Beruflich Dokumente
Kultur Dokumente
CONTENTS
1
Introduction
Splitting
the tractor
Engine
Clutch
Gearbox
Rear axle
Power Take-Off
Front Axle
Hydraulics
10
11
12
Electrical
equipment
Electronics
13
14
Accessories
Service tools
Cab and
Equipement
1 . INTRODUCTION
Contents
1A01
INTRODUCTION
Issue 1
May 2001
Introduction
1A01.1
1 A01 Introduction
CONTENTS
A.
B.
General specifications
C.
Safety instructions
19
D.
Practical advice
20
E.
23
F.
Conversion tables
24
G.
32
H.
Tightening torques
33
Issue 2
May 2002
Introduction
Page numbering
Example: 7C01.3
This manual is divided into chapters and sections, with
each page providing the following information:
7 = Chapter
C = Section
01 = Sequence number in the section
3 = Page number in the section.
Meaning of symbols
circle (..) : identifies the component part only
Amendments
Amended pages are issued using precisely the same
numbering system as the previous pages: only the issue
number and the date are changed.
The old pages should be removed from the manual and
destroyed.
Service tools
During operations where a specific service tool needs to
be used, the tool reference number is specified.
Issue 2
May 2002
Introduction
1A01.3
B . General specifications
Engine
Specifications
8210
8220 /
8220 Xtra
PERKINS ENGINE
1006
1006
8240 /
8240 Xtra
8250 /
8250 Xtra
620
634
VALMET ENGINE
Number of cylinders
Turbocharger
Yes
Yes
Yes
Yes
Yes
Yes
Yes
100
100
108
108
Stroke (mm)
127
127
120
134
Capacity (l)
6.6
7.4
113
119.5
125 / 142
136 / 159
2200
2200
2200
2200
620
663
727 / 855
797 / 920
1400
1400
1400
1400
Idle speed
950
950
950
950
2200
2200
2200
2200
2354
2354
2354
2354
Lubrication: By gear pump - suction strainer and interchangeable external cartridge filters
Valves: Overhead valves operated by pushrods
Rocker arm clearance (cold)
- Inlet - mm (inches)
0.20
0.20
0.35
0.35
- Exhaust - mm (inches)
0.45
0.45
0.35
0.35
Yes
Yes
Yes
Yes
8210
8220 /
8220 Xtra
8240 /
8240 Xtra
8250 /
8250 Xtra
Yes
Yes
Yes
Yes
No. of elements
Injection pump
Lucas
Lucas
Stanadyne/Bosch
Bosch
Lucas
Lucas
Stanadyne
Stanadyne
Fuel filter
Thermostart
Issue 2
May 2002
Introduction
8260 / 8260 Xtra
634
645
645
Yes
Yes
Yes
Yes / No
Yes / No
Yes / No
No / Yes
No / Yes
No / Yes
Bore (mm)
108
111
111
Stroke (mm)
134
145
145
Capacity (l)
7.4
8.4
8.4
162 / 172
181 / 192
200 / 212
2200
2200
2200
878 / 980
1002 / 1120
1150 / 1260
1400
1400
1400
Idle speed
950
950
950
2200
2200
2200
2354
2354
2354
VALMET ENGINE
Number of cylinders
Turbocharger
Lubrication: By gear pump - suction strainer and interchangeable external cartridge filters
Valves: Overhead valves operated by pushrods
Rocker arm clearance (cold)
- Inlet - mm (inches)
0.35
0.35
0.35
- Exhaust - mm (inches)
0.35
0.35
0.35
Yes
Yes
Yes
Yes
Yes
Yes
No. of elements
Injection pump
Bosch
Bosch
Bosch
Fuel filter
Stanadyne
Stanadyne/Bosch Stanadyne/Bosch
Two stage air filter, dry filter element with filter clogging indicator.
Start up in cold weather
Issue 2
Thermostart
May 2002
Introduction
1A01.5
Road speeds at 2200 rpm - Dynashift transmission with creeper unit - Heavy Duty
reduction drive units - 20.8R38 tyres.
RANGE
2
TORTOISE
HARE
FORWARD
Heavy Duty
Heavy Duty
reduction drive
reduction drive
unit km/h
unit km/h
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
A
B
C
D
2.36
2.76
3.26
3.81
3.58
4.19
4.94
5.79
5.11
5.98
7.06
8.27
6.96
8.14
9.61
11.25
7.77
9.09
10.73
12.56
11.79
13.80
16.29
19.06
16.84
19.71
23.27
27.23
22.92
26.83
31.67
37.06
0.6
0.7
0.8
0.9
0.9
1.0
1.2
1.4
1.2
1.5
1.7
2.0
1.7
2.0
2.3
2.7
1.9
2.2
2.6
3.1
2.9
3.4
4.0
4.7
4.1
4.8
5.7
6.6
5.6
6.5
7.7
9.0
Issue 2
REVERSE
Heavy Duty
reduction drive
unit km/h
Heavy Duty
reduction drive
unit km/h
2.30
2.70
3.19
3.74
3.51
4.10
4.84
5.67
5.01
5.86
6.92
8.10
6.82
7.98
9.42
11.02
7.61
8.91
10.51
12.30
11.55
11.55
15.95
18.67
16.50
19.31
22.79
26.68
22.45
26.28
31.02
36.31
0.6
0.7
0.8
0.9
0.9
1.0
1.2
1.4
1.2
1.4
1.7
2.0
1.7
1.9
2.3
2.7
1.9
2.2
2.6
3.0
2.8
2.8
3.9
4.6
4.0
4.7
5.6
6.5
5.5
6.4
7.6
8.9
May 2002
Introduction
Road speeds at 2200 rpm - Full Powershift transmission AG150, sealed Heavy Duty
reduction drive units - 20.8R38 tyres.
RANGE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Issue 2
FORWARD
(km/h)
2.28
2.94
3.80
4.32
4.91
5.59
6.33
7.21
8.18
9.31
10.54
12.01
13.62
15.52
17.57
22.69
29.28
37.82
May 2002
REVERSE
(km/h)
2.28
3.80
4.32
6.33
7.21
10.54
12.01
17.57
Introduction
1A01.7
Road speeds at 2200 rpm - Full Powershift transmission AG150, sealed Heavy Duty
reduction drive units with creeper unit - 20.8R38 tyres.
RANGE
FRONT
(km/h)
REAR
(km/h)
1
2
3
4
0,6
0,7
0,9
1,1
0,6
0,9
1,1
1,5
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1,2
1,4
1,5
1,8
2,0
2,3
2,6
2,9
3,3
3,8
4,3
5,5
7,1
9,2
1,8
2,6
2,9
4,3
Issue 2
May 2002
Introduction
1A01.8
Road speed at 2200 rpm - AG250 Full Powershift Transmission, double drive units
- 650 / 85R38 tires
RANGE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Issue 2
FRONT
(km/h)
REAR
(km/h)
2.40
3.10
4.00
4.60
5.10
5.90
6.70
7.60
8.60
9.80
11.10
12.70
14.30
16.30
18.50
23.90
30.90
39.80
2.40
4.00
4.60
6.70
7.60
11.10
12.70
18.50
May 2002
Introduction
1A01.9
Road speed at 2200 rpm AG250 Full Powershift Transmission, double drive units
- 650 / 85R38 tires with gearbox
RANGE
FRONT
(km/h)
REAR
(km/h)
1
2
3
4
0.60
0.80
1.00
1.10
0.60
1.00
1.10
1.60
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1.30
1.40
1.60
1.90
2.10
2.40
2.70
3.10
3.50
4.00
4.50
5.80
7.50
9.70
1.90
2.70
3.10
4.50
Issue 2
May 2002
Introduction
Electrical circuit
Voltage :
Batteries :
Alternator :
Starter safety :
Headlights :
Parking lights :
Direction indicators :
Number plate light :
Work lights :
Dials and signal lamp lighting :
Roof light:
Cooling system
Mode :
Fan:
Water pump :
Fan belt tension :
Transmission
Dynashift gearbox with mechanical
reverse shuttle
Clutch :
Creeper gearbox :
32 forward speeds
32 reverse speeds
four ratios selectable without declutching
synchromesh reverse shuttle
Filtering
- clutch controlled
- 6 forward speed discs
- 5 reverse speed discs
- clutch controlled
- 7 forward speed discs
- 6 reverse speed discs
- clutch controlled
- 8 forward speed discs
- 6 reverse speed discs
Creeper gearbox :
- 48 forward speeds
- 48 reverse speeds
Filtering
Issue 2
32 forward speeds
32 reverse speeds
four ratios selectable without declutching
power shuttle
May 2002
Introduction
1A01.11
Clutches :
Hydraulics :
1 "Gerotor" pump - Capacity 110 l/min at 2200 rpm provides (for lubrication and supply of clutches, cooling system and boosting of)
the master cylinders.
1 x 150 micron suction strainer, located inside the housing.
External 15-micron filter, 3-way filter protects solenoid valves
from particles.
Filtering :
6.21:1
6.21:1
7.14:1
9.47:1
Gear ratios:
Option available on models Carraro 20.29 and 20.43 (8210 to 8250) only
Electro-hydraulically controlled from a button on the armrest
inside the cab.
Differential lock coupling is electro-hydraulically controlled.
Lock :
- oil-bath clutch on Carraro (20.29 and 20.43) and Dana AG280 front axles
- hydromechanical dog coupling on Dana AG155 and AG200 front axles.
8210 / 8220 / 8240 ..... AG155
20,872/1
up to K137012
8210 / 8220 / 8240 ..... 20.29
20,769/1
from K137013
8240 /8245 /8250 /8260 AG200
20.475/1
8250 ........................... 20.43
20.769/1
From K116015
8250 Xtra .................... 20.48
20.945/1
8270 / 8280 ................ APL5052
8270 : 8280 ................ AG280
20.475/1
20.363/1
Up to L074008
From L074009
Power take-off
interchangeable shaft :
Shiftable :
750 rpm economy PTO :
Issue 2
May 2002
Introduction
1A01.12
Hydraulic circuit
Hydraulic lift
Type: 3-point, category 3
Lift rams: dia. 95 (8210, 8220, 8240, 8250) quantity 2 - capacity (see table)
Position of lift
rod on drawbar
(mm)
Length
of lift rod
(mm)
Horizontal
drawbar
(Kg)
Drawbar in
transport position
(Kg)
547.5
824
7149
9365
918
7373
8627
824
7769
9865
918
7927
9109
600.0
Issue 2
May 2002
Introduction
1A01.13
Lift rams: dia. 105 (8260 to 8280) quantity 2 - capacity (see table)
Position of lift
rod on drawbar
(mm)
Mini 530.4
Maxi 580.9
Length
of lift rod
(mm)
Horizontal
drawbar
(Kg)
Drawbar in
transport position
(Kg)
838
8741
11387
915
8994
10656
838
9475
12001
915
9667
11252
Brakes
Type
Lining internal dia.
Operation
Parking brake
Park lock
: disc brakes, two discs per wheel with double reduction unit constant flow
lubrication, external dia. 313 mm.
: 239 mm.
: Hydraulic, using two master cylinders.
: operates on intermediate shaft of drive pinion.
: mechanically locks the intermediate shaft of the drive pinion.
Issue 2
May 2002
Introduction
Steering
Type: Hydrostatic, telescopic or fixed tilting steering column double action steering ram (8200 with Dana or
Carraro front axle), two double action steering rams (8270 and 8280 with APL5052 front axle only).
Wheels
Front (4 wheel drive): adjustable steel rims
Rear: steel rims (fixed or adjustable), manually adjustable pressed steel rim with cast iron disc.
Capacities
Fuel tank with additional reserve : ............................................ 8210/8220/8240/8250/8260 :
......................................................................................................................... 8270/8280 :
410 l
456 l
28,5 l
34 l
15,6 l
20 l
19 l
123 l
157 l
Transmission / rear axle Dynashift gearbox (Heavy Duty sealed) ...................... 8220/8240 :
120 l
Transmission / rear axle Full Powershift (Heavy Duty sealed) ........................... 8220/8240 :
150 l
114 l
147 l
Transmission / rear axle Full Powershift gearbox (double drive unit) ......... 8260/8270/8280 :
156 l
Issue 2
May 2002
Introduction
1A01.15
10.2 l
10 l
16 l
20.29ACP and 20.43ACP fixed front axle assembly ............................................... 8210 to 8250
6l
20.29S and 20.43S suspension front axle assembly .............................................. 8210 to 8250
8.6 l
10 l
10 l
AG 155H front final drive unit (each) ............................... .................................... 8210 to 8240
1.6 l
20.29 or 20.43 front final drive unit (each) .............................................................. 8210 to 8250
1.3 l
1.9 l
1,8 l
APL 5052 front final drive unit (each) ................................................................. ... 8270/8280
4l
2.7 l
Heavy Duty Sealed Rear final drive unit (each) .................................................. .... 8220/8240
3,6 l
Composite rear final drive drive units (each) ......................... .................. 8240/8245/8250/8360
4,5 l
Issue 2
May 2002
Introduction
1A01.16
Tightening torque
350 - 460 Nm
350 - 460 Nm
500 - 600 Nm
640 - 680 Nm
250 - 350 Nm
640 - 680 Nm
250 - 350 Nm
400 - 450 Nm
Miscellaneous
- Extending arms .......................................................................
- Power take-off shaft ...............................................................
- Steering rams .........................................................................
- Engine oil drain plug ................................................................
- Fuel tank drain plug .................................................................
400 - 600 Nm
100 - 130 Nm
75 - 80 Nm
80 Nm
15 - 18 Nm
CEE 77/311
Appendix II
Type
Type
Windows
closed
Windows
open
78
80
8240 Xtra
75
80
77
83
8250 Xtra
74
79
8240
74
80
8260 Xtra
77
81
8250
77
84
8270 Xtra
76
81
8270
76
81
8280 Xtra
76
81
8280
77
82
8210
8220 / 8220 Xtra
Issue 2
May 2002
Windows
closed
Windows
open
Introduction
1A01.17
8210
A Wheelbase
B Overall length (with 3PT, without front weights)
C Height to roof (cab tractor)
D Overall width (1)
E Ground clearance
Min. weight (with full tank, without extra
weight steel wheels).
2825
2825
2985
3075
3075
4949/4951 4949/4951 5111/5109 5111/5201 5251
2980
2980
3042
3042
3038
2854
2854
2880
2998
3007
453
453
453
453
453
6750/6925 6885/7160 7580/7665 8295
8850
Front tyres
Rear tyres
8220
8240
8250
8260
4RM. Dynashift/Powershift
16.9R28
20.8 R38
16.9R30
20.8 R42
40
M22 x 1,5
10 x2
87 / 110
M22 x 1,5
10 x 2
480/70
620/70 R42
Front axle
20.48
1890
AG155
1892
AG200
1892
280
335
280,8
335
280,8
335
40
40
40
M22 x 1,5 M22 x 1,5 M22 x 1,5
10 x2
10 x2
10 x2
(1) These dimensions are for max. track (without straight shaft).
V
V
V
V642
G
D
A
B
e
V
V639
I
J
J
K
Issue 2
May 2002
Introduction
1A01.18
SPECIFICATIONS
mm - kg
8270
8280
4RM. Powershift
A Wheelbase
3075
3075
5251
3117
3032
432
9250
5251
3117
3030
432
9250
600/70R28
650/85R38
600/70R28
650/85R38
Front tyres
Rear tyres
Front axle
APL 5052
1875
-
AG 280
1892
-
H Stud distance
L Centring diameter
425
370
425
370
40
47
M22 x 1.5
12
M22 x 1,5
12
J Stud diameter
K Number of studs
(1) These dimensions are for maxi track (without straight shaft).
V
V
I
J
Issue 2
V642
G
D
A
B
e
V
V639
J
K
May 2002
Introduction
1A01.19
C. Safety instructions
See Operator Instruction Book
Issue 2
May 2002
Introduction
D . Practical advice
Safety
When working on machinery, of whatever type, the first
concern must always be the safety of oneself and
others. To work in complete safety it is necessary to fully
understand the nature of the work that has to be carried
out, to use the appropriate tools and various equipment
correctly and to employ common sense in all situations.
Troubleshooting
Using the information supplied in the workshop manual,
the following method enables problems on the tractor to
be pinpointed with accuracy.
The method consists of following a certain number of
logical steps to identify the problem, to locate it and then
to correct it:
1. Define the problem
2. List the possible causes for the problem
3. Discriminate between the causes
4. Carry out checks in logical order in order to
discover the exact cause
5. Evaluate the remaining life of components, the
price of the components and the cost of labour.
6. Carry out the repair thus judged necessary
7. Check for the correct operation of the system and
functions that were affected.
CORRECT
INCORRECT
B
C
D
Issue 2
May 2002
Introduction
1A01.21
Cleanliness
To ensure a long life cycle to any machine, it is important
that its moving parts are protected from dust and foreign
bodies. Precautions must be taken against such danger.
Sealed compartments, seals and filters ensure the cleanliness of air, fuel and lubricating oil. None of these
protection systems should be removed.
When disconnecting piping, whether it be hydraulic, fuel,
lubricating or air lines, clean both the connecting points
and the surrounding area. As soon as the piping is
disconnected insert a plug, a cover or fasten adhesive
tape over the opening to prevent foreign bodies from
entering.
In the same way, clean and cover all access covers and
inspection plates when they are removed. Clean and
check all components. Take care that all passageways
and holes are unobstructed. Cover all components so
that they remain clean. Ensure that all components are
clean at the time of reassembly. Leave new parts in their
packaging up until the time that they are actually used.
Assembly
To reassemble a piece of equipment, complete each
step in turn. Never partially assemble one subassembly
and then begin to assemble another. Carry out all the
recommended adjustments. Always recheck the work
that has been carried out to ensure that nothing has been
forgotten.
Check the various adjustments again before putting the
equipment back into service.
Note: Before fitting new parts, remove the anti-rust
compound from all machined surfaces (usually a peel-off
material).
Lubrication
According to recommendations, fill the compartments of
the repaired or replaced elements with the correct quantity of clean oil of the type recommended in the maintenance section of the Operator Instruction Book.
Shims
Whenever shims are removed, they should be attached
together and their location marked. Ensure that distance
pieces are clean and take care that they are not bent in
any way when refitting.
4
5
Seals
Take care that the holes in seals match exactly the
lubricating channels in the corresponding components. If
gaskets need to be made, select the thickness and type
of material carefully. Take care that the seal is correctly
shaped and cut. Badly cut and fitting seal can cause
major breakdowns.
SPY type lip seals
Before fitting, lubricate the lips of SPY type seals with oil.
Do not use grease on seals, unless they are grease
seals.
The main components of SPY type seals are the envelope (1), oil tightness element (2) and annular spring (3).
The cross section shows the heel (4) and the pivot (5),
these impart the dimensions to a single element seal.
With one or two exceptions, the pivot of a lip seal faces
the lubricant side. Some seals also have an auxiliary lip
without a spring.
Issue 2
May 2002
Introduction
Issue 2
May 2002
Introduction
E . Instructions for putting the
tractor in service
General
To ensure the regular servicing of the tractor during the
twelve-month warranty period, the AGCO supplying
Distributor or Dealer must carry out the first 50-hour and
250-hour servicing operations.
These periods are calculated so as to provide maximum
efficiency of the tractor throughout the warranty period,
and thus ensure later reliability of the tractor.
1A01.23
Issue 2
May 2002
Introduction
1A01.24
Instructions for the driver
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
F . Conversion tables
Units of Pressure
1 PSI = 1 lbf/in2 = 0.0689 bar
1 bar = 14.512 lbf/in2 = 14.512 PSI
Issue 2
Bar
lbf / in2
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
7.256
14.510
21.770
290.00
36.280
43.540
50.800
58.800
65.300
72.600
79.800
87.100
94.300
101.600
108.800
116.100
123.400
130.600
Bar
9.5
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
19.0
20.0
21.0
22.0
23.0
24.0
25.0
30.0
May 2002
lbf / in2
Bar
137.9
145.0
159.6
174.0
189.0
203.0
218.0
232.0
247.0
261.0
276.0
290.0
309.0
319.0
334.0
348.0
368.0
435
35
40
45
50
60
70
80
90
100
200
300
400
500
600
700
800
900
1000
lbf / in2
508
588
653
726
871
1029
1161
1306
1451
2903
4354
5805
7257
8708
10160
11611
13235
14514
Introduction
1A01.25
Units of torque
1 Nm = 0.7376 lbf/ft
1 lbf/ft = 1.3558 Nm
Nm
lbf/ft
Nm
lbf/ft
Nm
lbf/ft
1.3558
0.7376
46.0972
34
25.0784
90.8396
67
49.4912
2.7116
1.4752
47.4530
35
25.8160
92.1944
68
50.1568
4.0674
2.2128
48.8088
36
26.5536
93.5502
69
50.8944
5.4232
2.9504
50.1646
37
27.2912
94.9060
70
51.6320
6.7790
3.6880
51.5204
38
28.0288
96.2618
71
52.3696
8.1348
4.4256
52.8762
39
28.7664
97.6176
72
53.1072
9.4906
5.1632
54.2320
40
29.5040
98.9734
73
53.8448
10.8464
5.9008
55.5878
41
30.2416
100.329
74
54.5824
12.2022
6.6384
56.9436
42
30.9792
101.685
75
55.3200
13.5580
10
7.3760
58.2994
43
31.7168
103.041
76
56.0576
14.9138
11
8.1136
59.6552
44
32.4544
104.397
77
56.7952
16.2696
12
8.8512
61.0110
45
33.1920
105.752
78
57.5328
17.6254
13
9.5888
62.3668
46
33.9296
107.108
79
58.2704
18.812
14
10.3264
63.7226
47
34.6672
108.464
80
59.0080
20.3370
15
11.0640
65.0784
48
35.4048
109.820
81
59.7456
21.6928
16
11.8016
66.4342
49
36.1424
111.176
82
60.4832
23.0486
17
12.5392
67.7900
50
36.8800
112.531
83
61.2208
24.4044
18
13.2768
69.1458
51
37.6176
113.887
84
61.9584
25.7602
19
14.0144
70.5016
52
38.3552
115.243
85
62.6960
27.1160
20
14.7520
71.8574
53
39.0928
116.600
86
63.4336
28.4718
21
15.4896
73.2132
54
39.8304
117.955
87
64.1712
29.8276
22
16.2272
74.5690
55
40.5680
119.310
88
64.9088
31.1834
23
16.9648
75.9248
56
41.3056
120.666
89
65.6464
32.5392
24
17.7024
77.2806
57
42.0432
122.022
90
66.3840
33.8950
25
18.4400
78.6364
58
42.7808
123.378
91
67.1216
35.2508
26
19.1776
79.9992
59
43.5184
124.734
92
67.8592
36.6066
27
19.9152
81.3480
60
44.2560
126.089
93
68.5968
37.9624
28
20.6528
82.7038
61
44.9936
127.445
94
69.3344
39.3182
29
21.3904
84.0596
62
45.7312
128.801
95
70.0720
40.6740
30
22.1280
85.4154
63
46.4688
130.157
96
70.8096
42.0298
31
22.8656
86.7712
64
47.2064
131.513
97
71.5472
43.3856
32
23.6032
88.1270
65
47.9440
132.868
98
72.2848
44.7414
33
24.3408
89.4828
66
48.6816
134.224
99
73.0224
Issue 2
May 2002
Introduction
1A01.26
Units of Capacity
1 litre = 0.2199 imperial gallon
1 imp. gallon = 4.5459 litres
Imp. gal.
Litres
Imp. gal.
Litres
Litres
Imp. gal.
0.2199
4.5459
7.4766
34
154.561
14.7330
67
304.575
0.4398
9.0918
7.6965
35
159.107
14.9532
68
309.121
0.6597
13.6377
7.9164
36
163.652
15.1731
69
313.667
0.8796
18.1836
8.1363
37
168.198
15.3930
70
318.213
1.0995
22.7295
8.3562
38
172.744
15.6129
71
322.759
1.3194
27.2754
8.5761
39
177.290
15.8328
72
327.305
1.5393
31.8213
8.7960
40
181.836
16.0527
73
331.851
1.7592
36.3672
9.0159
41
186.382
16.2726
74
336.397
1.9791
40.9131
9.2358
42
190.929
16.4925
75
340.943
2.1990
10
45.4590
9.4557
43
195.474
16.7124
76
345.488
2.4189
11
50.0049
9.6756
44
200.019
16.9323
77
350.034
2.6388
12
54.5508
9.8955
45
204.566
17.1522
78
354.580
2.8587
13
59.0967
10.1154
46
209.111
17.3721
79
359.126
3.0786
14
63.6426
10.3353
47
213.657
17.5920
80
363.672
3.2985
15
68.1885
10.5552
48
218.203
17.8119
81
368.218
3.5184
16
72.7344
10.7751
49
222.749
18.0318
82
372.764
3.7383
17
77.2803
10.9950
50
227.295
18.2517
83
377.310
3.9582
18
81.8262
11.2149
51
231.841
18.4716
84
381.856
4.1781
19
86.3721
11.4348
52
236.387
18.6915
85
386.402
4.3980
20
90.9180
11.6547
53
240.933
18.9114
86
390.947
4.6179
21
95.4639
11.8746
54
245.479
19.1313
87
395.493
4.8378
22
100.0090
12.0945
55
250.025
19.3512
88
400.039
5.0577
23
104.5560
12.3144
56
254.570
19.5711
89
404.585
5.2776
24
109.1020
12.5343
57
259.116
19.7910
90
409.131
5.4975
25
113.6480
12.7542
58
263.662
20.0109
91
413.677
5.7174
26
118.1930
12.9741
59
268.209
20.2308
92
418.223
5.9373
27
122.7390
13.1940
60
272.754
20.4507
93
422.769
6.1572
28
127.2850
13.4139
61
277.299
20.6706
94
427.315
6.3771
29
131.8310
13.6338
62
281.846
20.8905
95
431.861
6.5970
30
136.3770
13.8537
63
286.392
21.1104
96
436.406
6.8169
31
140.9230
14.0736
64
290.938
21.3303
97
440.952
7.0368
32
145.4690
14.2935
65
295.483
21.5502
98
445.498
7.2567
33
150.0150
14.5134
66
300.029
21.7701
99
450.044
Issue 2
May 2002
Introduction
1A01.27
Units of Capacity
1 litre = 1.7599 imperial pints
1 imp. pint = 0.5682 litres
Imp. pt.
Litres
Imp. pt.
Litres
Imp. pt.
Litres
1.7599
0.5682
59.8366
34
19.3188
117.913
67
38.0694
3.5198
1.1364
61.5965
35
19.8870
119.673
68
38.6376
5.2797
1.7046
63.3564
36
20.4552
121.433
69
39.2058
7.0396
2.2728
65.1163
37
21.0234
123.193
70
39.7740
8.7995
2.8400
66.8762
38
21.5916
124.953
71
40.3422
10.5594
3.4902
68.6361
39
22.1598
126.713
72
40.9104
12.3193
3.9774
70.3960
40
22.7280
128.473
73
41.4786
14.0792
4.5456
72.1559
41
23.2962
130.233
74
42.0468
15.8391
5.1138
73.9158
42
23.8644
131.993
75
42.6150
17.5990
10
5.6820
75.6757
43
24.4326
133.752
76
43.1832
19.3589
11
6.2502
77.4356
44
25.0008
135.512
77
43.7514
21.1188
12
6.8184
79.1955
45
25.5690
137.272
78
44.3196
22.8787
13
7.3866
80.9554
46
26.1372
139.032
79
44.8878
24.6386
14
7.9548
82.7153
47
26.7054
140.792
80
45.4560
26.3985
15
8.5230
84.4752
48
27.2736
142.552
81
46.0242
28.1854
16
9.0912
86.2351
49
27.8418
144.312
82
46.5924
29.9183
17
9.6594
87.9950
50
28.4100
146.072
83
47.1606
31.6782
18
10.2276
89.7549
51
28.9782
147.832
84
47.7288
33.4381
19
10.7958
91.5148
52
29.5464
149.592
85
48.2970
35.1980
20
11.3640
93.2747
53
30.1146
151.351
86
48.8652
36.9579
21
11.9322
95.0346
54
30.6828
153.111
87
49.4334
38.7178
22
12.5004
96.7945
55
31.2510
154.871
88
50.0016
40.4770
23
13.0686
98.5544
56
31.8192
156.631
89
50.5698
42.2376
24
13.6368
100.3140
57
32.3874
158.391
90
51.1380
43.9975
25
14.2050
102.0740
58
32.9556
160.151
91
51.7062
45.7574
26
14.7732
103.8340
59
33.5238
161.912
92
52.2744
57.5173
27
15.3414
105.5940
60
34.0920
163.671
93
52.8426
49.2772
28
15.9096
107.3540
61
34.6602
165.431
94
53.4108
51.0371
29
16.4778
109.1140
62
35.2284
167.191
95
53.9790
52.7970
30
17.0460
110.8740
63
35.7966
168.950
96
54.5472
54.5569
31
17.6142
112.6340
64
36.3648
170.710
97
55.1154
56.3168
32
18.1824
114.3940
65
36.9330
172.470
98
55.6836
58.0767
33
18.7506
116.1530
66
37.5012
174.230
99
56.2518
Issue 2
May 2002
Introduction
1A01.28
Units of Length
1 m = 3.2808 feet
1 foot = 0.3048 metres
ft
ft
ft
0.3048
3.2808
10.3632
34
111.549
20.4216
67
219.816
0.6096
6.5617
10.6680
35
114.829
20.7264
68
223.097
0.9144
9.8425
10.9728
36
118.110
21.0312
69
226.378
1.2192
13.1234
11.2776
37
121.391
21.3360
70
229.659
1.5240
16.4042
11.5824
38
124.672
21.6408
71
232.940
1.8288
19.6850
11.8872
39
127.953
21.9456
72
236.220
2.1336
22.9659
12.1920
40
131.234
22.2504
73
239.501
2.4384
26.2467
12.4968
41
134.514
22.5552
74
242.782
2.7432
29.5276
12.8016
42
137.795
22.8600
75
246.063
3.0480
10
32.8084
13.1064
43
141.076
23.1648
76
249.344
3.3528
11
36.0892
13.4112
44
144.357
23.4696
77
252.625
3.6576
12
39.3701
13.7160
45
147.638
23.7744
78
255.906
3.9624
13
42.6509
14.0208
46
150.919
24.0792
79
259.186
4.2672
14
45.9318
14.3256
47
154.199
24.3840
80
262.467
4.5720
15
49.2126
14.6304
48
157.480
24.6888
81
265.748
4.8768
16
52.4934
14.9352
49
160.761
24.9936
82
269.029
5.1816
17
55.7743
15.2400
50
164.042
25.2984
83
272.310
5.4864
18
59.0551
15.5448
51
167.323
25.6032
84
275.591
5.7912
19
62.3360
15.8496
52
170.604
25.9080
85
278.871
6.0960
20
65.6168
16.1544
53
173.885
26.2128
86
282.152
6.4008
21
68.8976
16.4592
54
177.165
26.5176
87
285.433
6.7056
22
72.1785
16.7640
55
180.446
26.8224
88
288.714
7.0104
23
75.4593
17.0688
56
183.727
27.1272
89
291.995
7.3152
24
78.7402
17.3736
57
187.008
27.4320
90
295.276
7.6200
25
82.0210
17.6784
58
190.289
27.7368
91
298.556
7.9248
26
85.3018
17.9832
59
193.570
28.0416
92
301.837
8.2296
27
88.5827
18.2880
60
196.850
28.3464
93
305.118
8.5344
28
91.8635
18.5928
61
200.131
28.6512
94
308.399
8.8392
29
95.1444
18.8976
61
203.412
28.9560
95
311.680
9.1440
30
98.4252
19.2024
63
206.693
29.2608
96
314.961
9.4488
31
101.7060
19.5072
64
209.974
29.5656
97
318.241
9.7536
32
104.9870
19.8120
65
213.255
29.8704
98
321.522
10.0584
33
108.2680
20.1168
66
216.535
30.1752
99
324.803
Issue 2
May 2002
Introduction
1A01.29
Units of Weight
1 kg = 2.2046 lb
1 lb = 0.4536 kg
kg
lb
kg
lb
lb
kg
0.4536
2.2046
15.4224
34
74.9564
30.3912
67
147.708
0.9072
4.4092
15.8760
35
77.1610
30.8448
68
149.913
1.3608
6.6138
16.3296
36
79.3656
31.2984
69
152.117
1.8144
8.8184
16.7832
37
81.5702
31.7520
70
154.322
2.2680
11.0230
17.2368
38
83.7748
32.2056
71
156.527
2.7216
13.2276
17.6904
39
85.9794
32.6592
72
158.731
3.1752
15.4322
18.1440
40
88.1840
33.1128
73
160.936
3.6288
17.6368
18.5976
41
90.3886
33.5664
74
163.140
4.0824
19.8414
19.0512
42
92.5932
34.0200
75
165.345
4.5360
10
22.0460
19.5048
43
94.7978
34.4736
76
167.549
4.9896
11
24.2506
19.9584
44
97.0024
34.9272
77
169.754
5.4432
12
26.4552
20.4120
45
99.207
35.3808
78
171.958
5.8968
13
28.6598
20.8656
46
101.412
35.8344
79
174.163
6.3504
14
30.8644
21.3192
47
103.616
36.2880
80
176.368
6.8040
15
33.0690
21.7728
48
105.821
36.7416
81
178.573
7.2576
16
35.2736
22.2264
49
108.025
37.1952
82
180.777
7.7112
17
37.4782
22.6800
50
110.230
37.6488
83
182.982
8.1648
18
39.6828
23.1336
51
112.435
38.1024
84
185.186
8.6184
19
41.8874
23.5872
52
114.639
38.5560
85
187.391
9.0720
20
44.0920
24.0408
53
116.844
39.0096
86
189.596
9.5256
21
46.2966
24.4944
54
119.048
39.4632
87
191.800
9.9792
22
48.5012
24.9489
55
121.253
39.9168
88
194.005
10.4328
23
50.7058
25.4016
56
123.458
40.3704
89
196.209
10.8864
24
52.9104
25.8552
57
125.662
40.8240
90
198.414
11.3400
25
55.1150
26.3088
58
127.867
41.2776
91
200.619
11.7936
26
57.3196
26.7624
59
130.071
41.7312
92
202.823
12.2472
27
59.5242
27.2160
60
132.276
42.1848
93
205.028
12.7008
28
61.7288
27.6696
61
134.481
42.6384
94
207.232
13.1544
29
63.9334
28.1232
62
136.685
43.0920
95
209.437
13.6080
30
66.1380
28.5768
63
138.889
43.5456
96
211.642
14.0616
31
68.3426
29.0304
64
141.094
43.9992
97
213.846
14.5152
32
70.5472
29.4840
65
143.299
44.4528
98
216.051
16.9688
33
72.7518
29.9376
66
145.504
44.9064
99
218.255
Issue 2
May 2002
Introduction
1A01.30
TEMPERATURES
Inches in mm
mm in inches
Fahrenheit to Celsius
Fractions
inches
Decimal
1/64
.015625
0.3969
- 20
- 28.9
- 30
- 22
1/32
.031250
0.7937
- 15
- 26.1
- 28
- 18.4
3/64
.468750
1.1906
- 10
- 23.3
- 26
- 14.8
1/16
.062500
1.5875
0.0001
0.00254
0.004
0.00015
- 5
- 20.6
- 24
- 11.2
5/64
.078125
1.9844
.0002
.00508
0.005
.00019
- 17.8
- 22
- 7.6
3/32
.093750
2.3812
.0003
.00762
0.006
.00023
- 17.2
- 20
- 4
7/64
.109375
2.7781
.0004
.01016
0.007
.00027
- 16.7
- 18
- 0.4
1/8
.125000
3.1750
.0005
.01270
0.008
.00031
- 16.1
- 16
3.2
9/64
.140625
3.5719
.0006
.01524
0.009
.00035
- 15.6
- 14
6.8
5/32
.156250
3.9687
.0007
.01778
0.010
.00039
- 15.0
- 12
10.4
11/64
.171875
4.3656
.0008
.02032
0.020
.00079
10
- 12.2
- 10
14
3/16
.187500
4.7625
.0009
.02286
0.030
.00118
15
- 9.4
- 8
17.6
13/64
.203125
5.1594
.001
.02540
0.040
.00157
20
- 6.7
- 6
21.2
7/32
.218750
5.5562
.002
.05080
0.050
.00197
25
- 3.9
- 4
24.8
15/64
.234375
5.9531
.003
.07620
0.060
.00236
30
- 1.1
- 2
28.4
1/4
.250000
6.3500
.004
.10160
0.070
.00276
35
1.7
32
17/64
.265625
6.7469
.005
.12700
0.080
.00315
40
4.4
35.6
9/32
.281250
7.1437
.006
.15240
0.090
.00354
45
7.2
39.2
19/64
.296875
7.5406
.007
.17780
0.100
.00394
50
10.0
42.8
5/16
.312500
7.9375
.008
.20320
0.200
.00780
55
12.8
46.4
21/64
.328125
8.3344
.009
.22860
0.300
.01181
60
15.6
10
50
11/32
.343750
8.7312
.01
.25400
0.400
.01575
65
18.3
12
53.6
23/64
.359375
9.1281
.02
.50800
0.500
.01969
70
21.1
14
57.2
3/8
.375000
9.5250
.03
.76200
0.600
.02362
75
23.9
16
60.8
25/64
.390625
9.9219
.04
1.01600
0.700
.02756
80
26.7
18
64.4
13/32
.406250
10.3187
.05
1.27000
0.800
.03149
85
29.4
20
68
27/64
.421875
10.7156
.06
1.52400
0.900
.03543
90
32.2
22
71.6
7/16
.437500
11.1125
.07
1.77800
1.900
.03937
95
35.0
24
75.2
29/64
.453125
11.5094
.08
2.03200
2.900
.07874
100
37.8
26
78.8
15,32
.468750
11.9062
.09
2.28600
3.900
.11811
105
40.6
28
82.4
31/64
.484375
12.3031
.10
2.54000
4.900
.15748
110
43.3
30
86
1/2
.500000
12.7000
.20
5.08000
5.900
.19685
115
46.1
32
89.6
33/64
.515625
13.0969
.30
7.62000
6.900
.23622
120
48.9
34
93.2
17/32
.53125
13.4937
.40
10.16000
7.900
.27559
125
51.7
36
96.8
Issue 2
mm
Inches
mm
mm
May 2002
Inches
Introduction
1A01.31
LENGTHS
1 Pouce (inch) = 25.4 mm
Fractions
of inches
Decimal
mm
Inches in mm
Inches
TEMPERATURES
Fahrenheit to Celsius
mm in inches
mm
mm
Inches
35/64
.546875
13.8906
0.5
12.70
0.31496
130
54.4
38
100.4
9/16
.562500
14.2875
.6
15.24
.35433
135
57.2
40
104.0
37/64
.578125
14.6844
.7
17.78
10
.39370
140
60.0
42
107.6
19/32
.593750
15.0812
.8
20.32
11
.43307
145
62.8
44
112.2
39/64
.609375
15.4781
.9
22.86
12
.47244
150
65.6
46
114.8
5/8
.625000
15.8750
25.40
13
.51181
155
68.3
48
118.4
41/64
.640625
16.2719
50.80
14
.55118
160
71.1
50
122.0
21/32
.656250
16.6687
76.20
15
.59055
165
73.9
52
125.6
43/64
.671875
17.0656
101.60
16
.62992
170
76.7
54
129.2
11/16
.687500
17.4625
127.00
17
.66929
175
79.4
56
132.8
45/64
.703125
17.8594
152.40
18
.70866
180
82.2
58
136.4
23/32
.718750
18.2562
177.80
19
.74803
185
85.0
60
140.0
47/64
.734375
18.6531
203.20
20
.78740
190
87.8
62
143.6
3/4
.750000
19.0500
228.60
21
.82677
195
90.6
64
147.2
49/64
.765625
19.4469
10
2540.0
22
.86614
200
93.3
66
150.8
25/32
.781250
19.8437
11
279.40
23
.90551
205
96.1
68
154.4
51/64
.796875
20.2406
12
304.80
24
.94480
210
98.9
70
158.0
13/16
.812500
20.6375
13
330.20
25
.98425
212
100.0
75
167.0
53/64
.828125
21.0344
14
355.60
26
1.02362
215
101.7
80
176.0
27/32
.843750
21.4312
15
381.00.
