JX60 -- JX70 -- JX80 -- JX90 -- JX95

MODEL TRACTORS
SERVICE MANUAL
SECTIONS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSMISSION OF MOTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER TAKE- OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AXLE AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUXILIARY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S

00
10
18
21
23
25
27
31
33
35
41
44
50
55
90

INTRODUCTION
This manual is divided into sections identified by two--figure numbers. Each section has independent page
numbering.
For ease of reference, these sections have the same numbers and names as the Repairs Rate Book sections.
The different sections can easily be found by consulting the table of contents on the following pages.
The document number of the manual and the edition/update dates are given at the bottom of each page.
The information contained in this manual was current on the date printed on each section. As CASE IH
constantly improves its product range, some information may be out of date subsequent to modifications implemented for technical or commercial reasons or to meet legal requirements in different countries.
In the event of conflicting information, consult the CASE IH Sales and Service Departments.

IMPORTANT WARNINGS
All maintenance and repair work described in this manual must be performed exclusively by CASE IH service
technicians in strict accordance with the instructions given and using any specific tools necessary.
Anyone who performs the operations described herein without strictly following the instructions is personally
responsible for resulting injury or damage to property.
The Manufacturer and all organisations belonging to the Manufacturers distribution network, including but
not restricted to national, regional or local distributors, will accept no responsibility for personal injury or damage to property caused by abnormal function of parts and/or components not approved by the Manufacturer,
including those used for maintenance and/or repair of the product manufactured or marketed by the Manufacturer.
In any case, the product manufactured or marketed by the Manufacturer is covered by no guarantee of any
kind against personal injury or damage to property caused by abnormal function of parts and/or components
not approved by the Manufacturer.

TEXT AND ILLUSTRATIONS ARE THE PROPERTY

OF CNH ITALIA S.p.A.
No part of the text or illustrations
may be reproduced

PRINTED IN ?????
CNH ITALIA S.p.A. -- Viale delle Nazioni, 55 -- 41100 MODENA -- Italy
Technical Support -- Technical Information
Print No. ?????? -- ?? -- ????

Repair Manual -- JX Series Tractors

CONTENTS
GENERAL

SECTION 00

General Instructions and Health and Safety

Section

Chapter 1

Description

00 000

Page

General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Notes for spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Notes for equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ENGINE

SECTION 10

Engine System

Chapter 1

Section

Description

10 000

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Injection pump calibration data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lubrication and cooling system diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Engine Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Engine Bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Checks, measurements and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Radiator Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Crankshaft front oil seal removal installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Coolant pump removal installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Cooling system thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Bosch injection pump removal installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Bosch injection pump timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Bosch injection pump air bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Injectors removal installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Valve clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

10 001 10
10 001 54
10 406 10
10 102 70
10 402 10
10 402 30
10 206 14

10 218 30
10 106 12

Page

10 402 28
10 001 30

Coolant pump overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

CLUTCH

SECTION 18

Clutches
Section

Chapter 1

Description

18 000

18 110 10

18 100 40

Page

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Minimum permissible dimensions after refacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Adjustment of the main and PTO clutch control linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

GEARBOX

SECTION 21

Mechanical Transmission (12x4)

Chapter 1

Section

Description

21 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3&5
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal -- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see sect 27

21 110

Reverser (12x12)

Page

Chapter 2

Section

Description

21 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

21 110

Reverser and Creeper (20x12)

Page

Chapter 3

Section

Description

Page

21 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

21 110

DRIVE LINES
Drive Lines

SECTION 23
Chapter 1

Section

Description

23 000

Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Torque settings and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cross--Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Transmission shafts and guard (Disassembly -- Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drive gear housing (Removal -- Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drive gear housing removed (Disassembly -- Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

23 101 26
23 101 40
23 101 42

FRONT AXLE MECHANICAL TRANSMISSION

Front Axle Mechanical Transmission

Page

SECTION 25
Chapter 1

Section

Description

25 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Complete front axle. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front axle. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Steering knuckle bearing pins. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Stub axle adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wheel hub bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bevel drive adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Front axle differential. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Front axle differential with LIM--SLIP. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Front axle differential with NO SPIN. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Leading drive wheels toe--in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

25 100 30
25 100 38
25 108 46--47

25 102 24
25 100 27
44 511 80

REAR AXLE AND TRANSMISSION

Rear Axle And Transmission

Page

SECTION 27
Chapter 1

Section

Description

Page

27 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description and operation and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

21.118.10 -- 12 Transmission--gearbox casing Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21.118.85
Transmission--gearbox casing Disassembly--Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox driven shaft end float adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential lock engagement sleeve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining the bevel pinion positioning adjustment ring . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the taper roller bearings for the bevel pinion shaft . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the bearings and checking the backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential pinion and side gear backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POWER TAKE--OFF
Mechanical Power Take -- Off

10
27
35
36
37
39
40
44

SECTION 31
Chapter 1

Section

Description

31 000

Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal -- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

31 101

BRAKING SYSTEM
Braking System

Page

SECTION 33
Chapter 1

Section

Description

33 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools -- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front brake assembly mod. JX60 and JX70 removal and refitting -overhauling on the bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service brake removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal--Refitting of front brake pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Bleeding air from the front braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Adjusting service brake pedals travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Parking brake travel adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

33.206
33.202.60
33.202.50
33.202.40
33.120.08
33.110.08

HYDRAULIC SYSTEM
Rear Mechanical Hydraulic Lift
Section
35 000

Description

Page

SECTION 35
Chapter 1
Page

Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Description and operation of lift phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
35 110.30
Hydraulic lift -- disassembly reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
35.110.40--42--46 Hydraulic lift -- bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjusting the lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
35.110.08
Linkage adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
35.110.30
Pressure relief valve -- disassembly reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
35.110.32
Pressure relief valve -- setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
35.110.14
Lift control valve -- disassembly assembly and overhaul on bench . . . . . . . . . . . . . . . . . . 36
35.0101.10
Lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Open Centre System Auxiliary Control Valves

Chapter 2

Section

Description

35 000

Main data -- Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

35 204 46

Trailer Brake Auxiliary Control Valve

Page

Chapter 3

Section

Description

Page

35 000

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

STEERING

SECTION 41

Steering

Chapter 1

Section

Description

41 000

Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hydrostatic steering control valve -- Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydrostatic steering control valve -- Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . 14
Hydrostatic steering control valve -- Bench testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hydrostatic steering oil pump -- Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Steering cylinder (two--wheel drive axle) -- Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . 32
Steering cylinder (four wheel drive axle) -- Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . 33

41 204 30
41 204 34
41 204 38
41 216 20

FRONT AXLE AND WHEELS

Page

SECTION 44

Front Axle And Wheels

Chapter 1

Section

Description

44 000

Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment -- Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal--Refitting--Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wheel hub disassembly--assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Stub axle overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Checking wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

44 101 30
44 101 22
44 101 46
44 101 80

Page

AUXILIARY UNITS

SECTION 50

Auxiliary Units

Chapter 1

Section

Description

Page

50 000

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main components of the cab air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Refrigerant recovery--recycling and evacuation--charging stations . . . . . . . . . . . . . . . . . . 20

50 200 04

Drying recharging and checking cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

50 200 03

Functional testing of air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Summary of the cab air--conditioning system charging operations . . . . . . . . . . . . . . . . . . 28
Checking for refrigerant leaks using an electronic leak detector . . . . . . . . . . . . . . . . . . . . . 30
Summary of fault diagnosis and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Air conditioning and heating pipes -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

50 200 04--74

Receiver--drier -- Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

50 200 04--72

Condenser -- Replacement

50 200 04--26

Compressor -- Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

50 200 10

Compressor drive belt tension adjustment

ELECTRICAL SYSTEM
Instruments
Section

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

SECTION 55
Chapter 1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

Analogue instruments Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Transmitter and switch
4 .

Components

Chapter 2

Section

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

55 500

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Starting System

Chapter 3

Section

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

55 000

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

55 201

Charging System

Chapter 4

Section

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

55 000

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

55 301

Battery

Chapter 5

Section

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

55 000

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

55.301.040

Electrical Circuits
Section

55 100

Chapter 6

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

Contents . . . . . . . .

Fuses (all versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Symbols used in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical wire colour coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ground locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- General diagrams (W/Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

-- Analogue instrument circuit and connector overview . . . . . . . . . . . . . . . . . . . . . . 19
-- Start--up circuit and connector overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
-- Direction indicator & hazard warning light circuit and connector overview . . . . 25
-- Windscreen and rear window wiper/washer circuit and connector overview . . . 31
-- Brake light circuit and connector overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
-- Heating and air--conditioning system circuit and connector overview . . . . . . . . 41
-- Work lamp (without cab circuit and connector overview) . . . . . . . . . . . . . . . . . . . 45
-- Work lamp (without cab circuit and connector overview) . . . . . . . . . . . . . . . . . . . 49
-- Side lights,main and dipped headlights, parking light circuit and connector
overview

BODYWORK AND DRIVER POSITION

Bodywork And Driver Position
Section

53

SECTION 90
Chapter 1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

90 160 42 -- 43
90 120 10
Control levers, seat and electrical controls -- disassembly and reassembly . . . . . . . . . . . . . 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 reassembly . . . . . . . . . . . . . . 11

90 154 10

Left--hand door -- disassembly and reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

90 160 60
55 518 52

Windscreen wiper motor -- disassembly and reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 13

90154 24
90 156 10 -- 14
90 156 28
Cab windows -- replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 00 GENERAL CHAPTER 1

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

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

ROTATING SHAFT SEALS

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

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

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

BEARINGS
It is advisable to heat the bearings to 80 to 90C 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.
???

SECTION 00 GENERAL CHAPTER 1

NOTES FOR SPARE PARTS
Use exclusively genuine CASE IH spare parts, the only ones bearing this logo.

Only genuine parts guarantee same quality, life, safety as original components as they are the same as mounted
in production.
Only the CASE IH genuine spare parts can offer this guarantee.
All spare parts orders should be complete with the following data:
tractor model (commercial name) and frame number;
engine type and number;
part number of the ordered part, which can be found on the Microfiches or the Spare Parts Catalogue,
which is the base for order processing.
NOTES FOR EQUIPMENT
Equipment which CASE IH proposes and shows in this manual are as follows:
studied and designed expressly for use on CASE IH tractors;
necessary to make a reliable repair;
accurately built and strictly tested to offer efficient and longlasting working means.
We also remind the Repair Personnel that having these equipment means:
work in optimal technical conditions;
obtain best results;
save time and effort;
work more safely.
NOTICES
Wear limits indicated for some details should be intended as advised, but not binding values. The words front,
rear, right hand, and left hand referred to the different parts should be intended as seen from the operators
seat oriented to the normal sense of movement of the tractor.
HOW TO MOVE THE TRACTOR WITH THE BATTERY REMOVED
Cables from the external power supply should be connected exclusively to the respective terminals of the tractor
positive and negative cables using pliers in good condition which allow proper and steady contact.
Disconnect all services (lights, windshield wipers, etc.) before starting the tractor.
If it is necessary to check the tractor electrical system, check it only with the power supply connected. At check
end, disconnect all services and switch the power supply off before disconnecting the cables.

????

SECTION 00 GENERAL CHAPTER 1

SAFETY RULES
PAY ATTENTION TO THIS SYMBOL
This warning symbol points out important messages involving personal safety.
Carefully read the safety rules contained herein and follow advised precautions to
avoid potential hazards and safeguard your safety and personal integrity.
In this manual you will find this symbol together with the following keywords:
WARNING it gives warning about improper repair operations and deriving potential
consequences affecting the service technicians personal safety.
DANGER it gives specific warning about potential dangers for personal safety of the
operator or other persons directly or indirectly involved.
if they are certified operators to assist in the
operation to be carried out.

TO PREVENT ACCIDENTS
Most accidents and personal injuries taking place in
workshops are due from nonobservance of some
simple and essential prudential rule and safety precautions. For this reason, IN MOST CASES THEY
CAN BE AVOIDED. It suffices to foresee possible
causes and act consequently with necessary caution
and care.
The possibility that an accident might occur with any
type of machines should not be disregarded, no matter how well the machine in question was designed
and built.
A wise and careful service technician is the best precautions against accidents.
Careful observance of this only basic precaution
would be enough to avoid many severe accidents.
DANGER: Never carry out any cleaning, lubrication
or maintenance operations when the engine is running.

Never operate the machine or use attachments

from a place other than sitting at the operators
seat.

Never carry out any operation on the machine

when the engine is running, except when specifically indicated.

Stop the engine and ensure that all pressure is

relieved from hydraulic circuits before removing
caps, covers, valves, etc.

All repair and maintenance operations should be

carried out with the greatest care and attention.

Service stairs and platforms used in a workshop

or in the field should be built in compliance with
the safety rules in force.

Disconnect the batteries and label all controls to

warn that the tractor is being serviced. Block the
machine and all equipment which should be
raised.

Never check or fill fuel tanks and accumulator

batteries, nor use starting liquid if you are smoking or near open flames as such fluids are flammable.

Brakes are inoperative when they are manually

released for maintenance purposes. In such
cases, the machine should be kept constantly
under control using blocks or similar devices.

The fuel filling gun should remain always in contact with the filler neck. Maintain this contact until
the fuel stops flowing into the tank to avoid possible sparks due to static electricity buildup.

SAFETY RULES
GENERALITIES

Carefully follow specified repair and maintenance procedures.

Do not wear rings, wristwatches, jewels, unbuttoned or flapping clothing such as ties, torn
clothes, scarves, open jackets or shirts with open
zips which could get hold into moving parts. We
advise to use approved safety clothing such as
antislipping footwear, gloves, safety goggles,
helmets, etc.

Never carry out any repair on the machine if

someone is sitting on the operators seat, except

???

SECTION 00 GENERAL CHAPTER 1

Use exclusively specified towing points for towing the tractor. Connect parts carefully. Ensure
that foreseen pins and/or locks are steadily fixed
before applying traction. Do not stop near towing
bars, cables or chains working under load.

In case of operations outside the workshop, drive

the tractor to a flat area and block it. If working on
an incline cannot be avoided, first block the tractor carefully. Move it to a flat area as soon as possible with a certain extent of safety.

To transfer a failed tractor, use a trailer or a low

loading platform trolley if available.

To load and unload the machine from the transportation mean, select a flat area providing a firm
support to the trailer or truck wheels. Firmly tie
the machine to the truck or trailer platform and
block wheels as required by the forwarder.

Ruined or plied cables and chains are unreliable.

Do not use them for lifting or trailing. Always handle them wearing gloves of proper thickness.

Chains should always be safely fastened.

Ensure that fastening device is strong enough to
hold the load foreseen. No persons should stop
near the fastening point, trailing chains or cables.

The working area should be always kept CLEAN

and DRY. Immediately clean any spillage of
water or oil.

Do not pile up grease or oil soaked rags, as they

constitute a great fire hazard. Always place them
into a metal container.
Before starting the tractor or its attachments,
check, adjust and block the operators seat. Also
ensure that there are no persons within the tractor or attachment operating range.

For electrical heaters, batterychargers and similar equipment use exclusive auxiliary power
supplies with a efficient ground to avoid electrical
shock hazard.

Always use lifting equipment and similar of

appropriate capacity to lift or move heavy components.

Pay special attention to bystanders.

Never pour gasoline or diesel oil into open, wide

and low containers.

Never use gasoline, diesel oil or other flammable

liquids as cleaning agents. Use nonflammable
nontoxic proprietary solvents.

Do not keep into your pockets any object which

might fall unobserved into the tractors inner
compartments.

Wear protection goggles with side guards when

cleaning parts using compressed air.

Do not exceed a pressure of 2.1 bar, in accordance with local regulations.

Whenever there is the possibility of being

reached by ejected metal parts or similar, use
protection eye mask or goggles with side guards,
helmets, special footwear and heavy gloves.

Do not run the engine in a closed building without

proper ventilation.

Do not smoke, use open flames, cause sparks in

the nearby area when filling fuel or handling
highly flammable liquids.

Do not use flames as light sources when working

on a machine or checking for leaks.

Wear suitable protection such as tinted eye

protection, helmets, special clothing, gloves and
footwear whenever it is necessary to carry out
welding procedures. All persons standing in the
vicinity of the welding process should wear tinted
eye protection. NEVER LOOK AT THE WELDING ARC IF YOUR EYES ARE NOT SUITABLY
PROTECTED.

Move with caution when working under a tractor,

and also on or near a tractor. Wear proper safety
accessories: helmets, goggles and special footwear.

Metal cables with the use get frayed. Always

wear adequate protections (heavy gloves, eye
protection, etc.)

During checks which should be carried out with

the engine running, ask an assistant to seat at the
operators seat and keep the service technician
under visual control at any moment.

Handle all parts with the greatest caution. Keep

your hands and fingers far from gaps, moving
gears and similar. Always use approved protective equipment, such as eye protection, heavy
gloves and protective footwear.

????

SECTION 00 GENERAL CHAPTER 1

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

ENGINE
Always loosen the radiator cap very slowly before
removing it to allow pressure in the system to dissipate. Coolant should be topped up only when
the engine is stopped or idle if hot.
Do not fill up fuel tank when the engine is running,
mainly if it is hot, to avoid ignition of fires in case
of fuel spilling.
Never check or adjust the fan belt tension when
the engine is running.
Never adjust the fuel injection pump when the
tractor is moving.
Never lubricate the tractor when the engine is running.

ELECTRICAL SYSTEMS
If it is necessary to use auxiliary batteries, cables
must be connected at both sides as follows: (+) to
(+) and () to (). Avoid shortcircuiting the terminals. GAS RELEASED FROM BATTERIES IS
HIGHLY FLAMMABLE. During charging, leave
the battery compartment uncovered to improve
ventilation. Avoid checking the battery charge by
means of jumpers made by placing metallic
objects across the terminals. Avoid sparks or
flames near the battery area. Do no smoke to prevent explosion hazards.
Prior to any service, check for fuel or current
leaks. Remove these leaks before going on with
the work.
Do not charge batteries in confined spaces. Ensure that ventilation is appropriate to prevent accidental explosion hazard due to buildup of gases
releaved during charging.
Always disconnect the batteries before performing any type of service on the electrical system.

HYDRAULIC SYSTEMS
Some fluid slowly coming out from a very small
port can be almost invisible and be strong enough
to penetrate the skin. For this reason, NEVER
USE YOUR HANDS TO CHECK FOR LEAKS,
but use a piece of cardboard or a piece of wood
to this purpose. If any fluid is injected into the skin,
seek medical aid immediately. Lack of immediate
medical attention, serious infections or dermatosis may result.
Always take system pressure readings using the
appropriate gauges.
WHEELS AND TYRES
Check that the tyres are correctly inflated at the
pressure specified by the manufacturer. Periodically check possible damages to the rims and
tyres.
Keep off and stay at the tyre side when correcting
the inflation pressure.
Check the pressure only when the tractor is
unloaded and tyres are cold to avoid wrong readings due to overpressure. Do not reuse parts of
recovered wheels as improper welding, brazing
or heating may weaken the wheel and make it fail.
Never cut, nor weld a rim with the inflated tyre
assembled.
To remove the wheels, block both front and rear
tractor wheels. Raise the tractor and install safe
and stable supports under the tractor in accordance with regulations in force.
Deflate the tyre before removing any object
caught into the tyre tread.
Never inflate tyres using flammable gases as they
may originate explosions and cause injuries to
bystanders.
REMOVAL AND INSTALLATION
Lift and handle all heavy components using lifting
equipment of adequate capacity. Ensure that
parts are supported by appropriate slings and
hooks. Use lifting eyes provided to this purpose.
Take care of the persons near the loads to be
lifted.
Handle all parts with great care. Do not place your
hands or fingers between two parts. Wear
approved protective clothing such as safety
goggles, gloves and footwear.
Do not twine chains or metal cables. Always wear
protection gloves to handle cables or chains.
???

SECTION 00 GENERAL CHAPTER 1

CONSUMABLES
COMPONENT TO BE FILLED OR
TOPPED UP

QUANTITY
litres/dm3

US gal

IMP gal

12
14

3.2
3.7

2.64
3.08

14
16

3.7
4.2

3.1
3.5

Windscreen washer bottle . . . . . . . . . .

0.53

0.44

Fuel tank
Additional fuel tank (Optional) . . . . . . .

90
27

23.8
7.1

19.8
5.94

7.6
10.5

1.98
2.77

1.67
2.31

8.3
11.2

2.19
2.96

1.83
2.46

Brake control circuit . . . . . . . . . . . . . . . .

0.4

0.1

0.09

Hydrostatic steering circuit . . . . . . . . . .

Front axle:
axle housing :
JX60, JX70 models
JX80, JX90, JX95 models
final drives (each) :
JX60, JX70 HP models
JX80, JX90, JX95 models
Rear transmission (bevel drive and
brakes), gearbox, hydraulic lift and
PTO
JX60, JX70, JX80, JX90,
JX95 models . . . . . . . . . . . . . . . . . .
with synchroreverser:
JX60, JX70, JX80, JX90,
JX95 models . . . . . . . . . . . . . . . . . .
Rear final drives (each) :
JX60, JX70 HP models
JX80, JX90, JX95 models

2.0

0.5

0.44

4.5
7.0

1.2
1.8

0.99
1.54

0.8
1.25

0.2
0.3

0.18
0.28

Cooling system:
JX60, JX70 models
JX80, JX90, JX95 models
with cab :
JX60, JX70 models
JX80, JX90, JX95 models

Engine sump:
without filter :
JX60, JX70 models
JX80, JX90, JX95 models
with filter :
JX60, JX70 models
JX80, JX90, JX95 models

Front wheel hubs . . . . . . . . . . . . . . . . . .

Grease fittings . . . . . . . . . . . . . . . . . . . .

????

46

12.15

10.12

46

12.15

10.12

3.9
5.3

1.03
1.40

0.86
1.17

CASE IH
RECOMMENDED
PRODUCTS

INTERNATIONAL
SPECIFICATION

Water & liquid

AKCELA PREMIUM
ANTIFREEZE
50% + 50%

Water & cleaning

liquid
Decanted and filtered
diesel fuel

AKCELA No.1
ENGINE OIL
API CH4 * ACEA
E5 * MB 228.3 *
CUMMINS CES
200072/20076/20077
AKCELA LHM
FLUID Oil

API CF4/SG
CCMC D4
MILL2104E

ISO 7308

Oil
AKCELA
NEXPLORE

API GL4
ISO 32/46
SAE 10W30

Grease
AKCELA
MULTIPURPOSE
GREASE
(251H EP)

NLGI 2

SECTION 10 -- ENGINE -- CHAPTER 1

SECTION 10 -- ENGINE

Chapter 1 -- Engine

CONTENTS
Section
10 000

Description

Page

General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Injection pump calibration data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lubrication and cooling system diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

10 001 10

Engine Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

10 001 54

Engine Bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Checks, measurements and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

10 406 10

Radiator Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

10 102 70

Crankshaft front oil seal removal installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

10 402 10

Coolant pump removal installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

10 402 30

Cooling system thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

10 206 14

Bosch injection pump removal installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Bosch injection pump timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Bosch injection pump air bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

10 218 30

Injectors removal installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

10 106 12

Valve clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

10 402 28

Coolant pump overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

10 001 30

Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

GENERAL SPECIFICATIONS
Engine type:
-- mod. JX60 normally aspirated -- type 8035.05D.939
(BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- mod. JX70 turbocharged -- type 8035.25C.939
(BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 cylinders

4 cylinders
--

see data pages

6--7
-see data pages
8--9

-- mod. JX80 normally aspirated -- type 8045.05R.939

(BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

--

see data pages

10--11

-- mod. JX90 turbocharged -- type 8045.25.939

(BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

--

see data pages

12--13

-- mod. JX95 turbocharged -- type 8045.25L.939

(BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

--

Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

see data pages

14--15
Diesel, 4--stroke
Direct
4
dry force--fitted in
cylinder block

Piston diameter
-- mod. JX60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 mm (4.0945 in.)
--- mod. JX70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 mm (4.0945 in.)
--- mod. JX80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-104 mm (4.0945 in.)
-- mod. JX90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-104 mm (4.0945 in.)
-- mod. JX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-104 mm (4.0945 in.)
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115 mm (4.5276 in.)
Total displacement:
-- mod. JX60--JX70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2931 cm3
-(178.8496 in.3)
-- mod. JX80--JX90--JX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-3908 cm3
(238.4662 in.3)
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 to 1 normally aspirated
16.5 to 1 turbocharged
Maximum power 2000/25 EC at 2500 rpm:
-- mod. JX60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43.4 kW (59 hp)
--- mod. JX70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50.7 kW (69 hp)
--- mod. JX80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-58.8 kW (80 hp)
-- mod. JX90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-65.5 kW (89 hp)
-- mod. JX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-69.1 kW (94 hp)
Maximum power ECE R 24 at 2500 rpm:
-- mod. JX60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41.2 kW (56 hp)
--- mod. JX70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47.8 kW (65 hp)
--- mod. JX80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-55.9 kW (76 hp)
-- mod. JX90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-63.3 kW (86 hp)
-- mod. JX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-66.9 kW (91 hp)
Fast idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2500 rpm.
Maximum torque (daNm) at 1500 rpm: JX60 model . . . . . . . . . . 20.7 (152.6753 ft lb)
-Maximum torque (daNm) at 1500 rpm: JX70 model . . . . . . . . . . 25.0 (184.3905 ft lb)
-Maximum torque (daNm) at 1500 rpm: JX80 model . . . . . . . . . .
-27.9 (205.9778 ft lb
Maximum torque (daNm) at 1500 rpm: JX90 model . . . . . . . . . .
-32.0 (236.0194 ft lb)
Maximum torque (daNm) at 1500 rpm: JX95 model . . . . . . . . .
-33.7 (248.5584 ft lb)
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
5
Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Structural, cast iron
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

3
(continued)

GENERAL SPECIFICATIONS

3 cylinders

4 cylinders

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

forced, with gear pump

Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

camshaft

Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . .

2:1

Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mesh filter on oil intake and

cartridge filter on delivery line

Normal oil pressure, with engine hot and at fast idling speed .

2.9 to 3.9 bar (42.06 to 56.56 psi)

Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

built into pump housing

Valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 bar (50.76 psi)

For further lubrication data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See page 23

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

coolant circulation

Radiator on JX60, JX70, JX80 and JX90 models . . . . . . . . . . .

three--row vertical pipes with copper fins

Radiator on JX95 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

four--row vertical pipes with

copper fins

Fan, attached to coolant pump pulley . . . . . . . . . . . . . . . . . . . . .

four--blade steel exhauster fan

6--blade steel exhauster fan (JX95)

Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

centrifugal vane--type

Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . .

1:1,403

Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermostat

Coolant temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

coloured scale divided into three sections

Temperature ranges corresponding to each section:

--

initial white section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

from 30 to 65 C (86 to 149 F)

--

middle green section . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

from 65 to 105 C (149 to 221 F)

--

final red section

from 105 to 115 C (221 to 300.2 F)

For further cooling system data . . . . . . . . . . . . . . . . . . . . . . . . . . .

See page 23

Rev counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

incorporated in control panel

Rev counter drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

from gear on camshaft

Hour counter calibrated for engine speed of . . . . . . . . . . . . . . . .

1800 rpm.
(Continued)

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

(continued)

GENERAL SPECIFICATIONS
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 cylinders

4 cylinders

overhead valves operated by a camshaft

located in the engine block through
tappets, pushrods and rockers.
Camshaft is driven by the crankshaft
through helical gears.

Intake:
-- start: before T.D.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

-- end: after B.D.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

Exhaust:
-- start: before B.D.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- end: after T.D.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50
16

Valve clearance for timing check . . . . . . . . . . . . . . . . . . . . . . . . . .

0.45 mm (0.0177 in.)

Valve clearance for normal running (engine cold):

-- intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 0.05 mm (0.0118 0.0020 in.)

-- exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 0.05 mm (0.0118 0.0020 in.)

See page 20

For further timing data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System
Air cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

dual cartridge dry air filter, with clogged

filter indicator with centrifugal pre--filter
and automatic dust ejector.

Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with double diaphragm

Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mesh filter in fuel supply pump, and

replaceable cartridge on delivery line to
injection pump.

Minimum fuel flow rate with pump shaft rotating at 1600 rev/min.

100 litres/hour

Operated by eccentric cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

on camshaft

BOSCH Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rotary distributor type

All--speed governor, incorporated in pump: BOSCH

Automatic advance regulator, incorporated in pump: BOSCH
For further fuel system data:
For fixed advance (pump setting for start of delivery before
TDC) -- Pressure setting -- Injection order, and other
information regarding the BOSCH pump

6- 62720 -- 09 -- 2006

centrifugal counterweights
hydraulic
see pages 5 to 15
refer to the data for the relevant engine
type in the tables from page 6 to page
14.

SECTION 10 -- ENGINE -- CHAPTER 1

DATA
Turbocharger (Model JX95):
-- . . . . . GARRETT type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T25

Fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

distributor type with incorporated speed

governor and automatic advance regulator

BOSCH pump:
-- . . . . . JX60 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VE 3/12 F 1250 L 976 -- 504054473

-- . . . . . JX70 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VE 3/12 F 1250 L 977 -- 504054474

-- . . . . . JX80 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VE 4/12 F 1250 L 985 -- 504041416

-- . . . . . JX90 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VE 4/12 F 1250 L 982 -- 504042214

-- . . . . . JX95 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VE 4/12 F 1250 L 952 -- 504042718

Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

anticlockwise

Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1--2--3 (JX60 and JX70)

1--3--4--2 (JX80, JX90 and JX95)

Fuel injectors:
BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . .
-- Nozzle holder type . . . . . . . . . . . . . . .
-- Nozzle type . . . . . . . . . . . . . . . . . . . . .
Number of nozzle holes . . . . . . . . . . . .

248--272 bar
(3596.9176--3945.0064 psi)

248--272 bar
(3596.9176--3945.0064 psi)

Diameter of nozzle orifices . . . . . . . . . .

Pressure setting . . . . . . . . . . . . . . . . . . .

JX70

JX95

JX60

JX80

JX90

--

--

--

--

--

Fuel delivery lines -- BOSCH pump

-- Type . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- Dimensions . . . . . . . . . . . . . . . . . mm

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

JX60 MODEL -- CALIBRATION DATA FOR BOSCH INJECTION PUMP
TYPE VE 3/12 F 1250 L 976 - 504054473

ASSEMBLY DATA
Pump timing on engine: delivery start 4 0.5
before TDC of cylinder 1 compression stroke.
Plunger pre--lift for timing on engine: 1 mm from BDC
(with tools 380000228 -- 380001601).
Cylinder no. 1 delivery line union on pump: marked
with letter A.

Test bench conforming to ISO 4008/1.../2

Injectors conforming to ISO 7440--A61 -(1688901027 with pad 0.5 mm)
Injector setting pressure: 250 bar (3625.925 psi).
Fuel supply pressure: 0.35 0.05 bar (kg/cm2).
(5.0763 0.7252 psi).
Delivery pipes (conforming to ISO 4093.2):
6 x 2 x 450 mm (0.2362 x 0.787 x 17.7165 in.).
Graduate drain time: 30 seconds
Test liquid: ISO 4113 at a temperature of 55 1C
(131 33.8F).

ASSEMBLY DIMENSIONS
SYMBOL

KF

MS1

ya

yb

mm

3.6 to 3.8

0.85 to
1.15

36.9 to
40.9

41.5 to
46.5

CALIBRATION TEST CONDITIONS

1. START OF DELIVERY
Plunger pre--lift from BDC:
mm --

Pump rotation (viewed from drive side):

anticlockwise

Injection order:1--2--3

2. ADVANCE REGULATOR STROKE

rpm: 1150

Advance stroke: mm 1.6 to 2.0

3. FUEL SUPPLY PUMP PRESSURE

rpm: 1150

Internal pressure: bar 8.4 to 8.8

4. FULL LOAD DELIVERY

rpm: 800

Delivery per 1000 shots: cm3 77.3 to 77.7

Spread: cm3 --

5. SPREAD GOVERNOR AT IDLE SPEED

rpm: 325

Delivery per 1000 shots: cm3 9.5 to 10.5

rpm: 1300

Delivery per 1000 shots: cm3 49.5 to 50.5

Spread: cm3 5.0

6. SPREAD GOVERNOR AT MAXIMUM SPEED

Spread:--

7. DELIVERY AT STARTING SPEED

Delivery per 1000 shots: cm3 70 to 110

rpm: 100

8. INJECTION ADVANCE PROGRESSION

Rev/min
Advance stroke

mm

1250

1150

1050

1.9 to 2.9

1.6 to 2.0

0.8 to 1.6

9. TRANSFER PRESSURE PROGRESSION

Rev/min
Internal pressure

bar

500

1150

--

4.8 to 5.8

8.4 to 8.8

--

10. BACKFLOW
Rev/min
Backflow

cm3/10

500

1250

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)

11. DELIVERY PROGRESSION

Rev/min

Delivery per 1000 shots: cm3

1390

0 to 3

1300

49.5 to 50.5

1250

63.5 to 68.5

800

77.3 to 77.7

450

68,0

12. ZERO DELIVERY (STOP)

Rev/min

Voltage (volts)

Delivery per 1000 shots: cm3

325

0 to 3

13. DELIVERY CHECK AT IDLE SPEED

Rev/min
Delivery per 1000 shots:

cm3

250

325

390

35

9.5 to 10.5

0 to 3.0

14. AUTOMATIC START SUPPLEMENT

Rev/min

Delivery per 1000 shots: cm3

100

70 to 110

250

67 to 77

Note: The values shown above in brackets must be used for checking purposes only.

BENCH TEST PERFORMANCE DATA

Test Conditions
TDC fixed advance with cylinder No. 1 in compression stroke:
(see previous page).

Relative humidity 70% 5.

Engine without fan, air filter and exhaust silencer.

Ambient temperature 25 C.

Atmospheric pressure: 990 mbar

Specific gravity of diesel fuel

830 10 g/litre.

Throttle
lever
position

Braking load applied

For maximum
torque
Maximum For maximum torque
Maximum

Engine rpm

Power output with engine

run--in for a total of:
2 hours
50 hours
kW (HP)
kW

Fuel
consumption
kg/h

2500

--

39,5 -- 42,0

9,1 -- 9,7

1500

--

31,5 -- 33,5

6,8 -- 7,2

Maximum

None (no--load)

2770 25

--

--

--

Minimum

None (no--load)

650 25

--

--

-6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

JX70 MODEL -- CALIBRATION DATA FOR BOSCH INJECTION PUMP
TYPE VE 3/12 F 1250 L 977 - 504054474

ASSEMBLY DATA
Pump timing on engine: delivery start 0 0.5
before TDC of cylinder 1 compression stroke.
Plunger pre--lift for pump timing on engine: 1 mm
from BDC with tools 380000228 -- 380001601).
Delivery line union on pump for cylinder no. 1:
marked with letter A.
ASSEMBLY DIMENSIONS
SYMBOL

KF

MS

ya

yb

mm

3.6 to 3.8

0.5 to 0.9

35.5 to
39.5

39.8 to
44.8

Test bench conforming to ISO 4008/1.../2

Injectors conforming to ISO 7440--A61 -(1688901027 with pad 0.5 mm (0.0197 in.))
Injector setting pressure: 250 bar (3625.925 psi).
Fuel supply pressure: 0.35 0.05 bar
(5.0763 0.7252 psi).
Delivery pipes (conforming to ISO 4093.2):
6 x 2 x 450 mm (0.2362 x 0.787 x 17.7165 in.)
Graduate drain time: 30 seconds
Test liquid: ISO 4113 at a temperature of 55 1C
(131 33.8F).

CALIBRATION TEST CONDITIONS

1. START OF DELIVERY
Plunger pre--lift from B.D.C.: mm --

Pump rotation (viewed from drive side):

anticlockwise

Injection order:1--2--3

2. ADVANCE REGULATOR STROKE

1100 rpm

LDA pressure: kPa 100

Advance stroke: mm 1.8 to 2.2

3. FUEL SUPPLY PUMP PRESSURE

rpm: 800

LDA pressure: kPa 100

Internal pressure: bar 7.7 to 8.3

4. FULL--LOAD DELIVERY WITH BOOSTER PRESSURE

rpm: 900

LDA pressure: kPa 100

Delivery per 1000 shots: cm3 76.5 to 76.9

Spread: cm3 3.5

5. FULL--LOAD DELIVERY WITHOUT BOOSTER PRESSURE

rpm: 600

LDA pressure: kPa 0

rpm: 325

LDA pressure: kPa 0

Delivery per 1000 shots: cm3 73.8 to 74.2

Spread: cm3 --

6. SPREAD GOVERNOR AT IDLE SPEED

Delivery per 1000 shots: cm3 12 to 13

Spread: cm3 4.5

7. SPREAD GOVERNOR AT MAXIMUM SPEED

rpm: 1350

LDA pressure: kPa 100

Delivery per 1000 shots: cm3 32.0 to 33.0

Spread: cm3 --

8. DELIVERY AT STARTING SPEED

Delivery per 1000 shots: cm3 100 to 140

rpm: 100

9. INJECTION ADVANCE PROGRESSION

LDA pressure

kPa

100

Rev/min
Advance stroke

mm

1250

1100

900

2.5 to 3.5

1.8 to 2.2

0.3 to 1.3

10. TRANSFER PRESSURE PROGRESSION

LDA pressure

kPa

Rev/min
Internal pressure supply:

bar

100
1250

1100

500

8,7

7.7 to 8.3

4.5 to 5.5

11. BACKFLOW
Rev/min
LDA pressure
Backflow for

kPa
cm3/10 s

1250

500

100

100

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

Delivery per 1000 shots: cm3

kPa

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

73.8 to 74.2

13. ZERO DELIVERY (STOP)

rpm:

325

Voltage (volts):

Delivery per 1000 shots: cm3:

0 to 3

14. DELIVERY CHECK AT IDLE SPEED

Rev/min

325

380

--

Delivery per 1000 shots: cm3

12 to 13

0 to 3.0

--

15. AUTOMATIC START SUPPLEMENT

Rev/min

Delivery per 1000 shots: cm3

100

100 to 140

300

77 to 87

Note: The values shown above in brackets must be used for checking purposes only.

BENCH TEST PERFORMANCE DATA

Test Conditions
TDC fixed advance with cylinder No. 1 in compression stroke:
(see previous page)

Relative humidity 70% 5.

Engine without fan, air filter and exhaust silencer.

Ambient temperature 25 C.

Atmospheric pressure: 990 mbar

Specific gravity of diesel fuel

830 10 g/litre.

Throttle
lever
position

Braking load applied

For maximum
torque
Maximum For maximum torque
Maximum

Engine rpm

Power output with engine

run--in for a total of:
2 hours
50 hours
kW (HP)
kW

Fuel
consumption
kg/h

2500

--

47.5 -- 50.5

11.1 -- 11.8

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

JX80 MODEL -- CALIBRATION DATA FOR BOSCH INJECTION PUMP
TYPE VE 4/12 F 1250 L 985 - 504041416

ASSEMBLY DATA
Pump timing on engine: delivery start 4o 0.5o before
T.D.C. of cylinder 1 on compression stroke.
Plunger pre--lift for timing on engine: 1 mm from BDC
(with tools 380000228 -- 380001601).
Delivery union of the pump corresponding to cylinder
no. 1: marked with letter A.

ASSEMBLY DIMENSIONS
SYMBOL

MS

ya

yb

mm

3.64 to
3.76

1.4 to
1.5

0.5 to 0.9

38,9

43,0

CALIBRATION TEST CONDITIONS

Test bench conforming to ISO 4008/1 .../2

Injectors conforming to ISO 7440--A61 -([Link] with calibrated pad 0.5 mm
(0.0197 in.)).
Injector pressure setting 250 to 253 bar
(3625.925 to 3699.4361 psi)
Fuel supply pressure:
0.35 0.05 bar (5.0763 0.7252 psi).
Delivery pipes (conforming to ISO 4093.2):
6 x 2 x 450 mm (0.2362 x 0.787 x 17.7165 in.).
Graduate drain time : 30.
Test liquid: ISO 4113 at a temperature of 55o 1oC
(131 33.8F).

1. START OF DELIVERY
Plunger pre--lift from BDC:
mm --

Pump rotation (viewed from drive side):

anticlockwise

Injection order:1--3--4--2

2. ADVANCE REGULATOR STROKE

rpm: 1250

Advance stroke: mm 2.0 to 3.2

3. FUEL SUPPLY PUMP PRESSURE

rpm: 1000

Internal pressure: bar 6.7 to 8.1

4. FULL LOAD DELIVERY

rpm: 1000

Delivery per 1000 shots: cm3 65.2 to 70.3

Spread: cm3 3.5

5. SPREAD GOVERNOR AT IDLE SPEED

rpm: 325

Delivery per 1000 shots: cm3 4.0 to 18.0

Spread: cm3 4.5

6. SPREAD GOVERNOR AT MAXIMUM SPEED

rpm: 1250

Delivery per 1000 shots: cm3 60.0 to 66.0

Spread:--

7. DELIVERY AT STARTING SPEED

Delivery per 1000 shots: cm3 75 to 115

rpm: 100

8. INJECTION ADVANCE PROGRESSION

Rev/min
Advance stroke

mm

1000

1250

0.5 to 1.7

2.0 to 3.2

9. TRANSFER PRESSURE PROGRESSION

Rev/min
Internal pressure

bar

1000

400

6.7 to 8.1

4.1 to 5.5

10. BACKFLOW
Rev/min
Backflow

l/h

400

1250

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)

11. DELIVERY PROGRESSION

Rev/min

Delivery per 1000 shots: cm3

1400

0 to 3

1250

60.0 to 66.0

1000

65.2 to 70.3

450

63.5 to 70.3

12. ZERO DELIVERY (STOP)

Rev/min

Voltage (volts)

Delivery per 1000 shots: cm3

0 to 3

325

13. DELIVERY CHECK AT IDLE SPEED

Rev/min

325

380

--

Delivery per 1000 shots: cm3

4.0 to 18.0

0 to 3.0

--

14. AUTOMATIC START SUPPLEMENT

Rev/min

Delivery per 1000 shots: cm3

100

75 to 115

250

60.5 to 74.5

Note: The values shown above in brackets must be used for checking purposes only.

BENCH TEST PERFORMANCE DATA

Test Conditions
TDC fixed advance with cylinder No. 1 in compression stroke:
(see previous page)

Relative humidity 70% 5.

Engine without fan, air filter and exhaust silencer.

Ambient temperature 25 C.

Atmospheric pressure: 990 mbar

Specific gravity of diesel fuel

830 10 g/litre.

Throttle
lever
position

Braking load applied

For maximum
torque
Maximum For maximum torque
Maximum

Engine rpm

Power output with engine run--in for a total of:

2 hours
50 hours
kW (HP)
kW (HP)

Fuel
consumption
kg/h

2500

--

54.0 -- 57.5

12.3 -- 13.1

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

JX90 MODEL -- CALIBRATION DATA FOR BOSCH INJECTION PUMP
TYPE VE 4/12 F 1250 L 982 - 504042214

ASSEMBLY DATA
Pump timing on engine: delivery start 1o 0.5o before
T.D.C. of cylinder 1 on compression stroke.
Plunger pre--lift for timing on engine: 1 mm from BDC
(with tools 380000228 -- 380001601).
Delivery union of the pump corresponding to cylinder
no. 1: marked with letter A.

ASSEMBLY DIMENSIONS
SYMBOL

MS

ya

yb

mm

3.64 to
3.76

1.4 to
1.5

0.7 to 0.9

37.9 to
39.9

39.3 to
44.7

CALIBRATION TEST CONDITIONS

Test bench conforming to ISO 4008/1 .../2

Injectors conforming to ISO 7440--A61 -([Link] with calibrated pad 0.5 mm
(0.0197 in.)).
Injector pressure setting 250 to 253 bar (3625.925 to
3741.9546 psi).
Fuel supply pressure:
0.35 0.05 bar (5.0763 0.7252 psi).
Delivery pipes (conforming to ISO 4093.2):
6 x 2 x 450 mm (0.2362 x 0.787 x 17.7165 in.).
Graduate drain time : 30.
Test liquid: ISO 4113 at a temperature of 55o 1oC
(131 33.8F).

1. START OF DELIVERY
Plunger pre--lift from BDC:
mm --

Pump rotation (viewed from drive side):

anticlockwise

Injection order:1--3--4--2

2. ADVANCE REGULATOR STROKE

rpm: 1250

Advance stroke: mm 2.4 to 3.6

3. FUEL SUPPLY PUMP PRESSURE

rpm: 1250

Internal pressure: bar 8.7 to 10.1

4. FULL LOAD DELIVERY

rpm: 900

Delivery per 1000 shots: cm3 77.5 to 82.5

Spread: cm3 3.5

5. SPREAD GOVERNOR AT IDLE SPEED

rpm: 375

Delivery per 1000 shots: cm3 5.5 to 19.5

Spread: cm3 4.5

6. SPREAD GOVERNOR AT MAXIMUM SPEED

rpm: 1250

Delivery per 1000 shots: cm3 69.5 to 75.5

Spread:--

7. DELIVERY AT STARTING SPEED

Delivery per 1000 shots: cm3 80 to 120

rpm: 100

8. INJECTION ADVANCE PROGRESSION

Rev/min
Advance stroke

mm

1000

1250

0.2 to 1.0

2.4 to 3.6

9. TRANSFER PRESSURE PROGRESSION

Rev/min
Internal pressure

bar

1250

400

8.7 to 10.1

3.6 to 5.0

10. BACKFLOW
Rev/min
Backflow

l/h

400

1250

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)

11. DELIVERY PROGRESSION

Rev/min

Delivery per 1000 shots: cm3

1400

0 to 3

1250

69.5 to 75.5

900

77.5 to 82.5

400

76.5 to 83.5

12. ZERO DELIVERY (STOP)

Rev/min

Voltage (volts)

Delivery per 1000 shots: cm3

0 to 3

375

13. DELIVERY CHECK AT IDLE SPEED

Rev/min

375

425

--

Delivery per 1000 shots: cm3

5.5 to 19.5

0 to 3.0

--

14. AUTOMATIC START SUPPLEMENT

Rev/min

Delivery per 1000 shots: cm3

100

80 to 120

275

68 to 92

Note: The values shown above in brackets must be used for checking purposes only.

BENCH TEST PERFORMANCE DATA

Test Conditions
TDC fixed advance with cylinder No. 1 in compression stroke:
(see previous page)

Relative humidity 70% 5.

Engine without fan, air filter and exhaust silencer.

Ambient temperature 25 C.

Atmospheric pressure: 990 mbar

Specific gravity of diesel fuel

830 10 g/litre.

Throttle
lever
position

Braking load applied

For maximum
torque
Maximum For maximum torque
Maximum

Engine rpm

Power output with engine run--in for a

total of:
2 hours
50 hours
kW (HP)
kW (HP)

Fuel
consumption
kg/h

2500

--

60.0 -- 64.0

13.7 -- 14.6

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

JX95 MODEL -- CALIBRATION DATA FOR BOSCH INJECTION PUMP
TYPE VE 4/12 F 1250 L 952 - 504042718

ASSEMBLY DATA
Pump timing on engine: delivery start 0o 0.5o before
T.D.C. of cylinder 1 on compression stroke.
Plunger pre--lift for timing on engine: 1 mm from BDC
(with tools 380000228 -- 380001601).
Delivery union of the pump corresponding to cylinder
no. 1: marked with letter A.

ASSEMBLY DIMENSIONS
SYMBOL

MS

ya

yb

mm

3.64 to
3.76

0.98 to
1.02

0.6 to
1.0

36.5 to
38.5

41.3 to
46.7

CALIBRATION TEST CONDITIONS

Test bench conforming to ISO 4008/1 .../2

Injectors conforming to ISO 7440--A61 -([Link] with calibrated pad 0.5 mm)
(0.0197 in.).
Injector pressure setting 250 to 253 bar (3625.925 to
3741.9546 psi).
Fuel supply pressure:
0.35 0.05 bar (5.0763 0.7252 psi).
Delivery pipes (conforming to ISO 4093.2):
6 x 2 x 450 mm (0.2362 x 0.787 x 17.7165 in.).
Graduate drain time : 30.
Test liquid: ISO 4113 at a temperature of 55o 1oC
(131 33.8F).

1. START OF DELIVERY
Plunger pre--lift from B.D.C.: mm --

Pump rotation (viewed from drive side):

anticlockwise

Injection order:1--3--4--2

2. ADVANCE REGULATOR STROKE

rpm: 1250

LDA pressure: kPa 100

Advance stroke: mm 2.2 to 3.4

3. FUEL SUPPLY PUMP PRESSURE

1100 rpm

LDA pressure: kPa 100

Internal pressure: bar 6.5 to 7.9

4. FULL--LOAD DELIVERY WITH BOOSTER PRESSURE

rpm: 900

LDA pressure: kPa 100

Delivery per 1000 shots: cm3 75.5 to 80.5

Spread: cm3 3.5

5. FULL--LOAD DELIVERY WITHOUT BOOSTER PRESSURE

rpm: 500

LDA pressure: kPa 0

Delivery per 1000 shots: cm3 66.0 to 72.0

Spread: cm3 --

6. SPREAD GOVERNOR AT IDLE SPEED

rpm: 350

LDA pressure: kPa 0

rpm: 1250

LDA pressure: kPa 100

Delivery per 1000 shots: cm3 8 to 23

Spread: cm3 5.5

7. SPREAD GOVERNOR AT MAXIMUM SPEED

Delivery per 1000 shots: cm3 66.0 to 72.0

Spread: cm3 --

8. DELIVERY AT STARTING SPEED

Delivery per 1000 shots: cm3 75 to 115

rpm: 100

9. INJECTION ADVANCE PROGRESSION

LDA pressure

kPa

100

Rev/min
Advance stroke

mm

1100

1250

1.4 to 2.6

2.2 to 3.4

10. TRANSFER PRESSURE PROGRESSION

LDA pressure

kPa

100

Rev/min
Internal pressure supply:

bar

500

1100

--

4.1 to 5.5

6.5 to 7.9

--

11. BACKFLOW
Rev/min
LDA pressure

kPa

Backflow for 10 sec.

l/h

500

1250

100

100

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

Delivery per 1000 shots: cm3

kPa

1405

100

0 to 3.0

1250

100

66 to 72

900

100

75.5 to 80.5

600

25

72 to 78

500

66 to 72

13. ZERO DELIVERY (STOP)

rpm: 300

Voltage (volts):

Delivery per 1000 shots: cm3:

0 to 3

14. DELIVERY CHECK AT IDLE SPEED

Rev/min

350

410

Delivery per 1000 shots: cm3

8 to 23

0 to 3.0

15. AUTOMATIC START SUPPLEMENT

Rev/min

Delivery per 1000 shots: cm3

100

75 to 115

250

63.5 to 77.5

Note: The values shown above in brackets must be used for checking purposes only.

BENCH TEST PERFORMANCE DATA

Test Conditions
TDC fixed advance with cylinder No. 1 in compression stroke:
(see previous page)

Relative humidity 70% 5.

Engine without fan, air filter and exhaust silencer.

Ambient temperature 25 C.

Atmospheric pressure: 990 mbar

Specific gravity of diesel fuel

830 10 g/litre.

Throttle
lever
position

Braking load applied

For maximum
torque
Maximum For maximum torque
Maximum

Engine rpm

Power output with engine

run--in for a total of:
2 hours
50 hours
kW
kW

Fuel
consumption
kg/h

2500

--

66 -- 70

15.5 -- 15.9

1500

--

51 -- 54

11 -- 11.7

Maximum

None (no--load)

2700 25

--

--

--

Minimum

None (no--load)

650 25

--

--

-6- 62720 -- 09 -- 2006

16

SECTION 10 -- ENGINE -- CHAPTER 1

FUEL SUPPLY PUMP DATA

mm (in.)

Eccentricity of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 (0.1181)

Diameter of drive shaft at bushings . . . . . . . . . . . . . . . . . . . . . . . . .

31.975 to 32.000 (1.1049 to 1.1050)

Internal diameter of installed and reamed bushings . . . . . . . . . . .

32.050 to 32.075 (1.2589 to 1.2628)

Interference between bushings and seats . . . . . . . . . . . . . . . . . . . .

0.063 to 0.140 (0.0025 to 0.0055)

Assembly clearance between shaft and bushings . . . . . . . . . . . . .

0.050 to 0.100 (0.0020 to 0.0039)

Thickness of internal washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.45 to 1.50 (0.0571 to 0.0591)

Thickness of external washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.93 to 3.00 (0.1154 to 0.1181)

CRANKCASE/CYLINDER BLOCK DATA

mm (in.)

Cylinder block (4--cylinder engines) . . . . . . . . . . . . . . . . . . . . . . . . .

cast--iron monobloc with replaceable

dry--fitted cylinder liners, incorporating
seatings for crankshaft bearings, camshaft and pushrod/tappet assemblies

Internal diameter of cylinder liners (4--cylinder engines) . . . . . . . .

104.000 to 104.024 (4.0945 to 4.0954)

(1)

External diameter 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)

Interference fit between cylinder liners and bores

(4--cylinder engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.120 to 0.200 (0.0047 to 0.0079)

Liner internal diameter oversizes (4--cylinder engines) . . . . . . . . .

0.4 to 0.8 (0.0157 to 0.0315)

Liner external diameter oversizes (4--cylinder engines) . . . . . . . .

0.2 (0.0079)

Maximum permissible liner ovality or taper due to wear (2)

(4--cylinder engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.12 (0.0047)

Diameter of main shell bearing seats . . . . . . . . . . . . . . . . . . . . . . .

84.200 to 84.230 (3.3150 to 3.3161)

Diameter of camshaft bearing seats:

-- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54.780 to 54.805 (2.1567 to 2.1577)

-- middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54.280 to 54.305 (2.1370 to 2.1380)

-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53.780 to 53.805 (2.1173 to 2.1183)

Diameter of standard tappet bores in crankcase . . . . . . . . . . . . . .

15.000 to 15.018 (0.5906 to 0.5913)

Spare tappet oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.1--0.2--0.3 (0.0039--0.0079--0.0118)

(1) Measured after press--fitting and reaming.

(2) Measure in the area swept by piston rings, both parallel and perpendicular to the crankshaft axis.

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

CRANKSHAFT AND BEARINGS DATA

17

mm (in.)

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

balanced with integral counterweights

Standard journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79.791 to 79.810 (3.1414 to 3.1421) (1)

Journal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.254 -- 0.508 -- 0.762 -- 1.016

(0.01 -- 0.02 -- 0.03 -- 0.04)

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)

Bearing shell to journal clearance . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.034 to 0.103 (0.0013 to 0.0041)

Maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . . . . . . .

0.180 (0.0071)

Standard crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63.725 to 63.744 (2.5089 to 2.5096) (1)

Crankpin undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.254 -- 0.508 -- 0.762 -- 1.016

(0.01 -- 0.02 -- 0.03 -- 0.04)

Standard big--end bearing shell thickness . . . . . . . . . . . . . . . . . . . .

1.805 to 1.815 (0.0711 to 0.0715)

Big--end 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 to crankpin clearance . . . . . . . . . . . . . . . . . .

0.033 to 0.087 (0.0013 to 0.0034)

Maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . . . . . . .

0.180 (0.0071)

Standard crankshaft thrust washer thickness . . . . . . . . . . . . . . . . .

3.378 to 3.429 (0.133 to 0.135)

Thrust washer oversizes (thickness) . . . . . . . . . . . . . . . . . . . . . . . .

0.127 -- 0.254 -- 0.381 -- 0.508

(0.005 -- 0.010 -- 0.015 -- 0.020)

Width of main bearing including thrust washers . . . . . . . . . . . . . . .

31.766 to 31.918 (1.2506 to 1.2566)

Width of corresponding crankshaft journal . . . . . . . . . . . . . . . . . . .

32.000 to 32.100 (1.2598 to 1.2638)

Crankshaft assembly endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.082 to 0.334 (0.0032 to 0.0131)

Maximum permitted wear endfloat . . . . . . . . . . . . . . . . . . . . . . . . . .

0.40 (0.0157)

Maximum ovality or taper of journals and crankpin after

regrinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.01 (0.0004)

Maximum ovality or taper of journals and crankpin . . . . . . . . . . . .

0.05 (0.002)

Maximum tolerance for alignment of crankshaft journals with

crankshaft supported on the two outer journals . . . . . . . . . . . . . . .

0.10 (0.0039)

Maximum tolerance for alignment, in both directions, of crankpins

(3--cylinder engines) or each pair of crankpins
(4--cylinder engines) relative to crankshaft journals . . . . . . . . . . . .

0.25 (0.0098)

Maximum tolerance for run--out between the outer surfaces of

the crankshaft journals and the crankshaft centreline . . . . . . . . . .

0.10 (0.004)
(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)

BENCH TEST PERFORMANCE DATA

mm (in.)

Maximum permitted tolerance on run--out of flywheel mounting

flange surface relative to the crankshaft centreline, measured
with 1/100 mm (0.0394/3.94 in.) scale dial gauge resting on front
flange surface at a diameter of 108 mm (4.252 in.)
(total gauge reading). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.025 (0.001)

Maximum permitted tolerance on co--axial alignment of flywheel

centering seat relative to the crankshaft journals
(total gauge reading) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.04 (0.0016)

CONNECTING ROD DATA

mm (in.)

Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

cast--iron with oil way

Diameter of small end bushing seat . . . . . . . . . . . . . . . . . . . . . . . . .

41.846 to 41.884 (1.6475 to 1.6490)

Outside diameter of small end bushing . . . . . . . . . . . . . . . . . . . . . .

41.979 to 42.017 (1.6527 to 1.6542)

Interference between small end bushing and seat . . . . . . . . . . . . .

0.095 to 0.171 (0.0037 to 0.0067)

Inside diameter of small end bushing (measured after fitting) . . .

38.004 to 38.014 (1.4962 to 1.4966)

Diameter of big end shell bearing seats . . . . . . . . . . . . . . . . . . . . . .

67.407 to 67.422 (2.6538 to 2.6544)

Maximum tolerance for parallelism between the small end and

big end axes measured at 25 mm (0.9843 in.) . . . . . . . . . . . . . . . .

0.07 (0.0028)

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

Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Light alloy with two compression and

one oil control rings

Standard piston diameter, measured at 57 mm (2.2441 in.) from

base and perpendicularly to the gudgeon pin axis . . . . . . . . . . . . .

103.852 to 103.870 (4.0886 to 4.0893)

Piston clearance in cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.130 to 0.172 (0.0051 to 0.0067)

Maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 (0.0118)

Piston oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.6 (0.0236)

Piston protrusion at TDC from cylinder block face . . . . . . . . . . . . .

0.355 to 0.761 (0.014 to 0.030)

Gudgeon Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37.983 to 37.990 (1.4954 to 1.4957)

Diameter of gudgeon pin seat in piston . . . . . . . . . . . . . . . . . . . . . .

37.994 to 38.000 (1.4958 to 1.4960)

Gudgeon pin to seat clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.004 to 0.017 (0.0001 to 0.0007)

Gudgeon pin to small end bearing clearance . . . . . . . . . . . . . . . . .

0.014 to 0.031 (0.0006 to 0.0012)

Maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . . . . . . .

0.06 (0.0024)

Maximum weight difference between pistons in same engine . . .

20 grams (0.00441 lb)

Piston ring groove clearance (measured vertically):

-- Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.090 to 0.122
(0.0035 to 0.0048)

0.105 to 0.155
(0.0041 to 0.0061)

-- Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.060 to 0.092 (0.0024 to 0.0036)

-- Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.040 to 0.075 (0.0016 to 0.0030)

Maximum permissible clearance (wear limit):

-- Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.50 (0.0197)

-- Second and bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.20 (0.0079)

Piston ring end gap (fitted):

-- Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.40 to 0.65
(0.0157 to 0.0256)

0.40 to 0.65
(0.0157 to 0.0256)

-- Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 to 0.55
(0.0118 to 0.0217)

0.30 to 0.55
(0.0118 to 0.0217)

-- Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 to 0.55 (0.0118 to 0.0217)

Maximum permissible gap (wear limit) . . . . . . . . . . . . . . . . . . . . . . .

1.20 (0.0472)

6- 62720 -- 09 -- 2006

20

SECTION 10 -- ENGINE -- CHAPTER 1

VALVE TIMING GEAR DATA

mm (in.)

Timing gear tooth backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.160 (0.0063)

Inside diameter of intermediate gear bushings

(fitted and reamed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37.050 to 37.075 (1.4578 to 1.4596)

Diameter of intermediate gear journal . . . . . . . . . . . . . . . . . . . . . . .

36.975 to 37.000 (1.4557 to 1.4567)

Journal to bushing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.050 to 0.100 (0.0020 to 0.0039)

Maximum permissible clearance (wear limit) . . . . . . . . . . . . . . . . .

0.15 (0.0059)

Bushing interference fit in seat in intermediate gear . . . . . . . . . . .

0.063 to 0.140 (0.0025 to 0.0055)

Outside diameter of camshaft bearings:

-- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54.875 to 54.930 (2.1604 to 2.1626)

-- middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54.375 to 54.430 (2.1407 to 2.1429)

-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53.875 to 53.930 (2.1175 to 2.1232)

Interference between bearings and seats in cylinder block . . . . .

0.070 to 0.150 (0.0028 to 0.0059)

Inside diameter of camshaft bearings (fitted and reamed):

-- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51.080 to 51.130 (2.0110 to 2.0130)

-- middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50.580 to 50.630 (1.9913 to 1.9933)

-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50.080 to 50.130 (1.9716 to 1.9736)

Diameter of camshaft journals:

-- front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50.970 to 51.000 (2.0067 to 2.0079)

-- middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50.470 to 50.500 (1.9870 to 1.9882)

-- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49.970 to 50.000 (1.9913 to 1.9933)

Clearance between camshaft journals and bearings . . . . . . . . . . .

0.080 to 0.160 (0.0031 to 0.0063)

Maximum permissible clearance (wear limit) . . . . . . . . . . . . . . . . .

0.20 (0.0079)

Camshaft endfloat between thrust plate and seat on camshaft . .

0.070 to 0.220 (0.0028 to 0.0087)

For further valve timing gear data . . . . . . . . . . . . . . . . . . . . . . . . . . .

See page 4

TAPPET DATA

mm (in.)

Tappet bore in crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15.000 to 15.018 (0.5906 to 0.5913)

Outside diameter of standard tappet . . . . . . . . . . . . . . . . . . . . . . . .

14.950 to 14.970 (0.5886 to 0.5894)

Tappet running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.030 to 0.068 (0.0012 to 0.0027)

Maximum permissible clearance (wear limit) . . . . . . . . . . . . . . . . .

0.15 (0.0059)

Spare tappet oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.1 -- 0.2 -- 0.3 (0.0039--0.0079--0.0118)

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

ROCKER ARM -- VALVE DATA

21

mm (in.)

Diameter of shaft bores in rocker arms . . . . . . . . . . . . . . . . . . . . . .

18.016 to 18.034 (0.7093 to 0.71)

Rocker--arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.982 to 18.000 (0.708 to 0.7087)

Rocker shaft to rocker arm bore clearance . . . . . . . . . . . . . . . . . . .

0.016 to 0.052 (0.0006 to 0.0020)

Maximum permissible clearance (wear limit) . . . . . . . . . . . . . . . . .

0.15 (0.0059)

Rocker arm spacing springs:

-- free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59.5 (2.3425)

-- length under load of 46 to 52 N (10.4 to 11.7 lb) . . . . . . . . . . . . .

44 (1.7323)

Valve clearance for timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.45 (0.0177)

Cam lift:
-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.97 (0.2350)

-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.25 (0.2460)

BALANCER DATA (FIG. 108, page 67) ((*))

(*) installed on 4--cylinder

engines only
mm (in.)

Interference fit between bushings (28) and seat in gear (26) . . . .

0.063 to 0.140 (0.0025 to 0.0055)

Clearance between intermediate gear journal (27)

and bushings (28) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.050 to 0.100 (0.002 to 0.004)

Interference fit between bushings and carrier (20) . . . . . . . . . . . . .

0.063 to 0.140 (0.0025 to 0.0055)

Clearance between gear shaft (22) and bushings . . . . . . . . . . . . .

0.050 to 0.100 (0.002 to 0.004)

Tooth backlash between splined sleeve (17) connecting drive

gear (22) and counterweight drive gear (13) . . . . . . . . . . . . . . . . . .

0.038 to 0.106 (0.0015 to 0.0041)

Interference fit between front bushing (16) and bore in

housing (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.063 to 0.140 (0.0025 to 0.0055)

Clearance between counterweight drive shaft (13) and front

bushing (16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.050 to 0.100 (0.002 to 0.004)

Interference fit between rear bushing of counterweight drive gear

(13) and seat in carrier (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.037 to 0.101 (0.0015 to 0.004)

Clearance between counterweight drive shaft (13) and rear bushing

0.013 to 0.061 (0.0005 to 0.0024)

Interference fit between bushing and seat in counterweight (8) . .

0.040 to 0.100 (0.0016 to 0.004)

Clearance between counterweight rotation shaft (4) and bushing . .

0.020 to 0.073 (0.0008 to 0.0055)

Interference fit between intermediate gear bushing (9) and related seat in housing (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.037 to 0.101 (0.0025 to 0.0029)

Clearance between intermediate gear shaft (9) and related bushing

0.013 to 0.061 (0.0005 to 0.0024)

Tooth backlash between meshed gears . . . . . . . . . . . . . . . . . . . . . .

0.080 (0.0031)

6- 62720 -- 09 -- 2006

22

SECTION 10 -- ENGINE -- CHAPTER 1

CYLINDER HEAD DATA

mm (in.)

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with valve seats cut directly in the

casting and press--fitted steel valve
guides.

Original height of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 (3.622)

Maximum surface regrinding depth . . . . . . . . . . . . . . . . . . . . . . . . .

0.5 (0.0197)

Diameter of standard valve guide bores in head . . . . . . . . . . . . . .

13.950 to 13.983 (0.5492 to 0.5505)

Outside diameter of standard valve guides . . . . . . . . . . . . . . . . . . .

13.993 to 14.016 (0.5509 to 0.5518)

Guide interference fit in bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.010 to 0.066 (0.0004 to 0.0026)

Inside diameter of valve guide (fitted in head) . . . . . . . . . . . . . . . .

8.023 to 8.043 (0.3159 to 0.3167)

Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. 985 to 8.000 (0.3144 to 0.3150)

Assembly clearance between valve stem and guide . . . . . . . . . . .

0.023 to 0.058 (0.0009 to 0.0023)

Maximum permissible clearance (wear limit) . . . . . . . . . . . . . . . . .

0.13 (0.0051)

Maximum run--out of valve guide on its stem measured through

360_ with dial gauge contact point resting on valve head contact
band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.03 (0.0012)

Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.2 (0.0079)

Valve seat angle in head:

-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 5

-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 5

Valve face angle:

-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 30 7

-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 30 7

Valve head diameter:

-- inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45.300 to 45.500 (1.7835 to 1.7913)

-- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37.500 to 37.750 (1.4764 to 1.4862)

Valve stand--in relative to cylinder head face . . . . . . . . . . . . . . . . .

0.7 to 1.0 (0.0276 to 0.0394)

Maximum permissible valve stand--in . . . . . . . . . . . . . . . . . . . . . . . .

1.3 (0.0512)

Inlet and exhaust valve springs:

-- free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 (1.7559)

-- length with valve closed, under load of 256 to 284 N

(57.54 to 63.71 lb) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 (1.3386)

-- length with valve open, under load of 502 to 544 N

(112.87 to 124.78 lb) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23.8 (0.9370)

Injector protrusion relative to head face:

D BOSCH injector

6- 62720 -- 09 -- 2006

0.3 to 1.1 (0.0118 to 0.0433)

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 gear . . . . . . . . . . . . . . . . . . . .

0.033 to 0.066
(0.0013 to 0.0026)

--

Tooth backlash between drive and driven gears . . . . . . . . . . . . . . .

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 gears . . . . . . . . . . . . . . . . . . . . . . . . .

40.961 to 41.000
(1.6126 to 1.6142)
41.025 to 41.087
(1.6152 to 1.6176)
0.025 to 0.126
(0.0010 to 0.0050)

--

Height of gear seat in pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Endfloat between gears and gear housing in pump . . . . . . . . . . . .

---

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 lb) . . . . . . . . . .

37.5 (1.4764)

--

-- length under load of 88 to 94 N (19.84 to 21.16 lb) . . . . . . . . . .

30.5 (1.2008)

--

-- length under load of 127.8 to 141.2 N (286.60 to 317.46 lb)

(2, fig. 182) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

--

29 (1.1417)

--

3.2 (0.9134)
See page 3

-- length under load of 233.4 -- 258 N (524.70 to 579.81 lb)

(2, fig. 182) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For further lubrication system data . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM DATA

mm (in.)

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 impeller . . . . . . . .

0.012 to 0.058 (0.0005 to 0.0023

For further cooling system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See page 3

6- 62720 -- 09 -- 2006

24

SECTION 10 -- ENGINE -- CHAPTER 1

ANGLE TIGHTENING TORQUE DATA
Preliminary torque
PART

Th d
Thread

A l
Angle
Nm

ft lb

Cylinder head bolts (2) fig. 3 or 5 . . . . . . . . . . . . . . . .

M 12 x 1.25

70

51.6293

90 + 90

Main bearing cap bolts (4) fig. 3 or 5 . . . . . . . . . . . . .

M 14 x 1.5

80

59.0050

90

Big--end cap bolts (5) fig. 3 or 5 . . . . . . . . . . . . . . . . .

M 11 x 1.5

40

29.5025

60

Flywheel mounting bolts (3) fig. 3 or 5 . . . . . . . . . . . .

M 12 x 1.25

40

29.5025

60

TIGHTENING TORQUE DATA

PART

Thread

Rocker shaft pedestal bolts (1) fig. 3 or 5 . . . . . . . . . . . . . . . . . . . .

Tightening torque
Nm

ft lb

M8

25

18.4390

Crankshaft hub retaining nut (7) fig. 3 or 5 . . . . . . . . . . . . . . . . . . .

M 30 x 1.5

294

216.8432

Fan and alternator pulley bolts (6) fig. 3 or 5 . . . . . . . . . . . . . . . . .

M 10 x 1.25

55

40.5659

Additional counterweight retaining bolts (1) fig. 6 for JX80, JX90

and JX95 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

110

81.1318

Inlet manifold retaining bolts (1) fig. 68 . . . . . . . . . . . . . . . . . . . . . .

M8

25

18.4390

Alternator and belt tension adjustment nut (1) fig. 54 . . . . . . . . . .

M 10 x 1.25

55

40.5659

Coolant pump retaining bolts (1) fig. 59 . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

55

40.5659

Nuts for injector mounting studs (1) fig. 138 . . . . . . . . . . . . . . . . . .

M8

25 (*)

18.4390(*)

Rocker cover nuts (1) fig. 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M8

15

11.0634

Rocker shaft pedestal bolts (2) fig. 81 . . . . . . . . . . . . . . . . . . . . . . .

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. 93 . . . . . . . . . . . . . . . . . .

M8

25

18.4390

Intermediate flanged journal bolts (1) fig. 96 . . . . . . . . . . . . . . . . . .

M 10 x 1.25

55

40.5659

Camshaft thrust plate retaining bolts (4) fig. 97 . . . . . . . . . . . . . . .

M8

35

25.8146

Rear crankcase cover bolts (2) fig. 117 . . . . . . . . . . . . . . . . . . . . . .

M8

25

18.4390

Tappet adjuster screw locknuts (1) fig. 137 . . . . . . . . . . . . . . . . . . .

M8

22

16.2263

Exhaust manifold retaining bolts (1) fig. 64 . . . . . . . . . . . . . . . . . . .

M8

25

18.4390

Injection pump mounting nuts (1) fig. 70 . . . . . . . . . . . . . . . . . . . . .

M8

25

18.4390

M 10 X 1.25

39 to 49

M 10 X 1.25

49 to 59

M 10 X 1.25

49 to 69

28.7692 to
36.1405
36.1405 to
43.5161
36.1405 to
50.8918

Sump pan retaining bolts (4) fig. 86, to

-- inner rear timing cover and gear case . . . . . . . . . . . . . . . . . . . . .
-- cylinder block and flywheel case
JX60, JX70, JX80 and JX90 models . . . . . . . . . . . . . . . . . . . . . .
JX95 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(*) Tighten the nuts in two stages: see the operation in figure 138.
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

25

X 380000219 Punch for valve guide extraction /

installation.

TOOLS

WARNING: The operations described in this section

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

X 380000276 Twist bit for enlarging valve guide

bore.
X 380000277 Tapered grinder for exhaust valve
guides.
X 380000242 Bush for valve guide installation
(with 380000219).
X 380000222 Valve guide reamer.
X 380000302 Valve spring compressor.

List of specific tools required for the various

operations described in this section.

X 380000246 Set of grinding tools for regrinding

injector seat.
X 380000223 Puller for coolant pump impeller.

X 380000236 Tractor dismantling stand.

X 380000247 Drift for installation of coolant pump

impeller seal.

380000216 Engine lifting hook.

380000301 Rotating engine service stand.
380000313 Engine mounting brackets
rotating stand 380000301.

for

380000311 Wrench for injection pump delivery

line unions.
380000254 Injector cleaning kit.

X 380000303 Compression test kit (complete with

dummy injector 380000617.
291966

Digital rev counter.

291979

Digital temperature gauge.

X 380000309 Wrench set for injector dismantling.

380000310 Injection check hand pump.

380000240 Engine oil pressure test kit.

293240

293679

380000308 Injector splitting support.

380000215 Hand pump for injector calibration

test.

Check set, turbocharger

(JX95 model).

293830

Adaptor for injector

(with 380000549).

removal

Filter cartridge removal tool

380000549 Slide hammer.

X 296118

Drive belt tension test tool.

Injection pump bench test

X 291160

Piston ring pliers.

X 291048

Piston ring clamp.

X 292248

Protractor for
measurement.

X 291504

Puller for crankshaft pulley hub.

X 380000232 Wrench for

adjustment.

angular

valve

torque

clearance

380000228 Dial gauge (1/100 mm (0.0394/

3.94 in.) scale, 5 mm (0.1968 in.)
stroke, 40 mm (1.5748 in.) with
380000229).
380000229 Device for BOSCH injection pump
timing on engine.
X 380000322 Extractor for injection pump drive
gear.
6- 62720 -- 09 -- 2006

26

SECTION 10 -- ENGINE -- CHAPTER 1

Splining tool to be manufactured for assembling the

crankshaft front seal (print on the tool no. 50138 -values in mm).
Material UNI C40.

26102

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

27

Splining tool to be manufactured for assembling the

crankshaft rear seal (print on the tool no. 50139 -values in mm).
Material UNI C40.

26103

6- 62720 -- 09 -- 2006

28

SECTION 10 -- ENGINE -- CHAPTER 1

MIG0491A

3
Longitudinal section of 3--cylinder JX60 and JX70 Models
1.
2.
3.
4.

Rocker shaft pedestal bolts

Cylinder head bolts
Flywheel bolts
Main bearing cap bolts

6- 62720 -- 09 -- 2006

5. Big--end cap bolts

6. Fan and alternator pulley bolts
7. Crankshaft hub bolts

SECTION 10 -- ENGINE -- CHAPTER 1

29

MIG0492A

4
Cross--section of 3--cylinder JX60 and JX70 Models

6- 62720 -- 09 -- 2006

30

SECTION 10 -- ENGINE -- CHAPTER 1

MIG0493A

Longitudinal section of 4--cylinder model JX80, JX90 and JX95 Models

1.
2.
3.
4.

Rocker shaft pedestal bolts

Cylinder head bolts
Flywheel bolts
Main bearing cap bolts

6- 62720 -- 09 -- 2006

5. Big--end cap bolts

6. Fan and alternator pulley bolts
7. Crankshaft hub bolts

SECTION 10 -- ENGINE -- CHAPTER 1

31

MIG0494A

Cross--section of 4--cylinder model JX80, JX90 and JX95

1. Counterweight retaining bolts

6- 62720 -- 09 -- 2006

7
Lubrication system of normally aspirated 3--cylinder 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

32

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

8
Lubrication system of normally aspirated 4--cylinder 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

33

6- 62720 -- 09 -- 2006

34

SECTION 10 -- ENGINE -- CHAPTER 1

2
c

3
4

25363

1
d

2
3
4

25364

5
Engine cooling system.

a.
b.
c.
d.
1.

Coolant circulation with thermostat valve closed

Coolant circulation with thermostat valve open
3--cylinder models
4--cylinder models
Thermostat

6- 62720 -- 09 -- 2006

2. Coolant pump
3. Temperature gauge for engine coolant
temperature
4. Temperature sender
5. Fan
6. Radiator

SECTION 10 -- ENGINE -- CHAPTER 1

35

ENGINE TROUBLESHOOTING
Faults
Engine does not start.

Possible Cause
1. Batteries partially discharged.
2. Battery terminal
corroded or loose.

Engine stalls.

Correction
Check and recharge battery. Replace
if necessary.

connections Clean, inspect and tighten terminal

nuts. Replace terminals and nuts if
excessively corroded.

3. Incorrect injection pump timing.

Adjust injection pump timing.

4. Impurities or water in fuel lines.

Disconnect fuel lines from injection

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

5. No fuel in tank.

Fill tank.

6. Fuel supply pump malfunction.

Check and replace pump if necessary.

7. Air in fuel system.

Check fuel lines, unions, supply

pump, filters and injection pump for
air, then bleed system.

8. Starter motor faulty.

Repair or replace starter motor.

9. Faulty thermostart.

Check and replace thermostart, if

necessary.

1. Idle speed too low.

Adjust idle speed.

2. Irregular delivery from injection Check injection pump delivery on test

bench.
pump.
3. Impurities or water in fuel lines.

Disconnect fuel lines from injection

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

4. Fuel filters clogged.

Renew filter cartridges.

5. Incorrect valve clearances.

Adjust valve clearance.

6. Burnt or cracked valves

Replace the valves.

7. Air in fuel system.

Check fuel lines, unions, supply

pump, filters and injection pump for
air, then bleed system.

8. Injection pump drive mechanism Replace damaged parts.

damaged.
(continued)

6- 62720 -- 09 -- 2006

36

SECTION 10 -- ENGINE -- CHAPTER 1

ENGINE TROUBLESHOOTING
(continued)

Faults
Engine overheats.

Possible Cause

Correction

1. Coolant pump malfunction.

Overhaul or replace pump.

2. Faulty thermostat.

Replace the thermostat.

3. Radiator inefficient.

Remove internal deposits by flushing.

Check for leaks and rectify.

4. Deposits in cylinder head and Flush cooling system.

crankcase coolant passages.
5. Coolant pump and fan drive belt Check and adjust belt tension.
slack.
6. Coolant level low.

Top up expansion tank with specified

coolant mixture.

7. Incorrect timing.

Check and adjust.

8. Injection
pump
calibration Calibrate pump on test bench to vaincorrect -- delivering too much or lues specified in calibration tables.
too little fuel.
9. Air cleaner restricted.

Engine lacks power and 1. Incorrect injection pump timing.

runs unevenly.

Clean filter unit and replace filter element if necessary.

Adjust pump timing.

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

on test bench to the values specified
pump damaged.
in calibration table.
3. Control valve journal worn.

Overhaul injection pump and adjust

on test bench to the values specified
in calibration table.

4. Irregular delivery from injection Overhaul injection pump and adjust

on test bench to the values specified
pump.
in calibration table.
5. All--speed governor damaged.

Overhaul injection pump and adjust

on test bench to the values specified
in calibration table.

