h e s
J X 6 0 and J X 7 0 M o d e ls ......................................................... m m (in.) 37.961 - 3 8 .0 0 0 (1 .4 9 4 5 - 1 .4 9 6 1 )
J X 8 0 , J X 9 0 and J X 9 5 M o d e ls ........................................... m m (in.) 43.961 - 4 4 .0 0 0 (1 .7 3 0 7 - 1 .7 3 2 3 )
- In sid e d ia m e te r o f in s ta lle d b u s h e s 0 .7 7 - 0 .8 3 (0 .0 3 0 3 - 0 .0 3 2 7 )
J X 6 0 and J X 7 0 M o d e ls ......................................................... m m (in.) 3 8 .0 8 0 - 3 8 .1 9 9 (1 .4 9 9 2 - 1 .5 0 3 9 )
J X 8 0 , J X 9 0 and J X 9 5 M o d e ls ........................................... m m (in.) 4 4 .0 8 0 - 4 4 .1 1 9 (1 .7 3 5 4 -1 .7 3 7 0 )
- C le a ra n c e b e tw e e n a x le s h a fts and b u s h e s ....................... m m (in.) 0 .0 8 0 - 0 .1 5 8 (0.0031 - 0 .0 0 6 2 )
(continued overleaf)
6-62720 - 09 - 2006
SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 3
MAIN DATA
- T h ic k n e s s o f s te e rin g k n u c k le b e a rin g a d ju s te r p la te s . . . . mm 0 .1 0 - 0 .1 5 - 0 .2 0 - 0 .2 5 - 0 .3 0
(in.) ( 0 .0 0 3 9 -0 .0 0 5 9 - 0 .0 0 7 9 -0 .0 0 9 8
0.0 1 1 8 )
- D rive n g e a r th ru s t w a s h e r th ic k n e s s 0 .7 7 - 0 .8 3 (0 .0 3 0 3 - 0 .0 3 2 7 )
A xle p iv o t
P iv o ttin g a n g le (on e ith e r s id e ) ....................................................... 11o
T u rn in g ra diu s:
(continued overleaf)
6-62720 - 09 - 2006
4 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
TIGHTENING TORQUES
T ig h te n in g to rq u e
PART T h re a d
Nm ft lb
F ro n t axle
L o c k ring, b e ve l p in io n (C-0
S te e rin g kn u c k le c a p s c re w (C 5)
W h e e l h u b b e a rin g s lo c k n u t (C 6):
6-62720 - 09 - 2006
SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 5
(*) S e e p a g e s 2 5 and 2 6 ( * * ) S e e p a g e 27 1
6-62720 - 09 - 2006
6 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
TOOLS
6-62720 - 09 - 2006
SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 7
2
C ro s s -s e c tio n a l vie w o f fro n t axle d iffe re n tia l
6-62720 - 09 - 2006
8 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
3
C ross -s e c tio n a l v ie w o f fro n t axle ste e rin g kn u ckle and h ub
S3 = K ing pin b e a rin g s h im 10. S e a l
C4 = K ing pin b e a rin g ca p s c re w . 11. K ing pin b e a rin g
C5 = S te e rin g k n u c k le ca p s c re w . 12. S e a l
C6 = W h e e l hu b b e a rin g lo ckrin g 13. S e a l
C7 = F in a l d riv e h o u s in g c a p s c re w 14. A x s u le s h a ft b u sh in g
15. S p a c e r
5. W h e e l s h a ft
16. T h ru s t w a s h e rs
9. B e a rin g c a rrie r c a p s c re w
17. P la n e t w h e e l jo u rn a ls
18. P la n e t w h e e l s h im s
19. S u n g e a r
6-62720 - 09 - 2006
SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 9
TRE0416A
H = 1 m m (0 .0 3 9 4 in.) 22. F ro n t th ru s t w a s h e r
L = 1 to 1.5 m m (0 .0 3 9 4 - 0 .0 5 9 0 in.) 23. R e a r th ru s t w a s h e r
S 5 = S le e v e p o s itio n s h im 24. R e a r b u sh in g
25. R e a r a x le p iv o t s u p p o rt
C 9 = A x le p iv o t s u p p o rt c a p s c re w 26. R e ta in in g rin g s
C 10 = D iffe re n tia l b e a rin g c a p ca p s c re w . 27. F ro n t s p lin e d s le e v e
C 11 = C a p s c re w s s e c u rin g fro n t a x le s u p p o rt 28. R e ta in in g rin g s
to e n g in e . 29. D riv e s h a ft g u a rd
20. F ro n t a xle p iv o t s u p p o rt 30. D riv e s h a ft
2 1 . F ro n t b u sh in g
6-62720 - 09 - 2006
10 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
----------- A DANGER A
L ift and h a n d le all h e a v y p a rts u sin g s u ita b le lifting
e q u ip m e n t w ith a s u ffic ie n t liftin g ca p a city.
C h e c k th a t th e a s s e m b lie s o r p a rts a re held firm ly
and s u p p o rte d by s u ita b le s lin g s and h o o ks. M a ke
s u re n o b o d y is s ta n d in g n e a r to th e load.
P ro c e e d as fo llo w s :
6-62720 - 09 - 2006
SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 11
6-62720 - 09 - 2006
12 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
11
8. U n s c re w u n io n s (1) o f th e rigid p ip e s to th e
p o w e r s te e rin g c y lin d e rs and d e ta c h th e tw o
fle x ib le h o se s
12
13
10. U n s c re w th e fro n t a x le re a r s u p p o rt re ta in in g
b o lts (1).
14
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SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 13
15
— F it th e fro n t w h e e ls .
— R a is e th e fro n t o f th e tra c to r u sin g th e h oist.
— R e m o v e th e fix e d s ta n d .
— D e ta ch th e n ylo n c a b le s.
— R e c o n n e c t th e d riv e s h a ft and re fit th e d riv e
s h a ft g u a rd .
— R e fit th e tw o fro n t m u d g u a rd s .
— A tta c h a nylo n c a b le to th e fro n t w e ig h ts , lift, re fit
to th e tra c to r and s e c u re w ith th e lo c k in g s c re w s .
— R e c o n n e c t th e n e g a tiv e b a tte ry lead.
— A d h e re to th e tig h te n in g to rq u e s in d ic a te d on
pag e 4.
6-62720 - 09 - 2006
14 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
FRONT A X LE
R e m o v a l-In s ta lla tio n (Op 25 100 38 )
JX60 and JX70 M odels
17
18
6. R e m o v e s te e rin g k n u c k le (10) w ith w h e e l hub
su p p o rt.
7. R e m o v e a rtic u la te d a x le s h a ft (9) w ith b e a rin g
ho u sin g . B a c k o ff th e c a p s c re w b e fo re w ith d ra w
ing th e a xle s h a ft.
8. R e p la c e w o rn b e a rin g s u sin g s u ita b le p u n c h e s
and u n iv e rs a l p u lle rs. C h e c k s e a l e fficie n cy.
19
20
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SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 15
A WARNING A -----------
H a n d le all p a rts w ith ca re .
D o n o t in s e rt h a n d s o r fin g e rs b e tw e e n o n e p a rt and
a n o th e r. W e a r s u ita b le s a fe ty c lo th in g , i.e. s a fe ty
g o g g le s , g lo v e s and s h o e s .
21
22
2. U n s c re w plug (1) on th e le ft- h a n d e p ic y c lic fin a l
d riv e c a sin g . R e p e a t th is o p e ra tio n on th e
rig h t-h a n d c a sin g .
23
24
6-62720 - 09 - 2006
16 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
25
26
6. R e m o v e th e c irc lip s (2) fro m th e c y lin d e r rod
p iv o t pins, u n s c re w th e pin re ta in in g b o lts o f th e
c y lin d e r (1), w ith d ra w th e p in s and d e ta c h th e
tw o cylin d e rs .
R e trie v e th e fo u r pins, w a s h e rs , s p a c e rs and
c y lin d e rs , c o m p le te w ith h o se s.
27
28
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SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 17
31
32
6-62720 - 09 - 2006
18 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
33
34
35
36
6-62720 - 09 - 2006
SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 19
16. U n s c re w th e a x le s h a ft re ta in in g b o lt and re m o v e
th e a xle sh a ft.
37
38
39
40
6-62720 - 09 - 2006
20 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
41
42
23. R e m o v e th e fro n t b ra k e h u b g e a r (1)
43
44
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SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 21
45
46
27. R e m o v e th e c ro w n w h e e l--d iffe re n tia l a s s e m b ly
(2) fro m th e h o u s in g (1).
47
48
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22 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
49
50
51
32. W ith d ra w th e b e ve l d riv e p in io n s h a ft (1) fro m th e
re a r o f th e ca s in g and re c o v e rth e sp a c e r, th e a d
ju s tm e n t s h im s and th e b e a rin g .
52
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SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 23
6-62720 - 09 - 2006
24 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
In th e e v e n t th a t th e s te e rin g k n u c k le p in s p ro ve
d iffic u lt to re m o v e , p ro c e e d as fo llo w s .
1. R e m o v e th e g re a s e n ip p le s and th e s te e rin g
k n u c k le pin re ta in in g b olts.
2. F it th e b o lts (1) o f to o l 380000265 .
3. F it th e p la te (2) o f th e to o l and fix it to th e th re e
b o lts w ith n u ts (5).
4. F it th e c e n tra l tie b o lt (4) s c re w in g it fu lly into th e
g re a s e n ip p le b o re on th e pin (6).
5. S c re w in th e n u t (3) to d riv e th e pin o u t o f its bore.
54
55
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SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 25
STUB A X LE AD JU STM EN T
1. S m e a r g re a s e A K C E L A M ULTI-PURPO SE
GREASE on th e o u te r ra c e s o f th e b e a rin g s and
fit th e u p p e r co ve r, w ith o u t th e a d ju s tm e n t plate,
b u t w ith to o l 380000235 (2). T ig h te n th e re ta in
ing b o lts (C 5, p a g e 5) to th e fo llo w in g to rq u e
va lu e s:
J X 6 0 and J X 7 0 64 Nm
(4 7 .2 0 4 0 ft lb)
J X 8 0 , J X 9 0 and J X 9 5 113 N m
(8 3 .3 4 4 5 ft lb)
56
2. F it th e lo w e r c o v e r w ith o u t th e a d ju s tm e n t pla te
and lu b ric a te th e th re e re ta in in g b o lts w ith
e n g in e oil.
3. G ra d u a lly tig h te n th e lo w e r c o v e r b o lts in
s e q u e n c e , w h ile s im u lta n e o u s ly ro ta tin g th e
c a sin g to a llo w e x c e s s g re a s e to e s c a p e .
57
4. U sin g a to rq u e w re n c h and to o l 380000235 (1),
c h e c k th a t th e to rq u e re q u ire d to ro ta te th e
ca sin g (ig n o rin g th e in itia l to rq u e ) is as fo llo w s :
m o d e ls J X 6 0 and J X 7 0 2 .9 N m
(2 .1 3 8 9 ft lb)
(w ith to rq u e in c re m e n t o f 0 .9 8 N m - 0 .7 2 2 8 ft lb)
J X 8 0 , J X 9 0 and J X 9 5 15 - 2 5 N m
(1 1 ,0 6 3 4 - 1 8 .4 3 9 0 ft lb)
If th e re c o rd e d to rq u e is n o t as s p e c ifie d , a d ju s t
by w a y o f th e lo w e r c o v e r b olts.
5. M e a s u re th e g a p (H ) c re a te d b e tw e e n th e lo w e r
c o v e r and th e c a s in g a d ja c e n t to e a ch o f th e
th re e bolts. 58
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26 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
6. C a lc u la te th e a v e ra g e o f th e th r e e v a lu e s
m e a s u re d . T h e to ta l th ic k n e s s o f th e a d ju s tm e n t
s h im s (p a g e 8 ) to b e fitte d u n d e r th e lo w e r
c o v e r is to b e c a lc u la te d a s fo llo w s :
JX 60 and JX 7 0 S 3= H
JX 80, JX 9 0 and JX 9 5 S 3 = H - 0.20 mm
(0.0079 in .)
If n e c e s s a ry , ro u n d u p th e v a lu e to th e n e x t
0 .0 5 m m (0 .0 0 2 0 in .).
JX 60 and JX 7 0 64 Nm
(4 7 .2 0 4 0 ft lb)
JX 80, JX 9 0 and JX 9 5 113 N m
(8 3 .3 4 4 5 ft lb)
8. A f te r h a v in g ro ta te d th e c a s in g a fe w tim e s to
a llo w th e c o m p o n e n ts to b e d d o w n , c h e c k th a t
th e to r q u e n e c e s s a ry to r o ta te th e c a s in g
(ig n o rin g th e in itia l to r q u e ) is fo llo w s : 59
J X 6 0 a n d J X 7 0 2 .9 - 7 .8 N m
(2 .1 3 8 9 - 5 .7 5 3 0 ft lb)
9. If th e to r q u e v a lu e m e a s u r e d is g r e a te r th a n th e
p re s c rib e d v a lu e , in c re a s e th e th ic k n e s s o f th e
s h im s . If th e m e a s u r e d v a lu e is le s s th a n th e
p re s c rib e d v a lu e , r e d u c e th e th ic k n e s s o f th e
s h im s .
10. F it th e g r e a s e n ip p le s in th e u p p e r a n d lo w e r
c o v e rs a n d g r e a s e th e a s s e m b ly .
6-62720 - 09 - 2006
SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 27
P ro c e e d a s fo llo w s :
- In s ta ll w h e e l h u b a n d fix e d g e a r u n it o n to th e
s te e rin g k n u c k le ;
- U s in g a to r q u e w r e n c h a n d lo c k rin g w re n c h
380000616 (fo r JX 60 and JX 70 m o d e ls )
p ro g r e s s iv e ly tig h te n th e rin g n u t (C6, p a g e 8)
to 1 4 7 - 1 9 6 N m ( 1 5 - 2 0 k g m ). W h ile tig h te n
in g th e rin g n u t, r o ta te th e h u b to s e ttle t h e b e a
60
rin g s .
- S e c u re th e lo c k rin g b y b e n d in g o v e r a lo c k -
w a s h e r ta b ( if n e c e s s a ry , fu r t h e r tig h te n th e
lo c k rin g to a lig n a s lo t w ith th e ta b )
- T u rn th e h u b b y h a n d to c h e c k f o r e x c e s s iv e
p la y o r b in d in g .
- C a r e fu lly s e c u r e th e rin g n u t.
6-62720 - 09 - 2006
28 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
-- P r o g r e s s iv e ly tig h te n th e rin g n u t, u s in g th e
to r q u e w r e n c h a n d w r e n c h 380000269 (1 ) to o b
ta in a to r q u e v a lu e o f 3 9 2 N m ( 2 8 9 .1 2 4 3 2 ft lb);
a t th e s a m e tim e , r o ta te th e w h e e l h u b to e n s u re
t h a t th e b e a rin g s a re c o r r e c tly s e a te d .
- M e a s u re th e ro llin g re s is ta n c e (R t) o f t h e w h e e l
h u b u s in g th e r e la tiv e to r q u e w r e n c h , o r a to r q u e
m e te r a n d c o rd p o s itio n e d o n th e b a s e o f th e
w h e e l d is k fla n g e .
61
- L o o s e n th e rin g n u t b y h a lf a tu rn a n d m e a s u r e
th e ro llin g re s is ta n c e (R ) as d e s c rib e d
p re v io u s ly . The d iffe re n c e b e tw e e n th e tw o
m e a s u r e m e n ts is th e ro llin g to r q u e v a lu e o f th e
w h e e l h u b b e a rin g s (R c ):
- R c = R t - R = 5 .9 + 1 4 .7 N m ( 4 .3 5 1 6 + 1 0 .8 4 1 6
ft lb ) o r if m e a s u re d w ith a to r q u e m e te r.
R c = R t - R = 7 .5 + 1 8 .7 5 kg (4 1 .3 5 5 4 lb).
- If th e m e a s u re m e n t is le s s th a n 5 .9 Nm
(4 .3 5 1 6 ft lb ) o r w ith th e to r q u e m e te r o n 4 .8 kg
(1 0 .5 8 7 0 lb ) it is n e c e s s a r y to re p la c e th e a f
fe c te d p a rts a n d re p e a t th e c h e c k .
-- P r o g r e s s iv e ly tig h te n th e rin g n u t, u s in g th e
to r q u e w r e n c h an d w re n c h 380000269 (1 ) to
o b ta in a to r q u e v a lu e o f 3 9 2 N m ( 2 8 9 .1 2 4 3 2 ft
lb ); a t th e s a m e tim e , r o ta te th e w h e e l h u b to
e n s u re t h a t th e b e a rin g s a re c o r r e c tly s e a te d .
-- C a r e fu lly s e c u r e th e rin g n u t.
6-62720 - 09 - 2006
SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 29
Proceed as follows. 61
62
63
64
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30 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
6-62720 - 09 - 2006
SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 31
E xam ple 1:
- D is ta n c e m e a s u r e d u s in g m ic r o m e te r H 5 = 1 0 3 .3
m m ( 4 .0 6 6 9 in .).
- N o m in a l d is ta n c e b e tw e e n c ro w n w h e e l a x is a n d
la rg e d ia m e te r b a s e o f p in io n H4 = 100 m m
(3 .9 3 7 0 in .).
-- C o rr e c tio n v a lu e C = + 0 ,2 m m (0 .0 0 7 9 in .).
- C o r re c te d n o m in a l d is ta n c e H 5 = 1 0 0 + 0 .2 =
1 0 0 .2 m m (3 .9 3 7 0 + 0 .0 0 7 9 = 3 .9 4 4 9 in .).
-- T h ic k n e s s o f a d ju s tm e n t s h im
S 2 = 1 0 3 .3 - 1 0 0 .2 = 3.1 m m (4 .0 6 6 9 - 3 .9 4 4 9
= 0 .1 2 2 0 in .).
E xam ple 2:
- D is ta n c e m e a s u r e d u s in g m ic r o m e te r H 3 = 1 0 3 .3
m m ( 4 .0 6 6 9 in .).
- N o m in a l d is ta n c e b e tw e e n c ro w n w h e e l a x is a n d
la rg e d ia m e te r b a s e o f p in io n H6 = 100 m m
(3 .9 3 7 0 in .).
- C o rr e c tio n v a lu e C = - 0 .2 m m ( 0 .0 0 7 9 in .).
- C o r re c te d n o m in a l d is ta n c e H 7 = 1 0 0 - 0 .2 =
9 9 .8 m m (3 .9 3 7 0 - 0 .0 0 7 9 = 3 .9 2 9 1 in .).
-- T h ic k n e s s o f a d ju s tm e n t s h im
S 2 = 1 0 3 .3 - 9 9 .8 = 3 .5 m m (4 .0 6 6 9 - 3 .9 2 9 1 =
0 .1 3 7 8 in .).
E xam ple 3:
- D is ta n c e m e a s u r e d u s in g m ic r o m e te r H 3 = 1 0 3 .3
m m ( 4 .0 6 6 9 in .).
- N o m in a l d is ta n c e b e tw e e n c ro w n w h e e l a x is a n d
la rg e d ia m e te r b a s e o f p in io n H4 = 100 m m
(3 .9 3 7 0 in .).
- C o rr e c tio n v a lu e C = 0 m m (0 in .).
- C o r re c te d n o m in a l d is ta n c e H 5 = H 6 = 1 0 0 m m
(3 .9 3 7 0 in .).
-- T h ic k n e s s o f a d ju s tm e n t s h im
S 2 = 1 0 3 .3 - 1 0 0 = 3 .3 m m ( 4 .0 6 6 9 - 3 .9 3 7 0 =
0 .1 2 9 9 in .).
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32 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
P ro c e e d a s fo llo w s .
6. U n s c re w th e rin g n u t a n d fit th e s e a l a n d th e
re la tiv e d u s t s e a l rin g . T ig h te n th e n u t to a
to r q u e v a lu e o f 2 9 4 N m ( 2 1 6 .8 4 3 5 2 ft lb ) w h ile 69
s im u lta n e o u s ly ro ta tin g th e p in io n s h a ft to
e n s u re t h a t th e b e a rin g s a re s e a te d c o rre c tly .
6-62720 - 09 - 2006
SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 33
8. In s ta ll th e d iffe re n tia l u n it in th e c a r r ie r e n s u
rin g t h a t rin g g e a r is n o t fo rc e d o n to th e p in io n .
T ig h te n s c r e w s ( C 10) to 5 9 N m (4 3 .5 1 6 2 ft lb)
th e n s la c k e n a n d r e tig h te n to 2 0 N m ( 1 4 .7 5 1 2
ft lb).
70
10. U s in g w r e n c h (1 ) 380000252 , f o r J X 6 0 o r
J X 7 0 m o d e ls , o r w r e n c h 380000253 , f o r J X 8 0 ,
J X 9 0 o r J X 9 5 m o d e ls , c h e c k t h a t t h e to r q u e is
3 9 to 5 9 N m (2 8 .7 6 4 9 to 4 3 .5 1 6 2 ft lb ) to
e s ta b lis h th e s p e c ifie d a x ia l p r e - lo a d .
11. M e a s u re b e v e l d r iv e b a c k la s h (1, fig . 7 2 ) u s in g
a d ia l g a u g e p o s itio n e d a t rig h t a n g le s to a
b e v e l g e a r to o th .
12. R e p e a t th e m e a s u r e m e n t a t tw o o th e r e q u id i
s ta n t p o in ts , 1 2 0 ° a p a rt. C o m p a re t h e a v e ra g e
of th e th r e e r e a d in g s w ith th e s p e c ifie d
b a c k la s h o f 0 .1 5 - 0 .2 0 m m (0 .0 0 5 9 - 0 .0 0 7 9
in .) (a v e ra g e 0 .1 8 m m (0 .0 0 7 1 in .)).
71
13. If th e m e a s u re d b a c k la s h e x c e e d s t h e p r e s c r i
b e d v a lu e , fit a t h in n e r a d ju s tm e n t s h im .
72
6-62720 - 09 - 2006
34 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
S = Sp + {(0.18 - G m ) x 1.35}
w h e re :
Sp = th ic k n e s s o f te s t s h im in s ta lle d in th e b e v e l
d r iv e - d iff e r e n t ia l h o u s in g .
Gm = a v e ra g e b a c k la s h m e a s u r e d b e tw e e n th e
s id e s o f th e te e th o f t h e b e v e l d riv e .
15. F it a s h im o f th e c a lc u la te d th ic k n e s s a n d w ith a
1 /1 0 0 s c a le d ia l g a u g e p o s itio n e d p e r p e n d ic u la r
to th e o u ts id e e d g e o f o n e o f th e c ro w n w h e e l
te e th , c h e c k t h a t th e b a c k la s h b e tw e e n th e
p in io n a n d th e c ro w n w h e e l is w ith in th e p re
s c rib e d to le r a n c e lim its 0 .1 5 * 0 .2 0 m m (0 .0 0 5 9
to 0 .0 0 7 9 in .).
16. U s in g w r e n c h 380000252 , f o r J X 6 0 o r J X 7 0
m o d e ls , o r w r e n c h 380000253 , f o r J X 8 0 , J X 9 0 o r
J X 9 5 m o d e ls , tu r n th e a d ju s te r rin g n u t a n d ,
u s in g w r e n c h 380001633
to r q u e fitte d on
w re n c h 380000257 (1, fig . 7 3 ), c h e c k t h a t th e
ro llin g re s is ta n c e to r q u e o f th e c ro w n w h e e l a n d
p in io n b e a rin g s , as m e a s u re d in th e sam e
c o n d itio n s u s e d to c h e c k o n ly th e p in io n , is:
73
17. T ig h te n th e c a p b o lts (C 1 , p a g e 4 ) to a to r q u e
o f 113 N m (8 3 .3 4 4 5 ft lb).
18. F it th e s a fe ty p la te s , s c re w in g th e a d ju s tm e n t
rin g n u t in o r o u t, to re a c h th e n e a re s t n o tc h .
74
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SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 35
T h e ty p e s o f m a s tic to u s e a re lis te d o n p a g e 1 o f
s e c tio n 0 0 .
75
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36 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
FRONT A X LE DIFFERENTIAL
O verhaul (Op. 25 102 2 4 )
Proceed as follows:
76
6. Repeat the above operations to measure the
endfloat on the right-hand side gear (Gd).
The endfloat should be 0.25 m m (0.0098 in.).
Therefore the shims to be inserted in the differ
ential housing are given by:
Ss = Gs - 0.25 m m (0.0098 in.) fo rth e left-hand
side gear;
Sd = Gd - 0.25 m m (0.0098 in.) for the right-
hand side gear.
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SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 37
2. R e m o v e th e b o lts (2 ) a n d th e le f t - and
r ig h t - h a n d rin g n u t Io c k p la te s (3 ).
3. C h e c k t h a t th e rig h t a n d I e f t- h a n d c a p s (1 ) a re
c le a rly m a rk e d , s o a s n o t to m ix th e p a rts d u rin g
re a s s e m b ly .
4. R e m o v e th e le f t - a n d r ig h t - h a n d b e a rin g
a d ju s tm e n t rin g n u ts (G d ) fr o m th e c ro w n w h e e l.
5. R e m o v e th e b o lts (C g ), s e c u rin g th e c a p s (1)
a n d s e p a r a te th e c ro w n w h e e l fr o m th e b e v e l
79
p in io n s u p p o r t.
6. If n e c e s s a ry , u n s c re w th e re ta in in g b o lts (C 3 ,
p a g e 4 ) a n d re m o v e th e c ro w n w h e e l.
6-62720 - 09 - 2006
38 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
80
6-62720 - 09 - 2006
SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 39
82
S e ctio n th ro u g h d iffe re n tia l w ith NO -SPIN u n it
C 1 = C a s e c a p s c re w , tig h te n in g to r q u e 5 6 to 6 2 N m (4 1 .3 0 3 4 to 4 5 .7 2 8 8 ft lb)
6-62720 - 09 - 2006
40 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
NOTE:
- R e p e a t th e a b o v e o p e r a tio n s w h ile h o ld in g th e c u rv e .
R .H . w h e e l.
o p e r a t io n
NOTE: F o r c o r r e c t NO SPIN d iffe re n tia l o p e ra tio n ,
The NO SPIN d iffe re n tia l p e rfo rm s th e fo llo w in g k e y ty r e s m u s t b e e q u a l (w ith in a fe w m illim e tre s ) in
fu n c tio n s : ro llin g c ir c u m fe r e n c e . S m a ll d iffe re n c e s m ay be
c o r re c te d b y a d ju s tin g ty r e in fla tio n p re s s u re . To
- P e rm its fu ll u s e o f t r a c t o r p u ll. c h e c k th e ro llin g c ir c u m fe r e n c e o f a ty re , p ro c e e d a s
fo llo w s :
- P re v e n ts w h e e l- s p in w hen one wheel Io s e s
tra c tio n . W ith th e t r a c t o r o n a h a rd , le v e l s u rfa c e , m a r k th e
e d g e o f th e ty re , w ith c h a lk , a t th e lo w e s t p o in t
- C o m p e n s a te s f o r d iffe re n c e s in w h e e l tr a v e l
(w h e r e it c o n ta c ts th e g ro u n d ) . M a r k th e g ro u n d a t
w h ic h occur w hen tu r n in g o r tr a v e lin g over
th e s a m e s p o t.
u n e v e n g ro u n d .
M o v e th e t r a c t o r fo rw a rd s o t h a t th e ty r e ro ta te s
e x a c tly o n e re v o lu tio n , i.e ., w h e n th e c h a lk m a r k on
th e ty r e c o n ta c ts th e g ro u n d a g a in . M e a s u r e th e
d is ta n c e tra v e lle d . T h is is th e ro llin g c ir c u m fe r e n c e
o f th e ty re .
R e p e a t o n th e o p p o s ite w h e e l to c h e c k t h a t b o th
ty r e s h a v e th e s a m e ro llin g c ir c u m fe r e n c e .
6-62720 - 09 - 2006
SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 41
WARNING
H a n d le a ll p a rts w ith c a re fu lly . D o n o t p u t y o u r h a n d s
o r fin g e r s b e tw e e n p a r ts .W e a r s u ita b le s a fe ty c lo
th in g , s a fe ty g o g g le s , g lo v e s a n d fo o tw e a r.
1 . R e m o v e th e b e v e l d r iv e - d iff e r e n t ia l c a s in g
a s s e m b ly fr o m th e fr o n t a x le a n d a tta c h to th e
s u p p o r t 380000255 (4 ). L o c k th e s u p p o r t in a v ic e
a n d p ro c e e d w ith d is a s s e m b ly , a s fo llo w s .
2. R e m o v e th e b o lts (2 ) and th e left-- and
r ig h t - h a n d rin g n u t Io c k p la te s (3 ).
3. C h e c k t h a t th e rig h t a n d I e f t- h a n d c a p s (1 ) a re
c le a rly m a rk e d , s o a s n o t to m ix th e p a rts d u rin g
re a s s e m b ly .
4. R e m o v e th e le f t - a n d r ig h t - h a n d b e a rin g
a d ju s tm e n t rin g n u ts (G d ) fr o m th e c ro w n w h e e l.