27
1.06299
220
104.4
85
185.0
55/64
.859375
21.8281
16
406.40
28
1.10236
225
107.2
90
194.0
7/8
.875000
22.2250
17
431.80
29
1.14173
230
110.0
95
203.0
57/64
.890625
22.6219
18
457.20
30
1.18110
235
112.8
100
212.0
29/32
.906250
23.0187
19
482.60
31
1.22047
240
115.6
105
221.0
59/64
.921875
23.4156
20
5080.0
32
1.25984
245
118.3
110
230.0
15/16
.937500
23.8125
21
533.40
33
1.29921
250
121.1
115
239.0
61/64
.953125
24.2094
22
558.80
34
1.33858
31/32
.968750
24.6062
23
584.20
34
1.37795
63/64
.984375
25.0031
24
609.60
36
1.41732
1.000000
25.4000
25
635.00
37
1.45669
26
660.40
38
1.49606
39
1.53543
40
1.57480
Issue 2
May 2002
Introduction
1A01.32
Loctite
industrial name
Brand
AGCO
reference
Frenetanche
3 930 904 M1
270
Frenbloc
3 405 352 M5
510 - 221
Formajoint
3 900 613 M2
638 - 648
Scelbloc
1 633 268 M2
Silicomet
Auto-joint clair
3 405 423 M2
Issue 2
May 2002
Note:
a) Apply the minimum quantity of product required in
order to avoid sticking adjacent parts.
b) Do not further tighten or loosen bolts after 5 minutes
of polymerisation in order not to break the film.
c) If the ambient temperature is less than +10 C and
in order to speed up the process (except with
SILICOMET), after operation 2 use LOCTITE T 747
quick setting on at least one of the parts. Any excess
of product outside the sealed area will not harden
(anaerobic product polymerises only in the absence of oxygen).
Grease
When grease is used in components that are in contact
with transmission oil, employ a miscible grease to avoid
clogging the hydraulic filters.
Use Amber Technical grease, supplied by WITCO
76320 Saint-Pierre les Elbeuf.
Introduction
1A01.33
H . Tightening torques
Use the recommended tightening torques for nuts and
bolts in accordance with tables:
- 1 and 2: for metric threads
- 3 and 4: for non-metric threads
Where a particular torque is required, it is mentioned in
the text.
Tables 1 and 3 indicate the normal values of the tightening torques applicable with zinc-plated threaded elements with normal nuts, coarse or fine threads, with or
without flat or lock washers, and weld nuts having a
height greater than 0.8 d.
Tables 2 and 4 indicate the lower torque values applicable to threaded elements in assemblies using selflocking safety nuts, zinc-plated, phosphate coated nuts
and bolts, flat nuts, and weld nuts having a height less
than 0.8 d.
These values apply to all dry assemblies. If the threads
are lubricated, reduce the tightening torques in consequence.
Example:
8,8
Issue 2
May 2002
Introduction
1A01.34
Table 1
Tightening torque values: zinc-plated metric threads
Nominal
dimension d.
M3
M4
M5
M6
M8
M10
M12
M16
M20
M24
M30
M36
Strength classification
Strength classification
Torque Nm
Torque Nm
Max
Min
1.7
4.1
8.7
14.7
35.7
70.7
120.7
260.7
560.7
960.7
1800.7
3300.7
1.3
3.1
6.7
10.7
25.7
50.7
90.7
200.7
420.7
720.7
1400.7
2500.7
Min
Max
2.4
5.7
11.5
20.7
46.7
96.7
160.7
400.7
800.7
1300.7
2800.7
4800.7
1
4
8
14
36
72
120
300
600
1000
2100
3600
Table 2
Reduced tightening torque values: metric threads
Nominal
dimension d.
Strength classification
Strength classification
Torque Nm
Torque Nm
Max
M3
M4
M5
M6
M8
M10
M12
M16
M20
M24
M30
M36
Issue 2
1.4
3.3
6.4
11.7
28.7
56.7
96.7
210.7
450.7
770.7
1400.7
2600.7
Min
1
2.5
4.8
8.7
20.7
40.7
72.7
160.7
340.7
570.7
1100.7
2000.7
May 2002
Max
1.9
4.6
9.2
16.7
37.7
77.7
130.7
320.7
640.7
1040.7
2200.7
3800.7.7
Min
1
3
6
12
29
57
100
240
480
800
1700
2900
Introduction
1A01.35
Table 3
Tightening torque values: zinc-plated non-metric threads
Nominal
dimension d.
#6
#8
#10
1/4
5/16
3/8
7/16
1/2
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
Strength classification
Strength classification
Torque Nm
Torque Nm
Max
Min
2.4
4.4
6.3
15.7
30.7
53.7
86.7
130.7
260.7
460.7
760.7
1120.7
1390.7
2000.7
3400.7
1.8
3.4
4.7
11.7
22.7
39.7
64.7
100.7
200.7
350.7
560.7
840.7
1050.7
1500.7
2600.7
Min
Max
3.3
6.3
8.9
22.7
43.7
75.7
120.7
180.7
370.7
660.7
1060.7
1600.7
2200.7
3200.7
5400.7
2
4
6
16
31
55
90
140
280
490
800
1200
1700
2400
4100
Table 4
Tightening torque values: zinc-plated non-metric threads
Nominale
dimension d.
#6
#8
#10
1/4
5/16
3/8
7/16
1/2
5/8
3/4
7/8
1
1 1/8
1 1/4
1 1/2
Strength classification
Strength classification
Torque Nm
Torque Nm
Max
Min
1.9
3.5
5.7
12.7
24.7
42.7
69.7
104.7
210.7
370.7
610.7
900.7
1100.7
1600.7
2700.7
1.5
2.7
3.8
8.8
18.7
31.7
51.7
80.7
160.7
280.7
450.7
670.7
840.7
1200.7
2100.7
Max
Issue 21
Issue
2.6
5.6
7.1
18.7
34.7
60.7
96.7
140.7
300.7
530.7
850.7
1280.7
1760.7
2560.7
4320.7
Min
2
3.
5
13.
25
44
72
110
220
390
640
960
1360
1920
3280
May 2002
2002
May
Contents
2A01
2B01
2C01
2D01
2E01
2F01
CHASSIS REINFORCEMENTS
2G01
Issue 1
May 2001
2A01.1
CONTENTS
General ________________________________________________
A.
B.
Disassembling __________________________________________
C.
Reassembling __________________________________________
D.
E.
F.
11
Issue 12
May 2001
2002
General
This section presents a general disassembly procedure.
Due to the diversity of the hydraulic or mechanical
options available on the 8200 series tractors, mention
will only be made of those pipes or main connections to
be disconnected.
For this reason, before and when disassembling the
tractor, ensure no connections remain between the fixed
assembly and the moving assembly.
Disassembling the front frame and the engine allows
working on the mechanical parts located at the front of
the engine.
A . Preliminary operations
1. Remove the side panels. Unlock and hinge open the
bonnet, or remove (if necessary).
Position of locks:
- tractors 8210 8220 and 8240 to 8260: below the
front nose assembly;
- tractors 8270 and 8280: below the front nose
assembly, on the rear left-hand side of the bonnet.
Disconnect the battery terminals.
2. Disconnect the front differential-locking control pipe
at both ends (front axles AG155H and AG200) (blank
the pipe).
Remove the transmission guard and shaft (4 WD)
(all tractor types).
3. Remove the guards located either side of the radiator.
4. Disconnect the horn wiring harness located inside
the nose assembly.
5. Mark then disconnect the steering hoses from the
side pipes fitted on the engine mount. Blank the
pipes.
6. Disconnect the vacuum-gauge harness. Remove
the suction pipe from the air cleaner above the
radiator.
7. Drain the cooling system.
8. On the radiator, disconnect:
- the hoses (lower and upper),
- the hose connecting the radiator and the expansion
tank.
9. Remove the cleat above the radiator.
10. Mark the position then disconnect the following
hoses:
Full Powershift gearbox
- the hoses from the cooler to the thermostatic
valve.
Heavy Duty gearbox
- the cooler hoses routed to the right-hand hydraulic
cover.
Issue
Issue 12
May
May 2002
2001
Fig. 1
11. Disconnect the air conditioning intakes at the front
left of the cab. Fit blanking plugs.
12. Remove the compressor from its mounting and tilt
forward without disconnecting the hoses.
13. If necessary, remove the steering cylinder (front
axles AG155H and AG200H) to gain access to the
screws securing the frame to the engine.
14. Remove the chassis reinforcements located either
side of the engine (if installed) (see section 2F01).
Set the handbrake and block front axle (1), using
suitable chocks "C" (Fig. 1). Chock the rear wheels.
15. Remove one screw (3) (Fig. 2 - 3) on each front
engine mount, replacing by two guide studs of
sufficient length.
2A01.3
2
3
1
A : Perkins engine
B : Valmet engine
Issue 1
Fig. 3
Fig. 2
May 2001
B
A : Front axles AG155H or AG200H
B : Front axle ZF5052
C : 2 WD axle
Fig. 2
Issue 1
May 2001
Fig. 3
2A01.5
B . Disassembling (Fig. 4)
D . Final operations
22. Remove the shims between the frame and the front
axle.
If necessary, reinstall the chassis reinforcements (s
2F01) and the front weights.
23. If disassembled, reinstall the steering cylinder. Apply a light coating of Loctite 270 then torque the
screws to 180 - 200 Nm and torque ball nuts to 140
- 155 Nm. Lock the nuts using new pins.
24. Tilt the compressor towards the rear and rest it on the
support.
25. Remove the blanking plugs. Reconnect the air conditioning intakes.
26. Reconnect the hoses, reverse operation 10.
27. Reinstall the cleat above the radiator.
28. On the radiator, reconnect:
- the hoses (lower and upper),
- the hoses connected to the radiator seat and the
expansion tank.
29. Service the cooling system and the expansion tank.
30. Reinstall the suction pipe on the air cleaner above the
radiator.
Danger
- Ensure there is no risk of accidental tipping of the front
frame assembly during the disassembly operation.
C . Reassembling
20. Assemble the frame with the engine.
21. Remove the guide studs. Install and torque the
screws as follows (Fig. 2 - 3) :
- (1) : 670 - 900 Nm
- (2) : 520 - 640 Nm
- (3) : 300 - 400 Nm
Fig. 4
Issue 12
May 2002
2001
Issue 1
May 2001
2A01.7
Preliminary operations
1
Fig. 5
39. Set the handbrake and immobilize the front axle (5)
using triangular chocks C (Fig. 5). Chock the rear
wheels.
40. Remove the front weights (if fitted).
41. Remove the side panels. Unlock the bonnet and
hinge it open. Use a rope to hold the bonnet open and
disconnect the lower clamps on the holding cylinders.
42. Disconnect the negative terminals on the batteries on
the right-hand side of the tractor.
43. Remove the guards (2) (2A) and the universal drive
shaft (see section 8F03).
44. Remove the guards located either side of the radiator.
45. Remove the clamp that holds the tubes, hoses and
harnesses above the radiator.
46. Remove the chassis reinforcements on either side of
the engine (if fitted).
47. Mark and disconnect all the hydraulic or electric
unions connected to the frame / front axle and
steering cylinder unit, but leave the air conditioning
hoses in place.
Note
- These links are located above the radiator and on
the right- and left-hand sides of the tractor.
48. Remove the air filter intake pipe above the radiator.
49. Drain the cooling system.
Issue
Issue 11
May
May 2001
2002
Disassembling
Danger
- Remove the belly weight (if fitted).
54. Position a fixed axle stand under the engine sump.
55. Position a movable axle stand under the front axle in
the longitudinal axis of the tractor, or use a suitable
lifting fixture.
56. Finish removing the other attachment screws (1) (2)
(3) (Fig. 6 - 8) from the engine frame.
Fig. 7
Issue 11
May 2001
2002
2A01.9
B
3
Issue
Issue 1
May
May 2002
2001
Reassembling
58. Assemble the frame with the engine.
59. Remove the guide studs. Fit screws and torque to
(Fig. 8):
- (1) : 670 900 Nm
- (2) : 520 640 Nm
- (3) : 300 400 Nm
1
3
2
Issue 11
May 2002
2001
Fig. 8
2A01.11
Final operations
60. Refit the steering cylinder.
61. Refit the condenser.
62. Reconnect all the cooling hoses.
63. Refit the air filter intake pipe.
64. Reconnect the hydraulic and electric unions.
65. Refit the clamp above the radiator.
66. Reinstall the radiator side guards.
67. Refit the universal drive shaft and the guards (2) (2A).
68. Reconnect the negative terminals to the batteries.
69. Top up the fluid level in the cooling system and the
expansion tank.
70. Start the engine. Check the electrical equipment for
proper operation and check for hydraulic tightness:
- of hydraulic hoses and unions
- of hoses.
Fig. 9
F. Service tools
Tools available in the AGCO network
- 3376935M91 Set of plugs for air conditioning
unions (Fig. 9).
Issue 11
May 2002
2001
2B01.1
CONTENTS
-
General ________________________________________________
A.
B.
Disassembling __________________________________________
C.
Reassembling __________________________________________
D.
10
E.
11
Issue 2
May 2002
Issue 2
May 2002
A . Preliminary operations
1. Remove the side panels. Unlock and hinge open the
bonnet, or remove (if necessary).
Position of locks:
- tractors 8210-8220 and 8240 to 8260: below the front
nose assembly,
- tractors 8270 and 8280: below the front nose assembly, on the rear left-hand side of the bonnet.
2. Remove the front weights. Disconnect the battery
terminals.
3. Remove the turbocharger guard.
4. Remove the vertical exhaust assembly, the pipe
sleeve-fitted on the turbo, and the flexible sleeve
connected to the air cleaner.
5. Disconnect the front differential lock control pipe at
both ends (if fitted). Blank the pipe. Remove the
transmission guard and shaft (4 WD) (all tractor
types).
2B01.3
Issue 2
May 2002
14. Set the handbrake and block front axle (1) using
appropriate chocks "C" (Fig. 1). If necessary, remove
the chassis reinforcements (see section 2F01).
15. If required, raise the cab slightly and wedge in place.
Note: If the side tank was not removed, check
the condition of the flexible unions between the
tanks and the filler pipe hose connection.
On Heavy Duty gearboxes, check the condition
of the gear control and reverser lifting arm and
the selector cover. If the gear lifting arm interferes with raising of the cab, disconnect it (see
sections 5C01 - 5C02 and 5C03 depending on
option).
16. Remove screws (3) placed either side of the engine
(1) and gearbox (2) (Fig. 2 or 3 depending on version).
Replace with two guide studs of suitable length.
Note: If necessary, remove the access door set in
the inner floor of the cab, to gain easier access
to the upper screws fixing the engine to the
gearbox.
Fig. 1
Fig. 2
Issue 2
May 2002
Fig. 3
2B01.5
B . Disassembling (Fig. 4)
17. Position the disassembly tooling.
18. Finish removing the other attachment screws securing the engine on the gearbox.
19. Assisted by an operator, separate the assemblies.
(1)
(2)
(3)
(4)
4
2
Fig. 4
Issue 2
May 2002
C . Reassembling
Fig. 5
Issue 2
May 2002
2B01.7
Fig. 6
Issue 2
May 2002
Issue 2
May 2002
2B01.9
Fig. 7
1
2
F
AG150
3
4
5
6
9
Heavy Duty
F
7
F
10
Fig. 8
Issue 2
May 2002
D . Final operations
27. If the cab was raised, reposition it on its front
supports. On tractors fitted with the Heavy Duty
gearbox, monitor the behaviour of the gear control
lifting arm during refitting of the cab. If necessary,
reinstall and adjust the gear lifting arm (see section
5C01 - 5C02 or 5C03 depending on option). Install
and screws in silent blocks and torque to 200 270 Nm.
28. Remove the disassembly tooling.
29. Remove the chocks from the front axle. Reinstall
and if necessary adjust the chassis reinforcements
(see section 2F01).
30. Reinstall the engine oil filter (Valmet only).
Special point:
- The filter must be in contact with its support;
tighten it through an extra quarter-turn approximately.
31. Reconnect the steering-cylinder hoses.
32. Reconnect the main harness connections.
33. Assemble the air conditioning intakes.
34. Reconnect the heating hoses under the cab or on the
engine (depending on option).
35. Reconnect the throttle control at the fuel injection
pump.
If necessary, reinstall the guards located either side
of the radiator.
36. If disassembled, reinstall the side tank and reconnect the gauge harness, the gas-oil supply and the
return hoses.
37. Reinstall the starter. Tighten the screws. Reconnect
the harness.
38. Reconnect the hoses, reversing operation 6.
39. Reinstall the transmission shaft and guard. Reconnect the differential lock control pipe (4 WD)(if fitted).
40. Reinstall the flexible pipe connection, the tube on the
turbocharger and the vertical exhaust assembly.
Install the Guard.
41. Reconnecting the battery terminals.
42. Check the setting of the throttle control.
43. If the side tank was removed, pour fuel into the
tanks. Service the cooling system and the expansion tank.
Issue 21
May 2002
44.
45.
46.
47.
2B01.11
E . Service tools
Tools available in the AGCO network
- 3376935M91 - Set of plugs for air conditioning
couplings (Fig. 9).
Fig. 9
Issue 21
May 2002
2C01.1
CONTENTS
General ________________________________________________
A.
B.
Disassembling __________________________________________
C.
Reassembling __________________________________________
D.
E.
F.
Issue 12
May 2002
2001
General
This section presents a general disassembly procedure.
Due to the diversity of the hydraulic and mechanical the
options available on the 8200-Series tractors, mention
will only be made of those the pipes or main connections
to be disconnected.
For this reason, before and when disassembling the
tractor, ensure no connections remain between the fixed
assembly and the moving assembly.
The 8200-Series tractors may be equipped with either a
Full Powershift gearbox, or a Heavy Duty gearbox.
Disassembly remains basically identical for both versions.
A . Preliminary operations
1. Position the rear wheels in wide tread.
2. Remove the side panels. Unlock and hinge open the
bonnet and remove (if necessary).
Position of locks:
- tractors 8210-8220 and 8240 to 8260: below the front
nose assembly,
- tractors 8270 and 8280: below the front nose assembly, on the rear left-hand side of the bonnet.
3. Disconnect the battery terminals.
4. Remove the battery compartment and the right footstep.
5. Remove the turbocharger guard.
6. Disconnect the front differential-locking control pipe at
both ends ((if fitted). Blank the pipe.
7. Remove the guard and the 4 WD transmission shaft
(all tractor types).
Issue 1
May 2001
2C01.3
AG 250
AG 150
Fig. 1
Fig. 1A
Issue 1
May 2001
B . Disassembling (Fig. 2)
Separating the gearbox from the intermediate housing (Fig. 2)
27. In order to free lower shaft (2) (Fig. 3 - 3A), turn the
special screw on the Park lock control unit clockwise until a hard point is felt (see section 6F01, Full
Powershift gearbox only).
28. Install the disassembly tooling (see E).
29. Remove the screw attaching the gearbox to the
housing.
30. Assisted by an operator, separate the assemblies,
taking care to identify the position of the coupling
sleeves on connection shafts (1) and (2) (Fig. 3).
2
Fig. 3
1
Fig. 3A
Fig. 2
Issue 12
May 2002
2001
2C01.5
C . Reassembling
Assembling the gearbox and the intermediate housing
19
8
1
1
Section Y Y
Fig. 4
Issue 1
May 2001
D . Final operations
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
Issue 1
May 2001
Fig. 5
2C01.7
Fig. 6
E . Service tools
Tools available in the AGCO network:
- 3376935M91 - Set of plugs for air-conditioning couplings (Fig. 9)
Issue 12
May 2001
2002
Preliminary operations
Special point
68. Mark then disconnect the hoses coming from the
right-hand hydraulic cover to the cooler. Blank the
hoses and ports.
69. On the gearbox, mark then demate the connectors
on the solenoid valves at the Dynashift valve (version with mechanical reverse shuttle) or at the clutch
control unit (version with power shuttle).
70. Remove the chassis reinforcements located either
side of the gearbox (if installed, see section 2F01).
Remove:
- the pipes near the clutch control valve and remove
latter, without disconnecting the hose coming
from the master-cylinder (version with mechanical
reverse shuttle).
- the pipes near the clutch control unit (version with
power shuttle).
71. Remove clutch lube pipe (17) located between
intermediate housing (19) and spacer (16) (Fig. 7 7B).
72. Remove the 17-bar pipe coming from the right-hand
hydraulic cover to the selector cover and the 17-bar
hose feeding to the power-assisted braking.
73. Disconnect the end of the gearbox lube pipe fitted on
the outlet of the right-hand hydraulic cover.
Issue 12
May 2002
2001
2C01.9
19
16
17
Fig. 7
Fig. 7A
Version with power shuttle
19
16
17
Fig. 7B
Issue
Issue 12
May
May 2002
2001
47
Fig. 8
Issue 12
May 2002
2001
2C01.11
19
5
1
6
5
8
1
8
19
(8) Gearbox
(19) Intermediate housing
Fig. 9
Issue 12
May 2001
2002
Issue 12
May 2002
2001
Fig. 10
2C01.13
Final operations
Special point
85. During positioning of the cab, check the behaviour of
the gear control lifting arm. Reinstall and adjust the
gear lifting arm (see section 5C01 - 5C02 or 5C03
depending on version).
86. Reconnect and adjust the control cables of the
mechanical reverse shuttle (see section 5C01).
87. Reinstall or reconnect the following items on the
selector cover:
- creeper control, if fitted (see section 5K01),
- return hose from power-assisted braking and return
hose from Orbitrol steering unit,
- return hose from brake master-cylinder tank,
- harness of temperature sensor and Hare/Tortoise
solenoid valve.
88. Perform the following operations:
- reconnect the transmission lube pipe,
- reinstall the 17-bar pipe on the selector cover, and
the 17-bar hose feeding to the power-assisted
braking,
- reinstall lube pipe (17) (Fig. 8),
- clean the mating surfaces of the clutch valve or of
the clutch control unit (depending on version) and of
the housing.
- coat the mating face of the housing with sealing
product Loctite 510 or equivalent,
- reinstall the clutch control valve (version with
mechanical reverse shuttle) or the clutch control
unit (version with power shuttle).
Torque the screws to 25 - 35 Nm. Reconnect the
pipes and the solenoid valve connectors on the
Dynashift valve or on the clutch control unit (depending on version).
- Fit the solenoid-valve connectors onto the of
Dynashift valve.
- Reconnect the cooler hoses, observing the markings made during disassembly.
89. Reinstall the side tank. Reinstall and adjust the
chassis reinforcements (see section 2F01).
Issue 1
Issue
May 2002
2001
May
8200 SERIES-TRACTORS
2D01.1
CONTENTS
General ________________________________________________
A.
B.
Disassembling __________________________________________
C.
Reassembling __________________________________________
D.
Issue 2
May 2002
General
This Section presents a general disassembly procedure.
Due to the diversity of the hydraulic or mechanical
options available on the 8200-Series tractors, mention
will only be made of those pipes or main connections
requiring to be disconnected.
For this reason, before and when disassembling the
tractor, ensure no connections remain between the fixed
assembly and the moving assembly.
The 8200-Series tractors may be equipped with either a
Full Powershift gearbox, or a Heavy Duty gearbox.
Disassembly remains basically identical for both versions.
A . Preliminary operations
1. Set the lifting arm to the fully DOWN position.
2. Position the rear wheels in wide tread.
3. Remove the side panels. Unlock and hinge open the
bonnet.
Position of locks:
- Tractors 8210-8220 and 8240 to 8260: below the
front nose assembly;
- Tractors 8270 and 8280: below the front nose assembly, on the rear left-hand side of the bonnet.
4. Disconnect the battery terminals;
5. Disconnect the front differential-locking control pipe at
both ends (if fitted). Blank the pipe. Remove the guard
and (4 WD) transmission shaft (all tractor types).
6. Remove the left footstep and if necessary, the right
footstep and battery compartment.
7. Drain the fuel tanks.
Issue 2
May 2002
8200 SERIES-TRACTORS
2D01.3
AG 250
AG
150
Fig. 1
Issue 2
May 2002
19
16
17
Fig. 2
Version with power shuttle
19
16
17
Fig. 2A
Issue 2
May 2002
8200 SERIES-TRACTORS
2D01.5
B . Disassembling
Separating the gearbox from the intermediate housing
19. For tractors fitted with Park lock transmission locking, free lower shaft (2) (see section 2C01, Fig. 3) by
turning the special screw on the unit located on the
right-hand side of the intermediate housing clockwise until a hard point is felt (see section 6F01).
20. Install the disassembly tooling.
21. Remove the screws securing the gearbox to the
intermediate housing.
Issue 2
Fig. 3
May 2002
Fig. 5
(1)
(2)
(3)
(4)
1
Fig. 4
Issue 2
May 2002
8200 SERIES-TRACTORS
2D01.7
Fig. 6
C . Reassembling
Assembling the intermediate housing and
the centre housing
29. Clean the mating surfaces of the housings.
30. Coat the mating face of the centre housing with
sealing product - Loctite 510 or equivalent.
31. Check for presence and position of locating pin (1)
sleeve- itted into the centre housing (Fig. 7).
Note: The stud has two flats positioned parallel
with the centre line of the housing (Fig. 7).
32. If removed, reposition PTO shaft (28), checking the
position of land "D" (Fig. 7).
33. Screw two guide studs at diametrically opposite
positions on the centre housing.
34. Assemble the intermediate housing to the centre
housing. Turn the pump driving pinion in order to
mate the splines of shaft (28) with the splines on the
PTO clutch.
35. Remove the guide studs. Install screws (2) and
torque to 300 - 400 Nm.
36. Clean the mating surfaces of intermediate housing
(19) and cover (3) (Fig. 7).
Issue 2
May 2002
2D01.8
19
28
Fig. 7
Issue 2
May 2002
8200 SERIES-TRACTORS
2D01.9
D . Final operations
41. Reconnect the following items:
- PTO sensors
- position and status sensors
- solenoid valves (MoveUp - MoveDown) on lift
control valve
- load sensors
- switch harnesses (low pressure and clogging)
- solenoid-valve harness on the right-hand hydraulic
cover and Park lock transmission locking on intermediate housing (if installed)
- clutch lube pipe (17) (Fig. 2 - 2A) on Heavy Duty
gearbox
- suction pipe (1) at Gerotor pump and sleeves (Full
Powershift gearbox) (Fig. 1)
- creeper-speed control (if fitted) - for adjustment
instructions, see section 5K01 or 6H01, depending
on version)
- the supply and pilot-flow hoses to the Orbitrol
steering unit on the priority block(s)
- the 17 bar pipe on the right-hand hydraulic cover
(Heavy Duty gearbox),
- the cooler hoses routed to the right-hand hydraulic
cover (Heavy Duty gearbox)
- the 17-bar hose to the power-assisted braking on
the right-hand hydraulic cover
- the hoses on the brake pipes
- the return hose from the brake tank on the intermediate housing (Full Powershift gearbox)
42. Rest the cab on its rear supports (Fig. 8). Install the
screws in the silent blocks. Torque nuts (1) to 27 35 Nm and locknuts (2) to 13 - 20 Nm (installed with
Loctite 270). Reinstall and if necessary adjust the
chassis reinforcements (see section 2F01).
43. Reconnect the hoses of the compensating spool
valves and the control cables of the auxiliary spool
valve units (see section 9D01 B).
44. Reinstall the side tank.
45. Reconnect:
- the gas-oil supply and return hoses,
- the tank-gauge harness.
46. Reinstall the transmission shaft and guard.
47. Reconnect the front differential-locking control pipe
(if fitted).
2
Fig. 8
Issue 2
May 2002
Issue 12
May 2002
2E01.1
CONTENTS
A.
B.
Disassembling __________________________________________
C.
Reassembling __________________________________________
D.
Issue 1
May 2001
A . Preliminary operations
Fig. 1
2
2
2
1
4
Fig. 2
Issue 1
May 2001
Fig. 3
2E01.3
B . Disassembling (Fig. 4)
C . Reassembling (Fig. 4)
8. Remove the remaining screws. Unstick and disengage the PTO housing from the centre housing by
levering, then remove using suitable lifting equipment.
Note:
- The PTO housing comes out complete with the
clutch and driving/driven pinions. Shaft (28) remains
in the intermediate housing and centre housing.
28
4
12
24
20
7
18
12
1
7
18
Fig. 4
Issue 1
May 2001
D . Final operations
18.
19.
20.
21.
Issue 1
May 2001
2F01.1
CONTENTS
A.
General ________________________________________________
B.
Issue 1
May 2001
Issue 1
May 2001
2F01.3
3
A . General
The side-rails placed either side of the engine reinforce
the tractor chassis.
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
Perkins engine
Valmet engine
Heavy Duty gearbox
Full Powershift gearbox
Cab support
Crossbeams or side-rails
Torque values
Screw (7): 420-560 Nm
Screw (8): 480-640 Nm, plus Loctite 270 or equivalent
1
Fig. 1
Fig. 2
Fig. 3
4
c : Tractors 8250-8260
- Valmet engine
- Full Powershift AG250 gearbox
2
5
d : Tractors 8270-8280
- Valmet engine
- Full Powershift AG250 gearbox
Danger
- The chassis reinforcements are heavy items. They must
be handled with care, with presence of an operator
and possibly suitable lifting equipment.
8
b
c
8
6
d
Parts list
Issue 1
May 2001
Fig. 2
Fig. 3
Fig. 1
2F01.4
Notes:
Tractors 8240-8250 (Valmet engine) fitted with a Heavy
Duty transmission have additional reinforcements located of each side of the gearbox (Fig. 2).
These comprise two crossbeams maintained as follows:
- at the front, on the gearbox spacer,
- at the rear, on the intermediate housing of the rear axle.
Tractors 8210-8220 (Perkins engine) may be fitted with
the type of reinforcements described previously, provided that the "Front lifting arm" option is envisaged.
2
1
6
7
3
F
2
10
11
19
11
9
10
7
2
8
1
6
3
Bottom view
Fig. 3
Fig. 2
Parts list
Fig. 1
Parts list
Fig. 3
Issue 1
May 2001
Fig. 1
Fig. 2
2F01.5
Issue 1
May 2001
2G01.1
CONTENTS
General ________________________________________________
A.
B.
11
C.
15
Issue 1
May 2001
General
The 8200 tractors are fitted with quite different stub axles
whose specifications vary depending on the type of
trumpet (Figs. 1 to 8) and the transmissible torque:
- Flange shaft (3): 82 mm (Fig. 1),
- Long straight shaft (3) (smooth), short or long: 95 or
110 mm (Fig. 2 to 8).
Allocations
Tractors 8210 and 8220:
- Flange shafts: 82 mm or
- Long straight shafts: 95 mm
Tractors 8240 and 8250:
- Long straight shafts: 95 mm or 110 mm
Tractors 8260 to 8280:
- Long straight shafts: 110 mm
Changing tread is obtained:
- either by driving then locking the taper-fitting (long
straight shaft),
- or by turning over the rim and/or the disk (flange shaft).
The material used for making the rim disk may be steel
or cast iron.
The contour of the disk is also different depending on the
buyers option.
Issue 1
May 2001
(3)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Stubshaft
Circlip
Plastic plug
Single cone
Washer
Spline
Spline
Adaptor
Washer
2G01.3
Tightening torque
- Nuts (1): 400 - 450 Nm
3
1
Fig. 1
Issue 1
May 2001
Tightening torque
Heavy Duty
Heavy Duty sealed
with composite reducer
Long straight shaft (smooth): 95 mm with single cone
and adaptor
- "Steel" disc
13
4
9
5
Fig. 2
Issue 1
May 2001
Tightening torque
Heavy Duty
Heavy Duty sealed
with composite reducer
Long straight shaft (smooth): 95 mm with single cone
and adaptor
- "Steel" disc.
2G01.5
Fig. 3
Issue 1
May 2001
2G01.6
Tightening torque
- Nuts (2): 250 - 350 Nm
- Nuts (4): 640 - 680 Nm
- Screws (5): 350 - 460 Nm
3
2
4
5
6
8
10
11
12
Fig. 4
Issue 1
May 2001
Heavy Duty
Heavy Duty sealed
with composite reducer
Long straight shaft (smooth): 95 mm with single
cone
- "Cast iron" disc
2G01.7
Tightening torque
- Nuts (2): 250 - 350 Nm
- Screws (5): 350 - 460 Nm
Fig. 5
Issue 1
May 2001
2G01.8
Parts list (Figs. 6 to 8)
(3)
(6)
(7)
(8)
(10)
(11)
(12)
Tightening torque
Stubshaft
Circlips
"Plastic" plug
Single cones
Spline
Spline
Adaptor
10
11
7
8
12
Fig. 6
Issue 1
May 2001
Tightening torque
2G01.9
Fig. 7
Issue 1
May 2001
Tightening torque
- Nuts (4): 640 - 680 Nm
- Screws (5): 500 - 600 Nm
Fig. 8
Issue 1
May 2001
2G01.11
B . Changing track
Preliminary operations
1. Immobilise the tractor. Set the handbrake.
2. Chock the front wheels.
A
V
12
6
Fig. 9
Issue 1
May 2001
Special point:
- The tapered part of male single cones (8), adaptor (12)
or the "cast iron" disk (depending on option) must not be
greased. Before assembly, clean and dry the parts. On
the other hand, the stubshaft must be lightly coated
with "Antiseize" grease or equivalent, along the full
length, in order to avoid any corrosion spots and thus
facilitate travel movement of the wheel during treadchanging.
Danger
- When removing tractor wheels, use lifting equipment
and a suitable sling.
Issue 1
May 2001
Final operation
14. Remove the chocks from the front wheels, and
release the handbrake.
2G01.13
Long shaft
Min.
Max.
Theoretical tread 1
reinforced axle
sealed trumpet
composite 95
1636
1658
1702
2006
2020
2124
1636
1658
1702
2600
2664
2624
Theoretical tread 2
reinforced axle
sealed trumpet
composite 95
1960
1982
2026
2330
2344
2448
1960
1982
2026
2924
2988
2948
Theoretical tread 3
composite 110
Dual reductions
1632
1674
2054
2052
1632
1664
2554
2552
Theoretical tread 4
composite 110
Dual reductions
1954
2004
2376
2382
1954
1994
2876
2882
Tightening torques
- B = 35 to 46 daNm
- C = 64 to 68 daNm
Tightening torques
- C = 64 to 68 daNm
- D = 50 to 60 daNm
10951.4
10951.3
C
B
Issue 1
C
D
May 2001
2G01.14
Wheels fitted with cast-iron disk, hub with two single cones
Short shaft
Min.
Max.
Long shaft
Min.
Max.