6. Injectors partially obstructed or Clean and overhaul injectors and adjust pressure setting.
damaged.
7. Impurities or water in fuel lines.

Disconnect fuel lines from injection

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

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

37

ENGINE TROUBLESHOOTING
(continued)

Faults

Possible Cause

Correction

8. Fuel supply pump damaged.

Replace fuel supply pump.

9. Incorrect valve clearances.

Adjust valve clearance.

10. Cylinder compression low.

Test compression and

engine if necessary.

11. Air cleaner restricted.

Clear air filter unit and replace

element if necessary.

overhaul

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

lerator and injection pump
incorrectly adjusted.
13. Maximum
injection
adjusted.

speed
pump

screw on Adjust fast idling speed screw.

incorrectly

Engine produces abnormal 1. Injectors partially obstructed or Clean and overhaul injectors and
knocking noises.
adjust pressure setting.
damaged.
2. Impurities accumulating in fuel Clean fuel lines and replace severely
dented pipes. Clean injection pump if
lines.
necessary.
3. Incorrect injection pump timing.

Adjust injection pump timing.

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

excessive play in one or more crankpins. Fit oversize shell bearings
main or big--end bearings or and thrust washers.
excessive endfloat.
5. Crankshaft out of balance.

Check crankshaft alignment and

balance; if necessary, replace.

6. Flywheel bolts loose.

Replace any bolts that have worked

loose and tighten all bolts to the
specified preliminary and angular torque values.

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

axes parallelism; replace con rods if
necessary.
8. Piston knock due to excessive Rebore cylinder liners and fit oversize
pistons.
wear.
9. Noise caused by excessive play Fit oversize gudgeon pin, rebore
of gudgeon pins in small--end and piston seats and small--end bushings.
piston bushings, or loose fit of Replace bushings.
small--end bushing.
10. Excessive tappet/valve noise.

Check for broken springs or

excessive play between valve stems
and guides, cam followers and bores.
Adjust valve clearance.
(continued)

6- 62720 -- 09 -- 2006

38

SECTION 10 -- ENGINE -- CHAPTER 1

ENGINE TROUBLESHOOTING
(continued)

Faults

Possible Cause

Correction

Engine produces excessive 1. Maximum delivery of injection Adjust injection pump on test bench to
black or dark grey smoke.
the values specified in calibration
pump too high.
chart.
2. Injection
pump
delivery Adjust injection pump/engine timing
check
automatic
advance
excessively retarded or automatic or
regulator.
advance regulator damaged.
3. Injection pump delivery excessively Adjust injection pump/engine timing.
advanced.
4. Injectors partially
obstructed
or
adjusted.

or totally Clean and overhaul injectors and

incorrectly adjust pressure setting; replace if
necessary.

5. Air cleaner restricted.

Clean air cleaner and replace filter

element if necessary.

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

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

high--pressure

if

fuel Inspect and replace if necessary.

Blue, grey--blue or grey-- 1. Injection

pump
delivery Adjust injection pump/engine timing
white smoke.
check
automatic
advance
excessively
retarded
or or
automatic advance regulator regulator.
damaged.
2. Injectors obstructed or damaged. Clean and overhaul injectors and
adjust pressure setting; replace if
necessary.
3. Oil leaking past piston rings due Replace damaged parts or,
to sticking rings or cylinder liner necessary, overhaul the engine.
wear.

if

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

guides due to guide or valve stem
wear.
5. Engine does not reach correct Replace the thermostat.
operating temperature (thermostat
faulty).
Engine runs on after swit- 1. Engine stop solenoid damaged.
ching off.
2. All--speed governor damaged.

6- 62720 -- 09 -- 2006

Replace solenoid.
Overhaul injection pump and adjust
on test bench to the values specified
in calibration table.

SECTION 10 -- ENGINE -- CHAPTER 1

39

ENGINE
Removal -- Installation (Operation 10 001 10)

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

WARNING
Always use suitable tools to align holes in parts.
NEVER USE FINGERS OR HANDS.

1. Disconnect the battery negative cable.

2. Drain oil from the transmission/gearbox.
3. Drain the cooling system.

25621

10
4. Unscrew the nut (1) from the weight retaining pin.
1

TRE0601A

11
6- 62720 -- 09 -- 2006

40

SECTION 10 -- ENGINE -- CHAPTER 1

5. Remove the weights (1) from the front support.

1

TRE0602A

12
6. Remove the exhaust pipe, attach lifting chains to
the bonnet (1) and attach the chain to the hoist.

24872

13
7. Disconnect the electrical leads
headlamps (2).

(1) from

1
2

24873

14
8. Detach the gas struts (1) from the bonnet.

TRE0603A

15
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

41

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

the bonnet clear.
1

TRE0604A

16
10. Remove the wire mesh guard (1) from right-hand side of the fan.

25028

17
11. Disconnect the tachometer cable (1) and
remove the retaining ring and sleeve.

25046

18
12. Detach the throttle control spring (1) and remove
the throttle lever (2).

2
25183

19
6- 62720 -- 09 -- 2006

42

SECTION 10 -- ENGINE -- CHAPTER 1

13. After recovering the air--conditioner gas (HRC

134a) with the recovery and recycling station
294048, disconnect the pipes of the cab air
conditioner (1) and (2).

1
24892

20

14. Detach the cab heating pipes (1) and (2).

25411

21

15. Disconnect the power steering hoses (1).

TRE0605A

22

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

16. Disconnect the electrical connectors. Detach the
fusebox by unscrewing the nut (1).

43
1

TRE0606A

23

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

power steering cylinders.

TRE0607A

24

18. Remove the hose (1) from the lift pump suction
pipe.

1
TRE0608A

25

6- 62720 -- 09 -- 2006

44

SECTION 10 -- ENGINE -- CHAPTER 1

19. Detach the lift pump delivery pipe (1).

1
TRE0609A

26

20. Detach the fuel pipes from the injection pump

and fuel pump and the pipe connecting the tank
to the sedimentation filter.

TRE0610A

27

21. Remove the fuel filter (1) complete with its

support.

25035

28

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

45

22. Remove the front, centre and rear retaining bolts

from the front axle drive shaft guard and remove
the guard.

25038

29
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.

25039

30
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.

2
25040

31
25. Remove the middle support bolts (1) from the
propeller shaft and remove the shaft complete
with support.

25041

32
6- 62720 -- 09 -- 2006

46

SECTION 10 -- ENGINE -- CHAPTER 1

26. Withdraw the pin securing the differential lock (1)

knob, remove the knob and remove the mat (2)
from the floor.
1

TRE0611A

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.

TRE0612A

1
34

28. Unscrew the four lower bolts (1) securing the

engine to the transmission.

1
25049

35

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

47

29. Position stand 380000236 underneath the

tractor and insert a wedge (1), either side of the
axle, to prevent the axle from pivoting.

25050

36
30. Insert a wooden block between the stands and
the tractor.

25051

37
31. Place a fixed stand (1) underneath the drawbar
support and apply the handbrake.

1
25052

38
32. Unscrew the four remaining bolts securing the
engine to the transmission.
33. Separate the engine from the transmission.
34. Remove the spacer collar (1) between the
engine and the transmission on the JX95 model.

25055

39
6- 62720 -- 09 -- 2006

48

SECTION 10 -- ENGINE -- CHAPTER 1

35. Place a fixed stand (1) underneath the front

weight support and chock the wheels with
wooden wedges (2).

25056

40

36. Insert the pin of kit 380000612 (11/11 clutch) or

the pin 380000292 (12/12 clutch) (1) into the
central hole of the clutch. Unscrew the six bolts
(2) securing the clutch to the flywheel and
remove complete clutch assembly.

25057

2
41

37. Remove the radiator mounting bolt (1).

TRE0613A

42

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

49

38. Attach the engine to the hoist using an

adjustable chain (1) attached to the lifting
points provided on the engine.

25060

43

39. Remove the lift pump (1) complete with its filter
by unscrewing the four retaining bolts.

TRE0614A

1
44

40. Disconnect all electrical connectors and remove

the complete wiring harness (1).

1
TRE0615A

45

6- 62720 -- 09 -- 2006

50

SECTION 10 -- ENGINE -- CHAPTER 1

41. Slacken of the hose clamp and detach hose (1)

from the inlet manifold.

TRE0616A

46
42. Remove the left--hand side fan guard (1).

TRE0617A

47
43. Unscrew the bolts (1) securing the silencer to its
bracket.
1

TRE0618B

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 assembly.

TRE0613B

49
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

51

46. Using the hoist, raise the engine slightly and

position the moveable stand (1) under the front
axle.

1
25068

50
47. Undo the hose clamp and disconnect the bottom
radiator hose (1).
48. Unscrew the four bolts (2) securing the engine to
the front axle support, and lower the engine onto
a wooden platform.

25069

51
To re--install the engine, proceed as follows:
Attach the three hooks of an adjustable lifting
chain to the three eye bolts on the engine. Raise
the engine from the platform and position it in
front of the front axle support. Join the two units
using the four securing bolts.
Reposition the moveable stand from under the
front axle differential housing to under the engine
sump, inserting a suitably shaped block of wood
between the stand and the sump pan.
Attach the top radiator hose to the thermostat
housing and secure with an adjustable hose
clamp.
Connect the bottom radiator hose to the coolant
pump and secure at both ends with adjustable
hose clamps.
Refit the fuel pump.
Detach the lifting chain from the engine.
Connect the rigid pipe from the air cleaner to the
inlet manifold and secure with the relative clamp.

Reconnect all electrical leads: thermostart

glow plug, coolant temperature sensor, air
filter blocked sensor, horn, front axle support
earth, engine stop on injection pump, leads to
the alternator and relay, oil pressure sensor,
starter motor, fuel dryer filter. Secure all leads
with plastic ties.
Fit the clutch back on with the aid of kit
380000612 (11/11 clutch) or pin 380000292
(12/12 clutch). Fix clutch to the engine flywheel using the six retaining bolts.
Reconnect the oil delivery pipe to the 4WD
control valve. Tighten the pipe union on the
anti--cavitation accumulator; fix the bracket on
the left--hand side near the engine oil filter.
Clean the distance collar and the mating surfaces of the overdrive clutch housing; scrape
away all traces of old sealing compound.
Apply LOCTITE sealing compound to the
mating surfaces of engine and distance collar.
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

surfaces of the overdrive clutch housing.
Remove the fixed stand from under the front
weight support. Remove the wooden wedges from
under the front wheels.
Attach the adjustable lifting chain to the eyebolts
on the engine.
Place wooden wedges under the rear wheels,
check that the handbrake is fully on and that the
fixed and moveable stands are firmly in place.
Detach the lifting chain from the engine. Connect
the two wires still attached to the cab handrail to
the hook of the hoist. Raise the front part of the
cab about 6 cm.
Replace and tighten all the bolts securing the
engine to the overdrive clutch housing.
Bolt the brake pipe support bracket to the right-hand side of the engine. Lower the hoist and detach the cables from the cab handrail.
Lower the stands under the engine sump and the
clutch housing. Remove tool 380000236 and the
stand from under the drawbar support.
Fix the cab in place with the two front securing
bolts.
Connect the injector leak--off pipe. Connect the
pipes to the glowplug and to the fuel dryer filter.
Refit the fuel filter mounting to the engine. Connect
the two semi--rigid pipes to the mounting.
Connect the oil suction pipes to the pumps;
secure the rubber hoses with hose clamps.
Connect the rigid lift control valve supply pipe to the
relative pump, remembering to first fit the O--ring.
Secure the three pipes with the adjustable hose
clamp.
Connect up all the electrical leads to the
connectors on the vertical support bracket.

Connect the two flexible power steering pipes to

the union on the left--hand side of the front axle.
Secure the two pipes with the special clamp and
screw the clamp to the tractor.
Fit the tachometer cable and secure the sleeve
with the retaining ring.
Fit the silencer onto the exhaust manifold,
remembering to replace the gas seal. Fix the
front of the silencer to the vertical support
bracket. Attach the flexible DONASPIN pipe.
Attach the bonnet stay bracket to the radiator
bracket.
Refit the 4WD propeller shaft and the guard.
Re--connect the throttle cable to the accelerator
pedal. It may be necessary to adjust the cable at
the injection pump lever end.
Refit the clutch cable to the clutch pedal. Fix the
sleeve to the travel stop.
Replace the plastic plugs in the holes in the cab
floor. Replace the mat.
Refit the steering column cover panels.
Replace the wire mesh fan guards.
Attach slings to the bonnet in the manner described previously in the engine removal instructions. Screw the bonnet hinge to its bracket. Attach the gas strut, the electrical leads to the
headlamps and then remove the slings.
Refit the secondary bracket (battery support) to
the overdrive clutch housing. Fit the rotating
bracket with the battery to the fixed support.
Refit the front weights and secure with the lock
pin.
Refit the tool box support bracket and then the
tool box.
Fill the transmission/gearbox and power steering unit with oil.
Fill the radiator with coolant.

Fit the cab heater pipe union on the engine/

clutch distance collar. Connect the rubber heater
hoses to the union and, if necessary, restore the
gas in the air--conditioning system with tool
294030.

6- 62720 -- 09 -- 2006

Connect the battery positive and negative leads.

Replace the plastic battery cover.

SECTION 10 -- ENGINE -- CHAPTER 1

ENGINE
Removal -- Installation (Operation 10 001 54)

53

WARNING
Handle all parts carefully. Do not put your hands or
fingers between parts.
Wear suitable safety clothing, safety goggles, gloves
and footwear.

1. Remove the front and rear retaining screws from

the bonnet stay bracket (1).

25070

52
2. Remove the bonnet catch support side retaining
bolts (1) and back retaining bolts (2) take off the
bonnet catch and the bonnet stay bracket.

1
2

25071

53
3. Loosen the alternator pivot bolt.
4. Loosen the belt tension adjustment bolt (1).
5. Release the belt tension adjustment arm by
unscrewing the retaining nut.
6. Remove the alternator and coolant pump drive
belt.

25072

54
7. Unscrew the bolts securing the fan (1) and pulley
to the coolant pump. Remove the fan and pulley.

1
25073

55
6- 62720 -- 09 -- 2006

54

SECTION 10 -- ENGINE -- CHAPTER 1

8. Unscrew the union (1) from the water supply pipe

to the cab heater.

25074

56
9. Loosen the hose clamp (1) and detach the hose
from the coolant pump. Remove the curved hose
and flexible cab heater hoses.

25075

57
10. Remove the union (1) in order to gain access to
the pump retaining bolt.

25077

58
11. Unscrew the coolant pump retaining bolts (1)
and remove the pump.

25076

59
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

55

12. Unscrew the pump support bolts (1) and the

silencer support bolt. Remove the two supports.

25078

60
13. Fit mounting bracket (1) of the set 380000313 to
permit attachment of the engine to the rotary
stand 380000201.

1
25079

61
14. Fit an eyebolt (1) on the front of the engine in
place of the silencer support.
15. Raise the engine from the wooden platform and
move it to the rotary stand 380000301 (2).
Secure it to the stand by means of the bracket (3)
of the set 380000313.

25080

62
16. Undo the alternator support retaining bolts (1)
and remove the complete alternator assembly.

1
25081

63
6- 62720 -- 09 -- 2006

56

SECTION 10 -- ENGINE -- CHAPTER 1

17. Unscrew the bolts (1) securing the exhaust

manifold to the cylinder head and remove the
manifold.

25082

64
18. Detach the throttle control lever (1) from the
injection pump.

25083

65
19. Remove the thermostat housing retaining bolts
(1) and remove the thermostat housing.

25084

66
20. Unscrew the high pressure fuel line unions (1) on
the injection pump and remove the fuel lines.

25085

67
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

21. Unscrew the bolts (1) securing the inlet manifold
to the cylinder head and remove the manifold.

57

25086

68
22. Unscrew the unions (1) on the fuel supply pump
and detach the fuel lines.

25087

69
23. Unscrew the nuts (1) securing the injection pump
to the timing gear case.

25088

70
24. Undo screws (1) and remove the injection pump
drive gear cover.

25089

71
6- 62720 -- 09 -- 2006

58

SECTION 10 -- ENGINE -- CHAPTER 1

25. Unscrew the nut (1) securing the injection pump

drive gear to the pump shaft.

25090

72
26. Extract the injection pump gearing using tool
380000835 (1) and remove the injection pump.

NOTE: If the injection pump does not require any

specialist work it must be removed following the
instructions given on page 118.

25091

73
27. Undo the fuel line unions (1) on the fuel
sedimentation filter.

25092

74
28. Unscrew the bolts securing the sedimentation
filter support to the engine block and recover the
complete filter assembly.

25093

75
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

59

29. Unscrew the retaining nut (1) and remove the

fuel pump support complete with the pump.
Retain the gasket for re--use, if undamaged.

1
25094

76
30. Unscrew the power steering pump retaining
bolts (1) and remove the pump complete with
filter and accumulator on the delivery line.

1
25095

77
31. Remove spacer (3), gasket (2) and the pump
drive connector (1).

1
2

25096

78
32. Unscrew the starter motor retaining bolts (1) and
remove starter motor.

25097

79
6- 62720 -- 09 -- 2006

60

SECTION 10 -- ENGINE -- CHAPTER 1

33. Remove the injector mounting nuts and the

spherical washers beneath, then the supports
and the injectors themselves.
34. Remove the rocker cover bolts (1), washers and
seals and then the rocker cover and its gasket.

2
25098

80
35. Remove the rocker shaft retaining bolts (2), then
remove the entire rocker shaft assembly (1).

25099

81
36. Remove the valve collets (1) and withdraw the
pushrods (2). Retain the collets and pushrods for
re--installation later.

25100

82
37. Unscrew the cylinder head bolts (1) and remove
the head using a hoist and lifting hook
380000216.
38. Remove the cylinder head gasket.

25101

1
83

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

39. Turn the engine upside down on the rotary stand.
Remove the sump pan bolts, the sump pan (1)
and its gasket (2).

61

25102

84
40. Unscrew the retaining bolts and remove the oil
pick--up pipe (1) complete with the strainer and
seal.
41. Unscrew the retaining bolts (2) and free the
counterweight housing (3) by moving it outward.
Remove the sleeve coupling (4) and housing.

NOTE: Operations 39, 40 and 41 are to be carried

out on 4--cylinder models only. To disassemble and
reassemble the rotating counterweight dynamic
balance, see pages 67 and 68.

25103

85
42. Unscrew the sump pan retaining bolts (4) and
remove the sump pan using a hoist, lifting hook
380000216 and lifting chain with eyeholes.
43. Remove the half--gaskets (1) and (3) between
the crankcase and sump pan and the gasket (2)
between the timing gear carrier and sump pan.

4
3
25104

86
44. Remove the gasket (1) between the flywheel
carrier and the sump pan.
NOTE: When fitting the gaskets (1) and (3) (fig. 86),
apply RHODORSIL CAF1 silicone sealing
compound to the mating surfaces.

25105

87
6- 62720 -- 09 -- 2006

62

SECTION 10 -- ENGINE -- CHAPTER 1

45. Remove the rotating counterweight oil seal

O--ring (1) installed on the crankcase mating
surface.

25106

88
46. Undo the retaining bolts (1) and remove the
complete oil pump assembly.

NOTE: For JX90 and JX95 models see fig. 106 on

page 66.

25107

89
47. Unscrew the retaining bolts (2) and remove the
crankshaft pulley (1).

2
25108

90
48. Straighten the lock tab, preventing rotation of the
crankshaft and unscrew nut (1).

1
25109

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.

1
25110

92
50. Unscrew the retaining bolt (1) and remove the
timing cover and its gasket.

25111

93
51. Unscrew the retaining bolts and remove the lift
pump drive gear carrier (1).

25112

94
52. Remove the circlip (1) and remove the thrust
washer and the intermediate gear (2).

NOTE: When refitting the intermediate gear see

engine timing instructions on page 73.

25113

95
6- 62720 -- 09 -- 2006

64

SECTION 10 -- ENGINE -- CHAPTER 1

53. Unscrew the retaining bolts (1) and remove the

intermediate gear journal.

25114

96
54. Unscrew the retaining bolts (4) and withdraw the
camshaft (2) complete with the camshaft gear
(1) and the end plate (3).

1
2
4
3

25115

97
55. Remove the circlip (1) and the thrust washer.
Withdraw the gear with fuel supply pump
camshaft (2) from the opposite side.

NOTE: This gear transmits drive to the injection

pump. On re--assembly see timing instructions on
page 73.

2
25108

98
56. Unscrew the bolts (1) and remove the timing
gear case.

25109

99
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

65

57. Renew the O--ring seal (1) installed in the lift

pump drive shaft lubrication line.
58. Remove the crankcase -- timing gear case
gasket.

25118

100
59. Rotate the engine on the stand through 90_.
Unscrew the big--end cap bolts (2) and remove
the big--end caps (1), complete with their half
shell bearings.

25119

101
60. Slide the pistons (1), complete with rings,
gudgeon pins and connecting rods, out of the
cylinder liners.

1
25108

102
61. Rotate the engine on the stand through 90_ back
to the horizontal position. Unscrew the flywheel
bolts and remove the flywheel with the aid of a
hoist and hook 380000216.
62. Unscrew retaining bolts and remove the rear oil
seal carrier (1) complete with gasket.

25109

103
6- 62720 -- 09 -- 2006

66

SECTION 10 -- ENGINE -- CHAPTER 1

63. Unscrew the main bearing cap bolts (1) and

remove the main bearing caps with related
bearing shells. Remove the thrust washers
located on the penultimate main bearing, as
shown in the figure.
64. Lift the crankshaft clear of the crankcase using
a hoist and nylon sling. Remove the bearing
shells, thrust washers and tappets.

25122

104
65. Turn the engine on the stand 380000301 (2)
through 180_. Attach the lifting chain with eye
holes to the crankcase as shown in the figure.
Raise the hook 380000216 with the hoist so that
the lifting chain is under slight tension. Unscrew
the bolts securing the crankcase to the stand (2)
and mounting bracket (3) (from set 380000313).
66. Lift the engine clear of the stand.
67. Unscrew retaining bolts and remove the rear
crankcase housing (1) and its gasket.

25123

105
NOTE: The figure shows the oil pump for the JX90
and JX95 models
68. Remove the retaining screws (4), take off the
washers (3) and the engine lubrication oil pump
(2) complete with pressure relief valve (1).

1
2
3
4
26106

106

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

NOTE: Operations 1 to 9, relative to the dismantling
of the rotating counterweight dynamic balancer, only
apply to 4--cylinder models.

67
2

1. Remove the lubricating oil pipe (3) fig. 108.

2. Remove the circlip (18).
3. Remove the circlip (25) and cover (23) with relative O--ring seal (24).

4
5

4. Withdraw gear (22) from sump.

5. Remove the circlip (2), gear (26) and the two
thrust washers (1).

25159

107

6. Inspect shaft (27). If it shows signs of scoring or

wear it must be replaced.
7. Extract the roll pins and remove the
counterweight shafts (8) using a suitable drift.
8. Disassemble the counterweight gear unit (1)
fig. 107 by removing the circlip (5) and the
support retaining bolts (6).
9. Remove the circlip (3) and the intermediate gear
(4) fig. 107.

7
8

28
27
26
25
24
23
25160

22 21
11
20 19 18 17 16 15 14 13 12

10

Sectional view of dynamic balancer

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Thrust washers.
Circlip.
Lubricating oil pipe for bushing (28).
Counterweight rotation shaft.
Shaft retaining spring pin.
Carrier for counterweight drive gear (13).
Thrust washer.
Rotating counterweights.
Counterweight intermediate gear.
Bolts securing counterweight housing to sump.
Circlip.
Counterweight housing.
Counterweight drive gear.
Mesh filter.

15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.

108

Mesh filter retaining bolt.

Bushing.
Rigid coupling sleeve.
Circlip.
Thrust washer.
Carrier for gear (22).
Thrust washer.
Counterweight drive gear.
Cover.
O--ring seal.
Circlip.
Intermediate gear.
Shaft for gear (26).
Bushing.

6- 62720 -- 09 -- 2006

68

SECTION 10 -- ENGINE -- CHAPTER 1

GENERAL NOTES AND INFORMATION

After dismantling the engine, clean all parts
carefully.
To reassemble the engine, carry out the dismantling operations described on pages 53 to 67
in reverse order.
The following pages 68 to 77 concern those
assembly operations requiring particular attention.
Tightening torques are specified on page 24.
IN ADDITION, MAKE SURE TO:
Replace all seals and gaskets at each complete
or partial engine rebuild.
Lubricate all rotating parts and oil seals with
engine oil prior to installation.
Lubricate the oil filter mounting seal prior to fitting
the filter.
WARNING
Handle all parts carefully. Do not put your hands or
fingers between parts.
Wear suitable safety clothing, safety goggles, gloves
and footwear.

INSTALLING THE BALANCER GEARS WITH

COUNTER--ROTATING WEIGHTS (Disassembly
operations 1 -- 9)

Proceed as follows:
Assemble the counterweight components in the
housing (2) carrying out dismantling operations
7 to 9 in reverse order. Align the positioning
marks on the gear (4) and counterweights (1)
(indicated by arrows in figure 127).

24913

2
109

The intermediate gear (3) fig. 109 must be

installed with the longer side of its hub towards
the casing side;
The holes for the roll pins (1) in the counterweight
shafts (2) must be aligned with corresponding
holes in the casing.
Install the counterweight assembly on the sump
carrying out operations 1 to 9 (page 67) in
reverse order.

24914

110
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

69

INSTALLING THE TAPPETS AND CRANKSHAFT

WITH MAIN BEARING CAPS, BEARINGS AND
THRUST RINGS; CHECKING CRANKSHAFT
END FLOAT (Disassembly operations 63 -- 64)

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 semi--circular thrust washers (3) to both
sides of the penultimate main bearing with
grease.

25109

111

Lubricate the upper surfaces of the main bearing

shells with engine oil and lower the crankshaft (1)
into position taking care not to dislodge the
semi--circular
thrust
washers
installed
previously.

24718

112

Lubricate the crankshaft journals with engine oil

and fit the main bearing caps (3) with the
half--shells (4), fitting the top semi--circular thrust
washers (2) to the penultimate bearing cap.
Rotate the crankshaft (1) a few times to allow the
parts to settle into position.
Insert the main bearing cap bolts and screw in
until the head of the bolt is up against the cap.

25108

113

6- 62720 -- 09 -- 2006

70

SECTION 10 -- ENGINE -- CHAPTER 1

Tighten all cap bolts (1) to a torque of 80 Nm (8.2

kgm).

24720

114
Tighten each cap bolt (1) through a further 90
using tool 380000304 (2).

1
2

24744

115
Check that crankshaft endfloat does not exceed
the value specified on page 17.

24760

116

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

INSTALLING THE REAR COVER WITH SEAL,
AND ENGINE FLYWHEEL
(Disassembly operation 62)

71
1

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.

3
2

24752

117
Fit the inner rear oil seal using installer and hand
grip 50139 (1).

24761

118
Fit the flywheel and tighten the retaining bolts (1)
to a torque of 40 Nm (4.1 kgm).

24762

119
Using tool 380000304 (1), tighten each flywheel
bolt (2) through a further 60.

24763

120
6- 62720 -- 09 -- 2006

72

SECTION 10 -- ENGINE -- CHAPTER 1

INSTALLING THE PISTONS COMPLETE WITH

RINGS, PINS, CONNECTING RODS, BIG END
CAPS
AND
BEARINGS
-CHECKING
PROTRUSION IN RELATION TO CYLINDER
BLOCK FACE
(Disassembly operations 59 and 60)
Proceed as follows:
Lubricate pistons, rings and cylinder liners with
engine oil prior to fitting.
Fit the piston rings using piston ring pliers
380000221. Make sure that the piston ring gaps
are offset 180 apart.
Fit piston ring clamp 380000220 (1) to compress
the rings, making sure that the piston ring gaps
remain 180 apart.
Insert the piston/connecting rod into the cylinder
liner. Ensure that the connecting rod number
corresponds with the cylinder number and that
the number stamped on the connecting rod is
facing away from the camshaft.
Fit the big--end caps (2) complete with shells to
the crankpins and tighten the cap bolts (1) to a
torque of 40 Nm (29.5025 ft lb).

25163

121

25164

122

Using tool 380000304 (1), tighten each big--end

cap bolt (2) through a further 60.

25165

123
Rotate the engine on the stand through 180 and
clean the upper face of the cylinder block. Bring
the pistons (2) up to TDC and, using a dial gauge
with a magnetic base (1), check that the piston
protrusion from the cylinder block face is within
the tolerance limits specified on page 19.

25166

124
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

73

SYNCHRONIZING THE TIMING GEARS

(Disassembly operations 51 -- 55)
Proceed as follows:

Remove the cover and gasket from the flywheel

housing inspection window.

25167

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 inspection 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).

26107

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

REFITTING THE COUNTER--ROTATING WEIGHT

BOX TO THE OIL SUMP
(Disassembly operation 41)

When refitting the counter--rotating weight box,

synchronise as follows:

Bring piston no. 1 to TDC.

Position the rotating counterweights so that the
timing reference marks are aligned as shown in
the figure.

25170

128
Turn the rotating counterweight unit over and
insert the locating pin (2) in its hole. The pin
serves to hold the counterweights in the correct
timing position during installation of the unit.
Using the hoist and a lifting chain, lower the
counterweight unit onto its seating in the sump.

25171

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.

2
3
25172

130
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

75

REFITTING THE BOSCH INJECTION PUMP

(Disassembly operations 23 -- 26)

Fit the BOSCH injection pump and proceed with

the injection pump timing in the manner
described on pages 121 to 123.

2
25181

131
FITTING THE CYLINDER HEAD GASKET
(Disassembly operation 38)
Proceed as follows:

Before fitting the cylinder head, carefully clean

and degrease the mating surface of the cylinder
block. Locate a new cylinder head gasket (1)
with the word ALTO uppermost.

25173

132
6- 62720 -- 09 -- 2006

76

SECTION 10 -- ENGINE -- CHAPTER 1

FITTING AND TIGHTENING THE

CYLINDER HEAD
(Disassembly operation 37)
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).
25174

133
Fig. 134 -- Tightening sequence for cylinder head
bolts on 4--cylinder engines to be followed for
each of the four tightening stages (A = fan end).

25175

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).

25176

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).

2
25177

136
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

77

ADJUSTING VALVE/ROCKER ARM

CLEARANCE
(Disassembly operation 34)

Before refitting the rocker cover, adjust the valve

clearances as described on pages 128 -- 130.
Tighten the rocker arm adjuster screw locknuts
(1) to the torque specified on page 24.

25178

137
FITTING THE INJECTORS
(Disassembly operation 33)

Proceed as follows:
Insert the injectors (2) in their respective bores.
Position the injector support brackets and fit the
spherical washers.
Screw the bracket retaining nuts (1) up to the
spherical washers, then tighten to the torque
specified on page 24, in two stages:
first stage -- tighten nuts to 10 Nm (7.3756ft lb);
second stage -- tighten nuts to 25 Nm
(18.4390 ft lb).

1
2
25179

138

Tighten the leak--off pipe unions.

Tighten the high--pressure fuel line unions.
ADJUSTING COOLING SYSTEM BELT TENSION
(Disassembly operations 3 -- 6)

NOTE: Tension the belt correctly as described on

page 101.

6- 62720 -- 09 -- 2006

78

SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS -CYLINDER BLOCK and CYLINDER LINERS

WARNING
Handle all parts carefully. Do not put your hands or
fingers between parts.
Wear suitable safety clothing, safety goggles, gloves
and footwear.

Clean all parts carefully before proceeding with the

operations described below.
NOTE: Cylinder liner dimensions must only be measured when the liner is installed in the cylinder bore
as they are subject to deformation when not fitted.

Check liner wear as follows:

measure the inside diameter in the area swept
by the piston rings X (fig. 141);
measure the inside diameter at the upper and
lower ends of this area both parallel to the
crankshaft centre line (a) and at right angles to
the crankshaft centre line (b);
compare measurements thus obtained to
determine liner ovality and taper.
To check piston running clearance, measure the inside diameter of each liner in the area Z (fig. 141)
along the axis at right angles to the crankshaft centre
line.
If the bore is out of round or tapered by more than
0.12 mm (0.0047 in.) or the piston clearance exceeds 0.3 mm (0.0118 in.), it is necessary to re--bore
and re--grind (or perhaps replace) the liners, taking
them to one of the sizes specified in the chart on
page 16.
Then pair up the cylinder liners with the pistons of the
same dimensions (see page 19).

NOTE: If one of the liners requires reboring, all the

liners in the engine must be rebored to the same
oversize.
After reboring, the 0.5 mm (0.0197 in.) 30_
chamfer must be restored on the liner (1).
In case of replacement, remove and install the
liners in cylinder block cold using a press as follows:

1
25307

139
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

79

Press the worn liner out of the block, operating

from the bottom of the crankcase, using a
stepped plate of appropriate diameter.
Check the ovality of the bore in the block and
rebore if necessary to 0.22 mm (0.0087 in.)
oversize.
Press--fit the new liner (0.22 mm (0.0087 in.)
oversize if necessary) from the top of the block,
using the stepped plate referred to above.
Rebore and ream the liner to the specified inside
diameter (see page 16).
25308

140

25310

141

Standard dimensions (mm) of cylinder liners and bores in cylinder block

and positions for checking liner wear.
a,b. Position of dial gauge to measure liner inside
diameter.
c. JX70, JX90 and JX95 Models.
C. Dimension to achieve after press--fitting and
reaming of liner.
Z. Area for measurement of inside diameter of
used liner to determine piston running
clearance (measured along axis b at right
angles to crankshaft).

X.

Area for measurement of inside diameter of

worn liner (area swept by piston rings) to
determine ovality and taper (measure along
axes a and b, respectively parallel and at right
angles to crankshaft).
1,2,3. Points at which to measure inside diameter
of new or rebored liners along axes a and b.

6- 62720 -- 09 -- 2006

80

SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS -CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL

WARNING:
Handle all parts carefully. Do not put your hands or
fingers between parts. Wear suitable safety clothing,
safety goggles, gloves and footwear.
Crankshaft
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).
After 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.);

25311

142

c
c

a
b

d
d

25312

25313

143
Standard dimensions (mm) of main bearing journals and crankpins, main bearings
and semi--circular thrust washers.
a. JX60 and JX70 models.
b. JX80, JX90 and JX95 models.
c. Crankpin radii and fillets.
6- 62720 -- 09 -- 2006

d. Normal crankshaft journal radii and fillets.

e. Radii and fillets of crankshaft journal with
thrust washers.

SECTION 10 -- ENGINE -- CHAPTER 1

with the crankshaft resting on parallel gauge
blocks, the maximum misalignment of the main
bearing journals does not exceed 0.10 mm
(0.004 in.) (D) fig. 161;
the centrelines of the crankpins (mod. JX70) or
of each pair of crankpins (JX70, JX80, JX90
and JX95 models) lie in the same plane as the
main journal centrelines, with a maximum
deviation of 0.25 mm (0.0098 in.) as
measured perpendicularly to the same plane
(see fig. 143);
the distances between the outer surfaces of the
crankpins and the crankshaft centreline are
equal with a tolerance of 0.10 mm
(0.004 in.);

81

the run--out measured with the dial gauge

contact point resting on surface (A) or (B),
fig. 144, does not exceed the measurement
given in the chart on page 18;
the oil plugs seal against an oil pressure of 14.7
bar (213.2 psi);

if new plugs are fitted, punch--lock in position

and re--check oil tightness with the system
pressurised.

25314

a
25315

144
Maximum tolerances for alignment of main bearing journals and crankpin relative to
crankshaft centreline and alignment of crankpins relative to main bearing journals (a)
b. JX60 and JX70 models
c. JX80, JX90 and JX95 models
A. and B. Dial gauge contact point positions for
checking run--out of flywheel mounting flange.

D. Maximum permissible main bearing journal

alignment deviation
.

6- 62720 -- 09 -- 2006

82

SECTION 10 -- ENGINE -- CHAPTER 1

Bearings
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;

2
3

6
5

25316

145

lubricate the bolts (4, fig. 3 and 5) securing the

main bearing caps with engine oil and tighten
them to the prescribed torque using a torque
wrench (see page 24);

Main bearing cap bolts (4, figs. 3 and 5)

If the bolts are to be re--used, check that diameter d
(measured in area a shown in fig. 146) is greater
than 13.5 mm (0.5315 in.). If not, replace the bolts.

25318

146

remove the caps and determine the bearing

clearance by comparing the width of the calibrating wire at the widest point against the scale
printed on the packet (3) fig. 145, containing the
wire;
after refitting the crankshaft and the bearing
caps and bolts, check crankshaft endfloat about
the penultimate bearing with a dial gauge (1);
if the endfloat exceeds the specified value (see
page 17), replace the existing thrust washers
with oversized ones.

25317

1
147

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

83

Flywheel

The flywheel is fixed to the crankshaft flange by

means of self--locking bolts. The starter ring gear is
shrunk--fit, after pre--heating, to the register on the
engine side of the flywheel.

If the ring gear is to be replaced, heat in oil to 80 to

90 C (176 to 194 F) before fitting and position with
the bevel on the teeth facing inward towards the
starter motor.

The flywheel mounting holes are offset so that the

flywheel can only be mounted in one position.
NOTE: To regrind the flywheel, see section 18,
page 25.

lubricate the screws securing the engine

flywheel with engine oil, then tighten them to the
prescribed torque (see page 24) using a torque
wrench.

Flywheel bolts (3, figs. 3 and 5)

If the bolts are to be re--used, check that diameter d
(measured in area a shown in figures 148 and 149)
is greater than 13.5 mm (0.5315 in.). If not, replace
the bolts.

25318

148

25319

149
6- 62720 -- 09 -- 2006

84

SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS -CONNECTING RODS

CAUTION
Handle all parts carefully. Do not place hands or
fingers between one part and another. Wear the
recommended safety clothing such as goggles,
gloves and safety boots.

Clean all parts carefully before carrying out the

following operations.
Check that the bushings in the connecting rod small
ends are tight in their bores and are flush with the
sides of the rods.
If necessary, replace the bushings and ream after
fitting to the specified diameter (A) shown in the
drawing.

Dimensions (mm) of standard connecting rods,

bearing shells, bushings and gudgeon pins.
A = Dimension required by reaming after fitting
bushings -- L, M = Oil ports.
25320

150

Check parallelism of small end and big end axes.

Maximum permitted tolerance is 0.07 mm
(0.0028 in.) measured at 125 mm (4.9213 in.) from
longitudinal axis of the connecting rod.

Slightly twisted con rods can be straightened using

a press. Severely deformed rods should be
replaced.

New con rods must be marked with the number of the

cylinder in which they are to be fitted. Check that the
difference in weight of connecting rods in the same
engine does not exceed 25 grams (0.0551 lb).

Also check that the oil ways (L and M) fig. 150 are
not obstructed by scale or impurities.
6- 62720 -- 09 -- 2006

25321

151

SECTION 10 -- ENGINE -- CHAPTER 1

85

CHECKS, MEASUREMENTS AND REPAIRS -PISTONS

WARNING
Handle all parts carefully. Do not put your hands or
fingers between parts. Wear suitable safety clothing,
safety goggles, gloves and footwear.

Clean all parts carefully before carrying out the

following operations.
Determine the degree of piston and liner wear in the
manner described on pages 16 and 19 and the figures below.
If the piston running clearance exceeds 0.30 mm
(0.0118 in.), rebore and ream the liners and fit
oversize pistons and rings (see pages 16 and 19).
In case of piston replacement, check that the weight
difference between pistons in the same engine does
not exceed 20 grams (0.0441 lb).
Check that the piston ring groove clearance (b, fig.
152) and the end gap (c, fig. 152) are within the
tolerances specified on page 19. If the end gap is less
than that specified, correct by grinding the ends of
the piston ring.

25322

Checking pistons and rings

a. Checking piston diameter at a distance (L) from
the base of the skirt.
b. Checking piston ring groove clearance.

c.
L.

152

Checking the end gap with ring in cylinder bore.

Distance from base of piston skirt: 12 mm
(0.4724 in.).
6- 62720 -- 09 -- 2006

86

SECTION 10 -- ENGINE -- CHAPTER 1

MIG0495A

153
Dimensions (mm) of standard pistons, gudgeon pins and rings.

a. JX60 and JX80 models.

b. JX70, JX90 and JX95 models.
A. Measurement to be obtained with rings inserted
in cylinder liners.

Piston diameter measured at 12

(0.4724 in.) from the base of the skirt.

mm

To remove or fit piston rings (1), use pliers

380000221 (2).

1
Fit rings in grooves in the order indicated in fig. 153.

When fitting pistons on connecting rods, check that

the clearance between the gudgeon pin and its bore
in the piston is within the tolerance specified on page
19.

2
25324

154
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

87

Check that the piston/connecting rod assembly is

perfectly square.

If not, replace parts causing the problem.

25108

155

NOTES:

Oil the pistons, rings and liners before inserting

the pistons in their bores.
Before fitting the ring clamp 380000220 (1) to
compress the rings for insertion in the liner,
check that the ring end gaps are offset by an
angle of 180 i.e., opposite one another.
This will ensure better compression and better oil
sealing.

2
25326

156

Big end cap bolts (5, fig. 3 and 5)

If the bolts are to be re--used, check that diameter d
(measured as shown in the figure alongside, area a,
fig. 157) is greater than 10.5 mm (0.4134 in.). If not,
replace the bolts.

NOTE: It is advisable to replace the big end cap bolts

each time the connecting rods are dismantled.

25327

157
6- 62720 -- 09 -- 2006

88

SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS -CAMSHAFT, TAPPETS AND VALVES

WARNING
Handle all parts carefully. Do not put your hands or
fingers between parts. Wear suitable safety clothing,
safety goggles, gloves and footwear.
Clean all parts carefully before carrying out the
following operations.

Valves
Use tool 380000302 for valve removal and installation.
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.).
Dimensions (mm) of valves and valve guides
A. Intake.
B. Distance to be obtained by reaming fitted valve
guide.
S. Exhaust.
25330

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 adjuster 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.
25329

159
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

89

Camshaft
Place the camshaft on two parallel V blocks, as
shown. Using a dial gauge with 1/100 mm
(0.0394/3.94 in.) scale, check that journal run--out
relative to the axis of rotation does not exceed 0.02
mm (0.0008 in.).
If run--out does not exceed 0.2 mm (0.0008 in.), the
camshaft may be straightened using a press;
otherwise replace the camshaft.
Check cam lift using a dial gauge, which should be
as follows:

25328

160

-- inlet valves = 5.97 mm (0.235 in.);

-- exhaust valves = 6.25 mm (0.2461 in.).
Replace worn bushings using suitable extractors and
drifts. Ream to obtain the inside diameter indicated
in figure 161.

25331

Dimensions (mm) of camshaft journals and relative seats in cylinder block.

a. JX60 and JX70 models.

161

b. JX80, JX90 and JX95 models.

NOTE: The value indicated for the bushing inside diameter is for an installed bush.

6- 62720 -- 09 -- 2006

90

SECTION 10 -- ENGINE -- CHAPTER 1

Valve timing check

To check the valve timing after dismantling/assembly

or overhaul of the valve timing gear, proceed as
follows:

Check that the timing reference marks on the timing

gears are aligned as indicated on page 73.

Provisionally set valve clearances to 0.45 mm

(0.0177 in.).

Turn the crankshaft and, using a graduated timing

disc, check that valves open and close at the angles
indicated in the timing diagram.

On completion of timing check, set the valve clearances for normal running as detailed on pages 127
to 129.
Valve timing diagram.
A.
1.
2.
3.
4.
5.

Fixed advance (*).

TDC.
BDC.
Inlet.
Exhaust.
Injection.

(*) According to pump type and engine model (see page 2).

6- 62720 -- 09 -- 2006

25333

162

SECTION 10 -- ENGINE -- CHAPTER 1

91

CHECKS, MEASUREMENTS AND REPAIRS -CYLINDER HEAD

WARNING
Handle all parts carefully. Do not put your hands or
fingers between parts. Wear suitable safety clothing,
safety goggles, gloves and footwear.

Use valve spring compressor 380000302 to remove

and refit valve springs.

Clean all parts carefully before proceeding with the

operations described below.

Check that the cylinder head mating surface is flat

using a straight edge (2) and feeler gauge (1).
If deviations of more than 0.15 mm (0.059 in.) are
found, the head must be refaced.

25108

163

NOTE: Remove as little material as possible: the

maximum depth of material that can be ground from
the cylinder head is 0.5 mm (0.02 in.).

Using a dial gauge with magnetic base (1), check the

run--out of the valve head (2) in the guide and the
clearance between the valve stem and guide.

If the clearance exceeds the specified value (see

page 22), replace the valve and, if necessary, the
valve guide.

25108

164

6- 62720 -- 09 -- 2006

92

SECTION 10 -- ENGINE -- CHAPTER 1

VALVE GUIDES
Replacement (Operation 10 101 53)

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

WARNING
Always use suitable tools to align holes in parts.
NEVER USE FINGERS OR HANDS.
With the cylinder head on the test bench, proceed as
follows:

1. Enlarge the bore of the valve guide to be fitted

using twist drill 380000276.
2. Place the cylinder head on a suitable support and
remove the valve guide to be replaced, using drift
380000219 (1).

25334

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).

1
2
25335

166
4. Ream out the valve guide bore (2) using reamer
(1) 380000222.

1
2

25336

167
6- 62720 -- 09 -- 2006

93

SECTION 10 -- ENGINE -- CHAPTER 1

NOTE: When replacing exhaust valve guides you
must also carry out the following further operations.
5. Measure the distance (L) between the cylinder
head face and the base of the valve guide using
a caliper gauge and the special plate of tool
380000277.

25337

168
The depth of taper milling is given by:
B -- L = C
where:
B = depth of taper relative to cylinder head face (see
fig. 175).
L = distance measured between cylinder head face
and valve guide base.
C = depth of taper milling.

Example (4--cylinder engine)

B = 43.1 to 43.6 mm (1.6968 to 1.7165 in.)

L = 34 mm (1.3386 in.) (distance measured).

C = (43.1 to 43.6) -- 34 = 9.1 to 9.6 mm.

((1.6968 to 1.7165) -- 1.3386 = 0.3582 to 0.3779 in.)
Depth of taper milling.
6. From the upper side of the cylinder head, fit
guide bush (1) of tool 380000277 on the guide
valve to be milled (2).

25109

169
7. Slide the cutter (1) of tool 380000277, complete
with depth stop (2), into the previously located
guide bush until the cutting head is in contact
with the valve guide.

2
25339

170
6- 62720 -- 09 -- 2006

94

SECTION 10 -- ENGINE -- CHAPTER 1

8. Position the plate (3) of tool 380000277 flush

against the cylinder head face and slide the
depth stop (2) up to the plate. Measure the
distance (A) between the depth stop and the end
of the cutter shank (1).

25340

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.
Distance (D) is given by:

1
D = A -- C
where:
D = the distance determining the end of the taper
milling.

25341

172

A = the distance between the end of the cutter shank

and the depth stop, with the plate flush against the
cylinder head.
C = the depth of taper milling.

Example
A = 45.5 mm (1.7913 in.)
C = 9.1 to 9.6 mm (0.3583 to 0.3780 in.)
D = 45.5 -- (9.1 to 9.6) = 35.9 to 36.4 mm
(1.7913 -- (0.3583 to 0.3780) = 1.433 to 1.4133 in.).
10. Turn the cutting tool (2) until the plate (3) is
brought up to the cylinder head face by the depth
stop (1).
NOTE: Before fitting the cylinder head, clean it
thoroughly to remove all residue from the milling
operation.

2
1

25342

3
173

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

95

VALVE SEATS IN CYLINDER HEAD.

Reboring

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

11. If the valve seats need refacing to improve valve

sealing, use the universal valve grinder (1) and
remove as little material as possible.

25343

174
Dimensions (mm) of valve seats and guide
valves.
A. Inlet.
B. Depth of taper on 3 and 4--cylinder engines.
S. Exhaust.
C. Engines for JX60 and JX80 models.
D. Engines for JX70, JX90 and JX95 models

MIG0496A

175
6- 62720 -- 09 -- 2006

96

SECTION 10 -- ENGINE -- CHAPTER 1

INJECTOR SLEEVES -- Replacement

(Operation 10 101 60).

WARNING
Handle all parts carefully. Do not put your hands or
fingers between parts. Wear suitable safety clothing,
safety goggles, gloves and footwear.

1. If the cylinder head face has been reground,

check that injector protrusion is within the
tolerance limits specified on page 22.
Checking injector and valve height relative to
the cylinder head face.
a. Checking injector protrusion (see page 22)
b. Checking valve stand--in: 0.7 to 1.0 mm (0.0276
to 0.0394 in.) (max. permissible stand--in =
1.3 mm (0.0512 in.)).

25345

176

If injector protrusion exceeds the specified limit,

replace the injector sleeve using tool kit 380000246
and proceed as follows:

2. Set distance (A) on tap (3) 380000829 to 9 mm

(0.0295 in.) by means of the ring nut (5). Fix the
ring nut in position by tightening the set screw
(4).

3. Cut an internal thread (2) in the sleeve to be removed using tool 380000829 (M12 x 11.75) making sure that the thread is cut only in the sleeve.
4. Fit tool 380000832 (2) fig. 179 to the injector
mounting studs on the cylinder head by means
of the nuts (3) (M8 x 1,25).
5. Screw part (11) fig. 179) fully into the previously
cut thread and turn nut (1) to withdraw the injector sleeve (12) from the head.
6. Remove any copper residue from inside the
head using tool 380000370.
7. Fit seals (6, fig.179) onto the new injector sleeve
and fit the sleeve into its bore, making sure that
the sleeve butts up against the bottom of the
seating in the cylinder head, and dress with
dressing tool 380000834 (5).

6- 62720 -- 09 -- 2006

5
25346

177

97

SECTION 10 -- ENGINE -- CHAPTER 1

8. Fit guide bush 380000830 (10) fig.179 in the new
sleeve (12), securing it in position by turning the
ring nut (9) clockwise. Insert reamer (7)
380000831 in guide bush (10) and ream the lower part of the sleeve.
9. Remove the reamer (7) fig. 179 and back--off the
ring nut (9) by about 10 mm (0.0328 in.).
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 turning the ring nut (9) clockwise.
12. Work 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.
Cylinder head bolts (2, fig. 3 and 5)
If the bolts are to be re--used, check that diameter d
(measured in area a, as shown in fig. 178) is greater
than 11.5 mm (0.0377 in.). If not, replace the bolts.
25343

178

7
2

4
3

12

10

11

25348

Disassembly, removal of residue, installation and reaming

of injector sleeve in cylinder head using tool kit 380000246.
1, 2, and 11. Injector sleeve extractor 380000832.
3. M8 x 1.25 retaining nuts.
4. Waste removal tool 380000370.
5. Injector sleeve dressing tool 380000834.

6.
7.
8.
9.
10.
12.

179

O--ring seals.
Reamer 380000831.
Cutter 380000833.
Ring nut.
Guide bush 380000830.
Injector sleeve.

6- 62720 -- 09 -- 2006

98

SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS -ROTATING

COUNTERWEIGHT
DYNAMIC
BALANCER

WARNING
Handle all parts carefully. Do not put your hands or
fingers between parts. Wear suitable safety clothing,
safety goggles, gloves and footwear
Clean all parts carefully before proceeding with the
operations described below.
Check component wear and replace any defective
parts.
If the bushings of the counterweights are to be
replaced, pre--heat the counterweights in oil to a
temperature of 140 to 160 C (284 to 320 F) (or dip
the bushings in nitrogen) before shrink--fitting in their
bores.
Ream the new bushings after fitting using a reamer
with expanding cutters to the inside diameter
specified in the table on page 21.

28
27
26
25
24
22605

23 22 21 20 19 18 17 16 15 14 13 12

11

10

Cross--sectional view of rotating counterweight dynamic balancer.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Thrust washers.
Circlip.
Bushing lubrication tube.
Rotation shaft for counterweight (8).
Retaining spring pin for shaft (4).
Carrier for counterweight drive gear (13).
Thrust washer.
Counterweights.
Counterweight intermediate gear.
Circlip.
Bolts securing balancer housing to sump.
Dynamic balancer housing.
Counterweight drive gear.
Mesh filter.

6- 62720 -- 09 -- 2006

15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.

Mesh filter retaining bolt.

Bushing.
Sleeve coupling.
Circlip.
Thrust washer.
Carrier for gear (22).
Thrust washer.
Drive box gear for dynamic balancer.
Cover.
O--ring seal.
Circlip.
Intermediate gear.
Rotation shaft for intermediate gear (26).
Bushing.

180

99

SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS -LUBRICATION SYSTEM
WARNING
Handle all parts carefully. Do not put your hands or
fingers between parts. Wear suitable safety clothing,
safety goggles, gloves and footwear.

1
2

Clean all parts carefully before proceeding with the

operations described below.

OIL PUMP -- Overhaul

To access the oil pump, remove the sump pan.

When servicing the pump, check component wear
against dimensions specified in the table.

In case of replacement, note that the drive shaft (3)

and drive gear are supplied ready assembled, with
the gear hot shrink--fitted on the shaft.
25354

Cross--sectional view of engine lubrication oil

pump models JX60 and JX80 Models
1. External drive gear.
2. Bushing.
3. Drive shaft and gear.
4. Driven shaft and gear.
5. Pressure relief valve.

181

1
2

Cross--sectional view of engine lubrication oil

pump models JX90 and JX95 Models
1. Pressure relief valve.
2. Spring.
3. Pump housing.
4. Internal gears.

26109

182
Cross--sectional view of engine lubrication oil
pump models JX70 Model
1. Pump housing.
2. Internal gears.

MIG0497A

183
6- 62720 -- 09 -- 2006

100

SECTION 10 -- ENGINE -- CHAPTER 1

OIL FILTER -- Replacement

The oil filter (3) figs. 7 and 8 is of the full--flow, integral

paper cartridge type, and is installed in the pump
delivery line.
Should the filter become clogged, the safety valve (2)
will open to allow the oil to by--pass the filter, thus
ensuring that the engine continues to be lubricated,
although with unfiltered oil.

CHECKS, MEASUREMENTS AND REPAIRS -COOLING SYSTEM

Clean all parts carefully before proceeding with the

operations described below.

The cooling system is filled with a permanent coolant

mixture consisting of water and AKCELA
PREMIUM ANTIFREEZE antifreeze (up to 50% in
volume). This mixture prevents freezing down to the
following temperatures:

Replace the cartridge periodically (every 400

operating hours), remembering to:
oil the outer part of the seal in contact with the
mounting on the crankcase;
screw on the new cartridge until the seal is up
against the mounting;

Degrees C (F)

--8
(17.6)

--15
(5)

--25
(--13)

--35
(--31)

% in volume of
AKCELA
PREMIUM
ANTIFREEZE

20

30

40

50

tighten the cartridge, by hand only, through a

further 3/4 turn.
This mixture also has anti--oxidant, anti--corrosion,
anti--foaming and anti--scaling properties to ensure
long--term protection of the cooling system.
The same mixture can be kept in the cooling system
for a maximum of 2 years or 1600 operating hours,
whichever comes sooner; after which it must be
changed.
LOW OIL PRESSURE INDICATOR -- Functional
checks
The indicator consists of a control switch (4) figs. 7
and 8 and a red warning lamp in the instrument panel,
which illuminates in the following conditions:
low oil pressure (the warning lamp also
illuminates in normal conditions, with no faults
present, when the engine is hot and idling at low
speed);
control switch malfunction.
If the red lamp fails to illuminate when the engine is
stopped and the ignition switch is turned to the power
on position, the possible causes are:
blown fuse;
blown lamp;
interruption in wire to the control switch.

RADIATORS -- Flushing and checks

Two valves are built into the radiator cap, one
compression valve and one depression valve. Check
periodically that they are working correctly.
When overhauling, remove deposits of lime scale in
the radiator by means of a solution of water and
de--scaling agent in the proportions shown on the
container.
It is never advisable to limit flushing to the radiator
only -- always extend it to the entire cooling circuit
and top up the engine with the solution referred to
above.
Run the engine for about an hour. With the engine off,
drain the solution through the drain plug aperture.
In the event of leakage, the radiator is checked by
immersing it in a tank of water at a temperature of
20--40 C (68--104 F), introducing air into the
radiator at a pressure of 0.98 bar (14.1 psi) for
approximately two minutes (repeat the test at least
three times).

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

101

COOLANT THERMOMETER -- Testing

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

THERMOSTAT -- Replacement
The thermostat (1), fig. 9 is fitted in the cylinder head
coolant outlet union. The thermostat cannot be
adjusted and therefore must be replaced if does not
meet the temperature specifications in the table on
page 4.

COOLANT PUMP AND ALTERNATOR DRIVE

BELT -- Tension adjustment
(Operation 10 414 10).
The fan/coolant pump/alternator drive belt is
tensioned correctly when it deflects 10 to 11 mm
(0.3937 to 0.4331 in.) when a force of 78 to 98 N
(17.64 to 22.05 lb) is applied at the mid--point of the
run between the alternator and coolant pump
pulleys.

1. Check the tension using the belt tension tester

296118. Adjust tension if necessary as follows:

2. Slacken the nut (1) securing the alternator to the

tensioner bracket;

3. Move the alternator to achieve the required belt

tension and lock the nut (1).

NOTE: When fitting a new belt, check the tension

again after one hour of running.

22631

184
6- 62720 -- 09 -- 2006

102

SECTION 10 -- ENGINE -- CHAPTER 1

RADIATOR
Removal -- Installation (Operation 10 406 10)

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

1. Remove the exhaust pipe and open the bonnet.

2. Disconnect the battery negative cable.
3. Remove the left and right--hand safety guards
(1) from around the fan.

25028

185
4. Remove the hose clamp, detach the bottom radiator hose (1) and drain off the coolant.

25124

186
5. Unscrew the front axle earth cable fixing bolt (1).
6. Disconnect electrical leads from the horn.

1
TRE0035A

187
6- 62720 -- 09 -- 2006

103

SECTION 10 -- ENGINE -- CHAPTER 1

7. Disconnect electrical leads from air filter
restriction sensor (1).

1
TRE0620A

188
8. Remove the clamp (1) on the inlet manifold hose.

189
9. Remove the clamp (1) on the air filter hose.

1
25129

190
10. Remove the air filter restriction sensor (1) and recover the pipe.

25129

191
6- 62720 -- 09 -- 2006

104

SECTION 10 -- ENGINE -- CHAPTER 1

11. Unscrew the clamp and disconnect the pipe (1)

connecting the air filter to the exhaust aspirator.

25131

192
12. Unscrew the hose clamp (1) and remove the top
radiator hose.

TRE0619A
TRE0613A

193
13. Unscrew the clamp and remove the pipe (1) from
the radiator cap.

25133

194
14. Unscrew the two bolts (1) securing the radiator
to the front axle support and remove the bolts,
rubber mountings and spacers.

25134

195
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

105

15. Remove the radiator (1) and the upper rubber

mountings.

1
To refit the radiator proceed as follows:
Replace the radiator and secure with the two
bolts.
Refit the two rubber hoses to the coolant pump
and the thermostat housing. Reconnect the
pipe to the radiator cap.
Reconnect the bonnet stay bracket to the bracket mounted on the radiator and replace the retaining bolts.
Refit the hose to the exhaust aspirator.
Refit the hose connecting the air cleaner to the
inlet manifold. Refit the air filter clogging sensor.
Reconnect the electrical leads to the horn, air
filter restriction sensor and the front axle earth
lead.
Refit the two wire mesh guards around the fan.
Fill the radiator with coolant.
Reconnect the battery negative lead; close the
bonnet.

25135

196

6- 62720 -- 09 -- 2006

106

SECTION 10 -- ENGINE -- CHAPTER 1

CRANKSHAFT FRONT OIL SEAL

Removal/installation (Operation 10 102 70)

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

1. Remove the exhaust pipe and open the bonnet.

2. Disconnect the battery negative cable.
3. Remove the left and right--hand wire mesh
guards (1) from around the fan.

25028

197
4. Remove the hose clamp, detach the bottom
hose (1) and drain off the coolant.

25124

198
5. Unscrew the front axle earth cable fixing bolt (1).
6. Disconnect electrical leads from the horn.

1
TRE0035A

199
6- 62720 -- 09 -- 2006

107

SECTION 10 -- ENGINE -- CHAPTER 1

7. Disconnect electrical leads from air filter restriction sensor (1).

1
TRE0620A

200
8. Remove the clamp (1) on the inlet manifold hose.

201
9. Remove the clamp (1) on the air filter hose.

1
TRE0620B

202
10. Remove the air filter restriction sensor (1) and
pipe.

TRE0620B

203
6- 62720 -- 09 -- 2006

108

SECTION 10 -- ENGINE -- CHAPTER 1

11. Unscrew the clamp and disconnect the pipe (1)

connecting the air filter to the exhaust aspirator.

25131

204
12. Unscrew the hose clamp remove the top radiator
hose (1).

TRE0619A

205
13. Unscrew the clamp and remove the pipe (1) from
the radiator cap.

25133

206
14. Unscrew the two bolts (1) securing the radiator
to the front axle support and remove the bolts,
rubber mountings and spacers.

25134

207
6- 62720 -- 09 -- 2006

109

SECTION 10 -- ENGINE -- CHAPTER 1

15. Remove the radiator (1) and the upper rubber
mountings.

25135

208
16. Loosen the alternator pivot bolt.

25136

209
17. Loosen the belt tension adjuster bolt (1) and
remove the belt.

25137

210
18. Remove the radiator fan (1).

1
25138

211
6- 62720 -- 09 -- 2006

110

SECTION 10 -- ENGINE -- CHAPTER 1

19. Unscrew the retaining bolts (1) and remove the

crankshaft pulley.

25139

212

20. Straighten the tab on the lock washer, hold the

crankshaft against rotation and unscrew nut (1).

25140

213

21. Remove the pulley hub from the crankshaft

using tool 380000226 (1) and retrieve the woodruff key.

25141

214

6- 62720 -- 09 -- 2006

111

SECTION 10 -- ENGINE -- CHAPTER 1

22. Remove the oil seal (1) from it seat.

To install the front oil seal, proceed as follows:

Install the oil seal.
Refit the crankshaft hub and retaining nut; bend
tab over on lock washer.
Refit fan.
Refit the drive belt, adjust tension and tighten
alternator bolts.
Replace the radiator and secure with the two
bolts.
Refit the two rubber hoses to the coolant pump
and the thermostat housing.
Reconnect the pipe to the radiator cap.
Reconnect the bonnet stay bracket to the
bracket mounted on the radiator and replace the
retaining bolts.
Refit the hose to the exhaust aspirator.
Refit the hose connecting the air cleaner to the
inlet manifold. Refit the air filter restriction
sensor.
Refit the two wire mesh guards around the fan.
Fill the radiator with coolant.
Reconnect the battery negative lead; close the
bonnet.

25142

1
215

6- 62720 -- 09 -- 2006

112

SECTION 10 -- ENGINE -- CHAPTER 1

COOLANT PUMP
Removal--Installation (Operation 10 402 10)

WARNING

Always use suitable tools to align holes in parts.

NEVER USE YOUR FINGERS OR HANDS.

1. Remove the exhaust pipe and open the bonnet.

2. Disconnect the battery negative cable.
3. Remove the wire mesh guards (1) from the left
and right--hand sides of the fan.

25028

216
4. Remove the hose clamp, detach the bottom
radiator hose (1) and drain off the coolant.

25124

217
5. Remove the fan shroud (1) retaining bolts.

25143

218
6. Remove the two strips (1) from the sides of the
radiator.

25144

219
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

113

7. Move the fan shroud towards the engine.

8. Unscrew the three bolts securing the fan to the
coolant pump shaft. Remove the fan and the fan
cowling.

25145

220
9. Loosen the alternator pivot bolt (2).
10. Loosen the belt tension adjustment bolt (1).

1
2

25146

221
11. Remove the coolant pump pulley (1).

25147

222
12. Loosen the hose clamp (1) and detach the hose
from the coolant pump.

25148

223
6- 62720 -- 09 -- 2006

114

SECTION 10 -- ENGINE -- CHAPTER 1

13. Unscrew the belt tension adjustment arm

retaining nut (1) and move the alternator
outward.

25149

224
14. Remove pump connection pipe (1) to gain
access to the coolant pump retaining bolt (2).

25150

225
15. Unscrew the four bolts (1) fig. 226 securing the
coolant pump to its mounting.
16. Disconnect the hose from the coolant pump to
the thermostat housing, then remove the pump
(1) fig. 227.
To refit the coolant pump proceed as follows:
Refit the coolant pump. Take care not to lose the
seals on the upright hose connecting the pump
to the thermostat body.
Refit the connection pipe to the pump, and replace the two retaining bolts.
Refit the coolant pump pulley and the fan. Refit
the fan shroud and the two vertical side strips to
the radiator. Fix the belt tension adjustment arm.
Tighten the alternator pivot bolt.
Refit the bottom radiator hose to the connection
pipe on the coolant pump and the radiator.
Refit the right--hand wire mesh guard.
Refit the left--hand wire mesh guard.
Fill the cooling system from the radiator cap.
Reconnect the negative battery lead and refit the
exhaust pipe.

25151

226

25152

227
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

COOLING SYSTEM THERMOSTAT
Removal--Installation
(Operation 10 402 30)

115

WARNING
Always use suitable tools to align holes in parts.
NEVER USE YOUR FINGERS OR HANDS.
1. Disconnect the battery negative cable.
2. Remove the exhaust pipe, attach lifting chains to
the bonnet (1) and attach the chains to the hoist.

228
3. Disconnect the electrical leads (1) from headlamps
(2).

1
2

24873

229
4. Detach the gas struts (1) from the bonnet.
1

TRE0603A

230
5. Remove the four bonnet hinge bolts (1) and lift
the bonnet clear.
1

TRE0604A

231
6- 62720 -- 09 -- 2006

116

SECTION 10 -- ENGINE -- CHAPTER 1

6. Drain the cooling system from the drain plug on

the engine block.

24804

232
7. Remove the wire mesh guard (1) from the right-hand side of the radiator.

25028

233
8. Unscrew the hose clamp and disconnect the
hose (1) connecting the radiator to the
thermostat housing.

TRE0613B

234
9. Remove the thermostat housing cover screws
(1).

25156

235
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

117

10. Lever the cover (1) off the housing using a

screwdriver and remove the cover.

25157

236
11. Remove the thermostat valve (1).

1
25158

237
To refit the thermostat proceed as follows:
Fit the thermostat in its housing and locate the
gasket. Refit the cover to the housing.
Connect the top radiator hose to the thermostat
housing and secure with a hose clamp.
Refit the bonnet stay.
Refit the right--hand wire guard to the fan.
Refit the bonnet.
Fill the cooling system. Top up as necessary.
Reconnect the battery negative lead. Close the
bonnet and refit the exhaust pipe.

6- 62720 -- 09 -- 2006

118

SECTION 10 -- ENGINE -- CHAPTER 1

Op. 10 246 14
BOSCH INJECTION PUMP Removal--Installation, timing and air bleeding

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

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

Proceed as follows:
1. Raise the bonnet.
2. Unscrew the retaining bolts and take off the injection pump gearbox cover (2); if there is an air-conditioning system compressor, remove the
bracket (1) supporting the compressor.

27754

238

3. Unscrew and remove the fuel filter.

4. Remove the flywheel inspection window cover
(1) and the tappet cover.
5. Rotate the crankshaft to bring cylinder no. 1 to
T.D.C. and make sure the valves are closed
(compression stroke).

25704

239
6. Disconnect the throttle control cable (1) from the
lever on the injection pump, the engine cut--out
electromagnet connection and the connection of
the thermometric circuit breaker cutting out starting advance according to temperature (KSB).

27756

240
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

119

7. Unscrew the unions of the fuel supply lines (1)

from the injection pump, from the fuel return pipe
(2) and from the pump fuel supply line (3).
8. Disconnect the L.D.A. device connecting pipe to
the inlet manifold (only JX70 and JX95 models).

27757

241
9. Unscrew the injection pump locknut on the relative gearing (1).

27759

242
10. Using tool 380000322 (1) remove the injection
pump from the gearing and recover the pump.

27760

243
11. Unscrew the bolts (1) securing the injection
pump.

27758

244

6- 62720 -- 09 -- 2006

120

SECTION 10 -- ENGINE -- CHAPTER 1

12. To refit the injection pump, proceed as follows.

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

Respect the tightening torques prescribed on

page 24.

--

Check that cylinder no. 1 is at T.D.C. and the

valves are closed (compression stroke).

--

Position the injection pump in its seat and secure

it with the bolts, checking they are in the middle
of the slot.

--

Lock the injection pump drive gear with the nut

tightened to a torque of 90 Nm, making sure the
crankshaft does not turn.

--

Loosen the screw stopping the injection pump

from turning. Insert the relevant spacer and
tighten the screw back. In these conditions, the
pump spindle can turn freely.

--

Refit the injection pump drive gear box access

cover.

--

Assemble the LDA device connection pipe to the

inlet manifold (JX70 and JX95 models only).

--

Connect the fuel supply and return lines to the injection pump.

--

Connect the engine cut--out electromagnet cable

and the cable of the thermometric circuit breaker
cutting out starting advance according to temperature (KSB).

--

Connect the delivery pipes to the injectors, to the

injection pump.

--

Connect the throttle lead to the injection pump.

--

Fit the fuel filter.

--

Close the bonnet.

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

121

BOSCH INJECTION PUMP

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

245
2. Make sure that the KSB fork (1) is free to move.

MIG0498A

246
3. Unscrew the unions of the fuel supply lines (1),
detaching them from the injection pump.
If necessary, disconnect the injection pump supply and return lines (2 and 3) and the LDA/intake
manifold connecting pipe.

27757

247
4. Remove the flywheel inspection window cover
(1) and the tappet cover.
5. Rotate the crankshaft to bring cylinder no. 1 at
T.D.C. and make sure the valves are closed
(compression stroke).

25704

248

6- 62720 -- 09 -- 2006

122

SECTION 10 -- ENGINE -- CHAPTER 1

6. Check through the inspection window that the

pointer is aligned with reference marks 4_ for
mod. JX60, 0_ for mod. JX70 and JX95, or 1_
for mod. JX80 and JX90.

26107

249
7. With the injection pump in its seat, remove the
plug (1) on the pump cover.
8. Fit dial gauge 380000228 (1) fig. 251 and the associated tool 380000229 (2), pre--loading the
shaft by approximately 2.5 mm (0.0984 in.).
9. Turn the flywheel slowly backwards, so as to
bring the plunger to B.D.C. at the start of the delivery stroke (the point at which the dial gauge needle stops falling).

25711

250
10. Zero--set the dial gauge and slowly turn the
flywheel clockwise (as viewed from the fan end
of the engine) until the pointer lines up with
reference marks 4_ for JX60 models, 0_ for JX70
and JX95 models, or 1_ for JX80 and JX90
models.
11. Check on the dial gauge that the plunger has
completed a stroke of 1 mm (0.0394 in.) up to this
point, if not, slacken off the pump mounting bolts.
If the plunger stroke is checked with the pointer
at the T.D.C. there must be a stroke of: 1.47 mm
(0.0578 in.) for mod. JX60 or 1.00 mm (0.0394
in.) for mod. JX70 and JX95, or 1.12 mm
(0.0440 in.) for mod. JX80 and JX90.
12. Turn the pump anti--clockwise if the plunger has
completed a shorter stroke and clockwise if the
stroke is longer, repeating the test until the correct stroke is obtained.
13. Having obtained the correct plunger stroke, fix
the pump in position by tightening the mounting
nuts to the torque specified on page 24.
14. Remove the dial gauge 380000228 (1) and relative tool 380000229 (2) and replace the plug and
tighten to a torque of 8 -- 10 Nm (5.9005 -- 7.3756
ft lb).
15. Disconnect the KSB external power supply unit.
16. Refit other parts in the reverse of the dismantling
order.

6- 62720 -- 09 -- 2006

25712

251

SECTION 10 -- ENGINE -- CHAPTER 1

123

BOSCH INJECTION PUMP

Air bleeding
1. Unscrew the plug (1) on the filter.

252
2. Operate the priming lever (1) fig. 253 on the fuel
supply pump until the fuel coming out of the filter
orifice is free of bubbles, then replace and tighten
plug (1) fig. 252.

25199

253
3. Slacken the fuel line unions (1) on the injectors,
start the engine and then re--tighten the union (1)
when the fuel flows out free of bubbles.

25200

254

6- 62720 -- 09 -- 2006

124

SECTION 10 -- ENGINE -- CHAPTER 1

FUEL INJECTORS
Removal--Installation (Operation 10 218 30)

WARNING
Always use suitable tools to align holes in parts.
NEVER USE YOUR FINGERS OR HANDS.

1. Disconnect the battery negative cable.

2. Attach lifting chains to the bonnet (1) and then
attach the chains to the hoist.
24872

255
3. Disconnect the electrical leads (1) from headlamps (2).

1
2

24873

256
4. Detach the gas struts (1) from the bonnet.

TRE0603A

257
5. Remove the four bonnet hinge bolts (1) and lift
the bonnet clear.
1

TRE0604A

258
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

6. Unscrew the fuel leak--off pipe union (1) on the
injector.

125

25301

259
7. Unscrew the union (1) of the high--pressure fuel
line on the injector.

25302

1
260

8. Unscrew the two retaining nuts (1) and withdraw

the injector.

To refit the injector, proceed as follows:

Insert the injector into its seat.
Replace and tighten the two retaining nuts in two
stages. 1st stage: tighten nuts to 10 Nm (1 kgm)
2nd stage: tighten nuts to 25 Nm (2.6 kgm).
Reconnect the fuel leak--off pipe union.
Reconnect the high--pressure fuel line union.
Replace the bonnet.
Reconnect the battery negative lead.

25303

261

6- 62720 -- 09 -- 2006

126

SECTION 10 -- ENGINE -- CHAPTER 1

ADJUSTING VALVE CLEARANCE

(Operation 10 106 12)

1
WARNING
Always use suitable tools to align holes in parts.
NEVER USE YOUR FINGERS OR HANDS.
1. Disconnect the battery negative cable.
2. Attach lifting chains to the bonnet (1) and then attach them to the hoist.
24872

262
3. Disconnect the electrical leads
headlamps (2).

(1) from

1
2

24873

263
4. Detach the gas struts (1) from the bonnet.

TRE0603A

264
5. Remove the four bonnet hinge bolts (1) and lift
the bonnet clear.
1

TRE0604A

265
6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

127

6. Undo the hose clamp and detach the hose from

the silencer ejector.
7. Unscrew the two screws securing the silencer
front support.
8. Unscrew the retaining nuts securing the silencer
to the exhaust manifold and remove the silencer.

TRE0618B

266
9. Unscrew the four rocker cover nuts (1) and
remove cover.

25305

267
10. Remove the flywheel inspection window cover
(1).

25190

268
11. Adjust the clearance between the valves and the
rocker arms using a feeler gauge, wrench (1) and
the special tool 291883 (2).
NOTE: Before proceeding with adjustment
operations, position the valves as described on the
following page.

1
2

25306

269
6- 62720 -- 09 -- 2006

128

SECTION 10 -- ENGINE -- CHAPTER 1

To adjust valve clearances on the 3--cylinder JX60

and JX70 engines, proceed as follows:
Turn the crankshaft so that the inlet and exhaust
valves of cylinder no. 1 are balanced (start of
induction stroke). In this position the pointer will
be aligned with the reference mark PMS 1
(TDC 1) on the flywheel.
Rotate the crankshaft through a full revolution,
returning to TDC 1, then check that the valve
clearances correspond with the values specified
in the table on page 4.
Repeat this operation for the other valve pairs.
Note that the TDC positions of cylinders 2 and 3
are not marked on the flywheel.
To check valve clearances on 4--cylinder JX80, JX90
and JX95 models, proceed as follows:
Turn the crankshaft so that the inlet and exhaust
valves of cylinder no. 1 are balanced (start of induction stroke). In this position the pointer will be
aligned with the reference mark PMS 1 (TDC 1)
on the flywheel.
Check that the clearance between valves and
rocker arms on cylinder no. 4 corresponds with
the values specified in the table on page 4.
Rotate the crankshaft through 360_ and check
valve clearances on the opposing cylinder
(No. 1).
Repeat this operation for the other valve pairs.
Note that the opposing cylinders are 1--4 and
2--3.
To reassemble proceed as follows:
Refit the rocker cover.
Refit the flywheel inspection window cover.
Refit the exhaust silencer.
Refit the bonnet.
Reconnect the battery negative lead.

6- 62720 -- 09 -- 2006

SECTION 10 -- ENGINE -- CHAPTER 1

WATER PUMP -- Overhaul
(Operation 10 402 28)

129

WARNING
Use suitable tools for aligning holes. NEVER USE
FINGERS OR HANDS.

4
5

NOTE: The bearing (9) forms a single piece with the

control shaft (10). It is a sealed unit and requires no
lubrication during running.

6
10

14262

Overhaul the pump as follows:

270

Remove the cover (4) fig. 270, and the shaft

screw (2) retaining the shaft (10) and bearing (9).
Gently tap the end of the shaft (10) fig. 270 on the
rotor side (5) to break the film of oxide between
the shaft and the rotor. Install the extractor
291182 (1) fig. 271 and take out the rotor.

Remove the front sealing bushing (7) fig. 270.

Use a punch to extract from the pump housing
(6) fig. 270 the shaft (10) complete with bearing
(9) and the fan hub (1).
5976

271
NOTE: Remove the seal (8) fig. 270 only when it
needs to be changed.

1
Check components for wear, and change any that
are in poor condition.
Refit the parts, proceeding as follows:
Fit the shaft (10) fig. 270 complete with bearing
(9) and hub (1) on the pump housing (6) and secure it with the retaining screw (2), having first
coated it with LOCTITE 242.
If changing the seal (8) fig. 270, fit the seal into
the seat using tool 293280 (1) fig. 272.

21662

272

Heat the rotor (1) fig. 270 in an air oven, until it

reach a temperature of 130--150C higher than
the shaft (2).

Place the rotor (1) on the shaft (2), easing it onto

the end so as not to damage the bearing, until
you obtain the operating clearance of
G = 0.5--0.7 mm (see fig. 270).
Fit the seal (3) fig. 270 and the cover (4),
securing it with the relevant screws.

2
21663

273
6- 62720 -- 09 -- 2006

130

SECTION 10 -- ENGINE -- CHAPTER 1

5) Turn the engine over a few times with the starter
motor in order to expel any carbon residue.

ENGINE
Compression test (Operation 10 001 30)
In case of poor engine performance, in addition to
checking the fuel injection system (injector nozzles
and injection pump), also test the compression on
each cylinder.

DANGER
Do not use matches, lighters, blow torches or any
naked flame as a source of light when inspecting the
engine due to the presence of inflammable fluids and
vapour.

6) Fit the dummy injector 293862 in place of the

injector removed previously, inserting the copper
sealing washer.
7) Connect the compression tester 291309/1 and
take readings while turning the engine over with the
starter motor.
On engines in perfect working order, with the sump
oil at approx. 40_C, at sea level (760 mm mercury)
and at an engine speed of 200 -- 280 rev/min, the
compression should be 25.5 -- 27.5 bar
(26 to 28 kg/cm2).
8) Test the compression on the other cylinders,
repeating steps 4, 5, 6 and 7, bearing in mind that:

Compression ratio
The compression ratio is a measure of the quantity
of air drawn into the cylinder and provides an
indication of the efficiency of the sealing elements in
the cylinder (piston rings and valves).
Uniform compression in all the cylinders ensures that
they all perform an equal amount of work, provided
of course that each cylinder is injected with the same
quantity of fuel at the right time.