8. O p e n th e d iffe re n tia l c a s in g
9. R e m o v e th e c e n tra l d riv e n (7 ), re ta in in g th e
d iffe re n tia l h a lf -- c a s in g .
10. P r o c e e d w ith s e lf- lo c k in g th e d iffe ra n tia l
a s s e m b ly o p a r a tio n s , c a rry in g o u t th e p re v io u s ly
d e s c ir ib e d o p e r a tio n s in re v e r s e o r d e r T ig h te n th e
b o lts ( C i, fig . 8 4 ) to r g u e v a lu e o f 5 6 - 6 2 N m
( 4 1 .3 0 3 4 - 4 5 . 7 2 8 8 ft lb)
6-62720 - 09 - 2006
42 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
W h e n tr a v e llin g fo rw a rd in a s tr a ig h t p a th , th e w h e e ls
o f f o u r - w h e e l d riv e tr a c to r s m u s t b e p a ra lle l to th e
lo n g itu d in a l a x is o f th e tra c to r, a lte r n a tiv e ly a s lig h t
t o e - in o f th e fr o n t w h e e ls is p e r m is s ib le u p to a m a x i
m u m o f 6 m m ( 0 .2 3 6 2 in .) a s m e a s u re d a t t h e e d g e s
o f t h e w h e e l rim s .
To c h e c k th e e x a c t v a lu e o f th e t o e - in s e ttin g o f f o u r -
w h e e l d riv e tr a c to r s , p ro c e e d a s fo llo w s .
1. In fla te th e fr o n t t y r e s to th e p re s c rib e d p re s s u re .
3. C heck th a t th e w h e e ls a re p a ra lle l to th e
lo n g itu d in a l a x is o f th e tra c to r.
4. M a k e a c h a lk m a r k o n th e fro n t in s id e e d g e s o f
b o th w h e e l rim s , a t th e h e ig h t o f t h e w h e e l h u b
c e n tre s . M e a s u re th e d is ta n c e (1 ) b e tw e e n th e
c h a lk m a rk s .
5. M ove th e t r a c t o r fo r w a rd to tu rn b o th fr o n t
w h e e ls th r o u g h 1 8 0 o . T h e c h a lk m a r k s w ill n o w
b e m e a s u re b e tw e e n t h e rear in s id e e d g e s o f th e
wheel rim s a t th e h e ig h t o f th e w heel hub
c e n tre s . M o w m e a s u re t h e d is ta n c e (2 ) c h e c k in g
t h a t t h is n e w m e a s u r e m e n t is e q u a l to o r g r e a te r
th a n th e d is ta n c e (1 ) b y a m a x im u m o r 6 m m .
T h e ro ta tio n o f th e w h e e ls t h r o u g h 1 8 0 o is n e c e s s a r y
to e lim in a te th e e ffe c t o f w e a r, m is a lig n m e n t o r
d is to rtio n o f th e w h e e l rim s o n th e m e a s u r e m e n ts
o b ta in e d .
6. If it is n e c e s s a r y to c o r r e c t th e w h e e l a lig n m e n t,
re m o v e n u t (2 ) a n d p u ll th e tr a c k ro d e n d (1 ) o u t
o f its h o u s in g . S la c k e n o f f lo c k n u t (3 ) a n d s c r e w
th e t r a c k ro d e n d (1 ) in o r o u t to in c r e a s e o r
d e c r e a s e th e d is ta n c e (2 ) fig . 8 4 .
R e p o s itio n th e t r a c k ro d e n d (1 ) in its h o u s in g
a n d r e - c h e c k a lig n m e n t a s d e s c rib e d in p o in ts 4
and 5 above.
A f te r h a v in g a d ju s te d th e a lig n m e n t to w ith in th e
p re s c rib e d lim its , tig h te n lo c k n u t (3 ) to a to r q u e
o f 1 8 0 N m ( 1 3 4 . 9 7 3 8 f t lb ) a n d n u t (2 ) to 1 0 0
N m ( 7 3 .7 5 6 2 f t lb ).
NOTE: T h e s e lf- lo c k in g n u t (2 ) m u s t b e r e n e w e d
e a c h tim e it is r e m o v e d o r p a r tia lly u n s c re w e d . 85
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 1
SECTION 27 - REAR AXLE AND TRANSMISSION
CONTENTS
6-62720 - 09 - 2006
2 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
Adjusting ring bevel gear bearings and bevel gear pair coupling
clearance ....................................................................................... see page 181
Adjusting clearance between pinion and side gear teeth . . . . see page 185
11:67=1:6.1
Reduction ratio ............................................................................... 11:62= 1:5.6 (for JX80-JX90)
11:68=1:6.2
(for JX95)
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 3
Torque settings
PART TO BE TIGHTENED Thread
Nm ft lb
Retaining bolts for rear transmission/gearbox upper cover (C-i) . . . M 10 x 1.25 59 43.5161
Bolts for securing lift to rear transmission box (C2) ...................... M 12 x 1.25 98 72.2811
Bolts for securing PTO box to transmission / gearbox case (C3) M 16 x 1.5 221 163.0012
Bolts for securing torsion bar to transmission / gearbox case (C4) M 16 x 1.5 221 163.0012
Drive wheel hub to disc retaining nuts (C6) .................................... M 18 x 1.5 255 188.0783
Drive wheel rim to disc retaining nuts (C7) .................................... M 16 x 1.5 245 188.7027
Ring bevel gear retaining bolts (C3) ................................................ M 12 x 1.25 123 90.7201
Bevel drive - differential support retaining self-locking bolts (Cg) M 10 x 1.25 59 43.5161
Final drive casing cover retaining bolts (C 10) ................................ M 10 x 1.25 59 43.5161
Nuts for drive wheel ballast ring retaining bolts ............................ M 14 x 1.5 98 72.2811
6-62720 - 09 - 2006
4 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
SECTIONAL VIEWS
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 5
6-62720 - 09 - 2006
6 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
26259
Tool to make for adjusting the assembly position of the bevel pinion shaft
(Mark tool with no. 50004 - Measurements in mm)
Make using Aq 45 material.
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 7
1. Mid-range and reverse gear control rod 13. Range engagement safety pawl.
2. Slow and fast gear control rod. 14. Plug.
3. 1st and 2nd gear control rod. 15. Reverse gear support pin.
4. Detent balls. 16. Retaining bolt.
NOTE: Screw in plugs 12 and 14 using one of the sealing compounds listed on page 1, Section 00.
6-62720 - 09 - 2006
8 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
NOTE: During installation, apply sealing compound to surfaces X as shown in Section 00, Chapter 1, page 1.
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 9
The rear transmission transmits power from the Final drives are of the pinion type and are controlled
gearbox to the lateral final drives by means of the by the bevel gear pair output half-shafts, the same
bevel gear pair. The bevel gear pair is of the helical shafts that control the footbrakes.
tooth type and is supported by taper-roller bearings.
The differential has two pinions and is equipped with When the differential lock is not in use, it is kept dis
a mechanically controlled differential lock. engaged by a spring that exerts a force on the fork.
Transmission noisy while the trac 1. Incorrect adjustment of bevel Remove the rear transmission box
tor is moving, even when the gear pinion and / or ring bevel gear and adjust the pinion and ring bevel
box is in neutral (not arising from bearings. gear bearings correctly (page 36).
final drives).
Transmission noisy when tractor 2. Excessive clearance between Remove the rear transmission box
ia operated with or without load. pinion and ring gear teeth. and correctly adjust the pinion and
ring gear bearings (page 36).
Differential repeats noise within 3. An internal component is bro Remove the rear transmission box,
short intervals. ken or defective. replace the worn parts and correctly
adjust the differential gear clearance
(page 39).
Transmission noisy and assembly 4. Pinion and / or ring gear Remove the rear transmission box
overheats. bearing clearances insuffi and correctly adjust the pinion and
cient. ring bevel gear bearings (page 36).
6-62720 - 09 - 2006
10 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 11
10
11
6. Remove the socket (1) with its cable that passes
from the instrument panel and over the gearbox
to the rear fender.
12
7. Remove the support bolt (1) from the injection
pump and disconnect the hand and foot throttle
cables.
13
6-62720 - 09 - 2006
12 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
10. Remove the filter line (1) and pressure pipe (2)
from hydraulic pump.
17
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 13
19
14. Remove the compressor retaining bolts (1) and
take out the earth connection.
20
15. Move the disconnected compressor (1), con
denser (2) Fig. 19 and filter/dryer, together with
flexible hoses and valves, onto the platform.
6-62720 - 09 - 2006
14 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
22
23
18. Using an Allen key, unscrew the plug (1) and
drain the fuel tank using a suitable container
(Choose a container taking into consideration
the tank capacity of 90 litres (19.7879 gall. Imp.).
25
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 15
20. Remove the bolts (1) and (2) from steel support
bracket beneath the fuel tank.
26
27
22. Rest the front edge of the fuel tank on the
ground.
28
23. Loosen the clamps and remove the inlet (1) and
return (2) pipes from the fuel tank. Remove the
fuel tank completely.
29
6-62720 - 09 - 2006
16 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
24. Remove the pin (1) and remove the clutch pedal
cable from the upper surface of the cab/platform.
30
31
32
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 17
33
34
29. Pull up the plastic boot, remove the retaining bolt
(1) and take out the reverser control lever.
35
30. Unscrew the retaining bolts (1) and remove the
main and range gear selector levers.
36
6-62720 - 09 - 2006
18 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
38
33. Remove the retaining pins (1) and take out the
auxiliary hydraulic valve control rods.
39
34. Disconnect the auxiliary valve nuts (1) from their
pipes.
40
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 19
41
36. Remove the Lift-o-maticTM control cable (1)
from the lever and from its mounting (2).
42
37. Remove the retaining pin (2) from the bottom and
the support bracket bolts (1) from the top of the
hydraulic lift control rod. Remove the left- and
right-hand lift rods.
43
38. Remove the bolt (1) that secures the gearbox
breather pipe clamp.
44
6-62720 - 09 - 2006
20 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
39. Remove the bolt (1) that secures each side of the
front supports to the cab/platform.
45
40. Remove four bolts (1) that secure the rear of the
cab/platform to each end of the axle casing.
46
41. Attach the lifting bar to the lifting rings on the left
and right side of the cab roof. Take all necessary
precautions to prevent to prevent damaging the
structure by using supports, where required.
Raise the cab a little and check that there are no
forgotten parts that will prevent the cab from
being lifted further. If satisfactory, complete the
lifting operation.
47
42. Attach two hooks to the signal support bar at the
front and clamp the lifting tool to the roll-bar at
the rear.
48
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 21
51
46. Unscrew the drive shaft centre support bolts (1)
and remove the shaft complete with support.
6-62720 - 09 - 2006
22 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
53
54
49. Disconnect the trailer brake control pipe (1) and
the auxiliary valve pipes from the support plate
(2).
55
50. Connect a chain to one of the final drive
assemblies and remove it from the
transmission-gearbox case. Repeat on the
other side.
56
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 23
60
6-62720 - 09 - 2006
24 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
56. Unscrew the bolt (1) and remove the internal oil
tank (2) from the rear transmission case.
63
6-62720 - 09 - 2006
SECTION
27 - REAR AXLE AND TRANSMISSION
- CHAPTER
6-62720 - 09 - 2006
1
Diagram for application of sealing compound to the rear transmission-gearbox casing 64
The types of sealing compound to be applied are listed on page 1 o f Section 00. kj
Ol
26 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
58. Refit the rear transmission-gearbox case as Fit the rear wheels and remove stand
follows: 380000326.
— For the correct orientation of the various parts, Lower the cab onto the transmission casing and
refer to the illustrations on pages 10 to 26. secure using the retaining bolts.
— Fit the torion bar support complete with internal Connect the PTO speed selection cable.
connecting rod.
Connect the synchronised PTO control lever.
— Position the left and right brake friction discs. Fit
Connect the auxiliary hydraulic valve control
the brake assembly, and the lateral final drive
levers.
assembly.
Fix the fuel tank together with fixing brackets,
— Refit the PTO cover to the transmission-gearbox
mountings and rear transmission-gearbox
case.
breather pipes.
— Fit the internal tank complete with oil discharge Connect the pipes and connections to the fuel
pipe. tank.
— Fit the lower links and spacers. Refit and secure the compressor, the condenser
and the filter/dryer.
— Fit the tow hook assembly.
Connect and secure the heater control pipes.
— Re-install the hydraulic lift complete.
Connect the gearbox clutch control rod.
— Insert the springs and poppet balls and fit the
gearbox and final drive control rod support cover Connect the front service brake feed and control
to the rear transmission-gearbox case. pipes.
— Fit and connect the lift control and oil filler pipes. Connect the throttle control cable.
— Fit the three-point linkage support together with Make good all electrical socket connections
the quick-release fitting support plate and elec between the cab and the tractor body.
trical power sockets with related connectors.
Connect up the front headlights.
— Fit the trailer brake valve complete with hydraulic Screw in the engine cooling system drain plug.
valves. Fit and connect the auxiliary hydraulic
valve and trailer brake valve pipes. Fill up the fuel tank, the rear transmission-
gearbox case and the cooling system.
— Fit and connect all the hydraulic pump inlet and Recommended products and quantities are
outlet pipes and the connection pipes to the given on page 6 of Section 00.
auxiliary hydraulic valves, hydraulic lift, 4WD
transfer box, etc. Connect the negative terminal to the battery.
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 27
2
3. Turn the box back 180°, then use a punch to
remove the roll pins (1) and take out the rods, the
prongs, the gearbox and final drive control forks.
3
4. Use a punch to remove the roll pin (2) retaining
the differential lock engagement fork (1).
Withdraw the rod (4) and remove the helical
spring (3) and the fork.
6-62720 - 09 - 2006
28 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
6
8. Extract the internal lever (2) complete with spring
(1) and sliding block (3).
7
9. Straighten out the notches and undo the driven
shaft locking nut (1).
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 29
10. Remove from the rear the snap ring (1) that
retains the final drive driving shaft bearing.
9
11. Using a hammer and a brass punch (1) withdraw
the gear (2) for the mid-range speeds together
with the related bearings and engagement
sleeve (3).
10
12. Withdraw the final drive driving shaft (1).
11
13. Remove the snap ring (1) that holds the bearing
(2) onto the gearbox drive shaft.
12
6-62720 - 09 - 2006
30 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
14. Fit the tool 50006 (2) (see page 4, Section 21,
Chapter 1) onto the driving shaft and use the
extractor (1) to withdraw the driving shaft.
Remove the bearings, gears and respective
bushings.
25797 .4fK^ ^
14
16. Screw the adapter 380000838 (2) onto the slide
hammer 380000549 (1) to move the bevel pinion
by a few millimetres in the direction shown by the
arrow.
15
17. Move the engagement sleeve (1) until it is
possible to gain access with pliers (2) to remove
the retaining snap ring.
16
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 31
17
19. Undo the bolts (3), take out the support plate (1)
and remove the bearing (2).
18
19
6-62720 - 09 - 2006
32 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
20
24. Turn the box by 90°, fit the front bearing (1) and
the nut (2) and tighten to the prescribed torque.
21
25. Fit the bearing (2) in its housing on the box (front
end) and lock it using the plate (1).
22
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 33
26. Insert the gear shift forks (1) and (3) on the
sliding rings (2) and (4) of the synchronisers.
27. Fit the bevel pinion complete with all the parts
and carry out the adjustments given on pages 37
to 39.
23
28. Fit the gearbox drive shaft complete with all parts
and the adjuster shim, then position the bearing
(2) and secure it using the snap ring (1).
24
29. Insert the final drive driving shaft from the rear
end, fit the bearing (2) into its seat and secure
with the snap ring (1).
25
6-62720 - 09 - 2006
34 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
31. Fit the ring bevel gear complete with support and
adjuster shims (see adjustments on pages 37 to
39.
34. Fit all the rods, forks and gearbox and final drive
control prongs.
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 35
Proceed as follows :
6-62720 - 09 - 2006
36 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
TRANSM ISSION-GEARBOX
Adjusting the position of the differential lock en
gagement sleeve
Proceed as follows:
30
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 37
31
2. Position the bearing (2) on tool 50004 (1), insert
the bearing (3) and lock the tool (1).
32
3. Position the tool 380000249 (2) with two conical
parts in the ring gear supports and insert the
micrometer ( 1 ) with depth rod into its seat and
lock using the bolt.
6-62720 - 09 - 2006
38 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
Examples:
Distance measured with the micrometer gauge
H-i = 145.9 mm (5.7441 in.).
Thickness of test ring Sp = 1.90 mm (0.0748 in.).
Nominal distance between the ring gear axis and
major base of the bevel pinion H2 = 145.5 mm
(5.7283 in.).
a) Correction value C = + 0.2 mm (0.0079 in.).
Corrected nominal distance H3 = 145.5 + 0.2 =
145.7 mm (5.7283 + 0.0079 = 5.7362 in.).
Thickness of adjuster ring :
S = 145.9 + 1.90 - 145.7 = 2.10 mm (5.7441 +
0.0748 = 5.7362 in.). 35
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 39
38
6-62720 - 09 - 2006
40 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
39
40
4. Setting high - low backlash depends on the ratio
between the decrease - increase in clearance
and the movement of the differential casing.
As a result, the end displacement (Z) of the
differential unit is:
Z = (G -0.18) x 1.4
where:
1.4 = Ratio between decrease-increase in back
lash and movement of the differential casing.
G = bevel drive backlash, as previously measu
red.
After calculating Z, proceed as follows:
if Z < 0 move the crown wheel away from the
pinion.
if Z > 0 move the crown wheel nearer to the bevel
pinion.
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 41
TRE0519A
41
6. Making the differential turn, unscrew the right-
hand ring nut with tool 50027 (2) and tighten the
left-hand ring nut (1) by the same amount if Z >
0, otherwise unscrew the left-hand ring nut (1)
and tighten the right-hand ring nut by the same
amount if Z < 0 in order to obtain a backlash
initially of 0.18 mm.
Z = (60 : 360) x 2 = 0.33 mm (0.0130 in.)
42
ft lb Nm ft lb Nm ft lb Nm
torque
torque measured
measured on
on pinion
0.5421 to 2.8934 to + pinion
0.735 to 1.471 3.923 to 6.865 +
1.0849 5.0634
(0.7235 to
(0.981 to
1.4463)
1.961)
43
6-62720 - 09 - 2006
42 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
ft lb Nm lb N lb N
ft lb Nm lb N lb N
45
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 43
46
6-62720 - 09 - 2006
44 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
IMPORTANT
A ll parts o f the d iffe re n tia l m u st be cle a n e d so th a t oil
re s id u e d o e s n o t e ffe c t th e a c c u ra c y o f th e
a d ju s tm e n t.
47
2. M a n ip u la te th e RH side g e a r so th a t it co m e s into
c o n ta c t w ith th e s id e p in io n and, usin g a d e p th
m ic ro m e te r, m e a s u re th e d is ta n c e (H-0, m a kin g
tw o d ia m e tric a lly o p p o s e d m e a s u re m e n ts and
ta k in g th e a rith m e tic m e a n o f th e tw o v a lu e s
m e a s u re d .
48
3. P u s h th e s id e g e a r so th a t it to u c h e s th e
d iffe re n tia l ca s in g and m e a s u re th e
d is ta n c e (H 2).
4. R e p e a t th e s a m e o p e ra tio n s fo r th e le ft-h a n d
s id e g ear.
49
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 45
w h e re :
Gs = a xia l m o v e m e n t o f LH s id e g e a r;
Gd = a xia l m o v e m e n t o f RH s id e g e a r;
H1 and H2 = d is ta n c e s m e a s u re d on LH o r RH sid e
g e a r (s te p s 2 and 3).
T h e n o rm a l c le a ra n c e e n v is a g e d b e tw e e n th e s id e s
o f th e p in io n a n d s id e g e a r te e th is 0 .1 5 m m
(0 .0 0 5 9 in.) fo r J X 6 0 and JX 7 0 m odels. It is 0.18 m m
(0.0071 in.) fo r J X 8 0 , J X 9 0 and J X 9 5 m o d e ls . 50
B e a r in m ind th a t th e a v e ra g e ra tio b e tw e e n th e
n o rm a l cle a ra n ce o f d iffe re n tia l p in io n -s id e g e a r and
th e e q u iv a le n t a xia l m o v e m e n t o f th e s id e g e a rs
is 1 -1 .7 .
6-62720 - 09 - 2006
46 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
51
Longitudinal and Cross Sectional Views of Bevel Gear Pair and Differential Unit
a. JX60 and JX70 models 12. Side gear shim
b. JX80, JX90 and JX95 models 13. Side gear shim
c. Longitudinal section for all models 14. Differential box
C1. Ring gear retaining screw 15. Bevel pinion shaft
C2. Differential support retaining screw 16. PTO shaft
S. Bevel pinion positioning shim 17. PTO control sleeve
1. Differential support 18. Fork
2. Differential support 19. Differential lock shaft
3. Taper roller bearing 20. Range gear retaining ring
4. Taper roller bearing 21. Bevel pinion securing plate
5. Differential lock sleeve 22. Differential bearing ring nut
6. Ring gear 33. Reverse driven gear
7. Side gear 34. Driven gear for slow speed gears
8. Side gear 35. Engagement sleeve for slow and fast speed
9. Differential pinion gears
10. Differential pinion shaft 36. Transmission driven shaft ring
11. Differential pinion shaft retaining screw 37. Retaining half-ring
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 47
7. P o sitio n a s u p p o rt s ta n d u n d e r tra n s m is s io n
h o u s in g a nd re m o v e R O P S fra m e , w h e e ls ,
fe n d e rs a n d p la tfo rm .
8. T ake o u t c a p s c re w s (C 5) F ig .1 , P a g e 4 and
re m o v e fin a l d riv e a s s e m b ly as s h o w n at Fig.52.
52
Disassembly (Cover)
6-62720 - 09 - 2006
48 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
R e m o v e th e g e a r re ta in in g :
10. T ig h te n tw o M 1 6 x 1,5 s c re w s (C 5) Fig. 53, into
tw o o f th e w h e e l d is c h o le s on h u b a n d c la m p
w h e e l s h a ft in v ic e Fig. 53;
11. U n s c re w n u t (C 5, Fig. 6, p a g e 8) a s s h o w n in
Fig. 53 w ith a s u ita b le s p a n n e r (B).
53
54
Wheel shaft removal (installation) (Fig. 55)
(A rro w in d ic a te s s h a ft re m o v a l d ire c tio n )
55
DISASSEMBLY (housing) (Fig. - 56)
16. R e m o v e th e b e a rin g (5) fro m th e h o u s in g (10)
Fig. 56, w ith a s u ita b le p u lle r;
17. R e m o v e re taining ring (17) Fig. 56, and w ith d ra w
a xle s h a ft (9) Fig. 56, to g e th e r w ith b e a rin g (6)
Fig. 56, in th e d ire c tio n s h o w n by arrow .
56
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 49
ASSEMBLY
C a rry o u t th e a b o ve o p e ra tio n s in th e re ve rse order,
b e a rin g in m ind th e fo llo w in g :
26. T ig h te n all th e n u ts a n d s c re w s to th e to rq u e
v a lu e s g ive n on p a g e 3.
6-62720 - 09 - 2006
50 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
6-62720 - 09 - 2006
SECTION 31 - POWER TAKE-OFF - CHAPTER 1 1
CONTENTS
31 000 M a in s p e c if ic a t io n .......................................................................................................................................... 1
T ools ................................................................................................................................................................... 3
T o rq u e s e ttin g s .............................................................................................................................................. 4
S e c tio n a l d ra w in g s ....................................................................................................................................... 5
D e s c rip tio n and o p e ra tio n ......................................................................................................................... 9
T ro u b le s h o o tin g ............................................................................................................................................ 10
R e m o v a l - R e fittin g ....................................................................................................................................... 11
31 101 B e n c h o v e r h a u l ............................................................................................................................................. 14
M ECHANICAL POWER TA K E -O FF
P T O sp e e d w ith e n g in e a t m a x im u m p o w e r (2 5 0 0 re v /m in ) re v /m in 614
G ro u n d sp e e d P T O . R e a r w h e e l s p e e d w ith P T O s h a ft wheel
ro ta tin g a t 5 40 re v /m in speed
(30 km /h v e r s io n ) ................................................................................ re v /m in 8.2 8.9
G ro u n d sp e e d P T O . R e a r w h e e l s p e e d w ith P T O s h a ft wheel
ro ta tin g a t 5 40 re v /m in speed
(4 W D 4 0 k m /h v e r s i o n ) .................................................................. re v /m in 6 .7 3 7 .2 5
(continued overleaf)
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2 SECTION 31 - POWER TAKE-OFF - CHAPTER 1
M ECHANICAL POWER TA K E -O FF
(continued)
T y p e ....................................................................................................... as fo r s in g le -s p e e d P T O
S p e e d s e le c t io n ................................................................................ by m e a n s o f han d le v e r lo c a te d to
re a r R H s id e o f d riv e r’s s e a t
P T O sp e e d w ith e n g in e a t m a x im u m p o w e r sp e e d
(2 5 0 0 re v/m in ):
- fo r 5 4 0 re v /m in P T O ................................................................ re v /m in 614
- fo r 7 5 0 re v /m in P T O ................................................................ re v /m in 787
G ro u n d sp e e d P T O . R e a r w h e e l s p e e d w ith P T O s h a ft wheel
ro ta tin g a t 5 40 re v /m in speed s e e 5 4 0 re v /m in P T O
(30 and 4 0 km /h v e rs io n s ) ............................................................ re v /m in
G ro u n d sp e e d P T O . R e a r w h e e l s p e e d w ith P T O s h a ft wheel
ro ta tin g a t 7 50 re v /m in speed
(30 km /h v e r s io n ) .............................................................................. re v /m in 10.51 11.4
G ro u n d sp e e d P T O . R e a r w h e e l s p e e d w ith P T O s h a ft wheel
ro ta tin g a t 7 50 re v /m in speed
(40 km /h 4 W D v e r s io n ) .................................................................. re v /m in 8 .5 9 9 .3 6
T y p e ....................................................................................................... as fo r s in g le -s p e e d P T O
S p e e d s e le c t io n ................................................................................ by m e a n s o f han d le v e r lo c a te d on
re a r R H s id e o f d riv e r’s s e a t
P T O sp e e d w ith e n g in e a t m a x im u m p o w e r
(2 5 0 0 re v/m in ):
- fo r 5 4 0 re v /m in P T O ................................................................ re v /m in 61 4
- fo r 1000 re v /m in P T O .............................................................. re v /m in 1050
(continued overleaf)
6-62720 - 09 - 2006
SECTION 31 - POWER TAKE-OFF - CHAPTER 1 3
M ECHANICAL POWER TA K E -O FF
(continued)
JX60 and JX70 JX80, JX90 and
JX95
Ground speed PTO. Rear wheel speed with PTO shaft wheel
rotating at 540/750 rev/min speed as for single-speed PTO
(30 and 40 km/h versions) ...................................................... rev/min
Ground speed PTO. Rear wheel speed with PTO shaft wheel
rotating at 1000 rev/min speed
(30 km/h v e rs io n )...................................................................... rev/min 14.1 15.2
Ground speed PTO. Rear wheel speed with PTO shaft wheel
rotating at 1000 rev/min speed
(40 km/h 4WD v e rs io n )............................................................ rev/min 11.5 12.4
Clearance between shaft and front and centre bushings .. mm 0.009 - 0.073
(in.) (0.0004 - 0.0029)
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4 SECTION 31 - POWER TAKE-OFF - CHAPTER 1
TORQUE SETTINGS
C 3 - 162 Nm
26276
TORQUE SETTINGS
T o rq u e s e ttin g
PART TO BE T O R Q U E D T h re a d
Nm ft lb
D rive n g e a r s h a ft lo c k n u t:
(C 4, fig. 1) fo r s in g le - o r 2 -s p e e d P T O ................................................ M 3 2 x 1 .5 294 2 1 6 .8 4 3 2
6-62720 - 09 - 2006
SECTION 31 - POWER TAKE-OFF - CHAPTER 1 5
NOTE : W h en installing use sealing com p o u n d o f th e typ e show n on page 1 section 00 on su rfa ce X as show n above.
6-62720 - 09 - 2006
6 SECTION 31 - POWER TAKE-OFF - CHAPTER 1
NOTE : W h en installing use sealing com p o u n d o f th e typ e show n on page 1 section 00 on su rfa ce X as show n above.
6-62720 - 09 - 2006
SECTION 31 - POWER TAKE-OFF - CHAPTER 1 7
6-62720 - 09 - 2006
8 SECTION 31 - POWER TAKE-OFF - CHAPTER 1
S e ctio n vie w s - 540 - 1000 rev/m in PTO N orth A m e rica n ve rs io n (available on request), n o t
s y n c h ro n is e d w ith gearbox, w ith speed s e le c tio n by replacem en t o f s p lin e d o u tp u t shaft.
1. S p lin e d 1 3/g” o u tp u t s h a ft (6 s p lin e s ) fo r 5 4 0 rpm
P T O , o r 1 3/s ” o u tp u t s h a ft (21 s p lin e s ) fo r 1000 6. R e tu rn sp rin g .
rp m P T O .