1490
1810
1962
2294
1912
2232
2384
2716
1490
1810
1962
2294
2412
2732
2884
3216
Theoretical tread 5
composite 110
Dual reductions
1418
1460
1840
1838
1418
1450
2340
2338
Theoretical tread 6
composite 110
Dual reductions
1744
1785
2166
2163
1744
1776
2666
2664
Theoretical tread 7
composite 110
Dual reductions
1896
1938
2318
2316
1896
1928
2818
2816
2222
2264
2644
2642
2222
2254
3144
3142
Straight shaft 95
Theoretical treads1
2
3
4
Theoretical tread
- B = 35 46 daNm
- C = 64 68 daNm
- E = 25 35 daNm
Theoretical tread 8
composite 110
Dual reductions
Tightening torques
- C = 64 to 68 daNm
- D = 50 to 60 daNm
- E = 25 to 35 daNm
10951.5
10951.2
C
1
Issue 1
May 2001
2G01.15
Issue 1
May 2001
3 . ENGINE
Contents
3 A01
GENERAL
3 B01
3 C01
SPACER
3 C02
Issue 2
May 2002
Engine - General
3A01.1
3 A01 General
CONTENTS
A.
Introduction ____________________________________________
B.
C.
Issue 1
May 2001
Issue 1
Engine - General
May 2001
Engine - General
3A01.3
A . Introduction
This section is limited to providing general information on
the engines fitted in the 8200 range.
To obtain all information about technical data, adjustments, disassembly and assembly procedures, refer to
the following publications:
1. Perkins engines
- Workshop manual covering all Perkins diesel engines
in the 4.41, 900 and 1000 series for all Massey Ferguson
tractors and published by AGCO with the following
reference numbers:
. 1857075 M1 in English
. 1857076 M1 in French
. 1857077 M1 in Spanish
. 1857078 M1 in German
. 1857243 M1 in Italian
2. Valmet engines
- Workshop manual covering all 620 DS and 634 DS type
engines published in English by Valmet, reference
number 836 640 364.
- Workshop manual specific to the 645 engine published
in English by Valmet, reference number 836 841 000.
Issue 1
May 2001
Engine - General
B . Main characteristics
Tractors fitted with Perkins engine
Type of engine
Perkins engine list no.
No. of cylinders
Bore (mm)
Stroke (mm)
Capacity (litre)
Compression ratio
DIN (kw) at 2200 rpm
Max. torque (Nm)
at (rpm)
Idle speed (rpm)
Nominal speed (rpm)
Max. speed at no load (rpm)
Injection pump
Make and type
Boost control
Reference
Code
Pump code letter
Governor spring code
Rotation
Static timing angle
Engine position
Pump / engine check angle
Injectors
Make
Code
Nozzle holder
Nozzle
New and service calibration
Suction system
Issue 1
May 2001
8210
1006-60TWG
YH31441
6
100
127
6
17.25/1
145 (107)
620
1400
950
2200
2354
8220
1006-60TWG
YH31441
6
100
127
6
17.25/1
155 (114)
663
1400
950
2200
2354
Lucas DP203
Yes
8921A512T
2644K622
FH
1
Clockwise
7
TDC
Timing (using a
measuring gauge)
Lucas DP203
Yes
8921A283T
2644D133
DH
1
Clockwise
6
TDC
Timing (using a
measuring gauge)
Lucas
KP
2645A318
2645A636
294 atm
Turbowastegate
Lucas
KH
2645A314
2645A630
294 atm
Turbowastegate
intercooler
1035
138 5
20.03
1035
138 5
20.03
Single
Yes
45 / 45
0.2 / 0.45
Yes
2
82 / 96
Viscostatic
Yes
2
2
Single
Yes
30 / 30
0.2 / 0.45
Yes
2
82 / 96
Viscostatic
Yes
2
2
Engine - General
3A01.5
Injection pump
Make and type
Boost control
Reference
Code
Pump code letter
Governor spring code
Rotation
Static timing angle
Engine position
Pump / engine check angle
Injectors
Make
Code
Nozzle holder
Nozzle
New and service calibration
Suction system
Min. boost pressure at
2200 rpm at full load (mm Hg)
(Kpa)
(PSI)
Valve spring
Valve seat insert (inl / ex)
Valve angle (degree) (in / ex)
Valve clearance (mm) (in / ex)
Oil cooler
No. of thermostats
Opening temp. (begin / full)
Fan
Piston cooling nozzle
Oil filter
Fuel filter
8240
620DSRAE
V620DSRAE
6
108
120
6.6
16.5 / 1
170 (125)
744
1400
950
2200
2354
8250
634DWE
V634DSBAE
6
108
134
7.4
16.5 / 1
185 (136)
811
1400
950
2200
2354
Stanadyne DB4
Yes
DB4629/5347
5347 or 5535
A
Clockwise
16
TDC
Timing (using a
measuring gauge)
Bosch type P
Yes
PES6P
3382
G
Clockwise
13
TDC
Timing (using a
measuring gauge)
Stanadyne
446
M34446
M34447
270 atm
Turbo intercooler
Stanadyne
876
M33876
M33877
270 atm
Turbo intercooler
900
120
17.42
900
120
17.42
Single
Yes
35 / 45
0.35 / 0.45
Yes
2
82 / 96
Viscostatic
Yes
2
2
Single
Yes
35 / 45
0.35 / 0.45
Yes
2
82 / 96
Viscostatic
Yes
2
2
Issue 1
December 2000
Engine - General
Type of engine
Perkins/Valmet engine list no.
No. of cylinders
Bore (mm)
Stroke (mm)
Capacity (litre)
Compression ratio
DIN (kw) at 2200 rpm
Max. torque (Nm)
at (rpm)
Idle speed (rpm)
Nominal speed (rpm)
Max. speed at no load (rpm)
Injection pump
Make and type
Boost control
Reference
Code
Pump code letter
Governor spring code
Rotation
Static timing angle
Engine position
Pump / engine check angle
Injectors
Make
Code
Nozzle holder
Nozzle
New and service calibration
Suction system
Min. boost pressure at
2200 rpm at full load (mm Hg)
(Kpa)
(PSI)
Valve spring
Valve seat insert (inl / ex)
Valve angle (degree) (in / ex)
Valve clearance (mm) (in / ex)
Oil cooler
No. of thermostats
Opening temp. (begin / full)
Fan
Piston cooling nozzle
Oil filter
Fuel filter
1
Issue 2
December
2000
May 2002
8260
634DSBIE
V634DSBIE
6
108
134
7.4
16.5 / 1
210 (154)
897
1400
950
2200
2354
8270
645DSBIE
V645DSBIE
6
108
145
8.4
16.5 / 1
230 (169)
1002
1400
950
2200
2354
Bosch type P
Yes
PES6P
3382
C
Clockwise
13
TDC
Timing (using a
measuring gauge)
Bosch type P
Yes
PES6P120D
3382
A
Clockwise
14
TDC
Timing (using a
measuring gauge)
Stanadyne
876
M33876
M33877
270 atm
Turbo intercooler
Bosch
DLLA143P45
P495
250 atm
Turbo intercooler
1275
170
24.67
1125
150
21.77
Single
Yes
35 / 45
0.35 / 0.45
Yes
2
82 / 96
Viscostatic
Yes
2
2
Single
Yes
35 / 45
0.35 / 0.35
Yes
2
82 / 96
Viscostatic
Yes
2
2
Engine - General
Type of engine
Perkins/Valmet engine list no.
No. of cylinders
Bore (mm)
Stroke (mm)
Capacity (litre)
Compression ratio
DIN (kw) at 2200 rpm
Max. torque (Nm)
at (rpm)
Idle speed (rpm)
Nominal speed (rpm)
Max. speed at no load (rpm)
8280
645DSBIE
V645DSBIE
6
111
145
8.4
16 / 1
260 (191)
1150
1400
950
2200
2354
Injection pump
Make and type
Boost control
Reference
Code
Pump code letter
Governor spring code
Rotation
Static timing angle
Engine position
Pump / engine check angle
Bosch type P
Yes
PES6P120A
3382
Clockwise
14
TDC
Timing (using a measuring gauge)
Injectors
Make
Code
Nozzle holder
Nozzle
New and service calibration
Suction system
Min. boost pressure at
2200-rpm at full load (mm Hg)
Bosch
DLLA143P455
P495
250 atm
Turbo intercooler
(Kpa)
(PSI)
Valve spring
Valve seat insert (inl / ex)
Valve angle (degree) (in / ex)
Valve clearance (mm) (in / ex)
Oil cooler
No. of thermostats
Opening temp. (begin / full)
Fan
Piston cooling nozzle
Oil filter
Fuel filter
3A01.7
1275
170
24.67
Single
Yes
35 / 45
0.35 / 0.35
Yes
2
82 / 96
Viscostatic
Yes
2
2
Issue
Issue 21
May 2002
December
2000
Engine - General
C . Viscostatic fan
Description
The engines are fitted with a cooling fan equipped with a
viscostatic coupling. This device permits a gain in power
in the order of 2 to 3 horsepower.
The viscostatic coupling comprises three main parts:
- the driving part driven by the engine and composed of
a shaft (1) integral with a plate (2) fitted with annular
grooves,
- the driven part constituted by a hub (6) receiving the fan
and the body (7) and equally fitted with annular grooves,
- the regulating section comprising a thermostatic spring
(3) that controls valve (4).
The centre of the device contains a tank (5) filled with a
viscous silicone fluid.
Operation
When the temperature of the air passing through the
radiator reaches a preset value, thermostatic spring (3)
acts upon valve (4) which opens port a. The liquid is
directed by centrifugal force to the annular grooves of hub
(2) and body (7). The torque is transmitted through the
internal friction of the extremely viscous liquid and its
adherence to the inner walls. The fan is thus driven and
permits a better air cooling of the radiator.
The speed of the fan varies continuously over the whole
range of regulation depending on the temperature.
When the temperature of the air passing through the
radiator drops, the spring closes the valve and stops the
liquid from reaching the friction area. The fluid gradually
returns to the tank (5) via channel b, the fan thus
becomes de-clutched, leaving only residual resistive
torque.
Issue 1
December 2000
Engine - Flywheel
3B01.1
CONTENTS
A.
General ________________________________________________
B.
C.
D.
E.
Issue 1
May 2001
8200-ERIES TRACTORS
3B01.2
Engine - Flywheel
A . General
The Luk type damper (3) installed on the flywheel is
secured by splines onto main shaft (6). It provides a
flexible connection between the engine and gearbox and
damps any vibrations caused by the transmission. It is
installed on 8200-Series tractors fitted with the Full
Powershift (AG150 - AG250) and Heavy Duty gearboxes
Note
The part number of damper (3) differs according to the
version.
Issue 1
May 2001
Refitting
4. Check the parts and replace any that are faulty.
Special point
If the operation consists in changing the damper, also
replace the bearing (see C).
5. Lightly coat the splines of the damper hub with GN
grease + Molycote. Refit and centre the damper using
service tool, P/N 3378262M1 (see E) , the offset on
the hub pointing towards the gearbox (Figs. 1 - 2).
6. Lightly coat the threads of screws (4) with Loctite 270
and torque to following values:
- Full Powershift gearbox (AG150-AG250):
. M10 screws: 68 - 92 Nm.
- Heavy Duty gearbox:
. M12 screws: 102 - 138 Nm
7. Reassemble the tractor between the engine and
gearbox (see section 2B01).
Engine - Flywheel
Full Powershift gearbox AG150
Flywheel
Parts list
(1) Bearing
(2) Starter ring gear
(3) Damper
(4) Screw
(5) Spring
(6) Main shaft
(7) Gearbox
3B01.3
Distance btw.
Perkins
centres of
attachment holes "T"
Valmet
A
86 mm
107,95 mm
T
A
1
T
B
T
Parts list
(1) Bearing
(2) Starter ring gear
(3) Damper
(4) Screw
(5) Spring
(6) Main shaft
(7) Gearbox
(8) Circlip
Flywheel
86 mm
94 mm
Parts list
Fig. 2
Fig. 1
Issue 1
May 2001
Engine - Flywheel
3B01.4
Heavy Duty gearbox
Parts list
(1) Bearing
(2) Starter ring gear
(3) Damper
(4) Screw
(6) Main shaft
(7) Spacer / Gearbox
Flywheel
Perkins
Valmet
A-B
Parts list
Fig. 1
Fig. 2
Issue 1
May 2001
Engine - Flywheel
3B01.5
Refitting
13. Check the parts, replacing any that are defective.
14. Screw two guide studs opposite one another into the
holes used for attaching the flywheel on the crankshaft.
15. Refit the flywheel.
Note: Depending on the type of fixture, fit bearing (1) before or after refitting the flywheel, using
a suitable mandrel (dia. 62 mm, corresponding
to the hole in the external cage of the bearing).
16. Remove the guide studs. Torque the screws to
140 Nm (Perkins engine). For the screw torquing
values on Valmet flywheels, refer to the engine
repair manual.
17. Refit the damper (see B).
18. Reassemble the tractor between the engine and
gearbox (see section 2B01).
Issue 1
May 2001
8200-ERIES TRACTORS
3B01.6
Engine - Flywheel
Reassembly
23. Heat a new ring gear to 245 C in a furnace only.
24. Install ring gear (2) on the flywheel, with the teeth
opening pointing towards the starter, and fit rapidly
into abutment. Allow to cool slowly.
25. Refit the flywheel (see C) and the damper (see
B).
26. Reassemble the tractor between the engine and
gearbox (see section 2B01).
Fig. 3
E . Service tools
Tool available in the AGCO network
- 3378262M1 - Damper centring tool (Fig. 4)
Fig. 4
Issue 1
May 2001
Engine - Spacer
3C01.1
3 C01 Spacer
CONTENTS
A.
B.
Issue 1
May 2001
Engine - Spacer
General
Type-8210 - 8220 -8240 and 8250 tractors may be fitted
with either a Heavy Duty gearbox or a Full Powershift
gearbox.
This section is limited to parts concerning the Heavy
Duty gearbox. The Heavy Duty gearbox comprises two
casings:
- the main housing which encloses the pinions, the
shafts and the input unit,
- the spacer, providing the connection with the engine.
10
Preliminary operations
1. Split the tractor between the engine and gearbox (see
section 2B01).
2. Disassemble the four screws (dia. 10 mm) on each
front Silent Block on the right- and left-hand engine
bearers.
Note: If the side fuel tank was not removed during
the separation operation, drain the gas-oil and
remove the footstep in question then the fuel
tank.
3. Raise and block the cab. Remove the cab supports
(right and left) and any adjacent parts likely to obstruct
removal of the spacer. Drain the gearbox.
4. Install protector, P/N 3378012M2 (see B) on main
shaft (7) (Fig. 1).
5. Remove screws (5) (62) in order to facilitate unsticking
of closure disk (10) (Fig. 1). Use the tapped holes and
two screws of sufficient length to extract and maintain the disk before removing it.
6. Scrap seal (8) (Fig. 6).
7. Remove lube tube (17) from the engine clutch located
under the gearbox between spacer (16) and intermediate housing (19) (Fig. 4).
8. Remove tubes (20) (65) (70) and union (66) (Figs. 2 3).
9. Remove the clutch using locally procured tooling (see
section 4A01).
62
16
Fig. 1
66
Fig. 2
70
65
20
Fig. 3
Issue 1
May 2001
Engine - Spacer
3C01.3
Loctite 5206
1
16
16
17
19
A
A -A
Fig. 4
Issue 1
May 2001
Issue 1
Engine - Spacer
May 2001
Engine - Spacer
3C01.5
Refitting
13. Clean the parts and replace any that are defective.
14. Remove all traces of old Loctite from the mating
surfaces. Coat the mating face of the spacer (gearbox side) with Loctite 5206 or equivalent.
15. Ensure presence of locating pins (6) (Fig. 4).
Note: Studs (9) are smeared with Loctite 270
and locked into the gearbox.
16. Refit the spacer. Coat the screws and nuts with
Loctite 270 and torque to following values:
- screws (1) and nuts (2): 150 - 200 Nm,
- screws (4) (5) (7) and nuts (8): 100 - 130 Nm.
17. Coat union (66) with Loctite 542 then screw onto the
spacer (Fig. 2).
P
Fig. 5
12
Final operations
18. Refit the clutch and tubes. Reverse operations 7 to
9.
19. Ensure the presence of centring pins on the closure
disk, and shims on the clutch assembly. Replace
Orings (8) (Fig. 6).
20. Coat surrounds P of the tapped holes with
Loctite 5206. (Fig. 5).
21. Grease the lip of the seal. Fit the shaft with the
protector used during disassembly. Screw two guide
studs in opposing locations on the spacer, and
reinstall closure disk (10) and finger (63) in the slot in
pump body (12) (Fig. 6).
Install long screws (62) in the same holes as those
provided for the centring pins. Install screws (5) (Fig.
1). Torque all screws to 25 - 35 Nm.
63
8
10
Fig. 6
Issue 1
May 2001
Engine - Spacer
B . Service tools
Tool available in the AGCO network
- 3378012M2 - Protector (Fig. 7)
Issue 1
May 2001
Engine - Spacer
3C02.1
CONTENTS
A.
B.
Issue 1
May 2001
Engine - Spacer
General
8210 - 8220 - 8240 and 8250 series tractors equipped
with a Power Shuttle are fitted with a spacer (16) (Fig.
1) inserted between the engine and the gearbox. The
design of this spacer is similar to that fitted on the 8200
equipped with a mechanical reverse shuttle (see section 3C01).
However, it should be noted that its closure disk has a
different profile so that it can be fitted with the
hydromechanical assembly of the power shuttle.
Preliminary operations
1. Split the tractor between the engine and gearbox (see
section 2B01).
2. Disassemble the four screws (dia. 10 mm) on each
front Silent Block on the right- and left-hand cab
bearers.
Note: If the side fuel tank was not removed during
the separation operation, drain the gas-oil and
remove the footstep in question then the fuel
tank.
3. Raise and block the cab. Remove the cab supports
(right and left) and any adjacent parts likely to obstruct
removal of the spacer. Drain the gearbox.
4. Install protector 3378012M2 (see B) on main shaft
(19) (Fig. 1).
5. Remove screws (1) (2) (Fig. 1).
Special point
- In order to facilitate unsticking of closure disk (4)
(Fig. 1), use the tapped holes and two screws of
sufficient length to extract and maintain the disk
before removing it.
6. Scrap seal (3) (Fig. 6).
7. Remove lube tube (78) from the power shuttle clutches
located under the gearbox between spacer (16) and
intermediate housing (19) (Fig. 4).
8. Remove tubes (31) (86) (optional) and (74) (87) (94)
and finally union (66) (Figs. 2 - 3).
9. Remove the clutch from the power shuttle (optional)
using the locally-made tool (see section 5B06).
10
62
16
Fig. 1
66
Fig. 2
70
65
20
Fig. 3
Issue 1
May 2001
Engine - Spacer
3C02.3
Loctite 5206
1
16
16
17
19
A
A -A
Fig. 4
Issue 1
May 2001
Issue 1
Engine - Spacer
May 2001
Engine - Spacer
3C02.5
Refitting
13. Clean the parts and replace any that are defective.
14. Remove all traces of old Loctite from the mating
surfaces. Coat the mating face of the spacer (gearbox side) with Loctite 5206 or equivalent.
15. Ensure presence of locating pins (6) (Fig. 4).
Note: Studs (9) are smeared with Loctite 270 and
locked into the gearbox.
16. Refit the spacer. Coat the screws and nuts with
Loctite 270 and torque to following values:
- screws (1) and nuts (2): 150 - 200 Nm,
- screws (4) (5) (7) and nuts (8): 100 - 130 Nm.
17. If necessary, coat union (96) with Loctite 542 then
screw it onto the spacer (Fig. 2).
P
Fig. 5
Issue 1
May 2001
Engine - Spacer
Final operations
18. If necessary, refit the front clutch of the power
shuttle. Reconnect the tubes. Refit the clutch and
tubes. Reverse operations 7 to 9.
19. Ensure the presence of centring pins G (Fig. 1) on the
closure disk (4) and of shims lubricating pump cover.
Replace O'ring (3) (Fig. 6).
20. Coat surrounds P of the tapped holes with
Loctite 5206. (Fig. 5).
21. Grease the lip of the seal fitted on the closure disk.
Fit the shaft with the protector used during disassembly.
Screw two guide studs in opposing locations on the
spacer, and reinstall closure disk (4) and finger (2) in
the slot in pump body (1) (Fig. 6).
Install long screws (2) in the same holes as those
provided for the centring pins. Install screws (1) (Fig.
1). Torque all screws to 36 - 46 Nm.
22. Refit the cab supports and any neighbouring parts
that were removed. Coat the screws for the supports
with Loctite 270 then insert and torque to 200260 Nm. If it was removed, reinstall the access door
in the cab floor. Service the oil in the sumps and
check level on sightglass located on left of centre
housing.
23. Remove the props and set back the cab. Torque up
the screws ( 10 mm) on each Silent Block support
to 50 - 70 Nm.
24. Reassemble the tractor between the engine and
gearbox (see section 2B01).
25. Check the following:
- tightness of hydraulic unions and mating face.
- operation of the power shuttle.
Fig. 6
B . Service tool
Tool available in the AGCO network
- 3378012M2 - Protector (Fig. 7)
Fig. 7
Issue 1
May 2001
4 . CLUTCH
Contents
4 A01
Issue 1
May 2001
4A01.1
CONTENTS
-
General ________________________________________________
A.
B.
C.
10
D.
11
E.
13
F.
13
Issue 1
May 2001
General
Description
The engine clutch system installed on the Heavy Duty
gearboxes equipping type 8210 - 8220 - 8240 and 8250
tractors is of the oil-immersed multidisc type.
The hydraulic clutch - which transmits the movement is similar to a Direct-drive clutch but is larger.
This clutch is controlled by an hydraulic valve mounted
on the right-hand side of the gearbox, itself actuated by
the clutch master-cylinder.
Construction
The clutch assembly is installed between the flywheel
and the transmission shaft of the Dynashift unit.
Main shaft (7) penetrates closing plate (10) which separates the flywheel from the transmission fluid. Shaft (7)
is in constant engagement with the damper fixed on the
flywheel.
Due to the splines, it is rotates together with clutch
housing (23) which includes intermediate plates (45) and
which houses piston (46).
Drive hub (37) comprising discs (44) is integral with
clutch shaft (33).
Fixed unit (12) has two functions:
- it receives the 17-bar pressure,
- it serves as the lubrication and cooling pump body
(30 l/min, rated pressure 0.4 bar).
The pump supply is obtained from the centre housing via
a 500-micron strainer (replaceable), tube (17) placed
under the transmission, and a second tube (20).
Depending on the type, the clutch assembly comprises
a different number of discs and intermediate plates:
- 8210 and 8220: 6 discs, 6 intermediate plates
- 8240: 7 discs, 7 intermediate plates
- 8250: 8 discs, 8 intermediate plates.
Discs (44) have a paper lining for smoother engagement
and reduced noise.
Issue 1
May 2001
Clutching
When the clutch pedal is released, the hydraulic valve
located on the right-hand side of the gearbox delivers a
pressure of 17 bar which moves piston (46); the latter in
turn compresses intermediate plates (45) against discs
(44), entraining clutch shaft (33).
The valve monitors the smoothness and progressive
engagement of the clutch, and modulates the pressure
applied on the piston.
Release
Once the pressure is no longer applied, piston (46) is
pushed back by Belleville washers (42), and intermediate plates (45) are no longer in contact with the discs.
The lubrication and cooling flow to the discs is interrupted
in the declutched position to avoid driving the discs by
drag effect. For the same reason, the discs have a face
curved to facilitate disengagement.
Orings
Backup washers
Splined bush
Locking ring
Screw
Washer
Main shaft
Oring
Shim(s)
Closing plate
Pump cover
Pump body
Dynashift cover
Oring
Orings
Spacer
Tube
Screw
Flange
Tube
Spacer casing
Screw
Clutch housing
Pin
Flange
Screw
Dust shield
Oring
Oring
Seal holder
Screw
Direct-drive shaft
Clutch shaft
Circlip
Washer
Bearing
Drive hub
Screw
Clutch cover
Bearing
Belleville washers
Circlip
Disks
Intermediate plates
Piston
Clutch assembly
Seal
Seal
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
(58)
(61)
(62)
(63)
(64)
(65)
(66)
(67)
(68)
(69)
(70)
(71)
(72)
(73)
(74)
(75)
(76)
(77)
4A01.3
Bearing
Bush
Seal rings
Lubricating pump
Screw
Bearing
Circlip
Lip seal
Circlip
Centring pin
Screw
Finger
Union
Tube
Union
Diagnostic connector
1.5-bar valve
Oring
Tube
Oring
Union
Plug
500 micron strainer
Oring
Plug
Indexing port
Overall view
68
69
64
70
65
67
73
66
71
Fig. 1
72
Fig. 1A
30
26
30
29
28
Fig. 2
17
25
74
27
75
31
A-A
76
Parts list
Fig. 1A
Fig. 2
Fig. 1
Issue 1
May 2001
4A01.4
58
56
11
56
55
54
12
53
77
23
46
39
18
42
21
58
43
47
40
7
37
34
4
33
32
3
57
52
10
24
9
35
36
23
A
44
10
61
51
50
C
12
63
62
16
15
17
38
19
20
22
14
48
49
45
13
10
Fig. 1A
Issue 1
May 2001
Parts list
Fig. 1
Fig. 2
4A01.5
21
35
13
16
18
32
63
33
34
10
39
61
36
37
62
44
45
73
68
69
57
67
58
66
64
2
1
65
70
71
72
58
27
6
5
40
42
25
14
52
20
50
15
51
17
43
7
46
48
19
38
49
29
31
54
55
22
56
30
24
23
74
12
53
75
11
9
28
26
Issue 1
May 2001
Parts list
Fig. 1
76
Fig. 2
Fig. 1A
Issue 1
May 2001
4A01.7
A . Removing and refitting the closing plate and replacing lip seal (57)
and Oring (1)
Removal
1. Split the tractor between the engine and gearbox
(Section 2B01).
2. Drain the gearbox.
3. In order to facilitate unsticking of closing plate (10),
install two jacking screws of sufficient length in the
tapped holes in the closing plate, then remove the
disc.
4. Remove front circlips (58) and remove splined bush
(3), backup washers (2) and seal (1).
5. Extract seal (57).
P
Fig. 3
Refitting
6. Fit seal (57) using a suitable fixture.
7. Place Oring (1) between rings (2). Reinstall splined
bush (3). Replace front circlip (58) and position
correctly in the groove.
8. Ensure presence of centring pins (61) and shims (9).
9. Replace Oring (8).
10. Coat tapped-hole surrounds P with Loctite 5206 (Fig.
3).
11. Grease the lip of seal (57). Place protector P/N
3378012M2 (see F) on shaft (7). Screw two guide
studs in opposing locations on the spacer and
reinstall closing plate (10), with finger (63) in the slot
of pump body (12) (Fig. 4).
12. Install long screws (62) in the same holes as those
provided for centring pins (61). Install screws (5),
torque to 36 - 46 Nm.
13. Service the oil in the sumps and check on the
sightglass located on the left of the centre housing.
14. Reassemble the tractor between the engine and
gearbox (see section 2B01) and check adjustment of
the chassis reinforcements (if installed) (see section
2F01).
12
63
10
Fig. 4
1
Issue 2
2001
May 2002
4A01.8
Refitting
23.
24.
25.
26.
32
47
32
7
33
Fig. 5
Issue 1
May 2001
10
11
4A01.9
36
13
J1 = 0,60 / 0,80 mm
Fig. 6
Fig. 7
G
26
29
28
17
25
30
Issue 1
27
May 2001
Adjustin
g
Note: This operation consists in obtaining an axial
clearance of J1 = 0.60 to 0.80 mm between pump
cover (11) and closing plate (10) (Fig. 6)
44. Install a dial-gauge comparator on the end of shaft (7)
and check the play by moving the clutch assembly
sideways.
Note: Ensure bearing (36) in the clutch assembly
is fully abutted against cover (13) before pulling
on the shaft (Fig. 6)
45. Remove closing plate (10); depending on the measured clearance, select thickness of feeler gauges (9)
to obtain a clearance J1 of between 0.6 and
0.8 mm.
Final operations
46. Remove the clutch and reinstall Direct-drive shaft
(32), turning the undercut part (designed to receive
spring R towards the rear axle (Fig. 5).
47. Proceed to final refitting of the clutch assembly (see
B).
Issue 1
May 2001
4A01.11
Disassembly
48. Remove the clutch (see B) and place in the vertical
position, that is, cover (39) resting on a suitable
fixture.
49. Remove front circlip (58). Remove bush (3), rings (2)
and seal (1).
50. Remove circlip (56). Remove pump cover (11) and
bearing (55).
51. Extract lubrication pump (53) from pump body (12).
Separate the pump body from clutch housing (23).
52. Remove seal rings (52).
53. If necessary, extract bush (51) and disassemble 1.5bar valve (68).
54. Separate clutch housing (23) from cover (39). Remove discs (44) and intermediate plates (45).
55. Remove drive hub (37).
56. If necessary, extract bearing (36).
57. Using a suitable fixture (see F) , compress Belleville
washers (42). Remove rear circlip (58) (Fig. 8).
Remove locking ring (4). Untension the Belleville
washers.
58. Separate clutch housing (23) from shaft (7). Remove
the Belleville washers.
59. Remove piston (46). If necessary, extract bearing
(50).
60. If necessary, remove circlip (43) and bearing (40).
Reassembly
61. Ensure presence of pin (24).
62. If it was removed, refit bearing (50), using a suitable
fixture.
63. Install seals (48) (49).
64. Install piston (46).
Note: The angular position of the piston depends on that of the lubrication ports of clutch
housing (23). Align the indexing holes drilled in
the unit and piston (Fig. 9). Proceed by inserting
a suitable diameter pin.
Finish refitting the piston by progressively tapping around the edge, using a plastic hammer.
Ensure no seal fragment remains after assembly.
65. If it was removed, refit bearing (40), using a suitable
fixture, the sealed face pointing towards the Dynashift.
Fit circlip (43).
23
58
42
Fig. 8
23
46
Fig. 9
Remark
On type 8210 -8220 -8240 and -8250 tractors fitted with
the Heavy Duty gearbox, the hydraulic engine clutch
comprises six Belleville washers.
66. Fit Belleville washers (42) on shaft (7) (Fig. 8).
Issue 1
May 2001
4A01.12
Issue 2
1
May 2002
2001
51
Fig. 10
4A01.13
Removal
81. Drain the gearbox.
82. Remove any neighbouring parts likely to hinder
removal of the valve. Disconnect tubes (1) and (2),
hose (3), and the connectors to solenoid valves EV1
and EV2 (mark connector positions).
83. Remove the valve.
Refitting
84. Clean the mating surfaces. Coat the one on the
gearbox housing with sealing compound.
85. Replace the Orings on the 17-bar transfer tubes.
Reinstall the valve. Coat screws (5) with sealing
compound, install, and torque to 25-35 Nm.
86. Reconnect the tubes, the hose and the connectors.
87. Service the oil in the sumps and check the level on
the sightglass located on the left-hand side of the
centre housing.
88. Bleed the clutch control valve (see section 9I01).
89. Check the valve regulating pressure (see section
9N01 - Hydraulic Tests).
90. Reinstall any items previously removed from around
the valve.
91. Check the sealing of the mating face and the couplings, and operation of the Dynashift.
EV1
EV2
Fig. 11
Fig. 12
F . Service tools
1 . Tool available in the AGCO network
- 3378012M2 - Protector (Fig. 12)
Issue 1
May 2001
4A01.14
A -A
180
A
60
248
286
Fig. 13
86
1
23
80
86
2
100
165
Fig. 14
Issue
Issue21
May
May2002
2001
5 . GEARBOX
Contents
5 A01
5 A02
5 B01
5 B02
5 B03
5 B04
5 B05
5 B06
5 C01
5 C02
POWER SHUTTLE
SELECTOR COVER - GEARBOX WITH MECHANICAL REVERSE SHUTTLE
SELECTOR COVER - GEARBOX WITH POWER SHUTTLE
5 C03
5 D01
5 D02
5 E01
5 F01
5 F02
5 G01
5 H01
5 I01
5 J01
5 K01
Issue 2
May 2002
Gearbox - General
5A01.1
CONTENTS
A.
General ________________________________________________
B.
Operation ______________________________________________
C.
Specifications __________________________________________
11
Issue 1
May 2001
Issue 1
Gearbox - General
May 2001
Gearbox - General
A . General
Various types of transmissions are available:
- Type 8210 -8220 -8240 tractors: Heavy Duty gearbox or
Full Powershift AG 150
- Type 8250 tractors: Heavy Duty gearbox
- Type 8250 to 8280 tractors: Full Powershift gearbox
AG250.
This section covers only the Heavy Duty version. For the
Full Powershift version, refer to section 5H01.
The Heavy Duty gearbox comprises 32 forward speeds
and 32 reverse. The transfer shafts and output shafts are
supported by tapered roller bearings and are drilled as
necessary to pressure-lubricate the bearings, the idler
gears and the Hare/Tortoise synchronisation system.
The layshaft is supported at the front by a cylindrical roller
bearing and at the rear, by two tapered roller bearings.
The main gearbox comprises four synchronised gears.
An idler gear on the output shaft positively connected via
a double cone synchromesh doubles the four synchronised gears, to give the eight basic speeds.
All pinions are helically cut and in constant engagement.
The drive shaft of the direct-drive clutch traverses the
layshaft.
The input unit assembly located at the front (see section
5B01) provides four input ratios into the main box.
Description
The gearbox drive is provided by input gear (1) integral
with transfer shaft (7). The two hubs of synchromesh
gears (16) and (27), as well as gear (1) are hard-mounted
to transfer shaft (7) by splines. First gear (19) and fourth
gear (24) are idler gears on shaft (7). Second gear (13) is
an idler gear on bush (8), which is hard-mounted to shaft
(7) by splines. Third gear 3rd (35) is installed on tapered
roller bearings.
All the pinions on layshaft (51) are splined to and rotate
with the latter. The gear teeth on shaft (51) mesh with
tortoise gear (40) which idles on the output shaft.
5A01.3
Lubrication
The lube oil is supplied from tube (4) connected to the
input unit. It circulates in a series of axial channels, one
of which crosses the transfer shaft while the other is
blind, machined in the output shaft. Radial channels feed
the various pinions, the bearings and the Hare/Tortoise
synchromesh.
Needle roller bearings (67) are lubricated by an oil film
circulating between the direct-drive shaft and the layshaft.
The shaft-end bearings on shaft (51) are lubricated by an
additional oil flow from the drive bearing of the hydraulic
pumps located on the rear-axle intermediate housing, via
radial ports drilled respectively in shim (53) and the shaft.
Issue 1
May 2001
Gearbox - General
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
(65)
(66)
(67)
(68)
(69)
Input gear
Belleville washers
Special screw
Lube tube
Snap ring
Spring
Transfer shaft
Bush
Bearing cone
Bearing cup
Shim(s)
Thick shim
Driving pinion (2nd)
Synchromesh cone (2nd)
Synchro ring (2nd)
Synchro (1st - 2nd)
Synchro ring (1st
Synchromesh cone (1st )
Driving pinion (1st )
Bearing cone
Bearing cup
Bearing cup
Bearing cone
Driving pinion (4th)
Synchromesh cone (4th)
Synchromesh ring (4th)
Synchro (3rd - 4th)
Seal ring
Snap ring
Synchromesh ring (3rd)
Special washer
Synchromesh cone (3rd)
Bearing cone
Bearing cup
Driving pinion (3rd) (Hare)
Bearing cup
Bearing cone
Shim(s)
Thick shim
Tortoise gear
Centring pin
Bearing cone
Bearing cup
Shim(s)
Rear bearing
Output shaft
Screw
Bearing cup
Bearing cone
Layshaft
Nut
Shim
Bearing cone
Issue 1
Bearing cup
Circlip
Driven pinion (3rd)
Spacer
Driven pinion (4th)
Spacer
Driven pinion (1st)
Spacer
Shim(s)
Driven pinion (2nd)
Washer
Snap ring
Needle roller bearings
Gearbox housing
H/T synchromesh (double cone)
Legend:
G : Groove
Fig. 1
May 2001
Overall view
Gearbox - General
64
5A01.5
63
62
61
60
59
58
57
56
69
51
54
55
53
49
68
50
65
1
2
3
66
52
67
41
48
46
45
44
47
43
36
E
6
7
37
8
13
14
15
16
17
18
19
20
21
24
25
26
27
27
28
30
29
32
35
40
75
74
72
34
24
12
22
38
10
35
Issue 1
70
39
11
May 2001
71
23
C
31
33
73
Fig. 1
Parts list
Issue 1
Gearbox - General
May 2001
Gearbox - General
5A01.7
B . Operation
Notes
F
C
D
B
E
16
27
E
D
F
B
C
Fig. 2
Neutral position
Slide A is in the central position. The balls are pushed
back into the groove at V on slide A by pressure springs
F. The pinions are free to turn on the shaft. In this neutral
position, slide A is locked by three balls G maintained by
springs H.
Issue 1
May 2001
Gearbox - General
Overhaul
In the event of removal of the synchromesh gears, check
the wear of synchronisation brakes B (Fig. 2).
Place Cone C on a flat surface and position brake B in
abutment by rotating it a few turns under finger pressure
(Fig. 3).
Measure dimension X at several points using a set of
feeler gauges (Fig. 2 and 3): if a value of less than 0.8 mm
is found, check the cone and install a new brake B.
Value of dimension X with brake and new synchromesh cone
- synchro (1st - 2nd) (16): 0.9 to 1.5 mm
- synchro (3rd - 4th) (27): 0.9 to 1.5 mm
Fig. 3
Issue 1
May 2001
Gearbox - General
5A01.9
69
E
D
F
A
K
B
J
C
Fig. 4
Issue 1
May 2001
Gearbox - General
Fig. 5
Issue 1
May 2001
C . Specifications
Gearbox - General
5A01.11
J1 = 0,02 / 0,31
25 - 35 Nm
31 - 35 Nm
29 - 37 Nm
13 - 15 Nm
25 - 32 Nm
A
J = 0,60 / 0,80
241
241
8,60 / 8,68
72 - 96 Nm
31 - 35 Nm
100 - 150 Nm
270
603
638
510
P2 = 0,01 / 0,05
5206
5206
F =1,25 / 1,75
40 - 56 Nm
25 - 35 Nm
25,5 - 34,5 Nm
241
320 - 360 Nm
J = 0,05 / 0,18
270
P =0,10 / 0,20
57- 67 Nm
270
Fig. 6
Issue 1
May 2001
5A02.1
CONTENTS
A.