The minimum permissible compression on a used

engine is 21.6 bar (22 kg/cm2).
The maximum permissible compression difference
between cylinders is 3 bar (3 kg/cm2).
Every 100 metres above sea level corresponds to a
reduction in compression by about 1%.

Low compression not only reduces engine

performance, it also causes incomplete fuel
combustion due to the lack of available combustion
air.

CONSIDERATIONS:

The engine therefore gives poor performance with

excessive fuel consumption, and consequently
exhaust smoke and restriction of the exhaust
passages.

Although high compression is important, it is more

important as regards smooth running that the
compression is the same in all cylinders.

As the compression ratio also varies with the

temperature of the engine (cold engines produce
lower compression values than hot engines) the
compression should only be tested when the engine
is at normal operating temperature.
Compression should be tested using
compression test kit 291309 as follows:

the

1) Run the engine until it reaches normal operating

temperature.
2) Switch off the engine.
3) Disconnect the lead from the engine stop solenoid
on the injection pump in order to close the solenoid
valve and block the flow of fuel to the injectors.
4) Remove the injector from the cylinder to be tested.

6- 62720 -- 09 -- 2006

Uniform compression

Low compression readings

If very low compression readings are obtained on
one cylinder it is advisable to repeat the test.
Before testing this time, pour about a spoonful of
engine oil into the cylinder through the injector bore.
Turn the engine over a few times to distribute the oil
evenly over the cylinder walls, and then repeat the
test.
If the second test readings are significantly higher,
suspect worn piston rings, out--of--round or damaged
pistons or liners.
If the second test readings are not higher, the
problem will be the valves.
On the other hand, if the second test reading shows
only a slight improvement, the problem will be due to
both the valves and the rings.

SECTION 18 CLUTCH CHAPTER 1

SECTION 18 CLUTCH
Chapter 1 Clutch

CONTENTS
Section

Description

18 000

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Crosssectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Minimum permissible dimensions after refacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Adjustment of the main and PTO clutch control linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

18 110 10

18 100 40

Page

GENERAL SPECIFICATIONS, CLUTCH 11/11

(Models JX60, JX70, JX80 and JX90)

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dual clutch consisting of two

single dry plate clutches
control: pedal operation for
main clutch and hand lever
for power takeoff clutch

Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . . . .

single Belleville spring

Driven plate lining material for main transmission clutch (11) . . . .

Models JX60 and JX70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models JX80 and JX90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driven plate lining material for PTO clutch (11)

Organic agglomerate
cerametallic

Models JX60, JX70, JX80 and JX90 . . . . . . . . . . . . . . . . . . . . . . . . . .

Organic agglomerate

Driven plate thickness:

. main clutch (9, fig. 1)
.
VALEO
.
Organic agglomerate and cerametallic . . . . . . . . . . . . . . . . . . . .

mm
(in.)

10.2 to 10.8
(0.4016 to 0.4252)

mm
(in.)

7.3 to 7.9
(0.2874 0.3110)

See pages 18

mm
(in.)
mm
(in.)

Release lever coplanarity adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

0.050 to 0.151
(0.0020 to 0.0059)
0.050 to 0.151
(0.0020 to 0.0059)
See page 19

Clutch control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See page 21

. PTO clutch (11, fig. 1)

.
VALEO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance between main clutch release sleeve and related seat . .
Clearance between PTO clutch release sleeve and related seat . .

662720 09 2006

SECTION 18 CLUTCH CHAPTER 1

GENERAL SPECIFICATIONS, CLUTCH 11/11
(Model JX95)

Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dual clutch consisting of two

single dry plate clutches
control: pedal operation for
main clutch and hand lever
for power takeoff clutch

Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . . . .

single Belleville spring

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driven plate lining material for main transmission clutch (12) . . . . .

Model JX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cerametallic

Driven plate lining material for PTO clutch (12)

Models JX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Organic agglomerate

Driven plate thickness:

. main clutch (9, fig. 1)
.
VALEO
.
Organic agglomerate and cerametallic . . . . . . . . . . . . . . . . . . . .
. PTO clutch (11, fig. 1)
.
VALEO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

10.2 to 10.8
(0.4016 to 0.4252)

mm
(in.)

7.3 to 7.9
(0.2874 0.3110)

See pages 18

mm
(in.)
mm
(in.)

Release lever coplanarity adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

0.050 to 0.151
(0.0020 to 0.0059)
0.050 to 0.151
(0.0020 to 0.0059)
See page 19

Clutch control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See page 21

Clearance between main clutch release sleeve and related seat . .

Clearance between PTO clutch release sleeve and related seat . .

TIGHTENING TORQUES

Tightening torque
PART

Thread
Nm

ft lb

Clutch/flywheel retaining bolts

mod. JX60, JX70, JX80 and JX90 . . . . . . . . . . . . . . . . . . . . . . .
mod. JX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 8 x 1.25
M 10 x 1.25

25
59

18.439
43.5162

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

662720 09 2006

SECTION 18 CLUTCH CHAPTER 1

380000236 Tractor disassembly stand.

380000612 11/11 clutch adjustment kit

(pin and gauge).

380000292 Dowel for centring and adjustment of 12/12 clutches.

380000293 12/12 Clutch adjustment

gauge.

293650 Clutch overhaul outfit.

380000458 Press for clutch lever release

test.

662720 09 2006

SECTION 18 CLUTCH CHAPTER 1

LONGITUDINAL SECTION OF CLUTCH VALEO

1
a .
b .
C2
C3
C6
D.

Main clutch with driven disc made of organic material.

Main clutch with driven disc made of cerametallic.
Bolts securing clutch casing to the engine.
Fork lever retaining bolts.
Nuts for sleeve studs.
Nominal distance of lever (3) from clutch contact surface on flywheel (mod. JX60, JX70, JX80 and JX90,
11/11 clutch 98 mm (3.8583 in.) mod. JX95 12/12
clutch 103 mm (4.0551 in.)).
D1 Nominal distance of lever (2) from clutch contact surface on flywheel (mod. JX60, JX70, JX80 and JX90,
11/11 clutch 123 mm (4.8425 in.) mod. JX95
12/12 clutch 137 mm (5.3937 in.)).
L1 Clearance between PTO release lever and related
thrust bearing 2 mm (0.0787 in.).
L2 Clearance between main clutch release lever and related thrust bearing 2.5 mm (0.0984 in.).
1.
2.
3.

Belleville spring.
PTO clutch release lever.
Main clutch release lever.

662720 09 2006

4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Main clutch release sleeve, complete with thrust

bearings.
PTO clutch release sleeve, complete with thrust
bearings.
Power takeoff clutch release lever adjustment tie
rod.
Power takeoff clutch release lever stop nut.
Power takeoff clutch plate.
Main transmission clutch plate.
Bearing on flywheel.
PTO clutch release sleeve control fork.
Main clutch release sleeve control fork.
Main clutch release lever adjuster lever.
Main clutch release lever adjuster screw.
Main clutch release lever adjuster nut.

WARNING: When refitting the clutch, check that the

clutch plates are positioned as in the drawing.
NOTE: When refitting, carefully clean and degrease
the mating surfaces X and apply sealing compound.

SECTION 18 CLUTCH CHAPTER 1

CLUTCH TROUBLESHOOTING
Problems
Clutch slips

Possible causes

Correction

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
parts which are worn up to or over the
sure plate and flywheel.
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
clutch housing and thoroughly clean
oil and grease.
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
lever.
distorted.
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
inside the clutch housing and
(8 and 9, page 4).
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
lubricate.
linkage.
3. Controls badly adjusted.

Clutch noisy when engaged 1. Thrust bearing worn.

and/or disengaged

Adjust controls (see page 21).

Replace bearing.

2. Friction disc (9, page 4) with Replace friction disc.

damaged hub springs or loose
hub rivets.
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.

662720 09 2006

SECTION 18 CLUTCH CHAPTER 1

CLUTCH
RemovalRefitting (Operation 18 110 10)
To access the clutch it is necessary to separate the
engine complete with the front axle from the
transmission.

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

ATTENTION
Always use suitable tools to align holes. NEVER
USE FINGERS OR HANDS.

Proceed as follows:
1. Disconnect the negative battery lead.
2. Drain off the oil from the gearbox/transmission
casing.

25621

2
3. Drain off the coolant from the engine cooling system.
4. Disconnect two flexible houses from the power
steering control cylinder and drain off the oil from
the steering system.
5. Remove the front ballast (1).

TRE0159A

662720 09 2006

SECTION 18 CLUTCH CHAPTER 1

6. To access the engine
opened.

the hood

must be

TRE0159A

4
7. Remove the electrical connections (1)

TRE185A

5
8. After draining off the oil from the power steering
tank, disconnect the oil pipes (1) from the
hydrostatic steering control valve unit.

TRE0028A

6
9. Disconnect the multimeter cable (1) from the engine and undo the mounting retaining bolt (2).

TRE0410A

7
662720 09 2006

SECTION 18 CLUTCH CHAPTER 1

10. Detach the throttle control spring (1) and remove

the throttle lever (2).

2
TRE0411A

8
11. After recovering the airconditioner gas
(HRC _ 134a) with the recovery and
recycling station 294048, disconnect the
pipes of the cab air conditioner (1).

25183

24892

9
12. Slacken the clamps (1) and disconnect the cab
heating pipes (2), being sure to mark them first.

25411

10
13. Remove the clamp (1) from around the pump
and delivery pipes.

25029

11
662720 09 2006

SECTION 18 CLUTCH CHAPTER 1

14. Disconnect the rubber connecting hose (1) of the

hydraulic pump .

TRE0184A

12
15. Disconnect the lift pump delivery line (1).

TRE0183A

13
16. Disconnect the fuel line (1) from the glow plug.

TRE0183A

14
17. Remove the front, centre and rear screws
securing the front axle prop shaft guard and
remove the guard (1).

25038

15
662720 09 2006

10

SECTION 18 CLUTCH CHAPTER 1

18. Remove circlip (2) and move sleeve (1) in the

direction shown by the arrow to disengage it from
the splined shaft of the front axle.

25039

16
19. Remove circlip (2) and move sleeve (1) in the
direction shown by the arrow to disengage it from
the splined shaft of the drive.

25040

17
20. Remove the retaining bolts of the central support
(1) of the prop shaft and recover the shaft
complete with support.

25041

18
21. Withdraw the pin securing the differential lock (1)
knob, remove the knob and remove the mat (2)
from the cab floor.
1

TRE0161A

19
662720 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.

1
TRE0413A

20
23. Unscrew the four lower bolts (1) securing the
engine to the transmission.

25049

21
24. Position two wedges (3) on the front axle to
prevent any movement of 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.

25050

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.

26. Interpose wooden blocks (1) between the stands

and the tractor, and turn the stand height
adjustment screws to bring the blocks (1) into
contact with the tractor.
25051

23
662720 09 2006

12

SECTION 18 CLUTCH CHAPTER 1

27. Position a fixed stand (1) under the draw bar

support and pull on the hand brake.

25052

24
28. Remove the spacer collar (1) between the
engine and the transmission (Model JX95).

25055

25
29. Using tool 380000612 (mod. JX60, JX70, JX80
and JX90) or with tool 380000292 (mod. JX95)
(2), unscrew the retaining bolts (1) and remove
the clutch.

25055

26

662720 09 2006

SECTION 18 CLUTCH CHAPTER 1

To reinstall the engine, proceed as follows:

Check condition of ball bearings pressed in flywheel;
replace in the event of excessive noise or binding.
To install a new bearing pack, lubricate with grease.

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
six bolts.
Adjust the coplanarity of the clutch release levers as
described on page 20.
Clean the spacer collar and the mating surfaces of
the clutch housing, and also scrape all residue of old
sealing compound from the mating surface of the engine.

13

Remove the stands of tool 380000236 from under

the engine and the gearbox/transmission and the
stand under the draw bar.
Refit the cab heater pipe union on the clutch/engine
spacer collar. Connect the flexible rubber hoses to
the union.
Connect the flexible power steering pipes of the
front axle and add oil to the system.
Connect the flexible pipe to the injector fuel leakoff
pipe.
Refit the multimeter and secure the sleeve with the
relative clamp.
Connect the compressor, condenser and filter/dryer
inside the cab by connecting the pipes

Spread LOCTITE compound on the mating surfaces

of the engine and spacer collar. Install the spacer collar on the stud bolts screwed on the engine.

Connect all the electrical connections.

Before connecting the transmission casing to the engine front axle assembly, grease the discs hubs.

Refit the 4WD propeller shaft and the relative guard.

Chock up the rear wheels with wooden wedges,

check that the hand brake is fully on and that the fixed and mobile stands are well positioned.

Fit and tighten the bolts securing the clutch housing

to the engine.

Connect the throttle cable to the injection pump.

Refit the front ballast and secure with the vertical

lock pin.

Fill the gearbox/transmission with oil.

Fill the engine cooling system with coolant.

Connect the battery negative lead.

Make sure that no electrical leads or cables are trapped between the two units.

Next rotate the crankshaft by turning the cooling fan,

so as to allow the sleeve to engage the splines on the
power takeoff shaft.

662720 09 2006

14

SECTION 18 CLUTCH CHAPTER 1

OVERHAUL
The clutch is removed, refitted and adjusted with the
universal outfit 293650.
Parts of the universal outfit 293650 Necessary
to adjust the VALEO clutch.
A. Plate 293332.
B. Central spacer
293728. 35mm (1.3779 in.) for 11/11 clutch
293729. 40mm (1.5748 in.) for 12/12 clutch
C. Gauge 293731.
D. Locknut 293730 for central spacer.
E. Side spacers 293726.
F. Studs 293725.
I. Blocks.
L. Handwheel 293739 securing the gauge.
M. Handwheels 293740 securing the side spacers.
N. Spacers for studs.

MDH1883A

27

Note Before fitting the clutch on the outfit 293650

it is advisable to remove the three bolts retaining the
flexible tabs that drive the PTO clutch pressure plate
ring from the supporting housing.

28

662720 09 2006

SECTION 18 CLUTCH CHAPTER 1

15

To fit the clutch on the universal outfit 293650

proceed as follows:
place the central spacer (B) on the plate (A) and
position it with the gauge bearing surface at a
height of:
132 mm (5.1968 in.) (12/12 clutches)
123 mm (4.8425 in.) (11/11 clutch)
and lock it at this height with the locknut (D);
measure the thickness (S) of the PTO driven disc
of the relevant clutch and place the adjustable
side spacers (E) on the circumference of 240 mm
positioning them with the upper face at a height
(h) given by:
h = RV + S + B
where:
B additional distance to lower the PTO release
levers by 9 mm so as to use the gauge 293731
(with a difference in height between the PTO release levers and the transmission release levers
of 25 mm (0.9842 in.)) to check the coplanarity
2.2 mm (0.0886 in.) for 12/12 clutches
(mod. JX95)
no increase (already using gauge 293731) for
11/11 clutches
(mod. JX60, JX70, JX80 and JX90)
RV flywheel external lowering distance
2 mm (0.0784 in.) for 11/11 clutches
(mod. JX60, JX70, JX80 and JX90)
0.5 mm (0.0197 in.) for 12/12 clutches
(mod. JX95)
S = measured thickness of the PTO driven disc;

then lock the adjustable side spacers (E) with the

relevant handwheels (M);
rest the clutch assembly (of the PTO driven disc)
with the PTO pressure plate on the plate and secure it with the three stud bolts (F, page 14),
equipped with blocks (I) and spacers (N) of the
necessary size.

29

662720 09 2006

16

SECTION 18 CLUTCH CHAPTER 1

Remove the nuts (7; page 4) for the PTO clutch release 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

ATTENTION
When removing, overhauling and then refitting the
clutch, pay special attention not to move the main
clutch and PTO clutch pressure plate ring driving
tables from their original assembly position on the
pressure plate rings.
Check for wear on the clutch driven discs and replace
them if the retaining rivets are worn down to or
approaching the friction material. Replace the disc
when the oil has soaked into the organic
agglomerate surfaces.
Check the friction surface conditions of the pressure
plates and the clutch casing.
If necessary, it is possible to reface them bearing in
mind that the dimensions (A, B, C and D) of the
refaced parts must not decrease beyond the limits
shown in the figures below, in which case it would be
necessary to replace the parts.
Proceed as follows:
reface the surfaces of the pressure plates;
replace damaged or worn discs;
reface the surface of the clutch housing.

662720 09 2006

SECTION 18 CLUTCH CHAPTER 1

17

Calculate the distance (D), removing material from

the bottom of the clutch housing, using the following
formula.
D = A + B + S1 + S2 + P + L
where:
A and B

= distances measured of the two

pressure plates after refacing;
S1 and S2 = measurements of the PTO and main
clutch plates:
L
= 2 mm (0.0784 in.) for 11/11 clutches
mod. JX60, JX70, JX80 and JX90
= 0.5 mm (0.0197 in.) for 12/12 clutch
mod. JX95
Lowering on the flywheel;
P
= 4.20 P 4.30 mm (0.1653 P 0.1693 in.)
for 11/11 clutch
mod. JX60, JX70, JX80 and JX90
= 4.30 P 4.40 mm (0.1693 P 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 of the pressure
plates.

MMH1885B

32

For 11/11 clutches, check that the distance (E) is

greater than the value given on page 18 fig. 34 and
restore it if necessary.
If required, pass the friction surface over the engine
flywheel, remembering to restore the external
lowering of the flywheel on completing this process.
Refit the parts of the clutch using the specific tools of
outfit 293650 and taking care to:
position the Belleville spring (1) correctly on the
main clutch pressure plate (3), making the
centring dowels (2) correspond with the
notches (4);

adjust the clutch as directed below.

Note When reassembling, tighten the six bolts

fastening the flexible tabs driving the main and PTO
clutch pressure plates to the supporting housing to
a torque of 1.5 Nm (2.0337 ft lb).
33

662720 09 2006

18

SECTION 18 CLUTCH CHAPTER 1

MINIMUM PERMISSIBLE DIMENSIONS

AFTER REFACING PARTS SUBJECT TO
WEAR FOR VALEO CLUTCHES
11/11 dual clutches
If it is necessary to reface the friction surface on the
flywheel, bear in mind that the maximum amount that
can be removed in relation to the nominal thickness
is 1 mm (0.0394 in.).
Once terminated, moreover, the external lowering
will need to be restored to 2 mm (0.0784 in.)
(see fig. 34).
11/11 dual clutch
mod. JX60, JX70, JX80, JX90
A. 12.50 mm (0.4921 in.)
B. 20.00 mm (0.7874 in.)
C. 18.00 mm (0.7087 in.)
D. 12.50 mm (0.4921 in.)
E. 2.50 mm (0.0984 in.)
1.

Engine flywheel.

2.

PTO clutch pressure plate.

3.

Main transmission clutch pressure plate.

4.

Supporting housing.

34

12/12 dual clutches

If it is necessary to reface the friction surface on the
flywheel, bear in mind that the maximum amount that
can be removed in relation to the nominal thickness
is 1 mm (0.0394 in.).
Once terminated, the external refacing will need to
be reset to 0.5 mm (0.0197 in.), as shown in figure 35 and 36.

0.5 mm

A. = 352 E8 mm (13.8582 in.)

B. = 313 mm (12.3228 in.)
C. = 73.5 mm (2.8937 in.)

26166

35

12/12 dual clutch

mod. JX95

A. 15.50 mm (0.6102 in.)

B. 21.50 mm (0.8464 in.)
C. 20.50 mm (0.4921 in.)
D. 12.50 mm (0.8071 in.)

1.

Engine flywheel.

2.

PTO clutch pressure plate.

3.

Main transmission clutch pressure plate.

4.

Supporting housing.

662720 09 2006

36

SECTION 18 CLUTCH CHAPTER 1

19

ADJUSTING THE VALEO CLUTCH

To adjust the clutch correctly it is necessary for the
release levers to be coplanar and set at the distances
(D and D1, page 4) in relation to the bearing surface
on the engine flywheel.
NOTE: For the 12/12 clutches the distance D1 is
reduced by 9 mm (0.3543 in.) (137 9 = 128 mm
(5.3937 0.3543 =5.0394 in.), see page 15.),
lowering distance of the point of contact with the
thrust bearing of the PTO release levers so as to use
the gauge 293731 where the difference between the
release levers is 25 mm (0.9842 in.).
The adjustment can be made indistinctly with the
clutch on the bench or fitted on the engine flywheel.
1. Adjustment with clutch on bench.
Set the clutch on the plate of the universal outfit
293650 and lock it using the parts as described
above for disassembly.
Fit the gauge (C) and lock it with the handwheel (L)
for the universal outfit 293650.

Screw in or unscrew the adjuster screws (2) of the

release levers for the main clutch (1) to obtain the
clearance (V1) between the ends of the gauge pins
(C) and the main clutch release levers. Then lock the
screws with the nuts (3).

C. Gauge.
L.

Handwheel 293739.

V1 = 0.1 mm (0.0039 in.) Clearance to obtain between

the ends of the gauge pins (C) and release levers (1)
for 11/11 clutch (mod. JX60, JX70, JX80, JX90) or:
= 0.1 mm (0.0039 in.) for 12/12 clutch (mod. JX95).
1.
2.
3.

Release levers.
Hex wrench.
Adjuster screw and locknut.

37

Screw in or unscrew the nuts (2) for the adjuster tie

rods of the release levers for the PTO clutch (1) to
obtain the clearance (V2) between the end of each
release lever and the face of the gauge (C).

C. Gauge.
L.

Handwheel 293739.

V2 = 0.1 mm (0.0039 in.) Clearance to obtain between

the gauge face (C) and release levers (1) for 11/11
clutch (mod. JX60, JX70, JX80, JX90) or:
0.1 mm (0.0039 in.) for 12/12 clutch (mod. JX95).
1.
2.

Release levers.
Adjuster nut.

38
662720 09 2006

20

SECTION 18 CLUTCH CHAPTER 1

After adjusting the clutch lever, remove the handwheel (L, page 14) for the universal outfit 293650. Fit
the press 380000458 (P) on the plate of the outfit, adjust the length of the screws (1) so they are coplanar
and rest on the release levers (3) of the PTO clutch
and use the press lever (P), as shown in the figure,
checking the PTO clutch gets released.
Then rest the screws (2) on the main clutch release
levers (4) and check that this clutch gets released.

39
1. Adjustment with clutch fitted on engine flywheel
Insert the pin of the adjustment kit (pin T1 with gauge
T2) 380000612 (11/11, mod. JX60, JX70, JX80 and
JX90) or 380000292 (T1, for 12/12 clutch, mod.
JX95) into the clutch driven disc shaft seats, making
sure the end makes contact with the bearing (10,
page 4) and press the relevant gauge against it
380000612 (T2, for 11/11 clutch, mod. JX60, JX70,
JX80 and JX90) or 380000293 (T2, for 12/12 clutch,
mod. JX95).

T1

T2

40

Then proceed as follows:

screw in or unscrew the main clutch release lever

adjuster screws so as to create a clearance between the end of the pins of the gauge (1) and the
main clutch release levers of:
0.1 mm (0.0039 in.) for 11/11 clutch

mod. JX60, JX70, JX80, JX90

8.1 mm (0.3189 in.) for 12/12 clutch

25366

mod. JX95
662720 09 2006

41

SECTION 18 CLUTCH CHAPTER 1

screw in or unscrew the PTO clutch release lever
adjuster screws so as to create a clearance between the end of the gauge face (1) and the PTO
clutch release levers (2) of:
0.1 mm (0.0039 in.) for 11/11 clutch
mod. JX60, JX70, JX80, JX90
8.1 mm (0.3189 in.) for 12/12 clutch
mod. JX95

21

25367

42
ADJUSTMENT OF THE MAIN
CONTROL LINKAGE (Op. 18.100.40)

CLUTCH
1

Check that pedal free travel before clutch release is

approximately 40 mm . When free travel is down to
25 mm , adjust clutch as follows:

TRE0048A

43

Back off locknut (1) and rotate sleeve (2) counterclockwise.

Tighten locknut (1) ;
Ensure that pedal free travel is 25 mm (0.9842in.).
1

TRE0044A

44
PTO CLUTCH LINKAGE ADJUSTMENT
The only clutch adjustment required is to check and, if
necessary, adjust the clutch pedal free travel. This is the
amount of pedal movement from fully released position
(B) to the point where resistance is first encountered.

The clutch free travel (C, fig. 46) must be 4.5 mm

(0.1772 in.). When this distance is down to 2.5 mm
(0.0984 in.), adjust the clutch as follows:

Move the PTO clutch lever (A) to position (B) (fully

lowered).
TRE0171A

45
662720 09 2006

22

SECTION 18 CLUTCH CHAPTER 1

Loosen the locknut (1) and remove the split pin (2).

Turn the sleeve (3) to lengthen or shorten the operating rod, as required.

Lock the split pin (2) so as to restore the travel with

no load to 4.5 mm (0.1772 in.) then tighten the locknut (1).

TRE0173A

46

662720 09 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

SECTION 21 -- TRANSMISSIONS
Chapter 1 -- Mechanical Transmission (12 x 4)
CONTENTS
Section

Description

21 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3&5
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal -- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see sect 27

21 110

Page

21 000 -- MAIN DATA -- TIGHTENING TORQUES -- SECTIONS -- TOOL -DESCRIPTION AND OPERATION -- FAULT DIAGNOSIS
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4--speed, constant--mesh with synchronisers on all gears

Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

helical gears

Range gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ordinary gear train with 3 forward

ranges and 1 reverse range those giving a total of 12 forward and 4 reverse
speeds

-- Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

spur gears

-- Reduction ratios :
D Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23x17
= 1:(5.49)
43x50

D Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23x27
= 1:(2.35)
43x34

D Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearbox and range gear controls . . . . . . . . . . . . . . . . . . . . .

Independent, hand operated levers located on right--hand side of operator

Thickness of gearbox driving shaft adjustment ring

(5, page 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
3.00--3.25--3.50--3.75--4.00
(in.) (0.1181--0.128--0.1378--0.1476--0.1575)

Inside diameter of gearbox driven gears . . . . . . . . . . . . . . . .

mm
(in.)

50.050 -- 50.075
(1.9705 -- 1.9715)

Outside diameter of bushings (17, page 5) . . . . . . . . . . . . . . .

mm
(in.)

49.925 -- 49.950
(1.9655 -- 1.9665)

Clearance between gears and bushings . . . . . . . . . . . . . . . . .

mm
(in.)

0.100 -- 0.150
(0.0039 -- 0.0059)

Diameter of gearbox driven shaft (19, page 5) . . . . . . . . . . . .

mm
(in.)

39.175 -- 39.191
(1.5423 -- 1.5429)

Inside diameter of bushings (17, page 5) . . . . . . . . . . . . . . . .

mm
(in.)

39.200 -- 39.239
(1.5433 -- 1.5448)

Clearance between shaft and bushings . . . . . . . . . . . . . . . . .

mm
(in.)

0.009 -- 0.064
(0.0004 -- 0.0025)
(continued overleaf)
6- 62720 -- 09 -- 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

TRANSMISSION AND RANGE GEAR MAIN DATA
(continued)

Diameter of power take off (PTO) clutch shaft (4, page 5) . . . . . .

mm
(in.)

24.979 -- 25.000
(0.9834 -- 0.9843)

Inside diameter of fitted bushing (1, page 5) . . . . . . . . . . . . . . . . . .

mm
(in.)

25.040 -- 25.092 (1)

(0.9858 -- 0.9879)

Clearance between PTO clutch shaft and relative bushing . . . . .

mm
(in.)

0.040 -- 0.113
(0.0016 -- 0.0044)

Interference fit between bushing on driving shaft . . . . . . . . . . . . . .

mm
(in.)

0.037 -- 0.091
(0.0015 -- 0.0036)

-- Spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

30
(1.1811)

-- Length of spring under load of 50--56 N (11.3148--12.5059 lb)

mm
(in.)

25.5
(1.0039)

-- Spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

75
(2.9528)

-- Length of spring under load of 94--104 N (21.1740--23.3796 lb)

mm
(in.)

42
(1.6535)

Springs (16, page 7) for detent balls on gearbox and range gear
control rods :

Gearbox and range gear control lever retaining springs:

(1) Measurement to obtain after fitting without reaming.

TORQUE VALUES
Torque settings
PARTS

Thread
Nm

ft lb

Retaining bolts for upper cover of rear transmission / gearbox (C1)

M 10 x 1.25

59

43.5162

Bolts for securing lift to rear transmission box (C2) . . . . . . . . . . . . . .

M 12 x 1.25

98

72.2811

Bolts for securing PTO box to transmission / gearbox (C3) . . . . . . .

M 16 x 1.5

221

163.0012

Bolts for securing flexion bar to transmission / gearbox case (C4)

M 16 x 1.5

221

163.0012

Nuts for stud bolt securing final drive to transmission / gearbox (C5) .

M 12 x 1.25

98

72.2811

Nuts for securing steel plate disc to wheel drive hub (C6) . . . . . . . . . .

M 18 x 1.5

255

188.0783

Nuts for bolts securing steel plate disc to drive wheel rim (C7) . . . . .

M 16 x 1.5

245

180.7027

Ring bevel gear retaining bolts (C8)

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

M 12 x 1.25

123

90.7201

Bevel gear pair support retaining bolts (C9) . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

59

43.5162

6- 62720 -- 09 -- 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

MAIN DATA -- GEARBOX AND RANGE GEAR

C1 59 Nm

C2 98 Nm

C3 221 Nm

C4 221 Nm
C9 59 Nm
C7 245 Nm

C6 255Nm
C8 123 Nm
C5 98 Nm

TRE0550A

TOOLS
Warning -- The operations described in this Section
can only be carried out using the ESSENTIAL tools
marked on the right side with an (X).
However, for greater safety and to obtain the best
results while saving time and effort, it is
recommended that these essential tools are used
together with the special tools listed here as well as
certain tools which are to be made following the
sectional drawings given in this manual.

1
List of special tools required for the various
operations described in this Section:
380000236 Tractor dismantling trolley.
380000227 Clutch casing lifting hook.
380000301 Rotating overhaul stand.
380000271 Front bracket (with 380000301).
380000272 Rear bracket (with 380000301).
X 380000838 Adaptor for removal of reverse gear
pin (with 380000549).
6- 62720 -- 09 -- 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

Drift to be made for removal of gearbox driving shaft

(tool to be stamped no. 50006 -- measurement in
mm).
Make in material UNI C40.

26215

2
Tool to be made for adjustment of gearbox driving
shaft bearings (tool be stamped no. 50007 -measurement in mm).
Make in material Aq 45.

26216

26217

4
Tool to be made for removal of rear bearing of range gear driving shaft and the driving gear for the slow
speeds (tool to be stamped no. 50028 -- Measurements in mm).
Make in UNI C40.
Note -- Make two parts from the tool shown at Figure 4, uppermost one .
6- 62720 -- 09 -- 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

5
Longitudinal cutaway section through gearbox and range gear.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Power take--off (PTO) shaft support bushing.

Seal.
Gearbox driving shaft.
PTO shaft.
Driving shaft adjustment ring.
Range gear driving shaft.
Control gear for reverse and middle speeds.
Upper cover.
Driving gear for middle speeds.
Bevel pinion shaft.

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

Retaining half--rings.
Driven gear for reverse speeds.
Driven gear for low speeds.
Selector sleeve for high and low speeds.
Circlip.
Synchroniser for 1st and 2nd speeds.
Support bushings for gearbox driven gears.
Synchroniser for 3rd and 4th speeds.
Gearbox driven shaft.

Note -- On assembly apply sealant to surfaces X following the indications given on page 6 in this Section.
6- 62720 -- 09 -- 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

TRE0556A

6
Sealing compound application diagram for mating surfaces between engine, clutch casing and rear
transmission--gearbox.
The types of sealing compound to use are indicated on page 1, Sect. 00.
6- 62720 -- 09 -- 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

TRE0557A

Cross--section through gearbox and range gear

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Range gear control relay rod.

Gearbox control relay rod.
Low and high speeds selector rod.
Normal and reverse speeds selector rod.
3rd and 4th speed selector rod.
1st and 2nd speed selector rod.
Range gear driving shaft.
Intermediate gear for reverse speeds.
Control gear for normal and reverse speeds.
Driving gear for normal speeds.
Journal of intermediate gear (8).
Journal bolt (11).
Bearings.

14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.

Circlip.
Upper cover of transmission / gearbox.
Spring.
Detent ball.
Speed control safety pawl.
Plug.
Speed control safety pawl.
Range control safety pawl.
Plug.
Selector rod for low and high speeds.
Selector rod for middle and reverse speeds.
3rd and 4th speed selector rod.
1st and 2nd speed selector rod.

Note --Before plugs (19 and 22) are bolted in, they must be covered with one of the sealants listed on page 1,
Sect. 00.
6- 62720 -- 09 -- 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

DESCRIPTION AND OPERATION

4--speed gearbox with constant--mesh helical gears

controlled by two synchronisers.
The range gear has cascade--type constant--mesh
spur gears, excluding reverse.
The driven gears of the range gear are keyed directly
onto the bevel pinion shaft.

The range gear provides 3 forward ranges and 1 reverse range.

The gearbox and the range gears are controlled by
two independent levers located on the right--hand
side of the operator.

GEARBOX AND RANGE GEAR TROUBLESHOOTING

Problems

Possible causes

Remedies

Spontaneous disengagement of 1. Levers and relay linkages Adjust correctly.

gearbox and range gear.
incorrectly adjusted.
2. Selector rod retaining springs Replace the springs.
defective.
3. Defective teeth on synchro- Remove the transmission/gearbox
niser or engagement sleeve. and replace the synchronisers or the
engagement sleeves.
4. Incomplete
travel.

engagement Eliminate the cause and restore full

engagement travel.

Difficulty in engaging the gearbox 1. Control levers and linkages Adjust correctly.
and range gear.
incorrectly adjusted.
2. Stiffness and / or partial Check pivot points and lubricate.
seizure of control levers and
linkages.
3. Main clutch drag.

See page 5, Sect. 18.

4. Synchronisers or engage- Remove the transmission / gearbox

and replace the synchronisers or
ment sleeves defective.
engagement sleeves.
5. Internal controls do not slide Perform the checks and overhaul for
freely : rods, forks and needed parts.
sleeves.
Gearbox or range gear unduly 1. Internal component/s worn or Remove the transmission / gearbox
noisy.
and replace the worn / defective
defective.
parts.
6- 62720 -- 09 -- 2006

SECTION 21 TRANSMISSIONS CHAPTER 2

SECTION 21 TRANSMISSIONS
Chapter 2 Reverser

CONTENTS
Section

Description

21 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RemovalRefitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 110

Page
1
2
3
3
5
5
6

21 000 MAIN DATA TIGHTENING TORQUES SECTIONS TOOLS DESCRIPTION AND

OPERATION FAULT DIAGNOSIS

SYNCHRONISER REVERSER MAIN DATA

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical type spur gear unit,

located between the main clutch
and the gearbox. Comprises 1
driving gear, 1 intermediate gear
and
1 idle gear.

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand lever located on lefthand

side of the operator

GEARBOX MAIN DATA

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 speed, constantmesh, with

synchronisers on all gears

Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

helical

Reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ordinary gear train with 3 ranges

providing a total of 12 gears

Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

spur

Gearbox and reduction unit controls . . . . . . . . . . . . . . . . . . . . . . . .

Independent, with two hand levers

located on righthand side of the
operator

For other main data see chapter 1.

662720 09 2006

SECTION 21 TRANSMISSIONS CHAPTER 2

TORQUE VALUES
Torque Settings
PARTS

Thread
Nm

ft lb

Bolt or nut securing clutch / reverser casing to engine (C1) . . . . .

M 12 x 1.25

98

72.2811

Sleeve cover retaining nuts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 8 x 1.25

17

12.5386

Reverser driven shaft cover retaining bolts (C3) . . . . . . . . . . . . . . .

M 8 x 1.25

28

20.6517

Reverser driven shaft plate retaining bolts (C4) . . . . . . . . . . . . . . .

M 10 x 1.25

64

47.2040

Bolts securing clutch / reverser housing to gearbox / rear

transmission (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

98

72.2811

C1 98 Nm

C2 17 Nm

C3 28 Nm

C4 6 Nm
C5 98 Nm
TRE0558A

662720 09 2006

SECTION 21 TRANSMISSIONS CHAPTER 2

TOOLS

List of special tools required for the various

operations described in this Section :

Warning The operations described in this Section

can only be carried out using the ESSENTIAL tools
marked with an (X).
However, for greater safety and to obtain the best
results while saving time and effort, it is
recommended that these essential tools are used
together with the special tools listed here as well as
certain tools which are to be made following the
sectional drawings given in this manual.

380000236 Tractor dismantling trolley.

380000227 Clutch casing lifting hook.
380000301 Rotating overhaul stand.
380000271 Front
support
380000301).
380000272 Rear
support
380000301).

bracket

(with

bracket

(with

10
9
TRE0559A

8
9

Longitudinal cutaway section of synchroniser reverser

1. Synchroniser reverser control shaft.

6. Reverser control synchroniser.

2. Seal.

7. Seal.

3. Roller bearing.

8. Synchroniser reverser driven gear.

4. Synchroniser reverser driving gear.

9. Journal for driven gear (8).

5. Roller bearing.

10. Seal.

Note On assembly apply jointing compound to surfaces X as indicated on page 6, chapter 1.

662720 09 2006

SECTION 21 TRANSMISSIONS CHAPTER 2

TRE0560A

10

Synchroniser reverser sectional views

1. Synchroniser reverser selector fork.

11. Journal of idle gear (7).

2. Reverser synchroniser.

12. Stop plate for journals (11 and 13).

3. External reverser control lever.

13. Synchroniser reverser driven gear.

4. Seal.

14. Synchroniser reverser control rod.

5. Circlip.

15. Spacer.

6. Thrust washer.

16. Reverser synchroniser.

7. Synchroniser reverser idle gear.

17. Detent ball.

8. Roller bearing.

18. Spring for detent ball (17).

9. Thrust washer.
10. Seal.

662720 09 2006

19. Detent ball retaining bolt (the bolt must be

covered in one of the sealants listed on page 1,
Sect. 00).

SECTION 21 TRANSMISSIONS CHAPTER 2

DESCRIPTION AND OPERATION

The synchroniser reverser is a mechanical device
which makes it possible to obtain 12 forward and 12
reverse gears. It is controlled by a specific lever
located on the platform to the left of the operator.
The synchroniser reverser is comprised of a group
of three spur gears : driving reverser gear, intermediate gear and driven reverser gear. Selection is ef-

fected by means of a synchroniser located in the

group of gears.
The synchroniser reverser is installed inside the
clutch casing between the clutch and the gearbox.
It is lubricated by the oil in the rear transmission /
gearbox.

SYNCHRONISER REVERSER TROUBLESHOOTING

Problems

Possible causes

Remedies

adjustment
of Adjust correctly.
Spontaneous disengagement of 2. Incorrect
the synchroniser reverser.
external levers and linkages.
3. Synchroniser
engagement Remove the clutch casing and
replace the synchroniser.
teeth damaged.
4. Engagement
incomplete.

travel Eliminate the cause and restore full

engagement travel.

adjustment
of Adjust correctly.
Difficulty in engaging the reverser. 1. Incorrect
external levers and linkages.
2. Stiffness and / or partial Check pivot points and lubricate.
seizure of external levers and
linkages.
3. Dragging of main clutch.

See page 5, Sect. 18.

4. Synchroniser damaged.

Remove the clutch casing and

replace the synchroniser.

5. Internal controls do not slide Perform the checks and overhaul for
freely: rods, forks and needed parts.
sleeves.
Synchroniser
noisy.

reverser

unduly 1. Worn or damaged internal Remove the clutch casing and

replace damaged part/s.
part/s.

662720 09 2006

SECTION 21 TRANSMISSIONS CHAPTER 2

CLUTCH/REVERSER CASING
Replacement (Op. 21 110 85)

WARNING
Handle all parts with great care.
Never insert fingers or hands between one piece and
another. Wear suitable safety clothing, i.e., safety
goggles, gloves and shoes.

1. Fix the clutch / reverser casing (1) to stand

380000301 (2) using the two brackets
380000271 and 380000272.

24984

11
2. Withdraw the spring pin and recover the link
lever (1) and the internal lever (2).

26185

12
3. Unscrew the retaining bolt (1) and recover the
detent ball and spring.

24989

13

662720 09 2006

SECTION 21 TRANSMISSIONS CHAPTER 2

4. Remove the circlip (1) and take out : bearing,

thrust washers, synchroniser assembly together
with the selector fork and its rod, the reverser
driven gear (2) complete with roller bearings and
spacer.

1
2

26186

14
5. Remove the reverser driving gear (1) complete
with roller bearings.

24994

15
6. Remove the circlip (1) securing the reverser
driving shaft.

24995

16
7. Working from the front of the clutch / reverser
casing with an aluminium drift (2), drive out the
reverser driving shaft (1) and remove it from the
rear of the casing.

24997

17

662720 09 2006

SECTION 21 TRANSMISSIONS CHAPTER 2

8. Detach the retaining springs and withdraw the

sliding sleeves (1).

24999

18
9. Unscrew the retaining bolts and remove the
sleeve cover / support (1).

25000

19
10. Unscrew the two securing bolts (1) of the sliding
sleeve control forks (2).

25001

20
11. Withdraw the external clutch control levers (1)
and remove the forks (2).

2
25002

21

662720 09 2006

SECTION 21 TRANSMISSIONS CHAPTER 2

12. Relieve the staking and unscrew bolt (1)
securing the stop plate for the journal of the
reverser driven shaft (2) and the intermediate
gear journal, removing the latter from the rear of
the casing.

13. Refitting of the synchroniser reverser according

to the following instructions:
Refer to the illustrations on pages 3 and 4 to
check the correct orientation of the various parts.
Refer to the torque settings on page 2.
Install the intermediate gear journal complete
with the various associated parts, and the journal
of the reverser driven gear and secure with the
relative stop plate and bolt.
Fit the sliding sleeve control forks on the relative
clutch control levers and fix the previous to the
latter.
Fit the sliding sleeve cover and its support.
Fit the sliding sleeve assembly to the relative
support and secure with the springs.
Insert the reverser driving shaft from the rear of
the casing and fix it to the clutch / reverser casing
with the circlip.
Position the reverser driving gear complete with
bearings on the driven shaft.
Fit the reverser driving gear complete with the
bearings and spacers.
Fit the synchroniser assembly complete with
control forks, rod, thrust washers and bearing,
and fix in position with the relative circlip.
Fit the detent ball, spring, and bolt in the locked
position after covering the bolt using one of the
sealants listed on page 1, Sect. 00.
Position the internal lever and link lever and fix
with the relative spring pin.
Remove the clutch / reverser casing from the
stand 380000301.

2
25004

22

662720 09 2006

10

662720 09 2006

SECTION 21 TRANSMISSIONS CHAPTER 2

SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

SECTION 21 -- TRANSMISSIONS
Chapter 3-- Reverser and creeper unit
CONTENTS
Section

Description

21 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 110

Page
1
2
3
4
6
6
7

21 000 -- MAIN DATA -- TIGHTENING TORQUES -- SECTION VIEWS -- TOOLS -- DESCRIPTION AND
OPERATION -- FAULT DIAGNOSIS
SYNCHRONISER REVERSER--CREEPER UNIT MAIN DATA 1.
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical, spur gears, located

between engine and gearbox.
Comprising 1 driving gear, 1
intermediate gear and 1 idle
gear.

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by hand lever located on

left--hand side of operator

CREEPER UNIT MAIN DATA

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ordinary gear train with spur

gears, located between main
clutch and gearbox, in series
with the reverser.
Provides 20 forward speeds and
12 reverse speeds

Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18x26
= 1:5.524
55x47

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by hand lever located on

left--hand side of operator

GEARBOX MAIN DATA

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4--speed constant mesh,

synchronised on all gears

Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

helical

Range gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ordinary gear train with three

ranges for a total of 12 speeds

Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

spur gears

Gearbox and range gear controls . . . . . . . . . . . . . . . . . . . . . . . . .

Independent, by two hand levers

For further data see chapter 1.

6- 62720 -- 09 -- 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

TORQUE VALUES 2.
Torque Settings
PARTS

Thread
Nm

ft lb

Bolt or nut securing clutch casing -- reverser and creeper unit to the
engine (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

98

72.2811

Sleeve cover nuts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 8 x 1.25

17

12.5385

Synchroniser reverser -- creeper unit driven shaft cover nuts (C3)

M 8 x 1.25

17

12.5385

Gearbox driving and driven shaft bearings cover screws (C4) . .

M 8 x 1.25

28

20.6517

Bolt securing clutch casing -- reverse and creeper unit to the rear
transmission--gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

98

72.281117

TRE0561A

6- 62720 -- 09 -- 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

TOOLS 3.

List of special tools required for the various

operations in this Section :

Warning -- The operations described in this Section

can only be carried out using the ESSENTIAL tools
marked with an (X).
However, for greater safety and to obtain the best
results while saving time and effort, it is
recommended that these essential tools are used
together with the special tools listed here as well as
certain tools which are to be made following sectional
drawings given in this manual.

380000236 Tractor dismantling stand.

380000227 Clutch casing lifting hook.
380000301 Rotating overhaul stand.
380000271 Front bracket (with 380000301).
380000272 Rear bracket (with 380000301).

Support bracket for installation of gearbox driving

shaft seal (mark tool 50043) (Dimensions in mm).
Part of kit 50043 -- Make tool in UNI C40.

26191

26192

2
Tool for gearbox driving shaft seal (mark tool 50137)
(Dimensions in mm)
make tool in UNI C40.

6- 62720 -- 09 -- 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

10

TRE0562A

Longitudinal section through reverser--creeper unit

1. Reverser and creeper unit control shaft.

6. Gearbox driving shaft control gear.

2. Seal.

7. Creeper unit driven gear.

3. Circlip.

8. Thrust washer.

4. Creeper unit control gear.

9. Reverser driven shaft.

5. Reverser--creeper unit synchroniser.

10. Seal.

Note -- On assembly apply sealing compound to the surfaces X following the indications given on page 6 in
Chapter 1.

6- 62720 -- 09 -- 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

TRE0563A

Cross sectional views of synchroniser reverser -- creeper unit

1. Reverser control fork.

12. Roller bearing.

2. Detent ball.

13. Journal for gear (11).

3. Reverser synchroniser.

14. Seal.

4. Seal.

15. Reating screw for journal (13).

5. External reverser control lever.

16. Fast speeds lock pawl.

6. Creeper unit control fork.

7. Detent ball.
8. External creeper control lever.
9. Seal.
10. Creeper unit control gear.
11. Intermediate gear for reverser.

17. Reverser and creeper unit control rod.

18. Reverser synchroniser.
19. Creeper unit control gear.
20. Retaining screw for rod (17) (apply one of the
sealing compounds listed on page 1, Sect. 00 to
the screw).

6- 62720 -- 09 -- 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

DESCRIPTION AND OPERATION 4.

The reverser--creeper unit is a mechanical device

providing the possibility to obtain 20 forward speeds
and 12 reverse speeds.
The creeper unit engages only in slow and middle
ranges, a mechanical interlock prevents creeper
engagement in the fast ranges.
The creeper unit comprises a group of three spurs
gears : a sliding control gear, a synchroniser control
gear and a driven gear; the unit utilises the same
synchroniser as the reverser.
The creeper is installed in series with the reverser

and is controlled by a hand lever located on the

right--hand side of the operator.
The reverser comprises three spur gears : the
reverser driving gear, an intermediate gear and the
reverser driven gear; the reverser is engaged by
means of a synchroniser located in the gear
assembly.
The reverser--creeper unit is installed inside the
clutch casing between the clutch and the gearbox.
Lubrication is provided by the oil contained in the rear
transmission--gearbox.

SYNCHRONISER REVERSER--CREEPER UNIT TROUBLESHOOTING

Problems

Possible causes

Remedies

Spontaneous disengagement of 14. External levers and linkages Adjust correctly.

the reverser--creeper unit.
incorrectly adjusted.
15. Synchroniser teeth damaged. Remove the clutch casing and
replace the synchroniser.
16. Engagement
incomplete.
Difficulty
in
engaging
reverser--creeper unit.

travel Eliminate the cause and restore full

travel.

the 1. External levers and linkages Adjust correctly.

incorrectly adjusted.
2. Stiffness and / or partial Check pivot points and lubricate.
seizure of external levers and
linkages.
3. Main clutch drag.

See page 5, Sect. 18.

4. Synchroniser defective.

Remove the clutch casing--gearbox

and replace the synchroniser.

5. Internal control elements do Perform the checks and overhaul for

not slide freely : rods, forks needed parts.
and sleeves.
Reverser--creeper
noisy.

6- 62720 -- 09 -- 2006

unit

unduly 1. Internal component/s worn or Remove clutch casing and replace

defective parts.
defective.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

CLUTCH
CASING
-SYNCHRONISER
REVERSER AND CREEPER UNIT
Replacement (Op. 21 110 87) 5.

WARNING
Handle all parts with great care.
Never place your hands between one part and
another. Wear suitable safety clothing, i.e. safety
goggles, gloves and shoes.

To gain access to the synchroniser reverser--creeper

unit, first remove the cab or platform following the
instructions given in Sect. 27 and remove the clutch
casing as described in Sect. 18, and then proceed as
follows :
1. Fix the casing to the rotating stand 380000301
using the brackets 380000271 and 380000272.

22893

5
2. Remove circlip (1) and slide out constant mesh
gear (2).

1
2

22894

6
3. Remove circlip (1) of reverser transmission
driving shaft.

26198

6- 62720 -- 09 -- 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

4. Remove plug and remove the control lever

retaining pin (1).

26199

8
5. Remove the reverser synchroniser assembly (1)
together with control forks and gears.

26200

9
6. Withdraw the driven shaft gear (1) together with
the roller bearings and remove the thrust
washer.

26201

10
7. Remove the control fork retaining springs (2) and
withdraw the clutch pressure plate bearing
assembly (1).

26202

11

6- 62720 -- 09 -- 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

8. Unscrew the retaining screws (2) and remove

the control forks (1).

26203

12
9. Unscrew the retaining screw (15, page 5) and
withdraw the reverser intermediate gear
assembly (1).

26204

13
10. Unscrew the retaining bolts and remove the
cover (1).

22902

14
11. From the rear of the casing, withdraw the shaft
(1) complete with the relative bearing.

26205

15

6- 62720 -- 09 -- 2006

10

SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

12. Unscrew the retaining bolts and remove the

cover--support (1).

26206

16
13. Remove the circlip (2) and withdraw the
drive--shaft (1) complete with bearing.

26207

17
14. Remove the circlip (1).

26208

18
15. Remove the driveshaft seal (1) using a suitable
implement.

26209

19

6- 62720 -- 09 -- 2006

SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

11

16. To refit all the reverser and creeper components

in the casing follow the instructions below :
Refer to the illustrations on pages 4 and 5 for
the orientation of the various components.
Adhere to the torque setting values prescribed
on page 2.
To install the seal (1, fig.19 ) follow the
instructions in steps 17.-- 24.
Install the driveshaft complete with bearing and
circlips.
Fit the cover--support.
Install the reverser and creeper driven gear
shaft.
Fit the cover for the driven gear shaft and secure
with the relative screws.
Install the reverser intermediate gear assembly
and secure with the relative screw.
Install and fix the clutch control forks to the
relative levers.
Install the pressure plate bearings and hold in
place with the relative springs.
Install the driven gear complete with bearing and
thrust washer.
Install the complete synchroniser assembly and
secure with the relative circlip.
Fit the rod retaining screw coated with one of the
sealing compounds listed on page 1, Sect. 00.
Install the gear on the reverser driven shaft and
secure with the relative circlip.
Remove the clutch casing --reverser and creeper
unit from the stand 380000301.

WARNING
Always use suitable tools to align holes. NEVER
USE YOUR FINGERS OR HANDS.

17. Fit the circlip (1, fig.18 ) in its seat.

18. Make the bracket of tool 50043 (4) and the tool
50137 (5) (see page 3).
19. Fit the bracket (3) on the clutch casing, insert the
installation drift (4) in the seal seat in contact with
the circlip (1, fig. 18).
20. Screw in nut (1) to obtain a distance (H) between
the bracket and nut of 3.3 -- 3.6 mm (0.1299 -0.1417 in.) and secure the latter with the locknut
(5).

1
5
2
3
4

26210

20

6- 62720 -- 09 -- 2006

12

SECTION 21 -- TRANSMISSIONS -- CHAPTER 3

Note -- Leave the drift (1) with the nut in the position
reached on completion of the installation operation,
and on future seal installation operations simply
check that the distance (H, fig. 20) is as prescribed.

21. Remove the drift (1), the bracket (2) and the
circlip (1, fig. 18).
22. Locate the new seal in its seat (see page 6 for
correct orientation of seal), refit the bracket (2)
on the clutch casing and insert the drift in the
bracket.
23. Force the seal in until the nut (1, fig. 20) reaches
up against the bracket (2).
24. Dismantle the bracket (2), remove the drift (1)
and proceed with the installation of the other
components.

6- 62720 -- 09 -- 2006

26211

21

SECTION 23 -- DRIVE LINES -- CHAPTER 1

SECTION 23 -- DRIVE LINES

Chapter 1 -- Drive Lines
CONTENTS
Section
23 000

23 101 26
23 101 40
23 101 42

Description

Page

Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque settings and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross--Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission shafts and guard (Disassembly -- Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive gear housing (Removal -- Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive gear housing removed (Disassembly -- Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1
2
3
4
5
7

MAIN SPECIFICATION
34/24x24/34= 1 to 1

Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay lever pad width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

7.978 -- 8.000
(0.3141 -- 0.3150)

Pad seat width in driven gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

8.280 -- 8.370
(0.3260 -- 0.3295)

Pad clearance in seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

0.280 -- 0.460
(0.0110 -- 0.315)

Relay lever pivot diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

15.973 -- 16.000
(0.6289 -- 0.6299)

Pivot housing bore in casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

16.016 -- 16.059
(0.6305 -- 0.6322)

Pivot clearance in housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

0.016 -- 0.086
(0.0006 -- 0.0124)

-- Free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

130
(5.1181)

-- Under 178.2 to 197.8 N (40 to 44 lb ) . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

142.5
(5.6102)

Relay lever detent spring length

MAIN SPECIFICATION OF DRIVE SHAFT

see page 4

Front drive sleeve adjustment

Front drive sleeve shim thickness . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

2.2.--2.5--2.8--3--3.3--3.7--4--4.3
(0.0866--0.0984--0.1102--0.1181-0.1299--0.1457--0.1575--0.1693)

6- 62720 -- 09 -- 2006

SECTION 23 -- DRIVE LINES -- CHAPTER 1

TORQUE SETTINGS

C12
C13

TRE0401A
TRE0400A

1
PART TO BE TORQUED

Thread

Transmission shaft central support retaining bolt (C12) . . . . . . . . .

Drive gear housing retaining bolt (C13) . . . . . . . . . . . . . . . . . . . . . .

TOOLS
380000821 Drive shaft seal key

6- 62720 -- 09 -- 2006

Torque setting
Nm

ft lb

M 12 x 1.5

98

72.2811

M 12 x 1.25

98

72.2811

SECTION 23 -- DRIVE LINES -- CHAPTER 1

5
22

25

x
10
11

C12

30

56

39

27
28

29

12

TRE0402A
TRE0403B

Sectional views of transfer box:

C12 = Drive shaft centre bearing capscrew

C13 = Axle drive housing capscrew
X = On assembly,thoroughly clean and degrease
mating surface X.
4. Driven gear
5. Intermediate gear
6. Needle roller bearing
10. Driven shaft
11. Guide screws
22. Dentent plunger

25.
26.
27.
28.
29.
30.
39.
56.

Roll pin
Intermediate shaft
Dust exculuder
Seal
Retaining ring
Splined driven shaft
Drive shaft guard
Centre bearing

6- 62720 -- 09 -- 2006

SECTION 23 -- DRIVE LINES -- CHAPTER 1

Op. 23 101 26
TRANSMISSION SHAFTS AND GUARD
Disassembly -- Assembly

WARNING
Handle all parts with great care.
Do not place hands or fingers between one part and
another.
Always wear the prescribed safety clothing, including
protective glasses, gloves and shoes.

To remove, proceed as follows:

[Link] the negative battery lead.

25621

3
[Link] the front, centre and rear screws securing
the front axle prop shaft guard and remove the
guard (1).
[Link] circlip (2) fig. 5 and move sleeve (1) in the
direction shown by the arrow to disengage it from
the splined shaft of the front axle.
[Link] re--fit the transmission shaft and guard, proceed
as follows:

WARNING

Use suitable tools to align holes. NEVER USE

FINGERS OR HANDS.

25038

--Fit and secure the transmission shaft in position

NOTE:
Move the front splined sleeve (27) against
retaining ring (28). Using a feeler gauge,
measure gap between the sleeve and the
retaining ring (26) and install shim (S 5) to
obtain sleeve end play (L) of 1 to 1.5 mm
(0.0394 to 0.0591 in.) (see Section 25 page 9).
25040

-- Fit and secure the guard.

6- 62720 -- 09 -- 2006

SECTION 23 -- DRIVE LINES -- CHAPTER 1

Op. 23 101 40
DRIVE GEAR HOUSING ASSEMBLY
Removal-- Installation

WARNING
Handle all parts with great care.
Do not place hands or fingers between one part and
another.
Always wear the prescribed safety clothing, including
protective glasses, gloves and shoes.

To remove, proceed as follows:

[Link] out operation 23 101 26 Transmission
shafts and guard removal (see page 4)
[Link] the plug (1) and drain the oil from the
transmission box/gearbox.

TRE0404A

6
[Link] the drive gear engagement control lever(1)

TRE0405B

7
[Link] the screws (1) that hold the drive gear
housing (transfer box) to the transmission housing.

[Link] the drive gear housing from the

transmission housing.

TRE0406A

6- 62720 -- 09 -- 2006

SECTION 23 -- DRIVE LINES -- CHAPTER 1

[Link] refit the drive gear housing, proceed as

follows:

WARNING
Use suitable tools for aligning holes. DO NOT USE
YOUR HANDS OR FINGERS.
Refer to the tightening torques shown on page 2.
Carefully clean the contact surfaces.
Apply sealing compound (approx. 2 mm (0.0787 in.)
wide strip) to the contact surface of the drive gear
housing.
Fit the drive gear housing to the transmission
housing.
Connect the drive gear engagement control lever
Replace the transmission oil drain plug.
Carry out operation 23 101 26 Transmission shafts
and guard installation (see page 4).
Fit the drive shaft guard.
26283

9
Mastic application diagram for assembly of
drive gear housing to transmission housing.

6- 62720 -- 09 -- 2006

SECTION 23 -- DRIVE LINES -- CHAPTER 1

TRANSFER BOX, UNIT REMOVED

Disassembly -- Assembly (Op. 23 101 42)

WARNING
Handle all parts with great care.
Do not place hands or fingers between one part and
another.
Always wear the prescribed safety clothing, including
protective glasses, gloves and shoes.

With the transfer box on the bench, proceed as

follows:
s
[Link] out operation 23 101 26 Transmission shafts
and guard removal (see page 4).
[Link] out operation 23 101 40 Drive gear housing
removal (see page 5).

25725

10
[Link] the special punch to withdraw the snap ring
(1), then the pin (2). Remove the roller bearing, the
spacer, the thrust washers and the intermediate
gear (3).
[Link] the parking brake control lever.

TRE0407A

11
[Link] a screwdriver to remove the dust ring (1).
[Link] the splined driven shaft, complete with
parts, parking brake discs and the driven gear.

TRE0408A

12

6- 62720 -- 09 -- 2006

SECTION 23 -- DRIVE LINES -- CHAPTER 1

[Link] refit the transfer box, proceed as follows:

WARNING
Use suitable tools to align holes. NEVER USE
FINGERS OR HANDS.

TRE0119A

13

Insert the shaft in the housing, then assemble the

gear unit, washer and circlip.
Fit the internal lever ,the external lever, the
coupling pad and secure in position by means of
the washer and relative circlip.
Fit the bearing and relative circlips
Using tool 380000821, fit the seal and dust ring
(use the spacer to fit the dust ring).
Carry out operation 23101 40 Drive gear housing
installation (see page 5).
Carry out operation 23 101 26 Transmission
shafts and guard installation (see page 4).

TRE0118A

14

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION

Chapter 1 -- Front axle mechanical transmission
CONTENTS
Section

Description

25 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Complete front axle. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Front axle. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Steering knuckle bearing pins. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Stub axle adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wheel hub bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bevel drive adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Front axle differential. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Front axle differential with LIM--SLIP. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Front axle differential with NO SPIN. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Leading drive wheels toe--in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

25 100 30
25 100 38
25 108 46--47

25 102 24
25 100 27
44 511 80

Page

MAIN DATA
steering, load bearing structure,
pivoting at centre

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bevel gear pair -- differential
Pinion--crown gear ratio: 30 km/h:
-- JX60 and JX70 Models

9/38 = 1:4.2

-- JX80, JX90 and JX95 Models

9/39 = 1:4.3

Pinion--crown gear ratio: 40 km/h:

-- JX60 and JX70 Models

11/38 = 1:3.45

-- JX80, JX90 and JX95 Models

11/39 = 1:3.54

Backlash between bevel gear pair:

-- JX60 and JX70 Models

mm
(in.)

0.18 -- 0.23
(0.0071 -- 0.0091)

-- JX80, JX90 and JX95 Models

mm
(in.)

0.15 -- 0.20
(0.0059 -- 0.0079)

-- JX60 and JX70 Models

mm
(in.)

1.386
(0.545)

-- JX80, JX90 and JX95 Models

mm
(in.)

1.378
(0.542)

Ratio between front wheel revs and rear wheel bevel drive revs

-- JX95 Model

1.398
(0.550)
(continued overleaf)

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

MAIN DATA

Bevel Drive and Differential

-- Thickness of pinion bearing adjustment spacer
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . .

mm

(in.)

JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . .

mm

(in.)

-- Thickness of crown wheel position adjustment spacer

JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . .

JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . .

-----

--

---

--

--

Clearance between sides of planet and side pinion teeth .

Thickness of planet pinion thrust washers . . . . . . . . . . . . .
Thickness of side gear thrust washers . . . . . . . . . . . . . . . .
Diameter of cross pin for planet pinions
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . .
JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . .
Side diameter cross pin bore diameter
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . .
JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . .
Clearance between cross pin and bores . . . . . . . . . . . . . . .
Diameter of outer axle shafts and corresponding bushes
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . .
JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . .
Inside diameter of installed bushes
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . .
JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . .
Clearance between axle shafts and bushes . . . . . . . . . . .

6- 62720 -- 09 -- 2006

2.5--2.55--2.6--2.65--2.7--2.75--2.8--2
.85--2.9--2.95--3.00--3.05--3.10-3.15--3.2--3.25--3.3--3.35--3.4--3.45
--3.5--3.55--3.6--3.65-- 3.7
(0.0984--0.1004--0.1024--0.1043-0.1063--0.1083--0.1102--0.1122-0.1142--0.1161--0.1181--0.1201-0.1220--0.1240--0.1260--0.1280-0.1299--0.1319--0.1339--0.1358-0.1378--0.1398--0.1417--0.1437-0.1457)
2.2--2.25--2.30--2.35--2.40--2.45--2.5
--2.55--2.6--2.65--2.7--2.75--2.8--2.85
--2.9--2.95--3.00--3.05--3.1--3.15--3.2
--3.25--3.3--3.35--3.4
(0.0866--0.0886--0.0906--0.0925-0.0945--0.0965--0.0984--0.1004-0.1024--0.1043--0.1063--0.1083-0.1102--0.1122--0.1142--0.1161-0.1181--0.1201--0.1220--0.1240-0.1260--0.1280--0.1299--0.1319-0.1339)

mm

2.5--2.6--2.7--2.8--2.9--3.00--3.1-3.2--3.3--3.4--3.5--3.6--3.7
(0.0984--0.1024--0.1063--0.1102-(in.)
0.1142--0.11811--0.1220--0.1260-0.1299--0.1339--0.1378--0.1417-0.1457)
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
(0.0984--0.1024--0.1063--0.1102-(in.)
0.1142--0.11811--0.1220--0.1260-0.1299--0.1339--0.1378--0.1417-0.1457)
mm (in.)
0.15 (0.0059)
mm (in.)
1.470 -- 1.530 (0.0579 -- 0.0602
mm (in.)
1.50 to 1.60 (0.0591 to 0.0630)
mm (in.) 21.939 -- 21.960 (0.8637 -- 0.8646)
mm (in.) 23.939 -- 23.960 (0.9425 -- 0.9433)
mm (in.) 22.040 -- 22.961 (0.8677 -- 0.9040)
mm (in.) 23.940 -- 23.961 (0.9425 -- 0.9433)
0.080 -- 0.122 (0.0031 -- 0.0048)
mm (in.) 37.961 -- 38.000 (1.4945 -- 1.4961)
mm (in.) 43.961 -- 44.000 (1.7307 -- 1.7323)
0.77 -- 0.83 (0.0303 -- 0.0327)
mm (in.) 38.080 -- 38.199 (1.4992 -- 1.5039)
mm (in.) 44.080 -- 44.119 (1.7354 --1.7370)
mm (in.) 0.080 -- 0.158 (0.0031 -- 0.0062)
(continued overleaf)

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

MAIN DATA
Axle shafts and steering knuckles
-- Diameter of outer axle shafts and corresponding bushes
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in.) 29.914 -- 29.935 (1.1777 -- 1.1785)

JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . .

mm (in.) 41.975 -- 42.000 (1.6526 -- 1.6535)

-- Inside diameter of installed front bush

JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in.) 30.050 -- 30.105 (1.1831 -- 1.1852)

JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . .

mm (in.) 42.100 -- 42175 (1.6575 -- 1.6604)

-- Clearance between pin and bush

JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in.)

0.115 -- 0.191 (0.0045 -- 0.0075)

JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . .

mm (in.)

0.100 -- 0.200 (0.0039 -- 0.0079)

mm (in.)

0.064 -- 0.129 (0.0025 -- 0.0051)

mm
(in.)

0.10--0.15--0.20--0.25--0.30
(0.0039--0.0059--0.0079--0.0098-0.0118)

JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in.)

15:(15+54) = 1:4.6
0.5906:(0.5906+2.1260) = 1:4.6

JX80 and JX90 Models . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in.)

16:(16+62) = 1:4.88
0.6299:(0.6299+2.4409) = 1:4.88

-- Interference fit between bushes and respective bores

-- Thickness of steering knuckle bearing adjuster plates . . . .

Planetary Final Drives

-- Reduction ratio

-- Driven gear thrust washer thickness

0.77 -- 0.83 (0.0303 -- 0.0327)

Axle pivot
11o

Pivotting angle (on either side ) . . . . . . . . . . . . . . . . . . . . . . . . .

Centre pivot and support end float . . . . . . . . . . . . . . . . . . . . . .

mm (in.)

0.3 -- 1.1 (0.0118 -- 0.0433)

Max. wear clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in.)

2 (0.0787)

Centre pivot diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in.) 52.652 -- 52.671 (2.0729 -- 2.0737)

Centre pivot front bushing fitted . . . . . . . . . . . . . . . . . . . . . . . .

mm (in.) 52.720 -- 52.790 (2.0756 -- 2.0783)

Centre pivot working clearance in bushing . . . . . . . . . . . . . . .

mm (in.)

0.049 -- 0.138 (0.0019 -- 0.0054)

Rear bevel pinion carrier spigot . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in.)

99.040 -- 99.72 (3.8992 -- 3.9063)

Rear bushing fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in.) 99.146 -- 99.221 (3.9034 -- 3.9063)

Spigot fitted clearance in bushing . . . . . . . . . . . . . . . . . . . . . . .

mm (in.)

0.074 -- 0.181 (0.0029 -- 0.0071)

Axle front and rear thrust washer thickness . . . . . . . . . . . . . .

mm (in.)

4.95 -- 5.00 (0.1949 -- 0.1969)

-- Live axle in Brakes on JX60 and JX70 Models . . . . . . . .

mm (in.)

3600 (141.732)

Brakes on JX80, JX90 and JX95 Models . . . .

mm (in.)

4100 (161.417)

-- Live axle in Brakes off JX60 and JX70 Models . . . . . . . .

mm (in.)

5300 (208.661)

Brakes off JX80, JX90 and JX95 Models . . . .

mm (in.)

5600 (220.472)

-- Live axle out Brakes on JX60 and JX70 Models . . . . . . . .

mm (in.)

4200 (141.732)

Brakes on JX80, JX90 and JX95 Models . . . .

mm (in.)

4500 (165.354)

-- Live axle out Brakes off JX60 and JX70 Models . . . . . . . .

mm (in.)

4900 (192.913)

Brakes off JX80, JX90 and JX95 Models . . . .

mm (in.)

5100 (200.787)

Turning radius:

(continued overleaf)

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

TIGHTENING TORQUES
Tightening torque
PART

Thread
Nm

ft lb

Front axle
Lock ring, bevel pinion (C1)
JX60 and JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 35 x 1.5

294

216.8432

JX80 JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 40 x 1.5

294

216.8432

Capscrew, differential case to axle casing (C2) . . . . . . . . . . . . . . .

M 12 x 1.25

113

83.3445

Capscrew, ring gear to differential case (C3) . . . . . . . . . . . . . . . . .

M 12 x 1.25

113

83.3445

M 12 x 1.25

113

83.3445

-- JX60 and JX70 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 45 x 1.5

118

87.0323

-- JX80, JX90 and JX95 models . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 75 x 2

392

289.11243

Capscrew, planetary final drive housing (C7) . . . . . . . . . . . . . . . . .

M 10 x 1.25

64

47.2040

Front axle front and rear pivot support bolt (C9) . . . . . . . . . . . . . . .

M 18 x 1.5

392

289.11243

Differential cage support cap bolt (C10) . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

113

83.3445

Front axle support to engine retaining bolt (C11) . . . . . . . . . . . . . .

M 18 x 1.5

314

231.5945

Steering knuckle capscrew (C5)

-- models JX60 and JX70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel hub bearings lock nut (C6):

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

C3 -- 113 Nm

C12 -- 64 Nm

C6 (**)

C4 (*)

26125

C7 -- 64 Nm

C2 -- 113 Nm

C1 -- 294 Nm

26124

C11 -- 314 Nm
C9 -- 314 Nm
26126

C10 -- 113 Nm

C9 -- 314 Nm

C5 -- 113 Nm

(*) See pages 25 and 26

(**) See page 27

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

TOOLS

WARNING: The tools marked below with an (X) are

ESSENTIAL for the operations described in this section. To work in safety and obtain the best results
whilst saving time and energy, these essential tools
should be supplemented by the specific tools listed
below and other tools which are to be made from the
drawings provided in this manual.
List of specific tools required for the various operations described in this section.

380000251 Front axle overhaul stand.

380000227 Hook for removal--installation of the
front differential assembly.
380000255 Overhaul support for front axle differential casing.
380000249 Universal gauge for positioning of
front bevel drive pinion.

6- 62720 -- 09 -- 2006

X 380000248 Bevel pinion positioning adjustment

tool
X 380000532 Pinion ring nut wrench mod. JX60
and JX70
X 380000268 Pinion ring nut wrench mod. JX80,
JX90 and JX95
X 380000257 Pinion grooved profile fastener
wrench.
X 380000252 Bevel drive bearing preloading ring
nut wrench mod. JX60 and JX70
X 380000253 Bevel drive bearing preloading ring
nut wrench mod. JX80, JX90 and
JX95
X 380000234 Front axle pivot bearing outer ring
removal tool.
X 380000235 Tool for measurement of rolling drag
torque of front axle bearings.
X 380000616 Wheel hub ring nut wrench. (JX60,
JX70 models)
X 380000269 Wheel hub ring nut wrench. (JX80,
JX90 and JX95 models)

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

TRE0414A

2
Cross--sectional view of front axle differential
S1 = Bevel pinion bearing shim
S2 = Bevel pinion position shim
C1 = Bevel pinion bearing lockring.
C2 = Differential carrier capscrew.
C3 = Ring gear capscrew.
Gd, Gs= R.H. and L.H. Differential bearing
lockring.

1.
2.
3.
4.
5.
6.
7.
8.
60.
61.
62.
63.

Bevel pinion
Seal
Bevel pinion bearing spacer
Ring gear
Axle shaft with universal joint
Side gear washers
Differential pinion washers
Differential pinion journal capscrew
Side gear
Side gear
Differential pinion
Differential pinion journal

NOTE: During installation, apply sealing compound to surfaces X as shown in Section 00, Chapter 1, page 1.

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

3
Cross--sectional view of front axle steering knuckle and hub
S3 = King pin bearing shim
10. Seal
C4 = King pin bearing capscrew.
11. King pin bearing
12. Seal
C5 = Steering knuckle capscrew.
13. Seal
C6 = Wheel hub bearing lockring
14. Axsule shaft bushing
C7 = Final drive housing capscrew.
15. Spacer
5. Wheel shaft
16. Thrust washers
9. Bearing carrier capscrew
17. Planet wheel journals
18. Planet wheel shims
19. Sun gear
NOTE: During installation, apply sealing compound to surfaces X as shown in Section 00, Chapter 1, page 1.

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

TRE0416A

Cross--sectional view of front axle pivot

H
L

S5

= 1 mm (0.0394 in.)
= 1 to 1.5 mm (0.0394 -- 0.0590 in.)
= Sleeve position shim

C9 = Axle pivot support capscrew

C10 = Differential bearing cap capscrew.
C11 = Capscrews securing front axle support
to engine.
20. Front axle pivot support
21. Front bushing

22.
23.
24.
25.
26.
27.
28.
29.
30.

Front thrust washer

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

DESCRIPTION AND OPERATION

JX60, JX70, JX80, JX90 and JX95 models have a
centrally pivoting front axle with the pivot and the
drive shaft coaxial with the longitudinal axis of the
tractor. The drive shaft has no universal joints.

The differential has two planet pinions; drive is

transmitted to lateral epicyclic final drive units
(installed on the wheel hubs) through universal joints
which require no maintenance.

6- 62720 -- 09 -- 2006

10

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

COMPLETE FRONT AXLE

Removal-- installation (Op. 25 100 30)

DANGER
Lift and handle all heavy parts using suitable lifting
equipment with a sufficient lifting capacity.
Check that the assemblies or parts are held firmly
and supported by suitable slings and hooks. Make
sure nobody is standing near to the load.

Proceed as follows:
NOTE: The front axle assembly can be removed
from the tractor either with or without previously
removing the drive shaft. The description below
refers to removal of the front axle with the drive shaft
installed on the tractor. For removal of the drive shaft
refer to section 23.

1
1. Disconnect the negative battery lead (1).

25621

5
2. Unscrew bolts (1) and remove the front
mudguard supports (2).

2
1

25575

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

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

11

TRE0159A

7
4. Unscrew bolts (1) and remove the drive shaft
guard (2).

25576

8
5. Remove the circlip (1) from the front of the drive
shaft. Slide the sleeve rearwards and detach the
drive shaft from the front axle.

25584

9
6. Pass two nylon slings around the front axle and
attach them to a hoist.

25580

10

6- 62720 -- 09 -- 2006

12

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

7. Lift the tractor with the hoist and place a stand

under the sump pan.

TRE0417A

11
8. Unscrew unions (1) of the rigid pipes to the
power steering cylinders and detach the two
flexible hoses

TRE0176A

12
9. Unscrew the wheel bolts and remove the front
wheels.

25582

13
10. Unscrew the front axle rear support retaining
bolts (1).

25585

14

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

13

11. Unscrew the front axle front support retaining

bolts (1.

25586

15
12. Using a hoist and two nylon cables (one for each
side) detach the front axle from the tractor.
13. Refit the front axle following the instructions
below.

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

Refit the axle and bolt the front and rear supports
in position.
Reconnect the the power steering pipes.
Fit the front wheels.
Raise the front of the tractor using the hoist.
Remove the fixed stand.
Detach the nylon cables.
Reconnect the drive shaft and refit the drive
shaft guard.
Refit the two front mudguards.
Attach a nylon cable to the front weights, lift, refit
to the tractor and secure with the locking screws.
Reconnect the negative battery lead.
Adhere to the tightening torques indicated on
page 4.

25583

16

6- 62720 -- 09 -- 2006

14

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

FRONT AXLE
Removal--Installation (Op 25 100 38 )

C6

JX60 and JX70 Models

WARNING
Handle all parts with care.
Do not insert hands or fingers between one part and
another. Wear suitable safety clothing, i.e. safety
goggles, gloves and shoes.
TRE0418A

17
1. Unscrew the drain plug and drain the oil from the
axle casing.
2. Remove the planetary final drive housing (1)
complete with planet wheels.
3. Remove sun gear (2).
4. Remove final drive ring gear -- fixed gear unit,
slacken ring nut using wrench 380000616 and
remove assy from knuckle.
5. Remove wheel hub (6) with taper roller bearing
cups (7) and associated seal. Be careful to
prevent seal damage.

4
3

TRE0419A

18
6. Remove steering knuckle (10) with wheel hub
support.
7. Remove articulated axle shaft (9) with bearing
housing. Back off the capscrew before withdrawing the axle shaft.
8. Replace worn bearings using suitable punches
and universal pullers. Check seal efficiency.
Assembly axle parts referring to
-- Before installing the final drive housing (1)
thoroughly clean and degrease mating surfaces and
apply 2 mm (0.0787 in.) of seaing compound.

TRE0420A

19
-- Insert articulated axle shaft (9) in axle case and
install steering knuckle carrier (8)
-- Adjust king pin bearing pre--load as directed in
the appropriate section.
-- Adjust wheel hub bearing pre--load as directed
in the appropriate section.
-- Fill wheel hubs and differential--bevel drive
housing with the specifed oil.

8
TRE0421A

10
20

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

15

JX80, JX90 and JX95 Models

WARNING
Handle all parts with care.
Do not insert hands or fingers between one part and
another. Wear suitable safety clothing, i.e. safety
goggles, gloves and shoes.
NOTE: For overhaul, the front axle should be mounted on stand No. 380000251.

25587

21
1. Unscrewthe plug (1) and drain the oil from the
axle casing.

1
25588

22
2. Unscrew plug (1) on the left--hand epicyclic final
drive casing. Repeat this operation on the
right--hand casing.

25589

23
3. Remove the front axle rear support (1). Remove
the front support and retrieve the washer.

25590

24

6- 62720 -- 09 -- 2006

16

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

4. Unscrew the two track rod retaining bolts (1).

25591

25
5. Using a suitable puller, withdraw the pins from
their bores in the stub axle housing and remove
the track rod.

24080

26
6. Remove the circlips (2) from the cylinder rod
pivot pins, unscrew the pin retaining bolts of the
cylinder (1), withdraw the pins and detach the
two cylinders.
Retrieve the four pins, washers, spacers and
cylinders, complete with hoses.

25593

27
7. Unscrew the retaining bolts from the left--hand
final drive casing cover (1). Screw in the two
dowels (2), as shown. Using a slide hammer
screwed into the oil drain plug hole, detach the
cover (1) from the casing.

25594

28

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

8. Remove the circlip (1) securing the sun gear (2)
and remove the gear.

17

25595

29
9. Remove the inner circlip (1) from the stub axle
shaft.

25596

30
10. Remove the staking (1) on the wheel hub bearing
lock ring (2).

25597

31
11. Remove the wheel hub bearing lock ring using
wrench 380000269 (1) for models JX80, JX90
and JX95.