7. R e tu rn rod.
2. D rive n s h a ft.
8. S p e e d s e le c to r le v e r s u p p o rt
3. S n a p ring s e c u rin g p a rt . 9. S p e e d s e le c to r lever.
4. S p e e d s e le c to r rod. 10 . S p e e d s e le c to r s le e v e .
5. S p e e d s e le c to r s le e v e c o n tro l fo rk. 11. T h ru s t w a s h e r.
6-62720 - 09 - 2006
SECTION 31 - POWER TAKE-OFF - CHAPTER 1 9
T h e P T O , lo ca te d a t th e re a r o f th e tra c to r, tra n s fe rs
p o w e r to th e im p le m e n t be in g tra n s p o rte d o r to w e d .
It can be c o n tro lle d e ith e r d ire c tly fro m th e e n g in e
c lu tch o r fro m th e g e a rb o x c lu tc h . T h e P T O is s h o w n
w ith th e s a fe ty ca p (1) and th e g u a rd (2) in p o sitio n .
T h e s a fe ty ca p m u s t be re m o v e d to c o u p le up an
im p le m e n t to th e P T O s h a ft.
— s in g le -s p e e d P T O , 5 4 0 re v /m in (s ta n d a rd )
— tw o -s p e e d P T O , 5 4 0 /7 5 0 re v /m in (o p tio n )
— tw o -s p e e d P T O , 5 4 0 /1 0 0 0 re v /m in (o p tio n ).
In d e p e n d e n t PTO
P ro c e e d as fo llo w s :
— e n g a g e th e P T O by s lo w ly m o v in g th e le v e r (1)
fig. 7, fo rw a rd to p o s itio n D.
W h e n e n g a g e d , th e P T O s h a ft ro ta te s and th e P T O
w a rn in g la m p on th e in s tru m e n t p a n e l lig h ts up.
In th e se conditions th e operation o f th e P T O is
co m ple tely ind ependent o f th e tra ve l o f th e tractor, so:
— th e P T O ca n be s to p p e d w ith o u t s to p p in g th e
tra c to r (b y d is e n g a g in g th e P T O c lu tc h ).
To d is e n g a g e th e P T O m o v e th e P T O c lu tc h c o n tro l
le v e r (1) fig. 7, re a rw a rd to p o s itio n A th e n m o v e th e
sp e e d s e le c to r (1) fig. 8, to th e c e n tra l p o s itio n E.
6-62720 - 09 - 2006
10 SECTION 31 - POWER TAKE-OFF - CHAPTER 1
G ro u n d speed PTO
P ro c e e d as fo llo w s :
— fu lly d e p re s s th e g e a rb o x /e n g in e c lu tc h p edal;
— w a it briefly, th e n m o v e th e P T O s p e e d s e le c to r
(1) fig. 8, fo rw a rd to p o s itio n C and re le a s e th e
g e a rb o x /e n g in e c lu tc h p edal;
NO TE : W h e n th e P T O is n o t be in g u se d , m o v e th e
le v e r (1) fig. 8, to p o s itio n E (th e n e u tra l p o s itio n o f
th e P T O e n g a g e m e n t s le e v e (3) fig. 9).
To c h a n g e P T O s p e e d , p ro c e e d as fo llo w s :
F a u lts P o s s ib le c a u s e s R e m e d ie s
6-62720 - 09 - 2006
SECTION 31 - POWER TAKE-OFF - CHAPTER 1 11
2. R e m o v e th e to p lin k (1) o f th e th r e e -p o in t
linkage.
12
4. R e m o v e th e to w b a r (1), if fitte d
13
6-62720 - 09 - 2006
12 SECTION 31 - POWER TAKE-OFF - CHAPTER 1
16
8. Remove the screws (2) that fasten the retaining
bracket (1) for the PTO speed selector control.
6-62720 - 09 - 2006
SECTION 31 - POWER TAKE-OFF - CHAPTER 1 13
9. R e m o v e th e tw o u p p e r s c re w s (1) w h ic h fa s te n
th e P T O u n it to th e tra n s m is s io n .
18
10. In s e rt th e tw o g u id e p in s 380001597 (1) and
re m o v e th e tw o lo w e r s c re w s (2) (F ig. 3
P a g e .6 ) w h ic h fa s te n th e P T O u n it to th e
tra n s m is s io n .
19
11. E ngage th e le ve r (1) fig. 8, in position (C), ground
speed P TO , so th a t th e sleeve (3) fig. 9, rests on
th e sh a ft (2) during th e rem oval operation.
W ith d ra w th e P T O unit by a fe w ce n tim e tre s and
detach using th e ho o k w ith lifting chain 380000227
(1).
To re in s ta ll p ro ce e d as fo llo w s :
— C le a n th e m a tin g s u rfa c e s b e tw e e n th e
tra n s m is s io n and P T O c o v e r and a p p ly s e a lin g
c o m p o u n d as s h o w n in fig u re 21.
— R a is e th e P T O u n it and p o s itio n it d ire c tly b e h ind
th e tra n s m is s io n c a s in g . S lid e th e P T O c o v e r
o n to th e g u id e p in s 380001597 , fo r e a s e o f
a sse m b ly.
— R e m o v e th e h o o k w ith ch a in (1) fig. 20, and
fa s te n th e P T O u n it u sin g th e tw o lo w e r s c re w s .
— R e m o v e th e tw o g u id e p ins 380001597 and
in sta ll th e tw o u p p e r s c re w s .
— R e in s ta ll th e b ra c k e t (1) fig. 17, th a t re ta in s th e
P T O sp e e d s e le c to r c o n tro l lever.
— R e fit th e to w b a r s u p p o rt.
— R e fit th e to w bar, th e to w h o o k and th e th r e e -
p o in t lin ka g e to p link.
— S c re w in and tig h te n th e oil d ra in plug and fill th e
tra n s m is s io n /g e a rb o x w ith oil.
— R e c o n n e c t th e n e g a tiv e b a tte ry ca b le .
21
6-62720 - 09 - 2006
14 SECTION 31 - POWER TAKE-OFF - CHAPTER 1
1. P la c e th e P T O u n it in th e v ic e on th e w o rk
b e n c h (1 ).
22
2. U se a p u n ch to s tra ig h te n th e c o rru g a tio n s (1) on
th e ring n u t th a t re ta in s th e d riv e n s h a ft
c o m p o n e n ts .
23
24
6-62720 - 09 - 2006
SECTION 31 - POWER TAKE-OFF - CHAPTER 1 15
4. R e m o v e th e fo u r P T O u n it in te rn a l s u p p o rt fixin g
s c re w s (1).
25
26
27
28
6-62720 - 09 - 2006
16 SECTION 31 - POWER TAKE-OFF - CHAPTER 1
29
30
— M o u n t th e se a l (9) (if re m o v e d in s te p 2 0 ), th e
re a r b e a rin g and th e re ta in in g s n a p ring (5) on
th e re a r cover.
— F a s te n th e rod th a t s u p p o rts th e P T O sp e e d
s e le c to r c o n tro l fo rk pin as re m o v e d in s te p 5.
— T ig h te n th e d riv e n s h a ft lo c k n u t to th e to rq u e
sp e c ifie d on p a g e 4, th e n , u sin g a s u ita b le
pu n ch , n o tch th e s a fe ty th ru s t w a s h e r in o rd e r to
p re v e n t it fro m lo o s e n in g .
6-62720 - 09 - 2006
SECTION 31 - POWER TAKE-OFF - CHAPTER 1 17
1. P la c e th e P T O u n it in th e v ic e on th e w o rk
b e n c h (1 ).
31
2. R e m o v e th e b o lts (1) and ta k e o ff th e c o v e r (2)
32
3. R e m o v e th e s p a c e r (1).
33
6-62720 - 09 - 2006
18 SECTION 31 - POWER TAKE-OFF - CHAPTER 1
34
35
36
7. R e m o v e th e s o c k e t h ead s c re w b o lt (1) on th e
sid e o f th e cover.
37
6-62720 - 09 - 2006
SECTION 31 - POWER TAKE-OFF - CHAPTER 1 19
8. R e m o v e th e c o v e r (1).
38
39
40
41
6-62720 - 09 - 2006
20 SECTION 31 - POWER TAKE-OFF - CHAPTER 1
6-62720 - 09 - 2006
SECTION 31 - POWER TAKE-OFF - CHAPTER 1 21
NOTE: T h e a d ju s tm e n t p ro c e d u re s h o u ld be d o n e
O N L Y w ith th e 100 0 rp m P T O s h a ft is in s ta lle d .
6-62720 - 09 - 2006
22 SECTION 31 - POWER TAKE-OFF - CHAPTER 1
6-62720 - 09 - 2006
SECTION 33 - BRAKING SYSTEM - CHAPTER 1 1
Type:
Control:
Disc thickness:
(see over)
6-62720 - 09 - 2006
2 SECTION 33 - BRAKING SYSTEM - CHAPTER 1
MAIN SPECIFICATION
(cont.)
T h ic k n e s s o f m o b ile s e c to rs fo r in d e p e n d e n t p a rk in g b ra ke :
- in te rm e d ia te s e c to rs .............................................................................. mm 4 .2 - 4 .5
(in.) (0 .1 6 5 3 - 0 .1 7 7 2 )
F ro n t b ra k e s (w ith 4 W D m o d e ls - on re q u e s t)
H y d ro s ta tic co n tro l
TORQUE SETTINGS
T ig h te n in g to rq u e
P A R T S T O B E T IG H T E N E D T h re a d
Nm ft lb
B ra ke b o x re ta in in g b o lt (C 5, p a g e 8 ) ..................................................... M 10 x 1.25 70 5 1 .6 2 9 3
6-62720 - 09 - 2006
SECTION 33 - BRAKING SYSTEM - CHAPTER 1 3
6-62720 - 09 - 2006
4 SECTION 33- BRAKING SYSTEM - CHAPTER 1
BRAKES
a. R.H. brake pedal in rest position and L.H. brake applied. SL. Slave cylinder 4. Brake actuator. 9. Axle shaft.
b. Brakes applied. MS. Master cylinder 5. Brakes discs. 12. Final drive housing.
c. Brakes in rest position. T. Parking brake link. 6. B ack-up discs. 13. Park brake control lever.
Lm. Parking brake hand lever. 1. Brake links. 7. Actuator return spring. 14. Park brake control cable
M. Brake pedal return springs. 3. Actuator ball. 8. Differential support. 15. Brake pivoting shaft.
Pd. R.H. brake pedal.
6-62720 - 09 - 2006
SECTION 33 - BRAKING SYSTEM - CHAPTER 1 5
6-62720 - 09 - 2006
6 SECTION 33 - BRAKING SYSTEM - CHAPTER 1
FRONT LIVE AXLE DRIVE SHAFT BRAKE (JX60 & JX70 MODELS)
Section through the brake fitted on drive shaft to front live axle
6-62720 - 09 - 2006
SECTION 33 - BRAKING SYSTEM - CHAPTER 1 7
4
View of brake mounted in front axle.
a. Cross-sectional view of axle with differential. 4. Seal.
b. Cross-sectional view of axle with NO -SPIN 5. Piston contact spring.
assembly. 6. Centring ring.
c. View of oil delivery union and brake bleed. 7. Gear.
C5 Brake box retaining bolt. 8. Circlip.
1. Brake box. 9. Drive oil inlet pipe union.
2. Brake drive piston. 10. Plug pipe with breather.
3. Seal. 11. Splined shaft.
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8 SECTION 33 - BRAKING SYSTEM - CHAPTER 1
T h e tw o c o n tro l p u m p s a re fe d fro m a s in g le ta n k
lo ca te d a b o v e th e p u m p s. PARKING BRAKE
R e fe r to th e illu s tra tio n s on p a g e 5. T h e s e rv ic e
b ra k e s are s la v e c y lin d e r o p e ra te d . W h e n th e R e fe r to th e illu s tra tio n s on p a g e 5. W h e n th e han d
le ft-h a n d b ra ke p e d a l (fig. a ) is d e p re s s e d , th e b ra k e le v e r (L m) is pulled, th e co n tro l ca b le (14) pulls
m a s te r c y lin d e r (M S ) s e n d s th e oil to th e s la v e th e co n tro l le v e r (13), a t th e d ire c tio n o f a rrow . T he n
c y lin d e r (S L). T h e b ra k e lin ks (1) m o v e a s in d ic a te d th e b ra k e lin k s (1) a c ts on th e b ra ke
by th e a rro w s, by th e h e lp o f s la v e c y lin d e r (S L ) th is d is c s .
6-62720 - 09 - 2006
SECTION 33 - BRAKING SYSTEM - CHAPTER 1 9
TOOLS
BRAKE TROUBLESHOOTING
P ro b le m s P o s s ib le c a u s e s R e m e d ie s
1. B ra k e d is c s w o rn . R e p la c e th e b ra k e d is c s .
P a rkin g b ra ke d o e s n o t lock.
1. B ra k e d is c s s e iz e d on b ra ke R e le a s e and re p la c e d a m a g e d p a rts.
B ra k e s lo cke d on w h e n th e p a rk d is c s .
ing b ra ke is d is e n g a g e d .
6-62720 - 09 - 2006
10 SECTION 33 - BRAKING SYSTEM - CHAPTER 1
P ro c e e d as fo llo w s to re m o v e th e unit:
1. A p p ly th e h a n d b ra k e .
2. U n s c re w th e re ta in in g b o lts and re m o v e th e
g u a rd s fro m th e p ro p e lle r sh a ft.
5
3. D is c o n n e c t w ire (10) fig. 5 o f th e brake pad w e a r
w a rn in g in d ic a to r and re m o v e th e p a d s (14 and
15) fig. 6.
6-62720 - 09 - 2006
SECTION 33 - BRAKING SYSTEM - CHAPTER 1 11
9
9. T ake o u t re ta in in g rin g s (8 a n d 9) fro m th e
s u p p o rt (4)
10
10. U sin g a s u ita b le p uller, re m o v e th e s h a ft/s le e v e
a s s e m b ly (3) fro m th e s u p p o rt (4).
11. R e m o v e th e b e a rin g (5) u sin g a s u ita b le p u lle r
and ta k e o u t th e w a s h e r (6) Fig. 3.
11
6-62720 - 09 - 2006
12 SECTION 33 - BRAKING SYSTEM - CHAPTER 1
R e v e rs e th e re m o v a l o p e ra tio n s e q u e n c e m in d in g
th e fo llo w in g p o in ts :
1. P o sitio n th e s h a ft/s le e v e a s s y (3) Fig. 3, upright,
in tro d u c e th e s u p p o rt (4) fig. 12, fo llo w e d by th e
w a s h e r (6) Fig. 3 in th e b e a rin g s e a t w ith th e
c h a m fe re d s id e fa c in g o u tw a rd s .
12
13
6-62720 - 09 - 2006
SECTION 33 - BRAKING SYSTEM - CHAPTER 1 13
SERVICE BRAKE
Removal - Installation (Operation 33 202 60)
14
3. R e m o v e th e v e rtica l rod (1) and th e LH s ta b ilis e r
s tru t (2).
15
4. R a ise th e re a r s e c tio n o f th e tra c to r and p la ce a
s ta n d (1) b e n e a th th e to w b a r s u p p o rt.
16
6-62720 - 09 - 2006
14 SECTION 33 - BRAKING SYSTEM - CHAPTER 1
17
18
8. R e m o v e th e plug (1) a n d d ra in th e oil fro m th e
re a r tr a n s m is s io n -g e a rb o x c a sin g .
19
9. U n d o th e b o lts s e c u rin g th e c a b to its m o u n tin g
(1).
20
6-62720 - 09 - 2006
SECTION 33 - BRAKING SYSTEM - CHAPTER 1 15
21
22
23
6-62720 - 09 - 2006
16 SECTION 33 - BRAKING SYSTEM - CHAPTER 1
14. C h e c k a c tu a to r and b ra k e d is c s fo r w e a r.
6-62720 - 09 - 2006
SECTION 33 - BRAKING SYSTEM - CHAPTER 1 17
26
Diagram for application of sealing compound when fitting braking assembly between the final drive
housing and the rear transmission box.
6-62720 - 09 - 2006
18 SECTION 33 - BRAKING SYSTEM - CHAPTER 1
A a t t e n t io n A ----------
H a n d le all p a rts ca re fu lly.
D o n o t in se rt fin g e rs o r h a n d s b e tw e e n o n e p a rt and
a n o th e r. A lw a y s w e a r th e p re s c rib e d s a fe ty c lo th in g,
in c lu d in g p ro te c tiv e g la s s e s , g lo v e s and s h o e s .
P ro c e e d as fo llo w s to re m o v e th e h y d ra u lic pu m p .
27
3. D is c o n n e c t th e e le c tric a l c o n n e c tio n s fro m th e
plug (2) o f th e ta n k (1) and a fte r re trieving th e oil,
re m o v e th e s e rv ic e b ra k e c o n tro l p ip e s (3).
28
29
6-62720 - 09 - 2006
SECTION 33 - BRAKING SYSTEM - CHAPTER 1 19
30
31
7. .Unscrew the rear hood screws (1)
TRE0436A
32
9. Remove the electrical connections:from the
pressure sensor (1) and remove the service
brake control pipes (2).
33
6-62720 - 09 - 2006
20 SECTION 33 - BRAKING SYSTEM - CHAPTER 1
34
35
Sectional drawing of service brake control pump (Master cylinder)
1. S p rin g . 4. R e a r se a l.
2. P u m p body. 5. C e n tra l se a l.
3. C o n tro l p isto n . 6. F ro n t se a l.
6-62720 - 09 - 2006
SECTION 33 - BRAKING SYSTEM - CHAPTER 1 21
36
37
17. R e m o v e th e fro n t h y d ra u lic p u m p in te rn a l parts.
C h e c k th e s e a ls and p isto n .
38
18. R e fit th e h y d ra u lic b ra k e s la v e c y lin d e rs as
fo llo w s .
— In s e rt th e m a s te r c y lin d e r (1) fro m link.
— F it th e pin (1).
— A s s e m b ly th e b o lts s e c u rin g th e p u m p (2).
— A s s e m b ly th e p ip e c o n n e c tio n s (3) a n d (4).
6-62720 - 09 - 2006
22 SECTION 33 - BRAKING SYSTEM - CHAPTER 1
1. T h o ro u g h ly cle a n th e e x te rn a l p a rts o f th e un it
a ro u n d th e b le e d s c re w s (1) fig. 4 0 , (1) fig. 42
and th e h y d ra u lic oil ta n k lid (1) fig. 39.
4. K e e p in g th e p e d a l d e p re s s e d , u n d o th e ble e d
s c re w (1) by h a lf a tu rn and a llo w th e oil m ixe d
w ith a ir b u b b le s to flo w out.
5. R e tig h te n th e s c re w (1) a n d re p e a t th e a b o v e
o p e ra tio n s u ntil th e oil th a t c o m e s o u t is fre e o f
a ir b u b b le s.
6. D e p re s s th e LH b ra k e p e d a l a g a in to p la ce th e
c irc u it u n d e r p re s s u re : th is o c c u rs w h e n th e
tra v e l o f th e p e d a l re tu rn s to n o rm a l.
7. R e p e a t th e a b o v e o p e ra tio n s fo r th e R H b ra ke
p e d a l fro m th e ble e d s c re w (2).
40
9. K e e p in g th e p e d a ls d e p re s s e d , u n d o th e ble e d
s c re w (1) on th e RH b ra ke s la v e c y lin d e r by h a lf
a tu rn and a llo w th e oil m ixe d w ith a ir b u b b le s to
flo w out.
6-62720 - 09 - 2006
SECTION 33 - BRAKING SYSTEM - CHAPTER 1 23
13. K e e p in g th e p e d a ls d e p re s s e d , u n d o th e ble e d
s c re w (1) by h a lf a tu rn and a llo w th e oil m ixe d
w ith a ir b u b b le s to flo w out.
42
1. W ith th e b ra k e p e d a ls c o n n e c te d to th e ir
re s p e c tiv e fo rk s a n d th e p e d a l c o n n e c tin g pin
re m o v e d , c h e c k th a t th e h e ig h t (A ) fro m th e
c e n tre o f th e p e d a ls to th e to p o f th e c a rp e t is:
162 m m fo r tra c to rs fitted w ith ca b o r 20 5 m m fo r
tra c to rs w ith o u t cab.
2. If a d ju s tm e n t is re q u ire d , s la c k e n th e lo c k nu ts
(2) an d tig h te n o r s la c k e n b o lt (1) u ntil th e
re q u ire d h e ig h t (A) is o b ta in e d . La stly tig h te n the
lo c k nuts.
6-62720 - 09 - 2006
24 SECTION 33 - BRAKING SYSTEM - CHAPTER 1
3. T h e le n g th o f th e b ra k e lin k s m u s t be 1 9 0 m m
0 1 m m . If a d ju s tm e n t is re q u ire d , fu lly re le a s e
th e h a n d b ra k e (le v e r d o w n ). R e m o v e th e
co n n e c tin g pin (3). S la cke n th e lo ck nuts (1) and
tu rn th e h e x a g o n s le e v e s (2) u n til th e le n g th o f
b ra ke links is 190 m m . F inally, tig h te n th e lo ck
n u ts (1).
46
6-62720 - 09 - 2006
SECTION 33 - BRAKING SYSTEM - CHAPTER 1 25
Proceed as follows.
47
6-62720 - 09 - 2006
26 SECTION 33 - BRAKING SYSTEM - CHAPTER 1
6-62720 - 09 - 2006
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 1
O p e ra tin g s y s te m ......................................................... tw o in d e p e n d e n t le ve rs
S in g le -a c tin g c y lin d e r:
- rate d d ia m e te r a n d stro k e :
A ll m o d e ls mm 100x128
(in.) (3 .9 3 7 0 x 5 .0 3 9 4 )
- ca p a c ity :
A ll m o d e ls cm 3 1005
(in .3) (6 1 .3 3 )
L ift p isto n d ia m e te r:
- A ll m o d e ls ................................................................... ......................... mm 9 9 .9 8 0 - 1 0 0 .0 0 0
(in.) (3 .9 3 6 2 - 3 .9 3 7 0 )
In te rn a l d ia m e te r o f c y lin d e r liner:
??.??.???.?? - ?? - ????
2 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
- A ll m o d e ls ................................................................................................ mm 1 0 0 .0 3 6 - 100.071
(in.) (3 .9 3 8 4 - 3 .9 3 9 8 )
C le a ra n c e b e tw e e n p isto n a n d l i n e r ....................................................... mm 0 .0 3 6 - 0.091
(in.) (0 .0 0 1 4 - 0 .0 0 3 6 )
D ia m e te r o f lift a rm s h a ft (11, fig. 3) a t p o s itio n o f b u s h in g s :
- rig h t-h a n d s id e ....................................................................................... mm 5 4 .9 7 0 - 5 5 .0 0 0
(in.) (2 .1 6 4 2 - 2 .1 6 5 4 )
- le ft-h a n d s id e ......................................................................................... mm 6 2 .6 7 0 - 6 2 .7 0 0
(in.) (2 .4 6 7 3 - 2 .4 6 8 5 )
In te rn a l d ia m e te r o f b u s h in g s fitte d on lift body:
- rig h t-h a n d s id e (8, fig. 3 ) ..................................................................... mm 5 5 .1 0 0 - 5 5 .1 8 4 (1)
(in.) (2 .1 6 9 3 - 2 .1 7 2 6 )
- le ft-h a n d s id e (12) ................................................................................ mm 6 2 .8 0 0 - 6 2 .8 8 4 (1)
(in.) (2 .4 7 2 4 - 2 .4 7 5 7 )
C le a ra n c e b e tw e e n lift a rm s h a ft and b u s h in g s ................................ mm 0 .1 0 0 - 0 .2 1 4
(in.) (0 .0 0 3 9 - 0 .0 0 8 4 )
In te rfe re n c e b e tw e e n b u s h in g s and th e ir s e a ts ................................ mm 0 .0 6 5 - 0 .1 8 5
(in.) (0 .0 0 2 6 - 0 .0 0 7 3 )
A x ia l c le a ra n c e o f s h a ft c o m p le te w ith lift a rm s ................................ mm 0 .2 - 1.4
(in.) (0 .0 0 7 9 - 0 .0 5 5 1 )
E x te rn a l d ia m e te r o f d ra ft c o n tro l id le r s h a f t ....................................... mm 2 1 .9 6 7 - 2 2 .0 0 0
(in.) (0 .8 6 4 8 - 0 .8 6 6 1 )
In te rn a l d ia m e te r o f s e a ts in s u p p o rt ..................................................... mm 2 2 .0 2 0 - 2 2 .0 7 2
(in.) (0 .8 6 6 9 - 0 .8 6 9 0 )
C le a ra n c e b e tw e e n d ra ft c o n tro l id le r s h a ft a n d p o s itio n c o n tro l mm 0 .0 2 0 - 0 .1 0 5
id le r s h a ft ......................................................................................................... (in.) (0 .0 0 0 8 - 0 .0 0 4 1 )
D ia m e te r o f p o s itio n c o n tro l id le r s h a f t .................................................. mm 1 3 .9 7 3 - 1 4 .0 0 0
(in.) (0.5501 - 0 .5 5 1 2 )
In te rn a l d ia m e te r o f p o s itio n c o n tro l id le r s h a f t .................................. mm 1 4 .0 1 6 - 1 4 .0 5 9
(in.) (0 .5 5 1 8 - 0 .5 5 3 5 )
C le a ra n c e b e tw e e n d ra ft c o n tro l id le r s h a ft a n d p o s itio n c o n tro l
id le r s h a ft ......................................................................................................... mm 0 .0 1 6 - 0 .0 8 6
(in.) (0 .0 0 0 6 - 0 .0 0 3 4 )
C le a ra n c e b e tw e e n c o n tro l v a lv e b lo c k pin (8, fig. 4) a n d its s e a t
on th e c o n tro l v a lv e b lo c k b o d y ................................................................ mm 0 .0 0 8 - 0 .0 1 2 (2)
(in.) (0 .0 0 0 3 - 0 .0 0 0 5 )
C le a ra n c e b e tw e e n lift c o n tro l v a lv e (10) a n d its s e a t on th e c o n
tro l v a lv e b lo c k b o d y ..................................................................................... mm 0 .0 0 8 - 0 .0 1 2 (2)
(in.) (0 .0 0 0 3 - 0 .0 0 0 5 )
C o n tro l v a lv e b lo c k pin re tu rn s p rin g (5, fig. 4):
- fre e s p rin g le n g th .................................................................................. mm 5 0 .5
(in.) (1 .9 8 8 2 )
- sp rin g le n g th u n d e r load o f 3 1 .7 - 35 N (7 .1 2 4 2 - 7.8741 lb) mm 34
(in.) (1 .3 3 8 6 )
C o n tro l v a lv e re tu rn s p rin g (9, fig. 4)
- fre e s p rin g le n g th .................................................................................. mm 44
(in.) (1 .7 3 2 3 )
- sp rin g le n g th u n d e r load o f 103 - 114.7 N mm 29
(in.) (1 .1 4 1 7 )
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 3
Filter
Pump
M o d e l.................................................................... A31
Direction o f rotation (as seen from drive side) left (counter clockwise)
Bench output at 1450 rpm and pressure of 172 bar ( 175 kg/cm2):
- for new or reconditioned p u m p .................................. dm3/min (in.3/min) 19 (1159.5)
- for worn pump ............................................................ dm3/min (in.3/min) 13.3 (811.6)
- test oil te m p e ra tu re ...................................................................... C°(F°) 55 - 65 (131 - 149)
- test oil v is c o s ity ............................................................................ SAE 20
(continued overleaf)
??.??.???.?? - ?? - ????
4 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
Driven and driving gear shaft diam eter .......................................... mm 17.400 - 17.418
(in.) (0.6850 - 0.6857)
Internal diam eter of seats in supports ............................................ mm 17.450 - 17.470
(in.) (0.6870 - 0.6878)
Clearance between gear shafts and their s e a ts ............................ mm 0.032 - 0.070
(in.) (0.0013 - 0.0025)
- maximum clearance due to w e a r .............................................. mm in.) 0.1 (0.0039)
Radial clearance of gears in pump b o d y ........................................ mm 0.020 - 0.064
(in.) (0.0008 - 0.0025)
Maximum w ear on pump body, suction side, at position of gears mm(in.) 0.1 (0.0039)
Width of gears (5, fig. 104) .............................................................. mm 24.000 - 24.015
(in.) (0.9449 - 0.9455)
Width of supports (4 and 6) .............................................................. mm 24.490 - 24.510
(in.) (0.9642 - 0.9650)
Width of pump body (3) for gear seats and supports .................. mm 73.135 - 73.160
(in.) (2.8793 - 2.8803)
Axial clearance of gears complete with supports in pump body
(recondition if n e c e s s a ry ).................................................................. mm 0.100 - 0.180
(in.) (2.8793 - 2.8803)
Filter
M o d e l.................................................................... Rexroth
Direction o f rotation (as seen from drive side) left (counter clockwise)
Bench output at 1500 rpm and a pressure of 2175 psi (150 bar):
- for pump with 300 hours o f w o r k .............. dm3/min (in.3/min) 22.3 (1360.83)
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 5
??.??.???.?? - ?? - ????