General ________________________________________________
B.
Operation ______________________________________________
C.
Specifications __________________________________________
D.
11
Issue 1
May 2001
A . General
Various types of transmissions are available:
- Type 8210 - 8220 - 8240 and 8250 tractors: gearbox
with Power shuttle
- Type 8210 - 8220 and 8240 tractors: Full Powershift
AG150 gearbox
- Type 8250 to 8280: Full Powershift AG250 gearbox.
This section only covers the version with Power shuttle.
For the Heavy Duty version with mechanical reverse
shuttle or the Full Powershift versions, refer to section
5B05 or 5H01 respectively.
The Heavy Duty gearbox with Power shuttle comprises
32 forward speeds and 32 reverse. The transfer shafts
and output shafts are supported by tapered roller bearings and are drilled as necessary to pressure-lubricate
the bearings, the idler gears and the Hare/Tortoise synchronisation system.The layshaft is supported at cylindical
roller bearing and at the rear, by twotapered roller bearings.
On gearboxes with a Power shuttle, 1st and 2nd gear
synchromesh gears (16) and 3rd and 4th gear synchromesh gears (27) are double cone type as well as the
Hare/Tortoise range one.
When the Hare/Tortoise synchromesh gear (69) is moved
to the rear, it makes the Tortoise pinion rotate and
doubles the four speeds to give the eight basic speeds.
All pinions have rectified teeth and are helically cut. They
are in constant engagement. The drive shaft of the directdrive clutch traverses the layshaft.
The input unit assembly located at the front (see section
5B02) provides four input ratios into the main box.
Issue 1
May 2001
5A02.3
Lubrication
The lube oil is supplied from tube (4) connected to the
input unit (Fig.1).
It circulates in a series of axial channels, one of which
crosses the transfer shaft while the other is blind,
machined in the output shaft. Radial channels feed the
various pinions, the bearings and the Hare/Tortoise
synchromesh.
Needle roller bearings (67) are lubricated by an oil film
circulating between the direct-drive shaft and the layshaft.
An oil deflector "C" maintains the oil near the bearing
mounted at the back of the input unit.
The shaft-end bearings on shaft (51) are lubricated by an
additional oil flow from the drive bearing of the hydraulic
pumps located on the rear-axle intermediate housing, via
radial ports drilled respectively in shim (53) and the shaft.
Issue 1
May 2001
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(19)
(20)
(21)
(22)
(23)
(24)
(27)
(28)
(30)
(31)
(33)
(34)
(35)
(36)
(37)
(40)
(41)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
(65)
(66)
(67)
(68)
(69)
(71)
(72)
(75)
Input gear
Washer
Nut
Lube tube
Snap ring
Spring
Transfer shaft
Bush
Bearing cone
Bearing cup
Shim(s)
Thick shim
Driving pinion (2nd)
Synchromesh cone (2nd)
Synchro ring (2nd)
1st - 2nd synchro (double cone)
Driving pinion (1st )
Bearing cone
Bearing cup
Bearing cup
Bearing cone
Driving pinion (4th)
3rd - 4th synchro (double cone)
Seal ring
Synchromesh ring (3rd)
Special washer
Bearing cone
Bearing cup
Driving pinion (3rd) (Hare)
Bearing cup
Bearing cone
Tortoise gear
Locating pin
Bearing cone
Bearing cup
Shim(s)
Rear bearing
Output shaft
Screw
Bearing cup
Bearing cone
Layshaft
Nut
Shim
Bearing cone
Issue 1
Bearing cup
Circlip
Driven pinion (3rd)
Spacer
Driven pinion (4th)
Spacer
Driven pinion (1st)
Spacer
Shim(s)
Driven pinion (2nd)
Washer
Snap ring
Needle roller bearings
Gearbox housing
Hare / Tortoise synchromesh (double cone)
Progressive sensor
Nut
Cover
Legend
G : Groove
May 2001
64
63
62
71
5A02.5
72
61
60
59
58
57
56
69
51
54
55
53
65
49
66
50
3
67
52
41
C
48
D
45
2
47
5
43
R
41
44
F
F
46
36
13
16
19
20
21
24
24
27
28
29
34
27
35
40
75
48
37
46
16
27
69
12
45
44
47
43
B
10
Issue 1
D
11
22
May 2001
23
A
31
33
35
Parts list
Fig. 1
Issue 1
May 2001
5A02.7
B . Operation
Notes
- On gearboxes with Power shuttle, all gears are synchronised including the Hare/Tortoise function. The
synchromesh gears are all double cone items.
69
E
D
F
A
K
B
J
C
Fig. 2
Issue 1
May 2001
Fig. 3
Issue 1
May 2001
C . Spcifications
A and B : Dtails
C : to turn adjustment
5A02.9
P= 0/0,10mm
C
J1= 0,02/0,31mm
X= 8,60/8,68mm
VALMET
PERKINS
P2= 0,01/0,05mm
J= 0,60/0,80mm
P1 = 0,10/0,20mm maxi
B
Fig. 4
Issue 1
May 2002
Issue 1
May 2002
D . Tightening torques
36 - 46 Nm
47 - 57Nm
242
5A02.11
A : Tighten at 30 - 70 Nm progressively. Rotate the shaft a few turns. Then, complete tighten at 100 - 150 Nm, with Loctite 270
plus mechanical lock.
B : Selector rail support.
31 - 35Nm
13 - 15Nm
12 - 16Nm
242
242
242
5 - 7Nm
577
29 - 37Nm
36 - 46Nm
242
221
5206
B
36 - 46Nm
A
57- 67Nm
102 - 138Nm
110 - 140Nm
270
270
25,5 - 34,5Nm
47 - 68Nm
12,5 - 13Nm
510
13 bar
F
36 - 46Nm
549
5206
648
47 - 68Nm
85 - 120Nm
130 - 170Nm
270
40- 48Nm
47 - 54Nm
29 - 37Nm
29 - 37Nm
10- 14Nm
1,5 bar
Fig. 5
Issue 1
May 2002
5B01.1
CONTENTS
General ________________________________________________
A.
B.
Issue 1
May 2001
5B01.2
General
1
Fig. 1
Removal
3376883M1
3378004M1
13
3378013M1
21
B
DANGER
- It is essential to use screws A of suitable length in order
to positively secure the sling and unit assembly.
B
Fig. 2
Issue 1
May 2001
5B01.3
Refitting
Special point
- To facilitate engagement of input unit end bearing (1)
into the gearbox layshaft (Fig. 4), coat the bearing rollers
with miscible grease to stick them in place.
13. Insert locating pin (1) (Fig. 3).
14. Screw two guide studs (L = 80 mm) in opposing
locations on the gearbox housing (optional). Using
sling, P/N 3376883M1 and adapter plate, P/N
3378013M1, engage the input unit in the clutch
housing. Tilt it fully downwards to allow the selector
rail support to pass through the front bore of the
gearbox.
Fig. 3
3376883M1
1 - Pull
2 - Tilt
Fig. 4
Issue 1
May 2001
Fig. 5
Fig. 6
B . Service tools
1 . Tools available in the AGCO network
- 3376883M1 - Sling for front unit (Fig. 5)
- 3378013M1 - Adapter plate (Fig. 6)
- 3378004M1 - Sleeve (Fig. 7)
Fig. 7
Issue 1
May 2001
5B01.5
2500
5x7
75
75
75
180
32
80
Fig. 8
Issue 1
May 2001
5B02.1
CONTENTS
.
General ________________________________________________
A.
B.
Removal ________________________________________________
C.
Refitting ________________________________________________
D.
E.
F.
Issue 1
May 2002
General
The power unit with power shuttle is in the form of an
interchangeable module on which a reverse shuttle is
assembled that can power the forward or reverse gear.
It is mounted at the input of the gearbox and is fitted on
tractors 8210 - 8220 - 8240 and 8250.
It is made of two distinct parts: the power shuttle (see
section 5B06) and the Dynashift.
Dynashift
The Dynashift electro-hydraulically controls four
powershift ratios using a lever mounted to the left under
the steering wheel.
It is located between the power shuttle and the driving
gear mounted in the rear housing.
The Dynashift function is performed by two epicyclic
gear trains associated with two hydraulic clutches. For
information on operation, see section 5B04.
Issue 1
May 2002
5B02.3
A. Preliminary operations
Special points
- A removable flange (2) supports the front end of the
selector rails (Fig. 1).
- This assembly enables easy horizontal removal of the
input unit (Fig. 2).
2
Fig. 1
Fig. 2
Issue 1
May 2002
3
Fig. 3
Issue 1
May 2002
5B02.5
B . Removal
Fig. 4
64
64A
70
64
64
64
64A
64A
70
Fig. 5
Issue 1
May 2002
C . Refitting
16. Install the previously removed rear clutch on the
input unit (see section 5B06).
17. If necessary, screw a guide stud (L = 55 mm) on the
gearbox housing, through the opening revealed by
the removal of the power shuttle control unit.
18. Place the locating pin (1). Check presence of the
flange (2), lubrication tube (4) (Fig. 6) and the locating
pins (3) (Fig. 3).
19. With the help of an assistant and using the tools used
during removal, position the input unit in the gearbox
housing taking the same safety precautions as
previously.
20. Push and position the input unit on the housing
mating face. Remove the guide stud (if used).
21. Remove the sling. Tighten the screws (64) (64A)
(Fig. 5) of the input unit to a torque of 47 - 57 Nm.
Note
- the thread of each screw should be cleaned and
lightly coated with Loctite 542 or equivalent. If new
screws are used, they should not be coated with
Loctite or equivalent since they are coated with a
locking product in the factory.
22. Reinstall and adjust the progressive sensor (see D).
23. Adjust the turned section of the PTO shaft to the rear
and insert the shaft into the upper shaftline of the
gearbox.
24. Refit the front clutch (see section 5B06).
Issue 1
May 2002
4
Fig. 6
Fig. 7
5B02.7
E . Final operations
F . Service tools
Fig. 8
2500
5x7
75
75
75
180
32
80
Fig. 9
Issue 1
May 2002
Gearbox - Dynashift
5B03.1
5 B03 Dynashift
CONTENTS
-
General _____________________________________________
A.
B.
10
D.
10
E.
11
F.
11
G.
12
H.
14
I.
15
J.
16
K.
16
C.
Issue 1
May 2001
Gearbox - Dynashift
General
The Dynashift is fixed on the front of the input unit. It is
an hydraulically controlled gear shifting device that provides four gearbox input ratios. This function is provided
by two epicyclic gear trains associated with two hydraulic clutches.
The design of the Dynashift allows selecting the four
ratios while moving, without needing to disengage the
clutch, using a lever located under the steering wheel.
The Dynashift unit is controlled by two solenoid valves
installed on the low-pressure hydraulic line (17 bar). Both
solenoid valves are monitored by the tractors electronic
system.
Theory of Operation
Issue 1
May 2001
Fig. 1
Fig. 2
Overall view
18
20
21
23
25
24
27
26
28
29
30
32
31
33
35
36
34
37
38
, ,
,,,,,,,,,,
,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,,,,,
,,,,,,,,,
,
,
,,,,,,,,
(1)
(2)
(3)
(4)
(5)
(7)
(10)
(13)
(14)
(15)
(16)
(17)
(18)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
(65)
(66)
(68)
(69)
(70)
(71)
(72)
(73)
(74)
(75)
(76)
(77)
(79)
(80)
5B03.3
,
,
,
,
,
,
,
,
,
,
,,,,,,,,,,,,,,,,,,,,,,,,, ,
,
,
,
,
,
,,,,,,,,,,,,,,,,,,,,,,,,,
, ,,,,,,,,,
Gearbox - Dynashift
15
39
17
41
16
40
15
42
,
14
13
10
79
80
7
76
69
43
44
45
46
48
49
51
47
52
50
77
53
70
71
72
54
55
59
56
57
61
58
73
22
75
64
62
68
66
63
Parts list
Issue 1
May 2001
60
Fig. 2
65
Fig. 1
Gearbox - Dynashift
5B03.4
Exploded view
69
10
27
79
25
13
1
36
18
37
7
35
80
32
50
29
48
23
22
59
20
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,,,,,,
38
17
54
15
77
,
,
,
,
,
,
,
,
,
,
,
,
,
,,,,,,
,
,
,
,,,,,,
,
,
,
,
,
,
,,,,,,,,
,
,
,,,,,,,,
,
,
,, ,,,
73
71
74
49
61
53
16
39
21
30
26
66
24
62
42
63
64
43
75
51
28
47
71
52
76
41
72
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,,,,,,,,,,,,,
,
,
,, ,
55
70
57
56
,
,
,,,,,,,
,
,
,
,
,
,,,,,,,,,,
,
,
,
,
,
,,,,,,,
,,
15
,
,
,
,,,,,,
,,,,,,,
,
,
,
,
31
14
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,,
33
34
60
58
68
40
65
46
Parts list
45
44
Fig. 1
Fig. 2
Issue 1
May 2001
Gearbox - Dynashift
Explanation of gearbox ratios
Ratio A : 1/1.620 reduction (Fig. 3)
Pistons (22) and (37) simultaneously receive the pressure of the 17-bar circuit.
Secondary ring gear (34) is locked to the housing by the
action of the front brake. Secondary sun gear (61) is
locked to the housing by the action of the rear brake.
Consequently, the secondary epicyclic train is locked.
Primary sun gear (64) is blocked.
5B03.5
37
34
22
64
61
Lubrication
May 2001
Gearbox - Dynashift
5B03.6
37
34
22
39
64
61
53
Lubrication
Fig. 4
Issue 1
May 2001
Gearbox - Dynashift
5B03.7
37
22
34
39
64
61
Lubrication
December 2000
Gearbox - Dynashift
5B03.8
Ratio D : Ratio 1/1 (Fig. 6)
34
61
53
Lubrication
Mechanical locking
Fig. 6
Issue 12
December
May 2000
2002
Gearbox - Dynashift
5B03.9
A . Preliminary operations
1. Split the tractor between the engine and gearbox
(see section 2B01).
2. Drain the gearbox.
3. Remove the selector cover (see section 5C01).
4. Remove the reverse shuttle selector (see section
5B01).
5. Remove the clutch assembly (see section 4A01).
6. Remove the direct drive shaft.
7. Remove the clutch control valve (see section 9J01)
as well as the transfer tubes connected to the unit
(lube and 17-bar pressure).
8. Remove the input unit (see section 5B01) and place
on a work bench in the vertical position.
13
21
Fig. 7
Fig. 8
34
25
Issue 1
May 2001
Gearbox - Dynashift
Issue 1
May 2001
Fig. 9
63
Fig. 10
Gearbox - Dynashift
E . Assembling the planet pinion
cages
29. Clean and check the parts, replacing any that are
faulty.
30. Ensure that the lube ports in the planet pinion cage
shafts are not blocked.
31. Manually check the axial play and rotation of each
sun gear.
32. Install primary sun gear (64) fitted with ring (62) and
oil splasher (75), in secondary planet-pinion cage
(39).
33. Insert three needles (63) through holes in primary
sun gear, so that they abut on bottom of groove in
secondary planet-pinion cage.
34. Fit bearing (58), install ring (60).
35. Assemble the secondary planet-pinion cage on primary planet-pinion cage (28). Turn the sun gears in
order to facilitate meshing.
36. Fit spacer (56) and bearing (57); install circlip (55).
37. Check manually for normal backlash between the
primary sun gears.
38. Install ring (49) (if it was removed) on secondary sun
gear (61).
5B03.11
42
Fig. 11
54
59
Fig. 12
Issue 1
May 2001
5B03.12
Gearbox - Dynashift
Fig. 13
Special point
If replacement of front cover (13) proves to be necessary,
degrease washer (79) and its mating face on the cover.
Lightly smear one face of this washer with Loctite 648 or
similar then stick on the cover. Leave to dry for a few
moments.
49. Ensure presence of rivets on cover.
50. Place the cover on a suitable support.
51. Check for presence of washer (79). Coat friction
washer (10) with miscible grease and apply to
housing (14). Install transmission shaft (7) and
housing.
52. Position cup washer (4) per Fig. 1, fit one disc (15)
and thrust plate (16).
53. Fit drive hub (5) with internal splines facing upwards
on transmission shaft (7) (Fig. 15). Install discs (3)
and intermediate plates (2).
54. Install the other two discs (15), separated by clutch
plate (17).
55. Refit springs (20). Fit Oring (73).
56. Ensure presence of rivets (23) and (29). Ensure that
the pipes to pistons (22) and (37) in housing (21) are
not blocked.
57. Lubricate seals (24) and (26) and install respectively
on piston (22) and inside housing (21).
58. Position the piston in the housing and fit using a
plastic hammer to tap progressively and alternately
around the edge.
59. Screw two guide studs into housing (21) and position
on cover (13). Check that the lube pipe in the housing
corresponds to the one on the cover.
53
59
Fig. 14
5
7
Fig. 15
Issue 22
1
Issue
March
2002
December
2000
May 2002
Gearbox - Dynashift
5B03.13
Special point
Replacing cover (13) on housing (21) or reverse-shuttle
housing (40) requires checking and if necessary readjusting the clutch (see section 4 A01).
60. Remove the guide studs. Coat screw (18) with Loctite 241, install, and torque to 29 - 37 Nm.
Issue 1
May 2001
Gearbox - Dynashift
,,, ,
,,,,,,,,,,,,
,
,
,
,
,
,
,
,
,
,
,
, ,,,,,,,,,,,
,,,,,,,,,,,,,
,,,,
,
,
,
,
,,,,,,,,,,,,,
,
,,,,,,
,
J1 = 0,50 / 0,70 mm
71
47
Fig. 16
,,,,,,,,,, , ,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,
,,,,,,,,,,,
,
,
,,,,
,
,,,
,,,,,,
,
,
,
,
,
,
,
,
,,, ,,,,,,
, ,,,,,
,,
,
,
65. Install secondary sun gear (61) complete with retaining ring (49) on ball bearing (57).
66. Measure dimension D using a depth gauge.
67. Determine gap E between primary planet-pinion
cage (28) and hub (54) (Fig. 19) according to the
formula: E = A + D
68. Fill space E with shims (71) having a value of E +0.50
mini to + 0.70 maxi, to give a clearance of :
J1 = E + 0.50 to 0.70 mm
J2 = 0 / 0,20 mm
61
49
57
Fig. 17
,
Issue 1
May 2001
42
Fig. 18
,,,
,
, ,,,,,
,
,,,
Gearbox - Dynashift
5B03.15
69. Place sun gear (61) on housing (59) and the planet
pinion cage assembly on shaft (53). Install washer
(76) and ring (72).
70. Position the feeler of a dial gauge per Fig. 20 and
check the clearance by moving the planet pinion
cage assembly vertically.
71. Depending on the measured clearance, select the
thickness of shims (71) to obtain J2 = 0 / 0.20 mm.
72. Remove the planet pinion cage assembly.
73. Install springs (65). Position clutch plate (38), ensuring that the notches align with the tabs of unit (42).
74. Ensure presence of shims (71) defined at operation
68.
75. Refit sun gear (61) and the planet pinion cage
assembly, and compress the parts using tool, P/N
3376920M2.
76. Set shims (71) selected at operation 71 against planet pinion cage (28). Install washer (76) and ring (72)
(Fig. 20).
77. Check manually for normal backlash between the
secondary sun gears.
28
54
Fig. 19
,,, ,,
,, ,,,,,,,,,
,,,,,,,,,,,,,,,,,,,,,,,
,,,,,,,,,,
72
76
,
,
,,,,
28
28
71
Fig. 20
Issue 1
May 2001
Gearbox - Dynashift
J . Final operations
83. Refit the input unit (see section 5B01) and the PTO
drive line.
84. Reassemble the front clutch (see section 4A01).
85. Refit the reverse shuttle (see section 5B01).
86. Refit the selector cover (see section 5C01).
87. Reassemble the tractor between the engine and
gearbox (see section 2B01).
88. Service the oil in the sumps and check the level in the
sightglass located on the left of the centre housing.
89. Bleed the clutch control if necessary (see section
9I01).
90. Proceed to road-test of all Dynashift controls and
gear ranges A, B, C and D.
91. Check for leaktightness at couplings and mating
face of selector cover.
,
,
,
,
,
,
,
,
,
,,,,,,,
,, ,,
Fig. 21
K . Service tools
Tools available in the AGCO network:
- 3376887M1 - Centring tool (Fig. 21)
- 3376888M1 - Secondary planet-gear cage holding
tool (Fig. 22)
- 3376920M2 - Planet-gear cage compression tool
(Fig. 7)
Fig. 22
Fig. 23
Issue 1
May 2001
5B04.1
5 B04 Dynashift
CONTENTS
-
General ________________________________________________
A.
B.
C.
11
D.
12
E.
12
F.
13
G.
14
H.
15
I.
17
J.
17
K.
18
Issue 1
May 2002
General
- On tractors 8210 - 8220 - 8240 and 8250, the Dynashift
can also be mounted on an input unit fitted with a
mechanical reverse shuttle.
- This section only describes the Dynashift with power
shuttle. For the Dynashift with mechanical reverse
shuttle, see section 5B03.
- The operating principles of the two Dynashift versions
are similar.
- However, housing profile of the Dynashift with power
shuttle is different because of the location of the power
shuttle rear clutch and the driving gear located at the
rear end of the housing.
- The Dynashift is located between the rear clutch and
the driving gear of the power shuttle (see section 5B06).
- It is a hydraulically controlled gear shift mechanism and
provides the gearbox with four input ratios.
- The function is ensured by two epicyclic gear trains
associated with two hydraulic clutches. Dynashift
design enables selection of each of the four ratios while
driving, and under load, without de-clutching, using a
lever mounted to the left under the steering wheel.
- The Dynashift housing is controlled by two solenoid
valves mounted on the clutch unit located on the front
right hand side of the gearbox.
- The two solenoid valves are controlled by the tractors
electronic system.
Operating principle
The Dynashift input unit comprises two epicyclic gear
trains:
- the primary epicyclic gear train is the input units main
component and transmits the movement of the engine
to the gearbox,
- the secondary epicyclic gear train controls the speed of
the primary sun gear.
Issue 1
May 2002
(55)
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
(65)
(69)
(70)
(71)
(72)
(74)
(75)
(76)
(77)
(78)
(79)
5B04.3
Circlip
Spacer
Ball bearing
Ball bearing
Rear clutch housing
Retaining ring
Secondary sun gear
Retaining ring
Needles
Primary sun gear
Springs
Circlip
Stop
Shim(s)
Retaining ring
Rivets
Oil splasher
Stud washer
Spring washer
Washer
Locating pin
Overall view
17
18
13
11
12
10
14
42
23
25
29
20
16
15
22
24
77
27
Fig. 1
Fig. 2
26
37
31
21
33
74
70
69
71
72
79
1
28
64
75
76
53
50
58
63
34
39
62
35
56
61
60
36
57
49
55
59
65
48
30
38
44
45
40
41
47
51
54
78
52
46
Parts list
Issue 1
May 2002
Fig. 2
Fig. 1
5B04.4
Exploded view
42
9
20
18
25
1
37
16
36
35
15
33
79
34
14
72
10
70
12
69
54
11
22
50
31
13
48
39
23
50
27
29
48
77
50
48
74
50
21
59
78
63
38
24
46
26
71
28
49
15
61
17
39
15
5
55
53
57
30
56
40
60
65
58
51
62
47
64
75
52
28
41
71
45
76
41
44
41
Parts list
Issue 1
May 2002
Fig. 1
Fig. 2
5B04.5
- Consequently:
. the secondary epicyclic gear train is locked
. the primary sun gear (64) is locked
. the reduction ratio is only set by the primary epicyclic
gear train.
- This is standard kinematics, movement comes in via
the ring gear and exits via the planet carrier; the sun gear
does not move.
37
22
34
64
61
Lubrication
17 bar low pressure
Fig. 3
Issue 1
May 2002
5B04.6
37
22
34
39
31
64
28
61
53
Lubrication
Issue 1
May 2002
5B04.7
22
37
34
39
7
64
61
Lubrication
May 2002
5B04.8
34
61
53
Lubrication
Transmission of movement to the gearbox
Mechanical locking
Fig. 6
Issue 1
May 2002
5B04.9
A . Preliminary operations
1.Uncouple the tractor between the engine and the
gearbox (see section 2B01).
2. Drain the gearbox.
3. Remove the selector cover (see section 5C02)
4. Remove the clutch cover plate (see section 3C02),
hydraulic control unit and front clutch from the power
shuttle (see sections 9K01 and 5B06 respectively).
Remove the input unit (see section 5B02).
5. Place the housing in vertical position and split the
power shuttle rear clutch from the input unit (see
section 5B06).
13
21
Issue 1
May 2002
5B04.10
Disassembly (Fig. 8)
3378004M1
37
69
27
34
31
33
35
77
26
36
24
21
16
22
20
25
10
14
17
15
13
Fig. 8
Issue 1
May 2002
5B04.11
63
Removal (Fig. 9)
15. Using tool ref. 3376920M2 (see K) gently compress the planet carrier assembly (Fig. 9).
16. Remove the retaining ring (72). Remove the stud
washer (76), planet carrier assembly and the shims
(71) mounted along the mating faces of the primary
planet carrier (28).
17. Remove the secondary sun gear (61) and the retaining ring (49) (if necessary).
18. Remove the circlip (55). Remove the bearing (57)
and the spacer (56).
Fig. 10
Splitting
19. Split the secondary planet carrier (39) from the
primary planet carrier (28).
20. Remove the retaining ring (60) and bearing (58).
21. Place the secondary planet carrier in vertical position. Remove the needles (63) (Fig. 10) by hitting the
planet carrier gently against a wooden shim. Split the
planet carrier from the primary sun gear (64) along
with the retaining ring (62) and oil splasher (75).
28
60
39
28
76
71
72
58
56
57
55
61
39
49
3376920M2
Fig. 9
Issue 1
May 2002
Issue 1
May 2002
5B04.13
54
59
61
Fig. 11
46
Fig. 12
54
53
65
59
Issue 1
51
41 44
Fig. 13
May 2002
Special point
- If either the cover (13) or the casing (21) is replaced it
is necessary to check and possibly renew the shimming of the power shuttle front clutch (see section
5B06).
Issue 1
May 2002
5
14
7
12
13
Fig. 14
5B04.15
J2 = 0/0,20 mm
J1 = 0,50/0,70 mm
71
Fig. 15
61
49
57
D
Fig. 16
Fig. 17
Issue 1
May 2002
28
54
Fig. 18
28
72
76
28
71
Fig. 19
Issue 1
May 2002
5B04.17
J . Final operations
82. Reinstall the power shuttle rear clutch (see section
5B06).
83. Refit the input unit (see section 5 B02) and the power
shuttle hydraulic unit (see sections 5B06 and 9K01
respectively).
Refit the clutch cover (see section 3C02).
84. Couple the tractor between the engine and the
gearbox (see section 2B01).
85. Top up housings with oil and check the level on the
sight-glass on left at rear of central housing.
86. Carry out a road test.
87. Check the oil tightness of the hydraulic unions and of
the selector cover mating face.
Issue 1
May 2002
K . Service tools
3376887 M1
Fig. 20
3376920 M2
Fig. 21
3378004 M1
Fig. 22
Issue 1
May 2002
5B05.1
CONTENTS
-
General ________________________________________________
Operation ______________________________________________
A.
B.
C.
D.
E.
Issue 1
May 2001
General
Type 8210 - 8220 - 8240 and 8250 tractors may be fitted
with a Heavy Duty gearbox featuring a mechanical
reverse shuttle.
The reverse shuttle transmits movement commanded at
the Dynashift into the transfer shaft installed at the front
of the main gearbox, by the action of the dual gear (see
section 5A01).
The reverse shuttle assembly is located in the rear cavity
of the input housing behind the Dynashift. It includes:
- two helically cut pinions (19) and (28) installed on two
needle bearings (4) and (5). These pinions are respectively in constant engagement with the dual gear at the
box main input drive and reverse-drive idling gear (17)
- twin-cone synchromesh assembly (34), the hub is
locked by the splines on secondary shaft (2)
- a synchromesh-control selector rail and fork assembly
(see section 5D01)
- secondary shaft (2) installed on two tapered roller
bearings supported by two bearings in the input housing
- reverse drive idling gear (17) rotating on two tapered
roller bearings installed on shaft (14) mounted in two
bores in the housing.
The latter gear is in constant engagement with the front
teeth of the gearbox dual input gear.
Operation
Forward drive
When the synchromesh slide is over on the right, it
transmits movement to forward drive gear (19) in direct
connection with the rear teeth of the gearbox dual input
gear.
Reverse drive
Forward-drive gear (28) is in constant engagement with
idling gear (17) which meshes with the front teeth of the
gearbox dual input gear.
Issue 1
May 2001
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
Shim(s)
Secondary shaft
Bearing cone
Needle roller bearing
Needle roller bearing
Bush
Washer
Bearing cone
Bearing cup
Roller bearing
Screw
Bearing cone
Bearing cone
Idling gear shaft
Bearing cup
Spacer ring
Reverse-drive idling gear
Bearing cup
Forward drive gear
Synchromesh slide
Rings
Rings
Cones
Synchromesh flanges
Locking device
Shoes
Synchromesh hub
Reverse-drive gear
Washer
Bearing cup
Screw
Retaining plate
Housing
Synchromesh assembly
Fig. 1
Fig. 2
5B05.3
Overall view
33
29
28
19
31
30
32
34
10
9
4
16
18
17
26
15
25
27
20
21
22
11
12
13
23
24
19
14
Parts list
Issue 1
Fig. 2
Fig. 1
May 2001
5B05.4
Exploded view
14
13
15
16
10
17
33
18
6
12
11
2
9
8
3
7
30
5
1
19
32
24
23
31
22
21
26
27
25
20
21
22
23
24
28
34
Parts list
Issue 1
Fig. 1
29
May 2001
Fig. 2
5B05.5
A . Preliminary operations
1. Split the tractor between the engine and gearbox
(see section 2B01).
2. Drain the gearbox and the intermediate housing.
Note: Visually identify the contour of the plugs.
3. Remove the hydraulic clutch (see section 4A01).
4. Remove the selector cover (see section 5C01).
5. Remove the input housing (see section 5B01).
6. Disassemble the locking device, the selector rail and
the reverse shuttle fork (see section 5D01).
7. Place the housing on a work bench in the vertical
position. Remove the sling.
8. Disassemble the Dynashift (see section 5B03).
7
19
28
34
Fig. 3
Issue 1
May 2001
Reassembly
17. Clean and check the parts and replace any that are
faulty.
18. Check that the pipes and ports in secondary shaft
(2), shaft (14), housing (33), synchromesh (34) and
bush (6) are not blocked.
19. Ensure that the plug (rivet) is crimped into the
housing, on the end of the lube pipe to the reversedrive idling gear.
20. If necessary, overhaul synchromesh (34) (see General and operation, section 5A01).
21. If it was removed, refit washer (29) on shaft (2) then
fit cone (3) in abutment on the washer, using a press
and a suitable fixture.
22. Lubricate the shaft, the cones and the bearing cups.
23. Assemble gear (19) and bush (6) by positioning the
inner recess towards drive hub (27) of the assembly
comprising (34), needle roller bearings (5), cones
(23), rings (21), rings (22), synchromesh flanges
(24), gear (28) and needle roller bearings (4).
31
32
30
2
28
34
19
7
Fig. 4
Issue 1
May 2001
5B05.7
Fig. 5
P1 = 0,10 / 0,20 mm
Preliminary steps
35. Calculate shim thickness E (1) to obtain a temporary
clearance of 0.10 to 0.20 mm maximum.
36. Position cup (30), shims (1) as calculated earlier, and
retaining plate (32).
37. Install and provisionally tighten screw (31) without
Loctite to 25 - 32 Nm.
Issue 1
May 2001
14
Preparation
46. Install minimum spacer ring (16) in the groove of
gear (17) then fit cups (15) and (18) in abutment on
the segment.
47. Position gear (17) per Fig. 7 and cones (12) and (13)
on the housing. Slide shaft (14).
48. Install screw (11) (Fig. 7) without Loctite, and torque
to 40-56 Nm.
49. Adjust shims (Fig. 8) to obtain a clearance:
J2 = 0.05 to 0.18 mm.
13
17
12
11
Fig. 7
Shimming
50. Apply the feeler of a dial gauge to gear (17) (Fig. 7).
51. Exert a hard push on the gear, alternately rotating to
right and left in order to seat the cones correctly in the
cups.
52. Adjust the dial gauge to zero.
53. Repeat operation 51, this time pulling on the shaft.
54. Depending on the value read on the dial gauge, select
the definitive spacer ring (16) to obtain J2.
55. If necessary, remove gear (17). Drive out cups (15)
and (18). Remove spacer ring (16).
Fit the spacer ring selected at operation 54.
Fit the cups. Reinstall the gear. Repeat operation 30.
56. Coat screw (11) with Loctite 241 or equivalent,
install and definitively torque to 40 - 56 Nm.
57. Check with fingers for normal backlash at gear (17)
and rotation of the gear train.
Issue 1
May 2001
0,05 //0,18
J2J2==0,05
0,18mm
mm
Fig. 8
5B05.9
E . Final operations
58. Reassemble the Dynashift (see section 5B03).
59. Reassemble the reverse shuttle fork, the selector
rail and the locking device (see section 5D01).
60. Refit the input housing (see section 5B01).
61. Refit the selector cover (see section 5C01).
62. Refit the hydraulic clutch (pressure loaded) (see
section 4A01).
63. Reassemble the tractor between the engine and
gearbox (see section 2B01).
64. Service the oil in the sumps and check the level on
the sightglass located on the left of the centre
housing.
65. If necessary, bleed the hydraulically controlled clutch
(see section 9I01).
66. Proceed to road test of all Dynashift controls (reverse
shuttle and ratios A, B, C, D).
67. Check the leaktightness of the hydraulic connections and the mating face of the selector cover.
Issue 1
May 2001
5B06.1
CONTENTS
General ________________________________________________
A.
11
B.
12
C.
15
D.
16
E.
Disassembling and reassembling the driving pinion Shimming the shaft _____________________________________
20
23
F.
Issue 1
May 2002
Issue 1
May 2002
5B06.3
Design
The front and rear clutches of the Power Shuttle are of
different design.
The front clutch consists of:
- a conventional type oil-bath multi-disc clutch consisting of a cover (33), the rear side of which is splined to
assemble the input sun gear (53),
- an input shaft (19) passing through the clutch cover
plate (4) that separates the engine flywheel from the
transmission oil. The shaft is constantly meshed with
the damper secured to the engine flywheel. It is splined
so as to rotate with the clutch unit (18) comprising the
intermediate plates (30) and the discs (29) in which
piston (28) moves,
- a drive hub (27) comprising the discs (29) and integral
with the primary shaft (55). The front clutch is centered
in the cover (38) of the rear clutch by ball bearing (32).
The rear clutch consists of :
- an epicyclic gear train consisting of three double pinion
gears (52) and three single pinion gears (59),
- a hydraulic braking device for planet carrier (49),
- a cover (38) supporting the front clutch and with an inner
side machined to assemble hydraulic parts.
- The double and single pinion gears (52) (59) of the
epicyclic gear train mesh respectively on the input and
output sun gears (53) (58). The pins (50) are mounted
idle and held in the planet carrier by plates (63). A central
drilled channel and radial ports supply lubrication to
needle bearings (60).
- The planet carrier braking device consists of an annular
piston (39) and a plate (43) that is loaded by springs (62)
and discs (47) integral with the planet carrier through
splines.
- The intermediate plates (46) are immobilised by the
pins (71).
- The fixed unit (1) performs two functions:
. it receives the low pressure supplying the front clutch
via pipe (74),
. it acts as the body of the clutch lubricating and cooling
pump.
Issue 1
May 2002
The pipes (31) (86) connecting the pump unit (1) and
cover (38) lubricate the rear clutch braking device. The
pipe (87) provides the hydraulic link to the lubrication
diagnostics connector.
The shims (3) located between clutch cover plate (4) and
the fixed pump unit (1) provide the axial clearance for the
front clutch.
Drive from the power shuttle is transmitted to a mechanical unit located in the rear compartment of the input box.
16
Fig. 1
Issue 1
May 2002
5B06.5
The input sun gear then drives the double pinion gears
(52) freely mounted on the pins (50) which, in turn, drive
the single pinion gear (59), integral with primary shaft (55)
thus reversing rotation of the output sun gear (58) splined
to the primary shaft (55). The primary shaft then sends
the movement from the engine to the layshaft of the main
gearbox via the input pinion.
Remark: As with Forward operation, simply pull the
control lever towards the steering wheel to obtain the
manual de-clutching of the rear clutch. A valve screwed
to the top of cover (38) ensures a small permanent bleed
starting from 13 bar to provide an automatic bleed of the
hydraulic supply of piston (39).
Lubrication
As piston (39) moves, it operates spools (44) that act as
valves and compress springs (45) via plate (43). The
spools have a drilled center channel and radial ports,
allowing oil to flow to the channels in cover (38) and the
channels in the front cover of the input unit, thus lubricating the discs (47) and the intermediate plates (46).
Lubrication of the mechanical parts of the epicyclic gear
train is via the lubricating system of the input unit.
At the same time, the lubricating oil flow to discs (29) and
intermediate plates (30) of the front clutch is stopped,
thus halting any possible driving of the discs through a
drag effect.