25598

32

6- 62720 -- 09 -- 2006

18

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

12. Remove the wheel hub (1) with the ring gear (2).
Retrieve all disassembled parts.

25599

33
13. Unscrew the three retaining bolts (1) of the lower
pin of the stub axle housing. Recover the lower
pivot pin and the related adjustment shims.

25600

34
14. Unscrew the three retaining bolts (1) of the
mudguard bracket (2).

25601

35
15. Withdraw the upper pivot pin (1) and detach the
stub axle housing (2). Retrieve the disassembled
parts.

2
1

25602

36

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

19

16. Unscrew the axle shaft retaining bolt and remove

the axle shaft.

25604

37
17. Remove bracket (1), unscrew the union (3) and
detach the front brake pipe (2).

25605

38
18. Unscrew two of the bolts fixing the bevel
drive--differential support to the axle casing.
Screw in the two dowels (1). Remove the
remaining bolts and separate the bevel drive-differential support from the axle casing. Attach
a cable (2) to the support and take up the strain
with the hoist. Remove the bevel drive-differential support (3) from the axle casing.

25606

39
19. Install tool 380000255 (1) in the vice on the work
bench. Bolt the bevel drive--differential support
on to the tool. Detach the lifting cable.

20. Unscrew the bolt (2) and remove the ring nut lock
tab (3).

25607

40

6- 62720 -- 09 -- 2006

20

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

21. Remove the front brake bolts (1).

TRE0231A

41
22. Remove the front brake housing (1).

TRE0422A

42
23. Remove the front brake hub gear (1).

TRE0233A
25609

43
24. Remove the friction discs (1) and metal discs (2).

TRE0234A

44

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

21

25. Remove front brake piston (1) and O--rings.

TRE0235A

45
26. Unscrew the two bolts (2) of the crown wheel-differential support caps (1).

1
TRE0232A

46
27. Remove the crown wheel--differential assembly
(2) from the housing (1).

46

TRE0423A

47
28. Remove the circlip (1) from the splined shaft (2).

25614

48

6- 62720 -- 09 -- 2006

22

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

29. Straighten the locking tab on the splined shaftlock nut (1).

25615

49
30. Unscrew the nut using wren8ch 380000268 (1)
while preventing rotation of the bevel drive pinion
shaft using wrench 380000257.

25616

50
31. Recover the splined shaft detent ball (1).

25617

51
32. Withdraw the bevel drive pinion shaft (1) from the
rear of the casing and recover the spacer, the adjustment shims and the bearing.

25618

52

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

33. Using a screwdriver, detach and recover the dust
seal, the oil seal (1) and the rear bearing.

23

25619

53

Reassemble the front axle adhering to the

following instructions:

-- Refer to the illustrations on pages 7, 8 and

9 to check the orientation of the various
components.

-- Install the bevel drive--differential housing on

-- Respect the tightening torques prescribed on

page 4.

-- Install the axle shaft and relative bolt.

-- Carry out the adjustments described on pages

29 to 36.
-- Install the rear bearing, the seal, the dust seal,
the adjustment shims, the spacer and the bevel
drive pinion shaft complete with front bearing.
-- Position the detent ball, screw in the bevel drive
pinion lock nut and secure in position by
staking. Finally, replace the circlip.
-- Install the crown wheel--differential assembly,
the support caps and tighten the relative bolts.
-- Install the front brake friction disc, metal disc
hub gear, piston and front brake housing.
Tighten the respective bolts.

the front axle casing and fit the external front

brake pipe.

-- Fit the stub axle, the adjustment shims, the

upper and lower pivot pins, the mudguard
bracket and related bolts.
-- Fit the wheel hub, the ring gear of the final drive
unit and the lock ring. Tighten to the prescribed
torque value, while simultaneously turning the
wheel hub, to ensure that the bearings are
correctly seated.
-- Fit the securing and stop circlips, the sun gear
and the cover of the final drive unit.
-- Fit the pins, washers, spacers and steering
cylinders.
-- Install the track rod, the front and rear supports
and the oil drain plugs.

6- 62720 -- 09 -- 2006

24

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

STEERING KNUCKLE PINS AND BEARINGS

Replacement (Op. 25 108 46 or 25 108 47)

WARNING
Handle all parts with great care.
Do not put your fingers or hands between one piece
and another. Wear suitable safety clothing, i.e. safety
goggles, gloves and footwear.
In the event that the steering knuckle pins prove
difficult to remove, proceed as follows.
1. Remove the grease nipples and the steering
knuckle pin retaining bolts.
2. Fit the bolts (1) of tool 380000265.
3. Fit the plate (2) of the tool and fix it to the three
bolts with nuts (5).
4. Fit the central tie bolt (4) screwing it fully into the
grease nipple bore on the pin (6).
5. Screw in the nut (3) to drive the pin out of its bore.

24596

54
6. Using extractor tool 380000234 (1) remove the
steering knuckle bearings.

7. Re--install the steering knuckle bearings using a

suitable drift.

24599

55

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

25

STUB AXLE ADJUSTMENT

WARNING
Handle all parts with great care.
Do not put your fingers or hands between one piece
and another. Wear suitable safety clothing, i.e. safety
goggles, gloves and footwear.

Install the front axle on stand 293460 and proceed as

follows.

1. Smear grease AKCELA MULTI--PURPOSE

GREASE on the outer races of the bearings and
fit the upper cover, without the adjustment plate,
but with tool 380000235 (2). Tighten the retaining bolts (C5, page 5) to the following torque
values:
JX60 and JX70
64 Nm
(47.2040 ft lb)
JX80, JX90 and JX95
113 Nm
(83.3445 ft lb)

24076

56

2. Fit the lower cover without the adjustment plate

and lubricate the three retaining bolts with
engine oil.
3. Gradually tighten the lower cover bolts in
sequence, while simultaneously rotating the
casing to allow excess grease to escape.

24077

57

4. Using a torque wrench and tool 380000235 (1),

check that the torque required to rotate the
casing (ignoring the initial torque) is as follows:
models JX60 and JX70
2.9 Nm
(2.1389 ft lb)
(with torque increment of 0.98 Nm -- 0.7228 ft lb)

JX80, JX90 and JX95

15 -- 25 Nm
(11,0634 -- 18.4390 ft lb)
If the recorded torque is not as specified, adjust
by way of the lower cover bolts.
5. Measure the gap (H) created between the lower
cover and the casing adjacent to each of the
three bolts.

24078

58

6- 62720 -- 09 -- 2006

26

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

6. Calculate the average of the three values

measured. The total thickness of the adjustment
shims (page 8) to be fitted under the lower
cover is to be calculated as follows:
JX60 and JX70 S3= H
JX80, JX90 and JX95

S3= H -- 0.20 mm
(0.0079 in.)

If necessary, round up the value to the next

0.05 mm (0.0020 in.).
7. Partially unscrew the bolts of the lower cover,
insert the selected shims (S3, page 8). Tighten
the bolts (C4, page 5) to the following torque
values:
JX60 and JX70 64 Nm
JX80, JX90 and JX95

(47.2040 ft lb)
113 Nm
(83.3445 ft lb)

8. After having rotated the casing a few times to

allow the components to bed down, check that
the torque necessary to rotate the casing
(ignoring the initial torque) is follows:
JX60 and JX70 2.9 -- 7.8 Nm
(2.1389 -- 5.7530 ft lb)
JX80, JX90 and JX95
118 -- 147 Nm
(87.0323 -- 108.4216 ft lb)
9. If the torque value measured is greater than the
prescribed value, increase the thickness of the
shims. If the measured value is less than the
prescribed value, reduce the thickness of the
shims.
10. Fit the grease nipples in the upper and lower
covers and grease the assembly.

6- 62720 -- 09 -- 2006

24079

59

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

WHEEL HUB BEARING ADJUSTMENT:

27

First class axle mod. JX60 and JX70

Proceed as follows:
-- Install wheel hub and fixed gear unit onto the
steering knuckle;
-- Using a torque wrench and lock ring wrench
380000616 (for JX60 and JX70 models)
progressively tighten the ring nut (C6, page 8)
to 147 -- 196 Nm (15 -- 20 kgm). While tightening the ring nut, rotate the hub to settle the bearings.

24093

60

-- Fully slacken the lock ring and retighten to 59

Nm (43.5162 ft lb) while rotating hub.
-- Secure the lock ring by bending over a lockwasher tab ( if necessary, further tighten the
lock ring to align a slot with the tab )
-- Turn the hub by hand to check for excessive
play or binding.
-- Carefully secure the ring nut.

6- 62720 -- 09 -- 2006

28

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

Second class axle mod. JX80, JX90 and JX95

Proceed as follows:
-- Progressively tighten the ring nut, using the
torque wrench and wrench 380000269 (1) to obtain a torque value of 392 Nm (289.12432 ft lb);
at the same time, rotate the wheel hub to ensure
that the bearings are correctly seated.
--

Measure the rolling resistance (Rt) of the wheel

hub using the relative torque wrench, or a torque
meter and cord positioned on the base of the
wheel disk flange.

61
--

Loosen the ring nut by half a turn and measure

the rolling resistance (R) as described
previously. The difference between the two
measurements is the rolling torque value of the
wheel hub bearings (Rc):

--

Rc = Rt -- R = 5.9 14.7 Nm (4.3516 10.8416

ft lb) or if measured with a torque meter.
Rc = Rt -- R = 7.5 18.75 kg (41.3554 lb).

--

If the measurement is less than 5.9 Nm

(4.3516 ft lb) or with the torque meter on 4.8 kg
(10.5870 lb) it is necessary to replace the affected parts and repeat the check.

--

Progressively tighten the ring nut, using the

torque wrench and wrench 380000269 (1) to
obtain a torque value of 392 Nm (289.12432 ft
lb); at the same time, rotate the wheel hub to
ensure that the bearings are correctly seated.

--

Carefully secure the ring nut.

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

29

BEVEL DRIVE ADJUSTMENTS

Adjustment of the preload of the pinion shaft
bearings

M
WARNING

Handle all parts with care.

Do not insert hands or fingers between one part and
another. Wear suitable safety clothing, i.e. safety
goggles, gloves and footwear.

7
9

TRE0424A

Proceed as follows.

61

H1

1. Install the bevel pinion bearing cones (7) and

(9) with spacer (8) on tool 293438 (E).

NOTE: For JX60 and JX70 models, place the

spacer M outside the bearings.

7
E

2. Fully tighten tool nut (M).

3. Measure the distance (H1) between the end of

the pin on the bottom of the tool and the top
surface of the tool.

9
TRE0425A

62
4. Remove the bearing cones and spacer from the
tool. Lubricate bearings with engine oil and
re--install onto the tool, inserting differential
carrier (10) with bearing cups.
5. Fully tighten tool nut (M) while rotating the
differential carier through ten revolutions to settle
the bearings.
6. Measure dimension (H3) of the tool in this
condition.

TRE0426A

63
7. Thickness of shims (S1) will be given by:

H3

S1= H3 -- H1 + 0.10 mm (0.00039 in.)

S1

If necessary, round off (S1) to the nearest 0.05 mm

(0.0020 in.)

7
E
G

NOTE On completing the adjustment, do not remove

the adjustment tool from the bevel drive--differential
housing. Leave in place for adjustment of the drive
pinion position. See following subject matter.

9
TRE0427A

10
64

6- 62720 -- 09 -- 2006

30

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

BEVEL DRIVE ADJUSTMENTS

Determining the thickness of the drive pinion
position adjustment shim
Proceed as follows.
1. Fit tool 380000249 (1) in the bevel drive--differential housing (2), complete with outer bearing
rings, crown wheel bearings adjustment ring,
crown wheel bearings adjustment shim, circlip
and differential housing caps, taking care to
tighten the bolts (C10) to a torque of 113 Nm
(84.3445 ft lb).
2. Screw the cones (3) of tool 380000249 (1) in or
out in order to position the micrometer shaft (4)
in the direction of the inner bearing ring (5) and
eliminate end float between the cones and the
outer rings of the bevel crown wheel bearings.
3. Adjust the micrometer so that the shaft (4) is in
contact with the inner bearing ring (5) and
measure the distance (H3).
4. Determine the correct distance (H5) between the
crown wheel axis and the large diameter base of
the pinion:
H5 = H4 C
where:
H4 = Nominal distance between crown wheel
centreline and pinion big end
-- 100 mm for JX60, JX70 models.
-- 15 mm for JX80, JX90, JX95 models.
C = a correction value stamped on the pinion
preceded by a + or -- sign (if other than 0). This
value to be added to or subtracted from the
nominal distance (H4) according to the sign.
5. The thickness of the adjustment shim (S2) will be
given by:
S2 = H3 -- H5
where:
H3 = the distance measured using the micrometer;
H5 = corrected nominal distance between the
crown wheel axis and the large diameter base of
the pinion.

6- 62720 -- 09 -- 2006

C10

1
2
4

TRE0428A

66
H3

TRE0428A

67

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

31

Examples (models JX60 and JX70)

Example 1:
--

Distance measured using micrometer H5 = 103.3

mm (4.0669 in.).

--

Nominal distance between crown wheel axis and

large diameter base of pinion H4 = 100 mm
(3.9370 in.).

--

Correction value C = + 0,2 mm (0.0079 in.).

--

Corrected nominal distance H5 = 100 + 0.2 =

100.2 mm (3.9370 + 0.0079 = 3.9449 in.).

--

Thickness of adjustment shim

S2 = 103.3 -- 100.2 = 3.1 mm (4.0669 -- 3.9449
= 0.1220 in.).

Example 2:
--

Distance measured using micrometer H3 = 103.3

mm (4.0669 in.).

--

Nominal distance between crown wheel axis and

large diameter base of pinion H6 = 100 mm
(3.9370 in.).

--

Correction value C = -- 0.2 mm (0.0079 in.).

--

Corrected nominal distance H7 = 100 -- 0.2 =

99.8 mm (3.9370 -- 0.0079 = 3.9291 in.).

--

Thickness of adjustment shim

S2 = 103.3 -- 99.8 = 3.5 mm (4.0669 -- 3.9291 =
0.1378 in.).

Example 3:
--

Distance measured using micrometer H3 = 103.3

mm (4.0669 in.).

--

Nominal distance between crown wheel axis and

large diameter base of pinion H4 = 100 mm
(3.9370 in.).

--

Correction value C = 0 mm (0 in.).

--

Corrected nominal distance H5 = H6 = 100 mm

(3.9370 in.).

--

Thickness of adjustment shim

S2 = 103.3 -- 100 = 3.3 mm (4.0669 -- 3.9370 =
0.1299 in.).

6- 62720 -- 09 -- 2006

32

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

BEVEL DRIVE ADJUSTMENTS

Adjustment of the crown wheel bearings and
checking the backlash between the pinion and
crown wheel.
Proceed as follows.

1. Install the bevel pinion with all parts (less the

seal but including shims (S1 and S2, page 7)
in the differential carrier. Shim sizes to be as
determined in the procedure described on
pages 29 and 30.
2. Fit pinion retaining tool 380000257.
3. Insert wrench 380000532 on the adjuster ring
nut mod. JX60 and JX70 380000268 mod.
JX80, JX90 and JX95.
4. Using the torque wrench on the pinion retaining wrench, hold the bevel pinion in position
and, using a torque wrench positioned exactly
as in fig. 68 on the ring nut wrench, tighten the
ring nut (C1) to a torque value of 294 Nm
(216.84352 ft lb) while simultaneously rotating
the pinion shaft to ensure that the bearings are
seated correctly.

24590

68

5. With torque wrench 380001633 (1) fitted on

pinion retaining wrench 380000257 (2), check
that the pinion rolling torque, without oil seal
and relative dust seal, is 0.5 1 Nm (0.3688
0.7376 ft lb).
If the rolling torque is less than the prescribed
value, fit a thinner adjustment shim (S1, page
7); on the contrary, if the torque is greater
than the prescribed value, fit a thicker adjustment shim.
6. Unscrew the ring nut and fit the seal and the
relative dust seal ring. Tighten the nut to a
torque value of 294 Nm (216.84352 ft lb) while
simultaneously rotating the pinion shaft to
ensure that the bearings are seated correctly.
7. With torque wrench 380001633 (1) fitted on
pinion retaining wrench 380000257 (2) check
that the pinion rolling torque, with the oil seal
and relative dust seal, is -- 0.50 Nm (0.3688 ft
lb) for mod. JX60 and JX70 or -- 0.75 Nm
(0.5532 ft lb) for mod. JX80, JX90 and JX95.
Finally, secure the ring nut and fit the circlip on
the bevel pinion shaft.

6- 62720 -- 09 -- 2006

TRE0428A

69

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

33

8. Install the differential unit in the carrier ensuring that ring gear is not forced onto the pinion.
Tighten screws (C10) to 59 Nm (43.5162 ft lb)
then slacken and retighten to 20 Nm (14.7512
ft lb).
9. Lubricate the ring gear bearings, fit the
adjuster shim on the left--hand side (front
brake side for four--cylinder models if this
variant is included in the tractor version),
rotate the bevel drive and tighten the differential bearing lock ring (GS, page 7).
24591

70
10. Using wrench (1) 380000252, for JX60 or
JX70 models, or wrench 380000253, for JX80,
JX90 or JX95 models, check that the torque is
39 to 59 Nm (28.7649 to 43.5162 ft lb) to
establish the specified axial pre--load.
11. Measure bevel drive backlash (1, fig. 72) using
a dial gauge positioned at right angles to a
bevel gear tooth.
12. Repeat the measurement at two other equidistant points, 120 apart. Compare the average
of the three readings with the specified
backlash of 0.15 -- 0.20 mm (0.0059 -- 0.0079
in.) (average 0.18 mm (0.0071 in.)).

24592

71
13. If the measured backlash exceeds the prescribed value, fit a thinner adjustment shim.

Note: On three--cylinder models or four--cylinder

models without the front brake, if the clearance value is not within the prescribed field of tolerance,
unscrew one of the ring nuts, whilst tightening the
other to an equal amount, so as to reset the prescribed clearance.

24593

72
The definitive value to fit on the bevel drive--differential support will be given by:
S = Sp + {(0.18 -- Gm) x 1.35}
where:
Sp = thickness of test shim installed in the bevel
drive--differential housing.
Gm = average backlash measured between the
sides of the teeth of the bevel drive.
14. If the backlash measured is less than the
prescribed value, it will be necessary to fit a
thicker adjustment shim, the value being given
by:

6- 62720 -- 09 -- 2006

34

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

S = Sp + {(0.18 -- Gm) x 1.35}

where:
Sp = thickness of test shim installed in the bevel
drive--differential housing.
Gm = average backlash measured between the
sides of the teeth of the bevel drive.
15. Fit a shim of the calculated thickness and with a
1/100 scale dial gauge positioned perpendicular
to the outside edge of one of the crown wheel
teeth, check that the backlash between the
pinion and the crown wheel is within the prescribed tolerance limits 0.15 0.20 mm (0.0059
to 0.0079 in.).
16. Using wrench 380000252, for JX60 or JX70
models, or wrench 380000253, for JX80, JX90 or
JX95 models, turn the adjuster ring nut and,
using torque wrench 380001633 fitted on
wrench 380000257 (1, fig. 73), check that the
rolling resistance torque of the crown wheel and
pinion bearings, as measured in the same
conditions used to check only the pinion, is:
A2 = A1 + 1 1.5 Nm (0.7376.5 to 1.1063 ft lb)
where:
A2 = pinion--crown wheel rolling resistance torque;
A1 = rolling torque of pinion only, 0.5 Nm (0.3688
lb) for JX60 or JX70 models and 0.75 Nm (0.5532
ft lb) with the pinion fitted with the seal, measured
previously;
1 1.5 Nm (0.7376.5 to 1.1063 ft lb) = rolling resistance torque of crown wheel only measured at
the end of the pinion, using wrench 380000257
and torque wrench 380001633.
24587

73

17. Tighten the cap bolts (C1, page 4) to a torque

of 113 Nm (83.3445 ft lb).
18. Fit the safety plates, screwing the adjustment
ring nut in or out, to reach the nearest notch.
19. Attach the differential bevel drive carrier to the
axle casing after having carefully cleaned and
degreased the mating surfaces and apply
sealing compound (approx. 2 mm (0.0787)
along the marked line shown in the drawing
below.
24591

74

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

35

20. Attach the differential bevel drive carrier to the

axle casing after having carefully cleaned and
degreased the mating surfaces and apply
sealing compound (approx. 2 mm) along the
marked line shown in the drawing below.

Sealing compound application diagram for

assembly of bevel drive unit and epicyclic
final drive unit.
The types of mastic to use are listed on page 1 of
section 00.

24596

75

6- 62720 -- 09 -- 2006

36

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

FRONT AXLE DIFFERENTIAL

Overhaul (Op. 25 102 24 )
When overhauling the differential assembly it is necessary to adjust the backlash between the teeth of
the planet pinions and the side gears.
Proceed as follows:
1. Thoroughly clean the components of the differential to remove any traces of oil which would
otherwise prevent accurate backlash measurement.
2. Install the two side gears without thrust washers.
3. Fit the planet pinions complete with thrust washers and pins and screw the pin retaining bolts in
by a few turns sufficient to hold the pins in place.
4. Position a dial gauge on the differential housing,
as shown.
5. Move the left--hand side gear to bring it into full
contact with the planet pinion and then push it up
against the differential housing, reading the endfloat (Gs) on the dial gauge.
24597

76

6. Repeat the above operations to measure the

endfloat on the right--hand side gear (Gd).
The endfloat should be 0.25 mm (0.0098 in.).
Therefore the shims to be inserted in the differential housing are given by:
Ss = Gs -- 0.25 mm (0.0098 in.) for the left--hand
side gear;
Sd = Gd -- 0.25 mm (0.0098 in.) for the right-hand side gear.

7. Install shims as near as possible to the calculated value and, using a dial gauge and following
the procedure described above, check that the
endfloat of the left and right--hand side gears is
approximately 0.25 mm (0.0098 in.).

6- 62720 -- 09 -- 2006

24598

77

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

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

37

78
LIMITED--SLIP self--locking differential lock

FRONT AXLE DIFFERENTIAL WITH LlMITED-SLlP UNIT

Overhaul (Op. 25 102 27 )

WARNING
Handle all parts with [Link] not put your hands
or fingers between parts. Wear suitable safety
clothing, safety goggles, gloves and footwear.
1. Remove the bevel drive--differential casing
assembly from the front axle and attach to the
support 380000255 (4). Lock the support in a vice
and proceed with disassembly, as follows.
2. Remove the bolts (2) and the left-- and
right--hand ring nut Iock plates (3).
3. Check that the right and Ieft--hand caps (1) are
clearly marked, so as not to mix the parts during
reassembly.
4. Remove the left-- and right--hand bearing
adjustment ring nuts (Gd) from the crown wheel.
5. Remove the bolts (C9), securing the caps (1)
and separate the crown wheel from the bevel
pinion support.
6. If necessary, unscrew the retaining bolts (C3,
page 4) and remove the crown wheel.

79

6- 62720 -- 09 -- 2006

38

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

Disassemble the LlM--SLlP self--locking differential Iock as follows:

7. Remove the retaining bolts (1) from the
differential half--casing.
8. Open the differential casing (6).
9. Remove the half--casing (7) the differential pin
(4), complete with the planet gears (3), the thrust
washers (2) and the pins (9).
10. Remove the side gear (5) the friction disc (11),
the metal discs (1 0) and the friction discs (12) from
the half--casing (8).
11. Check the wear on the metal discs (10) and the
friction discs (11) and (12) -- see table below.
Replace any parts that show signs of wear.
12. Proceed with the self--locking differential
assembly operations, carrying out the previously
described operations in reverse order. Apply
LOCTITE 270 to the threads on the screws (1) and
tighten to a torque value of 50 Nm (36.8781 ft lb).

80
LIM--SLIP self--locking differential lock

13. Re--install the crown wheel (if previously

disassembled) to the half--casing (8). Tighten the
screws (C3, page 4) to a torque of 113 Nm
(11.5 kgm).
14. Check the rolling torque of the bevel pinion as
indicated on page 32 and following.
15. Assemble the crown wheel, complete with
LIM--SLIP self--locking differential lock, onto the
bevel drive support. Do not forget to fit the
previously marked crown wheel bearing support
caps in the correct order. Assemble and then
adjust the crown wheel bearings as indicated on
page 32 and following.

Friction parts detail

81

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

Part no.

Description

Quantity

Thickness
mm (in.)

Maximum wear per disc

mm (in.)

10

Metal discs

10

1.5 (0.0591)

--

11

Friction discs

2.8 (0.1102)

0.10 (0.0039)

12

Friction discs

1.6 (0.0630)

0.15 (0.0059)

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

39

NO SPIN DIFFERENTIAL (optional)

82
Section through differential with NO--SPIN unit

C1 = Case capscrew, tightening torque 56 to 62 Nm (41.3034 to 45.7288 ft lb)

1

-- Case, flange half

-- Retaining ring

-- Case, cap half

-- Cam holdout rings

-- Side gear

10 -- Driven clutch

-- Side gear

11 -- Centre cam

-- Springs

12 -- Stop

-- Spring retainer

13 -- Ring gear

-- Central driven assembly

14 -- Axle shafts
15 -- Front axle housing

6- 62720 -- 09 -- 2006

40

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

NOTE:
Check NO SPIN differential unit operation as
follows:
-- With the engine off, engage a gear and the front
wheel drive, apply parking brake and raise front
of tractor.
-- Rotate the front wheels in a forward direction to
eliminate play. Hold the L.H. wheel and rotate
the R.H. wheel rearwards. The NO SPIN
differential will disengage and the wheel will
rotate with an indexing or metallic clicking
sound.

-- Stop the [Link], then turn forwards slightly.

The NO SPIN differential will engage and stop
the wheel. Rotate both wheels backwards to
eliminate play, hold the [Link] and rotate
the R.H. wheel forwards. The NO SPIN
differential will disengage and the wheel will
rotate with an indexing or metallic clicking
sound.
-- Stop R.H. wheel, then tum backwards slightly.
The NO SPIN differential will engage and stop
the wheel.
-- Repeat the above operations while holding the
R.H. wheel.

OPERATlON
The NO SPIN differential performs the following key
functions:
-- Permits full use of tractor pull.
-- Prevents wheel--spin when one wheel Ioses
traction.
-- Compensates for differences in wheel travel
which occur when turning or traveling over
uneven ground.

When the tractor is in a straight forward or reverse

mode of operation, the NO SPIN allows equal
speed to be distributed to both wheels.
When the tractor makes a turn or a front wheel
passes over an obstruction, the outer wheel or the
wheel on the obstruction must travel faster and
farther than the other. To do this it automatically
disengages, passes over the obstruction or negotiates the curve and re--engages again automatically.
If one wheel should Iose traction momentarily, the
opposite wheel, which still has traction, continues
to pull the vehicle until traction is regained by both
wheels.
Turning: In a left turn, for instance,the right--hand
wheel increases speed. The axle shaft (14) (page
39), transmits this speed increase to the left side
gear (3) to the left driven clutch (10) and to the
associated cam holdout ring (9). When the speed
difference between the two wheels reaches a
given value, ring (9) and clutch (10) overcome
spring Ioad and disengage from the centre cam
(11), remaining in this position until1he end of the
curve.

NOTE: For correct NO SPIN differential operation,

tyres must be equal (within a few millimetres) in
rolling circumference. Small differences may be
corrected by adjusting tyre inflation pressure. To
check the rolling circumference of a tyre, proceed as
follows:
With the tractor on a hard, level surface, mark the
edge of the tyre, with chalk, at the lowest point
(where it contacts the ground). Mark the ground at
the same spot.
Move the tractor forward so that the tyre rotates
exactly one revolution, i.e., when the chalk mark on
the tyre contacts the ground again. Measure the
distance travelled. This is the rolling circumference
of the tyre.
Repeat on the opposite wheel to check that both
tyres have the same rolling circumference.

6- 62720 -- 09 -- 2006

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

41

FRONT AXLE DIFFERENTIAL WITH NO SPIN

OP. 25 102 26
Overhaul

WARNING
Handle all parts with carefully. Do not put your hands
or fingers between [Link] suitable safety clothing, safety goggles, gloves and footwear.
1. Remove the bevel drive--differential casing
assembly from the front axle and attach to the
support 380000255 (4). Lock the support in a vice
and proceed with disassembly, as follows.
2. Remove the bolts (2) and the left-- and
right--hand ring nut Iock plates (3).
3. Check that the right and Ieft--hand caps (1) are
clearly marked, so as not to mix the parts during
reassembly.
4. Remove the left-- and right--hand bearing
adjustment ring nuts (Gd) from the crown wheel.
5. Remove the bolts (C10), securing the caps (1 )
and separate the crown wheel from the bevel
pinion support.
6. If necessary, unscrew the retaining bolts (C3
page 4) and remove the crown wheel.

C10

83

Disassemble the NO SPIN self--locking differential

Iock as follows.
7. Remove the retaining bolts (1) from the differential half--casing.
8. Open the differential casing
9. Remove the central driven (7), retaining the
differential half -- casing.
10. Proceed with self--locking the differantial
assembly oparations, carrying out the previously
desciribed operations in reverse order Tighten the
bolts (C1, fig. 84) torgue value of 56--62 Nm
(41.3034--45.7288 ft lb)
11. Refit the crown wheel bolts (C3, page 4) and
torque to a value of 113 Nm (83.3445 ft lb)
12. Assemble the crown wheel, complete with NO
SPIN self--locking differential lock, onto the bevel
drive support. Remember to fit the previously
marked crown wheel bearing support caps in the
correct order and assemble and then adjust the
crown wheel bearings as indicated on page 32 and
following.

84

6- 62720 -- 09 -- 2006

42

SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1

CHECKING THE ALIGNMENT OF STEERING

DRIVE WHEELS (Op 44 511 80 )
When travelling forward in a straight path, the wheels
of four--wheel drive tractors must be parallel to the
longitudinal axis of the tractor, alternatively a slight
toe--in of the front wheels is permissible up to a maximum of 6 mm (0.2362 in.) as measured at the edges
of the wheel rims.
To check the exact value of the toe--in setting of four-wheel drive tractors, proceed as follows.
1. Inflate the front tyres to the prescribed pressure.
2. Position the steering at the straight ahead
position (along the longitudinal axis of the
tractor).
3. Check that the wheels are parallel to the
longitudinal axis of the tractor.
4. Make a chalk mark on the front inside edges of
both wheel rims, at the height of the wheel hub
centres. Measure the distance (1) between the
chalk marks.
5. Move the tractor forward to turn both front
wheels through 180o. The chalk marks will now
be measure between the rear inside edges of the
wheel rims at the height of the wheel hub
centres. Mow measure the distance (2) checking
that this new measurement is equal to or greater
than the distance (1) by a maximum or 6 mm.
The rotation of the wheels through 180o is necessary
to eliminate the effect of wear, misalignment or
distortion of the wheel rims on the measurements
obtained.

6. If it is necessary to correct the wheel alignment,

remove nut (2) and pull the track rod end (1) out
of its housing. Slacken off locknut (3) and screw
the track rod end (1) in or out to increase or
decrease the distance (2) fig. 84.
Reposition the track rod end (1) in its housing
and re--check alignment as described in points 4
and 5 above.
After having adjusted the alignment to within the
prescribed limits, tighten locknut (3) to a torque
of 180 Nm (134.9738 ft lb) and nut (2) to 100
Nm (73.7562 ft lb).

24666

84

24667

NOTE: The self--locking nut (2) must be renewed

each time it is removed or partially unscrewed.

6- 62720 -- 09 -- 2006

85

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

SECTION 27 REAR AXLE AND TRANSMISSION

Chapter 1 Rear axle and transmission
CONTENTS
Section

Description

Page

27 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Crosssectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description and operation and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
21.118.10 12 Transmissiongearbox casing RemovalInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
21.118.85
Transmissiongearbox casing DisassemblyOverhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Gearbox driven shaft end float adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Differential lock engagement sleeve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Determining the bevel pinion positioning adjustment ring . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Adjusting the taper roller bearings for the bevel pinion shaft . . . . . . . . . . . . . . . . . . . . . . . . 39
Adjusting the bearings and checking the backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Differential pinion and side gear backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
27 000 MAIN SPECIFICATION TORQUE SETTINGS SPECIAL TOOLS SECTIONAL VIEWS
DESCRIPTION AND OPERATION FAULT FINDING
MAIN SPECIFICATION OF BEVEL GEAR PAIR AND DIFFERENTIAL
Bevel gear pair gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bevel gear pair tooth clearance . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

Type of differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical differential lock control . . . . . . . . . . . . . . . . . . .
Release for mechanically controlled differential lock . . . .

Differential pinion internal seat diameter . . . . . . . . . . . . . .

mm
(in.)

Differential pinion pin diameter . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

Clearance between differential pinions and their pins . . .

mm
(in.)
mm
(in.)
mm
(in.)
mm
(in.)

Diameter of side gear hub seats on differential box . . . .

Diameter of side gear hubs . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance between side gears and their seats . . . . . . . . .

JX60 JX70
JX80 JX90 JX95
9/43 = 1:4.8 (30 kph (18.6 mph))
11/43 = 1:3.9 (40 kph (24.9 mph))
0.18 0.23
(0.0071 0.0091)
with two planet gears
by means of pedal
controlled by foot brake pedals
25.04025.061
(0.9858
0.9867)
24.040 24.061
(for
JX80JX90)
(0.9465 0.9473)
28.04028.061
(1.1039 1.1048)
(for JX95)
23.939 23.960
24.93924.960
(0.9425 0.9433)
(0.9818 0.9823)
(for JX80JX90)
27.93927.960
(1.1000 1.1007)
(for JX95)
0.080 0.122
0.080 0.122
(0.0031 0.0048)
(0.0031 0.0048)
44.080 44.119
51.100 51.146
(1.7354 1.7370)
(2.0118 2.0136)
43.961 44.000
50.954 51.000
(1.7307 1.7323)
(2.0061 2.0079)
0.080 0.158
0.100 0.192
(0.0031 0.0062)
(0.0039 0.0076)
(see over)

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

MAIN SPECIFICATION OF BEVEL GEAR PAIR AND DIFFERENTIAL
(cont.)
JX60 JX70

Bevel pinion positioning adjustment . . . . . . . . . . . . . . . . . . . . . .

Adjuster shims for bevel pinion positioning . . . . . . . . . . . . . . . . .

see pages 39
1.85 1.90 1.95 2.00 2.05
2.10 2.15 2.20 2.40 2.45
2.50 2.55 2.60 2.65 2.70
(in.) (0.0728 0.0748 0.0. 768 0.0787
0.0807 0.0827 0.0846 0.0866
0.0945 0.0965 0.0984 0.1004
0.1024 0.1043 0.1063)

mm

Adjusting ring bevel gear bearings and bevel gear pair coupling
clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential pinion and side gear backlash . . . . . . . . . . . . . . . . .

JX80 JX90
JX95

see page 181

mm
(in.)

0.15
(0.0059)

0.18
(0.0071)

Thickness of differential side gear clearance adjustment shims mm

(in.)

1.51.6
(0.05910.0630)

Thickness of differential pinion thrust bearings . . . . . . . . . . . . .

1.471.53
(0.05790.0602)

mm
(in.)

Adjusting clearance between pinion and side gear teeth . . . .

see page 185

Adjusting differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

see page 177

Differential lock control fork adjuster shim . . . . . . . . . . . . . . . . .

mm
(in.)

0.5
(0.0197)

mm
(in.)

220
(8.6614)

length of spring under load of 177195 N (3.99224.3892 lb) mm

(in.)

157.5
(6.2008)

Spring for differential lock control fork:

free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAIN SPECIFICATIONS OF FINAL DRIVES

JX60 JX70
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

662720 09 2006

JX80 JX90
JX95

pinion type and spur gears

11:62= 1:5.6

11:67=1:6.1
(for JX80JX90)
11:68=1:6.2
(for JX95)

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

TORQUE SETTINGS Refer to fig. 1 on page 4

Torque settings
PART TO BE TIGHTENED

Thread
Nm

ft lb

Retaining bolts for rear transmission/gearbox upper cover (C1) . . .

M 10 x 1.25

59

43.5161

Bolts for securing lift to rear transmission box (C2) . . . . . . . . . . . .

M 12 x 1.25

98

72.2811

Bolts for securing PTO box to transmission / gearbox case (C3)

M 16 x 1.5

221

163.0012

Bolts for securing torsion bar to transmission / gearbox case (C4)

M 16 x 1.5

221

163.0012

Nuts for stud bolt securing final drive box to transmission /

gearbox case (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

98

72.2811

Drive wheel hub to disc retaining nuts (C6) . . . . . . . . . . . . . . . . . . .

M 18 x 1.5

255

188.0783

Drive wheel rim to disc retaining nuts (C7) . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

245

188.7027

Ring bevel gear retaining bolts (C8) . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

123

90.7201

Bevel drive differential support retaining selflocking bolts (C9)

M 10 x 1.25

59

43.5161

Final drive casing cover retaining bolts (C10) . . . . . . . . . . . . . . . . .

M 10 x 1.25

59

43.5161

Drive wheel axle retaining nut (C11) . . . . . . . . . . . . . . . . . . . . . . . . .

M 55 x 1.5
M 60 x 2

882
882

650.5297
650.5297

Differential lock pedal support retaining bolts . . . . . . . . . . . . . . . . .

M 10 x 1.25

49

36.1405

Nuts for drive wheel ballast ring retaining bolts . . . . . . . . . . . . . . .

M 14 x 1.5

98

72.2811

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

SECTIONAL VIEWS

C1 59 Nm

C2 98 Nm

C3 221 Nm

C4 221 Nm
C9 59 Nm
C7 245 Nm

C6 255Nm
C8 123 Nm
C5 98 Nm
C10 888Nm

TRE0550A

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

380000277 Hook for lifting clutch box.

SPECIAL TOOLS

380000301 Rotating stand for overhaul.

380000271 Rear mounting (with 380000301).
IMPORTANT: The operations described in this
Section must be performed only with the
ESSENTIAL tools marked with (X).
To work in complete safety and to ensure optimal
technical results with a minimum of time and effort,
they must be supplemented by the special tools
recommended below and with those to be specially
constructed by you and for which the construction
diagrams are given in this manual.
List of special tools required for the various
operations described in this Section :
380000236 Trolley for tractor disassembly.

380000272 Front mounting (with 380000301).

X 380000838 Adapter for extracting bevel pinion
(with 380000549).
380000549 Slide hammer.
380000249 Bevel pinion positioning gauge.
50006

Punch for removing gearbox drive

shaft (see page 4, Sect.21,
Chapter 1).

50007

Tool for adjusting gearbox drive

shaft (see page 4, Section 21,
Chapter 1).

HEXAGON CH 22

Tool to make for bevel pinion extraction

(Mark part with No. 50144 Measurements in mm)
Make in UNI C40 material. Spring pin 3 x 20 mm.

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

3
Tool to make for adjusting the bevel drive
(engrave number 50027 on the tool measurements in mm)
Make in Fe 42 C material.

26259

4
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.

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

TRE0551A

5
Sectional drawings of transmissiongearbox case
1. Midrange and reverse gear control rod.
2. Slow and fast gear control rod.
3. 1st and 2nd gear control rod.
4. Detent balls.
5. Spring for ball (4).
6. Gear engagement safety pawl.
7. Spring for ball (8).
8. Detent ball.
9. 3rd and 4th gear control rod.
10. PTO external control lever.
11. Gear engagement safety pawl.
12. Plug.

13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

Range engagement safety pawl.

Plug.
Reverse gear support pin.
Retaining bolt.
Reverse idler gear.
Thrust bearing.
Snap ring.
PTO shaft.
Reverser drive shaft.
Engagement gear for midrange and reverse
gears.
23. Driving gear for midrange gears.
24. Snap ring.

NOTE: Screw in plugs 12 and 14 using one of the sealing compounds listed on page 1, Section 00.

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

15

15

14 7

C3

C3

10
9

10

14 7

6
16

16
4
4

C4

C4
17
11

17

11

13

13
5

18

20
12

C1
TRE0552A

19

19

12

C5

C5
18
1

X
C1

1
6

Crosssectional view of final drive

a. JX70 models

6. Roller bearing

b. JX80, JX90, JX95 models

7. Ball bearing

C1. Final drive housing cover capscrews

8. Final drive driven gear

C2. Capscrews securing final drive housing to

transmission housing

9. Axle shaft

C3. Nuts securing disc to wheel rim

11,[Link]

C4. Capscrews securing disc to wheel hub

13. Seal guard

C5. Nut

14,15,[Link] rings

17. Seal thrust ring

Drain plug

10. Final drive casing

1. Wheel disc

18. Grease nipple

2. Wheel shaft

19. Lockwasher

3. Final drive housing cover

20. Seal

4,5. Ball bearings

NOTE: During installation, apply sealing compound to surfaces X as shown in Section 00, Chapter 1, page 1.

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

DESCRIPTION AND OPERATION

The rear transmission transmits power from the
gearbox to the lateral final drives by means of the
bevel gear pair. The bevel gear pair is of the helical
tooth type and is supported by taperroller bearings.
The differential has two pinions and is equipped with
a mechanically controlled differential lock.

Final drives are of the pinion type and are controlled

by the bevel gear pair output halfshafts, the same
shafts that control the footbrakes.
When the differential lock is not in use, it is kept disengaged by a spring that exerts a force on the fork.

FAULT FINDING FOR BEVEL GEAR PAIR AND DIFFERENTIAL

Problems

Possible causes

Remedies

Transmission noisy while the trac- 1. Incorrect adjustment of bevel Remove the rear transmission box
tor is moving, even when the gearpinion and / or ring bevel gear and adjust the pinion and ring bevel
box is in neutral (not arising from
gear bearings correctly (page 36).
bearings.
final drives).
Transmission noisy when tractor 2. Excessive clearance between Remove the rear transmission box
ia operated with or without load.
and correctly adjust the pinion and
pinion and ring gear teeth.
ring gear bearings (page 36).
Differential repeats noise within 3. An internal component is bro- Remove the rear transmission box,
short intervals.
replace the worn parts and correctly
ken or defective.
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
ring bevel gear bearings (page 36).
cient.
5. Insufficient coupling clear- Remove the rear transmission box
ance between the teeth of the and correctly adjust the ring bevel
gear bearings (page 39).
pinion and the ring gear.

FAULT FINDING FOR FINAL DRIVES

Problems

Possible causes

Remedies

Final drive noisy when tractor is

6. An internal component is bro- Remove the final drive box and removing, even with the gearbox in
place the damaged parts.
ken or defective.
neutral.

662720 09 2006

10

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

REAR TRANSMISSION GEARBOX CASE

RemovalRefitting (Op. 21 118 10 21 118 12)
Related service instructions up to item 44 see
pages from 10 to 20. Also describes removal
operations of suspended cab/platform (Op. 90 110
36) with the exception of heating pipes and air
conditioning components removal.

WARNING

Lift and handle all heavy parts using proper

equipment of adequate lifting capacity.
Make sure that the assemblies and parts are
supported by appropriate tools and hooks. Keep
personnel away from the vicinity of the load to be
lifted.
To remove the gearboxrear transmission, proceed
as follows:
1. Disconnect the negative terminal from the
battery. Remove the rear transmission drain plug
(1) and the gearbox drain plug (2). Drain the oil
into suitable containers.

TRE0209A

7
2. Remove the drain plug from the 4WD transfer
box (1) and drain the oil into a suitable container.

TRE0564A

8
3. Place the tractor dismantling stand 380000236,
so that the fixed support (1) is beneath the rear
transmission case in supporting the engine
coupling flange and the moveable support (2)
under the engine in supporting the flange
attached to the gearbox case.

25050

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

11

4. Place another moveable stand 380000236

under the front weight carrier to prevent any
possibility of the engine tipping forwards when
the gearbox is removed. Put wooden blocks (1)
between the stands and the tractor body. Turn
the stand height adjustment lever to bring the
blocks (1) into contact with the tractor.
1

25051

10
5. Remove electrical connections (1) going to the
instrument panel.

TRE0185A

11
6. Remove the socket (1) with its cable that passes
from the instrument panel and over the gearbox
to the rear fender.

TRE0216A

12
7. Remove the support bolt (1) from the injection
pump and disconnect the hand and foot throttle
cables.

TRE0177A

13

662720 09 2006

12

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

8. After retrieving the oil from the power steering

tank, disconnect the hoses (1) from the power
steering pump. (Mark the hoses, before removal,
to facilitate refitting in the correct position).

TRE0160A

14
9. Disconnect the proofmeter drive cable from its
adapter (1) and remove the retaining bolt (2).

TRE0501A

15
10. Remove the filter line (1) and pressure pipe (2)
from hydraulic pump.

TRE0201A

16
11. After draining off the coolant into suitable
containers, unscrew the clamp (1) and remove
the cab heating system intake pipe.

TRE0178A

17

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

13

12. Loosen the clamps (1) and remove the cab

heater outlet pipes (2). (Mark the hoses, before
removal, to facilitate refitting in the correct
position).

TRE0240E

18
13. Remove the wing nut (1) securing the condenser
(2).

25413

19
14. Remove the compressor retaining bolts (1) and
take out the earth connection.

24904

20
15. Move the disconnected compressor (1), condenser (2) Fig. 19 and filter/dryer, together with
flexible hoses and valves, onto the platform.

TRE5001A

21

662720 09 2006

14

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

16. Remove the rubber floor mat from the cab/

platform, then remove the surrounding bolts (1)
securing engineclutch assembly to the gearboxrear transmission case.

TRE0199A

22
17. Place a hydraulic jack (1) underneath the centre
of the fuel tank (2) and lift it, as necessary.

TRE0502A

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.).

TRE0181A

24
19. Remove the bolts (1) and (2) securing the fuel
tank to the footstep.

TRE0049A

25

662720 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.

TRE0206A

26
21. Remove the securing screws and remove the
sheet metal protector (1) from beneath the fuel
tank.

TRE0202A

27
22. Rest the front edge of the fuel tank on the
ground.

TRE0211A

28
23. Loosen the clamps and remove the inlet (1) and
return (2) pipes from the fuel tank. Remove the
fuel tank completely.

TRE0201A

29

662720 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.

TRE0222A

30

25. Remove the nut (1) from the parking brake

control cable. Remove the slave cylinder pipes
(2) on both sides.

1
2

TRE0194A

31

26. Remove the reatining pin (1) and disengage the

PTO clutch cable.

TRE0198A

32

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

17

27. Remove the retaining pin (1) from the 4WD

engagement lever and remove the lever.
1

TRE0040B

33
28. Remove the pin from the mechanical differential
lock pedal and take off the pedal head (1).

1
TRE0240A

34
29. Pull up the plastic boot, remove the retaining bolt
(1) and take out the reverser control lever.

TRE0180A

35
30. Unscrew the retaining bolts (1) and remove the
main and range gear selector levers.

TRE0179A

36

662720 09 2006

18

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

31. Remove the indicator and light connectors (1)

from both sides of tractor.

TRE0192A

37
32. Disconnect the retaining bolts (1) from the
electrical socket and remove the earth cable bolt
(2).

TRE0503A

38
33. Remove the retaining pins (1) and take out the
auxiliary hydraulic valve control rods.
1

TRE0504A

39
34. Disconnect the auxiliary valve nuts (1) from their
pipes.

TRE0200A

40

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

19

35. Remove the split pins (1) and respective draft

and position control levers.

TRE0505A

41
LiftomaticTM

36. Remove the

control cable (1)
from the lever and from its mounting (2).

24936

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
righthand lift rods.

TRE0205A

43
38. Remove the bolt (1) that secures the gearbox
breather pipe clamp.

TRE0126A

44

662720 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.

TRE0506A

45
40. Remove four bolts (1) that secure the rear of the
cab/platform to each end of the axle casing.

TRE0193A

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.

TRE0157A

47
42. Attach two hooks to the signal support bar at the
front and clamp the lifting tool to the rollbar at
the rear.

TRE0190A

48

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

21

43. Remove the front retaining bolts (1), the centre

bolts (2) and the rear retaining bolts from the
4WD drive shaft guard.

TRE0207A

49
44. Remove the snap ring (2) and withdraw the
sleeve (1) from 4WD transfer box, moving it in
the direction of the arrow.

25039

50
45. Remove the snap ring (2) and withdraw the
sleeve (1) from the 4WD transfer box, moving it
in the direction of the arrow.

25040

51
46. Unscrew the drive shaft centre support bolts (1)
and remove the shaft complete with support.

25041

52

662720 09 2006

22

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

47. Disconnect the trailer brake pump inlet pipes (1)

and (2) from the transmissiongearbox case.
Remove the coupling from the trailer brake
control valve supply pipe (3).

TRE0507A

53
48. After removing the trailer brake control pipe,
remove the retaining bolts (1) together with the
complete trailer brake valve assembly.

TRE0507A

54
49. Disconnect the trailer brake control pipe (1) and
the auxiliary valve pipes from the support plate
(2).

25537

55
50. Connect a chain to one of the final drive
assemblies and remove it from the
transmissiongearbox case. Repeat on the
other side.

TRE0188A

56

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

23

51. Remove the retaining bolts and lift the hydraulic

housing using the hoist.

TRE0187A

57
52. Use a chain to attach the tow hook and PTO to
the hoist. Remove the three retaining bolts (1)
from both sides and remove the unit from the
rear transmissiongearbox case.

TRE0191A

58
53. Unscrew the nut (1) and remove the bolt.
Remove the righthand lower link (3) and its
spacer (2). Repeat on the lefthand lower link.

25773

2
59

54. Attach a belt to both the ends of the torsion bar

(1). Ensure that belt is strong enough to lift the
assembly. Remove the retaining bolts (2) and
take off the assembly.

2
TRE0508A

60

662720 09 2006

24

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

55. Remove the bolts securing the gearbox cover

(1). Remove the cover.

TRE0104A

61

56. Unscrew the bolt (1) and remove the internal oil
tank (2) from the rear transmission case.

2
25774

62

57. Connect the rear transmissiongearbox case to

the hoist by chain. Remove the rear
transmissiongearbox case using trolley stand
380000236.

TRE0189A

63

662720 09 2006

TRE0553A

Diagram for application of sealing compound to the rear transmissiongearbox casing

The types of sealing compound to be applied are listed on page 1 of Section 00.

64

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

25

662720 09 2006

26

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

58. Refit the rear transmissiongearbox case as

follows:

WARNING
Use appropriate tools to align the holes. NEVER
USE YOUR FINGERS OR HANDS.

Fit the rear

380000326.

wheels

and

remove

stand

Fit the 4WD drive shaft and secure it by means

of the central support and, the front and rear
sliding sleeves.
Fix the guard onto the transfer box shaft.
Screw in the rear transmissiongearbox case oil
drain plugs and the fuel tank drain plug.

For the correct orientation of the various parts,

refer to the illustrations on pages 10 to 26.
Before refitting boxes, supports and covers,
thoroughly clean and degrease the mating
surfaces and apply a strip of sealing compound
of about 2 mm (0.0787 in.) diameter as shown in
the diagram on page 25.
Apply the torque settings given on page 3.
Using the stand 380000326, refit the rear
transmissiongearbox case onto the clutch box.
Fit the torion bar support complete with internal
connecting rod.

Lower the cab onto the transmission casing and

secure using the retaining bolts.
Connect the LiftomaticTM control cable.
Connect the differential lock control rod.
Connect the parking brake control cable.
Fit the gearbox and final drive control levers and
connect the HILO control connection, if
present.
Fit the reverser control lever.
Connect the PTO speed selection cable.
Connect the synchronised PTO control lever.

Position the left and right brake friction discs. Fit

the brake assembly, and the lateral final drive
assembly.

Connect the auxiliary hydraulic valve control

levers.

Refit the PTO cover to the transmissiongearbox

case.

Fix the fuel tank together with fixing brackets,

mountings and rear transmissiongearbox
breather pipes.

Fit the internal tank complete with oil discharge

pipe.

Connect the pipes and connections to the fuel

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.

Reinstall 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
to the rear transmissiongearbox case.

Connect the front service brake feed and control

pipes.

Fit and connect the lift control and oil filler pipes.

Connect the throttle control cable.

Fit the threepoint linkage support together with

the quickrelease fitting support plate and electrical power sockets with related connectors.

Make good all electrical socket connections

between the cab and the tractor body.

Fit the trailer brake valve complete with hydraulic

valves. Fit and connect the auxiliary hydraulic
valve and trailer brake valve pipes.

Screw in the engine cooling system drain plug.

Fit and connect all the hydraulic pump inlet and

outlet pipes and the connection pipes to the
auxiliary hydraulic valves, hydraulic lift, 4WD
transfer box, etc.

662720 09 2006

Connect up the front headlights.

Fill up the fuel tank, the rear transmission

gearbox case and the cooling system.
Recommended products and quantities are
given on page 6 of Section 00.
Connect the negative terminal to the battery.

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

27

TRANSMISSIONGEARBOX CASE
RemovalRefitting (Op. 21 118 85)

WARNING
Handle all parts with great care.
Never place your hands or fingers between one part
and another. Wear the prescribed safety clothing,
including glasses, gloves and protective footwear.
1. Secure the transmission boxgearbox to the
rotating stand 380000301 using the front
380000272 and rear 380000271 mountings.
TRE0509A

1
2. Turn the box by 180, undo the bolts (1) and
remove the transfer box (2).

TRE0510A

2
3. Turn the box back 180, then use a punch to
remove the roll pins (1) and take out the rods, the
prongs, the gearbox and final drive control forks.

25783

3
4. 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.

TRE0511A

662720 09 2006

28

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

5. Unscrew the lock rings of the differential support

bearing preload ring nuts (2) and slightly
slacken the ring nuts.
6. Unscrew the differential support retaining bolts
(1), retrieve the supports and then remove the
entire differential bevel crown wheel assembly
from the rear of the casing.

27300

5
7. Remove the roll pin (2) and withdraw the external
lever (1) that controls the PTO synchronised with
the gearbox.

2
TRE0512A

6
8. Extract the internal lever (2) complete with spring
(1) and sliding block (3).

25791

7
9. Straighten out the notches and undo the driven
shaft locking nut (1).

25792

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

10. Remove from the rear the snap ring (1) that
retains the final drive driving shaft bearing.

29

25793

9
11. Using a hammer and a brass punch (1) withdraw
the gear (2) for the midrange speeds together
with the related bearings and engagement
sleeve (3).

25794

10
12. Withdraw the final drive driving shaft (1).

25795

11
13. Remove the snap ring (1) that holds the bearing
(2) onto the gearbox drive shaft.

25796

12

662720 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

13
15. Straighten out the notches in the washer that
retains the nut (1). Loosen the nut.

25799

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.

25901

15
17. Move the engagement sleeve (1) until it is
possible to gain access with pliers (2) to remove
the retaining snap ring.

25800

16

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

18. Move the gear (1) in the direction shown by the
arrow and remove the two retaining halfrings
(2). Undo the nut (3) completely and withdraw
the bevel pinion, removing all parts.

31

25902

17

19. Undo the bolts (3), take out the support plate (1)
and remove the bearing (2).

2
3

25903

18

20. Use a brass punch (2) and a hammer to move the

driven shaft (1), withdraw the shaft and remove
all the parts.

21. Mount the rear transmissiongearbox case by

following sectional views and instructions given.
22. Apply the torque settings listed on page 3.

25904

19

662720 09 2006

32

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

WARNING

Use appropriate tools to align the holes. NEVER

USE YOUR FINGERS OR HANDS.

23. Position the box vertically, insert the gearbox

driven shaft gear set (2) and insert the shaft (1).

25907

20
24. Turn the box by 90, fit the front bearing (1) and
the nut (2) and tighten to the prescribed torque.

25908

21
25. Fit the bearing (2) in its housing on the box (front
end) and lock it using the plate (1).

25903

22

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

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.

33

3
4

25912

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).

25796

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).

25913

25

662720 09 2006

34

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

30. Fit the lever (1) that controls the PTO

synchronised with the gearbox, complete with
spring, pawl and external lever.

31. Fit the ring bevel gear complete with support and
adjuster shims (see adjustments on pages 37 to
39.
32. Fit the differential lock engagement control fork
complete with springrod unit, external plate and
the corresponding adjuster shims (see page 36).
25791

33. Fit the piston and the corresponding differential

lock control union.
34. Fit all the rods, forks and gearbox and final drive
control prongs.
35. Fit the transfer box assembly.

662720 09 2006

26

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

35

TRANSMISSIONGEARBOX CASE
Adjusting gearbox driving shaft axial clearance

WARNING
Use appropriate tools to align the holes. NEVER
USE YOUR FINGERS OR HANDS.
Proceed as follows :
NOTE: Once fitted, the driving shaft gears must have
an axial clearance of 00.25 mm (00.0098 in.). The
bearings must therefore be adjusted to prevent them
from being mounted with an axial preload.
To perform this adjustment, it is recommended making a tool in the workshop according to the specifications given in the drawing on page 4, Section 21,
Chapter 1.

1. On the bench mount all the various components

on the driving shaft together with the snap ring
(2), replacing the two rear bearings and the
adjuster ring with the tool 50007 (1) (see page 4,
Section 21, Chapter 1).

2
H

2. Insert a screwdriver between the gear and its

bushing and use a feeler gauge to measure the
clearance (H).

3
25910

3. Measure the height (C) of the tool 50007 and the

thickness of the inner rings of the two rear
bearings (1 and 2).
4. The adjuster shims to be fitted is given by :
S=H+CAB
where:
H = measured clearance
A and B = measured thickness of the bearings
C = height of the tool.
Example :
measured clearance H = 1.3 mm (0.0512 in.)
height of tool = 43.5 mm (1.7126 in.)
thickness of ball bearing (1) = 22.9 mm
(0.9016 in.)
thickness of roller bearing (2) = 18 mm
(0.7087 in.)
Thickness of adjuster ring :

27

25911

28

S = 1.3 + 43.5 22.9 18 = 3.9 mm

(0.0512 + 1.7126 0.9016 0.7087 = 0.1535 in.)
NOTE: The gears should be mounted with an axial
clearance of 00.25 mm. In this instance, it will be
necessary to fit a shim (S) of 3.75 mm to provide an
axial clearance of : 3.93.75 = 0.15 mm.

662720 09 2006

36

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

TRANSMISSIONGEARBOX
Adjusting the position of the differential lock engagement sleeve

WARNING
Use appropriate tools to align the holes. NEVER
USE YOUR FINGERS OR HANDS.

Proceed as follows:

1. Mount the differential release device without the

adjuster shim (S).
2. Fit the differential bevel crown wheel assembly
on its supports.
G. Clearance between differential lock sleeve and
the righthand bevel crown wheel bearing support.
0.5 P 1.25 mm (0.0197 P 0.0492 in.) All models
[Link] pedal support retaining bolt.
S. Differential lock sleeve travel adjuster shim.
1. Differential lock pedal.
2. Pedal support.
3. Fork control rod.
4. Fork.
5. Return spring.
6. Spring pin
7. Sliding Sleeve.
8. Differential support righthand bearing.

TRE0514A

29

3. Check there is a clearance (G) between the

sliding sleeve (7) of the differential lock and the
righthand support bearing of the differential (8)
of:
0.5 P 1.25 mm (0.0197 P 0.0492 in.)
mod. JX60 and JX70,
JX80, JX90 and JX95
that can be measured with the feeler gauge (T).
4. Adjust this clearance by varying the shims (S)
fitted between the support (2) and the transmission casing.
30

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

37

ADJUSTING THE BEVEL GEAR PAIR

Determining the
adjustment ring

bevel

pinion

positioning

Proceed as follows:
1. On the transmissiongearbox case mount the
outer ring of the bearing (1) fig. 31 with the test
shim (2) and the outer bearing ring (3) fig. 32.

25915

31
2. Position the bearing (2) on tool 50004 (1), insert
the bearing (3) and lock the tool (1).

1
2

25916

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.

25917

33
4. Screw down or unscrew the cones (1) and (2) so
as to align the micrometer rod with the bearing.
Adjust the cones (1) and (2) to lock the tool on the
supports and eliminate any axial clearance.
5. Move the depth rod of the micrometer into
contact with the bearing and measure the value
(H1).

1
H1

25918

34

662720 09 2006

38

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

6. Calculate the corrected nominal distance (H3)

between the ring gear axis and the major base of
the bevel pinion :
H3 = H2 + C
where :
H2 = 145.5 mm (5.7283 in.). Nominal distance
between the ring gear axis and major base of the
bevel pinion.
C = Correction value stamped on the pinion, expressed in mm and preceded by a + or sign (if
other than 0) to be added to or subtracted from
the nominal distance (H2) respectively.
7. Thickness of the adjuster ring (S) is given by :
S = H1 + Sp H3
where :
H1

H3

Sp =

Distance measured with the micrometer

gauge.
Corrected nominal distance between
the ring gear axis and the major base of
the bevel pinion.
Test ring.

Examples:
Distance measured with the micrometer gauge
H1 = 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.).
b) Correction value C = 0.2 mm (0.0079 in.).
Corrected nominal distance H3 = 145.5 0.2 =
145.3 mm (5.7283 0.0079 = 5.7204 in.).
Thickness of adjuster ring :
S = 145.9 + 1.90 145.3 = 2.50 mm (5.7441 +
0.0748 5.7204 = 0.0985 in.).
c) Correction value C = 0 mm.
Corrected nominal distance H3 = H2 = 145.5 mm
(5.7283 in.).
Thickness of adjuster ring:
S = 145.9 + 1.90 145.5 = 2.30 mm (5.7441 +
0.0748 5.7283 = 0.0906 in.).
8. Remove the tools 380000249 and 50004; take
out the bearing external rings, the test shim and
two differential supports.

662720 09 2006

1
H1

25918

35

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

39

ADJUSTING THE BEVEL GEAR PAIR

Adjusting the taperroller bearings for pinion
shaft

1. Mount the external track of the bearing together

with the previously calculated adjuster shim (S)
and the bevel pinion complete with its parts.
2. Tighten the bearing adjustment nut (1) while
turning the pinion shaft to allow the bearings to
bed in until rolling torque of 0.731.47 Nm
(1.10631.4751 ft lb) is obtained.
25799

36
3. Mesh the range selecting sleeve with the slow
range gear. Then measure the rolling torque with
a torque meter and a cord wound around the
slow range gear of the pinion; the prescribed
torque corresponds to a force measured with the
torque meter (1) of 8.63 17.2 N (1.9409
3.8598 lb)

25919

37
4. After obtaining the recommended torque, bend
the securing thrust washer (1) onto the adjuster
nut to prevent it unscrewing and decreasing the
bearing preload.

TRE0516A

38

662720 09 2006

40

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

BEVEL DRIVE ADJUSTMENTS

Adjusting the ring bevel gear bearings and
checking the clearance between the teeth of the
bevel gear pair.

WARNING
Handle all parts with great care.
Never place your hands or fingers between one part
and another. Wear the prescribed safety clothing, including glasses, gloves and protective footwear.

WARNING
Always use appropriate tools to align the holes.
NEVER USE YOUR FINGERS OR HANDS.
Proceed as follows :
1. With the bevel pinion fitted, insert the differential assembly complete with the bevel crown
wheel. Secure the right and lefthand supports on the gearbox transmission casing and
bring the relevant ring nuts into contact with
the races of the bearings.
2. Using wrench 50027 (see page 6) slightly
screw the righthand ring nut (2) onto the
support (1), and then do the same for the
lefthand ring nut. So as to obtain a slight
preload on the bearings.
27300

39
3. Using a 1/100 dial gauge (1) measure the
radial clearance on the sides of the bevel drive
teeth (three measurements at 120o and
arithmetic mean of the three readings, the
difference between the three measurements
must not exceed 0.05 mm) and compare the
result with the nominal clearance: 0.18
0.23 mm (0.0071 0.0090 in.).
We will initially be looking for a clearance of
0.18 mm (0.0071 in.).

TRE0518A

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 = (G0.18) x 1.4
where:
1.4 = Ratio between decreaseincrease in backlash and movement of the differential casing.
G = bevel drive backlash, as previously measured.
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.

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

41

5. One complete turn of the ring nut corresponds to

a 2 mm axial movement of the crown wheel. A
60 turn of the ring nut, equivalent to one side of
the ring nut hexagon, corresponds to an axial
movement of the ring nut of:
Z = (60 : 360) x 2 = 0.33 mm (0.0130 in.)

TRE0519A

41
6. Making the differential turn, unscrew the right
hand ring nut with tool 50027 (2) and tighten the
lefthand ring nut (1) by the same amount if Z >
0, otherwise unscrew the lefthand ring nut (1)
and tighten the righthand ring nut by the same
amount if Z < 0 in order to obtain a backlash
initially of 0.18 mm.

2
1

Z = (60 : 360) x 2 = 0.33 mm (0.0130 in.)

7. On obtaining a clearance of 0.18 mm, tighten the
righthand ring nut to obtain a rolling torque of:
28118

42

Pinion rolling torque

ft lb

0.5421 to
1.0849

Nm

0.735 to 1.471

Pinion rolling torque on

crown wheel (with bearings not
preloaded)
ft lb

2.8934 to
5.0634

8. Making sure you do not drive the shafts of the

gearbox, it is possible to check the rolling torque
with a torque meter (1) and a cord wound around
the outer diameter of the differential casing,
keeping to the values stated in the table:

Total rolling torque of pinion

measured on crown wheel (with
bearings not preloaded)

Nm

ft lb

Nm

3.923 to 6.865

torque measured
on pinion
+
(0.7235 to
1.4463)

torque
measured on
pinion
+
(0.981 to
1.961)

TRE0517A

43

662720 09 2006

42

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

Differential casing j 187 mm (7.3622 in.)

Pinion rolling torque

Force of the pinion at the torque meter measured on the

crown wheel (with bearings
not preloaded)

Force of the pinion at the torque meter

measured on the crown wheel (with bearings preloaded)

ft lb

Nm

lb

lb

0.5421 to
1.0849

0.735 to
1.471

9.4401 to
16.5201

41.97 to
73.45

Force on pinion
+
(2.36 to 4.72)

Force on pinion
+
(10.49 to 20.99)

Differential casing j 206 mm (8.1102 in.)

Pinion rolling torque

Force of the pinion at the torque meter measured on the

crown wheel (with bearings
not preloaded)

Force of the pinion at the torque meter

measured on the crown wheel (with bearings preloaded)

ft lb

Nm

lb

lb

0.5421 to
1.0849

0.735 to
1.471

8.5578 to
14.9982

38.05 to
66.68

Force on pinion
+
(2.1394 to 4.2789)

Force on pinion
+
(9.51 to 19.02)

9. Using a 1/100 dial gauge (1), check the

clearance between the teeth of the bevel
drive; if this backlash remains between 0.18
0,23 mm (0.0071 0.0090 in.) (0.21 mm
(0.0083 in.) on average) fine, otherwise:

if the backlash is any greater, use the wrench

50027 (1) to unscrew the righthand ring nut and
tighten the lefthand one by an equal amount.
if the backlash is any lower, unscrew the
lefthand ring nut and tighten the righthand one
by an equal amount.

TRE0518A

44

NOTE: It is important to unscrew one ring nut and

alternately tighten the opposite one by an equal
amount so as not to change the bearing preload
that has already been calculated.
TRE0520A

45

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

43

10. Lock the right and lefthand ring nuts in

position with the lock ring (1).

46

662720 09 2006

44

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

ADJUSTING THE BEVEL GEAR PAIR

Differential pinion and side gear backlash
adjustment
With the distmantled differential on the bench,
proceed as follows :

IMPORTANT
All parts of the differential must be cleaned so that oil
residue does not effect the accuracy of the
adjustment.

1. Mount the side gears (2) and (5) without rings (1)
and (6) on the differential box. Insert the
differential pinions (3) and (8) complete, with
their related clearance rings and with the pin (7).
Tighten the retaining bolt (4) by a few turns in
order to prevent the pin from moving.

5
6

7
8
25920

47
2. Manipulate the RH side gear so that it comes into
contact with the side pinion and, using a depth
micrometer, measure the distance (H1), making
two diametrically opposed measurements and
taking the arithmetic mean of the two values
measured.

H1
25921

48
3. Push the side gear so that it touches the
differential
casing
and
measure
the
distance (H2).
4. Repeat the same operations for the lefthand
side gear.

25922

H2
49

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

5. Axial movement of each side gear (2) and (5)
without shims is given as :
Gs or Gd = H1 H2

45

5
6

where :
Gs = axial movement of LH side gear;
Gd = axial movement of RH side gear;

H1 and H2 = distances measured on LH or RH side

gear (steps 2 and 3).
The normal clearance envisaged between the sides
of the pinion and side gear teeth is 0.15 mm
(0.0059 in.) for JX60 and JX70 models. It is 0.18 mm
(0.0071 in.) for JX80, JX90 and JX95 models.

8
25920

50

Bear in mind that the average ratio between the

normal clearance of differential pinionside gear and
the equivalent axial movement of the side gears
is 11.7.
The axial movement of the side gears corresponding
to the normal prescribed clearance between the
teeth is :
0.15 x 1.7 = 0.25 mm (0.0059 x 1.7 = 0.0098 in.) for
JX60 and JX70 models;
0.18 x 1.7 = 0.30 mm (0.0071 x 1.7 = 0.0118 in.) for
JX80, JX90 and JX95 models.
Thickness of the spacer rings (1) and (6) to be
inserted on the differential box are :
Ss = Gs 0.25 mm (0.0098 in.)
(for LH side gear of JX60 and JX70
models)
Sd = Gd 0.25 mm (0.0098 in.)
(for RH side gear of JX60 and JX70
models)
Ss = Gs 0.30 mm (0.0118 in.)
(for LH side gear of JX80, JX90 and
JX95 models)
Sd = Gd 0.30 mm (0.0118 in.)
(for RH side gear of JX80, JX90 and
JX95 models)
Available shims are 1.5 and 1.6 mm to use for the
side gear as shown on page 2. Fit shims of the
closest thickness for the LH and RH side gears
according to calculations).

662720 09 2006

46

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

TRE0554A

51

a.
b.
c.
C1.
C2.
S.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Longitudinal and Cross Sectional Views of Bevel Gear Pair and Differential Unit
JX60 and JX70 models
12. Side gear shim
JX80, JX90 and JX95 models
13. Side gear shim
Longitudinal section for all models
14. Differential box
Ring gear retaining screw
15. Bevel pinion shaft
Differential support retaining screw
16. PTO shaft
Bevel pinion positioning shim
17. PTO control sleeve
Differential support
18. Fork
Differential support
19. Differential lock shaft
Taper roller bearing
20. Range gear retaining ring
Taper roller bearing
21. Bevel pinion securing plate
Differential lock sleeve
22. Differential bearing ring nut
Ring gear
33. Reverse driven gear
Side gear
34. Driven gear for slow speed gears
Side gear
35. Engagement sleeve for slow and fast speed
Differential pinion
gears
Differential pinion shaft
36. Transmission driven shaft ring
Differential pinion shaft retaining screw
37. Retaining halfring

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

47

FINAL DRIVE REMOVAL

WARNING
Handle all parts with great care.
Never place your hands or fingers between one part
and another. Wear the prescribed safety clothing, including glasses, gloves and protective footwear.

WARNING
Always use appropriate tools to align the holes.
NEVER USE YOUR FINGERS OR HANDS.

CAUTION
Raise and handle all heavy components using a
suitable lift.
Ensure that units or parts are supported by suitable
slings or hooks. Ensure that there is no one in the
vicinity of the load to be lifted

Remove the final drive as follows :

6. Drain oil from rear transmission and final drive
housings.
7. Position a support stand under transmission
housing and remove ROPS frame, wheels,
fenders and platform.
8. Take out capscrews (C5) Fig.1, Page 4 and
remove final drive assembly as shown at Fig.52.

TRE3011A

52
Disassembly (Cover)
Remove the final drive as follows :
9. Take off capscrews (C1) Fig. 6, Page 8 and
remove final drive cover (3) Fig. 6 with driven
gear (8) Fig. 6.

662720 09 2006

48

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

Driven gear retaining nut removal

Remove the gear retaining :

10. Tighten two M16 x 1,5 screws (C5) Fig. 53, into
two of the wheel disc holes on hub and clamp
wheel shaft in vice Fig. 53;
11. Unscrew nut (C5, Fig. 6, page 8) as shown in
Fig. 53 with a suitable spanner (B).

C5

TRE3012A

53
12. Withdraw driven gear (8). Fig. 6, page 8 from
wheel shaft (2) using puller as shown in Fig. 54

TRE3013A

54
Wheel shaft removal (installation) (Fig. 55)
4

(Arrow indicates shaft removal direction)

13. Knock out wheel shaft (2) by beating with lead
hammer in the direction shown by arrow in Fig.
55.
14. Use puller to withdraw outer ring (7) from cover
(3);
15. Finally, withdraw the bearing (4) from cover,
having first removed retaining circlip (21).

21

TRE3014A

55
DISASSEMBLY (housing) (Fig. 56)
16. Remove the bearing (5) from the housing (10)
Fig. 56, with a suitable puller;
17. Remove retaining ring (17) Fig. 56, and withdraw
axle shaft (9) Fig. 56, together with bearing (6)
Fig. 56, in the direction shown by arrow.

10
5
6
9
7

TRE3015A

17
56

662720 09 2006

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

18. Remove the roller bearing internal ring (7)
Fig.56, page 48, from the axle shaft, using puller
seperator as shown in Fig.57, and the ball
bearing (7) Fig. 6, page 8, from the axle shaft (9)
Fig. 56, having first removed the lockring;
19. Check and replace damaged and worn parts;
20. Check lip seals (1112) Fig. 6, page 8, and
replace if necessary; position as shown in Fig. 6.

49

D
7

TRE3016A

57

ASSEMBLY
Carry out the above operations in the reverse order,
bearing in mind the following:
21. Place the roller bearing (7) Fig. 55, outer ring in
its seat in the final drive cover with mark on the
outside;
22. Install the other bearings, using appropriate
installers;
23. Fit the half shaft and wheel shaft, taking care not
to damage the seals (1112) Fig. 6;
24. Fit the roller bearing internal ring (7) Fig.56, page
48, on the half shaft (9) Fig. 56 having heated it
in the oil to 8090 C (176194 F);
25. Tighten the gear locknut (C5) Fig. 6 page 8, using
wrench (B) Fig. 53 page 48, previously used for
disassembly.
26. Tighten all the nuts and screws to the torque
values given on page 3.
27. Clean and grease the surfaces in contact
between the housing (10) Fig. 6 page 8 and the
cover (3) Fig. 6 page 8, inserting a new seal (20)
Fig. 6 page 8;
28. Throughly clean and grease the surfaces (X)
Fig.64 page 25, applying jointing compound.

662720 09 2006

50

SECTION 27 REAR AXLE AND TRANSMISSION CHAPTER 1

662720 09 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

SECTION 31 -- POWER TAKE--OFF

Chapter 1 -- Mechanical Power take--off

CONTENTS
Section

Description

31 000

Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal -- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

31 101

Page

31 000 -- MAIN SPECIFICATION -- TORQUE SETTINGS -- TOOLS -- SECTIONAL DRAWINGS -DESCRIPTION AND OPERATION -- TROUBLESHOOTING

MECHANICAL POWER TAKE--OFF

JX60 and JX70

JX80, JX90 and

JX95

540 rev/min PTO

1) Independent of tractor travel
speed
or:
2) Synchronized with gearbox

Type (Independent and ground speed PTO) . . . . . . . . . . . . .

Engagement and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical by means of hand

levers located on RH and LH side of
drivers seat (see page 9 and 10)

Direction of rotation (viewed from rear of tractor) . . . . . . . . .

clockwise

Engine speed with PTO shaft rotating at 540 rev/min . . . . .

rev/min

2200

PTO speed with engine at maximum power (2500 rev/min)

rev/min

614

Ground speed PTO. Rear wheel speed with PTO shaft

rotating at 540 rev/min
(30 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wheel
speed
rev/min

8.2

8.9

Ground speed PTO. Rear wheel speed with PTO shaft

rotating at 540 rev/min
(4WD 40 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wheel
speed
rev/min

6.73

7.25

Diameter of PTO shaft at position of bearings . . . . . . . . . . .

mm
(in.)

Diameter of PTO shaft at splined end . . . . . . . . . . . . . . . . . .

49.938 -- 50.000
(1.9661 -- 1.9685)
13/8 in. (6--spline)
(continued overleaf)

6- 62720 -- 09 -- 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

MECHANICAL POWER TAKE--OFF
(continued)
JX60 and JX70

JX80, JX90 and

JX95

2--speed 540/750 rev/min PTO (option -- all models)

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

as for single--speed PTO

Engagement and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

as for single--speed PTO

Direction of rotation (viewed from rear of tractor) . . . . . . . . .

as for single--speed PTO

Speed selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by means of hand lever located to

rear RH side of drivers seat

Engine speed with PTO shaft rotating at 540 rev/min . . . . .

rev/min

2200

Engine speed with PTO shaft rotating at 750 rev/min . . . . .

rev/min

2382

PTO speed with engine at maximum power speed

(2500 rev/min):
-- for 540 rev/min PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- for 750 rev/min PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rev/min
rev/min

614
787

Ground speed PTO. Rear wheel speed with PTO shaft

rotating at 540 rev/min
(30 and 40 km/h versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wheel
speed
rev/min

see 540 rev/min PTO

Ground speed PTO. Rear wheel speed with PTO shaft

rotating at 750 rev/min
(30 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wheel
speed
rev/min

10.51

11.4

Ground speed PTO. Rear wheel speed with PTO shaft

rotating at 750 rev/min
(40 km/h 4WD version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wheel
speed
rev/min

8.59

9.36

13/8 in. (6--spline)

Diameter of driven shaft at grooved terminal . . . . . . . . . . . .

2--speed 540/1000 rev/min PTO (option -- all models)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

as for single--speed PTO

Engagement and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

as for single--speed PTO

Direction of rotation (viewed from rear of tractor) . . . . . . . . .

as for single--speed PTO

Speed selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by means of hand lever located on

rear RH side of drivers seat

Engine speed with PTO shaft rotating at 540 rev/min . . . . .

rev/min

2200

Engine speed with PTO shaft rotating at 1000 rev/min . . . .

rev/min

2380

PTO speed with engine at maximum power

(2500 rev/min):
-- for 540 rev/min PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- for 1000 rev/min PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rev/min
rev/min

614
1050
(continued overleaf)

6- 62720 -- 09 -- 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

MECHANICAL POWER TAKE--OFF

(continued)
JX60 and JX70

JX80, JX90 and

JX95

Ground speed PTO. Rear wheel speed with PTO shaft

rotating at 540/750 rev/min
(30 and 40 km/h versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wheel
speed
rev/min

Ground speed PTO. Rear wheel speed with PTO shaft

rotating at 1000 rev/min
(30 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wheel
speed
rev/min

14.1

15.2

Ground speed PTO. Rear wheel speed with PTO shaft

rotating at 1000 rev/min
(40 km/h 4WD version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wheel
speed
rev/min

11.5

12.4

Diameter of PTO shaft at splined end:

-- 540 rev/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- 750 rev/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-- 1000 rev/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

as for single--speed PTO

13/8 in. (6--spline)

13/8 in. (6--spline)
13/8 in. (21--spline)

External diameter of driven gear support bushings . . . . . . .

mm
(in.)

49.925 -- 49.950
(1.9655 -- 1.9665)

Internal diameter of driven gears . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

50.050 -- 50.089
(1.9705 -- 1.9720)

Clearance between driven gears . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

0.100 -- 0.164
(0.0039 -- 0.0065)

Diameter of driven shaft at front and centre bushings . . . . .

mm
(in.)