6 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
TOOLS
HYDRAULIC LIFT EQUIPMENT X 380000225 Ring for fitting piston with lift seals.
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 7
TRE0700A
48
TRE0701A
49
Note - Install the O -ring 33 and anti-extrusion ring 32 as illustrated in the drawing (a) using the protection device
380000266 and heating the ring 32 in oil at 50 °C.
Take care to install ring 32 with the flat surface facing upwards and concave surface facing O -ring 20. Take
necessary precautions not to damage them.
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 9
□ S ta tic o il
□ O i l i n s u c tio n
| | T r a c to r b ra k e c irc u it o il (b ra k e s o f f )
□ P r e s s u r is e d o il
□ E x h a u s t o il flo w
50
□ Pressurised oil
□ Static oil
TRE0702A
51
F. Filter. 5. Plunger.
P. Hydraulic pump. 6 . Plunger spring
T. Lift arm piston. 8 . Piston seat.
V. Reliefvalve. 9. Piston.
1. Valve spool. 22 . Check valve.
When the position control lever (located on the Oil flow to piston (9) is cut off and plunger (5) is forced
operator’s right-hand side) is used to raise the arms, to the left by spring (6), thus closing the exhaust port.
the movement shown by the arrows is transmitted by Pressure oil opens check valve (22) and operates
the internal lever mechanisms to the control valve piston (T) to raise the arms.
block pin ( 1 ).
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 11
52
NEUTRAL PHASE
F. Filter. 9. Piston.
P. Hydraulic pump. 12 . Draft sensitivity valve.
V. Relief valve. 15. Cylinder safety valve.
1. Valve spool. 17. Arm lowering speed control valve
5. Plunger. 18. Ball.
6. Plunger spring. 22 . Check valve.
With spool (1) in the neutral position, oil is delivered and directs oil flow to the tank in the rear transmission
through the response adjusting valve ( 12 ) to piston housing rather than to the cylinder.
(9), which overcomes spring reaction (6) and moves
plunger (5) to the right. This opens the exhaust port
??.??.???.?? - ?? - ????
12 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
When the operator lowers the position control lever Unscrewing the screw (16) decreases the load on
on his right, the return spring (4) pulls spool (1) to the the spring (15), therefore the valve (14) can vibrate
right. Cylinder oil is exhausted under piston pressure faster, slowing down the descent speed. Tightening
(T) through lowering speed adjustment valve (17) the screw (16) slows down the vibration of the valve
and the port uncovered by spool. (14) that increases the descent speed of the arms
since the valve (14) can remain in position in corre-
Through spool port (F1) and draft sensitivity valve spondence with the larger orifice where the oil flows
(12) oil flows to piston (9), which holds plunger (5) in out from the cylinder.After adjusting the arm descent
the position shown, thus allowing pump delivery to be speed it will not depend on the weight bearing on the
exhausted past plunger (5). arms but will be virtually constant.
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 13
The lift does not raise. 1. Oil filter clogged. Replace filter.
2. Air has got into the pump suc Check that the couplings are airtight
tion line. and the seals are effective.
The lift raises too slowly. 1. Oil filter clogged. Replace filter.
The lift operates too quickly. 1. Foreign matter between the Take off the valve, remove the foreign
ball and its seat on the dis matter and inspect the oil filter.
charge control valve.
3. Discharge control valve piston Take off the valve and free the piston.
jammed.
The lift operates too slowly. 1. Discharge ports on the dis Take off the valve, unblock the holes
charge control valve blocked. and inspect the oil filter.
2. Discharge control valve piston Take off the valve and free the piston.
jammed.
(continued overleaf)
??.??.???.?? - ?? - ????
14 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
The lift is unable to keep the load 1. Defective seal on check valve. Take off, check, clean and if neces
raised (with the engine running, sary replace the parts concerned.
the load moves up and down
rhythmically; with the engine 2. Oil leaking past the seals on Replace seals.
turned off, the load lowers). the control valve block pin
seat.
3. Control valve block pin seal Take off and clean the seal and
defective. replace the control valve block pin
and its seat if defective.
The pressure relief valve cuts in 1. Lift arm travel set incorrectly. Set correctly.
when the lift arms reach their com
pletely raised position.
Lift has poor lifting capacity. 1. Pressure relief valve set Replace the valve.
incorrectly.
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 15
54
2. Remove the top link (1).
56
??.??.???.?? - ?? - ????
16 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
57
5. Unscrew: the trailer brake control pipe (1) and
the auxiliary control valve pipes from the support
plate (2 ).
58
6. Remove auxiliary control valve pipes (2) from
their support ( 1 ).
59
7. Undo the two bolts (1) that secure the seven-
pole socket (2 ) and remove the socket.
60
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 17
62
10. Remove the electric socket (1).
??.??.???.?? - ?? - ????
18 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
65
66
14. Unscrew the two cab front securing bolts (1).
67
15. Unscrew the two cab rear securing bolts (1).
Raise the cab approximately 5 -6 cm
(0.1969-0.2362 in.) and place wooden blocks
( 1 ) between the cab upright and the housing.
Lower the hoist so that the cab rests securely on
the wooden block.
68
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 19
16. Remove the pipes on the lift (1) and the control
valve body (2 ).
69
17. Unscrew the bolts (1) that secure the hydraulic
lift assembly to the transmission casing.
70
18. Fit tool 380000237 (1) on the lift and tighten the
four bolts (2 ).
71
19. Fit tool 380000224 (1) onto tool 380000238 (2).
Attach the hoist to tool 380000224, raise the
hydraulic lift by a few centimetres and pull it
backwards, tilting it so that it clears the breather
pipe (3) without damaging it.
??.??.???.?? - ?? - ????
20 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
Fit the trailer brake control pipe (if fitted) and the
oil filler pipe.
74
1. Position the hydraulic lift on a stand (1) fig. 74,
that will allow the assembly to be rotated.
2. Unscrew the securing bolts (1) and remove the
control valve block (2) fig. 75.
75
3. Unscrew the two cylinder securing bolts posi
tioned outside the cylinder body. Turn the lift
assembly and unscrew the lateral bolt (3).
4. Undo the bolts (1) that secures the internal
linkage (2 ) to the lift cylinder.
76
5. Remove the cylinder (1) complete with piston
77
??.??.???.?? - ?? - ????
22 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
78
7. Take off the snap ring and remove the internal
position control lever ( 1 ).
Unscrew the nuts (2) and remove the spring and
fixing bracket (4).
8. Take off the snap ring and remove lever (3), the
friction discs, lever (5) and the stud bolts.
79
9. Slacken the eccentric pin (2) retaining bolt (1),
withdraw the eccentric pin and remove the
internal linkage.
80
11. Remove the crimping on the internal arm locking
bolt (1) and unscrew the bolt. Withdraw the shaft
(2) and remove the seals (3).
81
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 23
82
83
16. Insert the piston (1) into its cylinder (3), using tool
380000225 (2).
84
17. Fit the lift arm shaft (2) and the internal arm (1)
inside the lift box, matching up the reference
marks, as shown. Tighten the securing bolt.
85
??.??.???.?? - ?? - ????
24 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
86
87
20. Fit the lift arms (1) on the shaft, matching up the
reference marks, as shown. Secure them by
tightening the bolts.
88
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 25
??.??.???.?? - ?? - ????
26 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 27
4. Fit tool 380000264 (4) fig 94, to the lift body. The
tool has a plunger operating in a tube, the outer
end of which has two reference surfaces ( 1 ) and
(5).
5. Using two spanners (2) and (3), unscrew the lock
nut (1) fig. 93 and tighten or loosen the
adjustable push rod (2) fig. 93, so that the end of
the plunger (5) fig 94, is flush with the outer
register surface (6) of the tool.
??.??.???.?? - ?? - ????
28 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
97
98
Adjusting draft control
Proceed as follows:
100
17. Fit tool 380000263 (1) to the lift body and fasten
it to the two holes in the box as shown in figure
10 1 .
18. Turn the screw (2) fig. 101 on the internal draft
control lever (3) fig. 101 until the end of the
plunger ( 1 ) fig. 102 is flush with the inner
reference surface (3) of tool 380000264 (2).
20. Again turn the screw (2) fig. 101 to adjust the
internal draft control lever (3) until the end of the
plunger fig. 103 is flush with the inner reference
surface (3) of the tool 380000264.
21. Finally turn the eccentric pin (1) fig. 103 until the
end of the plunger is flush with the outer register
surface (2) of the tool 380000264.
??.??.???.?? - ?? - ????
30 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
25. Fit the threaded dowel (3) and tighten the screw
( 1 ) without bending over the safety w asher (2).
26. Remove the tools 380000264 and 380000263
and fit the hydraulic control valve block on the lift
body.
107
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 31
NOTE - The distance (L6) the top end of rod (2) pro
trudes with respect to the transmission casing (with
flex bar removed) is given by:
L6 = L5 - L8
where:
L 5 and L8 = distance measured with tool 380000263
108
fitted on the surface plate (L5) fig. 107 or on the trans
mission casing (L8) fig. 109.
30. Fit the flex bar and measure the new distance
(L9) between the top end of the rod (3) and the
micrometer gauge resting surface on the tool.
NOTE - The distance (L7) fig. 108, that the top end
of the rod (2 ) fig. 108, protrudes with respect to the
transmission casing (with flex bar fitted) is given by:
L7 = L5 - L9
where:
L 5 and L9 = distance measured with tool 380000263
mounted on surface plate (L5) fig. 107 or on the
transmission casing (L9).
110
2. Move the external position control lever (1) fully
rearward, against the spacer.
111
Adjusting draft control linkage
Test conditions:
engine running at medium speed;
allow the oil in the system to reach a temperature
of 30 - 40 °C (86 - 104 °F).
Then proceed as follows:
5. Move the position control lever (1) fully forward
on the quadrant and the draft control lever (2 ) to
a distance (L1) of 15 - 20 mm
(0.5906 - 0.7874 in.) from the beginning of the
slot.
113
114
Adjusting LIFT-O -M A TIC device
Proceed as follows:
11. Move the position control lever (1) and the draft
control lever (2) fully forward in the sector.
115
12. Raise the lift arms by means of the lever (1).
116
13. Tighten the nut (1) fig. 117, until the arms lower.
14. With the lever (1) fig. 116, still in the same
position, unscrew the nut (1) fig. 117, until the
arms begin to rise.
16. Using the levers (1) and (2) fig. 116, lower and
raise the arms a few times to ensure that the
system is operating correctly.
117
? ? ? ? ? ? ? ? ? - ?? - ????
34 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
118
120
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 35
25720
121
A WARNING A
Handle all parts with the utmost care.
Do not place your hands or fingers between one part
and another. W ear the prescribed safety clothing, in
cluding glasses, gloves and protective footwear.
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 37
124
5. Remove the check valve union (1), spring (2) and
ball (3).
??.??.???.?? - ?? - ????
38 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
127
9. Fit the control valve block pin (2) complete with
seat (3) on the tool 380000274 (1).
128
10. Fit the control valve block pin spring (1) and the
cap (2) of tool 380000274. Tighten the cap as far
as it will go and check that the control valve block
pin slides in its seat.
129
11. Fit tool 380000274 (2) on the hand pump
380000215 (3), supplied with HYDROSYSTEM
68 oil. Connect a dial gauge (1) and secure it with
its screw.
130
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 39
131
15. Operate the hand pump until the oil in the system
is at an initial pressure of 245 bar - 3553.41 psi.
Using the pressure gauge, check that it takes
more than six seconds for the pressure to fall
from 196 bar - 2842.73 psi to
98 bar - 1421.36 psi. If it takes less than this,
replace the control valve block pin. Bear in mind
that this part is supplied together with its seat.
132
??.??.???.?? - ?? - ????
40 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
16. Fit the cylinder safety valve (1) on the valve union
380000218(2) and connect it to the hand pump
380000215 (3).
17. Operate the hand pump (3) and check that the
cylinder safety valve opens at a pressure of
210 - 215 bar (3045.78 - 3118.30 psi). If the
valve setting does not correspond to the speci
fied value, it is best to replace the valve straight
away. If necessary, however, it can be adjusted
by turning the threaded cap using spanner
380000230. Tighten to increase the valve setting
value, or slacken to decrease the value.
18. Fit the hydraulic control valve block as follows:
25720
133
Removal - refitting with pump removed 6. Remove the seals (2) and the anti-extrusion
(Op. 35 0101 10) rings.
Proceed as follows:
1. Remove the cover fastening nuts (20), then the
bolts (15) and the safety washers.
2. Remove the nut (14) that fastens the sleeve to the
pump driving shaft and the safety washer.
3. Remove the front cover (8), the snap ring (12)
and the seals (9 and 11).
4. Mark parts 3, 4, 5 and 6 to enable them to be
remounted in the same position if they are in
good condition.
5. Remove the supports (4 and 6) and the gears (5)
from the rear cover (8) and the pump body (3).
??.??.???.?? - ?? - ????
42 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
mount the seals (9) and (11) fig. 134, on the con
trol side cover (8), complete with spacer (10).
Mount them so that the cavity is between the seal
lips on the opposite side from this spacer. Finally
fill the cavity with AKCELA MULTI-PURPOSE
GREASE 251H EP grease.
??.??.???.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 1
CONTENTS
MAIN DATA
???.??.??.?? - ?? - ????
2 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2
TRE0711A
Section view
2. Spool.
23. Internal plunger. NOTE: Some parts releated with automatic detent
24. Spring. release are not shown in this view. Automatic detent
25. Cover. release working principle of valve shown in Fig. 2 is
26. Detent balls. same as the valve shown at Fig. 9 & Fig. 10.
27. Spool return spring.
28. Spring cup.
32. Float mode selection groove.
???.??.??.?? - ?? - ????
4 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2
□ Pressurised oil
□ Suction, delivery or exhaust oil
□ Static oil
\ \ \ \ \V
TRE0750B
LIFTING
When the spool (2) moves to left, the detent balls (26) exhaust line (T) by way of line (A), intercepting the
engage the groove (33), where they are held in place supply of oil to the hydraulic lift control valve. Automatic
by the support (28) and spring (24). The movement of detent release working principle is explained at
the spool (2) connects: the pressure line (P) with the page 6.
line (B), and also the upper cylinder chamber with the
□ Pressurised oil
□ Suction, delivery or exhaust oil
□ Static oil
TRE0750C
LOWERING
When the spool (2) moves to right, the detent balls line (B), while the upper chamber is connected with
engage in the groove (34) where they are held in the pressure line (P) by way of line (A). On
position by the support (28) and the spring (24). In completion of the lowering operation, the detent will
this condition the oil contained in the lower chamber be automatically released as explained at Page 6.
of the cylinder can flow to the exhaust (T) by way of
?? ? ?? ?? ?? - ? ? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 5
5
2. LOWERING - To lower the implement, push the
control lever (located in the cab) forward. The control
valve spool (2) will move to the position indicated in
fig. 6, thus allowing the oil in the lower cylinder
chamber to flow to the exhaust (T) through line (A),
while the upper chamber is connected to the
pressure line (P) through line (B) .
□ Pressurised oil
□ Static oil
???.??.??.?? - ?? - ????
6 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2
□ Pressurised oil
□ Suction, delivery or exhaust oil
□ Static oil
TRE0716A
©
9
LIFTING
On pulling back the control lever, the spool (2) moves through port (V), it overcomes the resistance of the
and the detent balls (26) engage the groove, where spring of the needle valve (23). Inside chamber (D), the
they are held in place by the support (28) and spring oil pressure increases and, acting on the detent ball
(24). The movement of the spool (2) connects: the support (28), it overcomes the resistance of the spring,
pressure line (P) with the line (B), and also the upper thus moving the support (28). In this condition the two
cylinder chamber with the exhaust line (T) by way of detent balls (26) drop onto the support, releasing the
line (A), intercepting the supply of oil to the hydraulic lift spool (2) which, under the action of spring (6) returns
control valve. to neutral position. Consequently the entire flow from
On completion of the lifting movement, the oil pressure the pump is conveyed to the lift control valve through
increases to 170-175 bar (173-178 kg/cm2). Acting lines (P).
10
LOWERING
To lower the implement, push the control lever by way o f line (B), while the upper chamber is
forward. The control valve spool (2) moves and the connected with the pressure line (P) by way of line
detent balls engage in the central groove where they (A). On completion of the lowering operation, the
are held in position by the support (28) and the spring detent will be automatically released in the manner
(24). In this condition the oil contained in the lower described previously.
chamber of the cylinder can flow to the exhaust (T)
???.??.??.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 7
11
???.??.??.?? - ?? - ????
8 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2
Convertible single/double-acting auxiliary control valve with float control and detent release.
???.??.??.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 9
A WARNING A
During the overhaul and disassem bly-assem bly of
the units, put special protective devices between the
bits of the vice, for preventing any damage to the
valve components.
???.??.??.?? - ?? - ????
10 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2
18
6. Complete spool assembly (Float & detent
release) is shown at Fig.19.
19
7. Remove circlip (1) and take off the washer (2)
Fig. 20. Disassamble the unit to all its
components.
20
8. Disassambled unit (Float & detent release) is
shown at Fig.21.
I
B z t n n o - *» i — udoO d- o o
21
???.??.??.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 11
22
10. Take off the cover (1) Fig. 23.
23
11. Remove the spool assembly (Detent release) (1)
Fig.24.
24
12. Remove the nut (1) Fig.25 fixing the assembly.
25
???.??.??.?? - ?? - ????
12 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2
14. Remove the nut fixing the detent body (1) Fig.27
???.??.??.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 13
30
18. Remove relief valve (1) Fig.31.
31
19. W ithdraw relief valve (1) Fig.32.
32
20. Slacken, single-double acting converting valve
(1) Fig.33.
33
???.??.??.?? - ?? - ????
14 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2
34
22. Take off the ball of, single-double acting convert
ing valve (1) Fig.35.
35
23. Slacken the allen screws (1) fixing the cover the
cover (2) Fig.36.
36
24. W ithdraw the cover (1) and the spacer (2) Fig.37.
25. Check the condition o f all seals before reas
sembly.
37
???.??.??.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 15
Control valve spool binding test (fig. 38). tion) the flow goes through the valve from inlet to
Install the auxiliary control valve assembly and the test outlet (tank line) (P) to (T). Now regulate the
apparatus as indicated in the diagrams (fig. 38 ) and re maximum pressure of the VS (main relief valve)
valve inside bank A (in the schematic). This
ferring to the following instructions:
pressure is the maximum pressure that can be
— The test is carried out with mineral oil in obtained with the type of valve and spring used.
accordance with DIN 32 norm. Flow rate is the Now move each single spool in each section.
nominal for the valve (for VDM07 it is 50 l/min). With the ports closed, the pressure will rise until
Connect line P (pump line) to the inlet port of the the relief valve opens. In this situation check if
valve and close the working ports A and B of spools move to the neutral (central) position
each section (see schematic) with plugs. without sticking, under the action of springs and
Start the test, increasing the flow coming from flow forces only. The relief valve D, in line before
the pump until nominal flow plus 25% is reached the directional valve, has to substitute the VS in
(in the case of VDM07 it is 75 l/min). With the A in case of problems or in case of directional
control lever in the neutral position (m id-posi- valve without VS.
???.??.??.?? - ?? - ????
16 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2
39
Valve leakage test seconds). From this stroke, calculate the volume of
oil per minute through that section of the cylinder.
After the binding test (with hot oil and valve), This check has to be carried out for each section
measure the leakage rate for each section. It is (each spool).
important to do this with the system hot. Connect After this check, with the pump disconnected, move
working ports A and B of each section to the cylinders the spool to its working position: now test the check
(one for each section). Alongside each cylinder lay a valve (VU:Check Valve) of the distributor. This valve
ruler to measure the stroke. closes the connection from P to T (N), also the
Supply oil to the cylinder, moving the spool to the connection P with A or P when B is open (spool in
working position (oil flowing from A or B) until it working position). If the check valve is working
reaches the end of its stroke and the main relief valve correctly, the normal flow rate will be seen (the same
opens. Now that the oil column is pressurised from value observed with spool in the neutral position). If
the working section to the cylinder allow the lever to it is see that one or more sections operates more
return to the neutral position (called 0). The spool than in a previous check, it means that check valve
closes A and B ports. Now check the position of the is not working properly (does not close completely).
cylinder observing the ruler beside it. As the cylinder
moves, check the stroke in a fixed time (say 60
???.??.??.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2 17
After servicing the detent regulating valve or if the will fluctuate and the handle return to the neutral
control levers and spool are returning to neutral pre position. Note the gauge reading immediately
prior to the needle fluctuation. The reading
maturely, the detent regulating valve should be
should be within the specified value
tested as follows: (1741-1886 lbf/in2) 120 bar+10 bar-0 bar.
- Install inlet hose of flowmeter (1) into lift coupler Remove the circlip (33) and the cover (25),
of valve to be tested. (Fig.1. Page.2) of the valve .
???.??.??.?? - ?? - ????
18 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 2
NOTES
???.??.??.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 1
CONTENTS
H y d ra u lic d ia g r a m .......................................................................................................................................... 2
1. F lo w c o n tro l va lv e .
2. P isto n .
3. C h e c k va lve .
4. R e lie f va lve .
T he tra ile r brake valve is m ounted on the rear T h e tra ile r brake valve has priority o v e r th e auxiliary
transm ission casing forw ard o f th e hydraulic lift. It is control valves and th e hydraulic lift.
supplied by the sa m e pu m p as the lift circuit. T h e hydraulic operation o f these valves is described on
pages 3 and 4.
???.??.???.?? - ?? - ????
2 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3
□ S ta tic o il
□ O i l i n s u c tio n
| | T r a c to r b r a k e c ir c u it o il (b ra k e s o f f )
□ P r e e u r is e d o i l
□ E x h a u s t o il flo w
26428
As the pressure of the oil in the trailer brake union (B) Start of braking
increases, it acts on the active surface (13) of the
spool (2), opposing the effect of control fork (F) on B. To trailer brake.
relief valve (4) N. To auxiliary control valves.
P 1 . Oil from the hydraulic pump to lift circuit.
R. Discharge line.
???.??.???.?? - ?? - ????
4 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3
□ Static oil
Braking
B. To trailer brake.
N. To auxiliary control valves.
Diaphragm (11) and restriction (9) cause a pressure P 1 . Oil from the hydraulic pump to lift circuit.
drop in flow control valve (1) which moves to the right R. Discharge line.
to close line (12) and consequently, check valve (3).
???.??.??.?? - ?? - ????
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3 5
V T ra ile r b ra ke c o n tro l v a lv e 7 - F o rk
???.??.???.?? - ?? - ????
6 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 3
999 99 99 99 - ?? - ????
SECTION 41 - STEERING - CHAPTER 1 1
SECTION 41 - STEERING
Chapter 1
CONTENTS
S e ctio n D e s c rip tio n Page
41 000 P r in c ip a l d a t a .............................................................................................................................................................. 1
T ig h te n in g to r q u e s ................................................................................................................................................. 3
S e c tio n v i e w s .............................................................................................................................................................. 4
H y d r a u lic d i a g r a m .................................................................................................................................................... 6
O p e ra tio n ..................................................................................................................................................................... 7
F a u lt d ia g n o s is ......................................................................................................................................................... 9
T o o ls ............................................................................................................................................................................ 10
41 204 30 H y d r o s ta tic s te e rin g c o n tro l v a lv e - R e m o v a l- I n s t a ll a t io n ....................................................................11
41 204 34 H y d r o s ta tic s te e rin g c o n tro l v a lv e - D is a s s e m b ly - A s s e m b ly ........................................................ 14
41 204 38 H y d r o s ta tic s te e rin g c o n tro l v a lv e - B e n c h te s tin g .............................................................................. 2 8
H y d r o s ta tic s te e rin g o il p u m p - D is a s s e m b ly - A s s e m b ly ................................................................ 3 0
41 216 20 S te e r in g c y lin d e r ( t w o - w h e e l d riv e a x le ) - R e m o v a l- R e fitt in g ..................................................... 3 2
S te e r in g c y lin d e r ( fo u r w h e e l d r iv e a x le ) - R e m o v a l- R e fitt in g .................................................... 3 3
PRINCIPAL DATA
HYDROSTATIC STEERING
C o n tro l valve
M ake ........................................................................................................................... DAN FO SS OR ORSTA
T y p e ............................................................................................................................. ro ta ry v a lv e c o n tro lle d d ir e c tly
fr o m th e s te e rin g c o lu m n ; th e
s te e rin g c o n tin u e s to fu n c tio n
e v e n if t h e p u m p is
n o n - f u n c tio n a l
O u tfit c o d e :
- D A N F O S S ............................................................................................................ O S P C 100
- O R S T A .................................................................................................................... L A G -B 1 0 0 -L V P 1 6 -2
- 4 W D m o d e ls ..................................................................................................... 1 2 5 b a r (1 8 1 2 .9 6 p si)
2 SECTION 41 - STEERING - CHAPTER 1
Pum p
B e n c h o u tp u t a t 1 4 5 0 re v /m in a n d p re s s u re o f
1 5 3 b a r (1 5 6 k g /c m 2):
- f o r n e w o r re c o n d itio n e d p u m p ......................... ................. l/m in (in.3/m in) 1 5 .3 (9 3 3 .6 6 )
-fo rw o rn pum p ........................................................... ................. l/m in (in.3/m in) 1 0 .7 (6 5 2 .9 5 )
- t e s t o il t e m p e r a t u r e ................................................. ............................. °C (°F ) 5 5 - 6 5 (131 - 1 4 9 )
- te s t o il v is c o s ity ......................................................... S A E 20
C y lin d e r
T y p e ...................................................................................... D o u b le a c tin g , lo c a te d b e h in d
fr o n t a x le
C o n s t r u c t io n ..................................................................... W E B E R o r S IM A o r E R B E R
S IM A .................................................................................... 2 1 4 m m (8 .4 2 5 in)
M a x im u m p is to n s tr o k e
W E B E R o r E R B E R ...................................................... 2 0 0 m m (7 .8 7 4 in)
S IM A .................................................................................... 1 9 4 m m ( 7 .6 3 8 i n )
SECTION 41 - STEERING - CHAPTER 1 3
TORQUE SETTINGS
T o rq u e s e ttin g
PART T h re a d
Nm ft lb
M 8x1* 29 2 1 .3 8 9 3
N u t, p is to n to ro d
- W E B E R c y lin d e r ....................................................................................................... M 1 6 x 1 .5 83 6 1 .2 1 7 7
- S I M A c y li n d e r ............................................................................................................... M 1 6 x 1 .5 98 7 2 .2 8 1 1
- E R B E R c y l i n d e r .......................................................................................................... M 1 6 x 1 .5 98 7 2 .2 8 1 1
C a p s c re w , c o n to l v a lv e s u p p o r t .......................................................................... M 1 6 x 1 .5 147 1 0 8 .4 2 1 6
C a p s c re w , L V P s a fe ty v a lv e b lo c k to b o d y .................................................... - 64 4 7 .2 0 4 0
* ORSTA
4 SECTION 41 - STEERING - CHAPTER 1
H y d ro s ta tic s te e rin g - O il p um p c o m p o n e n ts
1. F ro n t c o v e r 11. D riv in g s h a ft s e a l
2. C o v e r s e a ls 12. S n a p rin g
3. P um p body 13. Lock w asher
4. G e a r s u p p o rt 14. Nut
5. D riv e n a n d d riv in g g e a r s h a fts 15. B o lt
6. G e a r s u p p o rt 16. W asher
7. B u s h in g 17. Key
8. C o n tr o l s id e c o v e r 18. B u s h in g .
9. D riv in g s h a ft s e a l 19. S a fe ty w a s h e r
10. S pacer 20. N u t.
SECTION 41 - STEERING - CHAPTER 1 5
24725
1. D ust seal
2. R e flu x v a lv e b a lls 12. R o to r c o n tro l s h a ft -- s le e v e tr im pin
3. R e flu x v a lv e p in s 13. C o v e r fix in g s c re w s
4. C o n tro l v a lv e b o d y , ro ta ry v a lv e a n d ro ta r y 14. C h e c k v a lv e s e a t s c r e w
v a lv e s e a t s le e v e 15. W a s h e rs
5. C h e c k v a lv e b a ll 16. C over
6. T h re a d e d p lu g o f c h e c k v a lv e 17. O --rin g s
7. O - r in g s e a l 18. R o to r a n d fix e d rin g f o r ro to r
8. S u p p o r t rin g f o r O - r in g (7) 19. T h ru s t w a s h e r
9. T h r u s t b e a rin g c o m p o n e n ts 20. O --rin g
10. R e ta in in g rin g f o r s p r in g s (11) 21. R o to r c o n tro l s h a ft
11. S p rin g s f o r r e tu r n in g s le e v e to ne utra l p o s itio n 22. P r e s s u r e r e lie f v a lv e c o m p le te w ith s p rin g
6 SECTION 41 - STEERING - CHAPTER 1
TRE0431A
3
G eneral h y d ra u lic diagram
H P o w e r s te e rin g c y lin d e r 2 6 O il in in ta k e lin e
P Pum p S - O il a t lu b r ic a tio n p re s s u re
SECTION 41 - STEERING - CHAPTER 1 7
OPERATION d ir e c t m e c h a n ic a l c o n n e c tio n b e tw e e n th e c o lu m n
a n d th e s te e re d w h e e ls .