Neutral position
In neutral position, the supply to the solenoid valves is
cut, placing the front and rear clutches at rest and
eliminating transmission of the engine movement to the
gearbox.
The oil flow is also interrupted. The pressure in the circuit
opens the valve (1) (Fig. 17) and directs the oil to the
housing.
Note: After replacement of a solenoid valve or solenoid, power shuttle hydraulic unit or one of the
components of the transmission control unit, it is
necessary to carry out clutch calibration again (see
section 11).
Issue 1
May 2002
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
(65)
(66)
(67)
(68)
(69)
(70)
(71)
(72)
(73)
(74)
(75)
(76)
(77)
(78)
(79)
(80)
(81)
(82)
(83)
(84)
(85)
(86)
(87)
(88)
(90)
(91)
(93)
(94)
(95)
(96)
(97)
(98)
(99)
Pump unit
Pump cover
Shim(s)
Clutch cover plate
Locking ring
Splined ring
Oring
Anti-extrusion ring
Snap ring
Seal
Circlip
Ball bearing
Screw
Lubricating pump
Sealing rings
Ring
Centering pin
Front clutch unit
Input shaft
Pin
Circlip
Ball bearing
Snap ring
Seal
Belleville washers
Indexing ports
Drive hub
Front clutch piston
Front clutch discs
Front clutch intermediate plates
Lubricating pipe
Ball bearing
Front clutch cover
Planet carrier cover
Rivets
Seal
Rear clutch cover
Rear clutch piston
Rivets
Seal
Seal
Plate
Spools
Springs
Rear clutch intermediate plates
Rear clutch discs
Ring restrictor
Planet carrier
Pinion gear pin
Spacers
Double pinion gear
Input sun gear
Snap ring
Issue 1
Primary shaft
Snap ring
Ball bearing
Output sun gear
Single pinion gear
Needle bearings
Snap rings
Springs
Stop plates
Screw
Snap ring
Screw
Oring
Ball bearing
Seal
Screw
Pin
Unions
1.5 bar valve
Pipe
Orings
Pipe (17 bar rear clutch)
13 bar valve
Pipe (shuttle lubrication)
Screw
Flange
Seal
500 micron strainer
Union
Plug
Seal
Lubricating pipe
Pipe
Union
Diagnostics connector (lubrication)
Union
Union
Pipe
Orings
Union
Screw
Snap ring
Screw
Fig. 2
Fig. 3
Fig. 4
May 2002
5B06.7
Overall view
38
33
70
32
72
35
34
36
38
40
42
43
45
44
64
46
A
47
48
49
B
9
11
12
13
14
15
16
50
18
86
51
10
30
52
29
53
28
54
26
55
19
56
24
61
31
20
3
2
25
57
18
98
69
58
68
59
C
67
60
21
23
22
66
27
65
71
41
39
63
54
Fig. 3
38
43
62
Fig. 4
Issue 1
May 2002
Fig. 2
Overall view
73
31
72
86
76
72
75
88
74
75
89
83
91
Lubrication Dynashift
96
90
75
95
97
94
67
87
93
78
82
79
80
81
85
84
Fig. 3
Fig. 2
Issue 1
May 2002
Fig. 4
5B06.9
Exploded view
Front clutch
Rear clutch
65
45
33
44
27
54
77
53
32
29
30
46
62
47
71
49
6
17
9
57
43
56
42
98
41
63
36
25
52
39
15
60
38
40
51
70
60
50
63
21
34
19
99
22
2
28
13
59
24
23
60
69
51
18
12
60
66
11
50
20
61
68
58
16
61
1
14
Fig. 2
73
Fig. 4
Fig. 3
Issue 1
May 2002
Issue 1
May 2002
5B06.11
Final operations
Preliminary operations
1. Split the tractor between the engine and the gearbox
(see section 2B01).
2. Drain the gearbox and the centre housing.
3. Remove the clutch cover plate from the gearbox (see
section 3C02).
4. Remove the flange from each end of the pipe (78) and
remove it (Fig. 3).
5. Remove pipes (31) (74) (86) (87) and (94).
Removal
6. Remove the front clutch (2) (Fig. 5) and pull it from the
housing using a locally made tool (see F).
Refitting
7. Clean the parts. Replace any defective ones.
Remark: If front clutch shimming is necessary,
refer to C.
8. Check that PTO shaft (1) is installed (Fig. 5).
9. Refit the clutch using the tool used for removal.
Fig. 5
Issue 1
May 2002
5B06.12
Reassembly
32. Make sure that pin (20) is fitted.
33. If removed, fit the bearing (32) on cover (33), using
a press and a suitable tool. Install snap ring (65).
34. If disassembled, refit bearing (68).
40. Lubricate the new seals (24) (69) and fit them on the
piston.
25
F
F
Fig. 6
Issue 1
May 2002
5B06.13
18
28
Fig. 7
Fig. 8
16
Fig. 9
Issue 1
May 2002
Issue 1
May 2002
29
27
30
Fig. 10
5B06.15
65
38
4
3
19
32
J1 = 0,60/0,80 mm
Fig. 11
Issue 1
May 2002
64. Remove the thick springs (62) and the pins (71).
65. On cover (38), remove:
- the plate (43)
- the seal (42) and discard it
- the piston (39)
- the seals (36) (41) and discard them
- the unions (72), the 13 bar valve (77) (Fig. 17) and
seal (75) on the 17 bar supply port (Fig. 3).
61
70
38
58
99
56
34
17
98
61
44
62
45
71
55
Fig. 12
Issue 1
May 2002
5B06.17
99
34
49
Fig. 12A
59
49
52
Reassembly
73. Clean and check all parts. Replace any defective
ones.
74. Check that the ports in the pinion gear pins and the
channels in the planet carriers are not clogged.
75. Where necessary, fit the pinion gears with two rows
of needle bearings coated with miscible grease and
separated by a spacer.
76. On the planet carrier, refit:
- bearing (57) and position snap ring (56 ),
- the double and single pinion gears (52) (59) positioned as shown in Fig. 13,
- pins (50), with the lubricating ports placed facing
those in the planet carrier (49).
Fig. 13
Special points
Each end of the pins (50) contains:
- a port, one of which is closed off by a rivet (35) while
the other is used for pinion gear lubrication,
- a flat and a shoulder that stop any pin rotation or any
side movement.
Issue 1
May 2002
Issue 1
May 2002
R
52
52
"0"
Fig. 14
62
47
46
71
Fig. 15
5B06.19
38
P
44
45
71
Final operation
62
Fig. 16
96. Install the input unit (see section 5B02) and the front
clutch (see A).
77
38
Fig. 17
Issue 1
May 2002
Preliminary operations
97.
98.
99.
100.
Fig. 18
Issue 1
May 2002
5B06.21
13
16
9
8
14
R
Fig. 19
Issue 1
May 2002
Final operations
128.
129.
130.
131.
Issue 1
May 2002
1
3
P1=0,05 / 0,15mm
Fig. 20
5B06.23
F . Service tools
1. Tools available in the AGCO network
- 3378240 M1 - Planetary carrier immobilizing tool
(Fig. 21)
Fig. 21
86
1
23
80
86
2
100
165
Fig. 22
180
248
60
286
Fig. 23
Issue 1
May 2002
5C01.1
CONTENTS
-
General ________________________________________________
A.
Operation ______________________________________________
B.
C.
12
D.
12
E.
14
F.
18
G.
22
H.
23
Issue 1
December 2000
General
8200-series tractors with a mechanical reverse shuttle
are equipped with either a cab or a platform and a selector
cover of similar construction. For the version with the
footstep, see F.
The selector cover, installed on the right-hand side of the
housing on the Heavy Duty gearbox, has two separate
levers providing two different functions:
- front lever - for controlling the reverse shuttle,
- rear lever - for selecting the four basic speeds and the
two Hare / Tortoise ratios (Hi - Lo).
Special point
When the tractor is stopped, cell C mounted on a
bracket on the selector cover (Fig. 3) informs the user
that a gear has remained engaged, and that the handbrake is on.
The warning is issued by a buzzer located under the
instrument panel surround.
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Return ports
Grounding lug
Screw
Temperature probe with seal.
Seal
Shouldered ring
Selector cover
Finger-pin assembly (reverse shuttle)
Finger-pin assembly (speeds)
Grid
Screw
Spring
Spring cup
Spring cup
Spring
Spring cup
Seal
Shouldered ring
Seal(s)
Hare / Tortoise switch
Fig. 1
Fig. 2
Issue 21
May 2002
December
2000
5C01.3
Overall view
12
13
14
15
16
20
1.2
19
11
10
18
17
3.4
20
7
8
3
1
S
5
7
3
Parts list
Fig. 2
Fig. 1
Issue 1
May 2001
5C01.4
Exploded view
9
12
13
11
10
14
15
16
7
1
18
17
6
2
1
3
4
19
20
5
Parts list
Fig. 1
Fig. 2
Issue 1
May 2001
5C01.5
1/2
2
1
Z
9
1
3/4
C
Fig. 3
Issue 1
May 2001
Issue 1
May 2001
5C01.7
A . Operation
Reverse / Forward lever
On tractors with cabs, lever (1) (Fig. 3) has the following
positions:
- upwards (forward drive)
- downwards (reverse drive)
Moving lever (1) (Fig. 3) results in rotation of the pin which
is hard-mounted to finger (8); the follower moves selector S (Fig. 1).
Gear lever
Selecting 1st / 2nd gear
- Gear lever (2) pushes lever L (Fig. 3) and engages
finger (9) in the 1st / 2nd gear selector fork (Fig. 1).
- The first ratio is obtained by moving lever L upwards,
and the second ratio by moving it downwards.
Selecting 3rd / 4th gear
- In this configuration, gear lever (2) (Fig. 3) is in the
intermediate position; finger (9) integral with shaft A
is engaged in the 3rd / 4th gear selector fork (Fig. 1).
- The third ratio is obtained by moving lever L upwards,
and the fourth ratio by moving it downwards.
Issue 1
May 2001
5C01.8
Hare / Tortoise function
P
F1
S
A
B
Issue 1
May 2001
17 bar
Fig. 4
5C01.9
Preliminary operations
2
11
6
4
11
5
3
Fig. 5
Removal
Tractors with cabs
Gear control (Fig. 5)
8. Disconnect the harness from cell "C" (Fig. 3). Remove ball joint (4). Remove screw (3).
9. Remove pins (11). Disconnect ball joint (5).
10. Note the adjustment of cable (6). Slightly loosen
upper nut (12) and separate the cable from bracket
(2).
Issue 1
May 2001
Refitting
2
Fig. 6
Fig. 7
Issue 1
May 2001
5C01.11
Fig. 8
Final operations
22. Refit any items previously removed around the
cover.
23. Replace the wheel and torque the screws or nuts
depending on the version (see section 2G01).
24. Service the oil in the sumps and check the level in the
sightglass located on the left-hand of the centre
housing.
25. Remove the chocks between the frame and front
axle. Release the handbrake.
26. With the engine running, check passage of all gears
and the reverse shuttle. Also check the Hare/Tortoise position. If necessary, and with the engine
stopped, adjust the controls (see E).
27. Check that the buzzer of the safety cell vibrates
correctly (contact set, handbrake on and gear engaged).
28. Carry out a road test.
Issue 12
December
May 2000
2002
Reassembly
31. Clean and check the parts; replace any that are
faulty.
32. Without installing the Orings on the piston, check
that the latter slides freely in the bore in the cover.
33. After inspection, lubricate and fit new Orings. Reverse operation 30.
34. Refit the selector cover (see B).
Note
- Replacing piston (3), bearing (4) or circlip (6) implies
checking or repeating the setting of selector "S" on the
Hare/Tortoise range (see G).
Disassembly
Tractors with cabs
36. Remove screws (1) and (4). Remove selector (3),
link rod (5) and bracket (2) (Fig. 9).
37. Remove the pin integral with finger (8).
38. Remove screw (11). Remove the gear control assembly.
39. Remove cup washers (14) and (16) and spring (15).
40. Separate the assembly comprising pin and finger (9)
from grid (10). Remove spring cup (13) and spring
(12).
41. If necessary, unscrew and remove Hare/Tortoise
switch (20), the threaded fittings on return ports (1),
and temperature probe (4). Recover seal(s) (19) from
the Hare / Tortoise switch.
42. Extract seals (5) and (17).
Issue 1
December 2000
5
Fig. 9
5C01.13
Reassembly
Special point
If considered necessary to replace guide rings (6) and
(18), lightly coat the edges of the replacement rings with
Loctite 638 or equivalent and fit them tight so that they
come into contact with the shoulders on the cover.
Final operations
51. Check that the selector mechanisms move freely.
Remove the cover from the vice and refit to the
gearbox (see B).
29 mm
Fig. 10
Issue 1
May 2001
166
1
4
5
1
Fig. 11
12
X
9
D
3
4
6
12
1
11
7
9
11
10
5
L
8
Fig. 12
Issue 1
May 2001
5C01.15
Fig. 13
Remark
If no interference between the lever and the control panel
is observed, the setting is correct. Put back the boot.
If the position of the lever is incorrect, return to the
adjustment on the selector cover side.
- if interference in 1st or 3rd gears (Fig. 13), reduce dimension "X" (Fig. 12).
- if interference in 2nd or 4th gears (Fig. 13), increase
dimension "X" (Fig. 12).
- by playing on dimensions "C" and "D" (Fig. 12), the gear
lever can be moved around in the control-panel opening,
as shown by the arrows in Fig. 14.
Fig. 14
Issue 1
May 2001
4
6
7
3
4
Fig. 15
Issue 1
May 2001
5C01.17
R
4
1
Fig. 16
Inspection
78. Consecutively engage forward drive and reverse
drive.
79. Next check that linkage (5) (Fig. 16) locks correctly
without excessive tension in the cables.
X =Y
Fig. 17
Issue 1
May 2001
Layout
2
1
Remark
The operating principle (mechanical or hydraulic) remains identical to the system employed on the cab
version. In addition, removal, refitting and disassembly
of the cover are also similar operations.
It is worth noting that the position and contour of the
levers is generally different, and that the system is
simpler and more direct than on the cab version.
Issue 1
May 2001
Fig. 18
5C01.19
1.2
3.4
20
8
20
L
Fig. 19
Issue 1
May 2001
Issue 1
May 2001
5C01.21
1
Adjustment (Fig. 20)
Note: Before adjusting, partially coat the inside of
the covers with anti-seize grease or equivalent.
80. Set the reverse/forward lever and the gear lever to
the neutral position.
81. Loosen nuts (1). Adjust the covers according to
figure 20.
82. After adjustment, check the condition of the ball joint
in the cover, for all positions of the lever.
Tightening torque
- Nuts (1): 44 - 55 Nm
Fig. 20
Issue 1
May 2001
F
3
Fig. 21
0,2 mm
Fig. 22
Issue 1
May 2001
5C01.23
H . Service tools
- MF462A - Hare / Tortoise selector adjustment
gauge (Fig. 23).
Fig. 23
Issue 1
May 2001
Issue 1
May 2001
5C02.1
CONTENTS
-
General ________________________________________________
A.
Operation ______________________________________________
B.
C.
11
D.
11
E.
13
F.
15
G.
16
Issue 1
May 2002
General
Tractors fitted with a gearbox and power shuttle have a
selector cover that features a single control lever.
This lever selects the four basic gears as well as the
hydraulic Hare / Tortoise (Hi-Lo) function.
The gear lever (2) is controlled by a single linkage and
cable (Fig. 3) and is located on the right above the
console.
Special point
When the tractor is stopped with the handbrake on, a "C"
cell fixed onto the selector cover by means of a bracket
(Fig. 3) informs the user that a gear is still engaged and
that the handbrake is on.
This information is issued by a buzzer located under the
instrument panel surround.
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Return port
Grounding lug
Screw
Temperature probe and seal
Plug
hose pipes holding lug
Selector cover
Finger and pin assembly (gears)
Grid
Screw
Spring
Cup
Cup
Spring
Cup
Seal
Shouldered ring
Seal(s)
Hare / Tortoise switch
Issue 1
Fig. 1
Fig. 2
May 2002
5C02.3
Overall view
12
13
14
15
16
1.2
18
3.4
17
20
19
20
20
11
10
5
1
Parts list
Issue 1
May 2002
Fig. 2
Fig. 1
5C02.4
Exploded view
9
12
13
11
10
14
15
16
7
1
18
17
5
2
3
4
19
20
Parts list
Fig. 1
Fig. 2
Issue 1
May 2002
5C02.5
2
1
1/2
3/4
Fig. 3
Issue 1
May 2002
Issue 1
May 2002
5C02.7
A . Operation
The gear lever
Selecting 1st and 2nd gear ratios
- The gear lever (2) pushes lever "L" (Fig. 3) and engages
the finger (9) in the 1st and 2nd gear fork (Fig. 1).
- The first gear ratio is obtained by moving lever "L" upwards, and second gear by moving it downwards.
Selecting 3rd and 4th gear ratios
- In this configuration, the gear lever (2) (Fig. 3) is in the
intermediate position. The finger (9) integral with pin "A"
engages in the fork of the 3rd and 4th gear ratios (Fig. 1).
- Third gear is obtained by moving lever "L" upwards, and
the fourth gear by moving it downwards.
Issue 1
May 2002
5C02.8
P
F1
S
A
B
Issue 1
May 2002
17 bar.
Fig. 4
5C02.9
Preliminary operations
2
11
6
4
11
5
3
Fig. 5
Removal
Gear shift control (Fig. 5)
8. Disconnect the harness from cell "C" (Fig. 3). Remove the ball joint (4). Remove screws (3).
9. Remove pins (11). Remove the ball joint (5).
10. Note the adjustment of the cable (6). Slightly loosen the
top nut (12) and separate the cable from bracket (2).
11. Remove screws (3), mark the location of the grounding lug (2) and the the hose pipe clamp (6) (Fig. 1).
Note :
- On tractors fitted with a creeper unit, disconnect
the control cable (1) and remove bracket (2) (Fig. 6).
12. Loosen and remove the selector cover.
Refitting
13. Clean the mating faces of the gearbox and the cover.
14. Install :
On the cover: the Hare / Tortoise piston in the Hare
position.
On the gearbox: the Hare / Tortoise fork in the Hare
position, the 1st, 2nd, 3rd, and 4th forks in the neutral
position.
15. Lightly smear the housing /gearbox mating face with
Master Loctite 510 or equivalent.
Fig. 6
Issue 1
May 2002
16. Turn the gear shift control linkage on the cover so that
it fits into selectors "S" (Fig. 7) when positioning the
cover on the gearbox.
17. If necessary, refit the creeper unit cable bracket.
Reconnect and adjust the control (see section 5K01).
18. Refit the bracket (2). Fit and tighten up the screws (3)
to a torque of 34 - 70 Nm.
19. Refit the gear shift control. Carry out operations 8 to
10 in reverse order.
20. Using a grease gun, grease the various linkages of
the gear shift control on the selector cover.
Final operations
21. As necessary, refit those components removed
previously from around the cover.
22. Refit the wheel and tighten the wheel nuts or studs
to the correct torque depending on the version (see
section 2G01).
23. Top up the housing oil level and check it with the
sight glass located at the rear of the centre housing.
24. Remove the wedges from between the frame and
the front axle. Release the handbrake.
25. With the engine running, check the gear shifting of all
gears and Hare / Tortoise positions.
26. Stop the engine and where necessary adjust the gear
shift control (see E).
27. Check that the buzzer of the safety cell vibrates correctly (ignition on, handbrake on and gear engaged).
28. Carry out a road test.
Issue 1
May 2002
Fig. 7
5C02.11
Reassembly
31. Clean and check the parts. Replace any defective
components.
32. Without fitting Orings on the piston, check that the
piston slides smoothly in the bore of the cover.
33. The above check completed, lubricate and fit new
Orings. Carry out operation 30 in reverse order.
34. Refit the selector cover (see B).
1
Fig. 8
Remark
- The replacement of piston (3), bearing (4) or circlip (6)
requires the checking and readjustment of selector "S"
of the Hare / Tortoise range (see F).
Disassembly
36. Remove the screws (1) (4). Take off the selector (3),
and bracket (2) (Fig. 8).
37. Remove screw (11).
38. Remove the gear shift control assembly.
39. Remove the spring cups (14) (16) and spring (15).
40. Separate the finger and pin assembly (9) from the
grid (10). Remove spring cup (13) and spring (12).
41. If necessary, unscrew and remove the Hare/Tortoise switch (20), the unions screwed on the return
ports (1) and the temperature probe (4). Recover the
seal(s) (19) from the Hare/Tortoise switch.
42. Extract the seal (17).
Issue 1
May 2002
5C02.12
Reassembly
Special point
If the guide ring (18) has to be replaced, coat its rim lightly
with Loctite 638 or its equivalent and insert it in thrust
against the shoulder of the cover.
Final operations
51. Check that the selector mechanism moves freely
without constraint. Remove the cover from the vice
and refit it on the gearbox (see B).
29 mm
Issue 1
May 2002
Fig. 9
5C02.13
2
3
166
1
4
5
1
Fig. 10
12
1
C
X
9
D
3
4
6
12
1
11
7
9
11
10
5
L
8
Fig. 11
Issue 1
May 2002
Fig. 12
Remark
When there is no interference with the operation of the
lever by the console, then the adjustment is correct. Refit
the dust cover.
If the position of the lever is incorrect, repeat the
adjustment procedure at the selector cover end.
- if there is interference when engaging 1st or 3rd gears
(Fig. 12), reduce dimension "X" (Fig. 11)
- if there is interference when engaging 2nd or 4th gears
(Fig. 12), increase dimension "X" (Fig. 11)
- by altering dimensions "C" and "D" (Fig. 11), the gear
lever moves in the console opening in the direction
shown by the arrows in Fig. 13.
Fig. 13
Issue 1
May 2002
5C02.15
F
3
Fig. 14
MF 462A
0,2mm
Fig. 15
Issue 1
May 2002
G . Service tools
- MF462A - Hare / Tortoise adjustment gauge (Fig.
16)
Fig. 16
Issue 1
May 2002
5C03.1
General ________________________________________________
A.
B.
C.
12
D.
12
E.
15
F.
17
G.
18
Issue 1
May 2002
General
8210 - 8220 - 8240 and 8250 series tractors fitted with a
Heavy Duty gearbox now benefit from an optimised
selector cover.
It is located on the right-hand side of the gearbox and
comprises :
- a toggle (34)
- a neutral position switch (20).
This cover has been introduced on the previously designed tractors from serial number K309019 onwards.
The single lever, fitted on the cover, controls the gear
shifting for ratios 1 to 4. A hydraulic device provides the
Hare / Tortoise function.
The mechanical locking of the 1st - 2nd / 3rd - 4th selector
rails and the Hare / Tortoise range is carried out as
previously, by pins placed between the gear selector
rails and the selector rail located at the rear part of the
gearbox (see section 5D02 - General).
The ergonomics of the pulse button located on the
pommel of the gear lever, to the right of the driver, allows
the Hare / Tortoise range. To change the range, simply
put the gear lever in the neutral position and press the
button.
Special point
- In parallel with the selector covers already fitted on
tractors with different options (see section 5C01 and
5C02) a cell C (Fig. 3) informs the driver that a gear is
engaged and that the handbrake is on.
Issue 1
May 2002
(1)
(2)
(3)
(4)
(6)
(7)
(9)
(10)
(11)
(14)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(27)
(33)
(34)
Return ports
Grounding lug
Screw
Temperature probe
Hydraulic hose flange
Selector cover
Gear shift control finger
Bracket
Screw
Gear Selector grid
Seal
Shouldered ring
Screw
Neutral position switch
Washer
Circlip
Spring
Ball
Centring rings
Seal
Washer
Toggle
Fig. 1
Fig. 2
5C03.3
Overall view
12
13
14
15
16
1.2
18
3.4
17
20
19
20
20
11
10
5
1
Parts list
Issue 1
May 2002
Fig. 2
Fig. 1
5C03.4
Exploded view
9
12
13
11
10
14
15
16
7
1
18
17
5
2
3
4
19
20
Fig. 1
Fig. 2
Parts list
Issue 1
May 2002
5C03.5
2
1
1/2
3/4
Fig. 3
Issue 1
May 2002
Issue 1
May 2002
5C03.7
Switch (20)
- Controlled by the toggle, its function is to supply
information to the electronic system of the tractor when
the gear lever is in the Neutral position.
General operation
Gear lever
Selecting 1st - 2nd gear
- The gear lever (2) pushes lever L (Fig. 3) and engages
finger (9) in the 1st - 2nd fork (Fig. 3)
- The first ratio is obtained by moving lever L upwards
and the second ratio downwards.
Simultaneously the toggle (34) pivots with pin A and
leaves the Neutral position.
Issue 1
May 2002
5C03.8
Remark
- The new Parker Hare / Tortoise solenoid valve is now
fitted on the selector cover. This enhancement removes any risk of overtightening the spool.
P
F1
S
A
B
Issue 1
May 2002
17 bar.
Fig. 4
5C03.9
12
2
11
6
4
11
5
3
Fig. 5
Removal
Gear shift control removal (Fig. 5)
8. Disconnect the harness from cell C (Fig. 3). Remove
the ball joint (4). Remove screws (3).
9. Remove pins (11). Remove the ball joint (5).
10. Note the adjustment of the cable (6). Slightly loosen the
top nut (12) and separate the cable from bracket (2).
Fig. 6
Issue 1
May 2002
11. Remove screws (3), mark the location of the grounding lug (2) and the the hoses pipe clamp (6) (Fig. 1).
Reminder
- On tractors fitted with a creeper unit, disconnect
the control cable (1) and remove bracket (2) (Fig. 6).
12. Loosen and remove the selector cover.
Refitting
13. Clean the mating faces of the gearbox and the cover.
14. Install:
On the cover: the Hare / Tortoise piston in the Hare
position.
On the gearbox: the Hare / Tortoise fork in the Hare
position, the 1st, 2nd, 3rd and 4th forks in the neutral
position.
15. Lightly smear the housing /gearbox mating face with
Master Loctite 510 or equivalent.
16. Turn the gear shift control linkage on the cover so that
it fits into selectors S (Fig. 7) when positioning the
cover on the gearbox.
17. If necessary, refit the creeper unit cable bracket.
Reconnect and adjust the control (see section 5K01).
18. Refit the bracket (2). Fit and tighten up the screws (3)
to a torque of 34 - 70 Nm.
19. Refit the gear shift control. Carry out operations 8 to
10 in reverse order.
20. Using a grease gun, grease the various linkages of
the gear shift control on the selector cover.
Issue 1
May 2002
Fig. 7
5C03.11
Final operations
21. As necessary, refit those components removed
previously from around the cover.
22. Refit the wheel and tighten the wheel nuts or studs
to the correct torque depending on the version (see
section 2G01).
23. Top up the housing oil level and check it with the
sight glass located at the rear of the centre housing.
24. Remove the wedges from between the frame and
the front axle. Release the handbrake.
25. With the engine running, check the gear shifting of all
gears and Hare / Tortoise positions.
26. Stop the engine and where necessary adjust the gear
shift control (see E).
27. Check that the buzzer of the safety cell vibrates
correctly (ignition on, handbrake on and gear engaged).
28. Carry out a road test.
Issue 1
May 2002
Reassembly
31. Clean and check the parts. Replace any defective
components.
32. Without fitting Orings on the piston, check that the
piston slides smoothly in the bore of the cover.
33. The above check completed, lubricate and fit new
Orings. Carry out operation 30 in reverse order.
34. Refit the selector cover (see B).
Remark
- The replacement of piston (3), bearing (4) or circlip (6)
requires the checking and readjustment of selector S of
the Hare / Tortoise range (see F).
Disassembly
36. Remove screws (1). Take out key (4) and selector
(3). Separate the bracket (2) from the cover (Fig. 8).
37. Remove screws (11). Separate the bracket (10)
including the gear shift control asssembly, from the
cover. If necessary, extract the centring rings (25).
On cover (7)
38. Take off the Neutral position switch (20). Recover
seal (27) and ball (24).
39. If necessary, take off the temperature probe (4) and
the unions screwed onto the return ports (1).
40. Extract and discard seal (17).
Issue 1
May 2002
1
Fig. 8
5C03.13
Reassembly
Special point
- If guide ring (18) has to be replaced, lightly smear its rim
with Loctite 648 or its equivalent and insert it thrust
against the shoulder of the cover.
On the bracket (10)
44. If removed, insert the centring rings (25). Refit the
gear selector grid (14) and tighten screws (19)
previously lightly smeared with Loctite 271 or its
equivalent and tighten to a torque of 29 - 37 Nm.
45. Check that the flat on toggle (34) slides freely over
finger (9) flat.
46. Slide the pin and finger assembly (9) into bracket
(10).
47. Suitably turn toggle (34) and position it on the flat of
finger (9). Place washer (33).
48. Refit spring (23) and washer (21). Fit circlip (22).
On the cover (7)
49. Check for the presence of centring rings (25).
50. Refit the bracket (10) and gear shift control assembly.
51. Lightly smear the threads of screw (11) with Loctite
242 or its equivalent and tighten to a torque of 29 - 37
Nm.
52. Protect the lip of seal (17) by covering the cylindrical
end of finger (9) with a flexible protection. Lightly
smear the external rim of the seal with Loctite 542
or its equivalent and slide it over the protection.
Remove the protection. Insert the seal into the cover
using an appropriate fixture.
53. Place finger (9) in the Neutral position.
54. Slide ball (24) into the depression on the toggle (34).
Issue 1
May 2002
5C03.14
Final operation
60. Take out the cover from the vice and fit it on the
gearbox (see B).
29 mm
Fig. 9
Issue 1
May 2002
5C03.15
2
3
166
1
4
5
1
Fig. 10
12
1
C
X
9
D
3
4
6
12
1
11
7
9
11
10
5
L
8
Fig. 11
Issue 1
May 2002
Fig. 12
Remark
When there is no interference with the operation of the
lever by the console, then the adjustment is correct. Refit
the dust cover.
If the position of the lever is incorrect, repeat the
adjustment procedure at the selector cover end.
- if there is interference when engaging 1st or 3rd gears
(Fig. 12), reduce dimension X (Fig. 11),
- if there is interference when engaging 2nd or 4th gears
(Fig. 12), increase dimension X (Fig. 11),
- by altering dimensions C and D (Fig. 11), the gear lever
moves in the console opening in the direction shown by
the arrows in Fig. 13.
Fig. 13
Issue 1
May 2002
5C03.17
MF 462 A
7
V
3
3
F
Fig. 14
MF 462A
0,2mm
Fig. 15
Issue 1
May 2002
G . Service tools
- MF462A - Hare / Tortoise adjustment gauge
(Fig. 16).
Fig. 16
Issue 1
May 2002
5D01.1
CONTENTS
-
General ________________________________________________
A.
B.
Issue 1
May 2001
General
On 8200 series tractors fitted with a Heavy Duty gearbox,
the selector rails used for gear selection are located on
the right-hand side of the gearbox behind the control
cover.
The gear selector comprises four selector rails of which
three are for the gearbox and one for the input unit.
Each selector rail supports its own fork and respective
selector and moves longitudinally in end-bearings.
The forks are adjustable, thus ensuring a functional
clearance between the pads and the synchromesh
sliding coupler.
Operating principle
Example: Ratio 1 engaged - Hare range
When the selector rail is moved to select 1st gear, it
forces its lock to move out of its lodging place and to lock
the range selector rail in the "Hare" position. At the same
time, this lock pushes another lock that in turn locks the
3rd - 4th selector rail, thus prohibiting any undue movement that might block the gearbox.
The same reasoning applies to the Tortoise range and
other gear ratios.
Issue 1
May 2001
5D01.3
6
10
11
12
13
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Fig. 1
C
14
Fig. 2
16
17
4
10
11
15
4
18
3
Y
5
19
12
20
Parts list
Z
Partial view
View along F
Issue 1
Cross-section CC
May 2001
Fig. 2
Fig. 1
5D01.4
Exploded view
21
10
11
12
18
10
11
12
2
4
20
10
7
11
14
12
19
15
21
17
20
16
Parts list
Fig. 1
Fig. 2
Issue 1
May 2001
5D01.5
Special points
- The short locking pin (2) locks selector rail 1st - 2nd.
- The long locking pin (5) locks selector rail 3rd - 4th.
- The index assembly (10) (11) (12) (18) places selector
rail 1st -2nd.
- The index assembly (10) (11) (12) (19) places selector
rail 3rd - 4th.
12. Adjust forks and selector (7) (see below).
Disassembly
Remark
On tractors fitted with a creeper gearbox, the reducer unit
located on the rear face of the gearbox does not hinder
disassembly or reassembly of the selector.
3. Remove the bolts (20) from the selector (7) and forks
(15) (16).
Note: To carry out operations on the 1st - 2nd fork,
use a short Allen key due to the limited space
between the fork and the housing.
4. Disassemble the index assemblies (10) (11) (12)
(18).
5. Push selector rail (4) towards the front and remove
lock (2). Proceed in the same way for selector rail (1)
and locking pin (5).
6. Take out selector rails (1) (4) through the rear of the
gearbox.
7. Using a suitable pin punch, drive out pin (21) from the
Hare / Tortoise fork (17) (Fig. 2).
8. Take out selector rail (3) through the rear of the
housing.
9. Remove the 3rd - 4th (16) and the Hare / Tortoise forks.
Remark : The 1st - 2nd fork (15) cannot be removed
from the housing unless the main shaft has previously been removed (see section 5F01).
Reassembly
10. Clean and inspect the components. Replace any
defective parts.
11. Refit the selector rails, forks and selectors in the
reverse order of disassembly.
Note: During refitting, pin (21) on the Hare /
Tortoise fork must be replaced.
Issue 1
May 2001
Adjustment
Final operations
Principle
The positioning of forks (15) (16) and selector (7) is
obtained via the difference between the distance between the centre of threaded holes "Y" and mark "Z" on
the selector rails (1) (4) (Fig. 1).
A different forward or rearward movement of the forks is
obtained by acting on bolt (20) as required.
The adjustment of forks is carried out with the gear
engaged.
Tightening torques
- Bolt (20): 35 Nm without modifying its adjustment,
Loctite 221.
- Plug (12): 50 - 70 Nm, Loctite 542.
16. Next, adjust selector (7) in line with the selector
incorporated in fork (16).
17. Adjust the "S" Hare / Tortoise selector (see section
5C01).
Issue 1
May 2001
12
Preliminary operations
11
5D01.7
10
Disassembly (Fig. 3)
24. Disassemble the indexing assembly (10) (11) (12).
25. Remove bolt (20) from the reverse shuttle fork (14).
26. Take out selector rail (9) and fork.
Reassembly
14
20
Fig. 3
Adjustment
Principle
The positioning of fork (14) is obtained by the difference
between the distance between "Y" and mark "Z" on the
selector rails (9) (Fig. 4). A different forward or rearward
movement of the forks is obtained by acting on the
forward bolt (20) or the rear bolt, as required (Fig. 4).
30. Fit the locking stud (10), spring (11) and plug (12)
tightened to 50 - 70 Nm and previously smeared with
Loctite 542 or equivalent. Fit bolt (20) smeared with
Loctite 221 or equivalent.
31. Position the fork, locked at the front. Maintain the
synchromesh sliding coupler in thrust against the
pinion. Pre-adjust the fork in accordance with the
above principle.
32. Check that the front pads are not pinched against the
synchromesh sliding coupler.
33. Repeat the operation (fork locked at the rear). Check
that the rear pads are not pinched against the
synchromesh sliding coupler.
14
20
Z
Fig. 4
Remark
The adjustment is correct when the space is identical
between the pads located on either side of the fork and
the synchromesh sliding coupler, when in the forward
and reverse positions.
34. Alternatively and progressively tighten bolt (20) to
35 Nm without modifying its adjustment.
Issue 1
May 2001
Final operations
35. Fit the input unit (see section 5B01).
36. Couple the tractor between the engine and the
gearbox (see section 2B01).
37. Carry out a road test, checking for the correct
operation of the mechanical reverse shuttle .
38. Check for the oil tightness of the selector cover and
hydraulic unions.
Issue 1
May 2001
5D02.1
CONTENTS
-
General ________________________________________________
A.
Issue 1
May 2002
General
On 8200 series tractors fitted with a gearbox with Power
shuttle, the selector rails used for gear selection are
located on the right-hand side of the gearbox and behind
the control cover.
The gear selector comprises the following selector
rails for:
- 1st and 2nd gear
- Hare/Tortoise (Hi-Lo)
- 3rd and 4th gear
Each selector rail supports its own fork and respective
selector and moves longitudinally in end-bearings.
The front bearing fixed on the rear part of the input unit is
removable and serves as a support for the selector rails.
The forks are adjustable, thus ensuring a functional
clearance between the pads and the synchromesh
sliding coupler.
Operating principle
Example: Ratio 1 engaged - Hare range
When the selector rail is moved to select 1st gear, it
forces its lock to move out of its lodging place and to lock
the range selector rail in the "Hare" position. At the same
time, this lock pushes another lock that in turn locks the
3rd - 4th selector rail, thus prohibiting any undue movement that might block the gearbox.
The same reasoning applies to the Tortoise range and
other gear ratios.
Issue 1
May 2002
Gearboxes with
Power Shuttle - Selector rails
5D02.3
S
13
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
Fig. 1
Fig. 2
F1
21
16
17
4
2
3
10
11
15
4
18
3
Y
5
19
12
20
Partial view
Z
CC
View along F
View along F
Fig. 1
Issue 1
May 2002
Fig. 2
Parts list
Gearboxes with
Power Shuttle - Selector rails
5D02.4
Exploded view
23
10
11
12
18
7
4
15
3
21
17
10
11
12
19
20
16
1
22
C : Selector cover
Fig. 1
Issue 1
Parts list
May 2002
Fig. 2
5D02.5
Disassembly
Remark
On tractors fitted with a creeper gearbox, the reducer unit
(1) (Fig. 3) located on the rear face of the gearbox does
not hinder disassembly or reassembly of the selector.