39.166 -- 39.191
(1.5420 -- 1.5429)

Diameter of driven shaft at rear bushing . . . . . . . . . . . . . . . .

mm
(in.)

34.984 -- 35.000
(1.3773 -- 1.3780)

Internal diameter of front and centre bushing . . . . . . . . . . . .

mm
(in.)

39.200 -- 39.239
(1.5433 -- 1.5448)

Internal diameter of rear bushing . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

35.009 -- 35.048
(1.3783 -- 1.3798)

Clearance between shaft and front and centre bushings . .

mm
(in.)

0.009 -- 0.073
(0.0004 -- 0.0029)

Clearance between shaft and rear bushing . . . . . . . . . . . . . .

mm
(in.)

0.009 -- 0.064
(0.0004 -- 0.0025)

TOOLS

380000227 Hook for lifting PTO

Important -- The operations described in this section

must be performed solely with the ESSENTIAL tools
marked below with (X).
To work in complete safety and to ensure optimal
technical results with a minimum of time and effort,
they must however be supplemented with the
specific tools recommended below and with those to
be specially constructed by you and for which the
construction diagrams are given in this manual.

380001597 Guide pins for PTO unit

380000233 Installer for PTO driving shaft
bearings

6- 62720 -- 09 -- 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

TORQUE SETTINGS

C1 -- 221 Nm

C2 -- 25 Nm

C3 -- 162 Nm

C4 -- 294 Nm
2--speed 540/750 rev/min PTO

Single--speed 540 rev/min PTO

26276

TORQUE SETTINGS

PART TO BE TORQUED

Thread

PTO box fixing screws (C1, fig. 1) . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque setting
Nm

ft lb

M 16 x 1.5

221

163.0012

PTO guard fixing screws (C2, fig. 1) . . . . . . . . . . . . . . . . . . . . . . . .

M 8 x 1.25

25

18.439

Grooved endpiece self--locking nuts (2--speed PTO) (C3, fig. 1) .

M 12 x 1.25

162

119.485

Driven gear shaft locknut:

(C4, fig. 1) for single-- or 2--speed PTO . . . . . . . . . . . . . . . . . . . . . .

M 32 x 1.5

294

216.8432

Bearing support fixing screws (2-- and 3--speed PTO) (C5, fig. 35)

M 12 x 1.25

98

72.281

6- 62720 -- 09 -- 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

28

3
4

27
5
26
6
25
24

23
22
21

20
19

18
X

10

17
16

11

15
14
a -- single--speed 540 rev/min PTO

13

12

b - 2-- speed 540/750 rev/min PTO

26278

a.
b.
1.
2.
3.
4.
6.
7.
8.
9.
10.
11.
12.

Sectional diagrams of single-- and 2--speed PTO

13. Rear transmission support.
14. Driven gear.
15, 27, 28, 16 and 5. Snap rings.
17. PTO guard retaining screws.
18. 540 rev/min PTO driven shaft
19. Driven gear support bushings.
20. Driven shaft lock nut.
21. Fixed gear.
22. Coupling sleeve.
23. Driven gear for 750 rev/min speed.
24. Driven gear for 540 rev/min speed.
25. Double drive gear.
26. Drive gear.

Sectional diagram of single--speed PTO.

Sectional diagram of 2--speed PTO.
540 rev/min PTO cover.
540/750 rev/min PTO cover.
PTO unit fixing screw.
Drive shaft bearings.
Self--locking nut to secure splined shaft.
540 rev/min splined shaft.
750 rev/min splined shaft.
Seal.
Driven shaft bearings.
Cover locating pin.
Rear transmission casing.

NOTE: When installing use sealing compound of the type shown on page 1 section 00 on surface X as shown above.

6- 62720 -- 09 -- 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

2
3
4
27
5
6
25
24

23
22
21

20
19

9
X

10

11
2--speed 540/1000 rev/min PTO

13

12

26278

Sectional diagram of single-- and 2--speed PTO

2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

540/1000 rev/min PTO cover.

PTO unit retaining screw.
Drive shaft bearings.
Snap ring.
Self--locking nut to secure splined shaft.
540 rev/min splined shaft.
1000 rev/min splined shaft.
Seal.
Driven shaft bearings.
Cover locating pin.

12.
13.
19.
20.
21.
22.
23.
24.
25.
27.

Rear transmission casing.

Rear transmission support.
Driven gear support bushings.
Driven shaft lock nut.
Fixed gear.
Coupling sleeve.
Driven gear for 1000 rev/min speed.
Driven gear for 540 rev/min speed.
Double drive gear.
Snap ring.

NOTE: When installing use sealing compound of the type shown on page 1 section 00 on surface X as shown above.

6- 62720 -- 09 -- 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

TRE0308A

Sectional diagram of single-- and 2--speed PTO

17. PTO speed selector lever.
18. Roll pin.
19. Shaft.

20. Rear cover.

21. Fork.
22. O--ring.

6- 62720 -- 09 -- 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

10

3
11

9
8

4
5
6

TRE0990A

1.

2.
3.
4.
5.

Section views -- 540 -- 1000 rev/min PTO North American version (available on request), not
synchronised with gearbox, with speed selection by replacement of splined output shaft.
Splined 1 3/8 output shaft (6 splines) for 540 rpm
PTO, or 1 3/8 output shaft (21 splines) for 1000
6. Return spring.
rpm PTO.
7. Return rod.
Driven shaft.
8. Speed selector lever support.
Snap ring securing part .
9. Speed selector lever.
Speed selector rod.
10. Speed selector sleeve.
Speed selector sleeve control fork.
11. Thrust washer.

6- 62720 -- 09 -- 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

DESCRIPTION AND OPERATION OF

MECHANICAL PTO
The PTO, located at the rear of the tractor, transfers
power to the implement being transported or towed.
It can be controlled either directly from the engine
clutch or from the gearbox clutch. The PTO is shown
with the safety cap (1) and the guard (2) in position.
The safety cap must be removed to couple up an
implement to the PTO shaft.
The PTO with mechanical engagement
disengagement is available in three versions:

single--speed PTO, 540 rev/min (standard)

26280

two--speed PTO, 540/750 rev/min (option)

two--speed PTO, 540/1000 rev/min (option).
Independent PTO
Proceed as follows:
with the PTO clutch disengaged, i.e. with the
control lever (1) fig. 7, rearward at position A;
1

move the PTO selector lever (1) fig. 8, to position

B so as to engage the PTO sleeve (3) fig. 9, with
the toothed coupling of the shaft (2) which is
driven by the engine;

A
D

engage the PTO by slowly moving the lever (1)

fig. 7, forward to position D.
TRE0106A

When engaged, the PTO shaft rotates and the PTO

warning lamp on the instrument panel lights up.

In these conditions the operation of the PTO is

completely independent of the travel of the tractor, so:
the tractor can be stopped without stopping the
PTO;
the PTO can be stopped without stopping the
tractor (by disengaging the PTO clutch).
To disengage the PTO move the PTO clutch control
lever (1) fig. 7, rearward to position A then move the
speed selector (1) fig. 8, to the central position E.

1
C
E

B
TRE0043A

6- 62720 -- 09 -- 2006

10

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

Ground speed PTO

Proceed as follows:
with the PTO clutch control lever (1) fig. 7, at
position D;
fully depress the gearbox/engine clutch pedal;
wait briefly, then move the PTO speed selector
(1) fig. 8, forward to position C and release the
gearbox/engine clutch pedal;
In these conditions the PTO coupling sleeve (3) fig. 9,
is turned directly by the toothed coupling of gear (1) in
the gearbox.
When the tractor is stationary the PTO shaft does not
turn. When changing from forward to reverse gear,
the direction of rotation of the PTO shaft reverses.

NOTE: When the PTO is not being used, move the

lever (1) fig. 8, to position E (the neutral position of
the PTO engagement sleeve (3) fig. 9).
26281

PTO speed selector lever (2) fig. 10

2

To change PTO speed, proceed as follows:

lift the spring--loaded collar (1) upwards;
1

move the lever (2) forward to position (3) to select

750 or 1000 rev/min PTO speed.
This activates the external control lever (17) fig. 4
by means of a tie--rod. The external control lever in
turn rotates the internal fork device (21) and
selects the PTO speed by means of the coupling
sleeves

TRE0089A

10

TROUBLESHOOTING FOR MECHANICAL PTO

Faults

Possible causes

Remedies

Slipping with loss of speed of PTO Wear of clutch disc or of engine

output shaft.
flywheel pressure plate.
Poor adjustment of PTO clutch
control lever.

Check the data given in the

appropriate pages of section 18,
replace the worn parts and adjust the
clutch control lever.

Difficulty in selecting PTO speed External control stiff.

by means of lever (2) fig. 10.

Check the control lever.

6- 62720 -- 09 -- 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

11

540/750 MECHANICAL PTO

Removal -- Refitting (Op. 31 112 20)

WARNING
Lift and handle all heavy parts using lifting tackle of
sufficient capacity.
Make sure that the units or parts are supported by
suitable harnesses and hooks. Check that no one is
in the vicinity of the load to be lifted.

1. Disconnect the negative cable from the battery.

2. Remove the top link (1) of the three--point
linkage.

TRE0819A

11
3. Remove the tow hook (1), if fitted.

24953

12
4. Remove the tow bar (1), if fitted.

24954

13

6- 62720 -- 09 -- 2006

12

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

5. Remove the six tow hook support fixing

screws (1) (Three on left and three on right
side).

TRE0809A

14
6. Drain out the transmission/gearbox oil from the
drain plug (1) and collect it in a suitable
container.

24956

15
7. Remove the PTO speed selector control lever
(1).

TRE0002A

16
8. Remove the screws (2) that fasten the retaining
bracket (1) for the PTO speed selector control.

1
2

TRE0002B

17

6- 62720 -- 09 -- 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

13

9. Remove the two upper screws (1) which fasten

the PTO unit to the transmission.

1
1
TRE0820A

18
10. Insert the two guide pins 380001597 (1) and
remove the two lower screws (2) (Fig. 3
Page.6) which fasten the PTO unit to the
transmission.

1
1
24958

19
11. Engage the lever (1) fig. 8, in position (C), ground
speed PTO, so that the sleeve (3) fig. 9, rests on
the shaft (2) during the removal operation.
Withdraw the PTO unit by a few centimetres and
detach using the hook with lifting chain 380000227
(1).
To reinstall proceed as follows:
Clean the mating surfaces between the
transmission and PTO cover and apply sealing
compound as shown in figure 21.
Raise the PTO unit and position it directly behind
the transmission casing. Slide the PTO cover
onto the guide pins 380001597, for ease of
assembly.
Remove the hook with chain (1) fig. 20, and
fasten the PTO unit using the two lower screws.
Remove the two guide pins 380001597 and
install the two upper screws.
Reinstall the bracket (1) fig. 17, that retains the
PTO speed selector control lever.
Refit the tow bar support.
Refit the tow bar, the tow hook and the three-point linkage top link.
Screw in and tighten the oil drain plug and fill the
transmission/gearbox with oil.
Reconnect the negative battery cable.

24961

20

26282

21

6- 62720 -- 09 -- 2006

14

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

MECHANICAL PTO (540/750 rpm PTO)

Bench overhaul (Op. 31 112 45 -- 31 112 48)

WARNING
Handle all parts with great care.
Do not place hands or fingers between one part and
another.
Always wear the prescribed safety clothing, including
protective glasses, gloves and shoes.

1. Place the PTO unit in the vice on the work

bench (1).

24962

22
2. Use a punch to straighten the corrugations (1) on
the ring nut that retains the driven shaft
components.

24963

23
3. Remove the ring nut (1) from the driven shaft.

24964

24

6- 62720 -- 09 -- 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

4. Remove the four PTO unit internal support fixing
screws (1).

15

24965

25
5. Remove the pin (1) securing the fork rod.

TRE0153A

26
6. Withdraw the rod (1) from the rear cover.

24967

27
7. Partially withdraw the PTO output shaft (1) and
remove the internal support (3) together with the
drive shaft (2), the driven gears (4), the sleeve
and the engagement/disengagement/neutral
control fork of the 540/750 PTO. Also, retain the
thrust washer from the gear (11) fig 5, for reuse
during reassembly.

4
3
24968

28

6- 62720 -- 09 -- 2006

16

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

8. Remove the rear bearing thrust washer (1) and

remove the secondary shaft (2) complete with
PTO output shaft.

24969

29
9. Remove the retaining snap ring, the bearing (1)
and the seal (if it needs replacing) from the rear
cover.

24970

30
To reinstall, Refer to fig. 2b and proceed as follows:
Mount the seal (9) (if removed in step 20), the
rear bearing and the retaining snap ring (5) on
the rear cover.
Refit the thrust washer on the driven shaft.
Refit the driven shaft gear (23), the fixed gear
(21), the sleeve (22), the fork and the fork
support rod.
Insert the gear (24) onto the driven shaft, mount
the internal support (13) complete with drive
shaft (25). Fasten the support (13) using the four
screws, tightening them to the torque setting
specified on page 4.
Mount the thrust washer on gear (11) fig 5, and
install the bearing on the internal support (13) of
the driven shaft.
Fasten the rod that supports the PTO speed
selector control fork pin as removed in step 5.
Tighten the driven shaft locknut to the torque
specified on page 4, then, using a suitable
punch, notch the safety thrust washer in order to
prevent it from loosening.

6- 62720 -- 09 -- 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

17

MECHANICAL PTO (540/1000 rpm PTO)

(Interchangeable PTO Shaft) (NASO Version)
Bench overhaul (Op. 31--114)

WARNING
Handle all parts with great care.
Do not place hands or fingers between one part and
another.
Always wear the prescribed safety clothing, including
protective glasses, gloves and shoes.

1. Place the PTO unit in the vice on the work

bench (1).

24962

31
2. Remove the bolts (1) and take off the cover (2).

2
TRE1000A

32
3. Remove the spacer (1).

TRE1001A

33

6- 62720 -- 09 -- 2006

18

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

4. Remove the two socket head screws (1) and

take off the PTO engagement mechanism (2)
completely.

2
1

TRE1002A

34
5. Withdraw two rods (1) from the cover.
C4: Shaft securing nut tightening torque: 255Nm
(188.0783 ft lb)
C6: Cover retaining bolts tightening torque: 98 Nm
(72.2811 ft lb)

1
C4
C6

TRE1003A

35
6. Remove the nut (1) securing the shaft and take
off the 4 bolts (2).

1
2
TRE1004A

36
7. Remove the socket head screw bolt (1) on the
side of the cover.

TRE1005A

37

6- 62720 -- 09 -- 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

19

8. Remove the cover (1).

TRE1006A

38
9. Remove the washer (1) and take off the gear (2).

2
1

TRE1007A

39
10. Remove the rod (1), spring (2), fork (3) and the
synchroniser (4).

3
1
2

TRE1008A

40
11. Remove the driven gear (1).

TRE1009A

41

6- 62720 -- 09 -- 2006

20

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

12. Remove the circlip (1).

TRE1010A

42
13. Remove the drive shaft(1).

TRE1011A

43
14. Remove both bearings (1) and (2) .

TRE1012A

44
15. Remove the shaft (1) and the plate (2).

TRE1013A

45

6- 62720 -- 09 -- 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

21

To reinstall, reverse the removal procedure and refer

to fig. 5 and proceed as follows:
Mount the shaft (1) and the plate (2) on the rear
cover (fig. 45).
Refit the two bearings (1 and 2) (fig. 44).
Refit the drive shaft (1) (fig. 43)
Install the circlip (1) securing the bearing (fig. 42)
Insert the gear (1) (fig. 41).
Install the rod (1), spring (2), fork (3) and the
synchroniser (4) (fig. 40).
Install the washer (1) and the gear (2) (fig. 39)
Install the cover (1) fig. 38.
Install the socket head screw (1) on the side of
the cover (fig. 37)
Install the nut (1) securing the shaft and refit the
4 bolts (2, fig. 36). Tighten the nut (1) to 255Nm
(188.0783 ft lb) and bolts (2) to 98 Nm
(72.2811 ft lb).
Install the two rods (1) fig. 35.

Refit the PTO engagement mechanism (1) and

install the socket head screws securing the
mechanism fig. 34.
Install 1000 rpm PTO shaft with related circlip.

NOTE: The adjustment procedure should be done

ONLY with the 1000 rpm PTO shaft is installed.
Using a screwdriver (1) and a spanner (2) adjust
the distance X to 0 mm (0 in.) fig. 46.
Install the spacer (1) fig. 33.
Install the cover (2) fig. 32 and tighten the bolts
(1).

TRE1014A

X
46

Use suitable hooks to assemble the unit to the

tractor fig. 31.

6- 62720 -- 09 -- 2006

22

6- 62720 -- 09 -- 2006

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

SECTION 33 BRAKING SYSTEM CHAPTER 1

SECTION 33 BRAKING SYSTEM

Chapter 1 Braking system
CONTENTS
Section

Description

Page

33 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Crosssectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
33.206
Front brake assembly mod. JX60 and JX70 removal and refitting
overhauling on the bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
33.202.60
Service brake removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
33.202.50
RemovalRefitting of front brake pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
33.202.40
Bleeding air from the front braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
33.120.08
Adjusting service brake pedals travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
33.110.08
Parking brake travel adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
33 000 MAIN SPECIFICATION TORQUE SETTINGS TOOLS SECTIONAL DRAWINGS
DESCRIPTION AND OPERATION TROUBLESHOOTING
MAIN SPECIFICATION
Type:
service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with oil bath discs acting on

differential halfshafts

parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with oil bath discs acting on

differential halfshafts
with oil bath discs acting on the
bevel pinion shaft by means of a
gear (Optional)

Control:
service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical, with independent

pedals
(connected by means of a pin)

parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical, by means of a hand

lever

Disc material for service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

organic agglomerate

Disc material for parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

steel

Mobile sector material for parking brake . . . . . . . . . . . . . . . . . . . . .

sintered
or
organic agglomerate

Disc thickness:
service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

4
(0.1575)

JX60 and JX70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

no

JX80, JX90 and JX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

no

Discs for service brake:

(see over)
662720 09 2006

SECTION 33 BRAKING SYSTEM CHAPTER 1

MAIN SPECIFICATION
(cont.)

Thickness of mobile sectors for independent parking brake:

lateral sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

3.1 3.4
(0.122 0.1339)

intermediate sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

4.2 4.5
(0.1653 0.1772)

Front brakes (with 4WD models on request)

Hydrostatic control
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with 2 control pumps operated independently by means of

the brake pedals

Adjusting the control pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

see page 24

Bleeding air from the front brake circuits (Optional) . . . . . . . . . . . .

see page 23

TORQUE SETTINGS
Tightening torque
PARTS TO BE TIGHTENED

Thread
Nm

ft lb

Nuts securing final drive box to transmission box (C1) . . . . . . . . .

M 12 x 1.25

98

72.281

Brake box retaining bolt (C5, page 8) . . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

70

51.6293

TRE0300A

C1 98 Nm
1

662720 09 2006

SECTION 33 BRAKING SYSTEM CHAPTER 1

20

3
20

TRE0301A

a.
b.
1.
2.
3.
4.
5.

Sectional drawing of service and parking brakes

models JX60 and JX70.
6. Backup discs
models JX80, JX90 and JX95.
7. Actuator return spring.
Brake link.
8. Differential support.
Pin.
9. Axle shaft.
Ball.
10. Boot cover plate.
Brake actuator.
11. Boot.
Brake discs.
20. Differential support retaining bolt.

Note. When mounting apply sealing compound to surfaces X as shown on page 18.

662720 09 2006

SECTION 33 BRAKING SYSTEM CHAPTER 1

BRAKES

3
4

T
8

6
5
9
12

Lm
1

Pd

Ps

a
c

MS

PARK BRAKE & SLAVE CYLINDER

SL

14
13

15

View of service and park brake controls

a.
b.
c.
Lm.
M.
Pd.

R.H. brake pedal in rest position and L.H. brake applied.

Brakes applied.
Brakes in rest position.
Parking brake hand lever.
Brake pedal return springs.
R.H. brake pedal.

662720 09 2006

SL. Slave cylinder

MS. Master cylinder
T. Parking brake link.
1. Brake links.
3. Actuator ball.

4.
5.
6.
7.
8.

Brake actuator.
Brakes discs.
Backup discs.
Actuator return spring.
Differential support.

9.
12.
13.
14.
15.

Axle shaft.
Final drive housing.
Park brake control lever.
Park brake control cable.
Brake pivoting shaft.

SECTION 33 BRAKING SYSTEM CHAPTER 1

662720 09 2006

SECTION 33 BRAKING SYSTEM CHAPTER 1

FRONT LIVE AXLE DRIVE SHAFT BRAKE (JX60 & JX70 MODELS)

8
9

12975

3
Section through the brake fitted on drive shaft to front live axle

1.
2.
3.
4.
5.

Selfcentering brake disc

Disc retaining screw
Shaft/sleeve assembly
Carrier.
Bearing.

662720 09 2006

6.

Front washer.

7.

Rear washer.

8.

Outer retaining ring.

9.

Inner retaining ring

SECTION 33 BRAKING SYSTEM CHAPTER 1

FRONT BRAKE (MODELS JX80, JX90 and JX95)

C5

C5

4
View of brake mounted in front axle.
a. Crosssectional view of axle with differential.
4. Seal.
5, Piston contact spring.
b. Crosssectional view of axle with NOSPIN
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.
Note. When mounting apply sealing compound to surfaces X.

662720 09 2006

SECTION 33 BRAKING SYSTEM CHAPTER 1

DESCRIPTION AND OPERATION

SERVICE BRAKES
The service brakes are hydraulic with oil bath discs.
The two control pumps (one for each pedal) are
housed in the front section of the cab and are
connected to their respective pedals by means of two
rods.
These pumps can be actuated either independently
or together. If actuated together, the pedals are
connected by a pin.
A connecting pipe between the two pumps ensures
balanced braking even when the brake discs are not
equally worn.

causing actuator discs to turn, ball (3) in the tapered

seats to force the discs apart as shown in detail (c).
As a result, two simultaneous actions compress the
brake discs against the differential support (8) and
the back up discs, immediately upon releasing the
pedal spring (7), pull the actuator (4) back into the
rest position (figure b and detail d) and as a result the
discs are released. The action is similar when the
righthand brake pedal is pressed (Rd).
The brake discs (one for each rear wheel) are
positioned between the rear transmission box and
the lateral final drive box and are splined onto the
differential output halfshafts.

The two control pumps are fed from a single tank

located above the pumps.

PARKING BRAKE

Refer to the illustrations on page 5. The service

brakes are slave cylinder operated. When the
lefthand brake pedal (fig. a ) is depressed, the
master cylinder (MS) sends the oil to the slave
cylinder (SL). The brake links (1) move as indicated
by the arrows, by the help of slave cylinder (SL) this

Refer to the illustrations on page 5. When the hand

brake lever (Lm) is pulled, the control cable (14) pulls
the control lever (13), at the direction of arrow. Then
the brake links (1) acts on the brake
discs.

662720 09 2006

SECTION 33 BRAKING SYSTEM CHAPTER 1

TOOLS

WARNING The operations described in this section must be performed only with the ESSENTIAL
equipment marked with (X).
To operate safely and achieve best results however, while saving time and effort, essential equipment must be used in conjunction with the special
tools recommended below, and tools which you
must make yourself and for which you will find the
design in this manual.

List of special tools necessary for the various operations described in this section.
X 380000822 Driver for boot installation.
380000227 Lifting hook.

BRAKE TROUBLESHOOTING
Problems

Possible causes

Remedies

Braking ineffectual.

1. Friction material on brake Replace the brake discs.

discs worn.

Unbalanced braking.

1. Incorrect tyre pressure.

Inflate the tyres to the correct

pressure.

2. Friction material on one of the Replace the discs.

brake discs worn.
Braking noisy.

1. Friction material on brake Replace the discs.

discs worn.

1. Brake discs worn.

Replace the brake discs.

Parking brake does not lock.

Brakes locked on when the parking brake is disengaged.

1. Brake discs seized on brake Release and replace damaged parts.

discs.

662720 09 2006

10

SECTION 33 BRAKING SYSTEM CHAPTER 1

FRONT BRAKE ASSEMBLY

MOD: JX60 AND JX70
RemovalInstallation (Operation 33206)

DANGER
Lift and handle all heavy components using lifting
equipment of adequate capacity.
Make sure that the units or parts are supported by
appropriate harnesses and hooks. Check that no one
is in the vicinity of the load to be lifted.

Proceed as follows to remove the unit:

1. Apply the handbrake.
2. Unscrew the retaining bolts and remove the
guards from the propeller shaft.

10

13

11

Note. Should the caliper (11) not need any

servicing, back off its retaining screws (13) and
disconnect taking care not to uncouple the hose (12):
rest on suitable stand or suspend by wire.

13

12

TRE0950A

5
3. Disconnect wire (10) fig. 5 of the brake pad wear
warning indicator and remove the pads (14 and
15) fig. 6.

15

14

TRE0951A

6
4. Remove the front sleeve rear retaining ring and
back off the two screws (16) retaining the brake
sleeve assembly carrier.
5. Slide the front sleeve along the drive shaft and
remove the complete assembly (shaft and
brake/bearing carrier).

16

TRE0952A

662720 09 2006

SECTION 33 BRAKING SYSTEM CHAPTER 1

11

6. Take the two drive shafts out of the carrier and

clamp the latter in a vice.
18

17

4
TRE0953A

8
7. Unscrew the retaining bolts (17, fig. 8) of the
calliper bracket and remove the bracket.
8. Unscrew the retaining bolts (2) of the brake disc
and remove the disc (4).
4

TRE0954A

9
9. Take out retaining rings (8 and 9) from the
support (4)
4

TRE0955A

10
10. Using a suitable puller, remove the shaft/sleeve
assembly (3) from the support (4).
11. Remove the bearing (5) using a suitable puller
and take out the washer (6) Fig. 3.

TRE0956A

11

662720 09 2006

12

SECTION 33 BRAKING SYSTEM CHAPTER 1

Bench overhaul (Operation 33206)

DANGER
Always use suitable tools to align holes. NEVER
USE FINGERS OR HANDS.
Reverse the removal operation sequence minding
the following points:
1. Position the shaft/sleeve assy (3) Fig. 3, upright,
introduce the support (4) fig. 12, followed by the
washer (6) Fig. 3 in the bearing seat with the
chamfered side facing outwards.

5
4
TRE0957A

12
2. Insert bearing (5) fig. 3 on assembly (3) fig. 13
and bring into contact with seat using a suitable
drift or press tool; lock with the retaining ring (9)
fig. 3.
3. Clamp the carrier in a vice then, using a suitable
drift or press tool, locate properly against washer
(6) Fig. 3. Position washer (7) Fig. 3 with the
chamfered side facing the bearing (5) and lock
the assembly with the retaining ring (8) fig. 3.

4
3

TRE0958A

13

662720 09 2006

SECTION 33 BRAKING SYSTEM CHAPTER 1

13

SERVICE BRAKE
Removal Installation (Operation 33 202 60)

DANGER
Lift and handle all heavy components using lifting
equipment of adequate capacity.
Make sure that the assemblies and parts are
supported by appropriate tools and hooks. Check
that no one is in the vicinity of the load to be lifted.

Proceed as follows to remove the final drive box.

1. Disconnect the negative battery cable (1).
2. Chock the front wheels using suitable wheel
stops.

25621

14
3. Remove the vertical rod (1) and the LH stabiliser
strut (2).

1
2

26253

15
4. Raise the rear section of the tractor and place a
stand (1) beneath the tow bar support.

1
25647

16

662720 09 2006

14

SECTION 33 BRAKING SYSTEM CHAPTER 1

5. Undo the retaining bolts and remove the rear LH

wheel.

25646

17
6. Undo the bolts (1) securing the cab to its
mounting
7. Raise the cab slightly and place a suitable piece
of wood between the hydraulic lift and the cab,
taking care to avoid contact with pipes.

TRE0193A

18
8. Remove the plug (1) and drain the oil from the
rear transmissiongearbox casing.

25622

19
9. Undo the bolts securing the cab to its mounting
(1).

TRE0193B

20

662720 09 2006

SECTION 33 BRAKING SYSTEM CHAPTER 1

10. Position a stand (1) underneath the rear section
of the fuel tank.

15

25505

21

11. Fit lifting hooks (1) 380000227 onto the final

drive box. Connect a hydraulic lift to the hooks,
undo the retaining bolts and remove the LH final
drive box from the transmission box.
1

TRE0188A

22

12. Remove the pin (1).

TRE0214A

23

662720 09 2006

16

SECTION 33 BRAKING SYSTEM CHAPTER 1

13. Back off the link (1) and remove the complete
brake unit.

14. Check actuator and brake discs for wear.

ATTENTION

TRE0215A

Always use appropriate tools to align fixing holes.

NEVER USE FINGERS OR HANDS.
15. Refit the final drive box to the rear transmission
box as follows:
Refer to the illustrations on page 3 for the correct
orientation of the various components.
Before refitting the final drive box to the rear
transmission box, thoroughly clean and
degrease the mating surfaces and apply a strip
of sealing compound of diameter about 2 mm as
shown in the illustration on page 17.
Apply the torque settings given on page 2.
Using tool 380800022 (A) as shown, position
boot (11) correctly on brake link (1). (see fig. 25)
Fit the brake disc and spacers.
Using tool 380000227 and a hydraulic lift, refit
the final drive complete with axle shaft.
Fit the rear cab mounting retaining bolts.
Remove the piece of wood between the cab and
the lift body.
Tighten the bolt securing the cab to the rear LH
support.
Fit the LH wheel.
Fit the stabiliser strut and the vertical rod.
Remove the stands.
Screw in the oil drain plug and refill.
Connect the battery negative lead.

662720 09 2006

24

TRE0303A

25

SECTION 33 BRAKING SYSTEM CHAPTER 1

17

TRE0304A

26
Diagram for application of sealing compound when fitting braking assembly between the final drive
housing and the rear transmission box.
The types of sealing compound to be applied are listed on page 1 of Section 00.

662720 09 2006

18

SECTION 33 BRAKING SYSTEM CHAPTER 1

HYDRAULIC FRONT BRAKE PUMP

(OPTIONAL)
Removal Installation (Operation. 33 202 50)

ATTENTION
Handle all parts carefully.
Do not insert fingers or hands between one part and
another. Always wear the prescribed safety clothing,
including protective glasses, gloves and shoes.

Proceed as follows to remove the hydraulic pump.

1. Disconnect the negative battery cable (1).

2. Chock the front wheels using suitable wheel
stops.

25621

27
3. Disconnect the electrical connections from the
plug (2) of the tank (1) and after retrieving the oil,
remove the service brake control pipes (3).

2
1

TRE0305A

28
4. Remove the steering wheel (1) retaining nut and
remove the steering wheel and hand throtltle
lever.

25758

29

662720 09 2006

SECTION 33 BRAKING SYSTEM CHAPTER 1

19

5. Remove the four securing screws (1) from the

instrument panel (2).

25759

30
6. Disconnect the electrical leads (1) from the rear
of the instrument panel. Unscrew the the
tachometer cable (2). Remove the instrument
panel and store in a safe place.

2
TRE0435A

31
7.

.Unscrew the rear hood screws (1)

2

8. Take off the complete rear hood (2).

TRE0436A

32
9. Remove the electrical connections:from the
pressure sensor (1) and remove the service
brake control pipes (2).
1

10

2
TRE0436A

33

662720 09 2006

20

SECTION 33 BRAKING SYSTEM CHAPTER 1

10. Remove the retaining pins and withdraw the

brake pump control fork articulation dowels (1).
11. Undo the bolts (2) that secure the brake control
pumps to the cab and withdraw the pumps from
the engine side.

WARNING
Use appropriate tools to align the holes. NEVER
USE YOUR FINGERS OR HANDS.
26273

34

24664

Sectional drawing of service brake control pump (Master cylinder)

1. Spring.
2. Pump body.
3. Control piston.

12. Refit the hydraulic brake control pump unit as

follows.
Fit the pumps, secure them, then connect them
to the control pedals.
Connect the control pipes and the tank and
pressure sensor connections.
Connect the negative battery cable.
Carry out the following adjustment and bleed the
air from the circuit, observing the points
described on page 22.

662720 09 2006

4. Rear seal.
5. Central seal.
6. Front seal.

35

SECTION 33 BRAKING SYSTEM CHAPTER 1

HYDRAULIC BRAKE SLAVE CYLINDER

RemovalRefitting (Op. 33 202 50)

21
4

Proceed as follows to remove the hydraulic brake

slave cylinder:.
13. Remove the pin (1).

14. Remove the bolts securing the pump (2).

15. Take off the pipe connections (3) and (4).
TRE0214A

36
16. Withdraw the slave cylinder (1) from link.

1
TRE0213A

37
17. Remove the front hydraulic pump internal parts.
Check the seals and piston.

WARNING
Use appropriate tools to align the holes. NEVER
USE YOUR FINGERS OR HANDS.
TRE0306A

38
18. Refit the hydraulic brake slave cylinders as
follows.
Insert the master cylinder (1) from link.
Fit the pin (1).
Assembly the bolts securing the pump (2).
Assembly the pipe connections (3) and (4).

662720 09 2006

22
HYDRAULIC
(Optional)

SECTION 33 BRAKING SYSTEM CHAPTER 1

FRONT

BRAKE

SYSTEM

Air bleeding (Op. 33 202 04 )

2
1

Air must be bled whenever work is carried out on the

front brake hydraulic system.
Proceed as follows.
1. Thoroughly clean the external parts of the unit
around the bleed screws (1) fig. 40, (1) fig. 42
and the hydraulic oil tank lid (1) fig. 39.

TRE0305A

2. Make sure that the hydraulic oil tank (1) is filled

up before and during the bleeding operations.

39

N.B. Filter all drained oil before reusing.

3. Depress the LH brake pedal, slowly and to the

end of its travel, so that the oil is placed under
pressure.
4. Keeping the pedal depressed, undo the bleed
screw (1) by half a turn and allow the oil mixed
with air bubbles to flow out.
5. Retighten the screw (1) and repeat the above
operations until the oil that comes out is free of
air bubbles.
6. Depress the LH brake pedal again to place the
circuit under pressure: this occurs when the
travel of the pedal returns to normal.
7. Repeat the above operations for the RH brake
pedal from the bleed screw (2).

TRE0307A

40

8. Depress the LH and RH brake pedal, slowly and

to the end of its travel, so that the oil is placed
under pressure.

9. Keeping the pedals depressed, undo the bleed

screw (1) on the RH brake slave cylinder by half
a turn and allow the oil mixed with air bubbles to
flow out.
10. Retighten the screw (1) and repeat the above
operations until the oil that comes out is free of
air bubbles.
11. When the operation has been completed,
replenish the oil in the tank (1) fig. 39.

662720 09 2006

TRE0237A

41

SECTION 33 BRAKING SYSTEM CHAPTER 1

12. Depress the LH and RH brake pedal, slowly and
to the end of its travel, so that the oil is placed
under pressure.

23

13. Keeping the pedals depressed, undo the bleed

screw (1) by half a turn and allow the oil mixed
with air bubbles to flow out.
14. Retighten the screw (1) and repeat the above
operations until the oil that comes out is free of
air bubbles.
15. When the operation has been completed,
replenish the oil in the tank (1) fig. 39.

TRE0237A

42
16. For JX60 & JX70 models front brake bleeding
screw (1) is located on front wheel drive shaft
that is shown on fig. 43.

1
TRE0237A

43
SERVICE BRAKE PEDALS
Adjusting height of service brake pedals
(Op. 33 120 08 )
1. With the brake pedals connected to their
respective forks and the pedal connecting pin
removed, check that the height (A) from the
centre of the pedals to the top of the carpet is:
162 mm for tractors fitted with cab or 205 mm for
tractors without cab.

44
2. If adjustment is required, slacken the lock nuts
(2) and tighten or slacken bolt (1) until the
required height (A) is obtained. Lastly tighten the
lock nuts.

45

662720 09 2006

24

SECTION 33 BRAKING SYSTEM CHAPTER 1

3. The length of the brake links must be 190mm

1mm. If adjustment is required, fully release
the handbrake (lever down). Remove the
connecting pin (3). Slacken the lock nuts (1) and
turn the hexagon sleeves (2) until the length of
brake links is 190 mm. Finally, tighten the lock
nuts (1).

1
2
3

L
TRE0229A

46

SECTIONAL VIEW OF SLAVE CYLINDER

662720 09 2006

SECTION 33 BRAKING SYSTEM CHAPTER 1

25

HAND BRAKE CONTROL

Adjusting travel (Op. 33 110 08)
The travel of the parking brake control lever must be
adjusted whenever work is carried out on the unit and
when the lever is not on the third notch of the gear
sector when the brake is engaged.
Proceed as follows.

1. Slacken the lock nut (1).

2

2. Tighten or slacken the adjusting screw (2) until

the control lever is locked on the third notch.
3. Tighten the lock nut (1).

TRE0217A

47

662720 09 2006

26

662720 09 2006

SECTION 33 BRAKING SYSTEM CHAPTER 1

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

SECTION 35 HYDRAULIC SYSTEM

Chapter 1 Rear mechanical hydraulic lift
CONTENTS
Section

Description

Page

35 000

Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Crosssectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Description & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Description and operation of lift phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
35 110.30
Hydraulic lift disassembly reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
35.110.404246 Hydraulic lift bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjusting the lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
35.110.08
Linkage adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
35.110.30
Pressure relief valve disassembly reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
35.110.32
Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
35.110.14
Lift control valve disassembly assembly and overhaul on bench . . . . . . . . . . . . . . . . . . 36
35.0101.10
Lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
35 000 MAIN SPECIFICATION TORQUE SETTINGS TOOLS SECTIONAL DRAWINGS
DESCRIPTION AND OPERATION TROUBLESHOOTING
MAIN SPECIFICATION OF REAR MECHANICAL HYDRAULIC LIFT
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

position or draft control with a

combination of the two

Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

two independent levers

LIFTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

provides fast lifting/lowering

operations using pushbuttons,
without using the position or
draft control levers

Singleacting cylinder:

rated diameter and stroke:

All models

mm

100x128

(in.)

(3.9370x5.0394)

capacity:
cm3

1005

(in.3)

(61.33)

Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

bar
psi

186 191
(12697.69 2770.21)

Cylinder safety valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

bar
psi

210 215
(3045.78 3118.30)

All models

(continued overleaf)
MAIN SPECIFICATION OF REAR MECHANICAL HYDRAULIC LIFT
(continued)
Lift piston diameter:
All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

99.980 100.000
(3.9362 3.9370)

Internal diameter of cylinder liner:

??.??.???.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clearance between piston and liner . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter of lift arm shaft (11, fig. 3) at position of bushings:
righthand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

lefthand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Internal diameter of bushings fitted on lift body:

righthand side (8, fig. 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

lefthand side (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clearance between lift arm shaft and bushings . . . . . . . . . . . . . . .

Interference between bushings and their seats . . . . . . . . . . . . . . .
Axial clearance of shaft complete with lift arms . . . . . . . . . . . . . . .
External diameter of draft control idler shaft . . . . . . . . . . . . . . . . . .
Internal diameter of seats in support . . . . . . . . . . . . . . . . . . . . . . . .
Clearance between draft control idler shaft and position control
idler shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diameter of position control idler shaft . . . . . . . . . . . . . . . . . . . . . . .
Internal diameter of position control idler shaft . . . . . . . . . . . . . . . .
Clearance between draft control idler shaft and position control
idler shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance between control valve block pin (8, fig. 4) and its seat
on the control valve block body . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance between lift control valve (10) and its seat on the control valve block body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control valve block pin return spring (5, fig. 4):
free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

spring length under load of 31.7 35 N (7.1242 7.8741 lb)

Control valve return spring (9, fig. 4)

free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

spring length under load of 103 114.7 N

??.??.???.?? ?? ????

mm
(in.)
mm
(in.)

100.036 100.071
(3.9384 3.9398)
0.036 0.091
(0.0014 0.0036)

mm
(in.)
mm
(in.)

54.970 55.000
(2.1642 2.1654)
62.670 62.700
(2.4673 2.4685)

mm
(in.)
mm
(in.)
mm
(in.)
mm
(in.)
mm
(in.)
mm
(in.)
mm
(in.)
mm
(in.)
mm
(in.)
mm
(in.)

55.100 55.184(1)
(2.1693 2.1726)
62.800 62.884(1)
(2.4724 2.4757)
0.100 0.214
(0.0039 0.0084)
0.065 0.185
(0.0026 0.0073)
0.2 1.4
(0.0079 0.0551)
21.967 22.000
(0.8648 0.8661)
22.020 22.072
(0.8669 0.8690)
0.020 0.105
(0.0008 0.0041)
13.973 14.000
(0.5501 0.5512)
14.016 14.059
(0.5518 0.5535)

mm
(in.)

0.016 0.086
(0.0006 0.0034)

mm
(in.)

0.008 0.012(2)
(0.0003 0.0005)

mm
(in.)

0.008 0.012(2)
(0.0003 0.0005)

mm
(in.)
mm
(in.)

50.5
(1.9882)
34
(1.3386)

mm
(in.)
mm
(in.)

44
(1.7323)
29
(1.1417)

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

MAIN SPECIFICATION OF IMPLEMENT HITCHING DEVICE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

threepoint linkage

Category:
All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum liftable load with centre of gravity 610 mm from the
lower arm link ends: with arms horizontal
(with top link connected to hole on upper support):
JX60, JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum liftable load: with arms horizontal

(with top link connected to upper support pin):
JX60, JX70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

JX80, JX90 and JX95 Models . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flex bar diameter:

JX60, JX70, JX80, JX90, JX95 Models . . . . . . . . . . . . . . . . . .
Axial clearance of flex bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by means of lower arms

with flex bar

kg
(lb)
kg
(lb)

2260
(4982.45)
2700
(5952.48)

kg
(lb)
kg
(lb)

3000
(6613.87)
3565
(7859.48)

mm
(in.)
mm
(in.)

24.867 24.900
(0.9790 0.9803)
1.2 4.1
(0.0472 0.1614)

MAIN SPECIFICATION OF HYDRAULIC PUMP (All models)

Filter
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

paper cartridge

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

fixed to the pump housing on

suction side

Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

gear type with oil suction from

transmission casing

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flanged on the rear lefthand

side of the engine

Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BOSCH

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A31

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by means of the engine gears

Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . .

left (counter clockwise)

Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . .

1 : 0.931

Maximum speed of pump rotation (with engine at maximum

power equivalent to 2500 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm

2328

Bench output at 1450 rpm and pressure of 172 bar ( 175 kg/cm2):

for new or reconditioned pump . . . . . . . . . . . . . . . . . . dm3/min (in.3/min)

for worn pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (in.3/min)
test oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C(F)
test oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 (1159.5)
13.3 (811.6)
55 65 (131 149)
SAE 20
(continued overleaf)
??.??.???.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

MAIN SPECIFICATION OF HYDRAULIC PUMP (All models)
(continued)

Driven and driving gear shaft diameter . . . . . . . . . . . . . . . . . . . . . .

Internal diameter of seats in supports . . . . . . . . . . . . . . . . . . . . . . .
Clearance between gear shafts and their seats . . . . . . . . . . . . . . .

maximum clearance due to wear . . . . . . . . . . . . . . . . . . . . . . . .

Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . . . . .

Maximum wear on pump body, suction side, at position of gears
Width of gears (5, fig. 104) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Width of supports (4 and 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Width of pump body (3) for gear seats and supports . . . . . . . . . .
Axial clearance of gears complete with supports in pump body
(recondition if necessary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)
mm
(in.)
mm
(in.)
mm in.)

17.400 17.418
(0.6850 0.6857)
17.450 17.470
(0.6870 0.6878)
0.032 0.070
(0.0013 0.0025)
0.1 (0.0039)

mm
(in.)
mm(in.)

0.020 0.064
(0.0008 0.0025)
0.1 (0.0039)

mm
(in.)
mm
(in.)
mm
(in.)

24.000 24.015
(0.9449 0.9455)
24.490 24.510
(0.9642 0.9650)
73.135 73.160
(2.8793 2.8803)

mm
(in.)

0.100 0.180
(2.8793 2.8803)

LIFT HYDRAULIC PUMP (OPTIONAL) DATA

Filter
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

paper cartridge

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

fixed to the pump housing on

suction side

Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

gear type with oil suction from

transmission casing

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flanged on the rear lefthand

side of the engine

Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rexroth

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by means of the engine gears

Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . .

left (counter clockwise)

Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . .

1 : 1.080

Maximum speed of pump rotation (with engine at maximum

power equivalent to 2500 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm
Nominal flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . .

dm3/turn

(in.3/turn)

2700
0.01950 (1.1930)

Corresponding rated output for new pump . . . . . . . dm3/min (in.3/min)

48 (2929.14)

Corresponding rated output for pump with 300 hours

of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (in.3/min)

43 (2624.02)

Bench output at 1500 rpm and a pressure of 2175 psi (150 bar):

for new pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (in.3/min)

24.8 (1513.39)

for pump with 300 hours of work . . . . . . . . . . . . dm3/min (in.3/min)

22.3 (1360.83)

??.??.???.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

test oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

test oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F
(C)

131 to 149
(55 to 65)
16 CST

TORQUE SETTINGS
Thread

Torque setting
Nm

ft lb

Lift
Capscrew, lift to rear transmission case (C1, Fig.1) . . . . . . . . . . . . .

M 12 x 1.25

98

72.28

Capscrew, control valve body to lift (C3, Fig.28) . . . . . . . . . . . . . . . . .

M 8 x 1.25

26

19.18

Capscrew, lift arm plates (C2, Fig.1) . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 14 x 1.5

147

108.42

Plug, max. arm raising adjustment (3, Fig.28) . . . . . . . . . . . . . . . . . .

M 12 x 1.25

103

75.97

Nut, position control shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

59

43.52

Nuts for lever quadrant bracket securing stud bolts (2, Fig.32) . . . .

M8x1.25

25

18.44

Lift cylinder securing bolts:

M14x1,5
M16x1.5

211
260

155.63
191.77

Securing bolts for top link attachment bracket . . . . . . . . . . . . . . . . . .

M14x1.5

147

108.42

Inner lift arm securing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

61

44.99

Capscrew, suction connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

98

72.28

Capscrew, delivery connection on lift control valve . . . . . . . . . . . . . .

M 10 x 1.25

59

43.52

Capscrew, lift pump (Fig.86) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M6x1

5.90

Nut, pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

41

30.24

Capscrew, flexion bar support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

221

163.00

Capscrew, chain support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

221

163.00

Capscrew, check link support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

221

163.00

Nut, tow bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 18 x 1.5

343

252.98

Control valves
Nut, control valve links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

14.75

Connection, outlet to fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

14.75

Plug, relief bar spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

14.75

??.??.???.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

TOOLS

HYDRAULIC LIFT EQUIPMENT

X 380000225 Ring for fitting piston with lift seals.

X 380000274 Union for checking control valve
seal.

Warning The operations described in this section

cannot be carried out without the ESSENTIAL tools
marked below with (X).
However, to ensure greater safety and obtain the
best results while saving time and effort, we recommend that these essential tools are used in conjunction with the specific tools listed below as well as certain tools which are to be made following the
construction drawings given in this manual.

X 380000262 Punch for fitting lift arm shaft seals.

X 380000261 Punch for fitting needle bearings on
control valve block control lever
bushing.
X 380000260 Punch for fitting needle bearings to
upper/lower draft control levers and
to draft control link rod.
X 380000230 Wrench for cylinder safety valve
setting ring nut.
X 380000217 Union for lift pressure relief valve
calibration.

380000215 Hand pump for valve calibration.

380000224 Lifting hook.

X 380000218 Union for cylinder safety valve

calibration.
X 380000267 Wrench for maximum lift screw locknut.
X 380000263 Draft control setting tool.

380000238 Hook adapter 380000224.

??.??.???.?? ?? ????

X 380000264 Position control setting tool.

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

TRE0700A

48

Sectional drawing of lift

C1. .Lift capscrews.

8. [Link].

C2 .Thrust plate capscrews.

10. Thrust washers.

G = 0.2 to 1.4 mm (0.0079 to 0.551 in.)

Shaft end float.

11. Top link support.

1. Inner arm.
2. Cross shaft.

12. Piston rod pin.

13. Travel limit adjusting screw.

3. Link arm.

14. Travel limit adjusting screw locknut.

4. Arm thrust plates.

15. Travel limit control rod.

5. [Link].

16. Control valve link pin.

6. [Link].

18. Draft control inner lever pivot.

7. [Link].

19. Set screw.

??.??.???.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

TRE0701A

49

Sectional drawing of hydraulic lift control valve block

a. Detail of Oring and arm lowering adjuster valve
14. Ring.
antiextrusion ring.
15. Cylinder safety valve.
1. Spool valve.
16. Response control valve.
2. Spool valve seat.
17. Arm lowering speed control valve.
3. Plug.
18. Ball.
4. Spool return spring.
19. Response control valve adjusting pin.
5. Valve plunger.
20. Delivery connection.
6. Plunger spring.
21. Check valve spring.
7. Plug.
8. Piston seat.

22. Check valve.

9. Piston.
10. Spring cup.
11. Draft sensitivity adjustment valve spring.

23. Check valve seat.

12. Draft sensitivity adjustment valve.

13. Plug.

32. .Backup ring.

30. .Retaining ring.

31. .Roll pin.
33. .Oring.

Note Install the Oring 33 and antiextrusion 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 Oring 20. Take
necessary precautions not to damage them.

??.??.???.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

DESCRIPTION AND OPERATION

The mechanical lift can operate with controlled
Draft control is actuated by the flex bar positioned in
position or draft control and with a combination of the
the special box mounted under the rear
two. The lift is controlled by two levers located on the
transmission.
operators right. It also features the LiftOMatic
The lower lift arms and corresponding control rods
device which raises and lowers the implement
are connected to the flex bar.
without the need to use the position and draft control
levers.
Static oil
Oil in suction
Tractor brake circuit oil (brakes off)
Pressurised oil
Exhaust oil flow

2
4
5
1
9

8
7
26428

6
50

1.
2.
3.
4.
5.

Delivery line to control valve (3).

Trailer brake control valve.
Auxiliary control valves.
Auxiliary control valve lines.
Trailer brake control valve line.

HYDRAULIC LIFT CIRCUIT

6. Lift control valve.
7. Suction line.
8. Oil filter.
9. Hydraulic pump.
??.??.???.?? ?? ????

10

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

22

T1
1

9
T3

T2

Pressurised oil
Oil in suction, delivery or return
Static oil
TRE0702A

51
ARM LIFT PHASE

F.
P.
T.
V.
1.

Filter.
Hydraulic pump.
Lift arm piston.
Reliefvalve.
Valve spool.

When the position control lever (located on the

operators righthand side) is used to raise the arms,
the movement shown by the arrows is transmitted by
the internal lever mechanisms to the control valve
block pin (1).
??.??.???.?? ?? ????

5.
6.
8.
9.
22.

Plunger.
Plunger spring.
Piston seat.
Piston.
Check valve.

Oil flow to piston (9) is cut off and plunger (5) is forced
to the left by spring (6), thus closing the exhaust port.
Pressure oil opens check valve (22) and operates
piston (T) to raise the arms.

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

18 17

15

11

22

12
1

5
6

Pressurised oil
Oil in suction, delivery or return
Static oil

TRE0703A

52
NEUTRAL PHASE
F.
P.
V.
1.
5.
6.

Filter.
Hydraulic pump.
Relief valve.
Valve spool.
Plunger.
Plunger spring.

With spool (1) in the neutral position, oil is delivered

through the response adjusting valve (12) to piston
(9), which overcomes spring reaction (6) and moves
plunger (5) to the right. This opens the exhaust port

9.
12.
15.
17.
18.
22.

Piston.
Draft sensitivity valve.
Cylinder safety valve.
Arm lowering speed control valve.
Ball.
Check valve.

and directs oil flow to the tank in the rear transmission

housing rather than to the cylinder.

??.??.???.?? ?? ????

12

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

17

F1
1

4
12

Pressurised oil
Oil in suction, delivery or return
Static oil
TRE0704A

53

F.
P.
T.
V.
1.
4.

Filter.
Hydraulic pump.
Lift arm piston.
Relief valve.
Valve spool.
Spool return spring.

ARM LOWERING PHASE

5. Plunger.
9. Plunger spring.
12. Draft sensitivity valve.
17. Arm lowering speed control valve.
F1. .Spool port

When the operator lowers the position control lever

on his right, the return spring (4) pulls spool (1) to the
right. Cylinder oil is exhausted under piston pressure
(T) through lowering speed adjustment valve (17)
and the port uncovered by spool.
Through spool port (F1) and draft sensitivity valve
(12) oil flows to piston (9), which holds plunger (5) in
the position shown, thus allowing pump delivery to be
exhausted past plunger (5).
??.??.???.?? ?? ????

Unscrewing the screw (16) decreases the load on

the spring (15), therefore the valve (14) can vibrate
faster, slowing down the descent speed. Tightening
the screw (16) slows down the vibration of the valve
(14) that increases the descent speed of the arms
since the valve (14) can remain in position in correspondence with the larger orifice where the oil flows
out from the [Link] adjusting the arm descent
speed it will not depend on the weight bearing on the
arms but will be virtually constant.

13

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

HYDRAULIC LIFT DIAGNOSTICS

Problems
The lift does not raise.

Possible causes
1. Oil filter clogged.

Remedies
Replace filter.

2. Control valve jammed in dis- Release control valve.

charge position.

The lift operates jerkily.

3. Hydraulic pump defective.

Overhaul or replace pump.

1. Oil filter clogged.

Replace filter.

2. Air has got into the pump suc- Check that the couplings are airtight
and the seals are effective.
tion line.
The lift raises too slowly.

1. Oil filter clogged.

Replace filter.

2. Oil leaking past piston seals or Replace all defective seals.

seals on discharge fitting to
cylinder, with consequent loss
of pressure.
3. Hydraulic pump defective.
The lift operates too quickly.

Overhaul or replace pump.

1. Foreign matter between the Take off the valve, remove the foreign
ball and its seat on the dis- matter and inspect the oil filter.
charge control valve.
2. Discharge control valve ball Replace discharge control valve.
seal defective.
3. Discharge control valve piston Take off the valve and free the piston.
jammed.

The lift operates too slowly.

1. Discharge ports on the dis- Take off the valve, unblock the holes
charge control valve blocked. and inspect the oil filter.
2. Discharge control valve piston Take off the valve and free the piston.
jammed.
(continued overleaf)

??.??.???.?? ?? ????

14

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

HYDRAULIC LIFT DIAGNOSTICS
(continued)

Problems

Possible causes

Remedies

The lift is unable to keep the load 1. Defective seal on check valve. Take off, check, clean and if necessary replace the parts concerned.
raised (with the engine running,
the load moves up and down
rhythmically; with the engine 2. Oil leaking past the seals on Replace seals.
the control valve block pin
turned off, the load lowers).
seat.
3. Control valve block pin seal Take off and clean the seal and
replace the control valve block pin
defective.
and its seat if defective.
4. Oil leaking past the lift piston Replace the seals.
seal or the seals on the
cylinder oil discharge fitting.
5. Defective seal or cylinder safety Replace the valve.
valve set to very low value.
The pressure relief valve cuts in 1. Lift arm travel set incorrectly.
when the lift arms reach their completely raised position.
Lift has poor lifting capacity.

Set correctly.

1. Pressure relief
incorrectly.

valve

set Replace the valve.

2. Cylinder safety
incorrectly.

valve

set Replace the valve.

3. Poor pump efficiency (gener- Overhaul or replace the pump.

ally accompanied by a considerable increase in lift time).

??.??.???.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

15

REMOVAL REFITTING OVERHAUL OF REAR MECHANICAL HYDRAULIC LIFT ASSEMBLY

REAR HYDRAULIC LIFT ASSEMBLY
RemovalRefitting (Op. 35 110 30)

DANGER
Lift and handle all heavy parts using suitable lifting
equipment with sufficient hoisting capacity.
Check that the assemblies or parts are held firmly
and supported by suitable slings and hooks. Make
sure nobody is standing near to the load.

To remove the hydraulic lift assembly from the rear

transmission casing, proceed as follows.
1. Disconnect the negative cable (1) from the
battery.

TRE0035A

54
2. Remove the top link (1).

TRE0112A

55
3. Undo the bolts (1) and use a chain and hoist to
remove the pickup hitch hook (2) from the PTO
box.

2
1

TRE0113A

56
??.??.???.?? ?? ????

16

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

4. Remove the split pins and withdraw the shafts

(1). Remove the lift rods (2) and the lateral
stabiliser struts (3).

1
2
3

TRE0114A

57
5. Unscrew: the trailer brake control pipe (1) and
the auxiliary control valve pipes from the support
plate (2).

25537

58
6. Remove auxiliary control valve pipes (2) from
their support (1).

1
TRE0140A

59
7. Undo the two bolts (1) that secure the seven
pole socket (2) and remove the socket.

1
2

TRE0122A

60
??.??.???.?? ?? ????

17

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

8. Undo the bolts (1) and remove the support (2).

1
2

TRE0115A

61
9. Undo the bolt (1) and disconnect the breather
pipe connection.

TRE0126A

62
10. Remove the electric socket (1).

TRE0123A

63
11. Remove the retaining springs (1) and detach the
two control rods (2) from the lift levers.

2
1

TRE0127A

64
??.??.???.?? ?? ????

18

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

12. Remove the LIFTOMATIC control rod (1).

TRE0117A

65
13. Connect a suitable hoist (2) to the cab lifting
hooks (1) and tension the hoist.

2
1

TRE0137A

66
14. Unscrew the two cab front securing bolts (1).

TRE0129A

67
15. Unscrew the two cab rear securing bolts (1).
Raise the cab approximately 56 cm
(0.19690.2362 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.

TRE0128A

68
??.??.???.?? ?? ????

19

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

16. Remove the pipes on the lift (1) and the control
valve body (2).

2
TRE0138A

69
17. Unscrew the bolts (1) that secure the hydraulic
lift assembly to the transmission casing.

25556

70
18. Fit tool 380000237 (1) on the lift and tighten the
four bolts (2).

25558

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.

3
25559

72
??.??.???.?? ?? ????

20

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

20. Refit the hydraulic lift assembly to the transmission casing as follows.

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

Before refitting the hydraulic lift assembly to the

rear transmission casing, clean and degrease
the mating surfaces thoroughly and apply a strip
of sealing compound of about 2 mm (0.0787 in.)
diameter as shown in fig. 73.
Apply the torque settings listed on page 5.
Use tools 380000224 and 380000238 to fit the
hydraulic lift assembly to the transmission casing
and tighten the bolts securely.

26295

73
Insert the electric leads into their clips on the lift
body.
Fit the lift control pipe.
Raise the cab by a few millimetres, remove the
wooden blocks and tighten the bolts to secure
the cab.
Fit the trailer brake control pipe (if fitted) and the
oil filler pipe.
Connect the LiftoMatic control rod.
Connect the lift control levers to their linkages.
Fit the windscreen washer tank and transmission
breather pipes onto the cab upright.
Fit the top link attachment bracket and the quick
fitting support plate for auxiliary control valves.
Fit the sevenpole socket, the earth leads, the
quickfittings and the trailer brake control pipe to
their corresponding support brackets.
Fit the additional control valve rods and the PTO
operating mode rod.
Fit the ground lift control lever.
Fit the lift rods and the lateral stabiliser struts.
Fit the pickup hitch hook and the top link.
Connect the negative cable to the battery.
??.??.???.?? ?? ????

Diagram showing application of sealing

compound when fitting the hydraulic lift
assembly to transmission casing.
The types of sealing compounds to be applied are
specified on page 1, section 00.

21

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

REAR HYDRAULIC LIFT ASSEMBLY
DisassemblyAssembly
(Op. 35 110 40 35 110 42 35 110 46)

DANGER
Handle all parts with the utmost care.
Do not place your hands or fingers between one part
and another. Wear the prescribed safety clothing,
including glasses, gloves and protective footwear.
To disassemble the hydraulic lift, proceed as follows.

TRE0143A

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.

1
2

3
TRE0133A

75
3. Unscrew the two cylinder securing bolts positioned 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.

3
25626

76
5. Remove the cylinder (1) complete with piston.

25627

77
??.??.???.?? ?? ????

22

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

6. Remove the retaining pin from the internal draft

lever, unscrew the nut (1), then remove the unit
complete with internal linkages and the LIFT
OMATIC control lever.

TRE0134A

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.

5
2

3
4

TRE0132A

79
9. Slacken the eccentric pin (2) retaining bolt (1),
withdraw the eccentric pin and remove the
internal linkage.

10. Unscrew the bolt (3), remove the washer (4),

withdraw the lift arm (5) and remove the thrust
washer. Repeat on the other lift arm.

2
3
4
5
25631

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).

3
25632

81
??.??.???.?? ?? ????

23

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

12. Use compressed air to remove the piston (2)
from its cylinder (1).

26297

82
13. Use striker tool 380000260 (1) to replace the
bearings in the internal draft control lever (2).

14. Use striker tool 380000261 to replace the control

valve block control lever bearings.
15. Fit the hydraulic lift as follows.

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

26298

83
16. Insert the piston (1) into its cylinder (3), using tool
380000225 (2).

25634

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.

1
2
26299

85
??.??.???.?? ?? ????

24

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

18. To avoid damaging the internal seal lips, use a

flexible brass sheet (1) of size 200 x 90 mm
(7.8740 x 3.5433 in.) and thickness
0.05 0.1 mm (0.0020 0.0039 in.). Roll the
sheet up and insert the seal inside. Position the
unit on the spline and push the seal manually into
its seat. Then remove the sheet.

2
26300

86

19. Use striker tool 380000262 (1) to complete the

fitting of the seals into the their seats on the lift
arm shaft.

26326

87

20. Fit the lift arms (1) on the shaft, matching up the
reference marks, as shown. Secure them by
tightening the bolts.

25633

88

??.??.???.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

21. Fit the internal linkages and the corresponding
eccentric pin. Fasten the eccentric pin by
tightening the securing bolts.
22. Fit the control levers complete with friction discs,
snap rings and stud bolts.
23. Fit the spring and use the bracket to secure the
lever unit.
24. Fit the internal position control lever.
25. Fit the internal linkages and the LiftoMatic
control lever.
26. Fit the cylinder complete with piston and secure
it.
27. Fit the internal linkages and fasten them to the
cylinder.
28. Clean the mating surfaces thoroughly and apply
a 2 mm (0.0787 in.) diameter strip of sealing
compound to the lift box, as shown in fig. 89.
The types of sealing compound to be used are
shown on page 1, section 00.
Fit the hydraulic control valve block on the lift box
and secure it using the screws.
Make the following adjustments.

25

TRE0705A

89

NOTE The adjustments must be made in the order

specified.

??.??.???.?? ?? ????

26

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

ADJUSTING THE LIFT

The following adjustments refer to a lift assembly
without hydraulic control valve block and mounted on
a rotary stand.
These adjustments must be made in the order
specified.
The LIFTOMATIC device must be kept turned off
(external control lever (1) locked in the vertical
position) until otherwise specified.

1
TRE0131A

90
Adjusting position control
Proceed as follows:
1. Move the external position control lever (1) fully
forward, against the spacer for the stud bolt
securing the spring retaining bracket. Move the
external draft control lever (2) fully rearward
against the spacer.

2
1

2. Turn the lift arm control shaft until the internal

arm is in contact with the lift body.

TRE0135A

91
3. Use tool 380000267 (1) figure 92, to slacken the
lock nut (4) figure 93. Loosen the end stop
adjusting screw (5) until it is no longer in contact
with the control valve block control lever (3).

TRE0706A

92

F1

L1

25638

93
??.??.???.?? ?? ????

27

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

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.
NOTE This corresponds to a distance (L1 fig. 93)
of 82.0 82.1 mm (3.22833.2323 in.) between the
end of the lever (3) fig. 93 and the front surface of
the lift body when a force (F 1 fig. 93) of
4 4.5 da N (25.40 39.82 [Link]) is applied to the
end of the lever.

Adjusting the maximum height of the lift arms

Proceed as follows.
8. With tool 380000264 (4) fig. 94 fitted on the lift
body, move the external draft control lever (2)
fully rearward, against the spacer. Move the
external position control lever (1) fully forward
against the spacer.
9. Turn the lift arm control shaft until the internal
arm touches the lift body.

5
4
25639

94

6. Tighten the lock nut (1) fig. 93.

7. Move the external position control lever (1) fully
rearwards against the stud bolt spacer. Turn the
lift arm control shaft so that the piston is fully
forward and check that the plunger (5) fig. 94 is
flush with or slightly inside the inner reference
surface (1) of the tool (4).

NOTE This corresponds to a distance (L1) fig. 93,

of greater than 86.5 mm (3.4055 in.) between the
end of the lever (3) and the front surface of the lift
body
when
a
force
(F 1)
of
4 4.5 da N (25.40 39.82 [Link]) is applied to the
end of the lever.

TRE0136A

95

2
1

TRE0135A

96
??.??.???.?? ?? ????

28

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

10. Connect the fitting (5) of tool (2) to the workshop

compressed air system. Feed air into the
cylinder barrel to make the piston perform its
complete lifting stroke and use the air pressure
to keep it in this position.
11. Using tool 380000267 (1), tighten the screw (5)
fig. 93, until the end of the plunger (4) is flush with
the inner reference surface (3) of the tool (2) or
up to 0.5 mm (0.0197 in.) further in.

5
4
2
3
TRE0707A

97
NOTE This corresponds to a distance (L1) of
86.386.7 mm (3.39763.4134 in.) between the end
of the lever (3) and the front surface of the lift body.

4
5

F1

12. Tighten the lock nut (4) to a torque of 15 Nm

(11.0624 ft lb).

L1

25638

98
Adjusting draft control
Proceed as follows:
13. Remove the end section of the draft control rod
(3) and mount it on the rod (5) of tool 380000263
(1). Fasten it using lock nut (4).
14. Place the tool 380000263 (1) complete with its
rod (5) and the end section of the draft control rod
(3) on a surface plate. Using a micrometer depth
gauge (2), measure the distance (L3) between
the upper surface of the rod and the micrometer
gauge bearing surface on the tool (be sure to
tighten rod (3) onto rod (5) so that the surface of
rod (5) is a few mm lower than the micrometer
bearing surface on the tool).

L3

4
3
25645

99

15. With tool 380000264 (2) fig. 97 mounted on the

lift body and disconnected from the compressed
air system, move the position control lever (1)
fig. 100 and the draft control lever (2) fully back
against the spacer.

2
1

16. Move the eccentric pin (1) fig. 105, connected to

the internal draft control lever, to the horizontal
position with the eccentric cam pointed towards
the rear of the lift assembly.

TRE0136A

100
??.??.???.?? ?? ????

29

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

17. Fit tool 380000263 (1) to the lift body and fasten
it to the two holes in the box as shown in figure
101.

1
2
3

25642

101
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).

2
1

TRE0708A

102
19. Turn the eccentric pin (1) slightly to withdraw the
end of the plunger of tool 380000264 as far as
possible.
20. Again turn the screw (2) fig. 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.
TRE0709A

103
22. Insert rod of tool 380000263 (1) into the internal
draft control lever seat (2).

23. With the end of the plunger of tool 380000264

flush with the outer reference surface (2) fig. 103,
set the adjustable linkage (3) fig. 104 and use a
micrometer depth gauge to measure the distance (L2) between the upper surface of the rod
and the micrometer gauge bearing surface on
the tool 380000264 (1).

L2
2
3

26348

104
??.??.???.?? ?? ????

30

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

24. The distance (L2, page 29) must be:

L2 = L3 +L4
where:
L3 = distance measured with tool 380000263
mounted on a surface plate:
L4 = 22.9 23.1 mm (0.9016 0.9094 in.). Operating distance between the lift box bearing surface on the transmission casing and the rod resting surface on the lever (3, fig. 104).

NOTE This corresponds to a distance (L1, fig. 93)

of 82.0 82.1 mm (3.2283 3.2323 in.) between the
end of the lever and the front surface of the lift body,
measured with a force (F1) of 4 4.5 da N
(25.40 39.82 in. lb) applied to the end of the lever.

2
WARNING Always make sure that when the plunger of tool 380000264 is flush with the outer reference
surface (2) the the distance (L2, fig.104 ) is:
L2 = L3 +L4
where:
L3 = distance measured with the tool 380000263
mounted on the reference surface;
L4 = 22.9 23.1 mm (0.9016 0.9094 in.). Operating
distance between the lift box bearing surface on the
transmission casing and the rod bearing surface on
the lever (3) fig. 104.
If these conditions are not met, adjust the eccentric
pin (1) and the knurled screw (2) fig. 104 of tool
380000263 until they are.

TRE0710A

105

1
25. Fit the threaded dowel (3) and tighten the screw
(1) without bending over the safety washer (2).
26. Remove the tools 380000264 and 380000263
and fit the hydraulic control valve block on the lift
body.

26350

106
Proceed to mount the lift assembly onto the tractor
as follows.

WARNING First position tool 380000263 (1) on a

surface plate and use a micrometer depth gauge (2)
to measure the distance (L5) between the surface
plate and the point where the micrometer gauge
rests on the tool.
Make a note of the measured distance (L5).

L5

26352

107
??.??.???.?? ?? ????

31

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

27. Fit the draft measuring device complete with
transmission lever (3) and draft control lever (2),
but without the flex bar, onto the rear transmission casing.

L6

28. Rest the transmission lever (3) on the draft

measuring device box and fit tool 380000263.
Fasten it to two holes on the box so that the draft
control rod (2) fits exactly inside the tool hole as
shown in figure 109

29. Using a micrometer depth gauge (2) fig.109,

measure the distance (L8) fig.109, between the
top end of the rod (3) fig.109 and the micrometer
gauge resting surface on the tool.
NOTE The distance (L6) the top end of rod (2) protrudes with respect to the transmission casing (with
flex bar removed) is given by:
L6 = L5 L8
where:
L5 and L8 = distance measured with tool 380000263
fitted on the surface plate (L5) fig. 107 or on the transmission casing (L8) fig. 109.

L7

26353

108

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.

1
2

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:
L5 and L9 = distance measured with tool 380000263
mounted on surface plate (L5) fig. 107 or on the
transmission casing (L9).

L8/L9
3

26354

109
31. Check that the distance (L7) is at least 5 mm
(0.1969 in.) greater than the distance (L6).
32. Slacken the lock nut (1) fig. 108 and adjust the
length of the draft control rod until it protrudes by
a new distance (L7 = 18.3 18.5 mm (0.7205
0.7283 in.)).
33. This distance (L7) can be calculated by subtraction using tool 380000263:
L10 = L5 L7
where:
L7 = 18.3 18.5 mm (0.7205 0.7283 in.).
Distance the end of the rod (2) fig. 108, protrudes
with respect to the transmission casing during
operation.
L5 = distance measured with tool 380000263
mounted on the surface plate.
L10 = distance to be measured with the
micrometer gauge on tool 380000263.
34. Tighten the lock nut (1) fig. 108, and mount the
lift on the tractor.
??.??.???.?? ?? ????

32

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

ADJUSTING LINKAGES (Op. 35 110 08)

Adjusting position control linkage.
Proceed as follows.
1. Move the position control lever (1) fully forward
on the quadrant and check that the distance (L)
is
between
15
and
20
mm
(0.5906 and 0.7874 in.).

TRE0108A

110
2. Move the external position control lever (1) fully
rearward, against the spacer.
3. Connect the control linkage and adjust its length,
if necessary.
4. Fasten the linkage using the lock nuts.

2
1

TRE0121A

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.
6. Move the draft control lever (2) fully back against
the spacer.

L1

TRE0116A

112

7. Connect the control linkage and adjust its length

if necessary.

TRE0121A

113
??.??.???.?? ?? ????

33

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

8. Move the draft control lever (2) to a distance (L2)
of 95 105 mm (3.7402 4.1338 in.) from the
beginning of the slot and check that at this
position the arms start to rise.

L2

9. If they do not, adjust the eccentric pin (1) fig. 105,

to restore this distance.
10. Fasten the eccentric pin using the securing bolt
(1) fig. 106.

114
Adjusting LIFTOMATIC device
Proceed as follows:

11. Move the position control lever (1) and the draft
control lever (2) fully forward in the sector.

TRE0116A

115
12. Raise the lift arms by means of the lever (1).

TRE0017A

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.
15. Unscrew the nut (1) by another 1.5 turns.

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.

TRE0117A

117
??.??.???.?? ?? ????

34

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

LIFT PRESSURE RELIEF VALVE

RemovingRefitting (Op. 35 110 30)
Auxiliary control valve blocks. The lift pressure relief
valve (1) is located as shown in fig.118)
If defective, remove and change the valve.

TRE0139A

118
LIFT PRESSURE RELIEF VALVE
Calibration (Op. 35 110 32)
Proceed as follows.
1. Run the engine until the oil reaches a temperature of about 50C (122 F).

2. Insert the fitting 380000554 (1) in a quickfit

female halfcoupling and connect it to the 0
3555.84 psi scale pressure gauge supplied with
kit 380000240.
3. Activate the halfcoupling control valve block
lever until the pressure relief valve cuts in.
4. With the engine running at medium speed the
pressure gauge must show a pressure of about
186 191 bar (2697.69 2828.22 psi). If the valve setting does not correspond to the prescribed
value, it is best to change it immediately. If necessary it can be adjusted by turning the cap, after removing the plastic sealing and unscrewing
the locknut, with a 4mm hex wrench. Tighten it to
increase the valve setting, unscrew it to decrease the setting.
Pressure relief valve section.
1.
2.
3.
4.
5.
6.
7.

TRE0142A

119

Oneway valve.
Additional control valve body.
Pressure relief valve body.
Valve spring.
Locknut.
Adjustable needle (4 mm wrench).
Plastic sealing.

120
??.??.???.?? ?? ????

35

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

NOTE The pressure relief valve setting can be
bench tested as follows:

8. Fit the pressure relief valve (1) on the valve union

380000217 (2) and connect the union to the hand
pump 380000215 (3).
9. Operate the hand pump (3) and check that the
pressure relief valve opens at a pressure of about
186 191 bar (2697.69 2828.22 psi).
Warning During assembly, the pressure relief valve
is calibrated using oil flow and the check using hand
pump 380000215 is to be considered only approximate. It is therefore advisable to check the pressure
relief valve setting with the valve fitted on the tractor
as described above.

25720

121

??.??.???.?? ?? ????

36

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

LIFT CONTROL VALVE BLOCK, DETACHED

DisassemblyAssembly (Op. 35 110 14)
Proceed as follows.

WARNING
Handle all parts with the utmost care.
Do not place your hands or fingers between one part
and another. Wear the prescribed safety clothing, including glasses, gloves and protective footwear.

1. Before removing the control valve, first remove

the transmission cover (1).

TRE0104A

122
2. Before disassembly, thoroughly clean the surfaces of the control valve block. Lock the control
valve block in a vice.

3. Unscrew the cap (1) and remove the spring (2)

and the control valve (3).

25707

123
??.??.???.?? ?? ????

37

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

4. Take off the cylinder safety valve (4) and remove
the arm lowering speed adjustment valve (3), the
spring (2) and the pin (1).

25709

124
5. Remove the check valve union (1), spring (2) and
ball (3).

25711

125
6. Take off the control valve block pin (1) and
remove the seat (3) and the spring (2).

25713

126

??.??.???.?? ?? ????

38

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

7. Check the wear of the seals on the control valve

block pin seat. If damaged, replace them using
protection device 380000275 (1), following the
instructions given on page 9.

8. Check the efficiency of the control valve block pin

as follows.

25714

127
9. Fit the control valve block pin (2) complete with
seat (3) on the tool 380000274 (1).

25715

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.

25716

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.

1
2
3

25717

130
??.??.???.?? ?? ????

39

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

12. Operate the hand pump and at the same time
tighten screw (1) on the tool until oil stops flowing
out through the control valve block pin seat
outlet.
13. Now zero the dial gauge.
14. Tighten the screw (1) on the tool further to move
the control valve block pin by 1.8 2 mm
(0.0709 0.0787 in.), using the dial gauge to
read this distance.

25718

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.

25719

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 specified value, it is best to replace the valve straight
away. If necessary, however, it can be adjusted
by turning the threaded cap using spanner
380000230. Tighten to increase the valve setting
value, or slacken to decrease the value.
18. Fit the hydraulic control valve block as follows:

WARNING
Always use appropriate tools to align fixing holes.
NEVER USE YOUR FINGERS OR HANDS.
Refer to the illustrations on page 8 for the
orientation of the various components:
Apply the torque settings listed on page 5.
Fit the complete control valve block pin.
Fit the check valve.
Fit the cylinder safety valve.
Fit the control valve.
Fit the complete pressure control valve.
Fit the cover on the control valve block.
25720

133

??.??.???.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

41

24622

134
Hydraulic lift control pump components
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Front cover.
Cover seals.
Pump body.
Gear support.
Driven and driving gear shafts.
Gear support.
Bushing.
Control side cover.
Driving shaft seal.
Spacer.

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Driving shaft seal.

Snap ring.
Safety washer.
Nut.
Bolt.
Washer.
Key.
Bushing.
Safety washer.
Nut.

HYDRAULIC LIFT CONTROL OIL PUMP

Removal refitting with pump removed
(Op. 35 0101 10)
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).

6. Remove the seals (2) and the antiextrusion

rings.

??.??.???.?? ?? ????

42

SECTION 35 HYDRAULIC SYSTEM CHAPTER 1

Once the parts are removed, proceed as follows:

7. Check that the gear contact surfaces are flat and
perpendicular to their supports. Insert a thin layer
of carbon black. Small rough spots can be
removed using extremely fine and well lubricated
abrasive paper.
8. Check that the axial play of the gearsupport unit
in the pump body is 0.090 0.160 mm
(0.0035 0.0063 in.). The distance (2) must be
0.090 0.160 mm (0.0035 0.0063 in.) smaller
than the distance (1).
If necessary, true the flat surfaces involved using
lubricated abrasive paper to remove extremely small
quantities of material. Ensure that axial play is still
within the limits of 0.090 0.160 mm
(0.0035 0.0063 in.).
9. Clean all constituent parts thoroughly.
10. Replace the seals (2, 9 and 11).
11. Lubricate the parts with the same oil as the
system. Refit the pump, referring to fig. 134 and
proceed as follows:
12. refit, performing operations 6 to 1 in reverse
order;
always ensure maximum cleanliness to prevent
foreign matter from entering, as this could damage the pump;
fit together previously marked parts (3), (4), (5)
and (6) fig.134; see procedure on page 41 to refit
them in their original position;
mount the gear supports (4) and (6) fig. 134, in
the pump body. Mount them with the fittings on
the external circumference matched up with the
discharge pipes and the front faces with lubrication millings in contact with the gears;
fit the plastic antiextrusion rings on the seals (2)
fig. 134:
mount the seals (9) and (11) fig. 134, on the control side cover (8), complete with spacer (10).
Mount them so that the cavity is between the seal
lips on the opposite side from this spacer. Finally
fill the cavity with AKCELA MULTIPURPOSE
GREASE 251H EP grease.

??.??.???.?? ?? ????