T h e o il ta k e n in b y th e re a r a x le is p u s h e d in to th e
N eutral p o s itio n
p u m p th r o u g h a filte r, p re s s u r iz e d b y th e ro ta tin g W hen th e s te e rin g w heel is s ta tio n a ry , th e le a f
g e a r s a n d e x p e lle d fr o m th e d e liv e r y s id e o f th e s p rin g s in th e s te e rin g m o to r p u s h th e s p o o l a n d th e
p u m p to th e s te e rin g m o to r. O n c e in th e s te e rin g s le e v e in, a n d k e e p t h e m in th e n e u tr a l p o s itio n . T h is
m o to r, th e p r e s s u riz e d o il is d ire c te d to th e s te e rin g e n s u re s t h a t n o fu r t h e r o il is s u p p lie d to th e s te e rin g
c y lin d e r w h e n th e s te e rin g w h e e l is tu rn e d . c y lin d e r. T h e s le e v e a ls o b lo c k s th e o il in s id e th e
c y lin d e r, k e e p in g th e w h e e ls in a s e t p o s itio n , fig . 4.
In s id e th e s te e rin g m o to r, th e r e is a m e a s u rin g
d e v ic e w h ic h c o n tro ls th e v o lu m e o f o il s u p p lie d to □ O il in in ta k e lin e
th e c y lin d e r s o t h a t it is p r o p o rtio n a l to th e a n g u la r
m o v e m e n t o f th e s te e rin g w h e e l. T h e m e te rin g v a lv e □ O il
to g e t h e r w it h th e in ta k e v a lv e s a ls o a llo w s M ANUAL □ O il
□
o p e ra tio n o f th e s te e rin g , w ith o u t p re s s u r iz e d oil
b e in g e m itte d b y th e p u m p . O il
T h e s y s te m is t o ta lly h y d r o s ta tic a n d a s s u c h , h a s no
a 2 W D m o d e ls 7. P u m p
1. E q u a liz a tio n v a lv e 8. F ilte r
2. S te e rin g c y lin d e r 9. R e tu rn lin e to r e s e r v o ir
3. M e te rin g v a lv e 10. P re s s u r e r e lie f v a lv e
4. C h e c k v a lv e 11. C o n tro l v a lv e e x te rn a l ro to r
5. N o n - r e t u r n v a lv e 12. C o n tr o l v a lv e in te rn a l ro to r
6. R esonance dam per 13. A n t i- c a v it a t io n v a lv e s
8 SECTION 41 - STEERING - CHAPTER 1
□ O il re tu rn in g to r e s e r v o ir
SECTION 41 - STEERING - CHAPTER 1 9
P ro b le m P o s s ib le c a u s e s C o r r e c tiv e a c tio n
15. S e a lin g w a s h e rs (1 5 ) or R e n e w th e w a s h e r s a n d s e a ls .
O - r in g s (1 7 ) d e fe c tiv e .
S te e rin g w h e e l e x c e s s iv e ly s t if f 1. H y d r a u lic p u m p in e ffic ie n t. R e p a ir th e p u m p .
2. C h e c k v a lv e (5 ) h e ld o p e n b y E lim in a te fo re ig n b o d ie s a n d c le a n
fo re ig n b o d ie s o r o p e n d u e to th e filte r; p u t a n e w b a ll in to th e s e a t
a b s e n c e o f b a ll. ( if m is s in g ).
3. P re s s u r e r e lie f v a lv e (2 2 ) R e s e t th e v a lv e .
in c o r r e c tly s e t.
4. P re s s u r e r e lie f v a lv e (2 2 ) E lim in a te fo re ig n b o d ie s a n d c le a n
ja m m e d o r h e ld o p e n b y f o r th e filte r.
e ig n b o d ie s .
5. S te e r in g c o lu m n h a s b e c o m e E lim in a te th e c a u s e s .
s t if f on its b u s h in g due to
ru s tin g , s e iz in g , e tc .
3. E x c e s s iv e p la y in th e s p lin e d R e n e w th e w o r n p a rts .
c o u p lin g b e tw e e n th e s h a ft
(2 1 ) a n d th e r o to r (1 8 ).
4. C o m b in a tio n of e x c e s s iv e R e n e w th e m o s t w o rn p a rts .
p la y a s d e s c r ib e d a b o v e .
5. L e a f s p rin g s (1 1 ) b ro k e n or R e n e w th e s p rin g s .
fa tig u e d .
a . S lo w . 2. C y lin d e r ro d b ro k e n . R e n e w th e d a m a g e d p a rt.
2. C h e c k v a lv e d a m a g e d . R e n e w th e c o n tro l v a lv e .
(continued)
10 SECTION 41 - STEERING - CHAPTER 1
(continuation)
P ro b le m P o s s ib le c a u s e s C o r r e c tiv e a c tio n
T h e w h e e ls d o n o t m a in ta in th e 1. H y d r a u lic c y lin d e r p is to n s e a l R e n e w th e s e a l.
d e s ire d a lig n m e n t a n d c o n tin u a l w o rn .
c o r re c tio n w ith th e s te e rin g w h e e l 2. R e flu x v a lv e (2) d a m a g e d o r E lim in a te th e fo re ig n b o d ie s and
is n e c e s s a ry . he ld o p e n b y fo re ig n b o d ie s. c le a n th e filt e r o r r e n e w th e c o n tro l
v a lv e .
3. M e c h a n ic a l w e a r o f c o n tro l
v a lv e . R e n e w th e c o n tro l v a lv e .
L is t o f s p e c ia l to o ls n e c e s s a r y f o r th e v a rio u s
TOOLS o p e r a tio n s d e s c r ib e d in th is s e c tio n .
3. To a c c e s s th e e n g in e th e hood m u s t be
opened.
4. D is c o n n e c t th e o il p ip e s fr o m th e h y d r o s ta tic
s te e rin g c o n tro l v a lv e u n it (1 ).
5. R e m o v e th e s te e rin g w h e e l (1 ) re ta in in g n u t a n d
re m o v e th e s te e rin g w h e e l a n d h a n d th r o ttle
le v e r.
9
12 SECTION 41 - STEERING - CHAPTER 1
6. R e m o v e th e f o u r s e c u rin g s c r e w s (1 ) fr o m th e
in s tr u m e n t p a n e l (2 ).
10
7. D is c o n n e c t th e e le c tric a l le a d s (1 ) fr o m th e re a r
of th e in s tr u m e n t p a n e l. U n s c re w th e th e
t a c h o m e t e r c a b le (2 ). R e m o v e th e in s tr u m e n t
p a n e l a n d s to r e in a s a fe p la c e .
11
8. .U n s c re w th e r e a r h o o d s c r e w s (1)
12
9. T a k e o f f t h e c o m p le te re a r h o o d
13
SECTION 41 - STEERING - CHAPTER 1 13
14
-- R e fit th e c o m p le te re a r h o o d .
-- S e c u r e th e r e a r h o o d w ith th e s c r e w s p re v io u s ly
re m o v e d .
-- R e c o n n e c t th e e le c tric a l le a d s a n d re c o n n e c t
th e th e t a c h o m e t e r c a b le .
-- R e --in s ta ll th e fo u r s c re w s s e c u r in g th e
in s tr u m e n t p a n e l.
-- R econnect th e o il p ip e s to th e h y d r o s ta tic
s te e rin g c o n tro l v a lv e u n it.
-- R e c o n n e c t th e n e g a tiv e c a b le to th e b a tte ry a n d
c lo s e th e h o o d .
14 SECTION 41 - STEERING - CHAPTER 1
1. R e m o v e th e c o n tro l v a lv e c o v e r re ta in in g b o lts .
15
2. R e m o v e th e c o v e r b y s lid in g to o n e s id e .
16
3. R e m o v e th e r o to r fix e d rin g , th e r o to r a n d th e
in n e r s p a c e r.
4. R e m o v e th e tw o O --rin g s e a ls o n th e r o to r fix e d
rin g .
18
SECTION 41 - STEERING - CHAPTER 1 15
6. E x tr a c t th e th r u s t w a s h e r.
19
7. R e m o v e th e th r e a d e d p lu g o n th e n o n --re tu rn
v a lv e s e a t.
20
8. E x tr a c t th e O --rin g s e a l fr o m th e c o n tro l v a lv e
b o d y.
21
9. P o s itio n th e c o n tro l v a lv e b o d y a n d th e ro to r
d riv e s h a ft s o t h a t th e s le e v e --c o n tro l s h a ft trim
p in is in a h o r iz o n ta l p o s itio n .
10. P u s h th e r o ta ry v a lv e in w a rd s , s o t h a t th e v a lv e ,
th e v a lv e s e a t s le e v e a n d th e th r u s t b e a rin g c a n
b e e x tr a c te d fr o m th e c o n tro l v a lv e b o d y.
22
16 SECTION 41 - STEERING - CHAPTER 1
24
25
13. Extract the rotary valve from the valve seat sleeve
26
SECTION 41 - STEERING - CHAPTER 1 17
27
15. R e m o v e th e d u s t s e a l a n d th e O - r in g s e a l fro m
t h e ir s e a ts in th e c o n tro l v a lv e b o d y.
28
16. U s in g a 6 mm A lle n w re n c h , re m o v e th e
th r e a d e d p lu g s fr o m th e tw o c y lin d e r s a fe ty
v a lv e s a n d e x tr a c t th e s e a ls .
29
18. T u rn th e c o n tro l v a lv e b o d y o v e r a n d e x tr a c t th e
b a lls , th e s p r in g s a n d th e s p r in g g u id e s fr o m th e
tw o c y lin d e r s a fe ty v a lv e s .
30
18 SECTION 41 - STEERING - CHAPTER 1
C y lin d e r s a fe ty v a lv e s c o m p o n e n ts (o rd e r of
d is a s s e m b ly - a s s e m b ly ) .
1. C y lin d e r s a fe ty v a lv e b a ll.
2. P re s s u r e s p rin g .
3. S e ttin g a d ju s te r s c re w .
4. S e a l.
5. P lu g .
31
19. U s in g a 6 mm A lle n w re n c h , re m o v e th e
th r e a d e d p lu g o n th e p r e s s u re r e lie f v a lv e a n d
e x tr a c t th e s e a l.
32
20. R e m o v e th e p re s s u re r e lie f v a lv e a d ju s te r s c re w .
21. T u rn th e c o n tro l v a lv e b o d y o v e r a n d c o m p le te
d is a s s e m b ly b y e x tra c tin g th e s p r in g a n d th e
p r e s s u re r e lie f v a lv e p is to n .
33
P re s s u re r e lie f v a lv e c o m p o n e n ts (o rd e r of
a s s e m b ly ).
1. P re s s u r e r e lie f v a lv e .
2. P re s s u re s p rin g .
3. S e ttin g a d ju s te r s c re w .
4. S e a l.
5. P lu g .
34
SECTION 41 - STEERING - CHAPTER 1 19
35
36
28. A fter inserting the springs in the seat, align and
centre (as shown in the drawing).
37
20 SECTION 41 - STEERING - CHAPTER 1
40
1. B e a rin g e x te rn a l rin g .
2. T h r u s t b e a rin g .
©—
3. B e a rin g in te rn a l rin g w ith b e v e l fa c in g c o n ta c t
s u r fa c e o f p a rt (5 ).
4. R o ta ry v a lv e .
5. R o ta r y v a lv e s e a t s le e v e .
41
SECTION 41 - STEERING - CHAPTER 1 21
42
34. In s e rt th e c o m p le te d r ift in th e g u id e b u s h in g
p r e v io u s ly in s ta lle d .
44
22 SECTION 41 - STEERING - CHAPTER 1
45
48
SECTION 41 - STEERING - CHAPTER 1 23
39. R o ta te th e c o n tro l v a lv e b o d y a n d in s e r t th e
n o n --re tu rn v a lv e b a ll in to th e s e a t in d ic a te d b y
th e a rro w .
40. S c r e w th e th re a d e d p lu g in to th e n o n --re tu rn
v a lv e s e a t u n til th e u p p e r s u r fa c e is b e lo w th e
c o u p lin g s u r fa c e o f th e c o n tro l v a lv e b o d y.
50
41. L u b r ic a te th e O - r in g s e a l a n d in s e rt in to th e s e a t
o n th e c o n tro l v a lv e b o d y.
42. F it th e th r u s t w a s h e r, s o th a t th e h o le s c o in c id e
w ith th e h o le s in th e c o n tro l v a lv e b o d y.
52
24 SECTION 41 - STEERING - CHAPTER 1
53
44. Fit the rotor drive shaft into the control valve
body. Insert tool 380000307 for retaining and
centring the rotor drive shaft, between the rotor
drive shaft and the thrust washer. Rotate the
shaft so as to facilitate coupling between the seat
(2) fig. 53 and the trim pin installed in the sleeve.
54
55
SECTION 41 - STEERING - CHAPTER 1 25
56
57
59
26 SECTION 41 - STEERING - CHAPTER 1
50. T u rn o v e r th e c o n tro l v a lv e b o d y a n d in s e rt th e
p r e s s u re r e lie f v a lv e p is to n in th e s e a t, as
in d ic a te d in th e d ra w in g . See fig . 34 fo r
c o m p o n e n t a s s e m b ly o rd e r.
61
52. U s in g a n 8 m m A lle n w re n c h , in s e r t t h e p r e s s u re
r e lie f v a lv e s e ttin g s c re w .
62
53. T ig h te n th e p lu g (2 ), w ith th e a s s o c ia te d s e a l,
u s in g a n 8 m m A lle n w re n c h . T ig h te n to th e
p re s c rib e d to r q u e v a lu e 40 -- 60 Nm
(2 9 .5 0 2 5 - 4 4 .2 5 3 7 ft lb ), a f te r h a v in g c a rrie d o u t
th e s e ttin g o n th e w o r k b e n c h o r o n th e tra c to r.
54. In s e rt th e b a lls (1 ) in to th e tw o c y lin d e r s a fe ty
v a lv e s e a ts , in d ic a te d b y th e a rro w s . S e e fig . 6 4
c o m p o n e n t a s s e m b ly o rd e r.
63
SECTION 41 - STEERING - CHAPTER 1 27
C y lin d e r s a fe ty v a lv e s c o m p o n e n ts (o rd e r of
a s s e m b ly )
1. C y lin d e r s a fe ty v a lv e b a ll.
2 . P r e s s u r e s p rin g .
3. S e ttin g a d ju s te r s c re w .
4 . S e a l.
5. P lu g .
64
20475
65
66
58. W h e n th e u n it h a s b e e n a s s e m b le d , in s e rt th e
d u s t s e a l in th e s e a t in th e c o n tro l v a lv e b o d y.
24764
67
28 SECTION 41 - STEERING - CHAPTER 1
1. M a k e th e c o n n e c tio n s s h o w n in fig . 6 8 a n d
c o m p le te th e c ir c u it a s in fig . 6 9 . U s in g th e
s p lin e d c o n tro l s h a ft (1 ), h o ld th e s te e rin g c o n tro l
v a lv e in s te e rin g p o s itio n (rig h t o r le ft).
2. U s in g th e h a n d w h e e l (5 ), in c re a s e th e c irc u it
p r e s s u re to a s n e a r a s p o s s ib le th e p re s s u re
r e lie f v a lv e c ra c k in g p r e s s u re (p a g e 1) w ith o u t
th e v a lv e a c tu a lly o p e n in g .
3. U s in g a to r q u e w r e n c h (2 ), a p p ly a to r q u e o f
a p p ro x . 3 4 N m (2 5 .8 1 4 7 ft lb ) to th e c o n tro l s h a ft
(1 ), a n d c h e c k t h a t th e ro ta ry v a lv e ta k e s m o re
th a n 10 s e c o n d s to c o m p le te o n e fu ll ro ta tio n . If
it t a k e s le s s th a n 10 s e c o n d s , c h a n g e th e ro ta ry
v a lv e (4, fig . 2 ) a n d th e s le e v e .
SECTION 41 - STEERING - CHAPTER 1 29
24911
©
1. S p lin e d c o n tro l s h a ft 69
2. P lu g G 1 /2 ”
3. To th r o ttle
4. O u tle t
5. T h r e e - w a y c o u p lin g G 1 /2 ”
6. F ro m d e liv e r y lin e
CHECKING THE HYDROSTATIC STEERING 7. O u tle t c o u p lin g G 1 /2 ”
PRESSURE RELIEF VALVE W ITH STEERING
CONTROL VALVE INSTALLED ON TRACTOR.
P ro c e e d a s fo llo w s :
1. S ta r t t h e e n g in e a n d ru n u n til th e o il t e m p e r a tu r e
re a c h e s a p p ro x . 5 0 ° C ( 1 2 2 ° F ).
2. S w itc h o f f t h e e n g in e a n d u n s c r e w th e o il d e liv e ry
p ip e u n io n (4 ) o n th e h y d r a u lic c y lin d e r (5 ).
3. F it u n io n (2 ) in p la c e o f u n io n (4 ), a n d c o n n e c t th e
p r e s s u re g a u g e (1 ) w ith a 0 - 2 1 .3 3 5 0 p s i s c a le
b y w a y o f u n io n (3 ).
4. S ta r t th e e n g in e a g a in , b rin g th e s p e e d u p to
m e d iu m rp m , a n d a p p ly f u ll- s te e r in g lo c k to
b rin g th e h y d r a u lic c y lin d e r to th e s t r o k e - e n d
p o s itio n .
In th is c o n d itio n , th e p r e s s u re r e lie f v a lv e (2 2 , fig . 2 ) 380000240 )
1. P re s s u re g a u g e (s u p p lie d in k it
s h o u ld o p e n a n d th e p re s s u re g a u g e s h o u ld in d ic a te 2 . U n io n 380000618 (s u p p lie d in k it 380000240 ) to
th e v a lu e g iv e n o n p a g e 1. b e fitte d in p la c e o f o r ig in a l u n io n
5. If th e p re s s u r e g a u g e re a d in g d e v ia te s s ig n ifi 3. U n io n 380000613 (s u p p lie d in k it 380000240 )
c a n tly fr o m th e p re s c rib e d v a lu e , a d ju s t th e v a lv e 4 . H y d r a u lic c y lin d e r o il fe e d p ip e
o p e n in g p re s s u r e b y w a y o f t h e a d ju s te r s c re w . 5. H y d r a u lic c y lin d e r.
30 SECTION 41 - STEERING - CHAPTER 1
H y d ro s ta tic s te e rin g o il p um p c o m p o n e n ts
11 .D riv in g s h a ft s e a l.
1. F r o n t c o v e r
12. S n a p rin g
2. C o v e r s e a ls
13. S a fe ty w a s h e r
3. P u m p b o d y
14. N u t
4. G e a r s u p p o r t
15. B o lt
5. D riv e n a n d d r iv in g g e a r s h a fts
16. W a s h e r
6. G e a r s u p p o r t
17. K e y
7. B u s h in g
18. B u s h in g
8. C o n tro l s id e c o v e r
19. S a fe ty w a s h e r
9. D riv in g s h a ft s e a l
20. N ut
10. S p a c e r
P r o c e e d a s fo llo w s :
1. R e m o v e th e c o v e r fa s te n in g n u ts (2 0 ), th e n th e
b o lts (1 5 ) a n d th e s a fe ty w a s h e r s .
2. R e m o v e th e nut (14) th a t fa ste n s th e sle e ve to th e
p u m p driving sh a ft and th e sa fe ty w asher.
3. R e m o v e th e fr o n t c o v e r (8 ), th e s n a p rin g (1 2 )
a n d th e s e a ls ( 9 a n d 11 ).
4 . M a r k p a rts 3, 4, 5 a n d 6 to e n a b le th e m to be
re m o u n te d in th e s a m e p o s itio n if th e y a re in g o o d
c o n d itio n .
SECTION 41 - STEERING - CHAPTER 1 31
5. R e m o v e th e s u p p o r ts (4 a n d 6 ) a n d th e g e a rs
(5 ) fr o m th e re a r c o v e r (8 ) a n d th e p u m p b o d y (3 ).
6 . R e m o v e th e s e a ls (2 ) a n d th e a n ti--e x tru s io n
r in g s .O n c e th e p a rts a re re m o v e d , p ro c e e d a s
fo llo w s :
7. C h e c k t h a t th e g e a r c o n ta c t s u r fa c e s a re fla t
a n d p e rp e n d ic u la r to t h e ir s u p p o rts . In te rp o s e a
th in la y e r o f c a rb o n b la c k . S m a ll ro u g h s p o ts c a n
b e r e m o v e d u s in g e x tr e m e ly fin e a n d a d e q u a te ly
lu b ric a te d a b ra s iv e p a p e r.
8. C h e c k t h a t th e a x ia l p la y o f th e g e a r- -s u p p o rt
u n it in th e p u m p b o d y is 0 .1 0 0 - 0 .1 8 0 m m
(0 .0 0 3 9 - 0 .0 1 8 9 in .). T h e d is ta n c e (F ig 7 2 , 2 )
m u s t b e 0 .1 0 0 - 0 .1 8 0 m m ( 0 .0 0 3 9 - 0 .0 1 8 9 in .)
s m a lle r t h a n th e d is ta n c e (F ig 7 2 , 1 ) .If n e c e s s a ry ,
tr u e th e fla t s u r fa c e s in v o lv e d u s in g lu b ric a te d
a b r a s iv e p a p e r to re m o v e e x tr e m e ly s m a ll
q u a n titie s o f m a te ria l
9. C le a n a ll c o n s titu e n t p a rts th o ro u g h ly .
1 0. R e p la c e th e s e a ls (2, 9 a n d 11).
11. L u b r ic a te th e p a rts w ith th e s a m e o il a s th e
s y s te m R e fit th e p u m p , re fe rr in g to fig . 71 a n d
p r o c e e d in g a s fo llo w s :
1 2. re fit, p e rfo r m in g o p e r a tio n s 6 to 1 in re v e rs e
o rd e r;-- a lw a y s e n s u r e th e m a x im u m c le a n lin e s s
72
to p re v e n t fo re ig n m a tte r fr o m e n te rin g , a s th is
c o u ld d a m a g e th e p u m p ;-- fit t o g e t h e r p re v io u s ly
m a rk e d p a rts (3, 4, 5 a n d 6 , fig . 7 1 ); s e e o p . p a g e
4 5 to re fit th e m in t h e ir o r ig in a l p o s it io n ; - m o u n t
th e g e a r s u p p o r ts (4 a n d 6 fig . 7 1 ) in th e
p u m p b o d y ; o rie n t th e m w ith th e fittin g s o n th e
e x te rn a l c ir c u m fe r e n c e m a tc h e d u p w ith th e
d is c h a r g e p ip e s a n d th e fr o n t fa c e s w ith
lu b ric a tio n m illin g s in c o n ta c t w ith th e g e a r s ; - fit
th e p la s tic a n t i- e x t r u s io n rin g s o n th e s e a ls
(2, fig . 7 1 ) ; - m o u n t th e s e a ls (9 a n d 11, fig . 7 1 ) on
th e c o n tro l s id e c o v e r (8 ) c o m p le te w ith s p a c e r
(1 0 ); o r ie n t t h e m s o t h a t th e c a v ity is b e tw e e n th e
s e a l lip s o n th e o p p o s ite s id e fr o m th is s p a c e r;
la s tly fill th is c a v ity w ith A K C E L A MULTI -
PURPOSE GREASE g r e a s e .In s ta ll th e p u m p on
th e tr a c to r . F ill th e s u c tio n p ip e a n d th e p u m p
h o u s in g w ith A K C E LA NEXPLORE o il in o r d e r t o
f a c ilita te p rim in g a n d p re v e n t th e ris k o f s e iz u r e
d u rin g in itia l o p e ra tio n .
32 SECTION 41 - STEERING - CHAPTER 1
To re m o v e th e fr o n t a x le s te e rin g c y lin d e r, p ro c e e d
a s fo llo w s :
1. R e m o v e th e e x h a u s t p ip e , lift th e hood and
d is c o n n e c t th e n e g a tiv e c a b le fr o m th e b a tte ry . 73
2. U n s c re w t h e u n io n s s e c u rin g th e o il d e liv e r y a n d
re tu rn h o s e s (1 ) to th e c y lin d e r (2 ).
3. R e m o v e th e n u t s e c u rin g th e c y lin d e r ro d b a ll
e n d to th e s te e rin g a rm (1 ).
74
75
5. R e m o v e th e p in s e c u rin g th e s te e rin g c y lin d e r
(1 ) to th e a x le a n d re m o v e th e c y lin d e r.
6. To re fit t h e s te e rin g c y lin d e r, fo llo w t h e re m o v a l
p ro c e d u re in re v e r s e o rd e r.
76
SECTION 41 - STEERING - CHAPTER 1 33
To re m o v e th e fr o n t a x le s te e rin g c y lin d e r, p ro c e e d
a s fo llo w s :
1. D is c o n n e c t th e n e g a tiv e c a b le fr o m th e b a tte ry .
2. U n s c re w th e u n io n s s e c u r in g th e d e liv e r y a n d
re tu rn h o s e s to th e s te e rin g c y lin d e r.
3. R e m o v e th e s n a p rin g (1 ) a n d re m o v e th e
c y lin d e r ro d a r tic u la tio n p in (2 ) c o n n e c te d to
th e s tu b a x le h o u s in g .
78
4. R e m o v e th e re ta in in g s c r e w a n d e x tr a c t th e pin
(1 ) s e c u rin g th e s te e rin g c y lin d e r to th e a x le .
R e m o v e th e s te e rin g c y lin d e r.
NOTE: S h o u ld y o u w a n t to re m o v e b o th s te e rin g
c y lin d e rs c o m p le te w ith s u p p ly p ip e s , o m it s te p 3
d e s c rib e d a b o v e a n d c a r r y o u t s te p s 2 a n d 4 f o r th e
o th e r c y lin d e r to o .
79
5. R e m o v e th e tw o a c tu a to r c y lin d e rs c o m p le te
w ith s u p p ly p ip e s .
80
34 SECTION 41 - STEERING - CHAPTER 1
SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1 1
CONTENTS
44 000 P r in c ip a l d a t a .............................................................................................................................................................. 1
S e c tio n a l v ie w s ......................................................................................................................................................... 3
T o rq u e s e ttin g s ......................................................................................................................................................... 4
E q u ip m e n t - F a u lt d i a g n o s i s ............................................................................................................................. 5
44 101 30 R e m o v a l- R e fitt in g - O v e r h a u l ............................................................................................................................ 6
44 101 22 W h e e l h u b d is a s s e m b ly - a s s e m b ly ................................................................................................................ 9
44 101 46 S tu b a x le o v e rh a u l ................................................................................................................................................ 16
44 101 80 C h e c k in g w h e e l a l ig n m e n t ................................................................................................................................. 20
PRINCIPAL DATA
W h e e l a n g l e ............................................................................................................ 2 °, c o r re s p o n d in g to 15 m m
(0 .5 9 0 6 in .) f o r 16 in. w h e e ls
T o e - in ........................................................................................................................ m m (in .) 0 - 5 (0 - 0 .1 9 6 9 )
D ia m e te r o f s tu b a x le p in (7, p a g e 3 ) a t b u s h in g ................................ mm 3 7 .9 6 1 - 3 8 .0 0 0
(in .) (1 .4 9 4 5 - 1 .4 9 6 1 )
C le a r a n c e b e tw e e n s tu b a x le p in a n d r e la tiv e b u s h i n g s ................. mm 0 .0 5 0 - 0 .1 7 9
(in .) ( 0 .0 0 2 0 - 0 .0 0 7 0 )
C le a r a n c e b e tw e e n s tu b a x le p in a n d b u s h i n g ..................................... mm 0 .0 5 0 - 0 .1 7 9
(in .) ( 0 .0 0 2 0 - 0 .0 0 7 0 )
MAIN DATA
(cont.)
JX 80
1510 1410 1510 1610 1710 1810 1910
JX 90 7 . 5 0 - 1 8 in.
(5 9 .4 4 8 7 ) (5 5 .5 1 1 7 ) (5 9 .4 4 8 7 ) (6 3 .3 8 5 7 ) (6 7 .3 2 2 7 ) (7 1 .2 5 9 7 ) (7 5 .1 9 6 7 )
JX 95
1
SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1 3
F ro n t axle to rq u e s e ttin g s
TORQUE SETTINGS
T o rq u e s e ttin g
PART T h re a d
Nm ft lb
F ro n t axle
B o lt s e c u rin g a x le to e n g in e ( 5 ) .......................................................................... M 1 8 x 1 ,5 353 4 7 8 .6 0 4 5
EQUIPMENT
L is t o f s p e c ia l to o ls n e c e s s a ry f o r th e v a rio u s
W ARNING: T h e o p e r a tio n s d e s c rib e d in th is s e c tio n o p e r a tio n s d e s c r ib e d in th is s e c tio n .
m u s t b e p e r fo rm e d o n ly w ith th e ESSENTIAL
e q u ip m e n t m a rk e d w ith (X ) .