3. Remove the bolts (20) from the selector (7) and forks
(15) (16).
Note: To carry out operations on the 1st - 2nd fork,
use a short Allen key due to the limited space
between the fork and the housing.
4. Disassemble the index assemblies (10) (11) (12)
(18).
5. Push selector rail (4) towards the front and remove
lock (2). Proceed in the same way for selector rail (1)
and locking pin (5).
6. Take out selector rails (1) (4) through the rear of the
gearbox (Fig. 4).
7. Using a suitable pin punch, drive out pin (21) from the
Hare / Tortoise fork (17) (Fig. 2).
8. Take out selector rail (3) through the rear of the
housing (Fig. 4).
9. Remove the 3rd - 4th (16) and the Hare / Tortoise forks.
Remark : The 1st - 2nd fork (15) cannot be removed
from the housing unless the main shaft has previously been removed (see section 5F02).
Fig. 3
Fig. 4
Reassembly
10. Clean and inspect the components. Replace any
defective parts.
11. Refit the selector rails, forks and selectors in the
reverse order of disassembly.
Note: During refitting, pin (21) on the Hare /
Tortoise fork must be replaced.
Issue 1
May 2002
Special points
- The short locking pin (2) locks selector rail 1st - 2nd.
- The long locking pin (5) locks selector rail 3rd - 4th.
- The index assembly (10) (11) (12) (18) places selector
rail 1st -2nd.
- The index assembly (10) (11) (12) (19) places selector
rail 3rd - 4th.
Y
1
20
Adjustment
Principle
The positioning of forks (15) (16) and selector (7) is
obtained via the difference between the distance between the centre of threaded holes "Y" and mark "Z" on
the selector rails (1) (4) (Fig. 5).
A different forward or rearward movement of the forks is
obtained by acting on bolt (20) as required.
The adjustment of forks is carried out with the gear
engaged.
13. Smear the plugs of the indexing assemblies (10) (11)
(12) (18) with Loctite 542 or equivalent and tighten
onto the housing. Lock fork (15) in 1st. Maintain the
synchromesh sliding coupler against the pinion.
Check that the rear pads are not in contact with the
synchromesh sliding coupler by slightly moving the
selector rail without moving the sliding coupler itself.
14. Repeat the operation (fork locked in 2nd), checking
that the rear pads are not in contact with the
synchromesh sliding coupler, by using the same
method as in operation 13. If the pads are in contact
with the sliding coupler, adjust the fork using bolt (20)
lightly smeared with Loctite 221 or equivalent.
15. Proceed in the same way to adjust fork (16).
Tightening torques
- Bolt (20): 35 Nm without modifying its adjustment,
Loctite 221.
- Plug (12): 50 - 70 Nm, Loctite 542.
16. Next, adjust selector (7) in line with the selector
incorporated in fork (16).
17. Adjust the "S" Hare / Tortoise selector (see section
5C02).
Issue 1
May 2002
15 16
Z
Fig. 5
Final operations
18. Refit the selector cover (see section 5C02).
With the gear lever in neutral, check that locks (2) (5)
are free in the rear bearing in the Hare / Tortoise
range.
19. Couple the tractor between the gearbox and the
intermediate housing (see section 2C01).
20. Road test. Check:
- gear changing (all gears)
- correct operation of the Hare / Tortoise range.
21. Check oil tightness of the gearbox and intermediate
housing mating faces, selector cover and hydraulic
unions.
5E01.1
CONTENTS
-
General ________________________________________________
A.
B.
C.
D.
Issue 1
May 2001
Issue 1
May 2001
5E01.3
Parts list
(22)
(23)
(28)
(31)
(33)
(34)
(35)
(36)
(37)
(40)
(41)
(43)
(44)
(45)
(46)
(47)
(48)
(69)
(70)
Bearing cup
Bearing cone
Seal ring
Special washer
Bearing cone
Bearing cup
3rd Hare gear
Bearing cup
Bearing cone
Tortoise gear
Locating pin
Bearing cone
Bearing cup
Shim(s)
Rear bearing
Shaft
Bolt
Hare / Tortoise synchromesh (double cone)
Synchromesh ring (creeper gearbox option)
F
G
P
R
:
:
:
:
Fig. 1
Fig. 2
Issue 2
1
March
May 2002
December
2000
5E01.4
Overall view
48
46
41
40
35
36
37
34
33
69
22
47
43
C
23
45
B
A
44
A
B
31
28
P
35
Parts list
Fig. 2
Fig. 1
Issue 1
December 2000
5E01.5
Exploded view
46
41
45
44
48
43
70
47
40
37
69
36
35
34
33
31
28
23
22
Fig. 1
Parts list
Fig. 2
Issue 1
December 2000
A . Preliminary operations
1. Uncouple the tractor between the gearbox and the
intermediate housing (see section 2C01).
2. Remove the selector cover (see section 5C01 - 5C02
or 5C03 depending on the version).
Refitting
4. Clean and inspect the components. Replace any
defective parts.
5. Refit the forks and the selector rails (see section 5D01
- or 5D02, depending on assembly).
Issue 21
May 2002
December
2000
5E01.7
Reassembly (Fig. 3)
8. Clean and check the components. Replace any
defective part.
9. Check that the channels in shaft (47) and the decompression port of washer (31) are not blocked.
10. If necessary, insert:
- cup (22) in the layshaft
- cups (34) (36) in pinion (35)
- cone (43) on shaft (47)
11. Fit seal ring (28) in the throat of special washer (31).
12. Smear the special washer and the bearing cone (23)
with miscible grease. Place cone (23) and washer
(31), the seal turned towards the front in the bore of
the mainshaft (7).
A-A
V
A
D
A
V
47
Pre-assembly (detail E)
43
37
36
35
34
33
V
A
D
E
A
V
47
43
37
36
35
34
33
31
31
47
23
31
27
22
R
28
23
Fig. 3
Issue 1
May 2001
Assembly
16. In the housing, introduce:
- the Tortoise pinion (40)
- pinion (35), with mark R turned to face the
synchromesh (69) (Fig. 1) and with cones (33) (37)
moderately smeared with miscible grease.
17. Fit syncromesh flange G (Fig. 1) on the Hare /
Tortoise pinions.
18. Lightly smear the cones and synchromesh bushes
with miscible grease.
19. Fit the synchromesh, the drilled hole P or the paint
mark turned towards the Tortoise pinion (40) (Fig. 4).
20. Position and centre the Tortoise pinion by holding it
via the opening of the plate located below and at the
rear of the gearbox or by using two bolts V as
shown in figure 3.
21. If necessary, with the help of another operator,
engage the shaft with cone (43) in the pinion assembly by aligning the paint marks previously made on
the shaft, synchromesh and feed-through of the
gearbox (Fig. 5).
40
P
Fig. 4
Fig. 5
Issue 1
May 2001
5E01.9
Shimming
45
P2 = 0,01 / 0,05 mm
24. Place the index of the dial gauge on the end of the
shaft (47) (Fig. 7).
25. Push the short protruding length of the shaft using of
a suitably adapted vice jaw fitted with protection,
and turn the shaft left and right in order to seat the
bearing cones in their cups.
26. Set the dial gauge to zero.
27. Repeat operation 25, but this time while pulling.
28. In relation to the clearance shown, select the thickness of shim(s) required to obtain a pre-loading of:
P2 = 0.01 to 0.05 mm (Fig. 6)
29. Remove bolts (48) and bearing (46) (Fig. 7).
30. Take off bearing cup (44) and fit the definitive shims
(45) selected during operation 28.
31. Refit the cup. Place the bearing. Tighten bolts (48)
lightly smeared with Loctite 270 to a torque of 57 67 Nm (Fig. 7).
32. Manually check the rotation of the shaft and its gear
train.
48
Fig. 6
48
47
46
Fig. 7
D . Final operations
33. Refit the selector rails and adjust the forks (see B).
34. Adjust the Hare / Tortoise selector and refit the
selector cover (see section 5C01 - 5C02 or 5C03
depending on the version).
35. Re-couple the tractor between the gearbox and the
intermediate housing (see section 2C01).
36. Check for the oil tightness of all seals and hydraulic
unions.
37. Road test all controls.
2
Issue 1
March 2000
2002
December
Gearbox - Mainshaft
5F01.1
5 F01 Mainshaft
CONTENTS
-
General ________________________________________________
A.
B.
C.
D.
E.
Issue 1
May 2001
Gearbox - Mainshaft
Parts list
General
The mainshaft (7) fitted to Heavy Duty gearboxes rotates
on two taper roller bearings (9) (10) and (20) (21) lying in
the two lower bearings of the main gearbox. The input
gear (1) fitted at the front, engages with the shaft via
splines. It is held by Belleville washers (2) fixed by the
special cone-locking bolt (3).
The Belleville washers also provide a constant load on
bush (8), the synchromesh hub (16) and the shoulder of
the shaft.
This flexible assembly permits permanent contact of the
stated parts, when forces are applied to the gears.
Between the two lower bearings, the shaft bears the
freely rotating driving pinions of 2nd gear (13) and 1st gear
(19), as well as the synchromesh assembly of 1st and 2nd,
the hub of which engages splines on the shaft. At the
rear, it bears the freely rotating driving pinion of 4th gear
(24) and the synchromesh assembly for 3rd and 4th gear.
The rear bore receives bearing cup (22) of the taper roller
bearing of the output shaft.
The lubrication of 1st gear pinion and the bush of the 2nd
gear pinion are ensured by a central channel and radial
drillings.
The pre-loading of the bearings is adjusted by means of
shims (11) placed behind bearing cup (10). The input
pinion (1) is shimmed by means of shims (38) (39) fitted
on the special bolt (3) to obtain a flexing of the Belleville
washers (2).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(24)
(25)
(26)
(27)
(29)
(30)
(32)
(38)
(39)
Input pinion
Belleville washers
Special bolt
Lubricating pipe
Snap ring
Spring
Mainshaft
Bush
Bearing cone
Bearing cup
Shim(s)
Spacer
2nd gear pinion
2nd gear synchromesh bearing cone
2nd gear synchromesh ring
1st - 2nd synchromesh
1st gear synchromesh ring
1st gear synchromesh bearing cone
1st gear driving pinion
Bearing cone
Bearing cup
Bearing cup
4th gear driving pinion
4th gear synchromesh bearing cone
4th gear synchromesh ring
3rd - 4th synchromesh
Snap ring
3rd gear synchromesh ring
3rd gear synchromesh bearing cone
Shim(s)
Spacer
Fig. 1
Fig. 2
Issue 1
May 2001
Gearbox - Mainshaft
5F01.3
Overall view
11
12
21
20
19
10
13
6
29
5
22
4
3
32
30
27
26
25
24
18
17
16
15
14
38
Parts list
Fig. 2
Issue 1
39
Fig. 1
May 2001
Gearbox - Mainshaft
5F01.4
Exploded view
29
32
27
30
26
25
4
24
7
20
21
2
19
18
17
15
16
14
13
8
Parts list
Fig. 1
39
12
38
11
10
4
5
1
2
Fig. 2
Issue 1
May 2001
Gearbox - Mainshaft
5F01.5
A . Preliminary operations
Remark
To dismantle the mainshaft, it is necessary to remove
the gearbox.
57
56
51
8. Take off the snap ring (29). Remove 3rd - 4th gear
synchromesh (27) and mark its position.
9. Remove the synchromesh ring (26), the bearing
cone (25) and the pinion (24).
Note: Keep the synchromesh ring and bearing
cone together if they are to be re-used.
10. Keep the shaft under rotation by using a locally
manufactured tool and by using a 4 WD clutch, ref.
3617232M1 (Fig. 4).
11. If necessary, remove lubricating pipe (4) and spring
(6).
12. Unscrew bolt (3) by means of a 32 mm socket and
a suitable length extension.
13. Remove shims (38) (39), Belleville washers (2) and
input pinion (1).
14. Remove bush (8) fitted with cone bearing (9).
Issue 1
December 2000
Gearbox - Mainshaft
15. Remove the tool. Take out the shaft from its housing
with the 1st gear pinion (19) (Fig. 5) located at the
rear, through the bearing aperture, while maintaining
the fork, pinion and 1st - 2nd gear synchromesh
assembly.
Special point
The extracting of the 1st - 2nd gear fork from the
housing must be accompanied by the synchromesh
assembly (16) and the 2nd gear driving pinion (13).
16. Remove the whole assembly (synchromesh, 2nd
gear pinion assembly and fork) through the selector
cover aperture (Fig. 6).
17. Take off the bearing cups (10) (21).
Note: In the case of re-use, keep cups and cones
together.
18. Remove shims (11), spacer (12).
19. Where necessary, extract the bearing cones (9) (20),
cup (22). Take off snap ring (5) from bolt (3).
19
Fig. 5
Reassembly
20. Clean and inspect the components. Replace any
defective parts.
21. Check that the central channel and radial ports of
shaft (7) are not blocked.
22. If disassembled, with the aid of a press and a
suitable fixture, respectively insert bearing cones (9)
(20) on bush (8) and shaft (7). Position the snap ring
(5) in bolt (3). Insert bearing cup (22) in shaft (7).
23. Lubricate the bearing cones and cups.
24. Fit cup (21).
25. Place the spacer (12), the shims (11) selected during
operation 59 and the bearing cup (10) in the bore of
the housing.
Remark:
- The shims (11) must be fitted between the spacer
(12) and the bearing cup (10) (Fig. 1).
26. Check for wear on syncromesh rings (15) (17)
against bearing cones (14) (18) (see section 5A01).
27. Assemble the 2nd gear pinion (13), bearing cone
(14), synchromesh ring (15), 1st - 2nd gear synchromesh (16), 1st gear synchromesh ring (17) and
bearing cone (18) on the workbench.
28. Refit the entire assembly between the separations
with the 1st - 2nd gear fork correctly positioned (Fig. 6).
29. Slide in the shaft and 1st gear pinion (19) through the
rear of the housing (Fig. 5) while holding the pinion /
synchromesh assembly.
30. Slide synchromesh ring (8) fitted with bearing cone
(9) on to the shaft (7).
Issue 21
March
December
2000
May 2002
Fig. 6
Gearbox - Mainshaft
31. Fit the pinion (1), the Belleville washers (2) positioned as in Fig. 7, and the shims (39) (38) determined during operation 50, along with bolt (3).
Remark: The shims (38) must be placed against the
shoulder of the bolt (3).
32. Hold the shaft in place as in operation 10.
33. Tighten bolt (3) lightly smeared with Loctite 270 to a
torque of 320 - 360 Nm. Remove the tool. Manually
check the rotation of the shaft.
34. If disassembled, fit spring (6) and lubricating pipe (4)
with bolt (3).
35. Check for wear of synchromesh ring (26) against
cone (25) (see section 5A01).
36. Fit the pinion (24), cone (25), synchromesh ring (26)
and the 3rd - 4th gear synchromesh (27) while respecting the direction of assembly.
37. Advance pinion (57) on the intermediate shaft and
place circlip (56) in the throat without bending it and
ensuring that it is correctly fitted (Fig. 3).
38. Place snap ring (29).
39. Manually check:
- the axial clearance of the pinions
- the rotation of the shaft and its gear train.
5F01.7
39
38
Fig. 7
C . Final operations
40. Refit the output shaft (see section 5E01).
41. Refit the input unit (see section 5B01).
42. Refit the selector rails. Adjust the forks and selectors
of 1st - 2nd and Hare / Tortoise (see sections 5D01 and
5C01 respectively).
43. Replace the selector cover (see section 5C01).
Check that changing of the gears is correctly carried
out and that the Hare / Tortoise position is present.
44. Connect the gearbox to the engine (see section
2B01).
45. Reconnect the tractor between the gearbox and the
intermediate housing (see section 2C01).
46. Check the oil tightness of seals and hydraulic unions.
47. Road test the clutch controls, the reverse shuttle, the
Hare / Tortoise range of gears and the A, B, C, D
ratios of the Dynashift.
Issue 12
May 2000
2002
December
Gearbox - Mainshaft
38
39
48. Place the shaft (7) in a vice fitted with jaw protectors.
Provisionally fit the synchromesh (18), the ring (8),
input pinion (1), the Belleville washers (2) without the
shims (38) (39). It is essential that special bolt (3) is
tightened to a torque of 30 Nm maximum.
49. Place the dial gauge index on the end of the shaft,
measure axial clearance of pinion (1) (Fig. 8).
50. In relation to the clearance measured and the thickness of the shim removed (39), select shim thickness (38) to obtain a flexing of the Belleville washers
of between 1.25 mm and 1.75 mm.
Note: If the axial clearance is greater than 1 mm,
it is recommended to reduce it by adding only
one shim (38) in order to measure it again with
greater precision.
51. Take out bolts (3) and the elements provisionally
fitted during operation 48. Go on with the final
assembly of the shaft and carry out its shimming
(see E).
Remark: In cases where input pinion (1) is replaced
on the tractor (Fig. 9), the shimming method is
identical. First temporarily remove the cup (10) and
shims (11) (12) (Fig. 9) in order to eliminate the preloading effect on bearings (9) (10) and (20) (21).
When the shimming of the pinion is completed,
replace the shims and the cup (Fig. 9).
3
2
1
8
16
Fig. 8
11
12
10
Fig. 9
Issue 1
December 2000
Gearbox - Mainshaft
5F01.9
Shimming
55. Place the index of the dial gauge on the end of shaft
(7) (Fig. 10).
56. From the front of the housing, pull hard on the shaft
while turning it left and right to seat it correctly in the
bearing cups and cones.
57. Reset the dial gauge to zero.
58. Repeat operation 56 this time by pushing.
59. In relation to the clearance read on the gauge, select
the correct thickness for the definitive shims (11) in
order to obtain a pre-loading of:
P1 = 0.10 mm to 0.20 mm maximum (Fig. 11).
60. Fit the locking tool on the shaft. Unscrew bolt (3).
Take off the shims (38) (39), the Belleville washers
(2) and the pinion (1).
61. Take out bush (8) fitted with bearing cone (9) and cup
(10) (Fig. 1).
62. Place the shims (11), selected in operation 59,
between spacer (12) and cup (10) (Fig. 1).
63. Fit bush (8) fitted with cone (9), pinion (1), Belleville
washers (2) and shims (38) (39) placed as during
operation 31.
64. Tighten bolt (3) smeared with Loctite 270 to a final
torque of 320 - 360 Nm. Remove the tool.
65. Manually check the rotation of the shaft and its gear
train.
Fig. 10
P1
0,10 / 0,20
maxi
Fig. 11
Issue 12
December
May 2000
2002
5F02.1
5 F02 Mainshaft
CONTENTS
-
General ________________________________________________
A.
B.
C.
D.
E.
Issue 1
May 2002
General
The mainshaft (7) fitted to Heavy Duty gearboxes with a
power shuttle rotates on two taper roller bearings (9) (10)
and (20) (21) lying in the two lower bearing blocks of the
main gearbox. The input pinion (1), fitted at the front, is
integral with the shaft via splines. It is held by washer (2)
and nut (3).
Between the two lower bearing blocks, the shaft holds
the driving pinions of 2nd (13) and 1st (19) that run free, as
well as the synchromesh assembly for 1st and 2nd, the
hub of which is splined to the shaft. At the rear the shaft
holds the 4th gear driving pinion (24) that runs free and the
synchromesh assembly for 3rd and 4th gear.
The synchromesh is of the double cone type.
The rear bore receives bearing cup (22) of the taper roller
bearing of the output shaft.
The lubrication of the 1st gear pinion and 2nd gear bush is
ensured by a central channel with radial ports.
The pre-loading of bearings is adjusted by means of
shim(s) (11) placed behind bearing cup (10).
Issue 1
May 2002
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(16)
(18)
(19)
(20)
(21)
(22)
(24)
(25)
(27)
(29)
(32)
Input pinion
Tab washer
Nut
Lubricating pipe
Snap ring
Spring
Mainshaft
Bush
Bearing cone
Bearing cup
Shim(s)
Spacer
2nd gear driving pinion
2nd gear synchromesh cone
1st and 2nd gear synchromesh
1st gear synchromesh cone
1st gear driving pinion
Bearing cone
Bearing cup
Bearing cup
4th gear driving pinion
4th gear synchromesh cone
3rd and 4th gear synchromesh
Snap ring
3rd gear synchromesh cone.
Fig. 1
Fig. 2
5F02.3
Overall view
11
12
10
21
20
19
13
4
22
29
32
27
25
24
18
16
14
Fig. 2
Parts list
Issue 1
Fig. 1
May 2002
5F02.4
Exploded view
29
4
24
27
7
6
5
4
20
32
18
21
1
19
16
2
13
8
14
25
12
11
10
Fig. 1
1
2
Issue 1
May 2002
Parts list
Fig. 2
5F02.5
A . Preliminary operations
Remark
To take out the mainshaft, it is necessary to remove the
gearbox.
57
56
51
Fig. 3
Fig. 4
Issue 1
May 2002
15. Remove the tool. Take the shaft out of the housing
complete with the 1st gear driving pinion (19) (Fig. 5)
towards the rear via the bearing block opening, while
holding together the 1st and 2nd synchromesh, pinion
and fork assembly.
Special point
The extraction of the 1st and 2nd gear fork from the
housing is carried out along with the synchromesh
assembly (16) and the 2nd gear driving pinion (13).
16. Remove the complete assembly (synchromesh, 2nd
gear pinion and fork) through the selector cover
opening (Fig. 6).
17. Take out bearing cups (10) (21).
Note: Carefully match the cups and cones if they
are to be re-used.
18. Remove the shim(s) (11) and spacer (12).
19.
If necessary, extract bearing cones (9) (20)
and bearing cup (22). Take off snap ring (5).
19
Fig. 5
Reassembly
20. Clean and check the parts, discard any defective
ones.
21. Ensure that the central and radial lubricating channels of shaft (7) are not blocked.
22. If removed, using a press and a suitable fixture,
insert the bearing cones (9) (20) on bush (8) and shaft
(7). On the latter, also position snap ring (5) and insert
cup (22).
23. Lubricate the bearing cups and cones.
24. Fit bearing cup (21).
25. Check for wear on synchromesh parts of 1st and 2nd
gear (see section 5A02).
26. Outside the housing, assemble the 2nd gear pinion
(13), new synchromesh parts and 1st and 2nd gear
synchromesh.
Remark
- If the synchromesh parts are to be re-used, refit
each part in its initial position, as marked during
disassembly.
27. Between the two compartments, refit the complete
assembly with the 1st and 2nd gear fork correctly
positioned (Fig. 6).
28. Slide the shaft and 1st gear pinion (19) through the
rear of the housing (Fig. 5) while holding the pinion /
synchromesh assembly.
29. Shim the shaft (see D).
30. Fit pinion (1).
Issue 1
May 2002
Fig. 6
5F02.7
Fig. 7
C . Final operations
40. Reassemble the output shaft (see section 5E01).
41. Refit the input unit (see section 5B02).
42. Reassemble the selector rails. Adjust the 1st - 2nd
and Hare / Tortoise forks and selectors (see sections
5D02, 5C02 or 5C03 respectively, according to
version).
43. Refit the selector cover (see section 5C02 or 5C03
depending on version). Check that the gear shifting
operates correctly and also check for the presence
of the Hare / Tortoise position.
44. Connect the gearbox with the engine (see section
2B01).
45. Couple the tractor to the gearbox and the intermediate housing (see section 2C01).
46. Check the oil tightness of mating faces and hydraulic
unions.
47. Carry out a road test of the Power Shuttle, gears,
Hare / Tortoise range and A, B, C and D ratios of the
Dynashift.
Issue 1
May 2002
Fig. 8
Shimming
52. Place the finger of the dial gauge on the end of the
shaft (7) (Fig. 8).
53. From the front of the housing, pull hard on the shaft,
turning alternately from left to right to correctly seat
the cones in their bearing cups.
54. Set the dial gauge to zero.
55. Repeat operation 53, this time pushing.
56. In relation to the clearance measured, select a
definitive thickness for shim (11) in order to provide
a pre-loading of (Fig. 9):
P1 = 0.10 to 0.20 mm maximum.
Remark:
- Preferably shim to the maximum tolerance.
57. Place the locking tool on the shaft, loosen nut (3) and
take off the pinion (1).
58. Take off bush (8) complete with bearing cone (9)
from shaft (7). Remove bearing cup (10) from the
housing.
59. Place shims (11) selected during operation 56 between spacer (12) and bearing cup (10) (Fig. 1).
60. Slide the bush (8) and cone (9) assembly onto shaft
(7).
61. Proceed with the reassembly phase. Carry out
operations 30 to 39.
11
12
P1 = 0.10/0.20
0,10/0,20
maxi
max.
Fig. 9
Issue 1
May 2002
5F02.9
E . Service tools
1. Tool available in the AGCO network
- 3378009 M1: Nut socket - Mainshaft (Fig. 10).
Fig. 10
a
c
Fig. 11
Issue 1
May 2002
Gearbox - Layshaft
5G01.1
5 G01 Layshaft
CONTENTS
-
General ________________________________________________
A.
B.
C.
D.
E.
F.
G.
10
Issue 1
May 2001
Gearbox - Layshaft
Parts list
General
The layshaft and its pinions form the upper transmission
line of the Heavy Duty gearbox with mechanical reverse
shuttle or Power shuttle.
Shaft (51) bears, in this order, the driving pinions of 2nd
gear (64), 1st gear (61), 4th gear (59) and 3rd gear (57).
These pinions are splined to the shaft and separated by
spacers (62) (60) and (58). Axial clearance of the gear
train is provided by one or more shims (63). The rear teeth
of the layshaft (51) continuously engage the Tortoise
pinion mounted on the output shaft. The front of the shaft
is supported by a roller bearing fitted to the rear of the
input unit. Its rear extremity is supported by two taper
roller bearings (49) (50) and (54) (55).
The adjustment of these bearings is of the "Semi Set
Right" type. It is carried out by placing a shim (53)
between the bearing cones (50) (54) in order to obtain a
clearance of a predetermined value between the cups
(49) (55) (see F).
Special points
- The friction ring (76) forms an oil tight link of the upper
shaftline between the gearbox and the intermediate
housing (see section 9G01). It is adjusted and sealed
with Loctite 648 or its equivalent in the rear bore of the
shaft (Fig. 6).
- Shim (53) has several radial ports permitting lubrication
of bearings (49) (50) and (54) (55).
Issue 2
1
December
May 2000
2002
(49)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
(65)
(66)
(67)
(76)
Bearing cup
Bearing cone
Layshaft
Nut
Shim
Bearing cone
Bearing cup
Circlip
3rd gear driven pinion
Spacer
4th gear driven pinion
Spacer
1st gear driven pinion
Spacer
Shim(s)
2nd gear driven pinion
Washer
Snap ring
Needle bearing
Friction ring with shoulder
Fig. 1
Fig. 2
Gearbox - Layshaft
5G01.3
Overall view
76
52
51
57
61
59
63
64
56
58
60
50
54
49
55
62
65
66
67
53
52
Parts list
Issue 12
Fig. 2
Fig. 1
December
May 2000
2002
Gearbox - Layshaft
5G01.4
Exploded view
52
50
49
53
55
54
51
67
56
57
58
59
60
61
62
63
64
Parts list
Issue
Issue 21
May 2002
December
2000
65
Fig. 1
66
Fig. 2
Gearbox - Layshaft
5G01.5
A . Preliminary operations
Remark
To take out the layshaft it is necessary to remove the
gearbox.
1. Uncouple the tractor between the gearbox and the
intermediate housing (see section 2B01).
2. Separate the gearbox from the engine (see section
2B01).
3. Take off the selector cover (see section 5C01 or
5C02 depending on assembly).
4. Place the gearbox on a suitable fixture.
5. Remove the input unit (see section 5B01 or 5B02
depending on assembly).
6. Disassemble the selector rails and the forks (see
section 5D01 or 5D02 depending on assembly).
7. Where necessary, immobilise the gear train in the
gearbox. Unlock and slightly loosen nut (52) with the
aid of an appropriate chisel in order to overcome the
resistance of the Loctite.
Remark :
- Of course, this nut is replaced during reassembly.
This operation facilitates the removal of the nut
with the service tool once the output shaft and
mainshaft have been disassembled.
8. Remove the output shaft (see section 5E01).
9. Remove the mainshaft (see section 5F01 or 5F02
depending on assembly).
Fig. 3
Issue 12
May 2000
2002
December
Gearbox - Layshaft
Disassembly
14. On shaft (51) remove the snap ring (66) and washer
(65) and mark the locations. Take off the 2nd gear
pinion (64), shim(s) (63), spacer (62), 1st gear pinion
(61), spacer (60), 4th gear pinion (59), spacer (58),
3rd gear pinion (57) and circlip (56) (Fig. 4).
15. If necessary, drive off needle bearing (67) (Fig. 4).
65
67
66
64
63
62
60
61
59
58
Reassembly
16. Clean and inspect the components. Replace the
defective parts.
17. On the shaft, check that the lubricating ports leading
to the bearing cones (50) (54) are not blocked. Check
for the presence of friction ring (76) (Fig. 4).
18. If disassembled, insert the needle bearing (67) to
thrust against the shoulder of shaft (51) with the aid
of a suitable fixture.
Note: Check that the needle bearings turn freely
in the cage after insertion.
19. Fit a new circlip (56).
Replace the 3rd gear pinion (57), spacer (53), 4th
gear pinion (59), spacer (60), 1st gear pinion (61) and
spacer (62).
Replace 2nd gear pinion (64) without the shims (63).
Carry out the shimming of the pinions (see E).
20. Shim the pinions (see E).
57
51
56
76
Fig. 4
Refitting
Reminder
- If necessary, shim the bearings (54) (55) and (49) (50)
(see F).
21. Lubricate the cones (50) (54) and the bearing cups
(49) (55).
22. If disassembled, insert the cups to thrust against the
shoulder of the housing, with large cup (49) fitted into
the rear bore of the gearbox (Fig. 5).
23. Slide cone (54) onto shaft with shim (53) the thickness of which has been determined at operation 46.
24. Place the assembled shaft in the housing. Fit cone
(50). Pre-tighten nut (52) in contact with the cone
(50).
49
55
Fig. 5
Issue 1
December 2000
Gearbox - Layshaft
5G01.7
Special point
- This nut will be definitively tightened to torque once the
input unit has been refitted, in order to obtain the correct
alignment of the layshaft in the two bearings.
52
D . Final operations
25. Reassemble the layshaft (see section 5F01 or 5F02
depending on assembly).
26. Reassemble the output shaft (see section 5E01).
27. Refit the input unit (see section 5B01 or 5B02
depending on assembly).
76
Fig. 6
Reminders (Fig. 6)
- Tighten nut (52) to a torque of 50 Nm. Rotate the
layshaft several times to progressively seat the bearings. Carry out final tightening of the nut to a torque of
100 - 150 Nm, the threads having previously been lightly
smeared with Loctite 270 or equivalent.
- Lock the nut by bending the collar without breaking it
into grooves "R" on the shaft with the aid of an
appropriate pin punch.
28. Reassemble and adjust the gear selector device
(see sections 5D01 or 5D02 and 5C01 or 5C02
depending on assembly).
29. Refit the selector cover (see section 5C01 or 5C02
depending on assembly).
30. Check that the gears change correctly and that the
Hare / Tortoise position functions.
31. Couple the gearbox to the engine (see section 2B01).
32. Couple the tractor between the gearbox and the
intermediate housing (see section 2C01).
33. Check the oil tightness of seals and hydraulic unions
34. Road test the clutch controls, the A, B, C, D ratios of
the Dynashift mechanical reverse shuttle or power
shuttle, the gears and the Hare / Tortoise range.
Issue 12
December
May 2000
2002
Gearbox - Layshaft
65
66
63
J1 = 0,02/0,31
64
62
Fig. 7
50
Remark
53
54
49
55
Fig. 8
Issue 1
December 2000
Gearbox - Layshaft
5G01.9
Shimming (Fig. 9)
Measure the distance between the bearing cones
(50) (54)
43. Position the pressure plate of the tool on the face of
the cone (54). Place the index of the dial gauge on the
extremity of the pressure plate.
44. On the dial gauge:
- set the long hand to zero
- note the position of the short hand
45. Turn the pressure plate half a turn while maintaining
it on the face of the cone (50).
Immobilise the rod by moderately manually tightening the stop bolt.
46. In relation to the measurement noted on the dial
gauge, select the corresponding shim (53) to be
definitively fitted between the bearing cones (50)
(54).
47. Carry out the remaining operations (see C and D).
54
55
50
Fig. 9
Issue 12
December
May 2000
2002
Gearbox - Layshaft
G . Service tools
1. Tools available in the AGCO network
- MF391 - Socket for layshaft nut (Fig. 10).
- 3378263M11 - Bearing shimming tool (Fig. 11).
Fig. 10
Fig. 11
Issue 1
December 2000
5H01
5H01.1
General
CONTENTS
A.
General ________________________________________________
B.
Characteristics __________________________________________
C.
Transmission ___________________________________________
D.
12
E.
18
F.
21
Issue 1
May 2001
A . General
The AG150 and AG250 Full Powershift gearboxes comprise forward and rear housings containing seven shafts
and nine clutches. Six speed clutches and three range
clutches. Three clutches must be hydraulically engaged
in order to transmit engine power. These transmissions
are fitted with their own Gerotor hydraulic pump, filter,
pressure regulating valve, lubricating metering valve and
nine proportional solenoid valves to engage the clutches.
These transmissions use an oil tank that is common to
the gearbox and axle assembly. The gearbox is coupled
to the engine via a splined coupling shaft situated in the
transmission and a damper located on the engine flywheel.
Fig. 1
B . Characteristics
The AG150 and AG250 Full Powershift gearboxes have
the following characteristics:
- 18 forward speeds
- 6 or 8 reverse speeds depending on the specifications
in each country
- constant meshing, helicoidal gears
- ball and roller bearings to eliminate all vibration
- common axle / gearbox oil tank
- hydraulically controlled multi-plate clutches
- electro-hydraulic gear changes
- 100% modulated gear changes
- adaptation to speed of movement
- reverse shuttle
- compact design in a 2-part housing
- housing also acts as the tractor chassis between the
engine and rear axle unit
- pressure lubrication of all clutches
- self-controlled hydraulic pump
- vibration damper in the engine flywheel
- electronically protected.
Issue 1
May 2001
5H01.3
C . Transmission (Figs. 2 to 7)
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Issue 21
May 2002
2001
5H01.4
Overall view
2
15
26
27
21
26
13
24
17
16
1
11
12
26
14
27
Fig. 4
Fig. 5
Fig. 6
18
28
Fig. 3
Parts list
Fig. 7
Fig. 2
Issue 2
1
May 2002
2001
5H01.5
Front view
10
3RD
2ND
4TH
19
11
7TH
6TH
5TH
Fig. 2
Fig. 4
Fig. 5
Fig. 6
Issue 1
18
Fig. 7
Parts list
Fig. 3
May 2001
5H01.6
Top view
26
27
14
26
27
21
16
26
11
12
17
19
24
13
15
Fig. 2
Fig. 3
Fig. 5
Fig. 6
Parts list
Fig. 7
Fig. 4
Issue 1
May 2001
5H01.7
Right-hand view
29
35
13
23
13
12
27
20
19
Parts list
Fig. 2
Fig. 3
Fig. 4
Issue 1
Fig. 6
Fig. 7
Fig. 5
May 2001
5H01.8
Left-hand view
25
16
27
14
15
18
24
34
17
33
32
11
22
31
Parts list
Fig. 2
Issue 1
Fig. 3
Fig. 4
May 2001
Fig. 5
Fig. 7
Fig. 6
5H01.9
Bottom view
26
27
26
28
26
28
Parts list
Fig. 2
Fig. 3
Fig. 4
Issue 1
Fig. 5
Fig. 6
Fig. 7
May 2001
5H01.10
74T
5TH STAGE
40T
70T
71T
42T 70T
71T
42T
71T
INPUT
4TH STAGE
62T
3RD STAGE
62T
2ND STAGE
48T
1ST STAGE
32T
48T
72T
65T
40T
6TH STAGE
PTO OUTPUT
OUTPUT
7TH STAGE
Fig. 8
Issue 1
May 2001
5H01.11
80T
5TH STAGE
44T
80T
82T
48T 60T
82T
48T
82T
INPUT
76T
3RD STAGE
76T
59T
38T
53T
81T
75T
47T
4TH STAGE
2ND STAGE
1ST STAGE
6TH STAGE
PTO OUTPUT
OUTPUT
7TH STAGE
Fig. 9
Issue 1
May 2001
5H01.12
SPEED
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
R1
R2
R3
R4
R5
R6
R7
Issue 1
CLUTCHES
AG15O
RATIO
AG250
RATIO
1-A-L
2-A-L
1-B-L
1-A-M
2-B-L
2-A-M
1-C-L
1-B-M
2-C-L
2-B-M
1-A-H
1-C-M
2-A-H
2-C-M
1-B-H
2-B-H
1-C-H
2-C-H
R-A-L
R-B-L
R-B-M
R-C-L
R-B-M
R-A-H
R-C-M
10,241
7,929
6,145
5,397
4,757
4,179
3,687
3,238
2,854
2,507
2,214
1,943
1,714
1,504
1,329
1,029
0,797
0,617
10,241
6,145
5,397
3,687
3,238
2,214
1,934
10,227
7,940
6,136
5,386
4,764
4,181
3,682
3,231
2,858
2,509
2,208
1,939
1,714
1,505
1,325
1,029
0,795
0,617
10,227
6,136
5,386
3,682
3,231
2,208
1,939
May 2001
POWER TRANSMISSION
ROUTE (Fig. 10)
A-C-E-F-G-I-H-J-K-L-M-P
A-B-I-H-J-K-L-M-P
A-C-E-F-J-K-L-M-P
A-C-E-F-I-O-Q-P
A-B-G-F-J-K-L-M-P
A-B-I-O-Q-P
A-C-K-L-M-P
A-C-E-F-H-I-O-Q-P
A-B-G-F-E-K-L-M-P
A-B-G-F-H-I-O-Q-P
A-C-E-F-G-I-O-N
A-C-K-J-H-I-O-Q-P
A-B-I-O-N
A-B-G-F-E-K-J-H-I-O-Q-P
A-C-E-F-H-I-O-N
A-B-G-F-H-I-O-N
A-C-K-J-H-I-O-N
A-B-G-F-E-K-J-H-I-O-N
A-D-F-G-I-H-J-K-L-M-P
A-D-J-K-L-M-P
A-D-F-G-I-O-Q-P
A-D-F-E-K-L-M-P
A-D-H-I-O-Q-P
A-D-F-G-I-O-N
A-D-F-E-K-J-H-I-O-Q-P
5H01.13
5TH STAGE
3RD STAGE
INPUT
4TH STAGE
2ND STAGE
1ST STAGE
6TH STAGE
PTO OUTPUT
OUTPUT
7TH STAGE
Fig. 10
Issue 1
May 2001
5H01.14
5TH STAGE
4TH STAGE
3RD STAGE
2ND STAGE
1ST STAGE
INPUT
6TH STAGE
PTO OUTPUT
OUTPUT
7TH STAGE
Fig. 11
Issue 1
May 2001
5H01.15
5TH STAGE
4TH STAGE
3RD STAGE
2ND STAGE
1ST STAGE
ENTREE
6TH STAGE
PTO OUTPUT
OUTPUT
7TH STAGE
Fig. 12
Issue 1
May 2001
5H01.16
5TH STAGE
4TH STAGE
3rd STAGE
2nd STAGE
INPUT
1st STAGE
6TH STAGE
PTO OUTPUT
SORTIE
7TH STAGE
Fig. 13
Issue 1
May 2001
5H01.17
5TH STAGE
4TH STAGE
3RD STAGE
2ND STAGE
INPUT
1ST STAGE
6TH STAGE
1ST STAGE
OUTPUT
7TH STAGE
Fig. 14
Issue 1
May 2001
Engine flywheel
LUK damper
Bearing
Coupling shaft
Spring
Input shaft seal
1st stage shaft
Bolt
Tightening torque
- M10 bolt (43): 68 92 Nm.