25227

135

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

SECTION 35 HYDRAULIC SYSTEM

Chapter 2 Open centre system auxiliary control valves
CONTENTS
Section

Description

35 000

Main data Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

35 204 46

Page

35 000 MAIN DATA TORQUE DATA TOOLS SECTIONAL VIEWS

DESCRIPTION AND OPERATION
MAIN DATA
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

fullflow filter, with paper

cartridge, (common to the
hydraulic lift circuit)

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

gear pump (common to the

hydraulic lift circuit, see chapter 1)

Auxiliary control valves

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

valve stack (up to a maximum of

3 valves) attached to the rear of
the centre housing

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

manually with hand lever

Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TOOLS
WARNING: The operations described in this section
must only be carried out using the ESSENTIAL tools
marked below with an (X).
For greater safety and to obtain the best results while
saving both time and effort, we recommend that
these essential tools are used in conjunction with the
specific tools listed below, and with certain tools
which are to be made following the constructional
drawings in this manual.

bar
(psi)

186191
(2697.70 2770.22)
convertible for operation of single
or doubleacting cylinders,
convertible for operation of single
and doubleacting cylinders and
with automatic detent release, for
operation of doubleacting
cylinders with float control and
automatic detent release

List of specific tools required for the various

operations described in this section.
380000240 Universal pressure testing kit.

???.??.??.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

TRE0711A

Auxiliary control valves Section views

a. Auxiliary control valve for convertible single/
doubleacting cylinder.
b. Auxiliary control valve for convertible single/
doubleacting cylinder with automatic
hydraulic release.
NOTE: Section view of auxiliary control valve
configured for operation of doubleacting cylinder
with float and automatic detent release was shown
at page 3 .
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Cover.
Spacer.
Spool.
Check valve.
Single/doubleacting conversion valve body.
Seal.
Seal
Single/doubleacting switchover screw.
Single/doubleacting operation adjusting spool
Valve body.

???.??.??.?? ?? ????

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.

Spool return spring.

Spring cup.
Seal.
Seal.
Control lever
Control lever support.
Tapered needle.
Seal.
Spring.
Detent balls.
Detent ball support.
Seal.
Internal plunger.
Spring.
Cover.
Detent release pressure adjuster screw.
Spool return spring.
Spring cup.
Seal.
Seal.
Detent notch body.
Detent screw locknut.
Circlip.

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

DESCRIPTION AND OPERATION

The auxiliary control valves serve to control hydraulic
3. Neutral When the lever is released from the
loads external to the tractor.
lifting and lowering positions it will automatically
return to neutral position.
Up to a maximum of three auxiliary control valves may
be mounted at the rear of the centre housing.
4. Float Push the lever forward beyond the
The auxiliary control valves are operated by hand
lowering position to select float position. In this
levers located to the right of the driving position.
position the only force exerted on the implement
Each control lever will have three or four positions
will be that created by its own weight, thus allowing
depending on the type of control valve it operates.
the implement to follow the profile of the terrain.
1. Lifting Pull lever back to lift the implement.
2. Lowering Push the lever forward to lower the
The operation of the hydraulic control valves is
implement.
described in the following pages.
OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR OPERATION OF A DOUBLEACTING
CYLINDER WITH AUTOMATIC DETENT RELEASE AND FLOAT POSITION

TRE0750A

2
Section view
2.
23.
24.
25.
26.
27.
28.
32.

Spool.
Internal plunger.
Spring.
Cover.
Detent balls.
Spool return spring.
Spring cup.
Float mode selection groove.

NOTE: Some parts releated with automatic detent

release are not shown in this view. Automatic detent
release working principle of valve shown in Fig. 2 is
same as the valve shown at Fig. 9 & Fig. 10.

FLOAT CONTROL OPERATION

To select float control operation, push the control leexhaust lines T. No pressure applied to both ports. In
ver (located in the cab) fully forward. The control
this condition, the only force acting on the attached
valve spool (2) will move and detent balls (26) will enimplement is that created by its own weight and the
gage in the grooves (32) where they will be held in
hydraulic lift may be operated. Automatic detent reposition by the support and the spring (24). In this
lease does not occur during float control as there is
position the spool directs the oil at A and B ports to
no pressure inside the auxiliary control valve.

???.??.??.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR OPERATION A DOUBLE ACTING
CYLINDER AUTOMATIC DETENT RELEASE AND FLOAT POSITION

TRE0750B

3
LIFTING
When the spool (2) moves to left, the detent balls (26)
engage the groove (33), where they are held in place
by the support (28) and spring (24). The movement of
the spool (2) connects: the pressure line (P) with the
line (B), and also the upper cylinder chamber with the

exhaust line (T) by way of line (A), intercepting the

supply of oil to the hydraulic lift control valve. Automatic
detent release working principle is explained at
page 6.

TRE0750C

LOWERING
When the spool (2) moves to right, the detent balls
engage in the groove (34) where they are held in
position by the support (28) and the spring (24). In
this condition the oil contained in the lower chamber
of the cylinder can flow to the exhaust (T) by way of
???.??.??.?? ?? ????

line (B), while the upper chamber is connected with

the pressure line (P) by way of line (A). On
completion of the lowering operation, the detent will
be automatically released as explained at Page 6.

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR OPERATION OF A DOUBLEACTING

CYLINDER (FIGS. 5 & 6) AND SINGLE ACTING CYLINDER (FIGS. 7 & 8)
1. LIFTING On pulling back the control lever, (located
in the cab) the control valve spool (2) moves to
connect: pressure line (P) with the lower chamber of
the cylinder by way of line (A), and also exhaust line (T)
by way of line (B), intercepting the supply of oil to the
lift control valve. Keep the lever pulled back, to extend
the cylinder to its full stroke. On releasing the lever it
will automatically return to neutral position, under the
action of the return spring, and the entire flow from the
pump will be conveyed to the lift control valve by way
of line (P).
TRE0712A

2. LOWERING To lower the implement, push the

control lever (located in the cab) forward. The control
valve spool (2) will move to the position indicated in
fig. 6, thus allowing the oil in the lower cylinder
chamber to flow to the exhaust (T) through line (A),
while the upper chamber is connected to the
pressure line (P) through line (B) .

3. LIFTING On pulling the control lever back, the

control valve spool (2) fig. 7 moves to connect the
cylinder with the pressure line (P) by way of line (A).
Line (C), for the control of singleacting cylinders, is
used in this stage as it is permanently connected to the
exhaust (T) by the open position of the switching valve
(1).

TRE0713A

4. LOWERING On pushing the control lever forward,

the spool (2) will move to the position indicated in fig.
8. The oil contained in the cylinder, pressurised by the
weight of the lifted implement, will flow to the exhaust
(T) by way of line (A), while the entire flow from the
pump is also conveyed to the exhaust (T) through the
line (B).
TRE0714A

Pressurised oil
Suction, delivery or exhaust oil
Static oil

NOTE: To operate a doubleacting cylinder, tighten

screw (1) fully home. To operate a singleacting
cylinder, fully undo screw (1).

TRE0715A

8
???.??.??.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

OPERATING STAGES OF AUXILIARY CONTROL VALVE OPERATING A DOUBLEACTING CYLINDER

WITH AUTOMATIC DETENT RELEASE

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 170175 bar (173178 kg/cm2). Acting
lines (P).

TRE0717A

10
LOWERING
To lower the implement, push the control lever
by way of line (B), while the upper chamber is
forward. The control valve spool (2) moves and the
connected with the pressure line (P) by way of line
detent balls engage in the central groove where they
(A). On completion of the lowering operation, the
are held in position by the support (28) and the spring
detent will be automatically released in the manner
(24). In this condition the oil contained in the lower
described previously.
chamber of the cylinder can flow to the exhaust (T)
???.??.??.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

AUXILIARY CONTROL VALVES (REMOVED FROM TRACTOR)

Disassembly Assembly (Op. 35 204 46)
of valves removed from tractor

3
6
5
7
8

1
7

2
9

4
TRE1100A

11
Convertible single/doubleacting auxiliary control
valve.
Disassemble the auxiliary control valve into its
component parts referring to the sectional views (fig.
1) and the following instructions:

1. Remove cover (3) and Orings (7).

2. Remove the control lever support (4) and take out
the seal (7).
3. Withdraw the spool (8).
4. Remove plug (6) and extract the single/double
acting switching valve (5).
5. Remove relief valve block (1) and check valve (2)
6. Remove the valve housing (9)
7. Check the condition of the seals before re
assembly.

WARNING
Handle all parts with care.
Do not insert fingers or hands between one part and
another.
Wear suitable safety clothing, i.e., safety goggles,
gloves and shoes.

WARNING
Always use suitable tools to align holes. NEVER USE
YOUR FINGERS OR HANDS.

???.??.??.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

Convertible single/doubleacting auxiliary control valve with float control and detent release.

WARNING
Handle all parts with care.
Do not insert fingers or hands between one part and
another.
Wear suitable safety clothing, i.e., safety goggles,
gloves and shoes.

WARNING
Always use suitable tools to align holes. NEVER USE
YOUR FINGERS OR HANDS.

3
5
7
9
8
7
8

1
2

TRE1101A

4
12

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

Pressure relief valve.

Check valve
Kickout (detent) and float control assembly
Control lever support
Single double acting converting valve
Oil return valve
Spool Oring kit
Kickout control assembly.

Disassemble the auxiliary control valve into its

component parts referring to the sectional views (fig.
1) and the following instructions:

???.??.??.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

WARNING

During the overhaul and disassemblyassembly of

the units, put special protective devices between the
bits of the vice, for preventing any damage to the
valve components.
1. Remove Allen screws (1) Fig.14.

TRE1102A

14
2. Remove both covers (1) Fig.15
1

TRE1103A

15
3. Remove both spacers (1) Fig.16
1

TRE1104A

16
4. Remove the circlip (1) and take the cover (2)
Fig.17 of the valve (Float & detent release)

2
1

TRE1105A

17
???.??.??.?? ?? ????

10

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

5. Withdraw the spool assembly (1) Fig.18.

1

TRE1106A

18
6. Complete spool assembly (Float & detent
release) is shown at Fig.19.

TRE1107A

19
7. Remove circlip (1) and take off the washer (2)
Fig. 20. Disassamble the unit to all its
components.
2

1
TRE1108A

20
8. Disassambled unit (Float & detent release) is
shown at Fig.21.

TRE1109A

21
???.??.??.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

11

9. Remove circlip (1) Fig.22.

1

TRE1110A

22
10. Take off the cover (1) Fig. 23.
1

TRE1111A

23
11. Remove the spool assembly (Detent release) (1)
Fig.24.

TRE1112A

24
12. Remove the nut (1) Fig.25 fixing the assembly.
1

TRE1113A

25
???.??.??.?? ?? ????

12

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

13. Remove the spring and the detent body (1)

Fig.26.

TRE1114A

26
14. Remove the nut fixing the detent body (1) Fig.27

TRE1115A

27
15. Complete spool assembly (Detent Release) is
shown at Fig.28.

TRE1116A

28
16. Remove oil return valve (1) Fig.29.

TRE1117A

29
???.??.??.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

13

17. Take off oil return valve (1) Fig.30

TRE1118A

30
18. Remove relief valve (1) Fig.31.
1

TRE1119A

31
19. Withdraw relief valve (1) Fig.32.
The relief valve can be checked when the engine is
running. When the relief valve is tested as explained
Section 35 Chapter 1 Page 35 the pressure gauge
must show a pressure of 186191 bar
(2697.69 2828.22 psi).
If the valve does not correspond to the prescribed
value, it is best to change it immediately.

TRE1120A

32
20. Slacken, singledouble acting converting valve
(1) Fig.33.

TRE1121A

33
???.??.??.?? ?? ????

14

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

21. Remove, singledouble acting converting valve

(1) Fig.34.
1

TRE1122A

34
22. Take off the ball of, singledouble acting converting valve (1) Fig.35.
1

TRE1123A

35
23. Slacken the allen screws (1) fixing the cover the
cover (2) Fig.36.

TRE1124A

36
24. Withdraw the cover (1) and the spacer (2) Fig.37.
25. Check the condition of all seals before reassembly.

1
2

TRE1125A

37
???.??.??.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

Doubleacting auxiliary control valve with float
control and automatic detent release.
Disassemble the auxiliary control valve into its
component parts referring to the sectional views (fig. 1)
and the following instructions:

15

3. Withdraw the spool (10).

4. Remove the valve housing and extract the check
valve and spring.

1. Unscrew the retaining screws and remove the

cover (11) and the distance piece.
2. Unscrew the retaining screws and remove the
control lever support (12) and related seal.

5. Check the condition of the seals before re

assembly.

SPOOL BINDING TEST

A
T
A

TRE0719A

38
Control valve spool binding test (fig. 38).
Install the auxiliary control valve assembly and the test
apparatus as indicated in the diagrams (fig. 38 ) and referring to the following instructions:
The test is carried out with mineral oil in
accordance with DIN 32 norm. Flow rate is the
nominal for the valve (for VDM07 it is 50 l/min).
Connect line P (pump line) to the inlet port of the
valve and close the working ports A and B of
each section (see schematic) with plugs.
Start the test, increasing the flow coming from
the pump until nominal flow plus 25% is reached
(in the case of VDM07 it is 75 l/min). With the
control lever in the neutral position (midposi-

tion) the flow goes through the valve from inlet to

outlet (tank line) (P) to (T). Now regulate the
maximum pressure of the VS (main relief valve)
valve inside bank A (in the schematic). This
pressure is the maximum pressure that can be
obtained with the type of valve and spring used.
Now move each single spool in each section.
With the ports closed, the pressure will rise until
the relief valve opens. In this situation check if
spools move to the neutral (central) position
without sticking, under the action of springs and
flow forces only. The relief valve D, in line before
the directional valve, has to substitute the VS in
A in case of problems or in case of directional
valve without VS.

???.??.??.?? ?? ????

16

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

SPOOL LEAKAGE TEST

A
T

TRE0720A

39

Valve leakage test

After the binding test (with hot oil and valve),
measure the leakage rate for each section. It is
important to do this with the system hot. Connect
working ports A and B of each section to the cylinders
(one for each section). Alongside each cylinder lay a
ruler to measure the stroke.
Supply oil to the cylinder, moving the spool to the
working position (oil flowing from A or B) until it
reaches the end of its stroke and the main relief valve
opens. Now that the oil column is pressurised from
the working section to the cylinder allow the lever to
return to the neutral position (called 0). The spool
closes A and B ports. Now check the position of the
cylinder observing the ruler beside it. As the cylinder
moves, check the stroke in a fixed time (say 60

???.??.??.?? ?? ????

seconds). From this stroke, calculate the volume of

oil per minute through that section of the cylinder.
This check has to be carried out for each section
(each spool).
After this check, with the pump disconnected, move
the spool to its working position: now test the check
valve (VU:Check Valve) of the distributor. This valve
closes the connection from P to T (N), also the
connection P with A or P when B is open (spool in
working position). If the check valve is working
correctly, the normal flow rate will be seen (the same
value observed with spool in the neutral position). If
it is see that one or more sections operates more
than in a previous check, it means that check valve
is not working properly (does not close completely).

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

17

ADJUSTMENT OF THE AUTOMATIC DETENT RELEASE PRESSURE

will fluctuate and the handle return to the neutral
position. Note the gauge reading immediately
prior to the needle fluctuation. The reading
should be within the specified value
(17411886 lbf/in2) 120 bar+10 bar0 bar.

After servicing the detent regulating valve or if the

control levers and spool are returning to neutral prematurely, the detent regulating valve should be
tested as follows:

NOTE: Detent release pressure is ONLY adjustable

on one spool in the valve that is NOT fitted with float.
The spools fitted with kick out and float have no
visible means of adjustment.

Install inlet hose of flowmeter (1) into lift coupler

of valve to be tested.

Install return hose from flowmeter into lift coupler

of the same valve on tractor.

If the reading is not to specification adjust the

detent pressure as follows:

. . . . . Remove the circlip (33) and the cover (25),

(Fig.1. Page.2) of the valve .
. . . . . Loosen locknut (32) on detent regulating adjuster screw (26).
. . . . . Turn detent regulating valve adjusting screw
(26) to change pressure setting.

Ensure load valve on flow meter is fully open;

Start tractor and set engine speed to 1700

rev/min;

Pull lever of remote control valve to be tested,

fully rearwards, to extend position.

Adjust load valve (2) on flowmeter until pressure

is 80 bar (1161lbf/in2) and run until hydraulic oil
is at an operating temperature of 65_C 5_C.

TRE1126A

With lever of remote control valve to be tested in

the cylinder extend position slowly close the
flowmeter load valve while observing the
flowmeter pressure gauge.

The pressure should steadily rise until the detent

regulating valve opens, at which point the needle

2
40

???.??.??.?? ?? ????

18

SECTION 35 HYDRAULIC SYSTEM CHAPTER 2

NOTES

???.??.??.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 3

SECTION 35 HYDRAULIC SYSTEM

Chapter 3 Trailer brake auxiliary control valve

CONTENTS

Section

Description

Page

35 000

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

Section view of auxiliary control valve for trailer

braking
1.
2.
3.
4.

Flow control valve.

Piston.
Check valve.
Relief valve.

TRE0721A

DESCRIPTION AND OPERATION

The trailer brake valve is mounted on the rear
transmission casing forward of the hydraulic lift. It is
supplied by the same pump as the lift circuit.

The trailer brake valve has priority over the auxiliary

control valves and the hydraulic lift.
The hydraulic operation of these valves is described on
pages 3 and 4.

???.??.???.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 3

HYDRAULIC DIAGRAM OF TRAILER BRAKE AUXILIARY CONTROL VALVE

Static oil
Oil in suction
Tractor brake circuit oil (brakes off)
Preeurised oil
Exhaust oil flow

2
4
5
1
9

8
7
6
26428

2
Diagram of the hydraulic trailer brake circuit
1.
2.
3.
4.
5.

Delivery line to control valve (3).

Trailer brake control valve.
Auxiliary control valves.
Auxiliary control valve lines.
Trailer brake control valve line.

???.??.??.?? ?? ????

6.
7.
8.
9.

Lift control valve.

Suction line.
Oil filter.
Hydraulic pump.

SECTION 35 HYDRAULIC SYSTEM CHAPTER 3

TRAILER BRAKES OFF When tractor brakes are
inactive, pressure limiter (4) and slide piston (2) take
up the positions shown in fig 3.

11 1
Pf

Oil from hydraulic pump (8, fig 2) is directed to fitting

(P1) through diaphragm (11) and restriction (9) which
causes a pressure drop to move flow control valve
(1) to the right.

P1

10

Most of the oil flows through connection (N) to the

auxiliary control valves. The remaining output is
drained into the hydraulic lift through port (10), piston
(2) and union (R).

TRE0722A

Trailer brakes off

Pressurised oil

N. To auxiliary control valves.

P1. From hydraulic pump to lift circuit.
R. To lift return line.

Oil in suction, delivery or return

Static oil

START OF BRAKING On operating the tractor

brake pedal (Pf), the fork (F) shifts the pressure relief
valve (4) and the slide piston (2) to the left, which in
its turn closes the passage between the oil return
port (R), trailer brake port (B) and the line (10).

12

11

P1

Pf

The oil inside the flow control valve (1) is maintained

at a uniform pressure and so the valve element,
under the action of the spring, shifts to the left to
assume the position indicated in fig.4.

B
13

As the pressure of the oil in the trailer brake union (B)

increases, it acts on the active surface (13) of the
spool (2), opposing the effect of control fork (F) on
relief valve (4)

10
4

Part of the oil from the hydraulic pump in union (P1)

flows to the auxiliary control valves through union
(N). while the remaining part arrives at the trailer
braking element via the diaphragm (11), line (12),
check valve (3) and port (B).

R
2

TRE0723A

4
Start of braking
B.
N.
P1.
R.

To trailer brake.
To auxiliary control valves.
Oil from the hydraulic pump to lift circuit.
Discharge line.

???.??.???.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 3

BRAKING Continued brake pedal application

causes an increase in oil pressure at trailer brake
connection (B) which, acting on active surface (13)
of slide piston (2), moves the latter to the right threby
overcoming the opposition of relief valve springs (8).

12

11

P1

10

Pf

When the trailer brake circuit oil pressure is equal to

spring (8) pressure, slide piston (2) stabilises as shown
in fig 5 and establishes communication between oil
from pump and lift drain through connection (P1),
diaphragm (11), restriction (9), port (10) and
connection (R).

13

R
2

TRE0724A

Pressurised oil
Oil in suction, delivery or return
Static oil
Braking

Diaphragm (11) and restriction (9) cause a pressure

drop in flow control valve (1) which moves to the right
to close line (12) and consequently, check valve (3).

Further pressure on the tractor brake pedals (Pf)

causes a leftward movement of relief valve (4) and
piston (2), with a consequent increase in trailer brake
circuit oil pressure as the sequence described in
paragraph b START OF BRAKING on page 3.

Upon releasing brake pedals, system returns to the

conditions shown in fig 3 at page 3.

???.??.??.?? ?? ????

B.
N.
P1.
R.

To trailer brake.
To auxiliary control valves.
Oil from the hydraulic pump to lift circuit.
Discharge line.

SECTION 35 HYDRAULIC SYSTEM CHAPTER 3

TRE0725A

Trailer brake remote control valve linkage adjustment

C. Wrench flats on link (6)

3 Delivery line to trailer brake

G = 0,30,5mm. Clearance between fork (7) and piston (10)

4 Cup

M Pressure gauge with 0 to 250 kg/cm2 scale of kit

380000240

5 Locknut
6 Link

V Trailer brake control valve

7 Fork

1 Connection 380000841 supplied in kit 380000240

8 Brake pedals

2 Connection 380000840 supplied in kit 380000240

10 Trailer brake control valve piston

???.??.???.?? ?? ????

SECTION 35 HYDRAULIC SYSTEM CHAPTER 3

TRAILER BRAKE REMOTE CONTROL VALVE LINKAGE ADJUSTMENT

Proceed as follows:
1. Adjust the brake pedal (8) free travel as indicated
before in Section 33.
2. Adjust parking brake lever as indicated before in
Section 33.
3. Fully tighten cup (4), slacken lock nut (5) and
adjust lenght of link (6), using wrench flats (C) to
obtain a clearance (G) of 0,3 to 0,5 mm (0.0118
to 0.0197 in.) between fork (7) and piston (10).
4. Tighten loc nut (5).
5. Disconnect trailer brake oil delivery line (3) from
brake control valve body (V).
6. Connect pressure gauge (M) with 0 to 250 kg/
cm2 scale of kit 380000240 to control valve body,
using connections 380000841 (1) and
380000840 (2) (Both connections belong to kit
380000240)
7. Start the engine and take the oil up to a
temperature to 50 60 0C (122 140 oF).

???.??.??.?? ?? ????

8. Run engine at around 2000 rpm.

9. Check that pressure gauge (M) reading is zero
when brake pedals (8) are not applied.
10. Depress brake pedals until pedal free travel is
taken up and check on pressure gauge (M) that
pressure is 100 bar (1450.37 psi)
11. Repeat this operation at least three times,
checking that system pressure reading drops to
zero when pedals (8) are released.
12. Apply parking brake (9) a few times without
depressing brake pedals and check that
pressure reading on pressure gauge (M)
remains at zero.

SECTION 41 -- STEERING -- CHAPTER 1

SECTION 41 -- STEERING
Chapter 1
CONTENTS
Section

Description

41 000

Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hydrostatic steering control valve -- Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydrostatic steering control valve -- Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . 14
Hydrostatic steering control valve -- Bench testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hydrostatic steering oil pump -- Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Steering cylinder (two--wheel drive axle) -- Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . 32
Steering cylinder (four wheel drive axle) -- Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . 33

41 204 30
41 204 34
41 204 38
41 216 20

Page

PRINCIPAL DATA
HYDROSTATIC STEERING
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

independent hydrostatic control,

feed by hydraulic pump

Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

metal cartridge, built

into oil reservoir

Control valve
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DANFOSS OR ORSTA
rotary valve controlled directly
from the steering column; the
steering continues to function
even if the pump is
non--functional

Outfit code:
-- DANFOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OSPC 100

-- ORSTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LAG--B 100--LVP16--2

Pressure relief valve setting (22) fig. 2

-- 2WD models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 bar (1450.37 psi)

-- 4WD models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

125 bar (1812.96 psi)

SECTION 41 -- STEERING -- CHAPTER 1

MAIN SPECIFICATIONS OF HYDRAULIC PUMP C25

Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

gear type with oil suction from

transmission casing
behind timing gear cover

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . . . . . .
Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum speed of rotation (with engine at maximum power) rev/min
Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . . l/min (in.3/min)

C 25
BOSCH
governed by timing gears
clockwise
1:0.931
2328
26.4 (1611.03)

Bench output at 1450 rev/min and pressure of

153 bar (156 kg/cm2):
-- for new or reconditioned pump . . . . . . . . . . . . . . . . . . . . l/min (in.3/min)
-- for worn pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/min (in.3/min)
-- test oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C (F)
-- test oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15.3 (933.66)
10.7 (652.95)
55 -- 65 (131 -- 149)
SAE 20

Diameter of driven and driving gear shafts . . . . . . . . . . . . . . . .

Internal diameter of seats in supports . . . . . . . . . . . . . . . . . . . .
Clearance between gear shafts and their seats . . . . . . . . . . . .
-- maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . .
Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . .
Maximum wear on pump body, suction side,
at position of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in.)
mm (in.)
mm (in.)
mm (in.)
mm (in.)

17,400 -- 17,418 (0.6850--0.6857)

17,450 -- 17,475 (0.6870--0.6880)
0,032 -- 0,075 (0.0013--0.0030)
0,1 (0.0039)
0,020 -- 0,064 (0.0008--0.0025)

mm (in.)

0,1 (0.0039)

Cylinder
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston rod diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum piston stroke
WEBER or ERBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum piston stroke
WEBER or ERBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Double acting, located behind

front axle
WEBER or SIMA or ERBER
48 mm (1.89 in)
22 mm (0.866 in)
215 mm ( 8.464 in)
214 mm (8.425 in)
200 mm (7.874 in)
194 mm (7.638 in )

SECTION 41 -- STEERING -- CHAPTER 1

TORQUE SETTINGS
Torque setting
PART

Thread
Nm

ft lb

Bolt fixing hydrostatic steering to tractor . . . . . . . . . . . . . . . . . . . . . . . .

3/8--16 UNC

44

32.4527

Bolt fixing cover to hydrostatic steering housing (13, fig. 2) . . . . . . . .

M8x1

34

25.0771

M 8 x 1*

29

21.3893

Hydrostatic steering control pump fixing bolt . . . . . . . . . . . . . . . . . . . .

M6x1

5.9005

Nut for bolt fixing cover to pump housing (20, fig. 1) . . . . . . . . . . . . . .

M 10 x 1,25

39

28.7649

Nut for securing thrust sleeve to pump drive shaft (14, fig. 1)) . . . . .

7/16 in
--20UNF--2B

28

20.6517

Nut, power cylinder pivot pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 18 x 1.5

294

216.8433

Nut, power cylinder piston rod to steering arm . . . . . . . . . . . . . . . . . . .

M 14 x 1.5

147

108.4216

--WEBER cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

83

61.2177

--SIMA cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

98

72.2811

--ERBER cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

98

72.2811

Capscrew, contol valve support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

147

108.4216

Capscrew, LVP safety valve block to body . . . . . . . . . . . . . . . . . . . . . .

--

64

47.2040

Nut, piston to rod

* ORSTA

SECTION 41 -- STEERING -- CHAPTER 1

1
Hydrostatic steering -- Oil pump components
1. Front cover
2. Cover seals
3. Pump body
4. Gear support
5. Driven and driving gear shafts
6. Gear support
7. Bushing
8. Control side cover
9. Driving shaft seal
10. Spacer

11. Driving shaft seal

12. Snap ring
13. Lock washer
14. Nut
15. Bolt
16. Washer
17. Key
18. Bushing.
19. Safety washer
20. Nut.

SECTION 41 -- STEERING -- CHAPTER 1

24725

Hydrostatic steering -- Control valve components

1. Dust seal
2. Reflux valve balls
3. Reflux valve pins
4. Control valve body, rotary valve and rotary
valve seat sleeve
5. Check valve ball
6. Threaded plug of check valve
7. O--ring seal
8. Support ring for O--ring (7)
9. Thrust bearing components
10. Retaining ring for springs (11)
11. Springs for returning sleeve to neutral position

12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

Rotor control shaft -- sleeve trim pin

Cover fixing screws
Check valve seat screw
Washers
Cover
O--rings
Rotor and fixed ring for rotor
Thrust washer
O--ring
Rotor control shaft
Pressure relief valve complete with spring

SECTION 41 -- STEERING -- CHAPTER 1

26

27

E
P
D1
H
T

TRE0431A

3
General hydraulic diagram
H
D1
E
T
P

Power steering cylinder

Hydrostatic steering control valve
Filter
Oil tank
Pump

26 Oil in intake line

27 Oil in delivery line from pump
M Oil delivery to control valve
S Oil at lubrication pressure

SECTION 41 -- STEERING -- CHAPTER 1

OPERATION
The oil taken in by the rear axle is pushed into the
pump through a filter, pressurized by the rotating
gears and expelled from the delivery side of the
pump to the steering motor. Once in the steering
motor, the pressurized oil is directed to the steering
cylinder when the steering wheel is turned.
Inside the steering motor, there is a measuring
device which controls the volume of oil supplied to
the cylinder so that it is proportional to the angular
movement of the steering wheel. The metering valve
together with the intake valves also allows MANUAL
operation of the steering, without pressurized oil
being emitted by the pump.

direct mechanical connection between the column

and the steered wheels.
Neutral position
When the steering wheel is stationary, the leaf
springs in the steering motor push the spool and the
sleeve in, and keep them in the neutral position. This
ensures that no further oil is supplied to the steering
cylinder. The sleeve also blocks the oil inside the
cylinder, keeping the wheels in a set position, fig. 4.
Oil in intake line
Oil in delivery line from pump
Oil at static rest
Oil returning to reservoir

The system is totally hydrostatic and as such, has no

a
1
13
12
3

11

5
10
6

TRE0432A

9
8

4
Diagram of hydrostatic steering operation
a 2WD models
1. Equalization valve
2. Steering cylinder
3. Metering valve
4. Check valve
5. Non--return valve
6. Resonance damper

7. Pump
8. Filter
9. Return line to reservoir
10. Pressure relief valve
11. Control valve external rotor
12. Control valve internal rotor
13. Anti--cavitation valves

SECTION 41 -- STEERING -- CHAPTER 1

Steering to the right (fig. 5)

When you turn the steering wheel clockwise, the
springs (11) fig. 2 deform, allowing the valve (12) fig.
4 to rotate in relation to the sleeve (11).
In this state, the following takes place:
-- de--synchronisation of the internal ducts with
parts (11) and (12) fig. 4, which were aligned in the
neutral phase, resulting in interruption of the flow
of oil to the outlet.
-- alignment with the same number of internal ducts
connected moment by moment with the rotor
compartments at intake from the pump (7) fig. 4
and in the delivery line to the steering cylinders
(2), thus allowing the wheels to be steered to the
right.
Steering to the left
When you turn the steering wheel anticlockwise, the
grooves inside parts (11) and (12) fig. 4 and the
delivery lines to the steering cylinders are reversed,
thus allowing the wheels to be steered to the left.

Steering to the right manually

If there is a fault or loss of oil pressure at the
hydrostatic steering pump, steering can also be
performed manually.
When you turn the steering wheel clockwise, the
rotor inside the hydrostatic steering control valve (3)
fig. 4 performs the function of a hand pump, sending
oil to the control cylinder rod side (2), thus allowing
the wheels to be steered to the right manually.
Steering to the left manually
When you turn the steering wheel anticlockwise, you
act upon the rotor inside the hydrostatic steering
control valve which, by operating as a hand pump as
previously described, sends oil to the control cylinder
piston side, thus allowing the wheels to be steered to
the left manually.

25162

5
Diagram showing operation of the hydrostatic steering
a 2WD models

Oil in intake line

A Steering to the right

Oil in delivery line from pump

B Steering to the left

Oil in delivery line to hydraulic cylinder

Oil returning to reservoir

SECTION 41 -- STEERING -- CHAPTER 1

HYDROSTATIC STEERING FAULT DIAGNOSIS

Refer to fig. 2 for component identification

Problem
Oil leaking from
steering unit:
a. Control side.
b. Cover side.

Possible causes
hydrostatic 13. O--ring seal defective (7).

Corrective action
Renew the seal and the stop ring
using special tool 380000836.

14. Screws (13) not sufficiently Tighten the screws to the prescribed
torque
tight.
(24--36 Nm, 17.7015--26.5522 ft lb).

Steering wheel excessively stiff

15. Sealing washers (15) or Renew the washers and seals.

O--rings (17) defective.
1. Hydraulic pump inefficient.
Repair the pump.
2. Check valve (5) held open by Eliminate foreign bodies and clean
foreign bodies or open due to the filter; put a new ball into the seat
(if missing).
absence of ball.
3. Pressure relief valve (22) Reset the valve.
incorrectly set.
4. Pressure relief valve (22) Eliminate foreign bodies and clean
jammed or held open by for- the filter.
eign bodies.
5. Steering column has become Eliminate the causes.
stiff on its bushing due to
rusting, seizing, etc.

Excessive play of steering wheel

1. Excessive play between the Renew the worn parts.

steering column and the
coupling with the rotary valve
(4).
2. Excessive play in the coupling Renew the worn parts.
between shaft (21) and trim
pin (12).
3. Excessive play in the splined Renew the worn parts.
coupling between the shaft
(21) and the rotor (18).

4. Combination of excessive
play as described above.
5. Leaf springs (11) broken or
fatigued.
The steering wheel turns normally, 1. Inadequate seal of control
but steering is:
cylinder.
a. Slow.
2. Cylinder rod broken.

Renew the most worn parts.

Renew the springs.
Renew the seal.
Renew the damaged part.

b. No steering.

3. Rotor control shaft (21) or pin Renew the damaged part.

(12) broken.
With the engine stopped, the 1. Excessive wear between rotor Renew the worn parts.
steering wheel can be turned
and fixed ring (18).
without turning the wheels.
2. Check valve damaged.

Renew the control valve.

(continued)

10

SECTION 41 -- STEERING -- CHAPTER 1

HYDROSTATIC STEERING FAULT DIAGNOSIS
Refer to fig. 2 for component identification

(continuation)
Problem

Possible causes

Corrective action

Steering wheel jolts, steering 1. Incorrect synchronization of Synchronize correctly.

uncontrollable, wheels steering in
hydrostatic steering.
Correct the connections.
the opposite direction to the 2. Hoses to cylinder reversed.
desired direction.
The wheels do not maintain the 1. Hydraulic cylinder piston seal Renew the seal.
desired alignment and continual
worn.
correction with the steering wheel 2. Reflux valve (2) damaged or Eliminate the foreign bodies and
is necessary.
clean the filter or renew the control
held open by foreign bodies.
valve.
3. Mechanical wear of control
Renew the control valve.
valve.
Neutral phase of hydrostatic 1. Leaf springs (11) for returning
steering unobtainable. During
sleeve (4) to neutral position
manual control, operation is
broken or fatigued.
normal. When stopping manual 2. Sleeve and rotary valve (4)
control, the steering wheel moves
blocked in delivery position by
on its own or remains stationary,
foreign bodies.
but steering continues slowly in
3. Crushing of sleeve (4) on
the
direction
first
turned
rotary valve due to excessive
(motoring), so the steering wheel
pressure.
must be continually corrected.

Renew the pack of leaf springs.

Front wheel vibration (shimmy).

Bleed the air and eliminate the causes

of possible infiltration.
Renew the worn parts.

1. Air pockets in the hydraulic

cylinder.
2. Wear of mechanical joints of
steering tie rods.
3. Reflux valve (2) damaged or
held open by foreign bodies.

Eliminate the foreign bodies and

clean the filter.
Check the setting of the pressure
relief valve (22).

Remove the foreign bodies and clean

the filter or renew the control valve.

Difficulty in steering in general, or 1. Insufficient pressure.

in one direction.

Check the hydraulic pump and the

setting of the pressure relief valve
(22).
2. Excessive leakage inside the Renew the control valve.
control valve.

TOOLS
WARNING: The operations described in this section
must be performed only with the ESSENTIAL
equipment marked with (X).
To operate safely and achieve best results, while
saving time and effort, essential equipment must be
used in conjunction with the special tools
recommended below, and tools which you must
make yourself and for which you will find the design
in this manual.

List of special tools necessary for the various

operations described in this section.
X 380000307 Hyd. steering rotor retaining lever.
X 380000223 Steering wheel extractor.
X 380000240 Universal pressure checking kit.
X 380000305 Tool for fitting hydrostatic steering
toroidal seal.
380000306 Plug for fitting hydrostatic steering
rotary valve return springs.

SECTION 41 -- STEERING -- CHAPTER 1

HYDROSTATIC STEERING CONTROL VALVE
Removal--Refitting (Op. 41 204 30)

11

WARNING
Handle all parts with great care. Do not put your
hands or fingers between one part and another.
Wear the recommended safety clothing such as
goggles, gloves and safety boots.
To remove the hydrostatic steering control valve,
proceed as follows:
1. Disconnect the negative cable (1) from the
battery.
2. Drain the oil from the steering system.
3. To access the engine
opened.

the hood

25621

must be

TRE0033A

7
4. Disconnect the oil pipes from the hydrostatic
steering control valve unit (1).

TRE0434A

8
5. Remove the steering wheel (1) retaining nut and
remove the steering wheel and hand throttle
lever.

25758

12

SECTION 41 -- STEERING -- CHAPTER 1

6. Remove the four securing screws (1) from the

instrument panel (2).

25759

10
7. Disconnect the electrical leads (1) from the rear
of the instrument panel. Unscrew the the
tachometer cable (2). Remove the instrument
panel and store in a safe place.

TRE0435A

2
11

8.

.Unscrew the rear hood screws (1)

TRE0436A

12
9. Take off the complete rear hood.

10

TRE0437A

13

SECTION 41 -- STEERING -- CHAPTER 1

13

10. Remove the hydrostatic steering unit support

bolts and take of the hydrostatic steering unit.

TRE0028A

14

--

To refit the control valve, proceed as follows:

--

Refit the hydrostatic steering unit

--

Refit the complete rear hood.

--

Secure the rear hood with the screws previously

removed.

--

Reconnect the electrical leads and reconnect

the the tachometer cable.

--

Re--install the four

instrument panel.

--

Re--install thehand throttle and steering wheel.

Secure the wheel with the central retaining nut.

--

Reconnect the oil pipes to the hydrostatic

steering control valve unit.

--

Fill the the steering system with oil.

--

Reconnect the negative cable to the battery and

close the hood.

screws

securing the

14

SECTION 41 -- STEERING -- CHAPTER 1

HYDROSTATIC STEERING CONTROL VALVE

Disassembly--Assembly on the bench
(Op. 41 204 34 )
To disassemble the hydrostatic steering control
valve, proceed as follows:
1. Remove the control valve cover retaining bolts.

24701

15
2. Remove the cover by sliding to one side.

24702

16
3. Remove the rotor fixed ring, the rotor and the
inner spacer.
4. Remove the two O--ring seals on the rotor fixed
ring.

24703

17
5. Extract the rotor drive shaft

24704

18

SECTION 41 -- STEERING -- CHAPTER 1

15

6. Extract the thrust washer.

24705

19
7. Remove the threaded plug on the non--return
valve seat.

24706

20
8. Extract the O--ring seal from the control valve
body.

24707

21
9. Position the control valve body and the rotor
drive shaft so that the sleeve--control shaft trim
pin is in a horizontal position.
10. Push the rotary valve inwards, so that the valve,
the valve seat sleeve and the thrust bearing can
be extracted from the control valve body.

24709

22

16

SECTION 41 -- STEERING -- CHAPTER 1

11. Extract the thrust bearing from the rotary valve,

complete with the two external rings. Remove
the spring retaining ring from the valve seat
sleeve.

24710

23
12. Extract the valve--sleeve trim pin.

24711

24
WARNING: On assembly, two reference marks
(arrowed) were made on the rotary valve and the
sleeve, corresponding to the neutral position
maintained by the springs. Before removing the
springs, check that the marks are clearly visible. If
not clear, make new reference marks.

24712

25
13. Extract the rotary valve from the valve seat sleeve.

24713

26

SECTION 41 -- STEERING -- CHAPTER 1

17

14. Remove the neutral position springs, extracting

them from their seats.

24714

27
15. Remove the dust seal and the O--ring seal from
their seats in the control valve body.

20428

28
16. Using a 6 mm Allen wrench, remove the
threaded plugs from the two cylinder safety
valves and extract the seals.

20429

29
17. Using a 6 mm Allen wrench, remove the setting
adjuster screws from the cylinder safety valves.
See also fig. 31.
18. Turn the control valve body over and extract the
balls, the springs and the spring guides from the
two cylinder safety valves.

20432

30

18

SECTION 41 -- STEERING -- CHAPTER 1

Cylinder safety valves components (order of

disassembly--assembly).

1. Cylinder safety valve ball.

2. Pressure spring.
3. Setting adjuster screw.
4. Seal.
5. Plug.
25790

31
19. Using a 6 mm Allen wrench, remove the
threaded plug on the pressure relief valve and
extract the seal.

20434

32
20. Remove the pressure relief valve adjuster screw.
21. Turn the control valve body over and complete
disassembly by extracting the spring and the
pressure relief valve piston.

20436

33
Pressure relief
assembly).

valve

components

(order

of

1. Pressure relief valve.

2. Pressure spring.
3. Setting adjuster screw.
4. Seal.
5. Plug.
27099

34

SECTION 41 -- STEERING -- CHAPTER 1

19

22. Thoroughly clean all control valve component

parts.
23. Replace the washers and seals.
24. Carefully check all mechanical parts, replacing
components that show signs of wear.
25. Before refitting, lubricate the components with
hydraulic oil.

26. Re--fit the rotary valve on the sleeve, checking

that the reference marks indicated in the drawing
coincide.

24726

35
27. Use tool 380000306 to insert the flat and curved
springs (12) fig. 2.
(Diagram for fitting springs (12) fig. 2 neutral position
for OSPC 80 ON--150N 1058 hydrostatic steering).

24728

36
28. After inserting the springs in the seat, align and
centre (as shown in the drawing).

24729

37

20

SECTION 41 -- STEERING -- CHAPTER 1

29. Fit the neutral position spring retaining ring on

the valve seat sleeve, remembering that the ring
must rotate freely without being impeded by the
springs.

24730

38
30. Insert the sleeve--rotor drive shaft trim pin.

24731

39
31. Fit the thrust bearing, following the order
indicated in fig. 41.

24732

40
1. Bearing external ring.

2. Thrust bearing.

3. Bearing internal ring with bevel facing contact

surface of part (5).

4. Rotary valve.

5. Rotary valve seat sleeve.

24733

41

SECTION 41 -- STEERING -- CHAPTER 1

21

32. Position the control valve body so that the

housing seat on the rotary valve sleeve is
positioned horizontally, then insert the guide
bushing (1) of tool 380000305.

1
24734

42
33. Lubricate the support ring (1) and O--ring seal (2)
with hydraulic oil and fit them on the head (3) of
the tool 380000305, as shown in the drawing.

2
1
3

Support head for support and seal rings

(part of tool 380000305)
24735

43
34. Insert the complete drift in the guide bushing
previously installed.

24736

44

22

SECTION 41 -- STEERING -- CHAPTER 1

35. Holding the external bushing in position

manually, press fully down, whilst simultaneously
rotating the drift, in order to facilitate the entry of
the O--ring seal in the control valve body seat.

24737

45
36. Extract the components of tool 380000305
(external bushing and drift).
NOTE: The support head of the support and seal
rings remains on the control valve body (see fig. 43).

46
37. Insert the parts that were previously fitted in
operations 26 -- 31 on the control valve body.
Hold the sleeve--to--rotor drive shaft trim pin in a
horizontal position, to prevent it from slipping out
and jamming in the slots inside the control valve
body.

24739

47
38. Press the rotary valve so as to bring the thrust
bearing into contact with the control valve body.
This operation simultaneously expels the head
(1) of tool 380000305, inserting the rings (1) and
(2) fig 43 into the seat of the control valve body
(see operation 33).

25795

48

SECTION 41 -- STEERING -- CHAPTER 1

23

39. Rotate the control valve body and insert the

non--return valve ball into the seat indicated by
the arrow.

24741

49
40. Screw the threaded plug into the non--return
valve seat until the upper surface is below the
coupling surface of the control valve body.

24742

50
41. Lubricate the O--ring seal and insert into the seat
on the control valve body.

24746

51
42. Fit the thrust washer, so that the holes coincide
with the holes in the control valve body.

24747

52

24

SECTION 41 -- STEERING -- CHAPTER 1

43. Make a reference mark on the upper part of the

teeth (1), in line with the seat (2), to indicate the
exact position of the valve--to--sleeve trim pin.

24748

53
44. Fit the rotor drive shaft into the control valve
body. Insert tool 380000307 for retaining and
centring the rotor drive shaft, between the rotor
drive shaft and the thrust washer. Rotate the
shaft so as to facilitate coupling between the seat
(2) fig. 53 and the trim pin installed in the sleeve.

24749

54

45. To refit the rotor, proceed as follows:

a) each time the hydrostatic steering is
disassembled, turn the rotor over so as to limit
wear to the splined coupling;
b) in the drawing below, the rotor shaft has been
removed in order to show the phasing between the
rotor, rotor drive shaft and the trim pin;
c) fit the rotor on the drive shaft, remembering that
phasing is obtained by aligning the teeth (1), on the
trim pin axis plane (shown in fig. 53) with the centre
line of one of the recesses between the lobes of the
rotor.

24750

55

SECTION 41 -- STEERING -- CHAPTER 1

25

46. Lubricate the two O--ring seals (1) with hydraulic

oil and insert them in the rotor fixed ring seat. Fix
in position by aligning the retaining holes (2) with
those on the thrust washer.

24751

56
47. Fit the cover, aligning the retaining holes with
those on the rotor fixed ring.

24753

57
48. Remove retaining tool 380000307 and fit the
special screw and washer in the non--return
valve seat, shown in the drawing.

24754

58
49. Fit the other six cover retaining bolts with the
washers and tighten in diagonal sequence to the
torque setting value shown in the table on page 3.

24755

59

26

SECTION 41 -- STEERING -- CHAPTER 1

50. Turn over the control valve body and insert the
pressure relief valve piston in the seat, as
indicated in the drawing. See fig. 34 for
component assembly order.

24756

60
51. Insert the pressure relief valve spring.

24757

61
52. Using an 8 mm Allen wrench, insert the pressure
relief valve setting screw.

NOTE: Setting should be carried out on the

workbench or on the tractor to the values shown in
the table on page 1.

24758

62
53. Tighten the plug (2), with the associated seal,
using an 8 mm Allen wrench. Tighten to the
prescribed torque value 40 -- 60 Nm
(29.5025 -- 44.2537 ft lb), after having carried out
the setting on the workbench or on the tractor.
54. Insert the balls (1) into the two cylinder safety
valve seats, indicated by the arrows. See fig. 64
component assembly order.

1
2

25789

63

SECTION 41 -- STEERING -- CHAPTER 1

Cylinder safety valves components (order of
assembly)
1. Cylinder safety valve ball.
2. Pressure spring.
3. Setting adjuster screw.
4. Seal.
5. Plug.

27

25790

64
55. Insert the springs (2, fig. 69) in the cylinder
safety valve seats.
56. Using a 6 mm Allen wrench, tighten the two
cylinder safety valve setting adjuster bolts
(3, fig. 69).
NOTE: Setting should be carried out on the
workbench or on the tractor to the values shown in
the table on page 1.

20475

65
57. Tighten the two plugs (5, fig. 69) and the
relative seals (4) using a 6 mm Allen wrench.
Once setting is completed, tighten to the
prescribed torque value of 30 Nm
(22.1269 ft lb).

20429

66
58. When the unit has been assembled, insert the
dust seal in the seat in the control valve body.

24764

67

28

SECTION 41 -- STEERING -- CHAPTER 1

HYDROSTATIC STEERING CONTROL VALVE

Bench testing (Op. 41 204 38 )
Test conditions.
Oil type . . . . . . . . . . . . . . . . . . . IDRAULICAR AP51
Oil viscosity . . . . . . . . . . . . . . . . . . . . . . . SAE 20 W
Oil temperature . . . . . . . . . . . . . . . . . 60_C (140_F)
Hydraulic pump capacity . . . . . . . . . . . litres/min 12
. . . . . . . . . . . . . . . . . . . . . . . . . . . (gall. imp/min 2.64)
Speed of electric motor . . . . . . . . . . . . . . . rpm 1450

2
1

5
4
24912

Installation diagram of equipment for testing the rotary valve,

seals and for setting the pressure relief valve.
4. Restriction
1. Splined control shaft
5. Pressure adjustment handwheel
2. Torque wrench
3. Delivery line
A -- CHECKING ROTARY VALVE WEAR
1. Make the connections shown in fig. 68 and
complete the circuit as in fig. 69. Using the
splined control shaft (1), hold the steering control
valve in steering position (right or left).
2. Using the handwheel (5), increase the circuit
pressure to as near as possible the pressure
relief valve cracking pressure (page 1) without
the valve actually opening.
3. Using a torque wrench (2), apply a torque of
approx. 34 Nm (25.8147 ft lb) to the control shaft
(1), and check that the rotary valve takes more
than 10 seconds to complete one full rotation. If
it takes less than 10 seconds, change the rotary
valve (4, fig. 2) and the sleeve .

68

SECTION 41 -- STEERING -- CHAPTER 1

B -- CHECKING RETURN TO NEUTRAL POSITION
In the same test conditions as A, check that the valve
automatically returns to neutral position when the
control shaft (1) is released after each simulated
steering movement.
C -- CHECKING SEAL EFFICIENCY
In the same test conditions as A, hold the valve in
steering position with the control shaft (1) for about
three minutes and check the seals for leaks.
D -- SETTING THE PRESSURE RELIEF VALVE
1. Make the connections as shown in figure (68)
and complete the circuit as in figure (69).
2. Using the control shaft (1), simulate a steering
cycle (to right or left) so as to interrupt the oil flow
to the outlet.
3. Gradually increase the pressure in the circuit by
turning the handwheel (5) fig. 68, and check on
the pressure gauge that the pressure relief valve
(22, fig. 2) cuts in at the pressure shown on
page 1. If not, increase or reduce the pressure
relief valve setting by tightening or slackening
the adjuster screw.

29

7
6

5
3

4
24911

CHECKING THE HYDROSTATIC STEERING

PRESSURE RELIEF VALVE WITH STEERING
CONTROL VALVE INSTALLED ON TRACTOR.
Proceed as follows:
1. Start the engine and run until the oil temperature
reaches approx. 50_C (122_F).
2. Switch off the engine and unscrew the oil delivery
pipe union (4) on the hydraulic cylinder (5).
3. Fit union (2) in place of union (4), and connect the
pressure gauge (1) with a 0 -- 21.3350 psi scale
by way of union (3).
4. Start the engine again, bring the speed up to
medium rpm, and apply full--steering lock to
bring the hydraulic cylinder to the stroke--end
position.
In this condition, the pressure relief valve (22, fig. 2)
should open and the pressure gauge should indicate
the value given on page 1.
5. If the pressure gauge reading deviates significantly from the prescribed value, adjust the valve
opening pressure by way of the adjuster screw.

1. Splined control shaft

2. Plug G 1/2
3. To throttle
4. Outlet
5. Three--way coupling G 1/2
6. From delivery line
7. Outlet coupling G 1/2

3
1

69

24915

70
1. Pressure gauge (supplied in kit 380000240)
2. Union 380000618 (supplied in kit 380000240) to
be fitted in place of original union
3. Union 380000613 (supplied in kit 380000240)
4. Hydraulic cylinder oil feed pipe
5. Hydraulic cylinder.

30

SECTION 41 -- STEERING -- CHAPTER 1

Hydrostatic steering oil pump components

Hydrostatic steering oil pump components

1. Front cover
2. Cover seals
3. Pump body
4. Gear support
5. Driven and driving gear shafts
6. Gear support
7. Bushing
8. Control side cover
9. Driving shaft seal
10. Spacer

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.

[Link] shaft seal.

12. Snap ring
13. Safety washer
14. Nut
15. Bolt
16. Washer
17. Key
18. Bushing
19. Safety washer
20. Nut

71

SECTION 41 -- STEERING -- CHAPTER 1

5. Remove the supports (4 and 6) and the gears

(5) from the rear cover (8) and the pump body (3).
6. Remove the seals (2) and the anti--extrusion
[Link] the parts are removed, proceed as
follows:
7. Check that the gear contact surfaces are flat
and perpendicular to their supports. Interpose a
thin layer of carbon black. Small rough spots can
be removed using extremely fine and adequately
lubricated abrasive paper.
8. Check that the axial play of the gear--support
unit in the pump body is 0.100 -- 0.180 mm
(0.0039 -- 0.0189 in.). The distance (Fig 72, 2)
must be 0.100 -- 0.180 mm (0.0039 -- 0.0189 in.)
smaller than the distance (Fig 72, 1).If necessary,
true the flat surfaces involved using lubricated
abrasive paper to remove extremely small
quantities of material
9. Clean all constituent parts thoroughly.
10. Replace the seals (2, 9 and 11).
11. Lubricate the parts with the same oil as the
system Refit the pump, referring to fig. 71 and
proceeding as follows:
12. refit, performing operations 6 to 1 in reverse
order;-- always ensure the maximum cleanliness
to prevent foreign matter from entering, as this
could damage the pump;-- fit together previously
marked parts (3, 4, 5 and 6, fig. 71); see op. page
45 to refit them in their original position;-- mount
the gear supports (4 and 6 fig. 71) in the
pump body; orient them with the fittings on the
external circumference matched up with the
discharge pipes and the front faces with
lubrication millings in contact with the gears;-- fit
the plastic anti--extrusion rings on the seals
(2, fig. 71);-- mount the seals (9 and 11, fig. 71) on
the control side cover (8) complete with spacer
(10); orient them so that the cavity is between the
seal lips on the opposite side from this spacer;
lastly fill this cavity with AKCELA MULTI -PURPOSE GREASE [Link] the pump on
the tractor. Fill the suction pipe and the pump
housing with AKCELA NEXPLORE oil in order to
facilitate priming and prevent the risk of seizure
during initial operation.

31

25227

72

32

SECTION 41 -- STEERING -- CHAPTER 1

FRONT
AXLE
STEERING
CYLINDER
(Two wheel drive axle) (Op. 41 216 20)
Removal--Refitting

WARNING
Handle all parts with great care. Do not put your
hands or fingers between one part and another.
Wear the recommended safety clothing such as
goggles, gloves and safety boots.
To remove the front axle steering cylinder, proceed
as follows:
1. Remove the exhaust pipe, lift the hood and
disconnect the negative cable from the battery.
2. Unscrew the unions securing the oil delivery and
return hoses (1) to the cylinder (2).
3. Remove the nut securing the cylinder rod ball
end to the steering arm (1).

24768

73

24858

74
4. Using a suitable puller (1), separate the cylinder
rod ball end from the steering arm.

24859

75
5. Remove the pin securing the steering cylinder
(1) to the axle and remove the cylinder.
6. To refit the steering cylinder, follow the removal
procedure in reverse order.

24860

76

SECTION 41 -- STEERING -- CHAPTER 1

FRONT
AXLE
STEERING
(Four wheel drive axle)
Removal--Refitting

33

CYLINDER
1

WARNING
Handle all parts with great care. Do not put your
hands or fingers between one part and another.
Wear the recommended safety clothing such as
goggles, gloves and safety boots.
To remove the front axle steering cylinder, proceed
as follows:
1. Disconnect the negative cable from the battery.
2. Unscrew the unions securing the delivery and
return hoses to the steering cylinder.

24863

77

3. Remove the snap ring (1) and remove the

cylinder rod articulation pin (2) connected to
the stub axle housing.

2
1

24861

78
4. Remove the retaining screw and extract the pin
(1) securing the steering cylinder to the axle.
Remove the steering cylinder.

NOTE: Should you want to remove both steering

cylinders complete with supply pipes, omit step 3
described above and carry out steps 2 and 4 for the
other cylinder too.

24862

79
5. Remove the two actuator cylinders complete
with supply pipes.

24864

80

34

SECTION 41 -- STEERING -- CHAPTER 1

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

SECTION 44 -- FRONT AXLE AND WHEELS

Chapter 1 -- Front axle and wheels

CONTENTS
Section

Description

44 000

Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment -- Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal--Refitting--Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wheel hub disassembly--assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Stub axle overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Checking wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

44 101 30
44 101 22
44 101 46
44 101 80

Page

PRINCIPAL DATA
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

inverted U--section, telescopic

and oscillating at centre

Wheel angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2,, corresponding to 15 mm
2
(0.5906 in.) for 16 in. wheels

Toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in.)

0 -- 5 (0 -- 0.1969)

Diameter of stub axle pin (7, page 3) at bushing . . . . . . . . . . . . . .

mm
(in.)

37.961 -- 38.000
(1.4945 -- 1.4961)

Bore of installed bushings (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

38.050 -- 38.140 (*)

(1.4980 -- 1.5016)

Clearance between stub axle pin and relative bushings . . . . . . . .

mm
(in.)

0.050 -- 0.179
(0.0020 -- 0.0070)

Diameter of axle articulation pin (1, page 3) . . . . . . . . . . . . . . . . . .

mm
(in.)

37.961 -- 38.000
(1.4945 -- 1.4961

Bore of installed bushings (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm
(in.)

38.050 -- 38.140 (*)

(1.4980 -- 1.5016)

Clearance between stub axle pin and bushing . . . . . . . . . . . . . . . .

mm
(in.)

0.050 -- 0.179
(0.0020 -- 0.0070)

Stub axle articulation

Axle articulation

(*) Value to be obtained without refacing.

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

MAIN DATA
(cont.)

MODEL

Tyres

Standard
wheel tracks
mm (in.)

Alternative track settings mm (in.)

A

JX60
JX70

7 50 16 in.
7.50--16
in

1500
(59.0550)

1400
1500
1600
1700
1800
1900
(55.1180) (59.0550) (62.9920) (66.9290) (70.8660) (74.8030)

JX80
JX90
JX95

7.50--18
7.50
18 in.

1510
(59.4487)
(59
4487)

1410
1510
1610
1710
1810
1910
(55.5117)
(55
5117) (59
(59.4487)
4487) (63
(63.3857)
3857) (67
(67.3227)
3227) (71
(71.2597)
2597) (75
(75.1967)
1967)

DIAGRAM OF 2WD FRONT WHEEL TRACKS

23928

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

26155

2
Sections of stub axle, articulation pin and front axle
1. Axle articulation pin
2. Axle articulation bushing
3. Steering transverse tie rod
4. Stub axle control lever
5. Axle support
6. Bushing
7. Stub axle pin
8. Support ring grub screw (13)
9. Cap

10.
11.
12.
13.
14.
15.
16.
17.
18.

Bronze thrust ring

Seal
Wheel hub
Steel thrust washer
Grub screw for cap (11) and thrust washer (12)
Taper roller bearing for wheel
Bearing cover for greasing and adjustment
Cylinder fulcrum pin (18)
Power steering cylinder installation position

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

C1 -- 49 Nm

C2 -- 314 Nm

C6 -- 186 -- 206 Nm

C5 -- 186 -- 206 Nm

C3 -- (*)
C4 -- 186 -- 257,7 Nm

26157

Front axle torque settings

C1
C2
C3
C4

Axle articulation pin fixing screw

Nut securing disc to wheel hub
Bearing adjuster nut
Axle end fixing nut

* See operations 12 and 13, page 15.

C5 Nut for stub axle pin control lever fixing screw

C6 Nut securing cylinder to fulcrum pin

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

TORQUE SETTINGS
Torque setting
PART

Thread
Nm

ft lb

Front axle
Bolt securing axle to engine (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 18 x 1,5

353

478.6045

Bolt securing axle articulation pin (9) . . . . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1,25

49

66.4352

Nut for axle end fixing screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1,5

211

155.6256

Nut securing LH and RH levers on the stub axles (4) . . . . . . . . . . . .

M 16 x 1,5

294

216.8433

Nut securing ball end for transverse steering tie rod . . . . . . . . . . . . .

M 14 x 1,5

118

87.0323

Nut securing transverse steering tie rod . . . . . . . . . . . . . . . . . . . . . . .

M 20 x 1

176

129.8109

Screw securing front wheel to hub (3) . . . . . . . . . . . . . . . . . . . . . . . . .

M 18 x 1,5

314

231.5945

EQUIPMENT
WARNING: The operations described in this section
must be performed only with the ESSENTIAL
equipment marked with (X).
To operate safely and achieve best results, while
saving time and effort, essential equipment must be
used in conjunction with the special tools
recommended below and tools which you must make
yourself and for which you will find the design in this
manual.

List of special tools necessary for the various

operations described in this section.

X 380000541 Adaptor (M12x1.25) for axle

articulation pin (use with slide
hammer 380000549)

380000237 Wheel lifting hook.

FAULT DIAGNOSIS

Problem
Abnormal wear of tyres.

Possible cause
1. Incorrect tyre pressure.

2. Incorrect toe--in of front

wheels.
Poor stability of tractor.

1. Incorrect tyre pressure.

Corrective action
Inflate the tyres to the correct
pressure, referring to the pressures
recommended in the Use and
Maintenance handbook, and more
especially,
to
the
pressures
recommended by the manufacturer of
the tyres fitted.
Correct the toe--in.
Inflate the tyres correctly as detailed
above.

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

FRONT AXLE
Removal--Refitting (Op. 44 101 30)

DANGER
Lift and handle all heavy parts with lifting equipment
of suitable capacity. Make certain that the units or
parts are supported by appropriate slings and
hooks. Ensure that there are no persons in the
vicinity of the load to be lifted.
To remove the complete axle from the tractor,
proceed as follows:
1. Disconnect the negative cable from the battery
and isolate it; chock the rear wheels.

2. Lift the front of the tractor.

24765

4
3. Place a stand (1) beneath the engine sump,
inserting a block of wood between the engine
sump and stand.

1
24766

5
4. Remove the front wheel fixing bolts (1).

24767

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

5. Disconnect the hoses (1) of the power steering

cylinder (2).

24768

7
6. Remove the axle articulation pin securing bolt (1).

24769

8
7. Secure the axle by means of a sling (1).

24770

9
8. Take out the axle articulation pin (1) using slide
hammer 380000549, equipped with adaptor
380000541 and extension.

24771

10

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

9. Remove the complete axle (1).

24772

11
10. To refit the complete axle, follow the disassembly
procedure in reverse order. Install the axle
articulation pin (1) using a bronze punch.
11. Fit the screw fixing the axle articulation pin.

24769

12
12. Reconnect the hoses (1) of the power steering
cylinder (2).

24768

13

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

AXLE WHEEL HUB

Removal--Refitting (Op. 44 101 22)
Removal:

WARNING
Handle all parts with great care. Do not put your
hands or fingers between one part and another.
Wear the recommended safety clothing such as
goggles, gloves and safety boots.
The wheel hubs can be removed with the axle
installed on the tractor. Proceed as follows for each
wheel.
1. Disconnect the negative cable of the battery and
isolate it; chock the rear wheels.
2. Lift the front of the tractor.

24765

14
3. Place al stand (1) beneath the engine sump,
inserting a block of wood between the engine
sump and stand.

1
24766

15
4. Remove the front wheel fixing bolts.

24767

16

10

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

5. Remove the wheel hub bearing cover (1).

1
24775

17
6. Remove the grease nipple as shown in figure.

TRE4001A

18
7. Remove the split pin (1) securing the wheel hub
bearing adjuster nut.

TRE4002A

19
8. Using a socket wrench, unscrew the wheel hub
bearing adjuster nut.

24777

20

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

9. Remove the wheel hub bearing adjuster nut (1).

11

TRE4003A

21
10. Remove the wheel hub bearing washer (1).

TRE4004A

22
11. Remove the wheel hub (2) and take out the
bearings (1 and 3).

24778

23
12. Remove the bearing (1).

TRE4005A

24

12

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

13. Remove black (Twin lip) wheel bearing seal (1).

TRE4006A

25

14. Remove white back up ring (1).

TRE4007A

26

15. Renew worn bearings and seals, using suitable

extractors and punches.

24780

27

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

13

AXLE WHEEL HUB

Removal--Refitting (Op. 44 101 22)
Refitting:

16. Place a hydraulic jack beneath the stub axle and

unscrew the bolt (1) fixing the control lever (2) to
the stub axle pin.

24782B

28
17. Withdraw the control lever (1) from the stub axle
pin (2).

24783B

29
18. Lower the hydraulic jack and remove the stub
axle (1).

1
24784

30
19. Put the stub axle on a suitable vice and install
white back up ring (1).

TRE4008A

31

14

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

20. Install black (Twin lip) wheel bearing seal (1).

TRE4008A

32
21. Install both black (Twin lip) wheel bearing seal
and white back up ring together with a suitable
installer and a hammer.

TRE4008A

33
22. Install bearing with a suitable installer and a
hammer.

TRE4008A

34
23. The wear sleeve (1) for the seal must be installed
in the hub with a high strength bearing fit
adhesive compound (loctite) to ensure the
secure retention in the hub.

The hub and the wear sleeve must be throughly

clean and dry. Apply high strength bearing fit
compound. Press in the wear sleeve, using a
suitable press.
After installing the wear sleeve, the compound must
be allowed to cure for a minimum of three hours prior
to assembling the bearings and seals in the hub.
TRE4008A

35

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

15

24. Pack the wheel hub with AKCELA NEXPLORE

grease.

25. Refit the wheel hub (2) complete with bearings

(1 and 3).

24778

36
26. Install a new nut and, using a torque wrench,
tighten the nut to a torque of 196 Nm
(265.7407 ft lb), turning the wheel hub (1)
simultaneously in order to settle the bearings.
27. Loosen the nut slightly and tighten it again to a
torque of 24 -- 29 Nm (32.5397 -- 39.3188 ft lb)
while continuing to turn the wheel hub.

Note -- the nut must be changed each time the wheel

hub is fitted.

28. Check the rolling torque R, bearing in mind that:

R 5.7864 ft lb

24779

37
29. Install the split pin (1) securing the wheel hub
bearing adjuster nut and bend it over the nut to
prevent turning the nut.

24776

38
30. Install the grease nipple as shown in figure.

TRE4001A

39

16

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

31. Install the wheel hub bearing cover (1).

1
24775

40
STUB AXLE
Overhaul (Op. 44 101 46)

WARNING
Handle all parts with great care. Do not put your
hands or fingers between one part and another.
Wear the recommended safety clothing such as
goggles, gloves and safety boots.
The stub axles can be removed with the axle
installed on the tractor. Proceed as follows for each
wheel.
1. Disconnect the negative cable of the battery and
isolate it; chock the rear wheels.
2. Lift the front of the tractor.

24765

41
3. Place al stand (1) beneath the engine sump,
inserting a block of wood between the engine
sump and stand.

1
24766

42

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

17

4. Remove the front wheel fixing bolts (1).

24767

43
5. Place a hydraulic jack beneath the stub axle and
unscrew the bolt (1) fixing the control lever (2) to
the stub axle pin.

24782

44
6. Withdraw the control lever (1) from the stub axle
pin (2).

24783

45
7. Lower the hydraulic jack and remove the stub
axle (1).

1
24784

46

18

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

8. Unscrew the axle end securing bolts (1).

24785

47
9. Remove the axle end (1).

24786

48
10. Clamp the end of the axle in a vice and using a
slide hammer, take out the stub axle pin
articulation bushing (1).

1
24787

49
11. To refit the stub axle, follow the disassembly
procedure in reverse order, using a suitable
hammer to fit the new bushings on the axle ends.

24788

50

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

19

12. Fit the axle end (1).

24786

51
13. At the base of the stub axle refit the cap (9, fig. 2),
then the levelling rings (1), inserting them on the
stop grub screws (8 and 14, as shown in figure 2).

24789

52
14. Fit the stub axle on the axle end.
15. Position the control lever (1) on the stub axle pin
(2) and tighten the securing screw.

24783

53

20

SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1

CHECKING THE ALIGNMENT OF THE FRONT

WHEELS (Op. 44 511 80)

A
Check the alignment of the front wheels, bearing in
mind that for driving in a straight line, the wheels must
be at an angle of 2 to the vertical. This corresponds
to a difference of approximately 15 mm (0.5906 in.) for
16 in. wheels, between the top edge of the rim (A) and
bottom edge (A + X).

A+X
B2

When driving in a straight line, the wheels must be

parallel to the longitudinal axis of the tractor or have
a maximum of 5 mm (0.1968 in.) toe--in at the front,
measured between the wheel--rims.
To check the toe--in, proceed as follows:

B1
1. Inflate the front tyres to a pressure of 2.5 bar
(36.25 psi).
2. Position the steering wheel in the middle of its
travel, with one spoke along the longitudinal axis
of the tractor.
3. Check that the wheels are parallel with the
longitudinal axis of the tractor.
4. With the tractor parked on a flat, level surface,
measure the distance (B1) between the front of
the wheel rims, at hub height. Make a chalk mark
on the rims where the measurement has taken
place. Move the tractor forward to rotate both
wheels exactly 180o and check the
measurements again at the chalk marks B2 (now
positioned at the rear of the wheels). This will
eliminate wheel rim run--out errors.
5. Correct the toe--in, if necessary, by adjustment
of the end of the transverse steering tie--rod.

8821

54

SECTION 50 AUXILIARY UNITS CHAPTER 1

SECTION 50 AUXILIARY UNITS

Chapter 1 Auxiliary units

CONTENTS
Section

Description

Page

50 000

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main components of the cab air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Refrigerant recoveryrecycling and evacuationcharging stations . . . . . . . . . . . . . . . . . . 20

50 200 04

Drying recharging and checking cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

50 200 03

Functional testing of air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Summary of the cab airconditioning system charging operations . . . . . . . . . . . . . . . . . . 28
Checking for refrigerant leaks using an electronic leak detector . . . . . . . . . . . . . . . . . . . . . 30
Summary of fault diagnosis and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Air conditioning and heating pipes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

50 200 0474

Receiverdrier Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

50 200 0472

Condenser Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

50 200 0426

Compressor RemovalRefitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

50 200 10

Compressor drive belt tension adjustment

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

SECTION 50 AUXILIARY UNITS CHAPTER 1

CAB AIR CONDITIONING SYSTEM

SAFETY

Refrigerant must be handled with extreme care to

avoid injury; always wear safety gloves and goggles.

freezing of the skin caused by contact with liquid

refrigerant can be treated by gradually warming
the injured area with cold water followed by
application of a greasy cream. Seek medical
assistance.

Liquid refrigerant can cause freezing of the skin and

serious damage to the eyes, even blindness in some
cases.

the air conditioning system contains a mixture of

refrigerant and oil under high pressure; under no
circumstances loosen pipe fittings/couplings or
work on pipes without having first evacuated the
system.

Keep refrigerant containers away from heat sources,

as the increase of internal pressure due to heating
could cause the container to explode.

for the same reason, never unscrew the

compressor oil level plug when the system is
charged.

In contact with a naked flame or hot metal surfaces

the refrigerant may give off a toxic gas. If inhaled this
gas can cause serious harm.

To avoid the possibility of accidents take the simple

precautions described below.

The operation of emptying the system must be

carried out in a wellventilated area, well away from
any naked flames.

During the charging and emptying operations, take

the necessary precautions to protect the face and
above all the eyes from accidental contact with
refrigerant.

In case of accident, proceed as follows:

if has entered the eyes, wash immediately with

a few drops of mineral oil, then wash them
thoroughly with a solution of boric acid and water
(one spoonful of acid in 1/4 cup of water) and
seek medical assistance immediately.

do not heat the refrigerant container. Above 50C

(122F) the pressure increases very rapidly.

keep the air conditioning system away from heat

sources to prevent possible explosion due to the
increase of pressure in the system.

When transferring refrigerant from one container to

another, only use homologated liquid refrigerant
containers equipped with safety valves.

Never fill liquid refrigerant containers over 80% of

their maximum capacity.

Do not modify the settings of safety valves and the

control devices.

Never connect the recovery/recycling and

evacuation/charging stations to electrical power
outlets with voltages other tan those specified; do not
leave the stations powered on unless they are to be
used immediately.

SECTION 50 AUXILIARY UNITS CHAPTER 1

CAB AIR CONDITIONING SYSTEM CHARACTERISTICS

SANDEN SD 7H15 Compressor

Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3(in.3)

155 (9.46)

Maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm

6000

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg (lb)

6,5 (14.33)

Quantity of lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3(in.3)

185 (11.29)

Type of lubricating oil (code) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAG SP 20

Air conditioning system

Gas HFC134a

Quantity of HFC134a refrigerant . . . . . . . . . . . . . . . . . . . . . . . gr (lb)

1600 (3.5274)

System delivery side pressure . . . . . . . . . . . . . . . . . . . . . . . . bar (psi)

1624 (232.06 348.09)

System suction side pressure . . . . . . . . . . . . . . . . . . . . . . . . bar (psi)

0,53 (7.2543.51)

Pressure switch setting (high pressure) . . . . . . . . . . . . . . . . bar (psi)

25 (362.59)

Pressure switch setting (high pressure) . . . . . . . . . . . . . . . . bar (psi)

2 (29.01)

Temperature of refrigerant fluid at outlet of compressor . . . .

oC(oF)

60120 (140248)

Temperature of refrigerant fluid at outlet of condenser . . . . .

oC(oF)

4060 (104140)

Temperature of refrigerant fluid at outlet of evaporator . . . . .

oC(oF)

015 (3259)

Maximum capacity of electric centrifugal fan I, II, III speed . m3/min

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (in.3/min)

3,58,5
(21.3651.87)

Remember that altitude affects pressure, as shown

in the table on the right.
To obtain the effective pressure in the system,
subtract the corresponding correction value from the
pressure gauge reading.

Altitude
(m)
s.l.m.

Absolute atmospheric
pressure (psi)

Correction
(psi)

14.63

300

14.13

0.50

600

13.64

1.00

900

13.14

1.49

1200

12.64

2.00

1500

12.14

2.50

1800

11.64

3.00

2100

11.25

3.39

2400

10.85

3.82

SECTION 50 AUXILIARY UNITS CHAPTER 1

TOOLS REQUIRED FOR SERVICING THE AIR CONDITIONING SYSTEM

Warning The operations described in this section cannot be carried out without the ESSENTIAL tools marked
(X) in the following list.
To work in safety and to obtain the best possible results whilst saving both time and energy, we recommend that
the other specific tools in the list are also used.

List of specific tools for the various operations in this section

X 294030

Evacuation and charging station

X 294048

Recovery and recycling station

294044

Set of flexible hoses for 294030 and 294048

294043

Tool kit for 294030

294042

Receiverdrier for 294048

294036

Gas leak detector with audible leak indication

293826

Athermal tape for expansion valve

X 293831

293825

Combs for cleaning and straightening the fins on the condenser

and evaporator
Oil for pumps of stations 294030 and 294048

SECTION 50 AUXILIARY UNITS CHAPTER 1

OPERATING PRINCIPLES
The function of the air conditioning system is to
create and maintain optimum working conditions
inside the tractor cab.

As regards the purity of the air, there are no precise

limits, but it is important to remember that the human
metabolism alters the composition of the
surrounding air, increasing the humidity and the
quantity of carbon dioxide, while decreasing the
percentage of oxygen, etc..

These conditions regard four main factors:

temperature;
humidity;
speed;
purity of the air in the cab.
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
specify a range of values within which the majority of
people will feel most comfortable.
As regards temperature and humidity, it is possible
to define a zone, known as the comfort zone, within
which the temperaturehumidity combination
corresponds to pleasant environmental conditions.
From the diagram it can be seen that humidity should
be within the range of 30% to 70% (below 30% there
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
areas of the body) whereas temperature can vary
between 18 and 28C ( 64.4 and 82.4F).
The air flow speed must not be so high as to cause
discomfort; speeds of 0.07 0.25 m/s
(0.2296 0.8200 ft/s) are normally acceptable

Simplified psychrometric diagram

1.
2.
3.
4.
5.

By drawing in small quantities of fresh air from

outside the cab, it is possible to eliminate impurities
in the air, particularly important in the case of
agricultural tractors, where dust from earth, hay etc.
can cause extreme discomfort, by installing dry
filters on the external air inlets.
Air conditioning systems in tractors and agricultural
vehicles in general thus serves to neutralise the heat
and humidity generated in the cab by controlling the
temperature and humidity of the air in or drawn into
the cab to create comfortable working conditions for
the operator.
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
physical process (evaporation of a liquid) which
absorbs heat from the surrounding air.
The liquid used in this process, known as the refrigerant, is product with a high refrigeration coefficient,
low toxicity, which mixes well with lubricating oil.
The various components of the system are
connected by suitable pipes which ensure that the
pressure of the system is maintained.

Relative humidity %

Sensation of unbearable cold.

Sensation of cold.
Comfort zone.
Sensation of heat.
Sensation of unbearable heat.

25372

Temperature oC

SECTION 50 AUXILIARY UNITS CHAPTER 1

There are five main components of the air

conditioning system:

(depending on the ambient temperature) which thus

changes its state from a vapour to a liquid.

1. compressor;
The refrigerant, in liquid state at high pressure, is
purified by passing through the receiverdrier (3)
from where it flows to the expansion valve (4), which
restricts the flow of refrigerant and thus reduces its
pressure.

2. condenser;
3. receiverdrier;
4. expansion valve;
5. evaporator.
To understand the operating cycle of the system,
follow the flow of the refrigerant starting from the
compressor (1).
The compressor draws in refrigerant in vapour form
at a pressure of 0.5 3 bar (7.25 43.51 psi) and it
compresses it to a pressure of 16 24 bar
(232.06 348.09 psi).
The refrigerant, heated by compression to hot
vapour with a temperature of 60120 C
(140248 F), enters the condenser coil (2) located
forward of the engine
radiator.
The air flow passing over the condenser fins and
tubes produced by the forward movement of the
tractor cools the refrigerant.
This action cools the refrigerant to the point of
condensation between 4060 C (104140 F)

As it passes through the expansion valve (4), part of

the refrigerant is transformed into vapour and the low
temperature mixture of vapour and liquid thus
formed enters the evaporator (5).
Here the electric fan causes a continuous circulation
of the cab air over the fins of the evaporator (5),
helping the refrigerant to absorb heat from the air and
thus change completely from a liquid to vapour.
The evaporation process removes heat from the air
passing over the evaporator (5) and thus reduces
the temperature inside the cab.
The flow of air over the cold surface of the evaporator
(5) also condenses some of the moisture in the air
and therefore reduces the humidity in the cab.
On leaving the evaporator (5) at 015 C (3259 F),
the low pressure mixture is aspirated by the compressor (1) to repeat the cycle.

25372

2
Simplified system diagram
1.
2.
3.

Compressor.
Condenser.
Receiverdrier.

4.
5.

Expansion valve with thermostatic sensor.

Evaporator.

SECTION 50 AUXILIARY UNITS CHAPTER 1

AIR CONDITIONING SYSTEM FAULT DIAGNOSIS

THE SYSTEM DOES NOT WORK

1.

Check fuses.

2.

Check compressor drive belt

tension.

3.

Check if the clutch coil is

receiving power.

4.

Check that the earth contact is

efficient.

5.

Check the system control

devices the relays, wiring,
thermostat, etc.
Visually check the condition of
all fittings, unions and pipes.
Check the clearance between
the front disc and pulley of the
electromagnetic clutch..

6.
7.

10

25374

3
Schematic of air conditioning system.
1.
2.
3.
4.
5.

Compressor.
Compressor inlet pipe (low pressure).
Compressor outlet pipe (high pressure).
Hot air.
Condenser.