To o p e ra te s a fe ly a n d a c h ie v e b e s t re s u lts , w h ile
X 380000541 A d a p t o r ( M 1 2 x 1 .2 5 ) fo r a x le
s a v in g tim e a n d e ffo rt, e s s e n tia l e q u ip m e n t m u s t be
a r tic u la tio n p in (u s e w ith s lid e
used in c o n ju n c tio n w ith th e s p e c ia l to o ls
ham m er 380000549 )
re c o m m e n d e d b e lo w a n d to o ls w h ic h y o u m u s t m a k e
y o u r s e lf a n d f o r w h ic h y o u w ill fin d th e d e s ig n in th is
m a n u a l.
380000237 W h e e l liftin g h o o k .
FAULT DIAGNOSIS
P r o b le m P o s s ib le c a u s e C o r r e c tiv e a c tio n
A b n o r m a l w e a r o f ty re s . 1. In c o rre c t ty r e p re s s u re . In fla te th e ty r e s to th e c o r re c t
p re s s u re , re fe rrin g to th e p re s s u re s
re c o m m e n d e d in th e U se an d
M a in te n a n c e handbook, and m o re
e sp e cia lly, to th e p re s s u re s
re c o m m e n d e d b y th e m a n u f a c t u r e r o f
2. In c o r r e c t to e --in o f fr o n t th e ty r e s fitte d .
w h e e ls . C o r r e c t th e to e --in .
FRONT A X LE
R e m o v a l-R e fittin g (Op. 44 101 30)
A DANGER A ---------
L ift a n d h a n d le a ll h e a v y p a rts w ith liftin g e q u ip m e n t
o f s u ita b le c a p a c ity . M a k e c e rta in t h a t th e u n its o r
p a rts a re s u p p o rte d b y a p p r o p r ia te s lin g s a n d
h o o k s . E n s u re t h a t th e re a re n o p e rs o n s in th e
v ic in ity o f t h e lo a d to b e lifte d .
To re m o v e th e c o m p le te a x le fr o m th e tra c to r,
p ro c e e d a s fo llo w s :
1. D is c o n n e c t th e n e g a tiv e c a b le fr o m th e b a tte ry
a n d is o la te it; c h o c k th e r e a r w h e e ls .
2. L ift th e fr o n t o f t h e tra c to r.
3. P la c e a s ta n d (1 ) b e n e a th th e e n g in e s u m p ,
in s e rtin g a b lo c k o f w o o d b e tw e e n th e e n g in e
s u m p a n d s ta n d .
6
SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1 7
5. D is c o n n e c t th e h o s e s (1 ) o f th e p o w e r s te e rin g
c y lin d e r (2 ).
7. S e c u re th e a x le b y m e a n s o f a s lin g (1 ).
10
8 SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1
9. R e m o v e th e c o m p le te a x le (1 ).
11
12
12. R e c o n n e c t th e h o s e s (1 ) o f th e p o w e r s te e rin g
c y lin d e r (2 ).
13
SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1 9
AX LE W H EEL HUB
R e m o v a l-R e fittin g (Op. 44 101 22)
R em oval:
------------ A WARNING A -----------
H a n d le a ll p a rts w ith g r e a t c a re . D o n o t p u t y o u r
h a n d s o r fin g e r s b e tw e e n o n e p a rt a n d a n o th e r.
W e a r th e re c o m m e n d e d s a fe ty c lo th in g s u c h a s
g o g g le s , g lo v e s a n d s a fe ty b o o ts .
1. D is c o n n e c t th e n e g a tiv e c a b le o f th e b a tte ry a n d
is o la te it; c h o c k th e r e a r w h e e ls .
2. L ift th e fr o n t o f t h e tra c to r.
14
3. P la c e a l s ta n d (1 ) b e n e a th th e e n g in e s u m p ,
in s e rtin g a b lo c k o f w o o d b e tw e e n th e e n g in e
s u m p a n d s ta n d .
15
4. R e m o v e th e fr o n t w h e e l fix in g b o lts
16
10 SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1
5. R e m o v e th e w h e e l h u b b e a rin g c o v e r (1 ).
17
6. R e m o v e th e g r e a s e n ip p le a s s h o w n in fig u re .
18
7. R e m o v e th e s p lit p in (1 ) s e c u rin g th e w h e e l h u b
b e a rin g a d ju s te r n u t.
19
8. U s in g a s o c k e t w r e n c h , u n s c r e w th e w h e e l h u b
b e a rin g a d ju s te r n u t.
20
SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1 11
9. R e m o v e th e w h e e l h u b b e a rin g a d ju s te r n u t (1 ).
21
10. R e m o v e th e w h e e l h u b b e a rin g w a s h e r (1 ).
22
11. R e m o v e th e w h e e l h u b (2 ) a n d ta k e o u t th e
b e a rin g s (1 a n d 3).
23
12. R e m o v e th e b e a rin g (1 ).
24
12 SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1
25
26
15. R e n e w w o rn b e a r in g s a n d s e a ls , u s in g s u ita b le
e x tr a c to r s a n d p u n c h e s .
27
SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1 13
AX LE W H EEL HUB
R e m o v a l-R e fittin g (Op. 44 101 22)
R e fittin g :
16. P la c e a h y d r a u lic ja c k b e n e a th th e s tu b a x le a n d
u n s c re w th e b o lt (1 ) fix in g th e c o n tro l le v e r (2 ) to
th e s tu b a x le p in .
28
29
18. L o w e r th e h y d r a u lic ja c k a n d re m o v e th e s tu b
a x le (1 ).
30
19. P u t th e s tu b a x le o n a s u ita b le v ic e a n d in s ta ll
w h ite b a c k u p rin g (1 ).
31
14 SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1
32
33
34
23. T h e w e a r s le e v e (1 ) f o r t h e s e a l m u s t b e in s ta lle d
in th e hub w ith a h ig h s tr e n g th b e a rin g fit
a d h e s iv e com pound (lo c tite ) to e n s u re th e
s e c u r e r e te n tio n in th e h u b .
T h e h u b a n d th e w e a r s le e v e m u s t b e th r o u g h ly
c le a n and d ry . A p p ly h ig h s tr e n g th b e a rin g fit
com pound. P re s s in th e w e a r s le e v e , u s in g a
s u ita b le p re s s .
A f t e r in s ta llin g th e w e a r s le e v e , th e c o m p o u n d m u s t
b e a llo w e d to c u re f o r a m in im u m o f th r e e h o u rs p rio r
to a s s e m b lin g th e b e a rin g s a n d s e a ls in th e h u b .
35
SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1 15
36
26. In s ta ll a n e w n u t a n d , u s in g a to r q u e w re n c h ,
tig h te n th e nut to a to r q u e of 196 Nm
(2 6 5 .7 4 0 7 ft lb ), tu r n in g th e wheel hub (1)
s im u lta n e o u s ly in o r d e r to s e ttle th e b e a rin g s .
27. L o o s e n th e n u t s lig h tly a n d tig h te n it a g a in to a
to r q u e o f 2 4 - 2 9 N m (3 2 .5 3 9 7 - 3 9 .3 1 8 8 ft lb)
w h ile c o n tin u in g to tu r n th e w h e e l h u b .
Note - th e n u t m u s t b e c h a n g e d e a c h tim e th e w h e e l
h u b is fitte d .
38
30. In s ta ll th e g r e a s e n ip p le a s s h o w n in fig u r e
39
16 SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1
31. In s ta ll th e w h e e l h u b b e a rin g c o v e r (1 ).
40
STUB AX LE
O verhaul (Op. 44 101 46)
2. L ift th e fr o n t o f t h e tra c to r.
41
3. P la c e a l s ta n d (1 ) b e n e a th th e e n g in e s u m p ,
in s e rtin g a b lo c k o f w o o d b e tw e e n th e e n g in e
s u m p a n d s ta n d .
42
SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1 17
4. R e m o v e th e fr o n t w h e e l fix in g b o lts (1 ).
43
5. P la c e a h y d r a u lic ja c k b e n e a th th e s tu b a x le a n d
u n s c re w th e b o lt (1 ) fix in g th e c o n tro l le v e r (2 ) to
th e s tu b a x le p in .
44
6. W ith d r a w th e c o n tro l le v e r (1 ) fr o m th e s tu b a x le
p in ( 2 ).
45
7. L o w e r th e h y d r a u lic ja c k a n d re m o v e th e s tu b
a x le (1 ).
46
18 SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1
8. U n s c re w th e a x le e n d s e c u rin g b o lts (1 ).
47
9. R e m o v e th e a x le e n d (1 ).
48
10. C la m p th e e n d o f th e a x le in a v ic e a n d u s in g a
s lid e h a m m e r, ta k e out th e s tu b a x le pin
a rtic u la tio n b u s h in g (1 ).
49
50
SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1 19
12. F it th e a x le e n d (1 ).
51
52
14. F it th e s tu b a x le o n th e a x le e n d .
15. P o s itio n th e c o n tro l le v e r (1 ) o n th e s tu b a x le pin
(2 ) a n d tig h te n th e s e c u rin g s c re w .
53
20 SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1
W h e n d riv in g in a s tr a ig h t lin e , th e w h e e ls m u s t be
p a ra lle l to th e lo n g itu d in a l a x is o f th e t r a c t o r o r h a v e
a m a x im u m o f 5 m m ( 0 .1 9 6 8 in .) t o e - in a t th e fro n t,
m e a s u r e d b e tw e e n th e w h e e l- r im s .
To c h e c k th e t o e - in , p ro c e e d a s fo llo w s :
1. In fla te th e fr o n t ty r e s to a p re s s u re o f 2 .5 b a r
(3 6 .2 5 p s i).
3. C h e c k t h a t th e w h e e ls a re p a ra lle l w ith th e
lo n g itu d in a l a x is o f th e tra c to r.
4. W ith th e t r a c t o r p a rk e d o n a fla t, le v e l s u r fa c e ,
m e a s u re th e d is ta n c e (B -i) b e tw e e n th e fro n t o f
th e w h e e l rim s , a t h u b h e ig h t. M a k e a c h a lk m a rk
o n th e rim s w h e r e th e m e a s u r e m e n t h a s ta k e n
p la c e . M o v e th e t r a c t o r fo rw a r d to r o ta te b o th
w h e e ls e x a c tly 180o and check th e
m e a s u r e m e n ts a g a in a t th e c h a lk m a rk s B 2 (n o w
p o s itio n e d a t th e r e a r o f th e w h e e ls ) . T h is w ill
e lim in a te w h e e l rim r u n - o u t e rro rs .
5. C o r r e c t th e t o e - in , if n e c e s s a ry , b y a d ju s tm e n t
o f t h e e n d o f th e tr a n s v e r s e s te e rin g t ie - r o d .
SECTION 50 - AUXILIARY UNITS - CHAPTER 1 1
CONTENTS
Equipment ..................................................................................................................................... 4
Use ............................................................................................................................................... 14
Keep refrigerant containers away from heat sources, — for the same reason, never unscrew the
as the increase of internal pressure due to heating compressor oil level plug when the system is
could cause the container to explode. charged.
Maximum capacity of electric centrifugal fan I, II, III speed . m3/min 3,5-8,5
.....................................................................................................(in.3/min) (21.36-51.87)
Remember that altitude affects pressure, as shown Altitude Absolute atmospheric Correction
in the table on the right. (m) pressure (psi) (psi)
To obtain the effective pressure in the system,
s.l.m.
subtract the corresponding correction value from the
pressure gauge reading. 0 14.63 0
Warning - The operations described in this section cannot be carried out without the ESSENTIAL tools marked
(X) in the following list.
To work in safety and to obtain the best possible results whilst saving both time and energy, we recommend that
the other specific tools in the list are also used.
X 293831 Combs for cleaning and straightening the fins on the condenser
and evaporator
OPERATING PRINCIPLES As regards the purity of the air, there are no precise
limits, but it is important to remember that the human
The function of the air conditioning system is to
metabolism alters the composition of the
create and maintain optimum working conditions
surrounding air, increasing the humidity and the
inside the tractor cab.
quantity of carbon dioxide, while decreasing the
percentage of oxygen, etc..
These conditions regard four main factors:
— temperature; By drawing in small quantities of fresh air from
— humidity; outside the cab, it is possible to eliminate impurities
— speed; in the air, particularly important in the case of
— purity of the air in the cab. agricultural tractors, where dust from earth, hay etc.
can cause extreme discomfort, by installing dry
filters on the external air inlets.
Obviously ”ideal” conditions will vary from person to
person, and so it is not possible to specify optimum
values for the above factors; however, we can Air conditioning systems in tractors and agricultural
specify a range of values within which the majority of vehicles in general thus serves to neutralise the heat
people will feel most comfortable. and humidity generated in the cab by controlling the
temperature and humidity of the air in - o r drawn into-
the cab to create comfortable working conditions for
As regards temperature and humidity, it is possible
the operator.
to define a zone, known as the ’’comfort zone”, within
which the tem perature-hum idity combination
corresponds to pleasant environmental conditions. The operating principle of an air conditioner is similar
to that of a domestic refrigerator: to cool an
environment, heat must be removed by means of a
From the diagram it can be seen that humidity should
physical process (evaporation of a liquid) which
be within the range of 30% to 70% (below 30% there
absorbs heat from the surrounding air.
is excessive dehydration of the mucous tissues of
the nose and throat, while above 70% the subject has
an uncomfortable sensation of dampness in many The liquid used in this process, known as the refriger
areas of the body) whereas temperature can vary ant, is product with a high refrigeration coefficient,
between 18 and 28°C ( 64.4 and 82.4°F). low toxicity, which mixes well with lubricating oil.
The air flow speed must not be so high as to cause The various components of the system are
discomfort; speeds of 0.07 - 0.25 m/s connected by suitable pipes which ensure that the
(0.2296 - 0.8200 ft/s) are normally acceptable pressure of the system is maintained.
1
6 SECTION 50 - AUXILIARY UNITS - CHAPTER 1
There are five main components of the air (depending on the ambient temperature) which thus
conditioning system: changes its state from a vapour to a liquid.
1. compressor;
2. condenser; The refrigerant, in liquid state at high pressure, is
purified by passing through the receiver-drier (3)
3. receiver-drier;
from where it flows to the expansion valve (4), which
4. expansion valve; restricts the flow of refrigerant and thus reduces its
5. evaporator. pressure.
To understand the operating cycle of the system, As it passes through the expansion valve (4), part of
follow the flow of the refrigerant starting from the the refrigerant is transformed into vapour and the low
compressor (1). temperature mixture of vapour and liquid thus
formed enters the evaporator (5).
2
Simplified system diagram
1. Compressor. 4. Expansion valve with thermostatic sensor.
2. Condenser. 5. Evaporator.
3. Receiver-drier.
SECTION 50 - AUXILIARY UNITS - CHAPTER 1 7
1. Check fuses.
2. Check compressor drive belt
tension.
3. Check if the clutch coil is
receiving power.
4. Check that the earth contact is
efficient.
1. Compressor. 6. Receiver-drier.
2. Compressor inletpipe (low pressure). 7. Sight glass.
3. Compressor outlet pipe (high pressure). 8. Expansion valve with thermostatic sensor.
4. Hot air. 9. Evaporator.
5. Condenser. 10. Cool, dehumidified air.
8 SECTION 50 - AUXILIARY UNITS - CHAPTER 1
Fan
The fan control switch (1, fig. 7) is powered when
the ignition switch (fig. 8) is in position B .
A. Low speed.
B. Medium speed.
C. High speed.
TRE0025A
A ir filter
6
HEATING
IGNITION SWITCH
TRE0012A
The air conditioning system provides cool, To lower the temperature and, at the same time, the
dehumidified air or warm dehumidified air. humidity of the air inside the cab, turn knob (2, fig. 9)
counter-clockwise until the desired temperature is
To operate the system proceed as follows.
obtained.
10
Compressor
SANDEN SD 7H15
Condenser
R eceiver-drier
R eceiver-drier
1. Sight glass.
2. Upper screen.
3. Disc.
4. Drying agent.
5. Lower screen.
11
SECTION 50 - AUXILIARY UNITS - CHAPTER 1 17
12
18 SECTION 50 - AUXILIARY UNITS - CHAPTER 1
13
As it passes through the evaporator it absorbs heat When disassembling pipes, plug the ends with
from the ambient air, vaporises and, having plastic caps to prevent moisture and dust getting
performed its cooling function, is aspirated by the inside.
compressor as a vapour.
When connecting the stations to the system service Graduated container for the discharge of recovered
valves, always connect the low pressure blue pipes contaminated oil.
(11, fig. 15, or 17, fig. 16) to the service valve on the
suction side of the compressor (S-Suction), and the Switch (5) 1 -0 -2 for recovery and cylinder heating.
high pressure red pipes (12, fig. 15, or 15, fig. 16) to
the service valve on the discharge side of the Indicator lights.
compressor (D-Discharge).
294044 flexible service pipes (11, 12 and 16) with
Important: check the seals in the pipe
safety cocks.
connectors (11, 12, 16, fig. 15), or (15, 17, 24, fig.
16) and replace if faulty. (kit 294052) Recovery capacity: 200 grams/minute
Remember that the pipe fittings fitted with seals (0.4411 lb/minute).
are to be hand-tightened only without forcing,
Power supply: 220 V (50 Hz).
otherwise the seal will be damaged.
Check filter connections for leaks (3) 8. Record the operation on the appropriate service
report card.
Refer to figure 15 and proceed as follows:
AIR CONDITIONING SYSTEM 7. Connect the blue service pipe (11) to the valve on
Dehydration, recharging and refrigeration check the suction (low pressure) side of the
(Op. 50 200 04) compressor (marked ”S”).
Recycling recovered refrigerant 19. Connect the 2 ends of the yellow (16) and blue
(11) pipes with connector supplied.
On completion of the recovery operation, the 20. Slowly open the cock (18-R EF) and the blue
refrigerant, which has already been through an oil cock (6-LO W ) on the pressure gauge manifold,
separation process, must now be completely and the cocks on the two previously connected
decontaminated. service pipes (16 and 11).
----------- A WARNING A ----------- 21. Set switch (5)to position ” 1” (RECOVERY) -
At this stage the recovered refrigerant has not yet green indicator light on.
been completely decontaminated and therefore The recovery compressor will start to operate
must not be used in the air conditioning system in this and the refrigerant will pass from the graduated
condition.
cylinder to the recovery circuit (distillation
Proceed as follows: cylinder, filter and compressor) and then return
to the graduated cylinder.
17. All cocks must be closed, with the exception of
22. Continue the operation until the circular sector of
cock (9, fig. 15) and the station must be switched
the humidity indicator (15) turns green.
off - switch (5) in position ”0” and green indicator
If after 15 minutes the circular sector of indicator
light off.
(15) still has not turned green, replace the filter
18. Connect the end of the yellow service pipe (16) (3) as described on page 20.
without the cock to the free connector (17)
located on the left-hand side of the pressure
gauge manifold.
1. Cylinder pressure gauge. 12. Red service pipe for connection to discharge
2. Recovery control pressure gauge. side of compressor.
3. A nti-acid and decontamination filter. 13. Recovered compressor oil discharge cock.
4. Recovered refrigerant/oil distillation cylinder. 14. Recovery compressor service valve (suction).
5. Switch. 15. Humidity indicator.
6. Refrigerant inlet control cock (LOW). 16. Yellow service pipe for refrigerant transfer.
7. Recovered oil discharge cock (yellow). 17. Fitting for refrigerant transfer.
8. Recoveered oil discharge pipe. 18. Cock (REF) for refrigerant transfer and
9. Oil return to compressor control cock (yellow). recycling.
10. Q uick-fit connectors. 19. Refrigerant cylinder.
11. Blue service pipe for connection to suction side 20. Safety valve.
of compressor. 21. Cylinder (gaseous stage) discharge cock
(yellow).
24 SECTION 50 - AUXILIARY UNITS - CHAPTER 1
25. Slowly open the yellow cock (7) and discharge 33. Open cocks (3, 9 and 10).
the recovered oil in the graduated container. 34. Start the pump by turning switch (19) to position
“1” to evacuate the cylinder (31). After 5 minutes
26. If no refrigerant leaks, w hether major or minor,
close cocks (3, 9 and 10) and switch off the
have ever been detected in the system, on
pump.
recharging, replace the contaminated oil with
same quantity o f new oil (see page 26).
Charging the graduated cylinder (31) of the
Transfer of decontaminated refrigerant from evacuation/charging station
cylinder (10) to an external cylinder
If the decontaminated refrigerant in the
If for any reason the decontaminated refrigerant is recovery/recycling station is to put back into the
not to be put back into the air conditioning system tractor air conditioning system immediately, it must
immediately, for reasons o f safety it must be be transferred from cylinder (19, fig. 15) to cylinder
transferred from cylinder (19) to a homologated (31, fig. 16) of the evacuation/charging station,
refillable gas container. proceeding as follows:
38. Check that all the cocks of the 42. Check the quantity of refrigerant in the graduated
evacuation/charging station are closed, with the cylinder (31).
exception of cock (27). 43. From the total quantity of refrigerant required in
39. Check that the stations are switched off with the air conditioning system indicated in the note
switches (5 and 19) in position ”0” . on page 26, calculate the quantity of refrigerant
that must be added to the cylinder (31) to make
40. With reference to figure 15, turn switch (5) to up the total amount required.
position ”2” HEATING CYLINDER to switch on
44. Transfer refrigerant from the external cylinder to
the refrigerant heater installed on cylinder (19),
the graduated cylinder (31) proceeding as
to facilitate the transfer of refrigerant to cylinder
follows.
(31) of the evacuation/charging station.
45. Connect the yellow pipe (24) to connector (28)
41. On completion of the refrigerant transfer and to the external cylinder containing the
operation, close all the cocks with the exception refrigerant (upside down if not equipped outlet
of cock (9, fig. 15) and switch off the valve).
recovery/recycling station by turning the switch 46. Open the cock on the external cylinder, the cock
(5)to position ”0” . on the charging pipe (24) and cock (27).
16
Evacuation/charging station.
1. Safety valve. 17. Blue service pipe for connection to suction side
2. Cylinder pressure gauge. of compressor.
3. Refrigerant charging cock. 18. Oil drain plug.
4. Low pressure side cock (LOW). 19. On/Off switch (I), heater (II).
5. Low pressure gauge. 20. Oil meter connector.
6. High pressure gauge (red). 21. Vacuum pump.
7. % -w ay pressure gauge manifold. 22. High pressure side cock (HIGH).
8. Vacuum meter. 23. Sight glass.
9. Vacuum test cock (VAC). 24. Yellow service pipe.
10. Vacuum meter test cock. 25. Cylinder heater.
11. Vacuum meter safety valve. 26. External ring.
12. Oil charging cock. 27. Refrigerant transfer cock (REF).
13. Oil filler cap. 28. Refrigerant transfer connector.
14. Sight glass. 29. Glass rod.
15. Red service pipe for connection to discharge 30. Outer casing (Plexiglas).
side of compressor. 31. Refrigerant charging cylinder.
16. Q uick-fit cocks.
26 SECTION 50 - AUXILIARY UNITS - CHAPTER 1
47. Rotate the outer casing (30) so that pressure Refer to figure 16 and proceed as follows:
value indicated on the graduated scale
corresponds with the value shown on pressure 56. Pour the oil into the graduated oil meter of kit
gauge (2). 294043.
48. When the refrigerant in the cylinder has reached 57. Connect the oil meter to the oil meter (20).
the required level, as indicated on the glass rod
(29), close the cock of the external cylinder, the 58. Close cocks (4 and 10).
cock on the charging pipe (24) and cock (27).
59. Set switch (19) to position ”2” to switch on the
refrigerant heater on cylinder (31).
Note - If excessive time is required to transfer 60. Open cock (12) and the cock on the graduated
refrigerant from the external cylinder to cylinder (31), oil meter.
slightly open valve (1) and discharge air from the
61. Check the quantity of oil flowing from the oil
cylinder (31); the pressure reading on gauge (2) meter, and once the required quantity has been
should not exceed 5 bar. reached, close cocks (12) and the cock on the oil
meter, and remove the graduated meter.
51. Connect the red service pipe (15) to the valve on 62. Keep switch (19) in position 2, with the refrigerant
the high pressure side of the compressor marked heater in cylinder (31) on, and heat the
“ D ”. refrigerant for approx. 10 ^ 15 minutes to
facilitate transfer from the cylinder to the air
52. Open the quick-fit cocks (16). conditioning system on the tractor.
53. Open cocks (4 - 9 - 10 - 22). 63. According to the refrigerant type, rotate the outer
casing (30) so that the graduated scale and the
54. Start the pump by turning switch (19) to position pressure values correspond with the pressure
“I” and evacuate the system for at least thirty reading on gauge (2).
minutes; pressure gauges (5 - 6 - 8) should
show a negative reading. If the evacuation 64. Move the external ring (26) along the cylinder
procedure dose not function correctly, check all glass to mark the quantity of refrigerant to be
connections. charged.
55. Close cock (9), switch off the pump by turning 65. Open cock (22) and charge from the high
switch (19) to position ”0” and check the vacuum pressure side.
seal for at least five minutes using vacuum meter
(8). This done, close all cocks. 66. Open cock (3), charge approx. 300 grams
(0.6617 lb) of refrigerant, close cock (3) and
check for leaks.
Charging the cab air conditioning system (after
evacuation) with new oil 67. If there are no leaks, continue charging up to the
prescribed quantity.
If no refrigerant leaks, whether major or minor, have
68. On completion of charging, turn switch (19) back
ever been found in the system, on recharging,
to position ”0”, close cocks (3 and 22),
replace the contaminated oil previously recovered in
disconnect pipes (17 and 15), and replace the
operations (25 and 26, page 24) with the same
caps on the service valves.
quantity of new oil. If, on the contrary, significant
leaks have occurred in the past, proceed with the Carry out functional tests with the system set to
compressor oil level check procedure. maximum performance levels, as described below.
SECTION 50 - AUXILIARY UNITS - CHAPTER 1 27
19
— Pressure gauge readings with cocks (4 - 10 - 22
and 9, fig. 16) open, cylinder (31) with 2000 gr of
refrigerant, red and blue service pipes connected
to tractor system, cocks (16) open and
compressor on (initial evacuation stage).
21
SECTION 50 - AUXILIARY UNITS - CHAPTER 1 29
22
23
Checking the temperature of the air coming out external ambient air temperatures specified, the
of the vents inside the cab. system is functioning efficiently.
25
Warning - If any of the system components requires — Check the condition and position of the
thermostatic sensor (fig. 13) in the evaporator.
replacement, it is always necessary to perform the
recovery, recycling and charging operations — Check that external air intakes are not blocked.
described on pages. 22 to 27.
— Check the condition of the condensate discharge
pipes.
32 SECTION 50 - AUXILIARY UNITS - CHAPTER 1
26
1. Compressor. 6. Receiver-drier.
2. Suction line (low pressure). 7. Sight glass.
3. Discharge line (high pressure). 8. Expansion valve with thermostatic sensor.
4. Hot air. 9. Evaporator.
5. Condenser. 10. Cool, dehumidified air.
SECTION 50 - AUXILIARY UNITS - CHAPTER 1 33
27
4. Remove the 4 cab roof retaining bolts (1)
28
5. Remove the cab roof as shown in the figure 29
29
34 SECTION 50 - AUXILIARY UNITS - CHAPTER 1
30
33
SECTION 50 - AUXILIARY UNITS - CHAPTER 1 35
34
11. Remove all electric connectors and take off the
A/C assembly (1) completely.
36
13. To reassemble, clean all parts and proceed as follows:
— Refit A/C assembly completely and refit all electric connectors.
— Assembly the bracket that secures the heater pipe.
— Assembly the heater pipe connections refit the pipes.
— Refit A/C assembly inlet & outlet pipes.
— Refit A/C assembly fastening screws.
— Refit top cover plate.
— Assembly the cab roof.
— Refit the 4 cab roof retaining bolts.
— Pour the previously drained coolant back into the radiator.
— Reconnect the negative battery lead.
— Charge the air conditioning system with HFC 134 a refrigerant, using the evacuation/ charging station
294030 as described on page 24.
36 SECTION 50 - AUXILIARY UNITS - CHAPTER 1
R ECEIVER-DRIER
Replacement (Op. 50 200 04 - 50 200 74)
37
5. Detach the flexible pipe (1) connecting the
condenser to the receiver-drier.
38
6. Detach the flexible pipe (1) connecting the
receiver-drier to the evaporator.
39
SECTION 50 - AUXILIARY UNITS - CHAPTER 1 37
41
CONDENSER
Replacement (Op. 50 200 04 - 50 200 72)
24893
COMPRESSOR
Rem oval-Refitting (Op. 50 200 04 - 50 200 26)
47
48
7. Disconnect the earth lead (1) from the
compressor.
49
40 SECTION 50 - AUXILIARY UNITS - CHAPTER 1
50
9. Remove the compressor bolt (1) and recover the
compressor.