Reminder
For additional information (see section 3B01).
Fig. 15
Fig. 16
Issue 1
May 2001
5H01.19
AG 150
40
43
37
39
41
42
A
36
38
Parts list
Issue 1
Fig. 16
Fig. 15
May 2001
5H01.20
AG 250
40
43
37
39
41
42
36
38
Issue 1
Parts list
May 2001
Fig. 15
Fig. 16
5H01.21
49
47
45
48
52
51
53
46
54
55
56
50
Fig. 17
Issue 1
May 2001
5H01.22
ATP 3030 Set of transmission pinion extractors also designed for the previous series of Full Powershift gearboxes (Fig. 18)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
57
64
59
58
61
62
60
63
Fig. 18
Issue 1
May 2001
5H01.23
Fig. 19
Issue 1
May 2001
5I01
5I01.1
CONTENTS
A.
Characteristics __________________________________________
B.
General ________________________________________________
C.
D.
E.
F.
10
G.
11
H.
12
I.
13
J.
14
K.
15
L.
16
Issue 1
May 2001
Issue 1
May 2001
5I01.3
71 C (160 F)
85 C (185 F)
6. Gerotor pump flow rate ...................................................................... 94.5 l/min (25 gpm min)
7. Lubricating oil flow rate thru oil cooler at 85 C (185 F) ..................... 75.7 l/min (20 gpm min)
8. Lubricating oil flow rate by-passing oil cooler at 60 C (140 F) .......... 75.7 l/min (20 gpm min)
9. Gearbox oil filter ................................................................................. 15 microns
Issue 1
May 2001
B . General
Clutch pressure circuit
The Full Powershift AG150 and AG250 transmissions are
fitted with their own Gerotor type toothed rotor hydraulic
pump mounted at the rear of the transmission. The pump
is driven at engine speed by the first stage shaft. When
the engine is running the pump supplies the pressure and
flow rate to activate the clutches and lubricate the
transmission. The oil is sucked through a strainer located
in the intermediate housing. The pump discharges oil
through the gearbox filter and by priority supplies the
clutch solenoid valves and the pressure regulating-valve.
Once the necessary pressure and flow rate for the clutch
supply is supplied, the pressure regulating-valve opens.
It maintains the operating pressure in the clutches. Three
solenoids are then simultaneously activated to engage
the three clutches and transmit the power from the
engine to the transmission. To obtain the various speeds,
it is possible to activate a combination of any three of the
nine solenoids. Once the required volume of oil to engage
the clutches is attained and the pressure regulating-valve
is open, the oil flows through the lubricating circuit via the
pressure regulating-valve and the thermostatic valve.
Issue 1
May 2001
5I01.5
2ND STAGE
"1"
"R"
"2"
"C"
"B"
"A"
6TH STAGE
3RD STAGE
14
4TH STAGE
7TH STAGE
"M"
"H"
"L"
"M"
"H"
INLET
"2"
"A"
"R"
"B"
12
"1"
Clutch "A"
Clutch "B"
Clutch "C"
Clutch "H"
Clutch "L"
Clutch "M"
Clutch "R"
Clutch "1"
Clutch "2"
:
:
:
:
:
:
:
:
:
"C"
A
B
C
H
L
M
R
1
2
14
"L"
Tank
Suction strainer (250 )
Suction pipe
Gerotor - toothed rotor pump
Pump discharge pipe
Main oil filter for the gearbox
Gearbox oil filter by-pass
Oil cooler
Oil cooler by-pass
Lubricating relief-valve
Clutch pressure regulating-valve (17 bar)
Proportional solenoid valve
Lubricating pressure pipe
Lubricating port
"A" clutch supply pipe
"2" clutch supply pipe
Clutch return port
Lubricating oil return port from relief-valve
5TH STAGE
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
17
Legend
Low pressure (17 bar)
Lubrication
Suction
Return
2
13
15
16
13
11
18
10
Fig. 1
Issue 1
May 2001
5I01.6
D . Oil filter (Fig. 2)
22
19
29
28
27
26
7
21
25
24
23
22
20
(6)
(7)
(19)
(20)
(21)
(22)
(23)
Filter element
By-pass
Filter head
Filter bowl
Oil inlet port
Oil outlet port
Oring
Issue 1
(24)
(25)
(26)
(27)
(28)
(29)
May 2001
By-pass seat
Oring
By-pass outlet to lubrication
Oring
By-pass spring
Oring
Fig. 2
5I01.7
Oil filtered under pressure flows into the chamber containing the by-pass valve spring and enables the spring
to keep the valve closed. If the filter becomes blocked,
the pressure on the outside of the filter element increases
while it drops in the centre of the filter element. The
pressure of the oil on the outside of the filter element then
exceeds that of the by-pass valve spring and the valve
therefore opens. The by-pass valve opens when the
pressure differential equals 3.1 - 3.7 bar (45 - 54 psi) (Fig.
3).
Fig. 3
Issue 1
May 2001
5I01.8
Thermostatic valve
"IN" oil inlet port
"OUT" oil outlet to oil cooler
"OUT" oil outlet to tank
Housing towards oil cooler
Housing towards tank
O'ring
Support bolts. Tighten to a torque of 6.7 Nm
Spring
Guide and spring seal
Thermic element
Guide washer
Screw adjustment. Smear the screw with Loctite
290. Tighten until contact, then add an additional
quarter turn.
31
41
33
40
39
36
30
35
35
37
38
34
36
32
Fig. 4
Issue 1
May 2001
5I01.9
INLET
INLET
GEARBOX
GEARBOX
Fig. 5
Issue 1
May 2001
5I01.10
45
49
50
51
53
55
46
47
48
52
51
54
42
43
44
11
Fig. 6
Issue 1
May 2001
5I01.11
56
57
58
12
59
60
61
62
63
64
Fig. 7
Issue 1
May 2001
Fig. 8
Fig. 9
11
Fig. 10
Issue 1
May 2001
5I01.13
Fig. 12
Fig. 13
Issue 1
May 2001
J . Pump reassembly
Reassemble the pump and fasten the cover on to the
body with the two bolts. Tighten to a torque of 24 Nm.
Lubricate the pump with transmission oil and fit the two
O'rings smeared with miscible grease into the pump
body. Fit the pump on to the rear housing of the gearbox.
Fix it in place with the six bolts removed previously.
Tighten the bolts to a torque of 24 Nm (Fig. 14 - 15).
Fig. 14
Fig. 15
Issue 1
May 2001
5I01.15
K . Clutch circuit
The oil flow in the clutch piston chamber is controlled by
the proportional solenoid valves (12) and they themselves are controlled by the transmission control unit
(TC). The oil is metered in the clutch pistons by the
proportional solenoid valves, in relation to the electrical
signal received by transmission control. The hydraulic
spools of the proportional solenoid valves cannot be
repaired, except for the O'rings and the solenoid. The
solenoid is fixed to the spool by an aluminium nut (56)
and mustd be tightened to a torque of 1.7 - 2.8 Nm maximum.
56
12
Fig. 16
Each clutch is fitted with a control channel located near
the solenoid valve concerned.
Each control channel is identified by a number or letter
moulded into the housing (Fig. 17) and corresponding to
the clutch. All the channels are closed by a small 7/16
plug.
Use ATP 3018-2 adaptors (see section 5H01) to check
the pressure. To correctly carry out a check on a gear
ratio, check the pressure in all three clutches concerned
at the same time.
Fig. 17
56
12
Fig. 18
Issue 1
May 2001
L . Lubricating circuit
The gearbox lubricating oil is supplied by the Gerotor
pump via the pressure regulating-valve. Lubricating oil
pressure is maintained by the pump flow and by the
lubricating relief-valve. The lubricating relief-valve (10) is
located at the bottom of the threaded port provided for the
oil cooler connector on the left hand side of the transmission (Fig. 19). The lubricating oil supplies each transmission shaft, lubricates the clutch plates, shafts and
bearings. To test the lubricating pressure, use test
connector ATP 3018-3. Screw the test connector into one
of the medium-sized plugs (27) (see section 5H01).
10
Fig. 19
10
Fig. 20
10
Fig. 21
Issue 1
May 2001
Fig. 22
5J01
5J01.1
Transmission - Repair
Contents
A.
B.
C.
D.
E.
F.
G.
10
H.
23
I.
24
Issue 1
May 2001
Preliminary operations
- Separate the tractor between the gearbox and the
intermediate housing (see section 2C01).
- Separate the gearbox from the engine (see section
2B01).
Fig. 1
24
Fig. 2
11
Fig. 3
Issue 1
May 2001
Fig. 4
5J01.3
Fig. 6
Issue 1
May 2001
Clean the work area and prepare shaft support plate (ATP
3019) on which the work will be carried out (Fig. 7). The
workshop must be accessible by a workshop crane or
suitable lifting tackle.
Position 1 - AG 150 gearbox
Stands (1) screwed directly into the plate (Fig. 8)
Position 2 - AG 250 gearbox
Stands (1) screwed into the bushes (Fig. 8)
- Remove the seal rings from all shafts to avoid damaging them before installing the shaft-lifting tool.
- Install lifting tool (AP 3017) on the shafts and fix each
shaft to the tool with the supplied locking devices.
Place the lifting ring of the tool in the correct position
(Fig. 11).
Fig. 7
Fig. 8
Fig. 9
Issue 1
May 2001
Fig. 10
5J01.5
Fig. 11
Fig. 12
Fig. 13
Issue 1
May 2001
Fig. 14
41
Fig. 15
Issue 1
May 2001
5J01.7
10
Fig. 16
Lubricating relief-valve
If the previous tests have shown that the lubricating
relief-valve is defective (10) (Fig. 16), it may be removed
from the interior at this time. It may also be removed
from outside the housing by taking off the oil cooler piping
and connection. Screw tap the inside of the valve (10)
(Fig. 26) and use an inertia extractor to remove it.
Fig. 17
Fig. 18
Issue 1
May 2001
Fig. 19
Fig. 20
Fig. 21
Issue 1
May 2001
Fig. 22
5J01.9
Fig. 23
Fig. 24
10
11
Fig. 26
Fig. 25
Issue 1
May 2001
Disassembly
- Using a clutch train sling (ATP 3021), remove the speed
clutch to be repaired from the pinion block support tool.
Place the clutch train on a clean workbench and turn the
groove of the seal ring upwards (Fig. 27).
Note: Take care that the gear train is properly
supported to avoid it toppling and damaging the
pinions.
- Install a split bearing extractor (OEM 4175 or equivalent) on the bearing (18) or (22). The split bearing
extractor must be fitted so that its flat surface is turned
towards the pinion. Tighten the tightening bolts of the
extractor until the bearing begins to extract (Fig. 28).
- Hook the pinion extractor below the split bearing extractor and extract the bearing from the shaft by pulling (Fig.
29).
- Remove the circlip (17) or (21) from the shaft.
- Place the extractor (ATP 3030) (Fig. 30) on the pinion
and tighten the bolt. To be able to remove the pinion
from the shaft, the extractor must be tightened around
the external diameter of the pinion (4) or (5). In some
cases, the main sleeve is necessary and must be fitted
beneath the pinion. Place the extractor by hooking it
beneath the sleeve and extract the pinion (4) and (5) and
the bearing (16) or (20) from the shaft by pulling (Fig. 31).
Note: To select the extraction sleeve that matches
the pinion, see the pages relating to the clutch
trains (pages 14 to 19).
Note: DO NOT USE THE EXTRACTOR WITHOUT AN
EXTRACTION SLEEVE TO REMOVE THE PINIONS THIS MAY DAMAGE THE TEETH OF THE PINIONS.
THE TEETH ARE HARDENED AND MAY SHATTER
LIKE GLASS. THE PINIONS MUST BE EXTRACTED
BY EFFECTING A TIGHTENING ON THE EXTERNAL
WALL OF THE PINION.
- Remove circlip (14), closing plate (13), thrust plates and
friction plates.
- Fit a suitable extractor on the bearing of the inside pinion
(15) (19) and remove the latter from the shaft.
Fig. 27
Fig. 28
Fig. 29
Issue
Issue21
May
May2002
2001
5J01.11
- Place the clutch train in a press. Fit tool ATP 3002 on the
Belleville washers (10). Compress the washers, remove the circlip (12) and release the pressure on the
washers (Fig. 32).
- Remove the clutch train from the press and remove the
locking washer from circlip (11) and the Belleville
washers (10).
- Remove the oil seal washer (9) that lies between the
Belleville washers (10) and the clutch piston (6) (Fig. 33).
Fig. 30
Fig. 31
10
Fig. 33
Fig. 32
Issue 1
May 2001
5J01.12
24
25
Inspecting components
Belleville washers
Check for:
- Cracks
- Wear on contact points
Piston, seals and piston bores
Check for:
- Seal hardening, cracking, nicks, etc.
- Piston seal groove: dents, burs, chipping, etc.
- Piston bores: chipping, dents, burs (Fig. 36).
Fig. 34
1.78 mm
2.79 mm
1
Fig. 35
Fig. 36
Issue 1
May 2001
Fig. 37
5J01.13
Inspection of components
Pinions
Check for:
- Pitting, flaking, ripples, broken teeth, cracks, bore wear
due to bearing creep, spline wear.
Bearings
Check for:
- Pitting, denting, grooving, cracks in the groove, wear
due to creep on internal and external rims.
Circlips and grooves
Check that circlips and grooves are in good condition.
Note: Circlips with rounded and square edges. The
square edge must always retain the load.
Shafts
Check for:
- Wear on splines, cracks, surface wear due to creep.
Check that seal ring grooves are square edged and
without burs, etc. That oil channels are not blocked; that
all port and stop plugs are correctly in place; that there
is no spline wear or cracking in the clutch housings; that
circlip slots are square edged.
Issue 1
May 2001
26
24
25
17
18
16
26
15
13
2
2nd STAGE
14
26
A
11
12
10
25
24
26
19
21
26
23
22
20
Fig. 38
Issue 1
May 2001
5J01.15
AG 150 transmission
(1) 2nd stage shaft pinion - 71 teeth
(2) "A" clutch linings - 10 thrust plates and discs
(3) "2" clutch linings - 10 thrust plates and discs
(4) "A" clutch hub pinion - 42 teeth
Use ATP 3030-1 and ATP 3030-3 sleeves to extract
the pinion
(5) "2" clutch hub pinion - 48 teeth
Use ATP 3030-1 and ATP 3030-6 sleeves to extract
the pinion
(6) Clutch piston
(7) Piston external seal - "D" bush type seal
(8) Piston internal seal - O'ring
(9) Oil seal washer
(10) Belleville washers - 6
(11) Circlip holding washer
(12) Circlip
(13) Closing plate
(14) Clutch lining circlip
(15) "A" clutch internal pinion hub ball bearing
(16) "A" clutch external pinion hub ball bearing
(17) Circlip
(18) Forward shaft roller bearing
(19) "2" clutch internal pinion hub ball bearing
(20) "2" clutch external pinion hub ball bearing
(21) Circlip
(22) Rear shaft ball bearing
(23) Lubricating port
(24) "2" clutch pressurized oil channel
(25) "A" clutch pressurized oil channel
(26) Pressurized oil channel
AG 250 transmission
(1) 2nd stage shaft pinion - 82 teeth
(2) "A" clutch linings - 10 thrust plates and discs
(3) "2" clutch linings - 10 thrust plates and discs
(4) "A" clutch hub pinion - 48 teeth
Use ATP 3030-1 and ATP 3030-6 sleeves to extract
the pinion
(5) "2" clutch hub pinion - 59 teeth
Use only ATP 3030-1 sleeve to extract the pinion
(6) Clutch piston
(7) Piston external seal - "D" bush type seal
(8) Piston internal seal - O'ring
(9) Oil seal washer
(10) Belleville washers - 6
(11) Circlip holding washer
(12) Circlip
(13) Closing plate
(14) Clutch lining circlip
(15) "A" clutch internal pinion hub ball bearing
(16) "A" clutch external pinion hub ball bearing
(17) Circlip
(18) Forward shaft roller bearing
(19) "2" clutch internal pinion hub ball bearing
(20) "2" clutch external pinion hub ball bearing
(21) Circlip
(22) Rear shaft ball bearing
(23) Lubricating port
(24) "2" clutch pressurized oil channel
(25) "A" clutch pressurized oil channel
(26) Pressurized oil channel
Instructions
(15) The ball bearing may be installed in either position.
(18) The roller bearing must be installed with the bearing
circlip facing the centre of the shaft.
Instructions
(15) The ball bearing may be installed in either position.
(18) The roller bearing must be installed with the bearing
circlip facing the centre of the shaft.
(22) The SH2 designation bearing must be installed
here. The SH2 bearing is a hardened bearing with
twice the normal life span.
Issue 1
May 2001
5J01.16
3rd stage shaft
26
24
18
25
26
17
15
16
13
14
27
11
28
12
26
10
7
R
24
19
25
rd
3 STAGE
20
26
21
22
23
Fig. 39
Issue 1
May 2001
5J01.17
Issue 1
May 2001
26
24
25
17
18
16
26
15
13
14
26
C
11
12
10
25
24
19
26
3
4th STAGE
26
5
20
23
21
22
Fig. 40
Issue 1
May 2001
5J01.19
AG 150 transmission
(1) 4th stage shaft pinion - 71 teeth
(2) "C" clutch linings - 10 thrust plates and discs
(3) "1" clutch linings - 10 thrust plates and discs
(4) "C" clutch hub pinion - 70 teeth
Use only ATP 3030-1 to extract the pinion
(5) "1" clutch hub pinion - 62 teeth
Use only ATP 3030-1 to extract the pinion
(6) Clutch piston
(7) Piston external seal - D bush type seal
(8) Piston internal seal - O-ring
(9) Oil seal washer
(10) Belleville washers - 6
(11) Circlip holding washer
(12) Circlip
(13) Closing plate
(14) Clutch lining circlip
(15) "C" clutch internal pinion hub ball bearing
(16) "C" clutch external pinion hub ball bearing
(17) Circlip
(18) Forward shaft roller bearing
(19) "R" clutch internal pinion hub ball bearing
(20) "R" clutch external pinion hub ball bearing
(21) Circlip
(22) Rear shaft ball bearing
(23) Lubricating port
(24) "1" clutch pressurized oil channel
(25) "B" clutch pressurized oil channel
(26) Pressurized oil channel
AG 250 transmission
(1) 4th stage shaft pinion - 82 teeth
(2) "C" clutch linings - 10 thrust plates and discs
(3) "1" clutch linings - 10 thrust plates and discs
(4) "C" clutch hub pinion - 80 teeth
Use only ATP 3030-8 to extract the pinion
(5) "1" clutch hub pinion - 76 teeth
Use only ATP 3030-1 to extract the pinion
(6) Clutch piston
(7) Piston external seal - "D" bush type seal
(8) Piston internal seal - O'ring
(9) Oil seal washer
(10) Belleville washers - 6
(11) Circlip holding washer
(12) Circlip
(13) Closing plate
(14) Clutch lining circlip
(15) "C" clutch internal pinion hub ball bearing
(16) "C" clutch external pinion hub ball bearing
(17) Circlip
(18) Forward shaft roller bearing
(19) "1" clutch internal pinion hub ball bearing
(20) "1" clutch external pinion hub ball bearing
(21) Circlip
(22) Rear shaft ball bearing - hardened bearing
(23) Lubricating port
(24) "1" clutch pressurized oil channel
(25) "C" clutch pressurized oil channel
(26) Pressurized oil channel
Instructions
(16) The roller bearing must be installed with a circlip in
the bearing located towards the front of the shaft
(18) The roller bearing must be installed with the bearing
circlip facing the centre of the shaft.
Instructions
(15) The SH2 designation bearing must be installed
here. The SH2 bearing is a hardened bearing with
twice the normal life span.
(16) The roller bearing must be installed with a circlip in
the bearing located towards the front of the shaft.
(18) The roller bearing must be installed with the bearing
circlip facing the centre of the shaft.
(22) The SH2 designation bearing must be installed
here. The SH2 bearing is a hardened bearing with
twice the normal life span.
Issue 1
May 2001
Fit an oil seal washer (9). All the clutch oil seal washers
are identical (Fig. 42).
Reassemble the Belleville washers (10). The diameter of
the first Belleville washer must be in contact with the oil
seal washer. The second Belleville washer must be in
contact with the external diameter of the first washer.
Alternate the Belleville washers until they are all installed
(Fig. 42).
(6) Piston
(9) Washer - oil stop
(10) Belleville washers
(12) Circlip holding washer and circlip.
Fig. 41
12
10
Fig. 42
Fig. 43
Issue 1
May 2001
Fig. 44
5J01.21
Piston travel
- The piston travel can be adjusted by selecting or
exchanging intermediate plates since their thickness
varies.
. With new thrust plates and discs:
Piston travel - 1.3 - 3.8 mm
. With used thrust plates and discs:
Piston travel - 1.8 - 5.5 mm
Fig. 45
Issue 1
May 2001
Fig. 46
15
Fig. 47
16
4
4
Fig. 48
Issue 1
May 2001
Fig. 49
5J01.23
AG 250 transmission
(1) 1st stage shaft - 38 teeth
(2) At the rear - roller bearing
(3) At the front - ball bearing
Instructions
(2) Install the roller bearing with the circlip facing the
pinion.
1st STAGE
PTO
Fig. 50
Issue 1
May 2001
L
M
Fig. 51
Disassembly
- Using a sling for the clutch train, remove the range
clutch shaft to be repaired from the support tool (ATP
3021). Place the shaft on a clean workbench and turn
the grooves of the seal rings upwards.
Note. Take care that the shaft is properly supported
to avoid toppling and damage to the pinions.
- Install a suitable split bearing extractor (OEM 4175 or
equivalent) on the first bearing (16) or (17). The split
bearing extractor must be placed in such a manner that
its flat surface is turned towards the pinion. Tighten the
extractor bolts until the bearing begins to extract from
the 7th stage shaft.
- Hook the pinion extractor beneath the split bearing
extractor and remove the bearing from the shaft by
pulling (Fig. 52). Remove the circlips (18) (19) or (20)
from the shaft (Fig. 53).
Fig. 52
20
Fig. 53
Issue 1
May 2001
5J01.25
Fig. 54
- Take off circlip (12) and closing plate (11), the thrust
plates, clutch discs and clutch housing.
- Place a suitable pinion extractor on the internal pinion
bearing (13) and remove it from the shaft (Fig. 57).
Fig. 55
12
13
11
Fig. 57
Fig. 56
Issue 1
May 2001
5J01.26
Fig. 58
8
9
10
Fig. 59
Fig. 60
Issue 1
May 2001
Fig. 61
5J01.27
Inspecting components
Belleville washers
Check for:
- Cracks
- Wear on contact points
Piston, seals and piston bores
Check for:
- Seal: hardening, cracks, nicks, etc.
- Piston seal groove: dents, burs, undercutting, etc.
- Piston bores: undercutting, dents, burs (Fig. 62)
Thrust plates and clutch discs
Check for:
- Buckling, heat discolouring, surface and spline wear.
- Nominal dimensions:
. thrust plates: 1.90 mm
. friction plates: 2.79 mm
- During the refitting of previously used thrust plates and
clutch discs, the piston travel determines whether they
should be replaced or not (Fig. 63)
Fig. 62
Pinions
Check for:
- Pitting, flaking, rippling, broken teeth, cracks, bore
wear due to bearing creep, spline wear.
Bearings
Check for:
- Pitting, dents, grooves, cracks in the groove, wear due
to creep on the internal and external rims.
Circlips and grooves
Check that:
- The edges of grooves and slots are square. The edges
of the circlips are square and that the springiness is
adequate.
Note: Circlips having one chamfered edge and one
square edge - the square edge must always bear the
load.
Fig. 63
Shafts
Check for:
- Spline wear, cracking, surface wear due to creep; that
grooves of seal rings have square edges, no burs, etc.;
that oil channels are not blocked; that all the stop plugs
and port plugs are in place; that there is no spline wear
or cracking on the clutch housings; that the circlip
grooves and slots are square.
Issue 1
May 2001
5J01.28
5th stage shaft
23
22
16
22
10
12
15
11
13
5th STAGE
23
14
19
18
24
17
Fig. 64
Issue 1
May 2001
5J01.29
AG 150 transmission
(1) 5th stage pinion shaft - 74 teeth
(2) "L" clutch linings - 10 thrust plates and discs
(3) Pinion "L" clutch hub - 40 teeth.
Use extractor sleeves ATP 3030-1 and ATP 303010 to removethe pinion.
(4) Clutch piston
(5) External piston seal - type "D" bush seal
(6) Internal piston seal - Oring
(7) Oil seal washer
(8) Belleville washers - 6
(9) Circlip retaining washer
(10) Circlip
(11) Closing plate
(12) Clutch lining circlip
(13) Protected ball bearing of "L"clutch internal pinion
hub
(14) Ball bearing of "L"clutch external pinion hub
(15) Clutch lubricating oil regulation Oring
(16) Forward shaft ball bearing
(17) Rear shaft roller bearing
(18) Circlip
(19) Circlip
(22) "L" clutch pressurized oil channel
(23) Pressurized oil channel
(24) Lubricating port
AG 250 transmission
(1) 5th stage pinion shaft - 80 teeth
(2) "L" clutch linings - 10 thrust plates and discs
(3) Pinion "L" clutch hub - 44 teeth.
Use extractor sleeves ATP 3030-1 and ATP 303012 to remove the pinion.
(4) Clutch piston
(5) External piston seal - type "D" bush seal
(6) Internal piston seal - Oring
(7) Oil seal washer
(8) Belleville washers - 6
(9) Circlip retaining washer
(10) Circlip
(11) Closing plate
(12) Clutch lining circlip
(13) Protected ball bearing of "L" clutch internal pinion
hub
(14) Ball bearing of "L" clutch external pinion hub
(15) Clutch lubricating oil regulation Oring
(16) Forward shaft ball bearing - hardened bearing
(17) Rear shaft roller bearing
(18) Circlip
(19) Circlip
(22) "L" clutch pressurized oil channel
(23) Pressurized oil channel
(24) Lubricating port
Instructions
(13) The protected ball bearing must be installed with
the protective device facing the clutch linings.
(17) The roller bearing must be installed with the bearing
circlip facing the centre of the shaft
Instructions
(13) The protected ball bearing must be installed with
the protective device facing the clutch linings.
(16) The SH2 bearing must be installed here. The SH2
bearing is a hardened bearing providing twice the
normal life span.
(17) The roller bearing must be installed with the bearing
circlip facing the centre of the shaft
Issue 1
May 2001
5J01.30
6th stage shaft
23
22
21
16
14
20
13
11
23
12
10
15
5
6th STAGE
23
22
17
24
Fig. 65
Issue 1
May 2001
5J01.31
AG 150 transmission
(1) 6th stage pinion shaft - 72 teeth
(2) "H" clutch linings - 10 thrust plates and discs
(3) Pinion - "H" clutch hub - 48 teeth.
Use extractor sleeves ATP 3030-1 and ATP 3030155 to remove the pinion.
(4) Clutch piston
(5) External piston seal - type "D" bush seal
(6) Internal piston seal - Oring
(7) Oil seal washer
(8) Belleville washers - 6
(9) Circlip retaining washer
(10) Circlip
(11) Closing plate
(12) Clutch lining circlip
(13) Protected ball bearing of "H" clutch internal pinion
hub
(14) Ball bearing of "H" clutch external pinion hub
(15) Clutch lubricating oil regulation Oring
(16) Forward shaft ball bearing
(17) Rear shaft roller bearing
(20) Circlip
(21) Distance piece sleeve
(22) "H" clutch pressurized oil channel
(23) Pressurized oil channel
(24) Lubricating port
AG 250 transmission
(1) 5th stage pinion shaft - 81 teeth
(2) "H" clutch linings - 10 thrust plates and discs
(3) Pinion "H" clutch hub - 53 teeth.
Use extractor sleeves ATP 3030-1 and ATP 303016 to remove the pinion.
(4) Clutch piston
(5) External piston seal - type "D" bush seal
(6) Internal piston seal - Oring
(7) Oil seal washer
(8) Belleville washers - 6
(9) Circlip retaining washer
(10) Circlip
(11) Closing plate
(12) Clutch lining circlip
(13) Protected ball bearing of "H" clutch internal pinion
hub
(14) Ball bearing of "H" clutch external pinion hub
(15) Clutch lubricating oil regulation Oring
(16) Forward shaft ball bearing - hardened bearing
(17) Rear shaft roller bearing - hardened bearing
(20) Circlip
(21) Distance piece sleeve
(22) "H" clutch pressurized oil channel
(23) Pressurized oil channel
(24) Lubricating port
Instructions
(13) The protected ball bearing must be installed with
the protective device facing the clutch linings.
Instructions
(13) The protected ball bearing must be installed with
the protective device facing the clutch linings.
(16) The SH2 bearing must be installed here. The SH2
bearing is a hardened bearing providing twice the
normal life span.
(17) The SH2 bearing must be installed here. The SH2
bearing is a hardened bearing providing twice the
normal life span.
Issue 1
May 2001
23
22
16
23
22
10
2
M
11
12
15
7th STAGE
14
13
18
23
24
17
Fig. 66
Issue 1
May 2001
5J01.33
AG 150 transmission
(1) 7th stage pinion shaft - 65 teeth
(2) "M" clutch linings - 10 thrust plates and discs
(3) Pinion "M" clutch hub - 40 teeth.
Use extractor sleeves ATP 3030-1 and ATP 303010 to remove the pinion.
(4) Clutch piston
(5) External piston seal - type "D" bush seal
(6) Internal piston seal - Oring
(7) Oil seal washer
(8) Belleville washers - 6
(9) Circlip retaining washer
(10) Circlip
(11) Closing plate
(12) Clutch lining circlip
(13) Protected ball bearing of "M" clutch internal pinion
hub
(14) Ball bearing of "M" clutch external pinion hub
(15) Clutch lubricating oil regulation Oring
(16) Forward shaft ball bearing
(17) Rear shaft roller bearing
(18) Circlip
(22) "M" clutch pressurized oil channel
(23) Pressurized oil channel
(24) Lubricating port
AG 250 transmission
(1) 7th stage pinion shaft - 75 teeth
(2) "M" clutch linings - 10 thrust plates and discs
(3) Pinion "M" clutch hub - 47 teeth.
Use extractor sleeves ATP 3030-1 and ATP 303013 to remove the pinion.
(4) Clutch piston
(5) External piston seal - type "D" bush seal
(6) Internal piston seal - Oring
(7) Oil seal washer
(8) Belleville washers - 6
(9) Circlip retaining washer
(10) Circlip
(11) Closing plate
(12) Clutch lining circlip
(13) Protected ball bearing of "M" clutch internal pinion
hub
(14) Ball bearing of "M" clutch external pinion hub
(15) Clutch lubricating oil regulation Oring
(16) Forward shaft ball bearing - hardened bearing
(17) Rear shaft roller bearing - hardened bearing
(18) Circlip
(22) "M" clutch pressurized oil channel
(23) Pressurized oil channel
(24) Lubricating port
Instructions
(13) The protected ball bearing must be installed with
the protective device facing the clutch linings.
Instructions
(13) The protected ball bearing must be installed with
the protective device facing the clutch linings.
(16) The SH2 bearing must be installed here. The SH2
bearing is a hardened bearing providing twice the
normal lifetime
(17) The SH2 bearing must be installed here. The SH2
bearing is a hardened bearing providing twice the
normal lifetime
Issue 1
May 2001
Fig. 67
10
8
Fig. 68
Issue 1
May 2001
5J01.35
Fig. 69
Fig. 70
Issue 1
May 2001
Piston travel
- The piston travel can be adjusted by selecting or
exchanging thrust plates since their thickness varies.
. With new clutch discs and thrust plates
Piston travel: 1.3 to 3.8 mm
. With used clutch discs and thrust plates
Piston travel: 1.8 to 5.5 mm
Issue 1
May 2001
Fig. 71
5J01.37
13
Fig. 72
15
Fig. 73
Fig. 74
Issue 1
May 2001
- Fit external pinion hub bearing (14) (Fig. 75) on the shaft
using a compression tool (ATP 3020) and push it into the
pinion hub. Fit a circlip (19) or (18) on the shaft of the fifth
or seventh stage, or a sleeve (21) and a circlip (20) on
the sixth stage shaft.
- Place an extraction sleeve (ATP 3030) on the pinion, pull
the pinion and the bearing upwards against the circlip to
avoid any lateral load on the bearings. The hub of the
pinion must move longitudinally.
- Place the bearings on the shaft (16) (17) and push them
home using a compression tool (ATP 3020).
Note: Bearing (17) of the fifth stage clutch train is
a roller bearing and must be installed so that the
bearing circlip faces the clutch.
- Repeat the procedure at each end of the shaft and for
all the speed clutch shafts.
14
Fig. 75
Issue 1
May 2001
5K01.1
CONTENTS
General _____________________________________________
Operation ___________________________________________
A.
B.
C.
12
D.
13
Issue 1
May 2001
General
The 8210 - 8220 - 8240 and 8250 fitted with a Heavy Duty
gearbox may also be fitted, depending on the options,
with a creeper gear reducer unit.
This reducer unit (24) consists of a simple epicyclical
gear train comprising a planetary carrier and a crown
and placed at the rear of the gearbox (Fig. 1).
24
The link fitted to the front right-hand side of the intermediate housing operates the control fork of the reducer via
a cable linked to a lever located in the tractor cab.
The coupler can only be activated when the tractor is
halted.
Issue 1
May 2001
22
Fig. 1
5K01.3
Operation (Fig. 2)
The coupler (29) is connected by splines to the drive
pinion (9). Moving the control lever towards the "Snail"
position moves the coupler to the rear and connects it to
the planetary carrier (20) via the intermediary of the
coupler ring (22) (Fig. 1).
The rotational speed of the drive pinion is one quarter of
that of the output shaft of the gearbox.
In normal gears, when the coupler is moved forward the
output shaft of the gearbox is linked to the drive pinion,
thus ensuring direct transmission.
Lubrication
The lubricating of the epicyclical reducer is carried out by
splashing caused by its moving components.
20
22
29
Fig. 2
Issue 1
May 2001
Parts list
(1)
(2)
(9)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(26)
(27)
(28)
(29)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)
Nut
Ring
Drive pinion
Snap ring
Friction washers
Pins
Friction plates
Planetary gears
Crown ring
Spacers
Needle bearings
Intermediate housing
Planetary carrier
Snap ring
Coupler ring
Bolt
Planetary carrier assembly (reducer)
Nut
Fork
Selector rail
Link
Locking stud
Spring
Plug
Pin
Index
Oring
pin
Link
Bolt
Housing
Shim(s)
Splined bearing
Output shaft
Bolt
Fig. 3
Fig. 4
Issue 1
May 2001
5K01.5
Overall view
11
12
13
14
18
15
17
12
16
14
44
20
21
22
19
23
29
1
9
F
38
45
19
27
37
36
35
39
41
40
B
19
F
47
46
48
24
23
26
28
27
43
42
Parts list
Fig. 4
Fig. 3
Issue 1
May 2001
5K01.6
Exploded view
37
26
28
36
35
42
27
40
43
41
45
46
47
39
38
11
48
12
19
16
20
21
22
12
44
23
2
29
18
17
14
15
14
13
Issue 1
Parts list
May 2001
Fig. 3
Fig. 4
5K01.7
Refitting
4. Carry out a visual inspection of all components.
5. Lightly smear the faces of the reducer with miscible
grease and fit the friction washers (12) with their tabs
located in the appropriate grooves.