6.
7.
8.
9.
10.

Receiverdrier.
Sight glass.
Expansion valve with thermostatic sensor.
Evaporator.
Cool, dehumidified air.

SECTION 50 AUXILIARY UNITS CHAPTER 1

AIR CONDITIONING SYSTEM FAULT DIAGNOSIS (cont.)

INSUFFICIENT
COOLING

HIGH DISCHARGE PRESSURE

AND/OR HIGH SUCTION
PRESSURE

DISCHARGE PRESSURE LOW

AND/OR SUCTION PRESSURE
LOW

CHECK THE
SIGHT GLASS (7, fig. 3)

INSPECT THE
SIGHT GLASS (7, fig. 3)

EXCESS REFRIGERANT
IN SYSTEM

BUBBLES VISIBLE IN SIGHT

GLASS
Insufficient quantity of refrigerant in
system. Possibly due to small leaks.
1. Check system for leaks and
eliminate if found.
2. Add refrigerant until the bubbles
disappear and both pressure
gauges indicate normal pressure.

Note: the sight glass may contain

bubbles. Evacuate refrigerant until
a large number of bubbles appear in
the sight glass, then add refrigerant
to the system until the bubbles
disappear

CONDENSER
1. Fins could be clogged thus
restricting the flow of air over the
condenser. Clean condenser fins.
2. The condenser must be
positioned at the distance from the
radiator specified in the system
design.

EXPANSION VALVE
Check the valve as indicated on
page 17.
[Link] the valve fails the test, replace it.

DISCHARGE PRESSURE
NORMAL AND/OR SUCTION
PRESSURE NORMAL

Note: during testing, the low

pressure gauge reading could fall to
negative values or remain normal.
HUMIDITY IN SYSTEM
1. Evacuate the refrigerant from the
system.
2. Replace the receiverdrier.
3. Bleed air from the system then
recharge.

SECTION 50 AUXILIARY UNITS CHAPTER 1

AIR CONDITIONING SYSTEM FAULT DIAGNOSIS (cont.)

INSUFFICIENT
COOLING

HIGH DISCHARGE PRESSURE

AND/OR NORMAL SUCTION
PRESSURE

DISCHARGE PRESSURE HIGH

AND/OR SUCTION PRESSURE
LOW

DISCHARGE PRESSURE
NORMAL AND/OR
SUCTION PRESSURE NORMAL/
HIGH

Note: the pressure reading of the

high pressure gauge should be
constant without any decrease.

OBSTRUCTION
Water or ice forms downstream of
the obstruction (on receiverdrier or
on the pipe between the condenser
outlet and the expansion valve).
[Link]
the
obstructed
component and eliminate the
obstruction or renew component.

ANTIFROST
SWITCH
With ambient temperature below
30_C (86_F) the electromagnetic
clutch is permanently engaged.
1. Check as described on page 18.
[Link] the antifrost switch
(1, fig. 13) if it does not function
correctly, being careful not to crush
the capillary tube, and install new
switch in the same position and at
the same depth inside the
evaporator as the previous switch.

AIR
IN SYSTEM
1. Recoverrecycle the refrigerant
in the system.
2. Replace the receiverdrier.
3. Evacuate the system and then
recharge.

10

SECTION 50 AUXILIARY UNITS CHAPTER 1

AIR CONDITIONING SYSTEM FAULT DIAGNOSIS (cont.)

COMPRESSOR AND
ELECTROMAGNETIC CLUTCH

ABNORMAL NOISE
WHEN CLUTCH ENGAGED

NO COOLING

1. Check all compressor mountings.

2. Check engine components in the
vicinity of the compressor.
3. Check if the electromagnetic
clutch operates intermittently or
slips.

The compressor runs noisily or

does not run.

4. Check the clutch bearing.

5. Check that the electromagnetic
clutch pulley runs smoothly.
6. Check the oil level in the
compressor.

1. Check the condition and tension

of the compressor drive belt
2. Check the clearance between the
front disc and the pulley of the
electromagnetic clutch.
3. Check the clutch supply voltage,
the current draw, the supply lead,
the earth point.

4. Check that the electromagnetic

clutch pulley runs smoothly.
5. Check that there is a sufficient
quantity of refrigerant in the system.
6. Check the compressor for leaks.
7. Check the system for leaks.

ABNORMAL NOISE
WITH CLUTCH DISENGAGED
OR VIBRATION

1. Check electrical power supply.

2. Check the clearance between the
front disc and the pulley.

SECTION 50 AUXILIARY UNITS CHAPTER 1

11

CAB HEATING AND VENTILATION CONTROLS

VENTILATION
Turn on cab ventilation by operating switch (2) fig. 4
and direct the air flow as required by positioning the
front vents (3, fig. 5).
The operator may select outside air or inside air by
adjusting the rear air recirculation vents (1, fig. 6)
which can assume two positions.
vents closed: air is drawn from outside the cab
through the lateral filters.
vents open: the greater part of the air is drawn
from inside the air through the vents.

TRE0024A

Fresh air drawn into the cab from outside is always

filtered.

With the fan in operation, and the doors, windows

and recirculation vents closed, the pressure inside
the cab is greater than the external pressure and thus
air can only enter the cab through the lateral filters
after it has been suitably filtered.

Note To increase the pressure inside the cab,

select outside air only
(air recirculation vents 1, fig. 6 closed).

TRE0011A

5
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

Air filter

DANGER
Remember that the filters of the cab provide no
protection against antiparasitic chemicals in general.
Therefore complete protection against these
products can only be achieved by the adoption of
additional specific safety measures for the individual
product. This applies to all types of filter, for which the
prescriptions for use and maintenance must be
followed [Link] the use of active carbon
filters does not exempt the operator from adopting
the personal safety precautions recommended for
the product in question.

TRE0024A

12

SECTION 50 AUXILIARY UNITS CHAPTER 1

HEATING
The heating control knob (1, fig. 4) allows the
operator to regulate the temperature of the air by
increasing or decreasing the circulation of coolant
from the engine.
The fan control switch (1, fig 7) allows the operator
to adjust the quantity of air blown into the cab through
the vents (3, fig 5)

Temperature control knob (1)

Turned fully counterclockwise = minimum
temperature (circulation of hot water shut off).
Turned fully clockwise = maximum temperature
(circulation of hot water fully open).

Note The total capacity of the cooling system

(*including the cab heating system) is 14 litres in the
JX60 model or 16 litres in JX70, JX80, JX90 and
JX95 models.

IGNITION SWITCH
The ignition switch (1) can assume four different
positions:

P
A. No circuits powered (key can be removed).
Engine stop:automatic operation of fuel injection
shutoff device.

B
C

B. Predisposition for engine starting. Turn signals

and instruments operational. Various devices
powered.
8
C. Start engine: key returns automatically to
position (B) when released.

P. Parking lights on, control panel illuminated,

auxiliary lights switch powered (key can be
removed).

SECTION 50 AUXILIARY UNITS CHAPTER 1

13

C
1
B
A

TRE0012A

9
CAB AIR CONDITIONING CONTROLS
SWITCHING ON THE AIR CONDITIONING
AND TEMPERATURE CONTROL
Air conditioning
button.

and

temperature

control

Operational when ignition switch is in the starting

position.
With fan control knob (1, fig 9) in positions AB or C,
turn knob (2, fig 9) to switch on the air conditioning.

Heating control knob (fig 4)

Turn the knob (1) fully clockwise for maximum
heating.
Turn knob (1) fully counterclockwise to shut off the
flow of water to the heater and thus switch the
heating off.

3speed fan control knob

Operational when ignition switch is in starting
position.
A. Low speed .
B. Medium speed.
C. High speed.

Note To pressurise the cab see the chapter

Ventilation on page 11 of this section.

14

SECTION 50 AUXILIARY UNITS CHAPTER 1

USE OF THE AIR CONDITIONING SYSTEM

The air conditioning system provides
dehumidified air or warm dehumidified air.

cool,

To operate the system proceed as follows.

Warning The air conditioning system is not

operational when the engine is not running as the
compressor is driven by the engine.

SWITCHING ON THE AIR CONDITIONING

With the engine running, turn knob (2, fig. 9) to start
the air conditioning.

Warning Before switching on the conditioner,

always switch on the fan.
When the fan control knob is in the off position, the
air conditioning cannot function.

After a few minutes of operation, liquid visible in the

sight glass (7, fig. 3) on top of the filter should be clear
and free of bubbles. If not, consult the specialised
personnel at your dealer.

ADJUSTMENT
To obtain correct cab air conditioning, when the
system is in operation keep the recirculation vents
open and keep the doors, hatch and rear window
closed.

To lower the temperature and, at the same time, the

humidity of the air inside the cab, turn knob (2, fig. 9)
counterclockwise until the desired temperature is
obtained.

Warning Before starting the engine, check that the

air conditioning knob (2 fig. 9) is in the off position.

Note When working in very dusty conditions, to

increase the pressure inside the cab to prevent dust
entering, it is advisable to close the recirculation
vents.

If you wish to use the dehumidifying function without

lowering the air temperature, turn knob (2, fig. 9)
clockwise to obtain the desired temperature.

After prolonged operation in hot sunshine, to bring

the air inside the cab back to the optimum
temperature, without the tractor moving switch on
the air conditioner and open the rear window or hatch
to discharge the hot air.

SWITCHING
SYSTEM

OFF THE AIR CONDITIONING

Before stopping the engine, always switch off the air

conditioner by turning knob (2, fig. 9), then turn the
fan control knob (1, fig. 9) to the off position.

SECTION 50 AUXILIARY UNITS CHAPTER 1

MAIN
COMPONENTS
CONDITIONING SYSTEM

OF

THE

15

AIR

Axial flow reciprocating piston compressor

SANDEN SD 7H15
1.
2.
3.
4.
5.

Combined inlet and discharge valve.

Piston with seal ring.
Drive gear.
Swashplate.
Cam rotor.

25375

10
Compressor
The compressor serves to pressurise the refrigerant
and force it through the system.

SANDEN SD 7H15
Axial reciprocating piston type, driven from the
engine crankshaft via a vbelt.
The operating principle of the compressor is as
follows:

The swashplate (4), on which pivot the ball ends of

the connecting rods of the pistons (2), rests on the
cam rotor (5).

As the cam rotor rotates it exerts a continuous thrust

on the swashplate which cannot rotate as it is held by
the fixed gear (3).

The angle of the swashplate relative to the axis of

rotation causes the pistons to reciprocate in their
bores.
A reed valve (1) in the cylinder head with seven lobes
(one for each piston) controls the inlet and discharge
stages of the cylinders.
The automatic opening and closing of these valves is
obtained by preloading of the reeds.
The rotating parts of the compressor are lubricated
by special oil, inserted during assembly, some of
which circulates through the system mixed with the
refrigerant.

16

SECTION 50 AUXILIARY UNITS CHAPTER 1

Condenser
In the condenser the refrigerant is transformed from
a vapour to a liquid state.
As this occurs by transfer of the heat from the
refrigerant to the ambient air, the condenser
functions in a similar way to the engine radiator.
The condenser consists of a series of tubes through
which the refrigerant circulates and a finned block
which is pressed onto the tubes to covers them
completely in thin aluminium fins to help dissipate
heat to the ambient air.
The condenser is installed in front of the engine
cooling radiator so as to benefit from the air flow
caused by forward motion of the tractor.

Receiverdrier
The receiverdrier, installed between the condenser
and the expansion valve, performs two basic
functions, acting as a filter to remove dirt and
moisture from the refrigerant and as a temporary
storage container during variable charge stages.

Water in the system can cause corrosion and

damage to system components.

For this reason the filter contains substances to

absorb humidity.

Solid contaminants, such as sand, metal particles

resulting from wear of compressor components,
oxides, particles from the pipes, etc., can cause
damage to the system and therefore must be
removed by suitable filters.

2
Receiverdrier
1.
2.
3.
4.
5.

Sight glass.
Upper screen.
Disc.
Drying agent.
Lower screen.

3
4
5
25376

11

SECTION 50 AUXILIARY UNITS CHAPTER 1

17

Thermostatic expansion valve

Serves to reduce the pressure of the refrigerant as it
enters the evaporator so that it can change state and
thus remove heat from the surrounding air.
The expansion valve performs two basic functions:
metering: the calibrated orifice (6, fig. 12) in the
valve body creates a difference in the pressure of
the refrigerant at the inlet (4) (liquid state) and the
outlet (7) (mixed liquid/vapour); the calibrated
orifice (6) also serves to atomise the refrigerant
to facilitate subsequent evaporation;
modulation: inside the valve body a thermostatic
sensor controls the valve aperture so that the
right quantity of refrigerant enters the evaporator
to ensure complete evaporation.
If the thermostatic sensor (2, fig. 12) detects an
increase in the cab temperature, the flow of
refrigerant is increased.
A drop in the temperature or an increase in the
compressor capacity (due to an increase in the
engine speed) will cause a reduction in the flow of
refrigerant into the evaporator.
The expansion valve is installed on the evaporator
inlet fitting (7), and as the internal refrigerant flow
control system is completely automatic, it requires no
special maintenance.
To perform functional testing, with the system is fully
charged, check that the system operating pressures
are those indicated on page 3.

Note In case of malfunction, replace the valve.

Expansion valve block.

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

From evaporator outlet.

Thermostatic sensor.
To compressor suction inlet.
From receiverdrier.
Spring.
Calibrated orifice and ball.
To evaporator inlet.

4
7
6

25389

12

18

SECTION 50 AUXILIARY UNITS CHAPTER 1

Thermostatic switch (ANTIFROST)

The thermostatic switch is a safety device equipped

with a sensor (1) which is inserted between the fins of
the evaporator (2) where it constantly monitors the
temperature.

25377

13
The bulb of the sensor (1) is filled with a special gas
which expands or contracts according to the
temperature and thus acts on a membrane
connected to a complex mechanism which opens or
closes a switch in the electrical circuit of the magnetic
clutch to switch the compressor on or off as required.

The thermostatic sensor (1) thus prevents ice

from forming on the evaporator and obstructing
the flow of air into the cab.

For this reason it is very important to insert the

sensor (1) between the fins of the evaporator (2) as
shown in figure 13.

Note In case of malfunction, replace the entire

thermostatic switch.

SECTION 50 AUXILIARY UNITS CHAPTER 1

Evaporator

19

WARNINGS REGARDING SERVICING AND

REPAIR OF THE AIR CONDITIONING SYSTEM

The cycle is completed inside the evaporator.

The refrigerant leaving the expansion valve is a low

temperature, low pressure mixture of vapour and
liquid.

As it passes through the evaporator it absorbs heat

from the ambient air, vaporises and, having
performed its cooling function, is aspirated by the
compressor as a vapour.

The operation of the evaporator is controlled by the

expansion valve which delivers the exact quantity of
refrigerant needed to produce the required air
conditioning effect.

The evaporator performs the opposite function to the

condenser, but its basic construction is the same, the
only differences being its overall dimensions and the
layout of the internal pipes.

Switching on the air conditioning system when the

ambient temperature is low can damage the
compressor. Only operate the air conditioner when
the engine is hot and the temperature inside the cab
is at least 20 C (68 F).

When disassembling pipes, plug the ends with

plastic caps to prevent moisture and dust getting
inside.

Handle the tube of the thermostatic sensor with great

care to avoid damage which could prevent the entire
system from operating correctly.

When unscrewing pipe fittings and unions, always

use two spanners to avoid undue torsion.

Do not use engine oil of any type to lubricate the

system or the compressor.
The evaporator also performs another function:
dehumidification of the cab.

The air passing over the evaporator contains a

certain quantity of moisture, and this must be kept
within certain limits for operator comfort.

Do not leave the compressor oil container open.

Make sure that the cap is replaced and fully
tightened. The oil will absorb moisture, which is
harmful to the system.

Do not transfer compressor oil from its original

container to another.
Part of the moisture condenses on the fins
evaporator and is thus removed from the air.

The centrifugal fan draws the ambient air through the

fins of the evaporator (where it is cooled and
dehumidified) and into the cab.

Do not add any substances to the refrigerant or

compressor oil. Any additives might contain
elements incompatible with the refrigerant and thus
alter its characteristics.

The housing around the evaporator is equipped with

a condensate trap from which the condensate is
carried outside the vehicle through discharge tubes.

Check that the thermostatic sensor is correctly

inserted between the fins of the evaporator.

20

SECTION 50 AUXILIARY UNITS CHAPTER 1

REFRIGERANT RECOVERYRECYCLING AND

EVACUATIONCHARGING STATIONS

2way pressure gauge unit, with refrigerant flow

indicator and pressure gauges (1 and 2) controlling
the pressure in the cylinder and at the inlet.

WARNING
Never
under
any
circumstances
use
recovery/recycling or evacuation/charging stations
designed for a different refrigerant than that used
in the system, as the different chemical
compositions of different types of refrigerant render
them incompatible with each other.

294053, Humidity indicator (15) for checking the

decontaminated refrigerant.

When connecting the stations to the system service

valves, always connect the low pressure blue pipes
(11, fig. 15, or 17, fig. 16) to the service valve on the
suction side of the compressor (SSuction), and the
high pressure red pipes (12, fig. 15, or 15, fig. 16) to
the service valve on the discharge side of the
compressor (DDischarge).

Graduated container for the discharge of recovered

contaminated oil.

Important: check the seals in the pipe

connectors (11, 12, 16, fig. 15), or (15, 17, 24, fig.
16) and replace if faulty. (kit 294052)
Remember that the pipe fittings fitted with seals
are to be handtightened only without forcing,
otherwise the seal will be damaged.

Low pressure switch for automatic cycling of the

compressor.

Switch (5) 102 for recovery and cylinder heating.

Indicator lights.
294044 flexible service pipes (11, 12 and 16) with
safety cocks.
Recovery capacity:

200 grams/minute
(0.4411 lb/minute).

Power supply:

220 V (50 Hz).

RECOVERY AND RECYCLING STATION (294048)

Description (Refer to figure 15)
The station is designed for the recovery and
recycling of refrigerants used in the cab air
conditioning systems.
The recovered refrigerant is first separated from the
system oil by means of a process of vaporisation
which takes place in a suitable container.
In the filter section, the acidity is neutralised,
moisture is absorbed and solid particles are
screened out.

Maintenance
Replacement of refrigerant decontamination
filter (3)
Refer to figure 15 and proceed as follows:
Warning Every 12 months or earlier if the humidity
indicator (15) turns yellow and stays yellow
throughout the recovery/recirculation stage, renew
the filter (3).

The decontaminated refrigerant is then stored in the

metering cylinder.
TECHNICAL CHARACTERISTICS
Recovery compressor equipped with oil level
indicator, discharge valve and service connection.
294042 antiacid decontaminating filter (3), with a
high moisture absorption capacity.
Refrigerant/oil distillation cylinder (4) with heating
element, automatic device for return of oil to the
recovery station compressor and automatic flow
control valve for refrigerant entering the station.
Graduated cylinder (19) for recovered refrigerant,
2.2 kg (4.8524 lb) capacity, with heater and a safety
valve.

6. Close all the valves including the yellow service

valve (9) installed below the distillation cylinder
(4).
7. If refrigerant is present in the circuit set
pushbutton (5) to position 1 and carry out the
refrigerant recovery operation. The compressor
will stop automatically when the pressure gauge
(2) drops to 0.3 bar (4.35 psi).
8. Remove and replace the contaminated filter (3).
9. Carry out a normal evacuation operation for
about 30 minutes using the evacuation/charging
system (294030) proceeding as follows:
connect the pipe (17, fig. 16) to the service valve
(14, fig. 15), open the cock installed on the pipe
itself and cocks (4, 10 and 9, fig. 16).
On completion of the evacuation operation, close
cocks (4, 10 and 9), the cock on the pipe (17) and
disconnect pipe (17).

SECTION 50 AUXILIARY UNITS CHAPTER 1

Check filter connections for leaks (3)
Refer to figure 15 and proceed as follows:

21

8. Record the operation on the appropriate service

report card.

10. To check for leaks at the connections of the

previously replaced filter (3) open the yellow
service cock (9) on the distillation cylinder (4).
EVACUATION/CHARGING STATION (294030)
11. Perform a brief recycling operation on the
refrigerant contained in the cylinder (19),
proceeding as described in the operations
1821, on page 23 and check with a leak detector
for leaks at the connections of the new filter.
12. Record the operation on the appropriate service
report card.

Description (Refer to figure 16)

The station is designed for the evacuation and
subsequent charging of refrigerant in the cab air
conditioning systems.
The system must first be evacuated to remove any
moisture and impurities.

Changing the compressor oil in the

recovery/recycling station
Refer to figure 15 and proceed as follows:

Warning The oil in the compressor of the

recovery/recycling station should be replaced with
new oil (code 293825) every 12 months to maintain
the stations refrigerant treatment capacity and to
protect the compressor.

The new refrigerant from the external cylinder is

transferred to the graduated cylinder before being
pumped into the air conditioning system.
Technical characteristics
Doubleacting, ballasted, rotary vacuum pump (21)
in oil bath.
Charging cylinder (31) with maximum level indicator
and graduated scale for measurement of quantity of
refrigerant.

1. Open cock (13), and drain the oil into a container

to be disposed of in accordance with local
regulations for waste oil disposal.

5way pressure gauge manifold with 2 pressure

gauges (5 and 6) and 1 vacuum meter.

2. Close cock (13).

3. Remove the caps from the service valves (14) on
the side of the compressor and (13) on the sight
glass.
4. Connect the service pipe of the evacuation
station (294030) to valve (14) and connect a
pickup pipe from kit 294043to valve (13) on the
sight glass.
5. Perform the evacuation operation with the pump
in operation. The new oil can be aspirated from
an external container by means of the pickup
pipe.
6. Once the compressor has been filled with correct
quantity of oil (halfway up the sight glass) close
valve (13), disconnect the pickup pipe, and
replace the cap on service valve (13). Continue
the evacuation for approx. 30 minutes.
7. On conclusion, close the cocks, switch off the
pump, disconnect the service pipe and replace
the cap on service valve (14).

294044 flexible service pipes (17, 15 and 24) with

safety cocks:
Power supply: 220V (50 Hz).

Maintenance
Check level and change oil in pump of
evacuation/charging station (periodic check)
Refer to figure 16 and proceed as follows:
Periodically check the level and condition of the oil.
Drain off the old oil, if necessary, through plug (18).
Old oil must be disposed of in accordance with local
regulations.).
Remove cap (13) and fill the vacuum pump (21) with
new oil of the type indicated by the pump
manufacturer up to the halfway line on the sight
glass (14).

22

SECTION 50 AUXILIARY UNITS CHAPTER 1

AIR CONDITIONING SYSTEM

Dehydration, recharging and refrigeration check
(Op. 50 200 04)
Recovery of refrigerant from the cab air
conditioning
system
using
the
recovery/recycling station 294048
Note the recovery operation can be performed
more quickly and completely if the system is
previously heated, as heat will cause the refrigerant
to evaporate and thus be more easily evacuated
from the system.
Refer to figure 15 and proceed as follows:
1. If possible, operate the air conditioning system
for a few minutes with the tractor engine running
and the hood down, so that the heat produced is
gradually transferred to the various components
in the system, thus allowing any pockets of very
cold fluid in the system to evaporate.
2. Stop the engine.

DANGER
The recovery operation must only be performed
with the tractor engine stopped.
3. If the charging cylinder (19) already contains
refrigerant, check that there is still sufficient free
volume to contain all the refrigerant in the system
(maximum cylinder capacity is 2 kg (4.4112 lb));
if not, transfer the excess refrigerant to an external cylinder in the manner described on page 24.
4. Connect the stations supply lead to a power
outlet.
5. Make sure that all cocks are closed except the
service cock (9).

7. Connect the blue service pipe (11) to the valve on

the suction (low pressure) side of the
compressor (marked S).
8. Connect the red service pipe (12) to the valve on
the discharge (high pressure) side of the
compressor (marked D).
9. Switch on the cab ventilation fan at maximum
speed to assist the transfer of heat between the
ambient air and the evaporator coil.
10. Open cock (10) on pipe (12).
11. Slowly open cock (6LOW) on the pressure
gauge manifold. Pressure gauge (2) will indicate
the presence and pressure of any refrigerant in
the system; if the needle is near the 0, the
system is empty.
12. Set switch (5) to position 1 (RECOVERY)
green indicator light will illuminate. The recovery
compressor will now start.
During the recovery operation, the refrigerant will
pass through the distillation cylinder (where it will
separated from the oil) and into the decontamination
filter (where it will partially cleaned of impurities) to
arrive finally in the graduated cylinder.
The compressor will stop automatically when the
pressure gauge (2) indicates a pressure of 0.3 bar
(4.35 psi).
13. Wait a few minutes to allow any pockets of liquid
refrigerant left in the system to evaporate and be
evacuated.
14. Check the pressure gauge (2): if the pressure
has risen above the previous value of 0.3 bar
(4.35 psi), the station will automatically start a
second
recovery operation; if on the contrary
the
pressure has remained near the value
obtained during the first recovery operation, this
indicates that all the refrigerant has been removed from the system and therefore the operation is
complete.
Note If after 10 minutes of operation the station has
not recovered more than 1 kg (2.2056 lb) of refrigerant, check pressure gauge (1). If the pressure reading is over 10 bar (145 psi) open cock (21) and discharge air, then check that pressure gauge (1) does
not exceed a maximum of 10 bar (145 psi) throughout the entire recovery operation.

25379

14
6. Remove the caps from the service valves
installed on the suction and discharge lines of the
compressor.

15. Close all the cocks except cock (9), disconnect

the service pipes (11 and 12) from the air
conditioning system compressor and switch off
the station.
16. Switch off the cab ventilation fan.

SECTION 50 AUXILIARY UNITS CHAPTER 1

Recycling recovered refrigerant
On completion of the recovery operation, the
refrigerant, which has already been through an oil
separation process, must now be completely
decontaminated.

WARNING
At this stage the recovered refrigerant has not yet
been completely decontaminated and therefore
must not be used in the air conditioning system in this
condition.
Proceed as follows:
17. All cocks must be closed, with the exception of
cock (9, fig. 15) and the station must be switched
off switch (5) in position 0 and green indicator
light off.
18. Connect the end of the yellow service pipe (16)
without the cock to the free connector (17)
located on the lefthand side of the pressure
gauge manifold.

23

19. Connect the 2 ends of the yellow (16) and blue

(11) pipes with connector supplied.
20. Slowly open the cock (18REF) and the blue
cock (6LOW) on the pressure gauge manifold,
and the cocks on the two previously connected
service pipes (16 and 11).
21. Set switch (5)to position 1 (RECOVERY)
green indicator light on.
The recovery compressor will start to operate
and the refrigerant will pass from the graduated
cylinder to the recovery circuit (distillation
cylinder, filter and compressor) and then return
to the graduated cylinder.
22. Continue the operation until the circular sector of
the humidity indicator (15) turns green.
If after 15 minutes the circular sector of indicator
(15) still has not turned green, replace the filter
(3) as described on page 20.

21

20

19

18

7
8
9

17
25378

16

15

14

13

12

11

10
15

Refrigerant recovery and recycling station

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Cylinder pressure gauge.

Recovery control pressure gauge.
Antiacid and decontamination filter.
Recovered refrigerant/oil distillation cylinder.
Switch.
Refrigerant inlet control cock (LOW).
Recovered oil discharge cock (yellow).
Recoveered oil discharge pipe.
Oil return to compressor control cock (yellow).
Quickfit connectors.
Blue service pipe for connection to suction side
of compressor.

12. Red service pipe for connection to discharge

side of compressor.
13. Recovered compressor oil discharge cock.
14. Recovery compressor service valve (suction).
15. Humidity indicator.
16. Yellow service pipe for refrigerant transfer.
17. Fitting for refrigerant transfer.
18. Cock
(REF) for refrigerant transfer and
recycling.
19. Refrigerant cylinder.
20. Safety valve.
21. Cylinder (gaseous stage) discharge cock
(yellow).

24

SECTION 50 AUXILIARY UNITS CHAPTER 1

and connect the other end (with the cock) to the
red connector of the external cylinder.

Note The circular sector of the humidity indicator

(15, fig. 15) must remain green throughout the
recycling operation.
If the colour of the sector tends to vary between
yellow and green, or turns completely yellow, this
means that the filter is saturated with moisture and
therefore must be replaced.

29. Set switch (5) to position 2 HEATING

CYLINDER to switch on the refrigerant heater
fitted to the cylinder (19) so as to facilitate the
transfer of the refrigerant from the cylinder to the
external cylinder.

23. On completion of the decontamination operation,

close the yellow cock (18REF) and continue to
recover the [Link] compressor will stop
automatically when .the pressure gauge (2)
shows a reading of 0.3 bar (4.35 psi).

31. On completion of the transfer, close all cocks and

switch off the station by turning switch (5) to
position 0.

24. Close the cock (6LOW), the two cocks on the

ends of the yellow (16) and blue (11) service
pipes, disconnect pipes (16 and 11) and switch
off the station, turning switch (5) to position 0.
Discharge of recovered oil
The presence of contaminated recovered oil can be
seen in the distillation cylinder (4). The recovered oil
must always bee discharged and disposed of
according to local regulations.

30. Open the yellow cock (18REF), the yellow cock

on the service pipe and red cock on the external
cylinder.

Evacuation and charging the cab air

conditioning system using the evacuation/
charging station 294030.

Note Operations 32 34, must only be carried out

if the graduated cylinder (31) is empty of refrigerant.

Evacuation of the graduated cylinder (31) of the

evacuation/charging station
Refer to figure 16 and proceed as follows:

Proceed as follows:

32. Close cocks (4, 22 and 27).

25. Slowly open the yellow cock (7) and discharge

the recovered oil in the graduated container.

33. Open cocks (3, 9 and 10).

26. If no refrigerant leaks, whether major or minor,

have ever been detected in the system, on
recharging, replace the contaminated oil with
same quantity of new oil (see page 26).
Transfer of decontaminated refrigerant from
cylinder (10) to an external cylinder
If for any reason the decontaminated refrigerant is
not to be put back into the air conditioning system
immediately, for reasons of safety it must be
transferred from cylinder (19) to a homologated
refillable gas container.
Proceed as follows:
27. Check that all the cocks are closed with the
exception of cock (9) and that the station is
switched off. Check that the container (cylinder)
is large enough to contain all the refrigerant to be
transferred without exceeding the permitted
safety level.
28. Connect the end of the yellow service pipe (16)
without the cock to the free connector on the
lefthand side of the pressure gauge manifold,

34. Start the pump by turning switch (19) to position

1 to evacuate the cylinder (31). After 5 minutes
close cocks (3, 9 and 10) and switch off the
pump.
Charging the graduated cylinder (31) of the
evacuation/charging station
If the decontaminated refrigerant in the
recovery/recycling station is to put back into the
tractor air conditioning system immediately, it must
be transferred from cylinder (19, fig. 15) to cylinder
(31, fig. 16) of the evacuation/charging station,
proceeding as follows:
35. With reference to figure 16, connect the end
(without cock) of the yellow service pipe (24) to
the free connector (28) on the lefthand side of
the pressure gauge manifold of the evacuation/
charging station..
36. Connect the other end (with cock) of the service
pipe to the free connector (17, fig. 15) on the
lefthand side of the pressure gauge manifold of
the recovery/recycling station.
37. With reference to figure 15, check that all the
cocks of the recover/recycling station are closed
with the exception of cocks (9 and 18) and that
on the pipe (16).

SECTION 50 AUXILIARY UNITS CHAPTER 1

38. Check
that
all
the
cocks
of
the
evacuation/charging station are closed, with the
exception of cock (27).

42. Check the quantity of refrigerant in the graduated

cylinder (31).
43. From the total quantity of refrigerant required in
the air conditioning system indicated in the note
on page 26, calculate the quantity of refrigerant
that must be added to the cylinder (31) to make
up the total amount required.
44. Transfer refrigerant from the external cylinder to
the graduated cylinder (31) proceeding as
follows.
45. Connect the yellow pipe (24) to connector (28)
and to the external cylinder containing the
refrigerant (upside down if not equipped outlet
valve).
46. Open the cock on the external cylinder, the cock
on the charging pipe (24) and cock (27).

39. Check that the stations are switched off with

switches (5 and 19) in position 0.
40. With reference to figure 15, turn switch (5) to
position 2 HEATING CYLINDER to switch on
the refrigerant heater installed on cylinder (19),
to facilitate the transfer of refrigerant to cylinder
(31) of the evacuation/charging station.
41. On completion of the refrigerant transfer
operation, close all the cocks with the exception
of cock (9, fig. 15) and switch off the
recovery/recycling station by turning the switch
(5)to position 0.

8
9

31

10

30
29

11

28

12
13

27
26

14

25

15

24

25378

25

23
22 21 20 19 18 17

16
16

Evacuation/charging station.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Safety valve.
Cylinder pressure gauge.
Refrigerant charging cock.
Low pressure side cock (LOW).
Low pressure gauge.
High pressure gauge (red).
%way pressure gauge manifold.
Vacuum meter.
Vacuum test cock (VAC).
Vacuum meter test cock.
Vacuum meter safety valve.
Oil charging cock.
Oil filler cap.
Sight glass.
Red service pipe for connection to discharge
side of compressor.
16. Quickfit cocks.

17. Blue service pipe for connection to suction side

of compressor.
18. Oil drain plug.
19. On/Off switch (I), heater (II).
20. Oil meter connector.
21. Vacuum pump.
22. High pressure side cock (HIGH).
23. Sight glass.
24. Yellow service pipe.
25. Cylinder heater.
26. External ring.
27. Refrigerant transfer cock (REF).
28. Refrigerant transfer connector.
29. Glass rod.
30. Outer casing (Plexiglas).
31. Refrigerant charging cylinder.

26

SECTION 50 AUXILIARY UNITS CHAPTER 1

47. Rotate the outer casing (30) so that pressure

value indicated on the graduated scale
corresponds with the value shown on pressure
gauge (2).

Refer to figure 16 and proceed as follows:

48. When the refrigerant in the cylinder has reached

the required level, as indicated on the glass rod
(29), close the cock of the external cylinder, the
cock on the charging pipe (24) and cock (27).

57. Connect the oil meter to the oil meter (20).

Note If excessive time is required to transfer

refrigerant from the external cylinder to cylinder (31),
slightly open valve (1) and discharge air from the
cylinder (31); the pressure reading on gauge (2)
should not exceed 5 bar.

60. Open cock (12) and the cock on the graduated

oil meter.

Evacuation of the cab air conditioning system

(previously discharged using the recovery/recycling
station)
49. Remove the caps from the service valves on the
suction and discharge lines of the compressor.
Refer to figure 16 and proceed as follows:
50. Connect the blue service pipe (17) to the valve on
the low pressure side of the compressor marked
S .
51. Connect the red service pipe (15) to the valve on
the high pressure side of the compressor marked
D .
52. Open the quickfit cocks (16).
53. Open cocks (4 9 10 22).
54. Start the pump by turning switch (19) to position
I and evacuate the system for at least thirty
minutes; pressure gauges (5 6 8) should
show a negative reading. If the evacuation
procedure dose not function correctly, check all
connections.
55. Close cock (9), switch off the pump by turning
switch (19) to position 0 and check the vacuum
seal for at least five minutes using vacuum meter
(8). This done, close all cocks.

Charging the cab air conditioning system (after

evacuation) with new oil
If no refrigerant leaks, whether major or minor, have
ever been found in the system, on recharging,
replace the contaminated oil previously recovered in
operations (25 and 26, page 24) with the same
quantity of new oil. If, on the contrary, significant
leaks have occurred in the past, proceed with the
compressor oil level check procedure.

56. Pour the oil into the graduated oil meter of kit
294043.

58. Close cocks (4 and 10).

59. Set switch (19) to position 2 to switch on the
refrigerant heater on cylinder (31).

61. Check the quantity of oil flowing from the oil

meter, and once the required quantity has been
reached, close cocks (12) and the cock on the oil
meter, and remove the graduated meter.

Charging the cab air conditioning system with

refrigerant (after evacuation)

Note The quantity of refrigerant to be put into the

system
is
1600
grams
(3.5274
lb)
(refrigerant R134a).
Refer to figure 16 and proceed as follows:
62. Keep switch (19) in position 2, with the refrigerant
heater in cylinder (31) on, and heat the
refrigerant for approx. 10 15 minutes to
facilitate transfer from the cylinder to the air
conditioning system on the tractor.
63. According to the refrigerant type, rotate the outer
casing (30) so that the graduated scale and the
pressure values correspond with the pressure
reading on gauge (2).
64. Move the external ring (26) along the cylinder
glass to mark the quantity of refrigerant to be
charged.
65. Open cock (22) and charge from the high
pressure side.
66. Open cock (3), charge approx. 300 grams
(0.6617 lb) of
refrigerant, close cock (3) and
check for leaks.
67. If there are no leaks, continue charging up to the
prescribed quantity.
68. On completion of charging, turn switch (19) back
to position 0, close cocks (3 and 22),
disconnect pipes (17 and 15), and replace the
caps on the service valves.
Carry out functional tests with the system set to
maximum performance levels, as described below.

SECTION 50 AUXILIARY UNITS CHAPTER 1

FUNCTION
TESTING
CONDITIONING SYSTEM
(Op. 50 200 03)

OF

CAB

27

AIR

With the pressure gauges connected to the system in

the manner described previously and the cocks
closed, proceed as follows:
1. Start the engine and bring it up to a speed of 1500
rpm.
2. Set the cab ventilation fan (1, fig. 9) to the
maximum speed.

25380

17

3. Turn knob (2, fig. 9) to switch on the air

conditioning.

After about 15 minutes of operation, take the

following readings:
4. Pressure on suction side of compressor as
indicated by low pressure gauge.
5. Pressure on discharge side of compressor, as
indicated on high pressure gauge.
6. Ambient air temperature.
7. Ambient relative humidity.

10. Check that the compressor does not make

undue noise; there should be an audible click
when the drive is engaged..

The sight glass on the receiverdrier can provide

useful information about system operation.
The four main possible conditions of the sight glass
are shown in figure 17.

8. Temperature of air leaving vents inside the cab.

The pressure values will depend on the external
ambient conditions and the altitude.
The system is to be considered as functioning
correctly if the pressure readings are within the value
ranges indicated on page 3, and the temperature
readings are within the value ranges indicated on
page 29.
9. Check also the temperature of the low and high
pressure sides of the system:
the high pressure side, from the compressor
discharge to the expansion valve on the
evaporator, should be uniformly hot to the touch;
the low pressure side, from the evaporator outlet
to the suction side of the compressor, should be
uniformly cold to the touch. There should not be
excessive condensation on the suction pipe and
the low pressure pipe connector on the
compressor.

A. Glass clear: indicates that the system is correctly

charged, or that there is no refrigerant in the system
( in the latter case the cooling action of the evaporator
would be absent). In some cases, the glass may be
clear when the system has been charged with an
excessive quantity of refrigerant; in this case it would
be necessary to check the pressure readings.

B. Bubbles: the formation of vapour or foam

bubbles indicates that the system contains an
insufficient quantity of refrigerant or the presence of
air in the system; bubbles may also be seen on
switching on the system and on disengagement of
the electromagnetic clutch.

C. Threads of oil: indicates a lack of refrigerant and

that the compressor oil is circulating the system.

D. Fluid appearance not uniform, streaky:

indicates that the drying agent in the filter has
escaped, as a result of the containment discs
breaking,, and is circulating in the system.

28

SECTION 50 AUXILIARY UNITS CHAPTER 1

SUMMARY OF THE AIR CONDITIONING

SYSTEM CHARGING OPERATIONS

Note The pressure readings reported below are

valid for an ambient temperature of 25 C (77 F).

Pressure gauge readings on completion of

refrigerant recovery and recycling operation.
25381

18
pressure gauge readings with cocks (4 10 22
and 9, fig. 16 page 25) open, cylinder (31) with
2000 gr (4.4112 lb) of refrigerant, red and blue
service pipes connected to tractor system, cocks
(16) closed and compressor off.

25382

19
Pressure gauge readings with cocks (4 10 22
and 9, fig. 16) open, cylinder (31) with 2000 gr of
refrigerant, red and blue service pipes connected
to tractor system, cocks (16) open and
compressor on (initial evacuation stage).

25383

20
Pressure gauge readings with cocks (4 10 22
and 9, fig. 16) open, cylinder (31) with 2000 gr
(4.4112 lb) of refrigerant, red and blue service
pipes connected to tractor system, cocks (16)
open and compressor on (final stage of evacuation after 30 minutes).

25384

21

SECTION 50 AUXILIARY UNITS CHAPTER 1

29

Pressure gauge readings with cocks (4 10 22,

fig. 16) open, cylinder (31) with 2000 gr
(4.4112 lb) of refrigerant, red and blue service
pipes connected to tractor system, cocks (16)
open, compressor off and cock (9) closed (check
on vacuum meter that no pressure drops occur
over a period of 5 minutes).

25385

22

Pressure gauge readings (start of charging end

of charging). All previously opened cocks are to
be closed, with the exception of (4 and 3, fig. 16),
compressor off. The level of refrigerant in the
charging cylinder can be seen to drop; proceed
until only 600 gr of refrigerant remain in the
charging cylinder (1400 transferred). The
reading of vacuum meter (8) remains the same
from the beginning to the end of the charging
operation.

25386

23

Checking the temperature of the air coming out

of the vents inside the cab.

external ambient air temperatures specified, the

system is functioning efficiently.

If the temperature of the air measured at the vents is

within the value range indicated in the table for the

If the temperature of the air at the vents exceeds the

maximum value indicated in the table, refer to the
fault diagnosis guide in the following pages.

AIR CONDITIONING SYSTEM OPERATING TEMPERATURE VARIATIONS

External ambient temperature

20 C
(68
F)

27 C
(80.6
F)

Temperature of air at vent outlets

(inside cab)

4 8 C
(39.246.4 F)

28 C
(82.4
F)

35 C
(95
F)

6 12 C
(42.853.6 F)

36 C
(96.8
F)

43 C
(109.
4 F)

12 20 C
(53.668 F)

30

SECTION 50 AUXILIARY UNITS CHAPTER 1

CHECKING FOR REFRIGERANT LEAKS

USING AN ELECTRONIC LEAK DETECTOR
Leak detector (294036)
The leak detector 294036 is supplied in its own
carrying case which also contains the two power
supply batteries, the sensitivity test phial and an ear
plug connection for audible leak indication.
The instrument consists of a handheld unit with a
flexible probe which houses the sensing tip.
To orient the flexible probe, first slacken off the lock
ring on the lower lefthand corner of the case.

25387

The front of case mounts the sliding on/off switch, the

red indicator led, and the audible leak indicator.
The rear of the case mounts the ear plug connection
[Link] battery compartment also houses a
sensing tip and a number of spare felt pads.
Use
Switch the unit ON: start looking for leaks; the
frequency and the amplitude of the audible signal will
increase if gas is detected.
In areas affected by gas leaks, switch the instrument
on and off; the detector will automatically select a
new acoustic level.. Perform this test each time the
instrument is to be used.
Hold the sensing tip near the open phial to test
sensitivity; when the instruments starts to emit a
signal, switch it on and then off.

24

Maintenance

Always make sure that the instrument is switched off

before replacing the sensing tip. To remove the tip,
unscrew it in a counterclockwise direction. Fit a new
tip and a new felt pad, screwing them in a clockwise
direction onto the flexible probe.
Do not switch on the instrument unless the sensing
tip is firmly screwed on to the end of the flexible
probe.
On fitting the tip, check that there is no grease or dirt
in the connecting hole between the probe and the tip.

Refrigerant leak test

In this stage the instrument automatically regulates
its sensitivity in accordance with the presence of gas
in the environment around the sensing tip, and the
test is performed solely by means of the on/off
switch.
In ventilated areas, it can be extremely difficult to
trace a large leak due to the rapid dispersion of gas
from the source; in this case, place screens around
the suspected source to enable more precise
localisation of the leak.

In cases where large leaks obscure the presence of

smaller leaks, locate and repair the large leaks first,
and then locate the small leaks.

25388

25
Leak detector probe
1.
2.
3.
4.

Flexible probe.
Sensing tip.
Felt pad.
Cover.

SECTION 50 AUXILIARY UNITS CHAPTER 1

AIR CONDITIONING SYSTEM

Testing for leaks with leak detector 294036 and

elimination of leaks (Op. 50 200 06)

With the system charged and the pressure gauges

connected, proceed as follows:

AIR
CONDITIONING
DIAGNOSIS SUMMARY

31
SYSTEM

FAULT

There are three main ways in which the system can

malfunction:

the system does not work at all;

the system does not provide sufficient cooling;

1. Start the engine.

2. Set the ventilation fan to maximum speed.

3. Turn knob (2, fig. 9) to switch on the air
conditioner.

4. Bring the engine up to a speed of approximately

1500 rpm.

the compressor operates irregularly.

Bearing in mind that insufficient cooling may also
result from causes external to the air conditioning
system, generally a mechanical check and visual
inspection will provide useful information about the
efficiency of the system.

This information can then be completed by electrical

testing.

5. Switch on the electronic leak detector.

6. Move the probe around all pipe connections and

all possible points of leakage:
The presence of refrigerant, and thus al leak, is
signalled by an increase in the frequency of the
audible signal.

If at this stage the problem has still not been

identified, it will be necessary to carry out a more
detailed search by analysing the pressure readings
in the various parts of the system.

Visual inspection of components

These checks are to be carried out with the engine
stopped and with the heating and air conditioning
system switched off.

Not Refrigerant is heavier than air, and so it is

easier to detect below the leak rather than above it.

Check the compressor mountings and the

relative support, pulley alignment, belt tension..
Look for visible signs of refrigerant leakage
(presence of oil on fittings).
Look for visible leaks of liquid refrigerant.

7. If leaks are found in the pipe connections, tighten

the fittings to eliminate them.

Inspect the condition of the pipes, particularly

those in contact with the engine, as well as pipe
fittings/connectors and hose clamps.
Check that the evaporator, the heater matrix,
and the condenser are clean and remove any
foreign bodies.

Warning If any of the system components requires

replacement, it is always necessary to perform the
recovery, recycling and charging operations
described on pages. 22 to 27.

Check the condition and position of the

thermostatic sensor (fig. 13) in the evaporator.
Check that external air intakes are not blocked.
Check the condition of the condensate discharge
pipes.

32

SECTION 50 AUXILIARY UNITS CHAPTER 1

MAINTENANCE OF THE AIR CONDITIONING

SYSTEM

Note Carry out the same checks on the

EVAPORATOR (9) and CONDENSER (5).

At the start of the season in which the system will be

used, check that the system is functioning correctly
and efficiently efficiency.
If the system has been out of use and charged for a
prolonged period, oil may have flowed out of the
compressor to other parts of the system and
consequently this oil must be returned to the
compressor.

3) RECEIVERDRIER: the sight glass on the

receiverdrier can provide useful information
regarding system operation; see page 27. Replace
the receiverdrier after the system has been
repaired on two occasions.

To do this, start the engine and run it at approximately

1500 rpm for about 10 minutes.

4) EXPANSION VALVE: does not require

maintenance; in the case of malfunction, check the
valve and thermostatic sensor as described on
pages 17 and 18 or refer to specialised personnel of
service network.

Switch on the ventilation fan at maximum speed.

Turn control knob (2, fig. 9) to switch on the air
conditioning.
Check that the relative temperatures of the external
ambient air and the air flowing out of the vents inside
the cab correspond to the values indicated in the
table on page 29.

If the temperature of the air at the vent outlets does

not conform to the indications given in the table on
page 29, proceed with the system fault diagnosis
procedure outlined on page 31.

If so, the system is operating efficiently, and a visual

inspection of the main components will be sufficient:
1) COMPRESSOR: check the mountings, drive belt
tension and oil level.

Warning Should one or more system components

require replacement, in all cases it will be necessary
to carry out the recovery, recycling and charging
operations described on pages 22 to 27.

2) CONDENSER: check mounting, and that the fins

are free from excessive deposits. Straighten any
bent fins using the special comb 293831.

10

25374

26
Schematic of the air conditioning system.
1.
2.
3.
4.
5.

Compressor.
Suction line (low pressure).
Discharge line (high pressure).
Hot air.
Condenser.

6.
7.
8.
9.
10.

Receiverdrier.
Sight glass.
Expansion valve with thermostatic sensor.
Evaporator.
Cool, dehumidified air.

SECTION 50 AUXILIARY UNITS CHAPTER 1

33

AIR CONDITIONING AND HEATING

PIPES
Replacement (Op. 50 200 04 50 206 56
50 206 51 50 206 66 50 200 40 50 200 60)

DANGER
When recovering refrigerant from the system adhere
to the safety rules on page 2.
1. Disconnect the negative battery lead.
2. Recover the refrigerant from the system using
the recovery/recycling station 294048 as
described on page 22.
3. Drain off approx. 3 litres (0.6599 gall. Imp.) of
coolant from the drain plug (1) on the engine
block.

27
4. Remove the 4 cab roof retaining bolts (1).

TRE0124A

28
5. Remove the cab roof as shown in the figure 29.

TRE0152A

29

34

SECTION 50 AUXILIARY UNITS CHAPTER 1

6. Remove plate fastening screws and take of the

plate (1)

1
TRE0155A

30
7. Remove A/C assembly fastening screws (1).

TRE0255A

31
8. Remove A/C inlet and outlet pipes (1).Remove
front retaining screws (2).

TRE0224A

32
9. Remove heater pipe connections (1) and take off
the pipes.

TRE0226A

33

SECTION 50 AUXILIARY UNITS CHAPTER 1

35

10. Remove the bracket (1) that secures the pipe.

TRE0227A

34
11. Remove all electric connectors and take off the
A/C assembly (1) completely.

TRE0228A

35
12. A/C assembly is shown in fig 36.

TRE0223A

13.

36
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

RECEIVERDRIER
Replacement (Op. 50 200 04 50 200 74)

DANGER
When recovering the refrigerant from the system
adhere to the safety instructions on page 2.
1. Recover the refrigerant from the system using
station 294048 as described on page 22.
2. Detach the exhaust pipe and raise the hood.
3. Disconnect the negative battery lead.

4. Disconnect the electrical connector (1) from the

receiverdrier.

24887

37
5. Detach the flexible pipe (1) connecting the
condenser to the receiverdrier.

24888

38
6. Detach the flexible pipe (1) connecting the
receiverdrier to the evaporator.

24889

39

SECTION 50 AUXILIARY UNITS CHAPTER 1

7. Remove the screw (1)
receiverdrier band clamp.

securing

37

the

1
24890

40
8. Recover the complete receiverdrier (1).

24891

41
To refit proceed as follows:
Replace the receiverdrier in the support clamp.
Reconnect the two flexible return and delivery
pipes. Connect the electrical connections on the
filter.
Connect the negative battery lead.
Evacuate the system then charge with HFC
134a refrigerant, using the evacuation/charging
station 294030,as described on page 24.
Close the hood.

38

SECTION 50 AUXILIARY UNITS CHAPTER 1

CONDENSER
Replacement (Op. 50 200 04 50 200 72)

DANGER
Recover the refrigerant from the system adhering to
the safety instructions on page 2.
1. Disconnect the negative battery lead.
2. Recover the refrigerant from the system using
the station 294048 as described on page 22.
3. Detach the flexible refrigerant delivery (1) and return pipes (2) from the condenser.

1
24892

42
4. Unscrew the
condenser.

wingnut

(1)

securing

the

24893

43
5. For tractors equipped with front mudguards,
remove the two screws (1) securing the top
bracket of the condenser (for tractors without
front mudguards turn the steering wheel to full
righthand lock and withdraw the condenser
from the righthand side of the tractor).

24894

44
6. For tractors with front mudguards, remove the
condenser group (1) with the top bracket.
To refit proceed as follows:
Refit the condenser and the relative bracket, and
secure the condenser with the wingnut and the
bracket with the two retaining screws.
Reconnect the two flexible pipes to the condenser.
Connect the negative battery lead.
Evacuate the air conditioning system and charge
with HFC 134 a refrigerant, using the evacuation/
charging station 294030 as described on page 24.
Close the hood.

24895

45

SECTION 50 AUXILIARY UNITS CHAPTER 1

39

COMPRESSOR
RemovalRefitting (Op. 50 200 04 50 200 26)
1

DANGER
Recover the refrigerant from the system adhering to
the safety instructions reported on page 2.
1. Recover the refrigerant from the system using
station 294048 as described on page 22.
2. Raise the hood.
3. Disconnect the negative battery lead.
4. Disconnect the flexible pipes (1) from the
compressor.

TRE0838A

46

5. Remove the righthand guard retaining screws (1).

24903

47
6. Remove the two securing nuts (1) of the
compressor belt tensioner arm.

24904

48
7. Disconnect the earth lead (1) from the
compressor.

24905

49

40

SECTION 50 AUXILIARY UNITS CHAPTER 1

8. Loosen the bolt (1) securing the compressor to

the engine and remove the drive belt from the
pulleys.

24906

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 righthand 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.
Close the hood.
COMPRESSOR OIL TYPE AND QUANTITY
The tractor is equipped with a SANDEN SD 7H15
compressor for refrigerant R134a.
The compressor is filled during assembly with
185cm3 (11.29in.3) of PAG SP 20 lubricating oil.
In case of top up or oil change only use this type of
oil.
It is not necessary to check the compressor oil level
unless the system develops significant gas leaks.

Warning If the system develops significant leaks

of R134a refrigerant, there will also be a significant
loss of compressor oil PAG SP20. It will therefore be
necessary to check the compressor oil level, bearing
in mind that, on average, only 130 135 cm3
(7.93 8.24 in.3), of the total quantity of lubricating
oil (185 cm3 (11.29 in.3)) will be present in the compressor, as the remaining 5055 cm3 (3.053.36 in3)
will be in circulation through the various system components. For problems of this type, we recommend
that you seek assistance from an authorised service
centre.

24907

51

SECTION 50 AUXILIARY UNITS CHAPTER 1

41

COMPRESSOR DRIVE BELT

Tension adjustment (Op. 50 200 10)
1213mm

The tension and condition of the belt transmitting

drive from the engine to the compressor is
particularly important as regards the correct
operation of the air conditioning system.
This drive belt therefore requires careful attention as
follows:
23927

52

1) Fit the belt correctly.

2) Check the tension.
3) Check the condition of the belt.
Periodic checking of drive belt

Fitting the compressor drive belt

When checking the tension, also check the amount

of drive belt wear.
The main problems are as follows:
a) Belt shiny : smooth sides may slip on pulleys.

When first fitted, the belt must not be forced, pulled

with a screwdriver, or rolled over the edge of the
pulley, as this would stretch the less deformable
fabric in the belt thus causing subsequent breakage
of the other fabrics.
When first fitted, the belt must more installed at a
greater tension than normal to compensate for initial
stretching during the runningin period. The belt
must therefore be checked again after 50 hours of
operation and adjusted to the normal tension.
This check is absolutely essential as if the belt is too
taut, in addition to damaging the pulley bearings, it
will cause premature fatigue of the reinforcement
fabrics and thus early deterioration of the belt.
If on the contrary the belt is too slack, it will start to
slip and overheat, and it will therefore wear out very
quickly.

b) Belt cracked : may break suddenly due to splits

on the inner surface caused by excessive
flexure.
c) Worn sides : with the sides worn or the inner
surface cracked, the belt can break at any
moment.
d) Belt impregnated with grease : the belt will
wear more rapidly as the grease will cause
softening of the internal part.
Take the following action:
a) If the belt is too slack, tension it correctly; if the
belt is very hot, renew it.
b) If cracking is deep, extending to half the
thickness of the belt, renew the belt.
c) Renew the belt.

Checking compressor drive belt tension

Check the tension only when the belt is cool (at a
temperature below a 40 0C (104 0F)).
Check the tension by applying a load of 7898 N
(17.645022.0562 lb) to the centre of the belt run indicated in the figure: the belt should deflect 1213
mm (0.03940.0426 ft).

d) If the belt is very hot.

If the belt squeaks when running, check the tension
and adjust if necessary. If the noise continues, renew
the belt.
If the belt has been overstretched and it is not
possible to tension it sufficiently, renew it.

42

SECTION 50 AUXILIARY UNITS CHAPTER 1

SECTION 55 ELECTRICAL SYSTEM CHAPTER 1

SECTION 55 ELECTRICAL SYSTEM

Chapter 1 INSTRUMENTS
CONTENTS
Description .

Page

Analogue instruments Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Transmitter and switch
4 .

ANALOGUE INSTRUMENTS
INTRODUCTION
1

TRE0027A

The analogue instrument panel consists of four display sections:

1) Warning and indicator lights;
2) Fuel level gauge;
3) Proofmeter;
4) Engine coolant temperature gauge.
[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 1

1
Condition

Indicator

1 Left direction indicator

2 Side ligts
3 Main beam headlights
4 Water in fuel
5 Air filter blocked
6 First trailer direction indicator
7 Second trailer direction indicator

Flashing (green)
Fixed (green)
Fixed (blue)
Fixed (red)
Fixed (amber)
Flashing (green)
Flashing (green)

TRE0073A

7
2

8 .Engine oil pressure low

9 Battery charge low
10 Brake fluid level low
11 Hand brake on
12 Right direction indicator
13 Power takeoff on

10

11

12

Fixed (amber)
Fixed (red)
Fixed (red)
Fixed (red)
Flashing (green)
Fixed (amber)
13
TRE0072A

Fuel level gauge (Fig. 3).

This instrument shows the level of fuel in the tank.
When the tank is full, the hand moves completely to
the right.
When the tank is less than 1/4 full, the hand moves
into the red area.

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 1

Proofmeter (Fig. 4).

Engine speed indicator and chronograph with a six
figure hourmeter. The figures on black background
count hours of work done and the figure on red
background (far right) shows tenths of an hour.
The green, blue and yellow sectors show the
engine speed at which optimum power takeoff
performance is achieved (respectively 540, 540E
and 1000 rev/min).

Green symbol = power takeoff at 540 rev/min

Blue symbol = power takeoff at 540E rev/min.

Yellow symbol = power takeoff at 1000

rev/min.

TRE0076A

TRE0076A

Engine coolant temperature gauge (Fig. 5).

Green area = normal temperature.

White area = temperature too low.

Red area = engine overheating.

TRE0075A

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 1

TRANSMITTERS, SENSORS AND SWITCHES

A.

MAIN FUSE BOX

The tractors fuses relays are housed under a plastic cover.

B.

BATTERY
The tractors are fitted with maintenancefree batteries. Keep the top part clean and dry. Check that the level
of electrolyte reaches the top mark and never falls below the lower mark.

C.

ALTERNATOR
This provides a square wave signal and recharges the battery. It also provides power required by electric
devices.

D.

TRANSMISSION CLUTCH PEDAL SWITCH

This switch is activated when the clutch pedal is pressed and it prevents starting if the clutch pedal is not
lowered.

E.

AIR CLEANER CLOGGED SENSOR

This is activated when the vacuum in the air operating system exceeds a preset value. It lights up the
warning light.

F.

FUEL SEDIMENTER
Activated when water gets into the fuel filter and the relevant warning light comes on.

G.

ENGINE OIL PRESSURE SWITCH

This is activated as soon as oil pressure in the engine drops less than 0.68 bar (9.86psi). It lights up the
warning light. This switch is usually closed.

H.

FUEL TANK LEVEL TRANSMITTER

A signal from the transmitter potentiometer defines the level of fuel in the tank. The level is shown by the
gauge.

I.

ENGINE COOLANT TEMPERATURE

The temperature transmitter resistance varies in proportion to the coolant temperature, generating a
modulated voltage signal picked up by the gauge.

J.

BRAKE LIGHT SWITCHES

These are activated when the brakes are on.

K.

BRAKE OIL LEVEL SWITCH

This switch is activated when the fluid level drops below the minimum value and lights up the warning light.

L.

PARKING BRAKE SWITCH

Activated when the parking brakes are applied, switching on the indicator light on the dashboard.

M.

OPERATOR SEAT TRANSMITTER (NAR MARKET ONLY)

A transmitter in the seat detects when an operator is seated.

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 1

TRANSMITTERS AND SWITCHES

D
26608

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 1

TRANSMITTERS AND SWITCHES

26608

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 1

TRANSMITTERS AND SWITCHES

26608

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 1

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 2

SECTION 55 ELECTRICAL SYSTEM

Chapter 2 COMPONENTS
CONTENTS
Section
55 500

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

55 500 INTRODUCTION
The components described in this section are located on the instrument console (rear hood), in the cab roof and
on the righthand fender, inside the cab.

COMPONENT DESCRIPTION

INSTRUMENT CONSOLE CONTROLS

1. Lights control lever.
The lever operates external lights, horn and the
direction indicators.

TRE0067A

REAR HOOD CONTROLS

Starter switch
To operate the four switch functions, turn the key
(1) through the following positions:

B
C

A. No power to circuits (key can be removed).

Engine stopped: automatic activation of fuel
injection cutoff.
B. Control instrument and indicator power supply.
Power supplied to various circuits.
C. Starting the engine: when released, the key
returns automatically to position (B).

TRE0018B

P. Parking lights on, instrument panel lighted (key

removable).

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 2

1. Starter switch.
2. Thermostarter.
3. Hazard warning lights switch.

4. Cigar lighter
4
1

TRE0018B

1. Beacon on/off switch (tractors without cab)

1
TRE0020A

INCAB CONTROLS
1. Fendermounted controls

2
3

1. Windscreen washer,
2. Windscreen wiper,
3. Rear working lights,
4. Front working lights and
5. Beacon controls (with cab)

1
TRE0042D

5
5

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 2

2. Heating and airconditioning controls

2

1. Electric fan speed control

2. Heating control
3. Airconditioning control

TRE0012B

6
3. Radio

TRE0077B

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 2

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 3

SECTION 55 ELECTRICAL SYSTEM

Chapter 3 STARTING SYSTEM

CONTENTS
Section

Description

55 000

Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Starting circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal and reinstallation of starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bench tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

55 201

Page

55 000 TECHNICAL INFORMATION

CHARACTERISTICS

JX60

JX70

Starter motor

JX90

JX95

BOSCH

Power (kW)

2.5

3.5

60 A
at 11,6 V
and 8600 rev/min

160
at 11.5 V
and 8000 rev/min

7.0 (0.2756)

42 (1.6535)

42.5 (1.6732)

0.5 0.8 (0.0197 0.0315)

0.4

Maximum current drain without load (Amp)

Minimum brush length (mm)
(in.)
Minimum switch
(mm) (in.)

JX80

diameter

Maximum armature shaft end

play (mm) (in.)

TIGHTENING TORQUES

Nm
Starter motor and engine block fastening bolts
Box on starter motor/earth (ground) cable side
Solenoid valve wire nuts

34 (25.0771)
16 (11.8010)
7 (5.1629)

Box nuts on starter motor side

Solenoid valve fastening bolts

10 (7.3756)
5 (3.6878)

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 3

DESCRIPTION AND OPERATION

means of an flexible joint mechanism, makes the

driving pinion engage the flywheel ring gear. The
moment the pinion touches the ring gear, the plunger
closes a series of contacts and powers all four field
windings directly from the battery, thus giving full
power to the starter motor.

The starting system installed depends on the type of

gearbox fitted on the tractor. All systems consist of
an ignition key switch, heavyduty wiring, a starter
motor with solenoid, a startup relay and a clutch
pedal switch. These are the basic circuit components
used on versions with mechanical gearbox. More
sophisticated systems include other components,
which ensure the engine can be started only under
the proper conditions.
At this stage, one end of the pullin coil is connected
to the positive battery pole through the starter switch,
while the other end in connected to the positive pole
through the solenoid valve contacts. The pullin coil
is thus bypassed, without absorbing power, and the
holdin coil alone keeps the plunger in position.

There are four types of gearbox: with range reduction

gear (synchro command), with range reduction gear
and inverter (shuttle command). The starting circuit
is illustrated in figure 1.
The starter motor includes a series of contacts and a
twopart solenoid plunger which completely closes
the contacts even if the pinion teeth are not perfectly
in line with the ring gear. When this happens, a clutch
spring compresses the pinion, forcing it to connect
completely as soon as the starter motor starts
turning.
There are two available types of starter motors: 2.5
kW or 3.5 kW rating. They both have four poles, four
brushes with integrated solenoid and positive mesh
engagement control.

When the key ignition switch is released, power is

taken from both the solenoid and the motor. The
solenoid return spring, acting on the flexible joint
mechanism, frees the driving pinion from the gear
and opens the solenoid valve contacts again.
The solenoid consists of two coils connected in
parallel. The low resistance pullin coil is earthed
(grounded) via the engine, while the high resistance
holdin coil is earthed (grounded) via the solenoid
body.
A roller type clutch is incorporated to the driving
pinion group. This prevents the pinion from
overspeeding if it stays engaged with the flywheel
ring gear after the engine has been started.
When the ignition switch is closed, with the clutch
pedal depressed and gear in neutral (except in the
case of mechanical gearboxes), the coils are
energised and the plunger is magnetically drawn
inside the solenoid. This movement, transmitted by
[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 3

STARTING CIRCUIT

6,0 N
30
57

15/54

58/57 50

35
16.0 NFUSE

2
6,0 N
6,0 N

6,0 N

13
B+
3,0 N/P

12
16.0 N

D+ 0,5 N/Y

0,5N/Y

16

11

3.0 B

14
31
2,5W/R

2,5W/Y

STARTING CIRCUIT
1
2
11
12
13
14
31
35

Instrument panel
Starter switch
Battery
Starter
Alternator
Over voltage circuit breaker (DIODE)
Starter inhibitor unit
Main Fuse

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 3

26629

TRE0069A

Fuse panel

Starter motor

SYSTEM TESTS
STARTING SYSTEM ON TRACTOR TEST
To easily and quickly troubleshoot the starting
system problems and reach conclusive results, it is
recommended that you use a battery/starting tester
(high discharge multimeter) with incorporated
020V voltmeter and 0500 A ammeter.
When using testing devices, follow test procedures
recommended by the manufacturer. If you do not
have access to testing devices, carry out the
following test using a normal 020V voltmeter and a
0500 Amp ammeter in order to check correct
starter motor functioning without removing it from
the engine.
Before carrying out the test:

check the battery is fully charged;

check that no wires in the starting system are

broken or frayed and that there are no loose
connections;

check the engine is not seized.

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 3

POWER ABSORPTION IN STARTER MOTOR

CIRCUIT (Fig. 4)
1. Disconnect earth (ground) (negative) battery
cable (3).
2. Disconnect positive battery cable from starter
solenoid. Connect the positive ammeter point
(1) to the positive battery terminal clamp and
the negative point to the solenoid input
terminal.

3. Reconnect earth (ground) (negative) cable to

negative battery terminal clamp (3).
4. Connect the positive voltmeter point (2) to the
positive battery terminal clamp and the
negative to the negative battery terminal
clamp.

26630

4
5. Disconnect the wire from the injection pump
shutoff solenoid.
6. Run the engine and note voltmeter and
ammeter readings. Voltage must be constantly
about 12V and absorption in the range of
250300 A.

If absorption corresponds to the readings

above, then the starter motor (4) fig. 4, is
working correctly. If voltage drops during the
test, follow Resistance in starting system
circuit procedure (see relative paragraph).

If absorption is higher than the readings above,

check the circuit as follows. If the starting
system circuits are in good condition, then the
starter motor is malfunctioning and must be
removed for further examination.

If absorption is lower than the readings above,

the starter motor is malfunctioning and must be
removed for further examination.

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 3

RESISTANCE IN IGNITION SYSTEM CIRCUIT

(VOLTAGE DROP) (Fig. 5)
If there is a higher than necessary power absorption, check the circuit to find the cause of the voltage drop occurring within circuit components.
IMPORTANT: Disconnect the injection pump solenoid fuel closing wire.

POSITIVE BATTERY CABLE

1. Connect the positive voltmeter point (1) to the
positive battery terminal clamp (2).

2. Connect the negative voltmeter point to starter

motor solenoid terminal (3).
3. Run the engine and check the readings on the
voltmeter. If voltage is higher than 0.2 V., check
and tighten wire connections. Check voltage
again and if it is still high install a new battery
cable.

26631

STARTER MOTOR EARTH (GROUND) (Fig. 6)

1. Connect the positive voltmeter point (1) to the

starter motor casing (2).
2. Connect the negative voltmeter point to the
engine block (3).
3. Run the engine and check the readings on the
voltmeter. If voltage is higher than 0.2 V., check
earth (ground) connections between the starter
motor flange and the rear engine cover.

26632

6
BATTERY EARTH (GROUND) CABLE (Fig. 7)

1. Connect the positive voltmeter point (1) to the

engine block (2).

2. Connect the negative voltmeter point to the

negative battery terminal clamp (3).
3. Run the engine and check the readings on the
voltmeter. If voltage is higher than 0.2 V., check
and tighten the earth (ground) cable
connections. Check the voltage again and if it is
still higher, then install a new earth (ground)
cable.

3
26633

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 3

STARTER MOTOR REMOVAL AND

REINSTALLATION (Fig. 8) (Op. 55 201 50)

1. Disconnect negative battery cable.

2. Unscrew the nut and bolt (1) and remove the

protection cover (2) from starter motor (3).
3. Unscrew the nut and remove power clamp (5)
and emergency switch clamp (4).

1
4

4. Remove the starter motor securing bolts (6)

and remove the starter motor.
5. To reinstall the starter motor, reverse the
order of removal.

26634

5
8

26635

Starter motor components

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

Solenoid
Solenoid bolts
Bolt and stud group
Control side support
Lever
Reducer

[Link] 12 1996

7.
8.
9.
10.
11.

Field windings and casing

Brush holder
Brush plate
Armature
Clutch

SECTION 55 ELECTRICAL SYSTEM CHAPTER 3

SERVICING
DISASSEMBLY (Op.55 201 54)
Refer to figure 9.
1. Place the starter motor in a vice with protected
jaws.
2. Disconnect the biggest braided wire which runs
from the field winding casing to the solenoid.
3. Remove the three screws from the front casing
and remove the solenoid. Note that the plunger
will remain connected to the control lever.
4. Remove solenoid plunger from the control lever
by holding and lifting it at the front in order to
unclip it from the lever.
5. Remove the two nuts from the rear casing and
the two screws which fasten the rear cover and
brush plate to the casing. Remove clamp C and
armature shaft end play spacers, leaving the
brush gear on the commutator. Remove the thin
metal washer on the commutator side of the
armature.
6. At this stage of the procedure, check the brushes
and commutator. Check that the brushes are not
sticking and, if necessary, clean the brushes and
their respective channels with a rag and solvent.
Check the brushes are not worn. If they are worn
and minimum length is less than that shown in
the technical information table, it will be
necessary to change the starter motor.
NOTE: The brushes are not serviced separately.
They are welded to their support and will not be
changed for the whole operating life of the starter
motor.

7. Remove the motor casing from the armature and

the control side bracket.
8. Remove the control lever knuckle pin from the
control side of the casing.
9. Remove the retaining ring which holds the
control group and the inner plate from the
armature shaft, by first removing the pressure
collar perpendicularly from the retaining ring
support by means of an appropriately sized tube.
Then lever the retaining ring from the groove.
10. Remove armature and control group.

REASSEMBLE
1. To reassemble the starter motor, reverse the
removal procedure.
Before reconnecting, test the armature shaft end
play and test the starter motor without load.

ARMATURE SHAFT END PLAY

1. Place the starter motor in a vice with protected
jaws and connect a dial gauge to the flange on
the control side of the casing. Position the dial
gauge pointer on the end of the armature shaft.
2. Push the armature forward and reset the gauge
to zero. Push the armature back as far as it will
go and note the gauge reading.
3. Readings must fall within the limits specified in
the technical information table. If the value is
higher, check that armature and brush plate are
not worn. Change the worn components, as
necessary, and check end play again.

[Link] 12 1996

10

SECTION 55 ELECTRICAL SYSTEM CHAPTER 3

STARTER MOTOR TEST WITHOUT LOAD (Fig.

10)
NOTE: A fully charged battery and a battery/starting tester (high discharge multitester) with carbon
battery (variable load resistance) are needed to
carry out this test.

7
1

1. Place the starter motor in a vice with protected

jaws.
2. Connect negative battery cable (4) to the
starter motor flange.
3. Bridge the solenoid contacts (6) with a short
wire (7).
4. Connect the positive voltmeter point (3) to the
positive battery terminal clamp and the
negative voltmeter point to the negative battery
terminal clamp. Connect the ammeter positive
point (1) to the positive battery clamp (4) and
the negative point to the battery or to the starter
motor terminal clamp.
5. Place a manual tachometer (5) on the end of
the armature shaft. Check maximum power
absorption. This value is specific for each
starter motor and must be included in the range
of values in the TECHNICAL INFORMATION
table. Regulate carbon battery voltage (2) and
armature speed according to the information in
the technical information table.
6. If the starter motor does not work according to
the technical information specification, check if
there are earthed (grounded) field windings, if
the armature is scuffed or scraped or if the shaft
is misshapen or otherwise damaged.
BENCH TESTS
ARMATURE (Fig. 11)
1. The commutator surface must be clean and
not burnt. If burning needs to be removed, use
fine sandpaper and not abrasive fabric (emery
cloth). Finally, clean the commutator with a
rag and solvent.
2. If the commutator needs refacing, check it is
not smaller than the minimum value specified
in the TECHNICAL INFORMATION table.
After refacing, the commutator must be
polished with sandpaper and cleaned with a
rag and solvent.
NOTE: Do not cut the armature metal when making insulation slots.

[Link] 12 1996

26636

10

SECTION 55 ELECTRICAL SYSTEM CHAPTER 3

3. Armature insulation can be checked by
connecting an ohmmeter (1) between
commutator segments and armature shaft.
This reading should show infinity, in other
words there should be no continuity.

11

4. To test there are no short circuits, use an

appropriate testing device. The only alternative
is to try changing the armature.
5. If the armature circumference has obviously
been in contact with pole pieces, the pole
bearings are probably worn. First check the
pole pieces are fixed and that the armature
spins well in a lathe. If necessary, change the
armature bearing.

26637

11

FIELD WINDINGS (Fig. 12)

1. To test field winding insulation, connect an
ohmmeter to each of the coil brushes in turn
and to a clean and unpainted area of the
casing. There should be no readings, that is,
there should be no continuity.
2. To test coil continuity, connect an ohmmeter to
each of the coil brushes in turn and to the main
power clamp (biggest braided wire). The
reading should be 1 W.
3. If there is a failure in the field windings, then it
will be necessary to change the whole box and
field winding system.

26638

1
12

BEARING BUSHINGS
1. Check if the bushing on the brush plate and in
the box on the pinion side are worn. Assemble
the armature shaft and note play. Change the
bushing if there is too much play. Check the
field poles to see if there are any signs of
scraping against the casing. This can also be
caused by a worn bushing.

DRIVING PINION
1. Check the roller clutch operation. The pinion
must spin clockwise only. If the pinion is either
seized or spins in both directions, or if the
pinion teeth are damaged, assemble a new
control group.
If there is clear evidence of damage to the pinion
teeth, check the flywheel ring gear, as described in
section 10, Engines.
[Link] 12 1996

12

SECTION 55 ELECTRICAL SYSTEM CHAPTER 3

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

SECTION 55 ELECTRICAL SYSTEM

Chapter 4 CHARGING SYSTEM

CONTENTS
Section

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page

55 000

Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
System testing and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal, reinstallation and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

55 301

55 000 TECHNICAL INFORMATION

TYPE OF ALTERNATOR
CHARACTERISTICS

BOSCH
14V45, 65 and 85A

Polarity

Negative earth

Nominal voltage (V)

14

Max rotation speed (rpm)

Maximum output (A)

15.000
45

65

85

Regulator controlled voltage (V)

13.6 14

13.6 14.4

Rotor field winding resistance (W)

3.4 3.8

2.9

Stator field winding resistance (W)

0.2

New brush length (mm) (in.)

20 (0.7874)

Minimum brush length (mm) (in.)

5 (0.1969)

Brush spring force (N) (lb)

1.32.7
(0.29-0.60)

TIGHTENING TORQUE
Nm (ft lb)
Alternator fastening bolts
Pulley fastening nut
Rectifier fastening screws

5.5 (4.0566)
70 (51.6293)
4.0 (2.9502)

Brush box and regulator screws

Terminal nuts

2.7 (1.9914)
2.7 (1.9914)

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

DESCRIPTION AND OPERATION

ALTERNATOR DESCRIPTION
Either a Magneti Marelli or a Bosch, 45 or 65 A,
alternator, with external cooling fan, is fitted on all
models. Stator winding is ventilated with an air
conducting diaphragm in the support on the rectifier
bridge side and peripheral openings in the support
on the control side. The alternator, installed on the
left side of the engine, is operated by a pulley and a
Vtype driving belt. Alternators are fitted with a
builtin regulator.
45 or 65 A alternator
1. Battery connection (B+ terminal)
2. Terminal protection sheath
3. Alternator charge indicator connection
(D+ terminal)

[Link] 12 1996

26639

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

5
2

4
26640

Alternator charging circuit

1. Ignition switch
2. Alternator charge warning light
3. Battery
4. Alternator
5. Alternator electronic voltage regulation circuit

ALTERNATOR FUNCTIONING

B+ Battery connection
D+ Alternator charge indicator

The direct current is then reintroduced into the circuit

to increase current flow through the rotor field
winding.

See figure 2.

When the ignition key is turned, a small current

passes from the battery through the rotor field
winding wiring. The circuit closes powering the
charge warning light, the alternator D+ terminal, the
rotor field winding, the alternator regulator and earth
(ground).

At this stage, the warning light comes on and the

rotor is partially magnetised.

When the engine starts and the rotor, partially

magnetised, turns inside the stator windings and
generates threephase alternating current. A
constant quantity of this current is transformed into
direct current by three field diodes built into the
rectifier.

This action causes a constant increase in the rotor

magnetic field and a fast increase of current and
voltage output.

As the generated voltage output (reflected by D+

terminal) increases, the warning light intensity decreases and when the voltage at the D+ terminal
equals that on the battery side of the warning light,
the light goes out.

Voltage increases until it reaches the preset

regulated voltage level.

If the driving belt breaks, there will be no voltage

accumulation in the alternator. The charge warning
light will stay on, thus indicating a fault.
[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

4
1

26641

26642

4
Fan belt tensioner
Fig. 3. Belt for versions without air conditioning
1. Alternator
2. Belt tensioner

Fig. 4. Belt for versions with air conditioning

3. Belt tensioner securing nut
4. Belt

SYSTEM TESTING AND TROUBLESHOOTING

PRECAUTIONS

1. CHECKING THE BATTERY

To avoid damaging alternator charging system

components, take the following precautions:

Check all battery elements with a densimeter. The

battery must be at least 70% charged and efficient.

2. CHECKING THE DRIVING BELT

DO NOT MAKE OR INTERRUPT any charging

circuit connection, including the battery, while
the engine is running.

NEVER SHORTCIRCUIT the alternator

positive terminal to check if it is working.

ALWAYS DISCONNECT battery cables when

recharging the battery in the tractor with a
battery charger.

ALWAYS CHECK battery polarity when

installing a battery or using a supplementary
battery to start the engine.

DO NOT SHORTCIRCUIT regulator input/

output terminals when the alternator is working.

CONNECT POSITIVE TO POSITIVE AND

NEGATIVE TO NEGATIVE.