To refit proceed as follows:
— Refit the compressor, the support/belt tensioner
arm. Reconnect the earth lead..
— Refit the right-hand guard.
— Reconnect the two flexible pipes to the
compressor.
— Connect the negative battery lead.
— Evacuate the air conditioning system and charge
with HFC 134a refrigerant, using the
evacuation/charging station 294030 as
described on page 24. 51
— Close the hood.
When first fitted, the belt must more installed at a c) Worn sides : with the sides worn or the inner
greater tension than normal to compensate for initial surface cracked, the belt can break at any
stretching during the running-in period. The belt moment.
must therefore be checked again after 50 hours of
operation and adjusted to the normal tension.
d) Belt impregnated with grease : the belt will
This check is absolutely essential as if the belt is too wear more rapidly as the grease will cause
taut, in addition to damaging the pulley bearings, it softening of the internal part.
will cause premature fatigue of the reinforcement
fabrics and thus early deterioration of the belt.
Take the following action:
If on the contrary the belt is too slack, it will start to a) If the belt is too slack, tension it correctly; if the
slip and overheat, and it will therefore w ear out very belt is very hot, renew it.
quickly.
b) If cracking is deep, extending to half the
thickness of the belt, renew the belt.
Chapter 1 - INSTRUMENTS
CONTENTS
Description . Page
ANALOGUE INSTRUMENTS
INTRODUCTION
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1
3) Proofmeter;
603.54.331.00 - 12 - 1996
2 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1
Condition Indicator
When the tank is less than 1/4 full, the hand moves
into the red area.
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 3
TRE0075A
603.54.331.00 - 12 - 1996
4 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1
B. BATTERY
The tractors are fitted with maintenance-free batteries. Keep the top part clean and dry. Check that the level
of electrolyte reaches the top mark and never falls below the lower mark.
C. ALTERNATOR
This provides a square wave signal and recharges the battery. It also provides power required by electric
devices.
F. FUEL SEDIMENTER
Activated when w ater gets into the fuel filter and the relevant warning light comes on.
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 5
603.54.331.00 - 12 - 1996
6 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 7
603.54.331.00 - 12 - 1996
8 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 2 1
Chapter 2 - COMPONENTS
CONTENTS
55 500 INTRODUCTION
The components described in this section are located on the instrument console (rear hood), in the cab roof and
on the right-hand fender, inside the cab.
COMPONENT DESCRIPTION
Starter switch
603.54.331.00 - 12 - 1996
2 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 2
1. Starter switch.
2. Thermostarter.
4. Cigar lighter
TRE0020A
IN -C A B CONTROLS
1. Fender-mounted controls
1. Windscreen washer,
2. Windscreen wiper,
3. Rear working lights,
4. Front working lights and
5. Beacon controls (with cab)
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 2 3
603.54.331.00 - 12 - 1996
4 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 2
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 3 1
CONTENTS
TIGHTENING TORQUES
Nm
603.54.331.00 - 12 - 1996
2 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 3
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 3 3
STARTING CIRCUIT
STARTING CIRCUIT
1 - In s tru m e n t p a n e l
2 - S ta rte r s w itc h
11 - B a tte ry
12 - S ta rte r
13 - A lte rn a to r
14 - O v e r v o lta g e c irc u it b re a k e r (D IO D E )
31 - S ta rte r in h ib ito r un it
35 - M ain F u se
603.54.331.00 - 12 - 1996
4 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
603.54.331.00 - 12 - 1996
F u se p a n e l 2 S ta rte r m o to r 3
SYSTEM TESTS
STARTING SYSTEM ON TRACTOR TEST
To e a s ily and q u ic k ly tr o u b le - s h o o t th e s ta rtin g
s y s te m p ro b le m s and reach c o n c lu s iv e results, it is
re c o m m e n d e d th a t you use a b a tte ry/sta rtin g te s te r
(h ig h d is c h a rg e m u ltim e te r) w ith in c o rp o ra te d
0 - 2 0 V v o ltm e te r a n d 0 - 5 0 0 A a m m e te r.
B e fo re c a rry in g o u t th e te st:
• c h e c k th e b a tte ry is fu lly c h a rg e d ;
• c h e c k th e e n g in e is n o t s e iz e d .
603.54.331.00 - 12 - 1996
6 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 3
3. R e c o n n e c t e a rth (g ro u n d ) (n e g a tiv e ) c a b le to
n e g a tiv e b a tte ry te rm in a l c la m p (3).
6. R un th e e n g in e a n d n o te v o ltm e te r and
a m m e te r re a d in g s. V o lta g e m u st be c o n s ta n tly
a b o u t 1 2 V a n d a b s o rp tio n in th e ra n g e o f
2 5 0 -3 0 0 A.
• If a b s o rp tio n c o rre s p o n d s to th e re a d in g s
a b o ve , th e n th e s ta rte r m o to r (4) fig. 4, is
w o rk in g co rre c tly . If v o lta g e d ro p s d u rin g th e
te s t, fo llo w “ R e s is ta n c e in s ta rtin g s y s te m
c irc u it” p ro c e d u re (se e re la tiv e p a ra g ra p h ).
• If ab so rp tio n is h ig h e r th a n th e re a d in g s above,
c h e c k th e c irc u it as fo llo w s . If th e s ta rtin g
s y s te m c irc u its a re in g o o d c o n d itio n , th e n th e
s ta rte r m o to r is m a lfu n c tio n in g and m u s t be
re m o v e d fo r fu rth e r e x a m in a tio n .
• If a b s o rp tio n is lo w e r th a n th e re a d in g s a b o ve ,
th e s ta rte r m o to r is m a lfu n c tio n in g and m u st be
re m o v e d fo r fu rth e r e x a m in a tio n .
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 3 7
603.54.331.00 - 12 - 1996
8 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 3
1. D is c o n n e c t n e g a tiv e b a tte ry ca b le .
3. U n s c re w th e n u t a n d re m o v e p o w e r c la m p (5)
and e m e rg e n c y s w itc h c la m p (4).
5. To re - in s ta ll th e s ta rte r m o to r, re v e rs e th e
o rd e r o f re m o v a l. 8
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 3 9
9. R e m o v e th e re ta in in g ring w h ic h h o ld s th e
1. P la ce th e s ta rte r m o to r in a v ic e w ith p ro te c te d
c o n tro l g ro u p and th e in n e r p la te fro m th e
ja w s .
a rm a tu re s h a ft, by firs t re m o v in g th e p re s s u re
2. D is c o n n e c t th e b ig g e s t b ra id e d w ire w h ic h runs c o lla r p e rp e n d ic u la rly fro m th e re ta in in g ring
fro m th e fie ld w in d in g c a s in g to th e s o le n o id . s u p p o rt by m e a n s o f an a p p ro p ria te ly sized tube.
T h e n le v e r th e re ta in in g ring fro m th e g ro o v e .
3. R e m o v e th e th re e s c re w s fro m th e fro n t ca sin g
and re m o v e th e s o le n o id . N o te th a t th e p lu n g e r 10. R e m o v e a rm a tu re and c o n tro l g ro u p .
w ill re m a in c o n n e c te d to th e c o n tro l lever.
603.54.331.00 - 12 - 1996
10 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 3
5. P la ce a m a n u a l ta c h o m e te r (5) on th e end o f
th e a rm a tu re s h a ft. C h e c k m a x im u m p o w e r
a b s o rp tio n . T h is v a lu e is s p e c ific fo r ea ch
s ta rte r m o to r and m u st be included in th e range
o f v a lu e s in th e T E C H N IC A L IN F O R M A T IO N
ta b le . R e g u la te c a rb o n b a tte ry v o lta g e (2) and
a rm a tu re sp e e d a cc o rd in g to th e in fo rm a tio n in
th e te c h n ic a l in fo rm a tio n ta b le .
6. If th e s ta rte r m o to r d o e s n o t w o rk a c c o rd in g to
th e te c h n ic a l in fo rm a tio n s p e c ific a tio n , c h e c k if
th e re are e a rth e d (g ro u n d e d ) fie ld w in d in g s , if
th e a rm ature is scuffed o r scraped o r if th e sh a ft
is m is s h a p e n o r o th e rw is e d a m a g e d .
BENCH TESTS
ARM ATURE (Fig. 11)
2. If th e c o m m u ta to r n e e d s re fa c in g , c h e c k it is
n o t s m a lle r th a n th e m in im u m v a lu e s p e c ifie d
in th e T E C H N IC A L IN F O R M A T IO N ta b le .
A fte r re fa c in g , th e c o m m u ta to r m u s t be
p o lis h e d w ith s a n d p a p e r and c le a n e d w ith a
rag and so lv e n t.
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 3 11
3. A rm a tu re in s u la tio n can be c h e c k e d by
c o n n e c tin g an o h m m e te r (1) b e tw e e n
c o m m u ta to r s e g m e n ts and a rm a tu re s h a ft.
T h is re a d in g s h o u ld s h o w in fin ity , in o th e r
w o rd s th e re s h o u ld be no c o n tin u ity.
5. If th e a rm a tu re c irc u m fe re n c e has o b v io u s ly
b een in c o n ta c t w ith p ole p ie ce s, th e p ole
b e a rin g s a re p ro b a b ly w o rn . F irs t c h e c k th e
p o le p ie ce s a re fix e d and th a t th e a rm a tu re
s p in s w e ll in a la th e . If n e c e s s a ry , c h a n g e th e
a rm a tu re b e a rin g . 11
3. If th e re is a fa ilu re in th e fie ld w in d in g s , th e n it
w ill be n e c e s s a ry to ch a n g e th e w h o le b o x and
fie ld w in d in g s y s te m .
12
BEARING BUSHINGS
1. C h e c k if th e b u s h in g on th e bru sh p la te and in
th e b o x on th e p in io n s id e are w o rn . A s s e m b le
th e a rm a tu re s h a ft a n d n o te play. C h a n g e th e
b u s h in g if th e re is to o m u ch play. C h e c k th e
fie ld p o le s to s e e if th e re a re a n y s ig n s o f
s c ra p in g a g a in s t th e c a s in g . T h is can a lso be
ca u s e d by a w o rn b u s h in g .
DRIVING PINION
1. C h e c k th e ro lle r clu tc h o p e ra tio n . T h e p in io n
m u s t spin clo c k w is e only. If th e pinion is e ith e r
se iz e d o r s p in s in b oth d ire c tio n s , o r if th e
p in io n te e th a re d a m a g e d , a s s e m b le a ne w
c o n tro l g ro u p .
If th e re is c le a r e v id e n c e o f d a m a g e to th e pinion
te e th , c h e ck th e flyw h e e l ring gear, as de scrib e d in
s e c tio n 10, E n g in e s .
603.54.331.00 - 12 - 1996
12 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 3
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4 1
CONTENTS
TYPE OF ALTERNATOR
CHARACTERISTICS BOSCH
14V-45, 65 and 85A
P o la rity N e g a tiv e e a rth
N o m in a l v o lta g e (V) 14
M a x ro ta tio n sp e e d (rpm ) 1 5 .0 0 0
M a x im u m o u tp u t (A) 45 65 85
R o to r fie ld w in d in g re s is ta n c e ( f i) 3 . 4 - 3.8 2 .9
S ta to r fie ld w in d in g re s is ta n c e ( f i) - 0 .2
N e w bru sh le n g th (m m ) (in.) - 2 0 (0 .7 8 7 4 )
M in im u m bru sh le n g th (m m ) (in.) - 5 (0 .1 9 6 9 )
B ru sh sp rin g fo rc e (N ) (lb) - 1 .3 -2 .7
( 0 .2 9 - 0 .6 0 )
TIGHTENING TORQUE
Nm (ft lb)
A lte rn a to r fa s te n in g b o lts 5 .5 (4 .0 5 6 6 )
P u lle y fa s te n in g nut 70 (5 1 .6 2 9 3 )
R e c tifie r fa s te n in g s c re w s 4 .0 (2 .9 5 0 2 )
B ru sh b o x and re g u la to r s c re w s 2 .7 (1 .9 9 1 4 )
T e rm in a l nuts 2 .7 (1 .9 9 1 4 )
603.54.331.00 - 12 - 1996
2 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4
ALTERNATOR DESCRIPTION
E ith e r a M a g n e ti M a re lli o r a B o s c h , 4 5 o r 6 5 A,
a lte rn a to r, w ith e x te rn a l c o o lin g fa n , is fitte d on all
m o d e ls. S ta to r w in d in g is v e n tila te d w ith an a ir
c o n d u c tin g d ia p h ra g m in th e s u p p o rt on th e re ctifie r
b rid g e s id e and p e rip h e ra l o p e n in g s in th e s u p p o rt
on th e co n tro l sid e . T h e a lte rn a to r, in s ta lle d on th e
le ft sid e o f th e en g ine , is o p e ra te d by a pulley and a
V - ty p e d riv in g belt. A lte rn a to rs a re fitte d w ith a
b u ilt-in re g u la to r.
45 or 65 A alternator
1. Battery connection (B+ terminal)
2. Terminal protection sheath
3. Alternator charge indicator connection
(D+ terminal)
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4 3
S e e fig u re 2.
T h is a c tio n c a u s e s a c o n s ta n t in c re a s e in th e ro to r
m a g n e tic fie ld and a fa s t in c re a s e o f c u rre n t and
W h e n th e ig n itio n ke y is tu rn e d , a s m a ll c u rre n t
v o lta g e o u tp u t.
p a s s e s fro m th e b a tte ry th ro u g h th e ro to r field
w in d in g w irin g . T h e c irc u it c lo s e s p o w e rin g th e
c h a rg e w a rn in g light, th e a lte rn a to r D + te rm in a l, th e
ro to r field w in d in g , th e a lte rn a to r re g u la to r and earth A s th e g e n e ra te d v o lta g e o u tp u t (re fle c te d by D +
(g ro u n d). te rm in a l) in c re a s e s , th e w a rn in g lig h t in te n s ity d e
c re a s e s and w h e n th e v o lta g e a t th e D + te rm in a l
e q u a ls th a t on th e b a tte ry s id e o f th e w a rn in g light,
th e lig h t g o e s out.
A t th is s ta g e , th e w a rn in g lig h t c o m e s on and th e
ro to r is p a rtia lly m a g n e tis e d .
V o lta g e in c re a s e s u ntil it re a c h e s th e p re - s e t
re g u la te d v o lta g e level.
W h e n th e e n g in e s ta rts and th e rotor, p a rtia lly
m a g n e tis e d , tu rn s in s id e th e s ta to r w in d in g s and
g e n e ra te s th r e e -p h a s e a lte rn a tin g c u rre n t. A
c o n s ta n t q u a n tity o f th is c u rre n t is tra n s fo rm e d into If th e d riv in g b e lt b re a k s , th e re w ill be no v o lta g e
d ire c t c u rre n t by th re e fie ld d io d e s b u ilt in to th e a c c u m u la tio n in th e a lte rn a to r. T h e c h a rg e w a rn in g
rectifier. lig h t w ill s ta y on, th u s in d ic a tin g a fa u lt.
603.54.331.00 - 12 - 1996
4 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4
3 4
Fan belt tensioner
Fig. 3. Belt for versions without air conditioning Fig. 4. Belt for versions with air conditioning
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4 5
If th e w a rn in g lig h t s ta y s on, c h e c k th e re is no s h o rt
c irc u it b e tw e e n D + w ire e n d in g a n d w a rn in g light.
Version w ith
out cab or Version with
with cab w ith cab and air PRELIMINARY TESTS
out air condi conditioning
tioning T h e s e p re lim in a ry te s ts ca n be c a rrie d o u t w ith o u t
Load (N ) (lb) 78 - 98 60 - 75 re m o v in g a n y c o m p o n e n ts fro m th e tra c to r ch a rg in g
(1 7 .2 0 -2 1 .6 1 ) (1 3 .2 8 -1 6 .5 3 ) c irc u it. T h e s e te s ts ch e ck:
603.54.331.00 - 12 - 1996
6 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4
S e e fig u re 5.
1. D is c o n n e c t th e battery.
5. D is c o n n e c t th e b a tte ry and re c o n n e c t th e
c a b le s to th e a lte rn a to r a t (2) and (3) fig. 5.
S e e fig u re 6.
3. C o n n e c t an a m m e te r (1) b e tw e e n th e
d is c o n n e c te d w ire (re d ) (4) and th e B+
a lte rn a to r te rm in a l (3).
6
4. C o n n e c t a v o ltm e te r (2) b e tw e e n th e B+
a lte rn a to r te rm in a l (3) a n d e a rth (g ro u n d ).
T h e v o ltm e te r re a d in g s h o u ld be h ig h e r th a n th e
b a tte ry v o lta g e and w h e n th e a m m e te r reading falls
b e lo w 10 A , th e v o ltm e te r re a d in g s h o u ld s ta b ilis e
a t 13.6 - 14 V (M a g n e ti M arelli a lte rn a to r) o r 13.6 -
14.4 V (B o sch a lte rn a to r).
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4 7
If th e v o ltm e te r re a d in g is h ig h e r th a n 14 V o r 14.4
V, fo r M a g n e ti M a re lli o r B o s c h a lte rn a to rs re s p e c
tive ly, th e a lte rn a to r re g u la to r m u st be ch a n g e d , as
d e s c rib e d in th is s e c tio n . (A fte r in s ta llin g a n ew
re g u la to r, c a rry o u t te s ts 4 and 5).
If th e a m m e te r re a d s z e ro a m p s, th e n o n e o f th e
a lte rn a to r c o m p o n e n ts is m a lfu n c tio n in g . T urn th e
e n g in e o ff and c a rry o u t th e a lte rn a to r c o m p o n e n t
te s t, as d e s c rib e d in th is ch a p te r.
S e e fig u re 7.
C h e c k th e ig n itio n ke y is in O F F p o sitio n .
A re a d in g h ig h e r th a n 4 0 0 m illiv o lts in d ic a te s m a l
fu n c tio n in g d u e to e x c e s s iv e re s is ta n c e in th e
e x te rn a l circu its .
8. S to p th e e n g in e .
603.54.331.00 - 12 - 1996
8 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4
S e e fig u re 8.
1. C h e c k th e ig n itio n ke y is in O F F p o sitio n.
2. T h e c irc u it is th e s a m e as th a t d e s c rib e d in th e
p re v io u s te st, e x c e p t th a t th e m illiv o ltm e te r (4)
is now co n n e c te d b e tw e e n th e n e g a tive b a tte ry
te rm in a l c la m p a n d th e a lte rn a to r c a sin g
(n e g a tiv e s id e o f ca s in g ).
3. S ta rt th e e n g in e a n d in c re a s e s p e e d to 2 0 0 0
re v/m in .
4. In c re a s e re s is ta n c e c u rre n t load (d e c re a s in g
re s is ta n c e itse lf) s lo w ly u ntil th e a m m e te r (2)
re a d s 45 o r 6 5 A . a c c o rd in g to th e ty p e o f
a lte rn a to r.
5. N o te th e re a d in g on th e v o ltm e te r. T h is m u st
no t be h ig h e r th a n 2 0 0 m illiv o lts .
A re a d in g h ig h e r th a n 2 0 0 m illiv o lts in d ic a te s
m a lfu n c tio n in g d u e to e x c e s s iv e re s is ta n c e in th e
e x te rn a l circu its .
6. S to p th e e n g in e .
S e e fig u re 9.
1. C h e c k th e ig n itio n ke y is in th e O F F p o sitio n .
2. D is c o n n e c t th e n e g a tiv e b a tte ry c a b le a n d th e
B + a lte rn a to r w ire (4).
3. C o n n e c t an a m m e te r (5) b e tw e e n B+
a lte rn a to r te rm in a l (4) a n d D + w ire (1)
(n e g a tiv e s id e o f th e w ire ).
4. C o n n e c t a v o ltm e te r (4) b e tw e e n th e B+
a lte rn a to r te rm in a l (5) and e a rth (g ro u n d ).
9
5. R e c o n n e c t th e n e gative b a tte ry cable. S ta rt th e
e n g in e and in c re a s e s p e e d to 2 0 0 0 re v/m in .
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4 9
603.54.331.00 - 12 - 1996
10 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4
1. D is c o n n e c t th e n e g a tiv e b a tte ry ca b le .
10
1. S la c k e n a n d re m o v e th e n u t a n d b o lt (3)
s e c u rin g the a lte rn a to r to th e belt te n s io n e r (4).
2. M o ve th e a lte rn a to r to re d u c e b e lt te n s io n (5)
a nd re m o v e it fro m th e a lte rn a to r p u lle y (6).
3. U n s c re w and re m o v e th e n u t a n d b o lt (7).
R e m o v e th e a lte rn a to r.
11
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4 11
Alternator components 12
13
603.54.331.00 - 12 - 1996
12 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4
• 12 volt battery
• multitester
• 2 watt test lamp.
If the test lamp does not light up, then the rotor
circuit is faulty. Check brushes, contact rings and
rotor field winding continuity.
15
16
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4 13
D is c o n n e c t th e te rm in a l w ire c o n n e c to r (1) o f th e
e x c ita tio n d io d e s fro m th e p o s itiv e b ru sh pin (F ig.
18)
In s e rt an o h m m e te r p o in t in th e c o n n e c to r m e n
tio n e d a b o v e (1) (F ig. 18). T h e s e c o n d p o in t m u s t
be put in co n ta c t su cc e s s iv e ly w ith e ach o f the three
te rm in a ls ( A - B - C ) : R e p e a t th e th re e m e a s u re
m e n ts a fte r re v e rs in g th e in s tru m e n t p o in ts (F ig.
20).
603.54.331.00 - 12 - 1996
14 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4
P u t an o h m m e te r p o in t in c o n ta c t w ith th e p o s itiv e
(X ) a lte rn a to r te rm in a l a n d th e o th e r s u c c e s s iv e ly
w ith each o f the th re e te rm in a ls ( A - B - C ) (Fig. 21).
21
P ut an o h m m e te r p o in t in c o n ta c t w ith th e n e g a tive
(Y ) d io d e s p la te a n d th e o th e r s u c c e s s iv e ly w ith
ea ch o f th e th re e te rm in a ls ( A - B - C ) (Fig. 22).
22
ROTOR
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4 15
24
25
a. B ru s h e s
b. P ins
26
26665
27
603.54.331.00 - 12 - 1996
16 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4
U n s c re w th e s c re w s (9) w h ic h fa s te n th e re c tifie r
b rid g e (10 ) to th e re a r s u p p o rt p la te (8) (F ig. 28).
29
30
P u t both o h m m e te r p o in ts (fixe d a t Q x 1 sc a le ) in
c o n ta c t re s p e c tiv e ly w ith a s lip ring and th e ro to r
ca sin g (see a rro w s ). T h e in s tru m e n t s h o u ld s h o w
in fin ity resista nce . If th is is not th e case, c h a n g e th e
ro to r (F ig. 31).
31
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4 17
P u t both o h m m e te r p o in ts (fixe d a t Q x 1 s c a le ) in
c o n ta c t re s p e c tiv e ly w ith th e s lip rin g s (se e a r
ro w s ). T h e in s tru m e n t s h o u ld s h o w a c e rta in
d e g re e o f re s is ta n c e (Fig. 32).
32
REASSEMBLY
To re a s s e m b le , re v e rs e th e o rd e r o f th e o p e ra tio n s
d e s c rib e d .
SERVICING
34
603.54.331.00 - 12 - 1996
18 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 4
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 5 1
Chapter 5 - BATTERY
CONTENTS
603.54.331.00 - 12 - 1996
2 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 5
REMOVAL
1. L ift th e e n g in e hood.
RE-INSTALLATION
1. To re - in s ta ll th e battery, re v e rs e th e re m o v a l
p ro c e d u re , w ith th e fo llo w in g p re c a u tio n s :
• C h e c k th a t th e b a tte ry is c le a n , th e re a re no
s ig n s o f e le c tro ly te le a k and th e b re a th e r c o ve rs
are c o m p le te ly in s ta lle d . C o a t th e te rm in a ls and
c la m p s w ith a p e tro le u m je lly (such as V a s e lin e ).
D o not use tra d itio n a l lu b rica n ts as th e y can lead
to e le c tro ly tic c o rro s io n .
• C h e c k th a t te rm in a l p o la rity is c o rre c t. C h e c k
te rm in a l c la m p c o n n e c tio n s a re n o t to o tig h t.
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 5 3
A lte rn a tiv e ly , a p p ro x im a te c h a rg e ca n be m e a s u re d
u sin g a d ig ita l v o ltm e te r (± 0.01 V ) as fo llo w s :
BATTERY MAINTENANCE
B a tte ry v o lta g e m u s t be re g is te re d on a fla t b a tte ry
c o n s id e rin g th e fo llo w in g :
A ) th e b a tte ry m u s t be fla t fo r a t le a s t 4 h o u rs
b ) if th e v e h ic le h a s bee n use d re ce n tly, o r if th e
b a tte ry has bee n c h a rg e d re ce n tly, s w itc h th e W ARNING: Batteries contain sulphuric acid and
h e a d lig h ts on fo r 2 m in u te s. generate a highly explosive hydrogen and oxygen
m ix during charging.
W h e n a b a tte ry is fla t, th e s u lp h u ric a cid in th e • Do not use devices producing flames or sparks
e le c tro ly te c o m b in e s c h e m ic a lly w ith th e p la te s and to inspect the electrolyte level.
th is d e c re a s e s th e re la tiv e d e n s ity o f th e s o lu tio n .
• Do not remove battery caps without protecting
your hands and your eyes.
1. K e e p th e e le c tro ly te le ve l 17 m m (0 .6 9 9 3 in.)
(o v e r th e plates. If th is is not re s p e c te d , th e acid
c o n c e n tra tio n w ill vary, w h ic h c o u ld d a m a g e
T h e lo w e r th e te m p e ra tu re a t w h ic h th e b a tte ry
s p a c e rs and c a u s e a d e te rio ra tio n in plate
o p e ra te s , th e m ore n e ce ssa ry it is to ke e p th e battery
p e rfo rm a n c e .
fu lly c h a rg e d . F o r e x a m p le , a b a tte ry w ith a re la tiv e
d e n s ity o f 1.2 25 a t 2 7 °C (8 0 °F ) can s ta rt th e e n g in e
a t m ild o u ts id e te m p e ra tu re s b u t m ig h t n o t d o so at
2. U se d istilled o r d e -m in e ra liz e d w a te r only. N e ve r
lo w e r te m p e ra tu re s b e c a u s e o f lo w e r b a tte ry
use ta p w a te r o r rain w a te r o r w a te r fro m a n y
p e rfo rm a n c e . o th e r s o u rc e .
3. K e e p th e b a tte ry c h a rg e d a t le a s t 7 5 % to a vo id
T able 1 s h o w s th e e ffe c t o f te m p e ra tu re on b a tte ry p la te s u lp h u riz a tio n , p e rfo rm a n c e lo ss and
p e rfo rm a n c e . p o s s ib le fre e z in g a t lo w te m p e ra tu re s .
603.54.331.00 - 12 - 1996
4 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 5
3. C h e c k e le c tro ly te le v e l in e a ch e le m e n t a g a in
1. R e m o v e th e b re a th e r c a p s fro m e a ch b a tte ry an d , if n e c e s s a ry , to p up w ith d is tille d w a te r.
e le m e n t.
W ARNING : Explosive gas is formed when a battery
2. Fill each e le m e n t to th e re c o m m e n d e d level w ith is charged. Do not smoke or use naked flames when
e le c tro ly te a t a re la tiv e d e n s ity o f 1.260. checking electrolyte level. Check that the battery
charger is switched off, before connection and dis
connection, to avoid sparks which could ignite the
NOTE: The electrolyte consists o f diluted sulphuric gas.
acid, preferably at a temperature o f 21° - 32°C (69.8
- 89.6°F).
3. A fte r fillin g , le a v e th e b a tte ry to re st fo r 15 CHARGING VERY FLAT BATTERIES
m in u te s . C h e c k th e e lectrolyte level and to p up, if
n e ce ssa ry.
To re c h a rg e a P b -C a m a in te n a n c e -fre e b a tte ry w e
4. C h a rg e th e b a tte ry fo r 4 h o u rs a t 5 - 8 A ., re c o m m e n d u sin g a c o n s ta n t v o lta g e b a tte ry
c h e c k in g th a t all th e e le m e n ts are p ro d u cin g gas c h a rg e r. F o r v e ry fla t b a tte rie s , c h a rg e fo r 48 hours,
freely. a t 16 V., w ith c u rre n t lim ita tio n (50 A . fo r 105 A h and
6 6 A fo r 120 A h ).
5. R e p la c e th e b re a th e r ca p s.
B e fo re c h a rg in g a b a tte ry:
If o n ly c o n s ta n t v o lta g e b a tte ry c h a rg e rs are
a v a ila b le , w e re c o m m e n d u sin g v o lta g e le v e ls and
1. C le a n th e b a tte ry c a s in g and e le m e n t c o v e rs tim e s sh o w n in ta b le 2. T h e s e fig u re s re fe r to v e ry flat
c a re fu lly w ith a m m o n ia d ilu te d in w a rm w a te r b a tte rie s . If th e b a tte ry is o n ly 5 0 % d is c h a rg e d , use
and cle a n th e te rm in a ls ; h a lf th e tim e s h o w n (slo w ch a rg in g p ro g ra m m e ). F o r
o th e r c o n d itio n s , re d u c e c h a rg in g tim e
2. C h e c k th e e le c tro ly te le ve l a nd, if it is b e lo w th e p ro p o rtio n a lly . W h e n fe a s ib le , use th e s lo w e s t
p la te level, to p up w ith d istille d w a te r to c o v e r the c h a rg in g p ro g ra m m e fo r in c re a s e d b a tte ry life.
p late s.