Inspect the alternator driving belt and pulley, checking that they are both clean, with no traces of oil or
lubricant and in good condition.
Check the alternator driving belt tension regularly. If
you suspect the belt is not tight, check the tensioner
as follows:
Belt for versions without air conditioning (Fig. 3)
slacken the nut (3) which secures the
alternator to the tensioner bracket (2).
with a lever, move the alternator (1) on the
tensioner bracket (2) to reach correct belt
tension and tighten the securing nut (3) to 55
Nm (40.5659ft lb).
Belt for versions with air conditioning (Fig. 4)

PRELIMINARY CHECKS
Before carrying out these electrical tests, carefully
inspect the charging system and the electrical
system in general.

slacken the belt tensioner securing nuts (3)

hold the belt tensioner arm (2) and move it on
the bracket to reach the correct belt tension,
then tighten the securing nuts (3) to 55 Nm
(40.5659ft lb).

Check continuity in all conductors and connections.

Check they are all clean and well fastened.

Correct deflection values, measured by applying the

following loads to the middle of the belt:

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

Load (N) (lb)

Deflection
(mm) (in.)

If the warning light stays on, check there is no short

circuit between D+ wire ending and warning light.

Version without cab or

with cab without air conditioning

Version with
cab and air
conditioning

78 98
(17.2021.61)

60 75
(13.2816.53)

1011
0.39370.4331)

10
(0.3937)

PRELIMINARY TESTS
These preliminary tests can be carried out without
removing any components from the tractor charging
circuit. These tests check:

the alternator wire connections

alternator charging current and controlled

voltage

voltage drop in the alternator charging circuit

maximum alternator output

3. CHECKING THE WARNING LIGHT

Turn the ignition key and check the light is completely
lit.
If the warning light does not light completely, check
the light bulb. If the light bulb has not blown, carry out
the alternator wiring connection tests as described in
the paragraph PRELIMINARY TESTS in this
section.

The following testing devices are required:

If the light is on, start the engine and run it above

minimum speed. The warning light should go out.
If the warning light does not go out, stop the engine
and disconnect the D+ terminal wire. If the warning
light goes out now, one of the alternator components
is malfunctioning. Carry out ALTERNATOR COMPONENT TESTS described in this section.

030V moving coil voltmeter

01V millivoltmeter

0110 A moving coil ammeter

1.5 ohm, 110 A varying load resistance

NOTE: Most testing devices on the market today

combine
several
electrical
test
functions
(multimeters). When using these devices, follow the
manufacturers instructions.

[Link] 12 1996

1.

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

ALTERNATOR WIRE CONNECTIONS TEST

See figure 5.
1. Disconnect the battery.
2. Disconnect B+ (2) and D+ (3) alternator
terminals.
3. Reconnect the battery and turn the ignition key
into position ON but without starting the engine.
Connect a voltmeter (4) between each terminal
and earth (ground) (1). There must be voltage
at the battery.

26643

If there is no voltage at the battery, check for a

continuity fault in the external wiring. See circuit
diagram in figure 2.
4. Connect D+ terminal, warning light wire (red)
and earth (ground). The warning light should
illuminate.
5. Disconnect the battery and reconnect the
cables to the alternator at (2) and (3) fig. 5.
NOTE: If the warning light does not light up when
the wire is connected to the alternator, this means
that there is a fault either in the alternator regulator
circuit or in the rotor circuit. Check D+ terminal is
clean and then test the alternator components as
described in this section.
2.

CHARGING CURRENT AND REGULATED VOLTAGE TESTS

See figure 6.
1. Check that all tractor electrical devices are
switched off and the ignition key is in the OFF
position.
2. Disconnect the negative battery terminal clamp
and the B+ negative alternator terminal.
3. Connect an ammeter (1) between the
disconnected wire (red) (4) and the B+
alternator terminal (3).
4. Connect a voltmeter (2) between the B+
alternator terminal (3) and earth (ground).
5. Reconnect the battery. Start the engine and run
it at 2000 rev/min. Note the readings on the
voltmeter and the ammeter.
The voltmeter reading should be higher than the
battery voltage and when the ammeter reading falls
below 10 A, the voltmeter reading should stabilise
at 13.6 14 V (Magneti Marelli alternator) or 13.6
14.4 V (Bosch alternator).
[Link] 12 1996

26644

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

If the voltmeter reading is higher than 14 V or 14.4

V, for Magneti Marelli or Bosch alternators respectively, the alternator regulator must be changed, as
described in this section. (After installing a new
regulator, carry out tests 4 and 5).
If the voltmeter reading is less than 13.6 V, there is
either a faulty component in the alternator or a
failure due to excessive resistance in the external
charging system connections.
If the ammeter reads zero amps, then one of the
alternator components is malfunctioning. Turn the
engine off and carry out the alternator component
test, as described in this chapter.

3.

CHARGING CIRCUIT VOLTAGE DROP TESTS

(a) Insulated side voltage drop test

See figure 7.
Check the ignition key is in OFF position.
1. Disconnect the negative battery cable and the
B+ alternator wire (1).
2. Connect a millivoltmeter (5) between the
positive battery terminal clamp and D+ wire (3)
(positive side of the wire)
3. Connect an ammeter (2) between the B+
alternator terminal and the D+ wire (negative
side of the wire).
4. Reconnect the negative battery cable and
connect a varying load resistance (4) with
cursor in minimum current absorption position
(maximum resistance) through the battery
terminal clamps.
5. Start the engine and increase speed to 2000
rev/min.
6. Decrease resistance charging load (decreasing resistance) slowly until the ammeter reads
45 or 65 A. according to the type of alternator.
7. Note the reading on the millivoltmeter. This
must not be higher than 400 millivolts.

26645

A reading higher than 400 millivolts indicates malfunctioning due to excessive resistance in the
external circuits.
If the alternator does not output required power and
the millivoltmeter reading is less than 400 millivolts,
there is a malfunctioning component in the alternator. Carry out the alternator component tests, as
described in this section.
8. Stop the engine.

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

(b) Ground side voltage drop test

See figure 8.
1. Check the ignition key is in OFF position.
2. The circuit is the same as that described in the
previous test, except that the millivoltmeter (4)
is now connected between the negative battery
terminal clamp and the alternator casing
(negative side of casing).
NOTE: Check the varying load resistance (3) is in
minimum current absorption position (maximum
resistance).

26646

3. Start the engine and increase speed to 2000

rev/min.
4. Increase resistance current load (decreasing
resistance itself) slowly until the ammeter (2)
reads 45 or 65 A. according to the type of
alternator.
5. Note the reading on the voltmeter. This must
not be higher than 200 millivolts.
A reading higher than 200 millivolts indicates
malfunctioning due to excessive resistance in the
external circuits.
If the alternator does not output required power and
the millivoltmeter reading is less than 200 millivolts,
there is a malfunctioning component in the alternator. Carry out the alternator component tests as
described in this section.
6. Stop the engine.

4. MAXIMUM ALTERNATOR OUTPUT TEST

See figure 9.
1. Check the ignition key is in the OFF position.
2. Disconnect the negative battery cable and the
B+ alternator wire (4).
3. Connect an ammeter (5) between B+
alternator terminal (4) and D+ wire (1)
(negative side of the wire).
4. Connect a voltmeter (4) between the B+
alternator terminal (5) and earth (ground).

26647

9
5. Reconnect the negative battery cable. Start the
engine and increase speed to 2000 rev/min.

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

6. Increase resistance current load (2)

(decreasing resistance) slowly until the
ammeter reads 45 or 65 A., according to the
type of alternator.
7. Note the reading on the voltmeter. This must
not be less than 13.6 V.
A reading lower than 13.6 V. shows there is a
malfunctioning component in the alternator. Carry
out the alternator component tests, as described in
this section.
ALTERNATOR COMPONENT TESTS
These alternator tests must be carried out only if
the PRELIMINARY TESTS have shown a malfunctioning alternator component. These tests check:
the regulator,
rotor field winding continuity,
rotor brushes, springs and contact rings.
NOTE: The previously described component tests
can be carried out with the alternator installed in the
tractor. In order to carry out the other alternator
tests, it will be necessary to remove the alternator
from the tractor. Refer to the section FUNCTIONAL TESTS in this chapter.

[Link] 12 1996

10

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

REMOVAL,
REASSEMBLY
SERVICING (Op. 55 301 10)

AND

IMPORTANT NOTE: Before disconnecting the

alternator wires, check that the ignition key is in the
OFF position.
REMOVING THE ALTERNATOR
See figures 10 and 11.
1. Disconnect the negative battery cable.
2. Disconnect B+ (1) and D+ (2) wires from the
alternator.

26648

10
1. Slacken and remove the nut and bolt (3)
securing the alternator to the belt tensioner (4).
2. Move the alternator to reduce belt tension (5)
and remove it from the alternator pulley (6).
3. Unscrew and remove the nut and bolt (7).
Remove the alternator.

26649

11

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

11

10

26650

Alternator components
1.
2.
3.
4.
5.

Pulley retaining nut

Pulley
Cooling fan
Front support plate
Rotor

6.
7.
8.
9.

12
10. Electronic voltage regulator with

Stator
Rear support plate
Rectifier bridge
Protection guard

builtin brushes

Firmly fix the alternator horizontally to an appropriate holder with internal surfaces protected with soft
material.
Remove the guard (1) after unscrewing the nuts
which fasten it to the alternator (Fig. 13)
Before dismantling the alternator completely, carry
out the operations and tests described on the
following pages.

26651

13

[Link] 12 1996

12

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

ROTOR AND REGULATOR FIELD CIRCUIT

TEST
The following testing devices are required:




12 volt battery
multitester
2 watt test lamp.

See figure 14.

1. Disconnect all alternator wires.
2. Connect a 12 V. battery and a 2.2 watt test lamp
(2) in series to D+ (1) and alternator casing
(negative side of the casing).

26652

14

3. The test lamp should light up.

If the test lamp does not light up, then the rotor
circuit is faulty. Check brushes, contact rings and
rotor field winding continuity.
If the test shows these components are satisfactory, then the regulator may be faulty.

CHECKING THE CONTINUITY OF THREE

STATOR WINDINGS

Position the points of an ohmmeter (regulated on W

x1 scale) so that they touch the stator phase ends
(a b c) in the three possible ways shown in
figures 15, 16 and 17. Each reading should show a
certain resistance value which should be the same
for all three readings.
If resistance shows infinity or zero, the measured
phase is either interrupted or shortcircuited and
the stator needs to be changed.

26653

15

26654

16

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

13

26655

17
CHECKING THE DIODES
Disconnect the terminal wire connector (1) of the
excitation diodes from the positive brush pin (Fig.
18)

26656

18
Unweld stator winding terminals (2) from the rectifier bridge (Fig. 19).

26657

19
EXCITATION DIODES TEST
Insert an ohmmeter point in the connector mentioned above (1) (Fig. 18). The second point must
be put in contact successively with each of the three
terminals (ABC): Repeat the three measurements after reversing the instrument points (Fig.
20).

26658

20
[Link] 12 1996

14

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

POSITIVE POWER DIODES TEST

Put an ohmmeter point in contact with the positive
(X) alternator terminal and the other successively
with each of the three terminals (ABC) (Fig. 21).
Repeat the three measurements after reversing the
instrument point connections.

26659

21
NEGATIVE POWER DIODES TEST
Put an ohmmeter point in contact with the negative
(Y) diodes plate and the other successively with
each of the three terminals (ABC) (Fig. 22).
Repeat the three measurements after reversing the
instrument point connections.

26660

22
In the three tests described above, the instrument
should show resistance at each terminal (ABC).
Reversing the instrument point connection, there
should be no resistance (Fig. 22). If there is resistance in both cases, this means shortcircuited
diodes. Otherwise, with a R=0 value (interrupted
diode), change the whole rectifier bridge.

ROTOR
CHECK ON ROTOR WINDING RESISTANCE
MEASURED BETWEEN PINS CONNECTED TO
BRUSHES
Disconnect the excitation diode terminal wire
connector (1) from the pin connected to the positive
brush. Put both points of an ohmmeter (regulated
on W x 1 scale) in contact with the two voltage
regulatorbrush holder pins. If resistance reading is
different from the indicated value or if it shows
infinity (interrupted circuit), check and, if necessary,
change the rotor (Fig. 23).

26661

23
[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

15

DISASSEMBLY (Op. 55 301 12)

Place a suitable Allen wrench in the hexagonal hole
in the alternator shaft to prevent the alternator shaft
from turning. With another wrench, unscrew the fan
and rotor pulley fastening nut. Draw out the above
mentioned parts, spacing collars and alternator
washers (Fig. 24).

26662

24
Disconnect the excitation diode terminal wire
connector (2) from the pin connected to the positive
brush. Unscrew and remove the screws (3) securing the electronic voltage regulator (4), complete
with brushes, to the rear alternator support.
Unscrew nuts (5) and remove the screws fastening
the alternator main external parts (Fig. 25).

26663

25
ELECTRONIC VOLTAGE REGULATOR (Fig. 26)

a. Brushes
b. Pins

26664

26
Separate the parts (as illustrated) bearing in mind
that it is necessary to apply a considerable degree
of pressure on the rotor shaft to free the front
support plate (6) and the rotor (7) (Fig. 27).
If you do not have a press, use a brass drift, to avoid
damaging the thread.

26665

27
[Link] 12 1996

16

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

Unscrew the screws (9) which fasten the rectifier

bridge (10) to the rear support plate (8) (Fig. 28).
The rectifier bridge must not be dismantled: the
spare part is supplied as a complete unit.

26666

28
Separate the rectifier bridge (10) from the rear
support plate. Unweld the stator winding terminals
(11) (Fig. 29).

26667

29
Separate the stator (12) and the terminals (11) from
the rear support plate (8) (Fig. 30).

26668

30
INDUCTOR COIL INSULATION TEST

Put both ohmmeter points (fixed at W x 1 scale) in

contact respectively with a slip ring and the rotor
casing (see arrows). The instrument should show
infinity resistance. If this is not the case, change the
rotor (Fig. 31).

26669

31
[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

17

Check rotor inductor resistance on slip rings

Put both ohmmeter points (fixed at W x 1 scale) in
contact respectively with the slip rings (see arrows). The instrument should show a certain
degree of resistance (Fig. 32).
If the instrument reading is different from the
prescribed value or shows infinity (interrupted
circuit), change the rotor.

26670

32
Check the ball bearing moves freely, without sticking
or noise. Check the collectors have not been
damaged by the brushes. If this is the case, change
the whole rotor.
REASSEMBLY

To reassemble, reverse the order of the operations

described.

SERVICING

1. Check the rotor and stator poles are not worn. If

this is the case, it means the ball bearings are
worn, the casings are not in line or the rotor
shaft is misshapen.

NOTE: alternator ball bearings cannot be serviced

separately. When necessary, therefore, both must
be changed.

1
2. Unscrew the screws (1) securing plate (2) that
locks bearing (3). Remove it from the front
support plate (4) (Fig. 33). Check if it is worn or
damaged; if so, change it. Before installing the
ball bearing, check the front support plate
holder and clean it carefully.

3
26671

33

3. Installation of bearing (5) on support plate side

is different from the one described above. A
new rotor complete with bearing must be
installed (Fig. 34).

26672

34
[Link] 12 1996

18

SECTION 55 ELECTRICAL SYSTEM CHAPTER 4

REINSTALLATION

Check the negative (ground) battery cable is

disconnected from the battery while reinstalling
the alternator.

Adjust the alternator drive belt, as described

previously in this chapter.

1. Reinstall the alternator by reversing the

removal procedure.
During reinstallation, remember to:

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 5

SECTION 55 ELECTRICAL SYSTEM

Chapter 5 BATTERY
CONTENTS
Section

Description

55 000

Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal and reinstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery checking and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery problems Frequent causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55.301.040

Page
1
1
2
3
4
7

55 000 TECHNICAL INFORMATION

TYPE OF BATTERY
JX95 model
JX60/JX70/JX80/JX90
(optional for
models
other models)
12
1x760
1x800
105
120
6
16
21
160
210
25 (55.12)
35 (77.16)
Negative

CHARACTERISTICS
Voltage (V)
Cold start amperage (C.C.A)
Capacity (Ah)
Number of elements
Number of plates per element
Energy reserve (SAE) (min.)
Weight (kg) (lb)
Earth (ground) terminal

DESCRIPTION AND OPERATION

Both types of battery
maintenancefree type.

are

of

the

sealed,

105 Ah batteries are fitted on JX60, JX70, JX80 and

JX90 models. The battery is positioned in front of the
radiator, in the front axle support compartment
(Fig. 1).
120 Ah batteries are fitted on JX95 models with cab
air conditioning and are optional for JX60, JX70,
JX80 and JX90 models. The battery is installed
above the front axle support (Fig. 2).
NOTE: Maintenancefree means that the battery
electrolyte, in normal conditions of use, does not
leak. It could leak if the battery is loaded over 14.4 V.
This, in fact, causes the water to boil due to gas
formed as the battery charges up completely. It can
be caused by a faulty charging system, by quick
charging or topping up.

to supply electricity when the power required is

higher than that produced by the alternator.
to support inactive loads from radio and
microprocessor memory.

Each element of the battery consists of positive and

negative plates, positioned alternatively, one next to
the other. Each positive plate is separated from the
adjacent negative plate by means of a porous
insulating spacer. If one of the positive plates
touches a negative plate in the element, the element
will shortcircuit and be irreversibly damaged. The
positive plates are welded to a collecting bar and
form a positive terminal. The negative plates are
welded to a similar collecting bar and form a negative
terminal.
Each positive plate consists of a lead grid with lead
peroxide pasted to the grid holes. The negative
plates consist of a lead grid with lead sponge pasted
to the grid holes.

The four main functions of a battery are:

to supply a source of electricity for starting,

ignition and instrument lighting and functioning.
to control voltage in the electrical system.

The plates are covered by an electrolyte which

consists of diluted sulphuric acid solution.
The battery casing is made of polypropylene.
[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 5

REMOVAL AND REINSTALLATION

(Op. 55 301 40)

REMOVAL

105 Ah and 120 Ah batteries fitted in front of the

radiator (Figures 1 and 2)
1. Lift the engine hood.
23753

2. Disconnect earth cable (ground) from tractor

structure and position it safely, away from the
structure itself.
3. Slacken the bolts on both terminal clamps and
disconnect the positive and negative battery
cables. Make sure they do not touch the battery
itself.
4. Lift the battery from the tractor by the two
handles at each end of the battery.
REINSTALLATION
Applicable to all types of battery.
24569

1. To reinstall the battery, reverse the removal

procedure, with the following precautions:

Check that the battery is clean, there are no

signs of electrolyte leak and the breather covers
are completely installed. Coat the terminals and
clamps with a petroleum jelly (such as Vaseline).
Do not use traditional lubricants as they can lead
to electrolytic corrosion.

Check the battery compartment or support. The

clamps should be clean and there should be no
stones or other small objects, which could pierce
the battery casing.

Check that terminal polarity is correct. Check

terminal clamp connections are not too tight.

If a radio is installed, it will lose all saved data and

will need to be reprogrammed. Electronic panels
and microprocessors, for those models to which
they are fitted, will not lose their memory
function.

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 5

BATTERY CHECKING AND MAINTENANCE

Table 1
Temperature

Fully charged battery

performance

25.0 C (77.0 F)
4.5 C (23.9 F)
24.0 C (11.2 F)
27.5 C (17.5 F)
31.0 C (23.8 F)
34.5 C (30.1 F)
37.5 C (35.5 F)

100%
82%
64%
58%
50%
40%
33%

RELATIVE DENSITY

The relative density of the battery electrolyte shows

the charge level of the battery. When the battery is
fully charged, the relative density of the electrolyte, at
25C (77F), is at least 1.280.

Alternatively, approximate charge can be measured

using a digital voltmeter ( 0.01 V) as follows:

less than
less than
less than
more than

10.5 V unusable battery*

11.8 V flat battery
12.3 V halfcharged battery
12.6 V fullycharged battery

Maximum battery life can be obtained by paying the

right attention and by carrying out regular checks.
The energy capacity output must not be exceeded by
constant overload and charging requirements must
be respected.

* See notes to paragraph TESTS for instructions on

how to recuperate a slightly sulphurized battery.

Battery voltage must be registered on a flat battery

considering the following:
A) the battery must be flat for at least 4 hours
B) if the vehicle has been used recently, or if the
battery has been charged recently, switch the
headlights on for 2 minutes.

When a battery is flat, the sulphuric acid in the

electrolyte combines chemically with the plates and
this decreases the relative density of the solution.

A battery densimeter will determine the relative

density of the electrolyte in an element. A reduction in
the amount of sulphuric acid in the solution will show
the degree of charge of that element.

The lower the temperature at which the battery

operates, the more necessary it is to keep the battery
fully charged. For example, a battery with a relative
density of 1.225 at 27C (80F) can start the engine
at mild outside temperatures but might not do so at
lower temperatures because of lower battery
performance.

Table 1 shows the effect of temperature on battery

performance.

BATTERY MAINTENANCE

WARNING: Batteries contain sulphuric acid and

generate a highly explosive hydrogen and oxygen
mix during charging.

Do not use devices producing flames or sparks

to inspect the electrolyte level.

Do not remove battery caps without protecting

your hands and your eyes.

During battery maintenance, follow the steps below:

1. Keep the electrolyte level 17 mm (0.6993 in.)
(over the plates. If this is not respected, the acid
concentration will vary, which could damage
spacers and cause a deterioration in plate
performance.
2. Use distilled or demineralized water only. Never
use tap water or rain water or water from any
other source.
3. Keep the battery charged at least 75% to avoid
plate sulphurization, performance loss and
possible freezing at low temperatures.
[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 5

4. Avoid overcharging the battery. Excessive

charge will generate high internal heat which will
cause grid deterioration and water loss.
5. During quick recharge, check the battery
temperature does not exceed 50C (122F).
6. Do not add sulphuric acid to an element unless
some electrolyte has been spilt. Before filling,
check the solution has the correct relative
density. Slow recharge is the only way to
recharge the battery completely. You can use a
high amperage battery charger to charge the
battery with high current intensity for short
periods of time. Use a slow charge to bring the
battery to its full capacity.

DRY CHARGED BATTERIES

Dry charged batteries must be prepared as followed:

1. Remove the breather caps from each battery
element.
2. Fill each element to the recommended level with
electrolyte at a relative density of 1.260.

NOTE: The electrolyte consists of diluted sulphuric

acid, preferably at a temperature of 21 32C (69.8
89.6F).
3. After filling, leave the battery to rest for 15
minutes. Check the electrolyte level and top up, if
necessary.
4. Charge the battery for 4 hours at 58 A.,
checking that all the elements are producing gas
freely.

NORMAL CHARGING (TOP UP)

1. Charge the battery completely with a slow
battery charger at 3 to 6 amperes for the required
time. This can last 36 hours, or more, if the
battery is very flat. A severely sulphated battery
may not charge. When the battery is completely
charged, the elements will produce gas freely
and the relative density will remain constant.
Disconnect the battery charger after three
consecutive densimeter readings, recorded
every hour, showing that relative density has
stabilised.
2. When using a fast or high ampere charge, follow
the manufacturers instructions carefully. High
charging amperage increases electrolyte
temperature and, if the battery charger is not
equipped with an automatic time or temperature
switch, it can cause the electrolyte temperature
to rise above 50C (122F). This can cause
violent boiling in the battery and damage internal
components.
3. Check electrolyte level in each element again
and, if necessary, top up with distilled water.
WARNING: Explosive gas is formed when a battery
is charged. Do not smoke or use naked flames when
checking electrolyte level. Check that the battery
charger is switched off, before connection and disconnection, to avoid sparks which could ignite the
gas.

CHARGING VERY FLAT BATTERIES

To recharge a PbCa maintenancefree battery we
recommend using a constant voltage battery
charger. For very flat batteries, charge for 48 hours,
at 16 V., with current limitation (50 A. for 105 Ah and
66 A for 120 Ah).

5. Replace the breather caps.

CHARGING THE BATTERY

Before charging a battery:
1. Clean the battery casing and element covers
carefully with ammonia diluted in warm water
and clean the terminals;
2. Check the electrolyte level and, if it is below the
plate level, top up with distilled water to cover the
plates.

This method is selfregulating. High current is

provided at the beginning (when the battery voltage
is very low). Current decreases progressively when
the battery is fully charged (and its voltage is high).
If only constant voltage battery chargers are
available, we recommend using voltage levels and
times shown in table 2. These figures refer to very flat
batteries. If the battery is only 50% discharged, use
half the time shown (slow charging programme). For
other
conditions,
reduce
charging
time
proportionally. When feasible, use the slowest
charging programme for increased battery life.
If violent boiling occurs during charging, due to gas
formation or electrolyte leakage, or if the battery box

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 5

is hot (50C (122F) or higher), temporarily reduce or
stop battery charging to avoid damaging the battery.

Table 2

Example 1:
Temperature below
Battery electrolyte temperature
Densimeter reading
Subtract 11.0 x 0.004
5.5
Correct relative density =

30 C (86 F)
19 C (66.2 F)
1.270
1.262

Type of battery
105Ah
(760 cca)
Slow charging
programmes

120Ah
(800 cca)

25 hrs at 5A 30 hrs at 5A
12,5 hrs at
15 hrs at 10A
10A

Fast charging pro- 7 hrs at 10A

grammes (emergency use only)

10 hrs at 18A

TESTS

Before carrying out battery tests, check the breathers are not blocked, there is no rust, the breather
caps are not open and the casing is not cracked.

Required testing equipment:

Densimeter

Battery starter tester (high amperage tester)

Thermometer

Battery charger

Example 2:
Temperature above
Battery electrolyte temperature
Densimeter reading
Add
10.0 x 0.004
5.5
Correct relative density =

30 C (86 F)
40 C (104 F)
1.220
0.007
1.227

2. Use the following table to determine the charge

level.

Charge
condition
100%
75%
50%
25%
Flat

Correct
Correct
relative
relative
density at density at
15C (865F) 25C (865F)
1.295
1.253
1.217
1.177
1.137

1.287
1.246
1.210
1.170
1.130

Average
battery
voltage
12.66
12.45
12.30
12.00
11.84

NOTE: Relative density should not vary more than

0.025 points between cells.

Relative density: This test shows the charge level of

a battery.

4. If relative density is 1.280 or higher, the battery is

fully charged and in good working condition.

1. With the float in a vertical position, note the

reading.

5. If the correct relative density is less than 1.280,

charge the battery and check the charging
system, to find the cause of low battery load.

2. Regulate the densimeter reading for battery

electrolyte temperature variations subtracting 4
points (relative density 0.004) for every 5.5 C
(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
this temperature.

The following examples have been calculated with a

densimeter calibrated at 30 C (86 F).

NOTE: If distilled water has recently been added, the

battery must be charged for a short period of time to
obtain precise densimeter readings.

If the battery has been loaded and kept still, the

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
amperage and allow more precise densimeter
readings during tests.
[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 5

Performance tests
Performance tests help to understand if a battery can
adequately run the engine. Voltage readings show
battery condition. Before carrying out the test, check
the battery electrolyte level is correct and the open
circuit voltage is 12.5V or more. The battery can be
tested in the tractor or removed.

1. Switch the battery start tester current control to

off (high amperage discharge tester). Calibrate
the voltage selection switch to the nominal
battery voltage or slightly higher. Connect the
positive tester conductors to the positive battery
terminal and the negative conductors to the
negative battery terminal.

2. Turn the current control knob until the ammeter

reading reaches half the cold start battery
amperage and note the voltage reading.

If the reading shows 9.6 V. or higher after 15

seconds, the battery has adequate power output
and can easily be charged following the normal
procedure.

If the reading is lower than 9.6 V., battery is not

satisfactory for use and the charge must be
tested as follows.

WARNING: Do not leave a high discharge tester on

the battery for more than 15 seconds.

3. Turn the battery charger timer to more than a 3

minute charge and then back to a 3 minute
charge.

4. Set the charging amperage as close as possible

to 40 A.

5. After a 3 minute fast charge, read the voltmeter.

NOTE: A slightly sulphated battery can be renewed

using a multiple type battery charger, with upper
open circuit voltage limit of 50V. A sulphated battery
has high resistance and for this reason it will be
necessary to set a high voltage at the beginning to
overcome resistance. At the beginning there may be
no visible sign of charging. After some minutes of
inactivity, a low charge will show. This is followed by a
fast rise in amperage. Amperage must not exceed
14.0 A. and the battery electrolyte temperature must
not exceed 50C (1225F). When amperage
stabilizes, set the voltage until amperage
corresponds to 5 A. Continue this amperage until the
relative density of the battery electrolyte stabilises
(1.275 1.280 at 20C (685F)). This could take
approximately 48 hours. Let the battery rest for 24
hours and then carry out the previously described
performance test.

Test charging: This test is only for those batteries

which have not passed the performance test above.

1. Connect the positive battery charger tester

conductors (high amperage discharge tester) to
the positive battery terminal and the negative
conductors to the negative battery terminal.

If the total voltage is higher than 15.5 V., the

battery is not satisfactory. It is probably
sulphated or worn and must be changed.

If the total voltage is less than 15.5 V., check the

relative density of each element and recharge
the battery according to the following scale:

Relative density

Fast charge up to:

1.150 or less

60 minutes

from 1.151 to 1.175

45 minutes

from 1.176 to 1.200

30 minutes

from 1,200 to 1.225

15 minutes
(slow charge only)

2. Connect the positive battery charger conductor

to the positive battery terminal and the negative
conductor to the negative battery terminal.
NOTE: When there are problems with a battery,
check fan belt tension and the complete charging
system.
[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 5

BATTERY PROBLEMS FREQUENT
CAUSES
1. Internal open circuit.
2. Internal shortcircuit.
3. Battery electrolyte leakage.

5. Crystals are formed when batteries are left flat.

High temperature and long periods with the
battery flat increase this condition. If a battery is
left at room temperature for a week it can rarely
be charged in the vehicle. Battery recharge
requires higher constant voltage. After three
weeks the battery will be permanently
jeopardized and it will be necessary to follow the
procedure described for very flat batteries.

4. Grid active material separation.

5. Accumulation of sulphate crystals too big to be
dispersed.

These problems are commonly caused by the

following:

Fully charged batteries have longer a life. A

leadcalcium battery discharges 3% a month. This
means that in 16 months it will reach 50% charge. In
the tractor, inactive load is approximately 50 mA. To
forecast discharge on a vehicle not in use add
approximately 8 Ah a week to this value.

1. Component failure inside the elements.

2. Excessive crystal growth which can pierce the
spacers and cause short circuits.
3. Excessive overload (bad charging system, high
voltage
fast charging, high operating
temperatures).
4. Battery electrolyte freezing.
A fully charged battery freezes at 65 C
(85 F). A 50% charged battery freezes
between 17 C and 27 C (16.6 F). A
completely flat battery freezes between 3 C
(26.6 F) and 11 C (12.2 F). Excessively fast
charging and boiling caused by gas formation
cause the separation of active material from the
grids. Separation destroys the battery chemical
function.

It is worth noting that if a battery is weak during

engine startup, it is best to let the battery rest for two
minutes. This rest time increases as the temperature
decreases.

When two batteries are installed, do not use an old

battery with a new one. One battery will always stop
before the other one. If the battery has lasted as
forecasted, charge both batteries. If one has stopped
before the forecasted time due to a defect, then
change only the defective battery.

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 5

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

SECTION 55 ELECTRICAL SYSTEM

Chapter 6 ELECTRICAL CIRCUITS
CONTENTS
Section

Description

55 100

Contents . . . . . . . .

Page
1

Fuses (all versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Symbols used in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical wire colour coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ground locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General diagrams (W/Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General diagrams (W/Out Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Analogue instrument circuit and connector overview . . . . . . . . . . . . . . . . . . . . . . 19
Startup circuit and connector overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Direction indicator & hazard warning light circuit and connector overview . . . . 25
Windscreen and rear window wiper/washer circuit and connector overview . . . 31
Brake light circuit and connector overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Heating and airconditioning system circuit and connector overview . . . . . . . . . 41
Work lamp (without cab circuit and connector overview) . . . . . . . . . . . . . . . . . . . 45
Work lamp (without cab circuit and connector overview) . . . . . . . . . . . . . . . . . . . 49
Side lights,main and dipped headlights, parking light circuit and connector
overview

53

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

FUSES AND RELAYS MAIN BOX

47
Fuses

PROTECTED CIRCUITS

Amps

Main beam headlights

15

Dipped beam headlights

10

Front right and rear left side lights

10

Front left and rear right side lights

7,5

Engine shutdown solenoid

7.5

Instruments, turn signal switch, horn

10

Hazard warning switch, fuel sedimentor

10

Relays

20

Hazard warning switch

15

10

Beacon lamp, (radio, interior lamps with cab models)

15

11

Cigarette lighter

15

12

Power for cab (with cab models)

30

13

Thermostart

15

14

Power socket (with cab models)

40

15

Power for cab (with cab models)

30

16

Turn signal switch

20

17

Brake lights

15

Dipped beam relay

II

Main beam relay

III

Horn relay

IV

Brake relay

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

Fuses and protected circuits are listed below:

FUSES AND RELAY BOX (INSIDE CAB)

FIG 48 49

PROTECTED CIRCUITS

10A

Fuses

2
3
4

ROLE
RELAY

7
8

25A 15A 10A 7,5A

20A 15A 7,5A

Amps

1.

Front wiper

10

2.

Washer

7.5

3.

Beacon lamp, interior lamps,

radio

15

4.

Heater/Air Conditioning

20

5.

Rear wiper

7.5

6.

Working lamps switches

10

7.

Front working lamps

15

8.

Rear working lamps

25

TRE0849A

48

Relays and related circuits are listed below:

Relays

CIRCUITS

1.

Front work lights

2.

Rear work lights

3.

Power supply

4.

Power supply

TRE0847A

49

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

SYMBOLS
THERMOSTARTER SWITCH
HEADLAMPS

WATER TEMP. GAUGE SENDING UNIT

BRAKE SWITCH
HANDBRAKE SWITCH
ENGINE OIL PRESSURE SWITCH
STARTER SWITCH

FRONT SIGNAL AND PARKING LIGHT

SOLENOID
FUEL SEDIMENTER
REAR INDICATOR LIGHT

SPEAKER
INTERIOR LIGHTS (LAMPS)

BEACON LAMP
LIGHTER
COMPRESSOR

NUMBER PLATE LAMP

SWITCHES
GROUND

RELAY
WORKLAMPS

REAR WIPER
MAIN FUSE
STARTER SWITCH

WASHER

HORN

THERMOSTARTER
STARTER
FUEL LEVEL SENSOR

HEATER
ALTERNATOR

FRONT BRAKE OIL UNIT

DIODE

AIR FILTER RESTRICTION SWITCH

BATTERY

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

ELECTRICAL WIRE COLOUR CODING

Black

Green

Pink

LG

Light green

LN

Tan

Brown

Orange

Purple

Red

Grey

TQ

Turquoise

Blue

White

Yellow

GROUND LOCATIONS (Pages 6 8)

1. Instrument cluster ground point

2. Fuse box ground point
3. Cab floor ground point
4. Steering pump pressure sensor ground point
5. Battery ground point
6. Windscreen washer pump ground point.
7. 7 pin trailer connector ground point
8. Evaporator top ground point
9. Upper cab ground point
10. Protective diode ground point

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

GROUND LOCATIONS
1

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

10

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

GENERAL DIAGRAM CENTRE(WITH CAB)

1,5 P
1,0 B

1,0 P/N
1,0 B

19

57

1,0 B
1,0 U/W
1,0 U/R
C
1,5 U/W
1,5 B
1,0 P/N
1,5 B
1,5 P
1,5 U/R

32

2,0 U/W
2,0 B
1,0 P/N
1,5 B
1,5 P
2,0 U/R

1,0 U/R
1,0 U/W
1,0 B

1,0 B
1,5 P

85 30

86 87

85 30

86 87

1,5 U/W
1,0 W/G

85 30

86 87

1,0 P/N
1,0 P

1.5 P/W
1,0 B

1.5 P/W
1,0 B
1,0 P/W
1,0 B

1,5 U/W
1,5 U/R
1,5 R
1,0 R
1,5 Y/W
1.5 Y/W
1,5 Y/W
3,0 Y/W
1,5 N

1,5 U/R
1,0 W/S

15A 1,5 U/W

10A 1,5 U/R
10A 1,5 R/W
7.5A1,0 R/B
7.5A1,5 P/Y
10A 1.5 G
10A
3,0 P/W
20A
15A 1,5 P

2,0 N
1,5 N
5,0 N
2,5 N/R
6,0 N
5,0 N
1,5 Y/W
1,5 G/O

9
1,0 LG/W
1,0 G
1,0 R
B

1,0 P/G
2,0 Y/W

15A
15A 1,5 P
30A 5,0 Y/W
15A 2,5 N/R
40A 6,0 N
30A 5,0 Y/W
20A 1,5 S
15A 1,5 G/O

1,0 LG/W
5,0 Y/W
5,0 Y/W
5,0 B
1,5 R
2,0 Y/W
6,0 N
6,0 B

1,5 G/O 1,5 G

30
2,5N/R

57

B
R
G/W

20

1,5 P
0,5 R

1,5 P
0,5 B

28

1,0 B
1,0 R
1,0 G/W
D

6,0 B
6,0 B

33

A
1,0 P/G
0,5 G/B
0,5 R/K
1,5 G
1,0 G/R
1,5 R
1,0 G/W
1,0 R/B
2,0 B
0,5 W/B

56
B
R/B
G/R

1,0 B
1,0 R/B
1,0 G/R

36
0,5 B

6,0 N
6,0 N
6,0 N
6,0 N

30
57 15/542,5 N/U
58/5750

0,5 B/S
0,5 G/W
0,5 U
0,5 G/B

0,5 B/S

0,5 G/U
0,5 B
0,5 LG/Y
0,5 LG/R
0,5 G/R
0,5 R/W
0,5 U/W

18
2,5 N/U

2,5 N/R

3,0 N/P

6,0 N

10
4

[Link] 12 1996

20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1

0,5 W/N

1,5 P/Y

0,5 G/U

2,5 W/Y

17
10,0 B

31
2,5 W/R

13

1,0 G/W
1,0 G/R
1,5 LG/N
1,0 B
0.5 R/B
1,5 P
1,0 G
1.5 O

14

D+0,5 N/Y
1,0 B
0,5 LG/Y
0,5 LG/R
1,5 LG/N
1.5 O

16,0 N

B+

3.0 B

12

11

1,0 R
0,5 U
1,0 B

50

2,5 W/Y

1,5 U

1.5 R

35

0,5 R/K
0,5 G
0,5 W/B
0,5 N/Y
0,5 W/N

16
0,5 B

1,5 U

16,0 NFUSE

0,5 W/B

6,0 N

6,0 Y/W

1
2
3
4
5
6
7
8
9

1,5 U
1,0 G/W
1,0 G/R
1,0 W/G
1,5 S
1,5 LG/N
1,0 W/S
1,0 P/B
1,0 P

15
UPG JX KABINLI 1

27

10

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

11

38
4,0 Y/W 25 A4,0 P/U
3,0 Y/W 15 A3,0 P/U
1,0 R/W
1,0 Y/W 10 A
1,0 R
1,5 Y/W 7.5 A1,5 U/LG
2,5 Y/W 20 A 2,5 G
2,5 W/Y 15 A
1,5 P/G
1,0 Y/W
1,5 W/K
7,5 A
1,5 Y/W 10 A
1,0 P/W
1,0 G
1,5 U/LG

1,0 B
1,0 B

1,0 LG/B
1,0 B

1,0 LG
1,0 B

1,0 LG
1,0 G

1,5 U/LG
1,5 U/LG

1,0 LG/B
1,0 G

2,5 P
1,0 W/B

1,5 P/R

86 87
86 87

4,0 G/N
1,0 W/B

1,5 P/G

85 30
85 30

3,0 P/U
1,0 R/W

86 87

52

85 30

53

4,0 P/U
1,0 R

5,0 Y/W
1,0 W/B

86 87

54

5,0 Y/W
1,0 R

5,0 Y/W
1,0 W/B

85 30

55
5,0 Y/W
1,0 R

1,0 R

1,5 B
1,5 U/LG

1,0 R

40

1,0 R/W

37

1,0 R/W

GENERAL DIAGRAM CENTRE(WITH CAB)

49

48
1,5 P/R
1,5 B

1,0 G/N
1,0 B

1,0 G/N
1,0 B

B
1,0 LG/W
5,0 Y/W
5,0 Y/W
5,0 B

1,0 LG/W
2,5 G
1,5 G
2,5 B

1,0 B

1,5 R
2,5 Y/W

41
47

6,0 N
6,0 B

1,0 G/N
1,0 B

1,0 P/G
1,0 B

0,5 B

6,0 B

A
1,0 P/G
0,5 G/B
0,5 R/K
1,5 G
1,0 G/R
1,5 R
1,0 G/W
1,0 R/B
2,0 B
0,5 W/B

24

0,5 G/B

23

29

1,5 R
1,0 G/W
1,0 G/P
1,0 B

1,0 B

1,5 B

1,0 LN/W
1
2
1,5 B
3
1,0 LN/R 4
1,0 R
5
1,0 G/P
6
1,0 R/B
7

34

1,0 B

1,0 P/W

1,0 B
1,5 W/K
1,5 G

46

39
25
42

[Link] 12 1996

45

43

1,0 G/W

1,0 G

1,0 P/B

1,0 P/B
1,0 G/W

1,0 P

26

51

1,0 B
1,0 P

1,0 B
1,0 R/B

1,5 W/LG
1,5 R/LG
1,5 U/LG
1,5 R/G

21

1,0 P
1,0 G
1,0 B

1,0 R/B
1,0 G/R
1,0 G/P
1,0 B

1,0 P/W

44

0,5 W/B
0,5 B

22

1,0 B
1,0 P

G
1,0 R/B
1,0 G/R
1,0 G/P
1,0 B

1,0 B
1,0 G/N

1,5 B
4,0 B
4,0 B

F
1,5 R
1,0 G/W
1,0 G/P
1,0 B

0,5 R/K

4,0 N
4,0 N
1,5 N

0,5 B

1,0 G/N
1,0 B

12

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

13

GENERAL DIAGRAM CENTRE(WITH CAB)

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 Wiper
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

1 Instrument panel
1 High beam
2 Park
3 Left signal
4 2 nd trailer
5 1 st trailer
6 Earth
7 Fuel gauge
10 Engine water temperature gauge
12 Right signal
13 Air filter
15 Oil pressure
18 Battery charge indicator
19 Parking brake
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
10 Flasher
11 Battery
12 Starter
13 Alternator
14 Over voltage circuit breaker (DIODE)
15 Engine oil pressure switch
16 Air cleaner restriction indicator sending unit
17 Water temperature gauge sending unit
18 Thermostarter button
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

AMain and chassis harness connector

BMain and cab harness connector
CMain and headlamp connector
DMain and right front signal connector
EMain and left front signal connector
FChassis and rear right indicator connector
GChassis and rear left indicator connector

[Link] 12 1996

14

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

15

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

GENERAL DIAGRAM CENTRE(WITHOUT CAB)

1,0 P/N
1,0 B

C
1,5 U/W
1,5 B
1,0 P/N
1,5 B
1,5 P
1,5 U/R

2,0 U/W
2,0 B
1,0 P/N
1,5 B
1,5 P
2,0 U/R

1,5 P
1,0 B

2,0 N
1,5 N

15A 1,0 P/G

15A 1,5 P

2,5 N/R

15A

1,5 Y/W
1,5 G/O

1,5 S
20A
1,5 G/O
15A

32
1,0 U/R
1,0 U/W
1,0 B

1,5 P
1,0 B

2,5 N/R

1,5 G/O

1,5 G

24

30
2,5 N/R

B
R
G/W

20

1,5 P
0,5 R

28

1,5 P
0,5 B

1,0 B
1,0 R
1,0 G/W
D

33

6,0 B

1,0 P/G
0,5 G/B
0,5 R/K
1,5 G
1,0 G/R
1,5 R
1,0 G/W
1,0 R/B
2,0 B
0,5 W/B

E
B
R/B
G/R

38

0,5 B

30

0,5 B/S

57
15/542,5 N/U
58/5750

6,0 N
6,0 N
6,0 N

1,0 R

2,5 W/Y

1,5 U

1.5 R

35

0,5 W/B

6,0 N

1,5 U

16,0 N FUSE

20
0,5 R/K
19
0,5 G
18
0,5 W/B
17
0,5 N/Y
16
0,5 W/N
15
14
0,5 B/S
13
0,5 G/W
12
0,5 U
11
0,5 G/B
10
9
8
0,5 G/U
7
0,5 B
6
0,5 LG/Y
5
0,5 LG/R
4
0,5 G/R 3
0,5 R/W 2
0,5 U/W
1

16

6,0 Y/W

0,5 U
1,0 B

9
18
2,5 N/U

2,5 N/R
6,0 N

2,5 W/Y

10

10,0 B

31
2,5 W/R

1,0 B
0,5 LG/Y
0,5 LG/R
1,5 LG/N
1.5 O

11

1,0 P/G
0,5 G/B
0,5 R/K
1,5 G
1,0 G/R
1,5 R
1,0 G/W
1,0 R/B
2,0 B
0,5 W/B

0,5 B

29
0,5 R/K

0,5 B

1,0 B
1,0 G/N
1,5 R
1,0 G/W
1,0 G/P
1,0 B

1,5 R
1,0 G/W
1,0 G/P
1,0 B

34

1,0 R/B
1,0 G/R
1,0 G/P
1,0 B

1,0 R/B
1,0 G/R
1,0 G/P
1,0 B
1,0 B
1,0 R/B

0,5 W/B
0,5 B

1,0 LN/W 1
2
1,5 B
3
1,0 LN/R 4
1,0 R
5
1,0 G/P
6
1,0 R/B 7

21

37

25

4
UPG JX ROPS 1

[Link] 12 1996

22

0,5 W/N

1,5 P/Y

27

23
0,5 G/B

15

17

14

1,0 G/W
1,0 G/R
1,5 LG/N
1,0 B
0.5 R/B
1,5 P
1,0 G
1.5 O

12
16.0 N

D+0,5 N/Y

0,5 G/U

3,0 N/P

13
B+

3.0 B

1
2
3
4
5
6
7
8
9

1,0 B
1,0 R/B
1,0 G/R

36 0,5 B

1,5 U
1,0 G/W
1,0 G/R
1,0 W/G
1,5 S
1,5 LG/N
1,0 W/S
1,0 P/B
1,0 P

57

1,0 P/G
1,0 B

1,5 U/W
15A
1,5 U/R
10A
1,5 R/W
10A
1,0 R/B
7.5A
1,5 P/Y
7.5A
1.5 G
10A
1,0 G
10A
3,0 P/W 1,0 R
20A
1,5 P
15A

1,5 B

86 87

1,0 P/N
1,0 P

1,5 U/W
1,5 U/R
1,5 R
1,0 R
1,5 Y/W
1.5 Y/W
1,5 Y/W
3,0 Y/W
1,5 N

1,0 B

85 30

86 87

1,0 B

85 30

1,0 P/W

1,5 U/W
1,0 W/G

86 87

1,0 B

1,5 U/R
1,0 W/S

85 30

1,0 B
1.5 P/W

57

1,0 B
1,0 U/W
1,0 U/R

6
1.5 P/W

19

26

16

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

17

GENERAL DIAGRAM CENTRE(WITHOUT CAB)

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

1 Instrument panel
1 High beam
2 Park
3 Left signal
4 2 nd trailer
5 1 st trailer
6 Earth
7 Fuel gauge
10 Engine water temperature gauge
12 Right signal
13 Air filter
15 Oil pressure
18 Battery charge indicator
19 Parking brake
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
10 Flasher
11 Battery
12 Starter
13 Alternator
14 Over voltage circuit breaker (DIODE)
15 Engine oil pressure switch
16 Air cleaner restriction indicator sending unit
17 Water temperature gauge sending unit
18 Thermostarter button

A Main and chassis harness connector

C Main and headlamp connector
D Main and right front signal connector
E Main and left front signal connector
F Chassis and rear right indicator connector
GChassis and rear left indicator connector

[Link] 12 1996

18

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

19

ANALOGUE INSTRUMENT CIRCUIT

1

Left turn indicator

Side lamps

10 Parking brake

Headlamp main beam

11

Ri ht turn indicator

Water in fuel

12

1st. trailer turn signal

Air filter blocked

13 [Link] turn signal

Unused

14 Unused

Engine oil pressure

15 Unused

Battery charger

Brake oil level low

[Link] 12 1996

20

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

0,5 G/B

0,5 G/U
0,5 B
0,5 LG/Y
0,5 LG/R
0,5 G/R
0,5 R/W
0,5 U/W

0,5 U
0,5 G/W
0,5 B/S

0,5 W/N
0,5 N/Y
0,5 W/B
0,5 G
0,5 R/K

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

21

STARTING CIRCUIT
6,0 N
30
57

15/54

58/57 50

35
16.0 NFUSE

2
6,0 N
6,0 N

6,0 N

13
B+
3,0 N/P

12
16.0 N

D+ 0,5 N/Y

0,5N/Y

16

11

3.0 B

14
31
2,5W/R

2,5W/Y

STARTING CIRCUIT
1
2
11
12
13
14
31
35

Instrument panel
Starter switch
Battery
Starter
Alternator
Over voltage circuit breaker (DIODE)
Starter inhibitor unit
Main Fuse

[Link] 12 1996

22

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

[Link] 12 1996

23

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

CONNECTOR OVERVIEW
0,5 G/B

0,5 G/U
0,5 B
0,5 LG/Y
0,5 LG/R
0,5 G/R
0,5 R/W
0,5 U/W

6N
6 Y/W
2,5 N/U
1,5 R
2,5 W/Y
1,5 U

0,5 U
0,5 G/W
0,5 B/S

0,5 W/N
0,5 N/Y
0,5 W/B
0,5 G
0,5 R/K

16N

14

12

2,5 W/R

3 N/P

3 N/P

3B

6N

13

18

0,5 N/Y

2,5 N/U

31

2,5 N/R

28
2,5 W/R
2,5 W/Y

2,5 N/R

[Link] 12 1996

24

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

CONNECTOR OVERVIEW

A
1 G/W
1,5 G
1 P/G

0,5 G/B
0,5 R/K
1 G/R
1,5 R
1 R/B
2B
0,5 W/B

[Link] 12 1996

25

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

DIRECTION INDICATOR AND HAZARD WARNING LIGHT CIRCUIT

6,0 B
D

20

1,0B

G/W

1,0G/W

56

1,0B

G/R

1,0G/R

1,0 G/R

1,0G/R

1,0 G/W

1,0G/W

2,0 B

2,0B

2 1,0 G/W
G/R
3 1,0

5 1,5S
6 1,5 LG/N

1,5Y/W
1,5 Y/W
1,5N

20A

2
6,0 Y/W

16.0 NFUSE

1,0 G/W

1,0 B

1,0 B

34

1,0G

10A
15A

1,5S

1,5P

1,0 G/R

1,0G/R

1,0 B

1,0 B

0,5 B 6
0,5 LG/Y
5
0,5 LG/R
4
0,5 G/R
3

6,0 N

35

1,0 G/W

0,5G/W
12

6,0 N

30
57

15/54
1,0 LN/W
1

58/57 50
6,0 N
6,0 N

1,5 B
3
1,0 LN/R
4

6,0 N

16.0 N

B+

12
13

10

[Link] 12 1996

1,5 B

1,0 B

10,0 B

1,5P
1,0G
1.5O

11

1,0G/W
1,0G/R
1,5LG/N
1,0B

D+
1,0B
0,5LG/Y
0,5LG/R
1,5LG/N
1.5O

25

21

26

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

DIRECTION INDICATOR AND HAZARD WARNING LIGHT CIRCUIT

1 Instrument panel
2 Starter switch
3 Turn signal switch
4 Hazard warning lights indicator sending unit
5 Fuse Box
10 Flasher
11 Battery
12 Starter
13 Alternator
20 Right front parking and turn signal lights
21 Rear left parking,turn signal and stop lights
25 Trailer plug
34 Rear right parking,turn signal and stop lights
35 Main fuse20 Right front parking and turn signal lights
56 Front left signal and parking light
A Main and chassis harness connector
D Main and right front signal connector
E Main and left connector
F Chassis and rear right indicator connector
GChassis and rear left indicator connector

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

27

CONNECTOR OVERVIEW

0,5 G/B

0,5 G/U
0,5 B
0,5 LG/Y
0,5 LG/R
0,5 G/R
0,5 R/W
0,5 U/W

6N
6 Y/W
2,5 N/U
1,5 R
2,5 W/Y
1,5 U

0,5 U
0,5 G/W
0,5 B/S

0,5 W/N
0,5 N/Y
0,5 W/B
0,5 G
0,5 R/K

1 G/R
1 G/W

1,5 U
1 S/B
1 P/B
1,5 G/B
1,5 S
1Y
1 TQ
1 W/G
1 W/S
1 TQ/B
1 W/B
1P

1,5 S
1 P/B
1,5 LG/N
1P

[Link] 12 1996

28

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

CONNECTOR OVERVIEW

4
0,5 LG/R

0,5 LG/Y

1B

10
1,5 O
1G
1,5 O

1,5 P

1,5 LG/N

0,5 R/B
1B
1,5 LG/N
1 G/R
1 G/W

20

1 G/W
16 N

1R

12

2,5 W/R

1B

21
1 R/B

25

1,5 B
1 LN/R
1 R/B
1R

1 G/R
1B
1 G/P
1 G/P
1 LN/W

[Link] 12 1996

29

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

CONNECTOR OVERVIEW
38

34
1,5 R
1 G/N
1R

1 G/R

1 G/W

1 R/B

1B
1 G/P

1B

1,5 R
1 G/W
1 G/P
1 B

1 R/B
1 G/R
1 G/P
1 B

[Link] 12 1996

30

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

CONNECTOR OVERVIEW

A
1 G/W
1,5 G
1 P/G

0,5 G/B
0,5 R/K
1 G/R
1,5 R
1 R/B
2B
0,5 W/B

[Link] 12 1996

31

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

WINDSCREEN AND REAR WINDOW WIPER/WASHER CIRCUIT

85

87

5,0 Y/W
1,0 W/B

38

48

1,5 Y/W7.5 A 1,5 U/LG

1,0 Y/W
7,5 A
1,5 Y/W
10 A

5
30A 5,0Y/W

G
10A 1.5

5,0 Y/W

5,0 Y/W

5,0 B

5,0 B

1,5 R

1,5 R

6,0B

6,0 B

1,5 W/LG
1,5 R/LG
1,5 U/LG
1,5 R/G

1.5Y/W

6,0 B

5,0N

6,0 N

2
35
16.0 NFUSE

30

6,0 Y/W
57

15/54

6,0 B
6,0 B

58/57 50
6,0 N
6,0 N

45

B+

16.0 N

D+

12
13

11

[Link] 12 1996

1,0 B
1,0 B

1,0 LG/B
1,0 B

1,0 LG
1,0 B

1,0 LG

1,5 U/LG
1,5 U/LG

1,0 R

86

5,0 Y/W

30

55

1,0 G

1,5 B
1,5 U/LG

1,0 LG/B

37

1,0 G

40

6,0 N

32

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

WINDSCREEN AND REAR WINDOW WIPER/WASHER CIRCUIT

2 Starter switch
5 Fuse Box
11 Battery
12 Starter
13 Alternator
35 Main Fuse
37 Rear wiper
38 Cabin fuse box
40 Switches
45 Wiper
48 Washer

55 Power relay
B Main and cabin harness connector

[Link] 12 1996

33

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

CONNECTOR OVERVIEW

16 N

6N
6 Y/W

12

2,5 W/R
2,5 N/U
1,5 R
2,5 W/Y
1,5 U

45
40
1.5 R/LG

1 R/W

1.5 R/G

1 R/W
1.5 W/LG
1.5 U/LG
1R
1R
481

1,5 P/G
1,5 P/R

1B
1 LG/B

482

1G
1G

1B
1 LG

1 LG/B

37
1 LG

1,5 U/LG
1,5 B

[Link] 12 1996

34

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

CONNECTOR OVERVIEW

5 Y/W
1 LG/W

5B

1,5 R

5 Y/W

2,5 Y/W

40
1,5 UL/G
1,5 UL/G
1,5 W/LG

1,5 R/LG
1,5 R/G

[Link] 12 1996

35

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

BRAKE LIGHT CIRCUIT

1,5G/O

1,5G/O

G/O
15A 1,5

1,5G

1,5 G

1,5G
F

30
6,0N

2,0 B

30

6,0 Y/W
57

15/54 2,5 N/U

1,0 G/P
1,0 B

2,0B

10,0 B

58/57 50

34

35
16.0 NFUSE

1,0 G/P
1,0 B

1,0 G/P
1,0 B

6,0 N

1,0 G/P
1,0 B

1,0 B

6,0 N
B+
D+

12
16.0 N

13
11

[Link] 12 1996

1
2
1,5 B
3
4
5
1,0 G/P
6
7

25

21

36
BRAKE

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

LIGHT CIRCUIT

2 Starter switch
11 Battery
12 Starter
13 Alternator
21 Rear left parking,turn signal and stop lights
25 Trailer plug
30 Stop light switch
34 Rear right parking turn signal and stop light
35 Main Fuse
A Main and chassis harness connector
F Chassis and rear right indicator connector
G Chassis and rear left indicator connector

[Link] 12 1996

37

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

CONNECTOR OVERVIEW
0,5 G/B

0,5 G/U
0,5 B
0,5 LG/Y
0,5 LG/R
0,5 G/R
0,5 R/W
0,5 U/W

6N
6 Y/W
2,5 N/U
1,5 R
2,5 W/Y
1,5 U

0,5 U
0,5 G/W
0,5 B/S

0,5 W/N
0,5 N/Y
0,5 W/B
0,5 G
0,5 R/K

16N
2,5 W/R

12

25
1,5 B
1 LN/R
1 R/B
1R

21

1 R/B
1 RB

1 G/R
1B
1 G/P

1 G/P
1 LN/W

[Link] 12 1996

38

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

CONNECTOR OVERVIEW

34
30
1,5 R
1 G/N
1,5 G

1R
1,5 G/O
1 G/W
1B
1 G/P

1,5 R
1 G/W
1 G/P
1 B

1 R/B
1 G/R
1 G/P
1 B

Turn signal switch

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

39

CONNECTOR OVERVIEW

A
1 G/W
1,5 G
1 P/G

0,5 G/B
0,5 R/K
1 G/R
1,5 R
1 R/B
2B
0,5 W/B

[Link] 12 1996

40

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

[Link] 12 1996

41

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

HEATING AND AIRCONDITIONING SYSTEM CIRCUIT

VI
II
III
MAX

1,0 N/U
1,0 P/K
1,0 P/U
1,0 N/U

1,0 B

1,0 B
1,0 G/P
1,0 P/G
1,0 G/Y

1,0 LG/W

VII

2.5 G
1,0 LG/W
2.5 B

L
M
C

9
KOMPRESOR
1,0 LG/W
COMPRESSOR

30A 5,0Y/W

16.0 N
FUSE

1,0 LG/W
5,0 Y/W

5,0 B

5,0 B

1,5 R

1,5 R

6,0B

6,0 B

2,5 Y/W 20 A 2,5 G

5,0 Y/W
1,0 W/B

6,0N
30

6,0 Y/W
57 15/54
58/57 50

6,0 B

1,0LG/W
5,0 Y/W

86 87

5,0 Y/W
1,0 R

Y/W 10A 1.5G

1.5

35

85 30

55

5
5,0N

38

6,0 B
6,0 B

6,0 N
6,0 N
B+

16.0 N

D+

12
13

11

[Link] 12 1996

H
V

2,5 G
1,0 LG/W
2,5 B

IV

6,0 N

47

42
HEATING

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

AND AIRCONDITIONING SYSTEM CIRCUIT

2 Starter switch
5 Fuse Box
9 Compressor
11 Battery
12 Starter
13 Alternator
35 Main Fuse
38 Cab fuse box
47 Heater
54 Compressor
55 Power relay
B Main and cab harness connector
I Electrical fans
II Air conditioningthermostat
[Link] pressure switch
IV Electric fan control switch
V Airconditioning control switch
VI Heating control
VII Airconditioning control switch connection

[Link] 12 1996

43

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

CONNECTOR OVERVIEW
2
16N
6N

12

2,5 W/R

6 Y/W
2,5 N/U
1,5 R
2,5 W/Y
1,5 U

9
47
1 LG/W

1 LG/W
2,5 B

2,5 G
1,5 G

5 Y/W
1 LG/W

5B
5 Y/W

1,5 R
2,5 Y/W

[Link] 12 1996

44

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

[Link] 12 1996

45

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

WORK LAMP (WITHOUT CAB) CIRCUIT

1,5P
C

1,5 P

1,5 P

1,0 B

1,5B

2,0 B

1,5P

1,5P

57
1,0 B
1,5P

33

5
1,5N

15A 1,5P

1,5R

R/W
10A 1,5

1,5Y/W

20A

1,5 R

1,5R

2,0 B

2,0B

1,5S

U
1 1,5
6,0 B
1,0 B

5 1,5S

1,5G/N

22

2
1,5 U
1.5 R

16.0 NFUSE

1,5 U

6,0 N

1,5 R

1,5R

1,0 B

1,0 B

34

30
57

15/54

58/57 50

6,0 N
6,0 N

35
12

B+
D+

16.0 N

11

1,0 B

13
10,0 B

6,0 Y/W

UPGRADE JX KABINSIZ CALISMA LAMBASI

[Link] 12 1996

46
WORK

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

LAMP (WITHOUT CAB) CIRCUIT

2 Starter switch
3 Turn signal switch
5 Fuse Box
11 Battery
12 Starter
13 Alternator
22 Work lamp
33 Worklight switch
34 Rear right parking,turn signal and stop lights
35 Main Fuse
57 Work lamp
A Main and chassis harness connector
CMain and headlamp connector
F Chassis and rear right indicator connector

[Link] 12 1996

47

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

CONNECTOR OVERVIEW
2
16N

6N
6 Y/W

2,5 W/R

12

2,5 N/U
1,5 R
2,5 W/Y
1,5 U

22

1 G/N

1B

34
1,5 R
1 G/N
1R

1 G/W
1B
1 G/P

[Link] 12 1996

48

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

CONNECTOR OVERVIEW

1,5 R
1 G/W
1 G/P
1 B

A
1 G/W
1,5 G
1 P/G

0,5 G/B
0,5 R/K
1 G/R
1,5 R
1 R/B
2B
0,5 W/B

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

1.5Y/W

87
86
87

85

30A 5,0Y/W
30A 5,0Y/W
G
10A 1.5

86

1,0 R/W

5,0N

52
3,0 P/U
30

5,0N

85

1,0 R

38
4,0 Y/W
3,0 Y/W
1,0 Y/W

5,0 Y/W
1,0 W/B

25 A 4,0 P/U
15 A 3,0 P/U
10 A

5,0 Y/W
5,0 B

1,5 R

1,5 R

1,0 W/B

2,5 P
1,0 W/B
1,0 G/N
1,0 B

6,0B

6,0 B

1,0 G/N
1,0 B

6,0 N
30

16.0 NFUSE

58/57 50

1,0 G/N
1,0 B

6,0 B
6,0 B

6,0 N
6,0 N

B+

16.0 N

D+

1,0 B
1,0 P

35

41

15/54

1,0 B
1,0 P

6,0 Y/W
57

6,0 B

1,0 R/W
1,0 R

4,0 G/N

5,0 Y/W

5,0 Y/W
5,0 Y/W
5,0 B

1,0 R

40

1,0 W/B

1,0 R

87
86

53
4,0 P/U
30

85

1,0 R

5,0 Y/W

1,0 R/W
86

54
5,0 Y/W
30

85

1,0 R

1,0 R/W

30

55
5,0 Y/W

87

WORK LAMP (WITH CAB) CIRCUIT

6,0 N

49

12
13
11

42

[Link] 12 1996

1,0 G/N
1,0 B

50
WORK

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

LAMP (WITH CAB) CIRCUIT

2 Starter switch
5 Fuse Box
11 Battery
12 Starter
13 Alternator
35 Main Fuse
38 Cab fuse box
40 Switches
41 Rear work lamps
42 Front work lamps
52 Front work lamps relay
53Rear work lamps relay
54Fronrt and rear work lamps relay
55Power relay
BMain and cab harness connector

[Link] 12 1996

51

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

CONNECTOR OVERVIEW
2
16N

6N
6 Y/W

12

2,5 W/R
2,5 N/U
1,5 R
2,5 W/Y
1,5 U

40
1 R/W
1 R/W

41
1R

1 G/N
1R

1,5 P/G

1B
1,5 P/R

1G

42
1G
1P

1 LG/B
1 LG

1B

[Link] 12 1996

52

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

B
5 Y/W
1 LG/W

5B
5 Y/W

1,5 R
2,5 Y/W

[Link] 12 1996

53

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

SIDE LIGHTS, MAIN AND DIPPED HEADLIGHTS, PARKING LIGHT CIRCUIT

1,0B

86
87

1,5U/R

1,5U/R

1,0W/S

1,5R
1,0R

3,0Y/W

1,5U/W

86

1.5P/W

30

1,0B

85

1.5 P/W

1,5U/W

87

30

85

1,5Y/W

1,0W/G

20

15A
10A
10A
7.5A
20A
20A

1,0 B

1,5U/W

2,0 U/W

1,0 U/W

1,5B

2,0 B

1,0 U/R

32

1,5U/W
1,5U/R

1,5U/R

1,0 U/R

2,0 U/R

1,5R/W

1,0 U/W

1,0R/B

1,0 B

3,0
P/W
1,5S

1,0B

1,0R

0,5 B

0,5 R

6,0 B

33

1,0 B

R/B

1,0R/B

1,0 R/B

1,0R/B

2,0 B

2,0B

1,5 U

1,0

1,5 S

1,0

1,5 R

1,5R

1,0 B

1,0 B

34

30
1,5 U
1.5 R

16.0 N FUSE

F
6,0 N

1,5 U

57
58/57

15/54

50

6,0 N

1,0 R/B

1,0 R/B

1,0 B

1,0 B

21

6,0 N

35

1,0 B

12

1,0B

B+

1,0 R/B

D+
16.0 N

1,5 B
1,5 B

11

1,0 B

0,5 R/W

13

10,0 B

1,5 R

0.5 R/B

1,5 R

56

6,0 Y/W

1,0 R
1,0 R/B

[Link] 12 1996

25
5
7

26

54
SIDE

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

LIGHTS, MAIN AND DIPPED HEADLIGHTS, PARKING LIGHT CIRCUIT

1 Instrument panel
2 Starter switch
3 Turn signal switch
4 Hazard warning lights indicator sending unit
5 Fuse Box
6 Low Beam Relay
7 High beam relay
11 Battery
12 Starter
13 Alternator
20 Right front parking and turn signal lights
21 Rear left parking,turn signal and stop lights
25 Trailer plug
26 Number plate lamp
33 Worklight switch
34 Rear right parking,turn signal and stop lights
35 Main Fuse
56 Front left signal and park lights
A Main and chassis harness connector
C Main and headlamp connector
D Main and right front signal connector
E Main and left connector
F Chassis and rear right indicator connector
G Chassis and rear left indicator connector

[Link] 12 1996

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

55

CONNECTOR OVERVIEW

0,5 G/B

0,5 G/U
0,5 B
0,5 LG/Y
0,5 LG/R
0,5 G/R
0,5 R/W
0,5 U/W

6N
6 Y/W
2,5 N/U
1,5 R
2,5 W/Y
1,5 U

0,5 U
0,5 G/W
0,5 B/S

0,5 W/N
0,5 N/Y
0,5 W/B
0,5 G
0,5 R/K

1 G/R
1 G/W

1,5 U
1 S/B
1 P/B
1,5 G/B
1,5 S
1Y
1 TQ
1 W/G
1 W/S
1 TQ/B
1 W/B
1P

1,5 S
1 P/B
1,5 LG/N
1P

[Link] 12 1996

56

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

CONNECTOR OVERVIEW

16 N

12

2,5 W/R

1,5 O
1G
1,5 P
0,5 R/B
1B
1,5 LG/N
1 G/R
1 G/W

D
21
1 R/B

1 G/W

1 G/R

1R

1B
1B

25

1 G/P

1,5 B

32

1 LN/R
1 R/B
1R

1U/R

1 G/P
1 LN/W

[Link] 12 1996

1U/W

1B

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

57

CONNECTOR OVERVIEW
33
34
1.5 P
1,5 R
0,5 R

1 G/N
1.5 B

1R

1 G/W

1B
1 G/P

1 G/W

1 R/B

1B
A
1 G/W
1,5 G
1 P/G

0,5 G/B
0,5 R/K
1 G/R
1,5 R
1 R/B
2B
0,5 W/B

[Link] 12 1996

58

SECTION 55 ELECTRICAL SYSTEM CHAPTER 6

CONNECTOR OVERVIEW

1,5 R
1 G/W
1 G/P
1 B

1 R/B
1 G/R
1 G/P
1 B

1,5 U/W

2,0 U/W

1,5 B

2,0 B
1,0 P/N
1,5 B
1,5 P

1,5 U/R

[Link] 12 1996

2,0 U/R

SECTION 90 -- CAB -- CHAPTER 1

SECTION 90 -- CAB
Chapter
1 -- Removing parts
CONTENTS
Section

Description

Page

90 160 42 -- 43
90 120 10
Control levers, seat and electrical controls -- disassembly and reassembly . . . . . . . . . . . . 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 reassembly . . . . . . . . . . . . . . 11

90 154 10

Left--hand door -- disassembly and reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

90 160 60
55 518 52

Windscreen wiper motor -- disassembly and reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

90154 24
90 156 10 -- 14
90 156 28
Cab windows -- replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

????

SECTION 90 -- CAB -- CHAPTER 1

CONTROL LEVERS, SEAT,

ELECTRICAL CONTROLS
Disassembly--Assembly
(Op. 90 160 43--90 160 42--90 120 10)

1. Disconnect the negative cable from the battery.

TRE0247A

1
2. Take out the four securing screws (1) and remove the covering of the control panel (2).
3. Disconnect the electrical connector from the cab
interior light switches (3) and remove the cover.

1
3

2
2
4. Remove the LH panel retaining screws (1).

3
5. Remove the three LH panel retaining screws (1).

1
TRE0146A

4
???

SECTION 90 -- CAB -- CHAPTER 1

6. Remove the screws (1) on rear panel

5
7. Remove the LH panel (1).

TRE0145A

6
8. Remove the screws (1) of the RH panel retaining
elements.
1

TRE0048A

7
9. Remove the screws (1) from the RH fenders.

TRE0147A

8
????

SECTION 90 -- CAB -- CHAPTER 1

10. Remove the screws (1) from the rear panel

TRE0230A

9
11. Remove the LH panel (1).
1

TRE0145A

10
12. Remove the the hand throttle lever (1).

2265
3

TRE0141A

11
13. Remove the retaining nut (1) and take out the
steering wheel.

TRE0141A

12
???

SECTION 90 -- CAB -- CHAPTER 1

14. Remove the retaining bolts on the control panel
and detach the electrical connector. Remove the
tachometer and the control panel (1)

2
TRE0026A

13
15. Unscrew the retaining screw (2) on the side of
the instrument console (rear hood) (1).

2
TRE0150A

14
16. Remove the retaining screws (1) on top of instrument console (rear hood) (2).

2
1

TRE0149A

15
17. Remove the instrument console (rear hood) (1).

TRE0148A

16
????

SECTION 90 -- CAB -- CHAPTER 1

18. Remove the screws (1) securing the knobs to the

control levers and remove the knobs.
1

17

19. Unscrew the four screws (1) securing the lever

panel.

18

20. Unscrew the lift--o--matic switch retaining screws

(1).
1

19

???

SECTION 90 -- CAB -- CHAPTER 1

21. Remove remove the protective cover and the

screws (1) securing the hydraulic control lever
support (2) to the platform.
2

1
TRE0154A

20
22. Remove the screws (1) holding the auxiliary
control valve levers in place.

TRE0041A

21
23. Remove the screws securing the parking brake
support (1) to the platform. Disconnect the
parking brake relay and the control lever from
vertical rod.

22
24. Unscrew the screws (1) securing the shuttle
lever (2).

2
1

TRE0180A

23
????

SECTION 90 -- CAB -- CHAPTER 1

25. Unscrew the control lever retaining screws (1)

and remove the control levers.
1

TRE0179A

24

26. Remove the PTO clutch lever support securing

screws (1). Disconnect the PTO control lever
from the patform.

25

27. Unscrew the retaining screws (1) from the PTO

synchronised control lever support (2).
2

1
TRE0043A

26

???

SECTION 90 -- CAB -- CHAPTER 1

28. Remove the four seat securing screws (1).

Remove the seat and the covering beneath it.
To refit, proceed as follows:
Refit the PTO clutch lever and
synchronised control lever support.

PTO

Refit the transmission control levers.

Refit the LIFT--O--MATIC cover, securing it to the
RH panel with the three screws.
Refit the RH side panel, securing it to the cab
body with the five screws.

1
24838

27
Refit the rectangular PTO cover, the yellow
pushbutton and plastic plug. Secure the cover
with the two screws.
Refit the the LIFT--O--MATIC switch , the protective cover and the control levers.
Refit the instrument panel and plug in the
electrical connector.
Secure the LH side
previously removed.

panel with the screws

Fix the RH side panel and cab light control unit

and with the securing screws. Reconnect the
electrical connector to the plug on the control
panel.
Reinstall the drivers seat.
Reconnect the negative cable to the battery.

????

10

SECTION 90 -- CAB -- CHAPTER 1

REAR WINDOW, HANDLE AND LOCK

Disassembly--Assembly (Op. 90 156 52)
1. Disconnect the negative cable from the battery.

2. Remove the handle (2), the seals and the

threaded pin (1).
1

2
TRE0151A

28
3. Disconnect the two gas struts at the ball and
socket joints (1).

1
3
2
TRE0021A

29
4. Remove the securing screws (1) fig. 30 from
the hinges and take out the cab rear
windscreen complete with frame (2) fig. 29.
5. With the cab rear windscreen removed, remove
the securing screws and the frame (2) fig. 29.
6.

To refit, proceed as follows:

Refit the complete handle unit.
Refit the locating pin.
Renew the rear window rubber seal.
Reconnect the negative cable to the battery.

24852

30
???

SECTION 90 -- CAB -- CHAPTER 1

11

LOCK AND EXTERIOR HANDLE

LH DOOR
Disassembly--Assembly (Op. 90 154 30)
1. Disconnect the negative cable from the battery.

2. Unscrew the three screws (1) securing the interior

lock cover (2).
2

TRE0239A

31
3. Remove the exterior handle by unscrewing the
two retaining screws (1) from the inside.
To refit, proceed as follows:
Refit the exterior handle.
Fit the lock.
Reconnect the negative cable to the battery.

24898

32
4. Remove two screws (1) securing the interior lock
(2).
1
2

24897

33
????

12

SECTION 90 -- CAB -- CHAPTER 1

LH DOOR
Disassembly--Assembly (Op. 90 154 10)
1. Disconnect the negative cable from the battery.

TRE0247A

34

2. Remove the door closure (gas strut).

1
TRE0238A

35
3. From inside the cab, unscrew the two top screws
(1) securing the door hinge.

TRE0238B

36
4. Remove the door.

To refit, proceed as follows:

Refit the left hand door.
Refit the left hand pillar seal.
Reconnect the negative cable to the battery.
TRE0001A

37
???

SECTION 90 -- CAB -- CHAPTER 1

13

WINDSCREEN WIPER MOTOR

Disassembly--Assembly
(Op. 90 160 60 -- 55 518 52)
1
1. Disconnect the negative cable from the battery.

TRE0247A

38
2. Remove the roof securing screws.

TRE0124A

39
3. Remove the cap top cover (1) and disconnect
the electrical connection from the front wiper
motor.

TRE0152A

40
4. Unscrew the wiper blade retaining screw (1).
1

24917

41
????

14

SECTION 90 -- CAB -- CHAPTER 1

5. Unscrew the small nut (1) securing the wiper motor unit.

24918

42
6. Unscrew the large nut and remove the wiper
motor unit (1) from top the cab.
1
To reinstall, proceed as follows:
Refit the motor unit and secure it with the two
nuts
Refit the wiper blade
Reconnect the electrical connector to the motor
Refit the cab roof lining and all the parts
previously removed.
Reconnect the negative cable to the battery.

TRE0225A

43

???

SECTION 90 -- CAB -- CHAPTER 1

15

CAB WINDOWS
Replacing bonded cab windows
(Op.90 154 24 -- 90 156 10 -- 90 156 14 -- 90 156 28)
Removing window

Proceed as follows.

WARNING
Handle all parts with great caution.
Do not insert your hands or fingers between one part
and another.
Wear the prescribed safety clothing, including
glasses, gloves and safety footwear.

TA6090018

44

1. If possible, remove any window support blocks

present as they can restrict the action of the
cutting wire.
2. From inside the cab use a pair of pliers to push
the cutting wire (1) fig. 44 through the adhesive
(2) between the glass and the frame.
3. Thread the cutting wire (1) fig. 45 into the handle
and lock it with the screw (2).

45

4. Anchor the pointed end of the the tool into the

adhesive (see figure A). Keep the wire close to
the glass and pull on the handgrip (2) fig. 46.
5. Pull the pointed tool from the adhesive and
reposition it further along, as shown at (2). Again,
pull on the wire, making long cuts on straight
sections and short cuts around corners to avoid
breaking the glass. Repeat this operation until
the window is completely detached.
6. Use a tool with suction cups to remove the
window and place it on a suitable surface to avoid
damaging it.
46
7. Completely remove the adhesive from the
window surround, taking care not to damage the
surround.
8. Remove the adhesive from the glass using a
suitable solvent.

NOTE: When replacing a broken window, remove

the glass fragments still attached to the cab and use
a knife blade to cut the adhesive (1) fig. 47, away
from the frame. Take care not to damage the frame.

9. Clean the frame, as described in operation 7.

47
????

16

SECTION 90 -- CAB -- CHAPTER 1

Refitting the window

Proceed as follows.
1. Make sure that the contact area between the
glass and the metal frame in the cab is perfectly
clean.
2. Using a clean tissue, apply the activator (VP
04604 GURIT ESSEX) around the edge of the
glass, where contact will be made with the metal
frame. Allow to dry.
3. Shake the bottle of glass primer (Betaprime 5100
GURIT ESSEX) for 60 seconds. Using the
applicator provided (1) fig. 48, apply the primer
(2) around the edge of the glass, over the top of
the dried activator. Allow to dry thoroughly.
4. Shake the bottle of metal plate primer
(Betaprime 5402 GURIT ESSEX) for 60
seconds. Using the applicator provided apply
around the metal frame, where contact will be
made with the glass. Allow to dry thoroughly.
5. Cut the spout of the adhesive dispenser as
shown in fig. 49 to obtain a bead of triangular
cross--section.
6. Apply a smooth, continuous bead of
polyurethane adhesive (Betaseal 1703 GURIT
ESSEX) around the edge of the glass over the
previously primed area (the cross--section of this
bead must be triangular, with a base width of 10
mm and a height of 10 mm).

48
60

65
7.0
3.0

NOTE: Make sure that the adhesive bead is

continuous, i.e., there are no areas where adhesive
is missing, otherwise water may penetrate.

7. Insert the window support blocks, if present.

8. Using a tool with suction cups, position the
window in its surround and use suitable clamps
to apply a uniform pressure to obtain a 4 mm
thickness of adhesive and ensure perfect
adhesion.
NOTE: Leave the clamps in place for 4 hours until the
adhesive has completely polymerised. To promote a
good bond, do not move the cab or the tractor during
this time.

???

49