If v io le n t b o ilin g o c c u rs d u rin g c h a rg in g , d u e to g a s
fo rm a tio n o r e le c tro ly te le a ka ge , o r if th e b a tte ry b o x
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 5 5
• Thermometer
NOTE: Relative density should not vary more than
• Battery charger 0.025 points between cells.
Relative density: This test shows the charge level of 4. If relative density is 1.280 or higher, the battery is
a battery. fully charged and in good working condition.
2. Regulate the densimeter reading for battery NOTE: If distilled water has recently been added, the
electrolyte temperature variations subtracting 4 battery m ust be charged for a short period o f time to
points (relative density 0.004) for every 5.5 °C obtain precise densimeter readings.
(41.9 °F) below the temperature the densimeter
is calibrated at and adding 4 points (relative
density 0.004) for every 5.5 °C (41.9 °F) above If the battery has been loaded and kept still, the
this temperature. battery electrolyte will be thicker at the base of the
elements. The battery must be shaken periodically to
mix the electrolyte. This will improve charging
The following examples have been calculated with a amperage and allow more precise densimeter
densimeter calibrated at 30 °C (86 °F). readings during tests.
603.54.331.00 - 12 - 1996
6 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 5
1 .1 5 0 o r less 6 0 m in u te s
2. C o n n e c t th e p o s itiv e b a tte ry c h a rg e r c o n d u c to r
to th e p o sitiv e b a tte ry te rm in a l and th e n e g a tiv e
c o n d u c to r to th e n e g a tiv e b a tte ry te rm in a l.
NOTE: When there are problems with a battery,
check fan belt tension and the complete charging
system.
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 5 7
BATTERY PROBLEMS - FREQUENT 5. Crystals are formed when batteries are left flat.
CAUSES High temperature and long periods with the
battery flat increase this condition. If a battery is
1. Internal open circuit. left at room temperature for a week it can rarely
be charged in the vehicle. Battery recharge
requires higher constant voltage. After three
2. Internal short-circuit. weeks the battery will be permanently
jeopardized and it will be necessary to follow the
3. Battery electrolyte leakage. procedure described for “very flat batteries”.
603.54.331.00 - 12 - 1996
8 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 5
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 1
CONTENTS
55 100 C o n te n ts ................ 1
F u s e s (all v e rs io n s ) ....................................................................................................................................... 2
G ro u n d lo c a tio n s .............................................................................................................................................. 5
E le c tric a l d ia g ra m s ..............................................................................................................................................
- G e n e ra l d ia g ra m s (W /C a b ) ........................................................................................................9
- G e n e ra l d ia g ra m s (W /O u t C a b ) ............................................................................................ 15
o v e rv ie w 53
603.54.331.00 - 12 - 1996
2 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
H 15A Ur 15A
Cl 1QA * - 15A
s 10 A i 30A
KORNAR&ESi
s 7,5A ■W1 5 A H0RNRB.AY
□ 7,5A
+ 40A
□ 10A 20A
H 20A
w 15 A
KORNAR^LESj
LOW BEAH RBAY
I5 A
□1
47
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 3
FUSES AND RELAY BOX (INSIDE CAB) F u s e s and p ro te c te d c irc u its a re lis te d be lo w :
FIG - 48 - 49
Fuses PROTECTED CIRCUITS Am ps
& * ■
0 <C
o 1.
2.
F ro n t w ip e r
W asher
10
7.5
<C
& * ■ B e a c o n la m p , in te rio r la m p s,
3. 15
radio
© -►
9k <c
<c
o
4.
5.
H e a te r/A ir C o n d itio n in g
R e a r w ip e r
20
7.5
® " * ' <N
6. W o rk in g la m p s s w itc h e s 10
<c 7. F ro n t w o rk in g la m p s 15
© -► □
8. R e a r w o rk in g la m p s 25
RELAY
<c
ROLE
© -► o
m
o <c
om
mi
o <c
© - *■ om <N
TRE0849A
48
Relays CIRCUITS
1. F ro n t w o rk lig h ts
2. R e a r w o rk lig h ts
3. P o w e r s u p p ly
4. P o w e r s u p p ly
603.54.331.00 - 12 - 1996
4 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
SYM BOLS
THERMOSTARTER SWITCH
HEADLAMPS WATER TEMP. GAUGE SENDING UNIT
BRAKE SWITCH
HANDBRAKE SWITCH
ENGINE OIL PRESSURE SWITCH
STARTER SWITCH
FRONT SIGNAL AND PARKING LIGHT
SOLENOID
FUEL SEDIMENTER
SPEAKER
INTERIOR LIGHTS (LAMPS) [C O
BEACON LAMP
LIGHTER
COMPRESSOR COMPRESSOR
SWITCHES
GROUND
WORKLAMPS
REAR WIPER
I FUSE I
-457 15y » STARTER SWITCH
I I MAIN FUSE
HORN
THERMOSTARTER
£
ALTERNATOR
DIODE
■i —
AIR FILTER RESTRICTION SWITCH
-mi— □
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 5
B B la c k
G G re e n
K P in k
LG L ig h t g re e n
LN Tan
N B ro w n
O O ra n g e
P P u rp le
R R ed
S G re y
TQ T u rq u o is e
U B lue
W W h ite
Y Y e llo w
2. F u se b o x g ro u n d p o in t
3. C a b flo o r g ro u n d p o in t
4. S te e rin g p u m p p re s s u re s e n s o r g ro u n d p o in t
5. B a tte ry g ro u n d p o in t
6. W in d s c re e n w a s h e r p u m p g ro u n d point.
8. E v a p o ra to r to p g ro u n d p o in t
9. U p p e r ca b g ro u n d p o in t
10. P ro te c tiv e d io d e g ro u n d p o in t
603.54.331.00 - 12 - 1996
6 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
GROUND LOCATIONS
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 7
603.54.331.00 - 12 - 1996
8 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 9
2,0 N
1,5 N 1,5 P
5,0 N 5,0 Y/W
2,5 N/R 2,5 N/R
6,0 N 6,0 N
5,0 N 5,0 Y/W
1,5 Y/W 1,5 S
1,5 G/O 1,5 G/O
UPG JX KABINLI 1
603.54.331.00 - 12 - 1996
10 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 11
n u
@
603.54.331.00 - 12 - 1996
12 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 13
2 - Starter switch
3 - Turn signal switch
4 - Hazard warning lights indicator sending unit
5 - Fuse Box
6- Low beam relay
7 - High beam relay
8- Horn relay
9 - Compressor
1 0 - Flasher
11- Battery
1 2 - Starter
1 3 - Alternator
1 4 - Over voltage circuit breaker (DIODE)
1 5 - Engine oil pressure switch
1 6 - A ir cleaner restriction indicator sending unit
1 7 - Water temperature gauge sending unit
1 8 - Therm ostarter button
1 9 - Horn
2 0 - Right front parking and turn signal lights
2 1 - Rear left parking,turn signal and stop lights
2 2 - Working lamp
2 3 - Fuel level sensor
2 4 - Beacon lamp
2 5 - Trailer plug
2 6 - Number plate lamp
2 7 - Engine shut off solenoid
6 0 3 .5 4 .3 3 1 .0 0 -1 2 - 1996
28- Thermostarter
29- Hand brake switch
30- Brake stop light switch
31- Starter inhibitor unit
32- Headlamps
33- Worklights switch
34- Rear right parking,turn signal and stop lights
35- Main fuse20
36- Front brake oil unit
37- Rear wiper
38- Cabin fuse box
39- Canin plug
40- Switches
41- Rear work lamps
42- Front work lamps
43- Speaker
44- Interior lamps
45- W iper
46- Radio
47- Heater
48- Washer
49- Beacon lamp
50- Fuel sedimenter
51- Brake disc
52- Front working lamp relay
53- Rear working lamp relay
54- Front and rear working lamp relay
55- Power relay
56- Front left signal and parking light
57- Front left signal and parking light
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 15
2,0 B
1,5 B / / 1 1,0 E
1,5 P
2,0 U/R
UPG JX ROPS 1
603.54.331.00 - 12 - 1996
16 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
2 - Starter switch
3 - Turn signal switch
4 - Hazard warning lights indicator sending unit
5 - Fuse Box
6- Low beam relay
7 - High beam relay
8- Horn relay
9 - Fuel sedimenter
1 0 - Flasher
11- Battery
1 2 - Starter
1 3 - Alternator
1 4 - Over voltage circuit breaker (DIODE)
1 5 - Engine oil pressure switch
1 6 - A ir cleaner restriction indicator sending unit
1 7 - Water temperature gauge sending unit
1 8 - Therm ostarter button
603.54.331.0 0 - 1 2 - 1996
19- Horn
20- Right front parking and turn signal lights
21- Rear left parking,turn signal and stop lights
22- Working lamp
23- Fuel level sensor
24- Beacon lamp
25- Trailer plug
26- Number plate lamp
27- Engine shut off solenoid
28- Thermostarter
29- Hand brake switch
30- Brake stop light switch
31- Starter inhibitor unit
32- Headlamps
33- Worklights switch
34- Rear right parking,turn signal and stop lights
35- Main fuse
36- Front brake oil unit
37- Brake disc
38- Front left signal and parking light
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 19
1- L e ft tu rn in d ic a to r 9 - B ra k e oil le v e l low
2- S id e la m p s 10 - P a rk in g b ra ke
3- H e a d la m p m a in b e a m 11- R iH ht tu rn in d ic a to r
7- E n g in e oil p re s s u re 15 - U nused
8- B a tte ry c h a rg e r
603.54.331.00 - 12 - 1996
20 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
0 ,5 G / B
0 ,5 G / U
0 ,5 B
0 ,5 L G / Y
0 ,5 L G / R
0 ,5 G / R
0 ,5 R / W
0 ,5 U / W
0 ,5 U
0 ,5 G / W
0 ,5 B / S
0 ,5 W / N
0 ,5 N / Y
0 ,5 W / B
0 ,5 G
0 ,5 R / K
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 21
STARTING CIRCUIT
STARTING CIRCUIT
1 - Instrument panel
2 - Starter switch
11 - Battery
12 - Starter
13 - Alternator
14 - Over voltage circuit breaker (DIODE)
31 - Starter inhibitor unit
35 - Main Fuse
603.54.331.00 - 12 - 1996
22 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 23
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
24 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 25
603.54.331.00 - 12 - 1996
26
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
1 - Instrument panel
2 - Starter switch
3 - Turn signal switch
4 - Hazard warning lights indicator sending unit
5 - Fuse Box
1 0 - Flasher
11- Battery
1 2 - Starter
1 3 - Alternator
2 0 - Right front parking and turn signal lights
2 1 - Rear left parking,turn signal and stop lights
2 5 - Trailer plug
3 4 - Rear right parking,turn signal and stop lights
3 5 - Main fuse2 0 - Right front parking and turn signal lights
5 6 - Front left signal and parking light
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 27
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
28 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 29
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
30 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 31
603.54.331.00 - 12 - 1996
32
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
2 - Starter switch
5 - Fuse Box
11- Battery
1 2 - Starter
1 3 - Alternator
3 5 - Main Fuse
3 7 - Rear wiper
3 8 - Cabin fuse box
4 0 - Switches
4 5 - W iper
4 8 - Washer
5 5 - Power relay
B - Main and cabin harness connector
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 33
CONNECTOR OVERVIEW
6 N
6 Y /W '
2 ,5 N / U ■
1 ,5 R -
2 ,5 W / Y
1 ,5 U -
1 R /W
1 R /W
1 R
1 R
1 ,5 P / G
1 ,5 P / R
1 G
1 G
1 LG /B
1 L G
603.54.331.00 - 12 - 1996
34 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
__________________ SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 35
603.54.331.00 - 12 - 1996
36 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
2 - Starter switch
11- Battery
1 2 - Starter
1 3 - Alternator
2 1 - Rear left parking,turn signal and stop lights
2 5 - Trailer plug
3 0 - Stop light switch
3 4 - Rear right parking turn signal and stop light
3 5 - Main Fuse
A - Main and chassis harness connector
F - Chassis and rear right indicator connector
G - Chassis and rear left indicator connector
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 37
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
38 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
CONNECTOR OVERVIEW
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
40 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 41
603.54.331.00 - 12 - 1996
42 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
2 - Starter switch
5 - Fuse Box
9 - Compressor
11- Battery
1 2 - Starter
1 3 - Alternator
3 5 - Main Fuse
3 8 - Cab fuse box
4 7 - Heater
5 4 - Compressor
5 5 - Power relay
B - Main and cab harness connector
I - Electrical fans
II- A ir conditioning-therm ostat
III-.Air-conditioning pressure switch
IV - Electric fan control switch
V - Air-conditioning control switch
V I- Heating control
V II- Air-conditioning control switch connection
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 43
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
44 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 45
603.54.331.00 - 12 - 1996
46 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 47
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
48 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 49
603.54.331.00 - 12 - 1996
50
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 51
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
52 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 53
603.54.331.00 - 12 - 1996
54
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 55
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
56 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 57
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
58 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
SECTION 90 - CAB - CHAPTER 1 1
SECTION 90 - CAB
Chapter
1 - Removing parts
CONTENTS
S e ctio n D e s c rip tio n Page
90 160 42 - 4 3
90 120 10 C o n tro l le v e rs , s e a t a n d e le c tr ic a l c o n tro ls - d is a s s e m b ly a n d r e a s s e m b ly ............................. 2
90 156 52 R e a r w in d o w , h a n d le a n d lo c k - d is a s s e m b ly a n d r e a s s e m b ly ................................................... 10
90 154 30 L e f t- h a n d d o o r e x te r io r h a n d le a n d lo c k - d is a s s e m b ly a n d r e a s s e m b l y .................................... 11
90 154 10 L e f t- h a n d d o o r - d is a s s e m b ly a n d r e a s s e m b ly ...................................................................................... 12
90 160 60
55 518 52 W in d s c r e e n w ip e r m o to r - d is a s s e m b ly a n d r e a s s e m b ly .................................................................. 13
90154 24
90 156 10 - 14
90 156 28 C a b w in d o w s - r e p la c e m e n t ............................................................................................................................. 15
????
2 SECTION 90 - CAB - CHAPTER 1
1. D is c o n n e c t th e n e g a tiv e c a b le fr o m th e b a tte ry .
2. T a k e o u t th e f o u r s e c u r in g s c r e w s (1 ) a n d re
m o v e th e c o v e rin g o f th e c o n tro l p a n e l (2 ).
3. D is c o n n e c t th e e le c tric a l c o n n e c to r fr o m th e c a b
in te r io r lig h t s w itc h e s (3 ) a n d re m o v e th e c o v e r.
4. R e m o v e th e L H p a n e l re ta in in g s c r e w s (1)
5. R e m o v e t h e th r e e L H p a n e l re ta in in g s c r e w s (1)
???
SECTION 90 - CAB - CHAPTER 1 3
6. R e m o v e th e s c r e w s (1 ) o n r e a r p a n e l
7. R e m o v e th e L H p a n e l (1 ).
8. R e m o v e t h e s c r e w s (1 ) o f th e R H p a n e l re ta in in g
e le m e n ts .
9. R e m o v e th e s c r e w s (1 ) fr o m th e R H fe n d e r s .
????
4 SECTION 90 - CAB - CHAPTER 1
10. R e m o v e th e s c r e w s (1 ) fr o m th e r e a r p a n e l
11. R e m o v e th e L H p a n e l (1 ).
10
12. R e m o v e th e th e h a n d th r o ttle le v e r (1 ).
11
13. R e m o v e th e re ta in in g n u t (1 ) a n d ta k e o u t th e
s te e rin g w h e e l.
12
???
SECTION 90 - CAB - CHAPTER 1 5
13
15. U n s c re w th e re ta in in g s c r e w (2 ) o n th e s id e o f
th e in s tr u m e n t c o n s o le ( r e a r h o o d ) (1 ).
14
16. R e m o v e t h e re ta in in g s c r e w s (1 ) o n t o p o f in s tr u
m e n t c o n s o le ( r e a r h o o d ) (2 ).
15
17. R e m o v e th e in s tr u m e n t c o n s o le ( r e a r h o o d ) (1 ).
16
????
6 SECTION 90 - CAB - CHAPTER 1
18. R e m o v e th e s c r e w s (1 ) s e c u r in g th e k n o b s to th e
c o n tro l le v e rs a n d re m o v e th e k n o b s .
17
19. U n s c re w th e fo u r s c r e w s (1 ) s e c u r in g th e le v e r
p a n e l.
18
20. U n s c re w th e l i f t - o - m a t i c s w itc h re ta in in g s c re w s
(1 ).
???
SECTION 90 - CAB - CHAPTER 1 7
21. R e m o v e re m o v e th e p r o te c tiv e c o v e r a n d th e
s c r e w s (1 ) s e c u rin g th e h y d r a u lic c o n tro l le v e r
s u p p o r t (2 ) to th e p la tfo rm .
20
22. R e m o v e th e s c r e w s (1 ) h o ld in g th e a u x ilia ry
c o n tro l v a lv e le v e rs in p la c e .
21
23. R e m o v e th e s c r e w s s e c u r in g th e p a rk in g b ra k e
s u p p o r t (1 ) to th e p la tfo rm . D is c o n n e c t th e
p a rk in g b ra k e re la y a n d th e c o n tro l le v e r fr o m
v e r tic a l ro d .
22
23
????
8 SECTION 90 - CAB - CHAPTER 1
24
26. R e m o v e th e P T O c lu tc h le v e r s u p p o r t s e c u rin g
s c r e w s (1 ). D is c o n n e c t th e P T O c o n tro l le v e r
fr o m th e p a tfo rm .
27. U n s c re w th e re ta in in g s c r e w s (1 ) fr o m th e P T O
s y n c h r o n is e d c o n tro l le v e r s u p p o r t (2 ).
26
???
SECTION 90 - CAB - CHAPTER 1 9
28. R e m o v e th e f o u r s e a t s e c u r in g s c r e w s (1 ).
R e m o v e th e s e a t a n d th e c o v e rin g b e n e a th it.
To re fit, p ro c e e d a s fo llo w s :
— R e fit th e tr a n s m is s io n c o n tro l le v e rs .
— R e fit th e L I F T - O - M A T I C c o v e r, s e c u rin g it t o t h e
R H p a n e l w ith th e th r e e s c r e w s .
— R e fit th e R H s id e p a n e l, s e c u rin g it to th e c a b
b o d y w ith th e fiv e s c re w s .
— R e fit th e r e c ta n g u la r P T O c o v e r, th e y e llo w
p u s h b u tto n a n d p la s tic p lu g . S e c u r e th e c o v e r
w ith th e tw o s c re w s .
— R e fit th e th e L I F T - O - M A T I C s w itc h , th e p ro
te c tiv e c o v e r a n d th e c o n tro l le v e rs .
— S e c u r e th e LH s id e p a n e l w ith th e s c re w s
p re v io u s ly re m o v e d .
— F ix th e R H s id e p a n e l a n d c a b lig h t c o n tro l u n it
a n d w ith th e s e c u rin g s c r e w s . R e c o n n e c t th e
e le c tric a l c o n n e c to r to th e p lu g o n th e c o n tro l
p a n e l.
— R e in s ta ll th e d r iv e r ’s s e a t.
— R e c o n n e c t th e n e g a tiv e c a b le to th e b a tte ry .
????
10 SECTION 90 - CAB - CHAPTER 1
1. D is c o n n e c t th e n e g a tiv e c a b le fr o m th e b a tte ry .
2. R em ove th e h a n d le (2 ), th e s e a ls and th e
th r e a d e d p in (1 ).
28
3. D is c o n n e c t th e tw o g a s s tr u ts a t th e b a ll a n d
s o c k e t jo in ts (1 ).
29
4. R e m o v e th e s e c u r in g s c r e w s (1 ) fig . 3 0 fro m
th e h in g e s and ta k e out th e cab re a r
w in d s c r e e n c o m p le te w ith fr a m e (2 ) fig . 2 9 .
5. W ith t h e c a b r e a r w in d s c r e e n re m o v e d , re m o v e
th e s e c u rin g s c r e w s a n d th e fr a m e (2 ) fig . 2 9 .
6. To re fit, p ro c e e d a s fo llo w s :
— R e fit th e c o m p le te h a n d le u n it.
— R e fit th e lo c a tin g p in .
— R e n e w th e re a r w in d o w r u b b e r s e a l.
— R e c o n n e c t th e n e g a tiv e c a b le to th e b a tte ry .
30
???
SECTION 90 - CAB - CHAPTER 1 11
1. D is c o n n e c t th e n e g a tiv e c a b le fr o m th e b a tte ry .
2. U n s c re w th e th r e e s c r e w s (1 ) s e c u rin g th e in te rio r
lo c k c o v e r (2 ).
31
3. R e m o v e th e e x te rio r h a n d le b y u n s c re w in g th e
tw o re ta in in g s c r e w s (1 ) fr o m th e in s id e .
To re fit, p ro c e e d a s fo llo w s :
— R e fit th e e x te rio r h a n d le .
— F it th e lo c k .
— R e c o n n e c t th e n e g a tiv e c a b le to th e b a tte ry .
32
4. R e m o v e t w o s c r e w s (1 ) s e c u r in g t h e in te r io r lo c k
(2 ).
33
????
12 SECTION 90 - CAB - CHAPTER 1
LH DOOR
D is a s s e m b ly -A s s e m b ly (Op. 90 154 10)
1. D is c o n n e c t th e n e g a tiv e c a b le fr o m th e b a tte ry .
34
2. R e m o v e th e d o o r c lo s u re (g a s s tru t).
35
3. F ro m in s id e t h e c a b , u n s c re w th e tw o t o p s c r e w s
(1 ) s e c u r in g th e d o o r h in g e .
36
4. R e m o v e th e d o o r.
To re fit, p ro c e e d a s fo llo w s :
— R e fit th e le ft h a n d d o o r.
— R e fit th e le ft h a n d p illa r s e a l.
— R e c o n n e c t th e n e g a tiv e c a b le to th e b a tte ry .
37
???
SECTION 90 - CAB - CHAPTER 1 13
1. D is c o n n e c t th e n e g a tiv e c a b le fr o m th e b a tte ry .
38
2. R e m o v e th e r o o f s e c u rin g s c re w s
39
3. R e m o v e th e c a p to p c o v e r (1 ) a n d d is c o n n e c t
th e e le c tric a l c o n n e c tio n fr o m th e fr o n t w ip e r
m o to r.
40
4. U n s c re w th e w ip e r b la d e re ta in in g s c r e w (1)
41
????
14 SECTION 90 - CAB - CHAPTER 1
5. U n s c re w th e s m a ll n u t (1 ) s e c u r in g t h e w ip e r m o
t o r u n it.
42
6. U n s c re w th e la rg e n u t a n d re m o v e th e w ip e r
m o to r u n it (1 ) fr o m t o p th e c a b .
To r e in s ta ll, p ro c e e d a s fo llo w s :
M R« s ' ^ . Q ....
— R e fit th e m o to r u n it a n d s e c u r e it w ith th e tw o : E = — - - -a • ••
. Ii '-----—
. : . / L/— \\ *■J o 1t
1
n u ts
— R e fit th e w ip e r b la d e
— R e c o n n e c t th e e le c tric a l c o n n e c to r to th e m o to r
— R e fit th e cab ro o f lin in g and a ll th e p a rts o
mT nr~x ^Dl 1
p r e v io u s ly re m o v e d .
— R e c o n n e c t th e n e g a tiv e c a b le to th e b a tte ry .
43
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SECTION 90 - CAB - CHAPTER 1 15
C A B W INDOW S
R eplacin g b on d e d cab w in d o w s
(Op.90 154 24 - 90 156 10 - 90 156 14 - 90 156 28)
R em oving w in d o w
P r o c e e d a s fo llo w s .
1. If p o s s ib le , re m o v e a n y w in d o w s u p p o r t b lo c k s
p re s e n t a s th e y c a n r e s tr ic t th e a c tio n o f th e
c u ttin g w ire .
2. F ro m in s id e th e c a b u s e a p a ir o f p lie rs to p u s h
th e c u ttin g w ire (1 ) fig . 4 4 th r o u g h th e a d h e s iv e
(2 ) b e tw e e n th e g la s s a n d th e fra m e .
3. T h re a d th e c u ttin g w ir e (1 ) fig . 4 5 in to th e h a n d le
a n d lo c k it w ith th e s c r e w (2 ).
4. A n c h o r th e p o in te d e n d o f th e th e to o l in to th e
a d h e s iv e (s e e fig u re A ). K e e p th e w ire c lo s e to
th e g la s s a n d p u ll o n th e h a n d g rip (2 ) fig . 4 6 .
5. P u ll th e p o in te d to o l fr o m th e a d h e s iv e a n d
re p o s itio n it fu r t h e r a lo n g , a s s h o w n a t (2 ). A g a in ,
p u ll o n th e w ire , m a k in g lo n g c u ts o n s tr a ig h t
s e c tio n s a n d s h o r t c u ts a ro u n d c o rn e r s to a v o id
b re a k in g th e g la s s . R e p e a t th is o p e ra tio n u n til
th e w in d o w is c o m p le te ly d e ta c h e d .
6. U s e a to o l w ith s u c tio n c u p s to re m o v e th e
w in d o w a n d p la c e it o n a s u ita b le s u r fa c e to a v o id
d a m a g in g it.
7. C o m p le te ly re m o v e th e a d h e s iv e fr o m th e
w in d o w s u rr o u n d , ta k in g c a re n o t to d a m a g e th e
s u rro u n d .
8. R e m o v e th e a d h e s iv e fr o m th e g la s s u s in g a
s u ita b le s o lv e n t.
NOTE: W h e n r e p la c in g a b ro k e n w in d o w , re m o v e
th e g la s s fr a g m e n ts s till a tta c h e d to th e c a b a n d u s e
a k n ife b la d e to c u t th e a d h e s iv e (1 ) fig . 4 7 , a w a y
fr o m th e fra m e . T a k e c a re n o t to d a m a g e th e fra m e .
9. C le a n th e fra m e , a s d e s c r ib e d in o p e ra tio n 7.
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16 SECTION 90 - CAB - CHAPTER 1
R e fittin g th e w in d o w
P ro c e e d a s fo llo w s .
1. M a k e s u re t h a t th e c o n ta c t a re a b e tw e e n th e
g la s s a n d th e m e ta l fr a m e in th e c a b is p e r fe c tly
c le a n .
2. U s in g a c le a n tis s u e , a p p ly th e a c tiv a to r (V P
0 4 6 0 4 G U R IT E S S E X ) a ro u n d th e e d g e o f th e
g la s s , w h e r e c o n ta c t w ill b e m a d e w ith th e m e ta l
fra m e . A llo w to d ry.
3. S h a k e th e b o ttle o f g la s s p r im e r ( B e ta p r im e 5 1 0 0
G U R IT ESSEX) fo r 6 0 seconds. U s in g th e
a p p lic a to r p ro v id e d (1 ) fig . 4 8 , a p p ly th e p r im e r
(2 ) a ro u n d th e e d g e o f th e g la s s , o v e r t h e to p o f
th e d rie d a c tiv a to r. A llo w to d r y th o ro u g h ly .
4. S hake th e b o ttle of m e ta l p la te p r im e r
( B e ta p rim e 5402 G U R IT ESSEX) fo r 60
s e c o n d s . U s in g th e a p p lic a to r p ro v id e d a p p ly
a ro u n d th e m e ta l fr a m e , w h e r e c o n ta c t w ill be 48
m a d e w ith th e g la s s . A llo w to d r y th o ro u g h ly .
5. C u t th e s p o u t o f th e a d h e s iv e d is p e n s e r a s
s h o w n in fig . 4 9 to o b ta in a b e a d o f t r ia n g u la r
c r o s s - s e c tio n .
6. A p p ly a s m o o th , c o n tin u o u s bead of
p o ly u re th a n e a d h e s iv e ( B e ta s e a l 1 7 0 3 G U R IT
E S S E X ) a ro u n d th e e d g e o f th e g la s s o v e r th e
p re v io u s ly p rim e d a re a (th e c r o s s - s e c tio n o f th is
b e a d m u s t b e tria n g u la r , w ith a b a s e w id th o f 10
m m a n d a h e ig h t o f 10 m m ).
7. In s e rt th e w in d o w s u p p o r t b lo c k s , if p re s e n t.
NOTE: L e a v e th e c la m p s in p la c e f o r 4 h o u rs u n til th e
a d h e s iv e h a s c o m p le te ly p o ly m e ris e d . To p ro m o te a
g o o d b o n d , d o n o t m o v e th e c a b o r t h e t r a c t o r d u r in g
t h is tim e .
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