6. Replace the reducer assembly on the output shaft.
Remarks
- a machined area on the external diameter of the
crown ring ensures that the rear cup of the layshaft
of the gearbox stands clear.
- the cutaway part of the housing (44) faces downwards.
7. Check the correct positioning of the components and
tighten bolts (23) smeared with Loctite 241 to a torque
of 10 - 14 Nm.
Manually check for the rotation of the gearbox output
shaft.
Final operation
8. Couple the tractor between the gearbox and the
intermediate housing (see section 2C01).
Issue 1
May 2001
5K01.8
12
11
29
12
37
36
35
26
38
28
19
39
41
45
40
43
42
Fig. 5
Issue 1
May 2001
Disassembly (Fig. 5)
Remark
- To take off the coupler (29), it is necessary to remove
drive pinion (1) from the hydraulic pumps.
11. Remove plug (37), recover spring (36) and locking
pin (35).
12. Remove the selector rail assembly (28) and nut (26).
If necessary, break the seal, unscrew and take off
nut (26).
13. Remove rear ring (2), take off the lug washer (3) and
spring (12).
14. Immobilize the pinion and remove bolts (4).
15. Extract pinion (1) from bearing (11) and simultaneously take out the assembly (pinion, fork and coupler) through the front of the housing.
16. Remove the control link (42) located on the righthand side of the intermediate housing. Drive out pin
(38) and remove index (39). Recover the shim(s) (45)
and remove pin (41) complete with oring (40).
5K01.9
Action
- If the clearance is outside the maximum allowed
tolerance, determine a new thickness of shims required. After shimming, check for correct orientation of
the index and the link. Definitively insert pin (38), fit and
tighten Allen screw (43).
19. Rearrange the assembly (pinion, coupler, and fork) in
the intermediate housing. Carry out operation 15 in
reverse order.
20. Immobilize the pinion again. Fit and tighten the bolts
(4) lightly smeared with Loctite 241 to a torque of 72
- 96 Nm.
21. On bearing (11), replace in their correct positions the
spring, lug washer and ring.
22. Refit the selector rail and nut assembly. Adjust the
fork (see operation further on).
Final operations
23. Couple the tractor between the gearbox and the
intermediate housing (see section 2C01).
24. Reconnect the control cable and where necessary
carry out its adjustment (see D).
Refitting (Fig. 5)
17. Lubricate a new oring (40) and place it on pin (41).
18. Place the pin in the chamfered port located on the
exterior of the intermediate housing (19).
Reminder
- To limit the axial clearance, it is recommended to shim
to a tolerance of 0.1 to 0.6 mm.
Shimming
- On the axle, place the approximate thickness of shims
(45). Fit index (39) and partially place the pin (38). Refit
the link (42) and bolt (43).
- Manually evaluate the clearance.
Remark
- The adjustment principle consists of obtaining the
minimum clearance between the various components.
Issue 1
May 2001
5K01.10
29
1
9
F1
19
F2
37
36
F3
F4
35
G2
B
26
28
19
27
B
X1
X2
Fig. 6
Issue 1
May 2001
5K01.11
Adjustment (Fig. 6)
- Fit locking stud (35), spring (36) and plug (37). Partially
tighten the plug.
- Place coupler (29) in the F1 creeper gear position, the
rear face thrusting against the M60 nut (1).
- In F2, maintain the fork thrust against the coupler.
- In F3, turn the selector rail (28) in nut (26) so as to place
in contact the oblique side of groove G2 with locking pin
(35) while simultaneously holding nut (26) against spotface B of the intermediate housing (19).
- Using a depth gauge, measure distance X1 between
the front face of the selector rail and face A of the
housing.
- In F2, maintain the fork thrust against the coupler.
- In F4, turn the selector rail in the nut so as to place the
other oblique face of groove G2 in contact with the
locking stud while maintaining nut (26) as previously.
- Measure distance X2 in the same way as X1.
- Determine the X adjustment position using the following formula:
X = (X1 + X2) 2
- Provisionally position the selector rail (28) at dimension
X.
- Place the coupler (29) in the "direct drive" position;
manually check the locking of the control and the
clearance between the fork and the coupler. Take care
also that the coupler is not in contact with the hydraulic
pumps drive pinion.
- If this check is satisfactory, take out plug (37), the
spring and the locking pin.
- Degrease the threads of the selector rail and those in nut
(26).
- Lightly smear the nut threads with Loctite, tighten the
nut and definitively position the selector rail, in accordance with the previously calculated dimension X.
- Lock the nut by bending its collar into the machined slot
on the selector rail.
- Replace the locking assembly. Tighten plug (37) to 50
- 70 Nm.
Issue 1
May 2001
5K01.12
33. Refit pins (13), correctly orienting them to correspond with snap ring (11).
34. Place the snap ring. Manually check the axial clearance and rotation of each planetary gear.
35. Lightly smear the faces of the reducer with miscible
grease and fit the friction washers (12), with their
lugs lodged in the appropriate grooves.
36. Refit the unit (see A).
Reassembly (Fig. 7)
30. Inspect and clean all components. Replace any
defective parts.
31. Fit each planetary gear with two rows of needles
smeared with miscible grease and separated by a
spacer.
32. Replace the planetary gears and position the friction
plates (14).
11
12
20
21
22
12
18
13
17
14
24
15
14
Fig. 7
Issue 1
May 2001
5K01.13
D . Control adjustment
On lever "A" (Fig. 8)
1
7
6
4
2
3
Fig. 8
14
13
12
6
11
10
B
Issue 1
Fig. 9
May 2001
6 . REAR AXLE
Contents
6 A01
6 B01
6 B02
DESCRIPTION
STANDARD TRUMPET HOUSINGS
TRUMPET HOUSINGS WITH SEALED COMPARTMENT
6 B03
6 B04
6 C01
6 D01
6 D02
6 D03
6 E01
6 F01
6 G01
6 H01
6 I01
6 J01
Issue 1
May 2001
6A01
6A01.1
Description
CONTENTS
A.
General ________________________________________________
B.
Issue 1
May 2001
A . General
The rear axle is made up of five main housings:
- The intermediate housing comprising:
Inside:
. the drive pinion (see sections 6D01, 6D02 or 6D03
according to the version)
. the hand brake unit (see section 6C01)
. the hydraulic pump pinion (see sections 9G01 - 9G02
depending on the hydraulic equipment)
. the 4 WD clutch (see section 8A01)
. the Park Lock system (if fitted) (see section 6F01)
. the PTO clutch transmission shaft.
Outside:
. the right-hand and left-hand side covers (see sections
9G01 - 9G02 and 9H01 depending on the hydraulic
equipment).
- The centre housing containing:
Inside:
. the drive pinion crownwheel and differential (see
sections 6D01 - 6D02 or 6D03 depending on the
version)
. the PTO brake (see section 7F01)
Outside:
. the two trumpet housings (see sections 6B01 and
6B04).
- The PTO housing containing:
. in the upper part, the clutch and double pinion driving
the 540 / 1000 rpm pinions (see section 7F01).
. in the lower part, the removable 540 or 1000 rpm shaft
depending on the desired speed and the 540 / 1000
rpm pinions (see respective sections 7A01 and 7E01).
- The left and right trumpet housings acting as the
housing for the rear wheel drive system.
Issue 1
May 2001
Intermediate housing
Centre housing
PTO housing
Bevel gear (crownwheel and drive pinion)
Handbrake unit
Creeper gearbox (if fitted)
PTO clutch and drive pinion(s)
540 / 1000 rpm pinions
4 WD clutch
Park Lock unit
Hydraulic pump drive pinion
Removable 540 / 1000 rpm shaft (Fig. 1)
Fig. 1
Fig. 2
6A01.3
Version with standard bevel gear - 8210 - 8220 - 8240 and 8250 tractors
Remark: On tractors fitted with Heavy Duty transmission, the drive unit (6) is fitted to the rear of the gearbox.
11
12
10
Parts list
Issue 1
May 2001
Fig. 2
Fig. 1
Remark: On a hypoid bevel gear, the axial line of the drive pinion is not common with the centre of the
crownwheel.
11
10
Parts list
Issue 1
May 2001
Fig. 1
Fig. 2
6B01
6B01.1
Standard trumpets
CONTENTS
-
General ________________________________________________
A.
B.
C.
D.
E.
10
F.
12
G.
13
Issue 1
May 2001
General
8210 tractors are fitted with standard trumpet housings;
also known has Heavy Duty "HD".
They may be fitted either with a plain axle shaft or with
a flanged axle shaft.
The flanged axle shaft type of trumpet housing is offered
as an option on 8220 series tractors.
Description
The trumpet housings support the left and right-hand axle
shafts and contain the final drive unit that receives the
rotation from the differential assembly. Both trumpet
housings are symmetrical and fitted on either side of the
centre housing.
Construction
The axle shaft (2), depending on the version, is supported
by two taper roller bearings comprising bearing cups (8)
(12) and cones (7) (13) fitted opposing each other.
The oil tightness of the drive unit compartment is provided by a lip seal (11).
The oil tightness of the crownwheel is ensured by two
beads of silicone (Silicomet type).
The lip seal (5) protects the external bearing. The planetary carrier (25) engages with the axle shaft (2) by
means of splines and contains three planetary gears (22)
that engage with the crownwheel (15) and the sun gear
(29).
The crownwheel placed between the trumpet housing
(10) and the brake plate (30) is centred by pins (14).
The sun gear (29) drives the brake disc (35).
The pre-loading of the taper roller bearings is obtained by
shim(s) (26) placed at the end of the shaft between
washers (1) (27).
The axle shaft (2), depending on version and planetary
carrier (25) are held by washer (27) and bolt (28).
The brake plate (30) possesses a port "O" providing
lubrication for the brakes (see section 6E01).
Issue 1
May 2001
(1)
(2)
(2)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(34)
(35)
(39)
(40)
Washer
Plain axle shaft
Wheel flange
3-lipped seal
Cage
Bearing cone
Bearing cup
Threaded plug
Trumpet housing
Seal
Bearing cup
Bearing cone
Pins
Crownwheel
Tab washer
Spacer
Bolt
Circlip
Planetary gear pin
Washer
Planetary gear
Needle bearings
Spacer
Planetary carrier
Shim(s)
Lock washer
Bolt
Sun gear
Brake plate
Ring (straight axle shaft)
Brake disc
Bolt
Bolt
Fig. 1
Fig. 2
Overall view
6B01.3
14
20 mm
B
6
39
39
39
10
11
16
25
19
20
21
24
15
23
22
21
6
39
35
40
29
39
34
39
17
18
8 mm
39
39
39
25
19
12
13
26
27
28
25
39
30
P1 = 0,02 / 0,12 mm
Parts list
Fig. 2
Fig. 1
Issue 1
May 2001
6B01.4
Exploded view
14
2
16
15
13
12
11
10
9
35
8
7
30
29
28
27
26
1
17
18
19
21
23
24
23
22
40
39
21
25
20
Parts list
Issue 1
May 2001
Fig. 1
Fig. 2
6B01.5
Remark
The piston of brake "P" remains in the housing (1) (Fig. 3).
Removal
Important:
15
30
35
29
39
40
P
35
1
Fig. 3
Issue 1
May 2001
Refitting
8. Clean the mating faces of trumpet and centre
housings. Remove any remaining traces of sealing
compound. Dry the parts.
9. Place a bead of silicone sealing compound (Silicomet
type) in angle "D" of the centre housing (1) (Fig. 4).
Reminder: The diameter of the bead must be uniform, of small section and without joins.
10. Introduce the sun gear shaft (29) into the differential.
Refit the brake disc (35) while checking that it slides
freely on the splines of the shaft.
11. Support the trumpet housing with the equipment
used to remove it. If necessary, screw two guide
studs on to the centre housing. Engage the trumpet
housing. Turn the axle shaft and push the trumpet
housing until it makes contact with the centre
housing.
12. If used, remove the guide studs. Smear the bolts (39)
with a sealing compound such as "Plastex" or
"Hylomar" and tighten them to a torque of 220 300 Nm.
13. Replace the various components around the trumpet
housing. Refit the wheel and tighten the studs or
wheel nuts to the correct torque depending on the
version (see section 2G01).
14. Top up the oil level in the housings and check it in the
transparent tube located on the left-hand side of the
centre housing.
15. Check the lift ram operation. Carry out a road test of
the brake circuit. Check the oil tightness of the
trumpet housing and hydraulic unions.
Issue 1
May 2001
Fig. 4
6B01.7
30
Removal
Refitting
10
Fig. 5
29
Fig. 6
Issue 1
May 2001
28
Disassembly
27. Remove the bolts (18) and spacer (17). Remove
snap ring (19) by opening its two ends (Fig. 8).
28. Drive out and remove the pins (20). Take out the
friction washers (21) and the planetary gears (22)
from the planetary carrier. Recover the two ranks of
needle bearings (23) separated by spacer (24).
27
26
25
16
17
18
17
25
F
40
19
18
Fig. 8
Issue 1
May 2001
Fig. 7
6B01.9
Refitting
31. Check for the presence of the tab washer (16). Refit
the planetary carrier assembly (25) (Fig. 7). If necessary, shim the bearings (see F).
32. Immobilise the axle shaft and the planetary carrier.
Fit washers (1) (27) with the shim(s) (26) between
them. Fit bolt (28) previously lightly smeared with
Loctite 270 or equivalent, and tighten to the following
torque:
- 270 - 440 Nm : flanged axle shaft, 82 mm.
- 340 - 500 Nm : straight axle shaft, 95 mm.
33. Refit the brake plate assembly (30) and crownwheel
(15) (see B).
34. Refit the trumpet housing (see A).
Issue 1
May 2001
12
Disassembly
8 mm
36. Take off tab washer (16) and shaft assembly (2).
37. On the shaft:
- remove bearing cone (13)
- extract bearing cone (7) and seal (5).
38. Using an extractor or a locally manufactured tool,
remove the bearing cups (8) (12) and cage (6).
Remark: During the replacement of the bearings, the
replacement of seal (11) is also recommended.
Reassembly
39. Clean and check the components. Replace any
parts found to be defective.
Issue 1
May 2001
11
Fig. 9
6B01.11
7
20 mm
Final operations
45. Refit the planetary carrier (25) assembly.
46. Carry out shimming of the bearings (see F).
47. Refit the brake plate assembly (30) and crownwheel
(see B).
48. Temporarily replace plug (9) with a grease nipple.
Partially fill cavity "A" (Fig. 11) of the trumpet housing
with grease (BP Agricharge or equivalent). Remove
the grease nipple. Screw in the plug.
49. Refit the trumpet housing assembly (see A).
Fig. 10
9
Fig. 11
Issue 1
May 2001
Remark
The pre-loaded shimming of taper roller bearings on the
axle shaft is carried out via the shim(s) (26) placed
between washers (1) (27) (Fig. 12).
27
Reminder
To carry out the correct shimming of the bearings, place
the trumpet housing in a vertical position (Fig. 12).
26
Preparation
50. With the bearing cone (13), tab washer (16), planetary carrier (25) and washer (1) already fitted, place
a thickness of shims (26) greater than the space
between washer (1) and the thrust face of the
washer (27) on the planetary carrier (Fig. 13), so as
to obtain a provisional clearance of approximately
0.10 mm to 0.15 mm, in order to carry out the final
shimming with pre-loading (see further on).
51. Place washer (27). Provisionally tighten bolt (28).
P1 =
0,02 / 0,12 mm
Fig. 12
Issue 1
May 2001
28
6B01.13
27
26
1
25
16
13
2
Fig. 13
Issue 1
May 2001
Issue 1
May 2001
6B02
6B02.1
Contents
-
General ________________________________________________
A.
B.
C.
D.
E.
F.
10
G.
12
H.
14
Issue 1
December 2000
6B02.2
General
The 8220 tractors can be fitted with trumpets containing
a sealed compartment, these are also known as "HDE"
or Heavy Duty Etanche.
The 8240 and 8250 tractors are fitted with Optimised
Heavy Duty trumpets with sealed compartment called
"HDEO".
HDEO trumpets have a crownwheel and sun gears that
have been carbon nitrided: this is a special heat treatment that makes them resistant to "pitting."
A final honing ensures the optimum bearing of the teeth
as a function of the high loads borne by the epicyclic gear.
The trumpets bear the right and left hand side axle shafts
and contain the final drive units that transmit the rotation
from the differential assembly. The trumpets are symmetrical and mounted either side of the centre housing.
The final drive unit is lodged in a sealed compartment
isolated from the centre housing and containing oil with
SAE 85W140 viscosity grade.
Construction
The axle shaft (2) is supported by two opposing taper
roller bearings comprising cups (8) (12) and cones (7)
(13).
The oil tightness of the final drive unit compartment is
ensured by lip seal (11) and compartment (30) fitted with
seals (31) mounted back-to-back. The oil tightness of the
crownwheel (15) is provided by two beads of silicone
(Silicomet type).
The three lipped seal (5) protects the outer bearing. The
planetary carrier (25) engages with the axle shaft (2) via
splines, it is made up of three planetary gears (22) that
engage with the crownwheel (15) and the sun gear (29).
The crownwheel is placed between the trumpet (10) and
compartment (30) and is centred via pins (14). The
compartment (30) equally serves as the brake plate.
The sun gear (29) drives the brake disc (35) through a
splined hub (32) held in place by a snap ring (33).
The pre-loading of the taper roller bearings is provided by
shim(s) (26) placed at the end of the shaft.
Axle shaft (2) and planetary carrier (25) are held in place
by washer (27) and bolt (28).
The compartment (30) possesses a port "O" providing for
lubrication of the brakes (see section 6E01).
The tube (38) linked to the breather tube screwed on the
left hand-side lifting support allows atmospheric pressure to be maintained in the trumpet.
Issue 1
2
December
May 2000
2002
(2)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(35)
(38)
(39)
(40)
(41)
(42)
(43)
Fig. 1
Fig. 2
Overall view
6B02.3
30
"O"
14
20 mm
D
B
C
10
39
39
16
25
19
38
20
21
23
24
15
22
21
35
39
6
2
30
41
31
31
39
40
29
42
33
39
32
2
5
8 mm
25
39
39
39
17
18
11
39
19
31
12
13
26
27
28
25
39
30
P1 = 0,02 - 0,12 mm
43
Fig. 1
Parts list
Issue 1
May 2001
Fig. 2
6B02.4
Exploded view
14
38
16
15
13
12
11
10
35
32
30
41
43
28
27
26
17
18
33
19
31
31
42
29
41
21
23
24
23
22
40
39
21
42
25
20
Parts list
Issue 1
May 2001
Fig. 1
Fig. 2
15
39
6B02.5
Important
- Take care not to press the brake pedal concerned,
or fix a piston retaining tool on to the centre
housing (see section 6E01).
30
29
40
P
1
35
Fig. 3
Issue 1
May 2001
Refitting
8. Clean the mating faces of the trumpet and centre
housings. Remove any traces of previous sealing
compound. Dry the parts.
9. Place a bead of silicone sealing compound (Silicomet
type) in angle "D" of the centre housing (1) (Fig. 4).
Reminder
- The diameter of the bead must be uniform, of small
section and without joins.
10. Replace the brake disc (35) checking that it slides
freely on the hub splines.
11. Support the trumpet using the equipment used when
removing it. If necessary, screw two gui-de studs
into the centre housing. Engage the trumpet. Turn the
axle shaft and push the trumpet until it makes
contact with the housing.
12. Remove the guide studs if used. Smear the bolts (39)
with an oil tightness product ("Plastex" or "Hylomar")
and tighten them to a torque of 220 - 300 Nm.
13. Refit the remaining components around the trumpet.
Refit the wheel and tighten the wheel nuts or studs
to the correct torque depending on the version (see
section 2G01).
14. Top up the oil level and check using it in the
transparent tube located on the left-hand-side of the
centre housing.
Remark
- In addition, check the oil level in the final drive unit.
15. Check the operation of the lift ram.
Road test the brake circuit.
Check the oil tightness of the trumpet, the hydraulic
unions and plugs.
Issue 1
May 2001
Fig. 4
6B02.7
33
32
30
15
28
29
26
27
25
16
29
F
F
40
Fig. 5
Fig. 6
Issue 1
May 2001
Refitting
18. Clean the mating surfaces of the trumpet, the
crownwheel and compartment with solvent. Remove all traces of the previous sealing compound.
Dry the components.
19. Seal angles B and C located on the trumpet (10) and
the compartment (30) with a Silicone sealing compound (Silicomet type) according to the arrows
shown in Fig. 7.
20. Refit the sun gear. Place protector 3376885M1,
compartment (30), hub (32), snap ring (33). Replace
and tighten bolt (40) to 100 - 130 Nm.
21. Refit the trumpet (see A) and top up and check the
oil level of the drive unit concerned.
30
C
B
10
Fig. 7
30
31
Reassembly
25. Using an appropriate assembly, insert the first new
seal (31) against the shoulder of compartment (30)
with the second seal back to back, employing the
same method (Fig. 8).
26. Refit the compartment assembly (30) and crownwheel (see B). Refit the trumpet assembly (see
A).
Issue 1
May 2001
31
Fig. 8
17
6B02.9
18
Removal
27. Remove the trumpet assembly (see A).
28. Remove the compartment assembly (30) and
crownwheel (see B).
29. Immobilise the axle shaft and planetary carrier.
30. Take out bolt (28), washer (27), shim(s) (26).
Remove the planetary carrier assembly (25) (Fig. 5).
17
25
19
Disassembly
31. Take out bolt (18) and spacer (17). Remove snap ring
(19) by opening its two extremities (Fig. 9).
32. Drive out and remove the pins (20). Take off the
friction washers (21) and the planetary gears. Recover the needle bearings that are arranged in two
rows separated by a spacer (24).
18
Fig. 9
Refitting
35. Check for the presence of washer (16). Refit the
planetary carrier assembly (25) (Fig. 5). If necessary, carry out shimming of the bearings (see G).
36. Immobilise the axle shaft and planetary carrier.
Place the shim(s) (26) and washer (27). Fit and
tighten bolt (28), lightly smeared with Loctite 270 or
equivalent, to a torque of 340 - 500 Nm.
37. Refit the compartment assembly (30) and crownwheel (see B). Refit the trumpet assembly (see
A).
Issue 1
May 2001
Preliminary operations
38. Remove:
- the trumpet assembly (see A).
- the compartment assembly (30) and crownwheel
(see B).
- the planetary carrier assembly (25) (see D).
Disassembly
39. Take off washer (16) and the shaft assembly (2)
(bearing cone (13) moves freely on the shaft).
40. Take off bearing cone (13). Extract bearing cone (7)
and seal (5) from the shaft.
41. Using an extractor or a locally manufactured tool,
take off the bearing cups (8) (12) and cage (6).
Remark
- When replacing the bearings, it is recommended
that the seal (11) is also replaced.
8 mm
11
2
Fig. 10
Reassembly
42. Clean and check the components. Replace any
parts found to be defective.
Issue 1
May 2001
20 mm
7
Fig. 11
6B02.11
Final operations
48. Refit the planetary carrier assembly (25).
49. Carry out shimming of the bearings (see G).
50. Refit the compartment assembly (30) and crownwheel (see B).
51. Temporarily replace plug (9) by a grease nipple.
Partially fill cavity A (Fig. 12) of the trumpet with
grease (BP Agricharge or equivalent). Remove the
grease nipple. Screw in the plug.
52. Refit the trumpet assembly (see A).
9
Fig. 12
Issue 1
May 2001
27
Remark
- The pre-loading shimming of the taper roller bearings on
the axle shaft is carried out via shims (26) placed
between the shaft (2) end and washer (27) (Fig. 13).
Reminder
- To carry out the shimming of the bearings correctly,
place the trumpet in a vertical position (Fig. 13).
26
P1 =
0,02 - 012 mm
Preparation
- The bearing cone (13), tab washer (16) and planetary
carrier (25) being fitted, place a thickness of shims (26)
greater than the space between the end of the axle shaft
(2) and the washer (27) thrust face on the planetary
carrier (Fig. 14), to obtain a provisional clearance of
approximately 0.10 mm to 0.15 mm, in order to be able
to carry out definitive shimming and pre-loading (see
further on).
Fig. 13
Issue 1
May 2001
6B02.13
28
27
26
25
16
13
Fig. 14
Issue 1
May 2001
H . Service tools
1. Tool available in the AGCO network
- 3376885 M1 - Oil seal protector (Fig. 15).
Fig. 15
85
30
R10
47-0-0,3
51-0-0,2
32,6 +0,1
+0,3
18
R10
41
35
20
45
180
0,5 x 45
61
71
+0,1
51,2 +0,3
30
Fig. 16
Issue 1
May 2001
6B03
6B03.1
Contents
-
General ________________________________________________
A.
B.
11
C.
12
D.
13
E.
14
F.
15
G.
16
H.
17
I.
18
J.
20
Issue 1
May 2001
Issue 1
May 2001
Description
6B03.3
Kinematics (Fig. 2)
The differential assembly drives the sun gear shaft (29)
that in turn transmits the movement to the axle shaft (2)
via double planetary gears (22), crownwheel (15) and
planetary carrier (25).
It is a classical kinematics train: the movement enters
the sun gear shaft and is output to the planetary carrier.
Construction
The axle shaft (2) is supported by two taper roller bearings comprised of cups (8) (12) and cones (7) (13)
mounted opposing each other.
The oil tightness of the final drive unit is provided by lip
seals (31) fitted back-to-back and orings (4). The cassette seal (3) protects the external bearing comprising
cup (8) and cone (7).
The planetary carrier (25) is separated from the centre
housing by a spacer (30) that also serves as the brake
plate.
The compartment containing the final drive unit contains
SAE 85W140 viscosity oil and is different from that used
in the transmission.
Axial and radial drilled holes in pin (20) permit lubrication
of the needle bearings (23) in the double sun gears.
The planetary carrier drives the axle shaft (2) via splines
and has three double pinions (22). The axial clearance of
these pinions is provided by shim(s) placed on pin (20)
against the 17-teeth pinion.
Shims (26) placed at the end of the axle shaft allow a preloading of the taper roller bearings. Shaft (2) and planetary
carrier (25) are held by washers (27) and bolt (28).
The reduction crown (15) squeezed between the trumpet
(10) and spacer (30) is centred by pin (14). Spacer (30) is
positioned by pin (5) on the centre housing. The rotation
of the differential is transmitted to the double sun gears
via a planetary gear shaft on which snap ring (33) retains
hub (32) driving the brake disc (35).
The compartment of spacer (30) possesses a port "O"
that provides for lubrication of the brakes (see section
6E01). Tube (38) linked to the breather tube screwed on
to the left-hand lift support allows atmospheric pressure
to be maintained in the trumpet.
Issue 1
May 2001
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(40)
(41)
(43)
Bush
Straight shaft
Cassette seal
Orings
Locating pin
Shim(s)
Bearing cone
Bearing cup
Washer
Trumpet
Nut
Bearing cup
Bearing cone
Pin
Crownwheel
Tab washer
Spacer
Bolt
Circlip
Planetary gear pin
Washer
Double planetary gear
Needle bearings
Spacer
Planetary carrier
Shim(s)
Lock washer
Bolt
Sun gear
Spacer (brake plate)
Seals
Splined hub
Snap ring
Stud
Brake disc
Studs
Stud
Tube
Bolt
Plug (filler and level)
Magnetic drain plug
Issue 1
Fig. 1
Fig. 2
Fig. 3
May 2001
Overall view
6B03.5
30
14
31
31
"O"
11
36
15
30
D
35
10
19
20
38
23
24
15
22
23
21
16
29
40
33
40
32
31
13
12
11
27
28
25
30
26
9
11
34
11
37
17
25
18
P1 =
0,02 - 0,12 mm
41
30
19
43
Fig. 1
Parts list
Issue 1
May 2001
Fig. 2
Fig. 3
6B03.6
Exploded view
29
16
4
15
22
14
4
13
12
15
10
8
7
1
30
25
41
29
28
27
35
26
33
25
32
19
31
5
9
11
43
36
40
40
21
22
23
17
24
18
20
11
34
11
37
Parts list
Fig. 1
Fig. 3
Fig. 2
Parts list
Issue 1
May 2001
Fig. 1
Fig. 2
Fig. 3
6B03.7
Removal
1. Drain the centre housing.
Remarks
- The oil used for the mechanical and hydraulic components of the transmission and that used for the
lubrication of the moving parts of the trumpet are not
of the same type and their viscosity is different.
- If the oils are not to be changed, they must not be
mixed when drained.
2. Immobilise the tractor. Take off the wheel. Position an
axle stand.
3. Remove the cab fixing bolts and the stabiliser support.
Note: If necessary slightly raise the side of the cab
concerned, check that nothing blocks its lifting.
Position an axle stand.
4. Drive out the holding snap ring (1) (Fig. 4). Push the
lower axle (2) of the lift ram outwards and remove it.
Fig. 4
Issue 1
May 2001
Important
- Take care not to press the brake pedal concerned or fix
a piston retaining tool to the centre housing (see section
6E01).
29
15
40
30
11
40
P
35
Fig. 5
Issue 1
May 2001
6B03.9
Refitting
Special points
- The threaded studs (34) (36) (37) screwed into the
centre housing have different lengths and their threads
must be lightly smeared with Loctite 270 or equivalent
before fitting (Fig. 6).
Important
- Place the studs in the housing, respecting their length
and locations in accordance with Fig. 1 :
. (34) : 16 mm - L 335 mm
. (36) : 16 mm - L 353 mm
. (37) : 16 mm - L 363 mm
8. Clean the mating faces of the trumpet and centre
housing. Remove all traces of previous sealing
compound. Dry the parts.
9. Place a bead of sealing compound (Silicomet type)
in angle "D" of the centre housing (1) (Figs. 7 and 9).
Reminder
- The diameter of the bead must be uniform, of small
section and without joins.
10. Refit the brake disc (35) while checking that it slides
freely on the splines of the hub (32). Check for the
presence of the locating pin (5) (Fig. 8).
11. Support the trumpet with the aid of the equipment
used when removing it.
12. Engage the trumpet on the original studs. Turn the
axle shaft and push the trumpet until it mates with
the housing.
13. Place a washer (9) on each stud. Screw on the nuts
and tighten to a torque of 247 - 253 Nm.
Fig. 6
Fig. 7
35
32
5
Fig. 8
Issue 1
May 2001
Issue 1
May 2001
Fig. 9
6B03.11
Removal
17. Remove the trumpet assembly (see A) and drain
the drive unit concerned.
18. If possible, place the trumpet in a vertical position,
the sun gear (29) at the top (Fig. 11). Remove bolts
(40), snap ring (33) and hub (32). Unstick and remove
the spacer (30) having previously placed a flexible
protection on the splines of the sun gear (29).
Take off the sun gear.
Remove the planetary carrier assembly (see E).
Unstick and remove the crownwheel (15) (Fig. 10).
19. Discard the orings (4) (Fig. 1).
32
30
29
28
27
15
26
16
25
29
40
F
F
40
Fig. 11
Fig. 10
Issue 1
May 2001
Refitting
20. Clean the mating faces of the trumpet, crownwheel
and spacer with solvent. Dry the parts.
21. Position new crownwheel orings (4) according to
the arrows in angles B and C (Fig. 12) between the
trumpet (10) and compartment (30).
22. Replace the trumpet assembly (see F) and the sun
gear. Fit protector ref. 3376885M1, the spacer (30),
hub (32), snap ring (33). Fit and tighten the bolts (40)
to a torque of 100 - 130 Nm.
23. Replace the trumpet assembly (see A) and top up
and check the drive unit oil level.
30
4
10
B
Fig. 12
30
31
Reassembly
27. Using a suitable fixture, insert the first new seal (31)
against the shoulder of the spacer (30) (Fig. 13) and
the second seal back-to-back using the same method.
28. Refit the spacer assembly (30) and the crownwheel
(see B).
29. Refit the trumpet assembly (see A).
Issue 1
May 2001
31
Fig. 13
6B03.13
Preliminary operations
30. Partially drain the concerned drive unit.
31. Chock the front wheels. Remove the rear wheel (see
section 2G01). Place an axle stand beneath the trumpet.
Removal
Special points
- The 8240 (depending on options) and 8250 tractors may
be fitted with axle shafts of 95 mm or 110 mm
diameter.
- Whatever the diameter of the shaft, the reference
number for bush (1) and cassette seal (3) (Fig. 14 - 15)
remains identical.
- If necessary, smear the bore of the bush with Loctite
648 or its equivalent and slide it on to the shaft flush with
the thrust face of bearing cone (7) (Fig. 15).
1
Fig. 14
32. Using a locally manufactured tool, extract the cassette seal (3), without damaging the trumpet or the
external diameter of the bush (1) (Fig. 14).
Refitting
33. Clean the location of the seal on the trumpet and
bush (1).
34. Lightly smear the external diameter of the seal with
Loctite 648 or its equivalent and moderately lubricate
its internal diameter with transmission oil.
35. Insert the seal using tool ref. 3378151M1 (see J).
Wipe off all remaining traces of Loctite.
Remark
- The design of the tool determines the position of the
cassette seal in the trumpet.
7
Fig. 15
Final operations
36. Refit the wheel and tighten the wheel studs or nuts
depending on the version (see section 2G01).
37. Top up and check the oil level in the drive unit.
38. Road test. Check the oil tightness of the cassette
seal.
Issue 1
May 2001
18
17
Disassembly
44. Take out bolt (18) and spacer (17) (Fig. 16).
Take off the circlip (19) by opening its extremities
(Fig. 17).
45. Drive out and remove the pins (20).
Remove the friction washers (21), shim(s) (6) and
planetary gears (22).
Recover the two rows of needle bearings (23) separated by spacer (24) (Fig. 18).
Fig. 16
19
Fig. 17
23
24
23
20
6
21
22
Fig. 18
Issue 1
May 2001
6B03.15
O
20
19
Fig. 19
17
18
17
Refitting
55. Refit the crownwheel (see B).
56. Check for the presence of washer (16). Refit the
planetary carrier assembly (25) (Fig. 10) turning the
marks stamped on each planetary gear to the position shown in Fig. 21.
If necessary, carry out shimming of the axle shaft
bearings (see I). Otherwise, continue the refitting
operation.
Remark
- Each planetary gear carries a punched mark on the
29 teeth pinion. These marks indicate the alignment of two teeth belonging to their respective
pinions (17 and 29 teeth). The marks must point
towards the centre of the planetary carrier.
57. Immobilise the axle shaft and the planetary carrier.
Place the shim(s) (26) and washer (27). Fit and
tighten bolt (28) previously lightly smeared with Loctite 270 or equivalent and tighten to a torque of 340
- 500 Nm.
58. Refit the sun gear shaft (29), spacer (30) and hub (32)
(see B).
59. Refit the trumpet assembly (see A) and top up and
check the oil level in the drive unit concerned.
19
18
Fig. 20
22
Fig. 21
Issue 1
May 2001
Preparation
60. Place the planetary gears (22), the 17-teeth pinion
facing the circlip (19).
Place washers (21) against the 29 teeth pinion and
average thickness provisional shim(s) (6) against
the 17 teeth pinion.
61. Engage the three pins (20), turning the lubricating
ports towards the circlip (19).
Shimming
62. Using a feeler gauge (Fig. 22) determine the thickness of the definitive shim(s) (6) to be fitted so as to
obtain a clearance of between 0.15 mm and 0.6 mm
on each planetary gear.
Note: Where possible shim to the minimum
tolerance.
63. Slightly retract the pins (20) and place the shim(s) (6)
(Fig. 23) whose thickness was previously determined.
Reminder
- The thickest shim must be placed against the row
of needle bearings.
64. Refit the pins. Fit circlip (19). Position the spacer (17)
and tighten bolt (18), previously lightly smeared with
Loctite, to a torque of 34 - 50 Nm.
Issue 1
May 2001
Fig. 22
20
Fig. 23
6B03.17
Disassembly
66. Take off washer (16) and shaft assembly (2).
Remark
- The bearing cone (13) runs free on the shaft.
67. Remove the bearing cone (13). Extract bearing cone
(7).
68. Drive out the cassette seal (3).
69. Using an extractor or locally manufactured tool,
remove bearing cups (8) (12).
Reassembly
70. Clean and check the components. Replace any
parts found to be defective.
71. Insert:
- bearing cups (8) (12) thrusting against their respective shoulders
- bearing cone (7) previously lubricated with transmission oil and thrusting against the shoulder on
the shaft.
72. Introduce the prepared shaft into the trumpet fitted
with its cups.
73. Assemble cone (13) and refit tab washer (16).
Final operations
74. Place the crownwheel (see B). Refit the planetary
carrier assembly (25) (see F) and carry out shimming of the bearings (see I).
75. Refit the spacer assembly (30) (see B).
76. Refit the trumpet assembly (see A).
77. Insert a new cassette seal (see D).
78. Refit the wheel and tighten the wheel nuts or studs
to the correct torque depending on the version (see
section 2G01).
79. Top up and check the oil level in the housings and
check the level in the transparent tube located on the
left-hand side of the centre housing.
In addition, top up and check the oil level of the drive
unit concerned.
Issue 1
May 2001
Remark
- The shimming for pre-loading of the taper roller bearings
on the axle shaft is carried out using shim(s) (26) placed
between the end of shaft (2) and washer (27) (Fig. 24).
P1 =
0,02 - 0,12 mm
27
26
Reminder
- To carry out the correct shimming of the bearings, place
the trumpet in a vertical position (Fig. 24).
Preparation
80. With bearing cone (13), tab washer (16) and planetary carrier (25) fitted, place a thickness of shim(s)
(26) greater than the space between the end of the
axle shaft (2) and the thrust face of washer (27) on
the planetary carrier (Fig. 25) to obtain a provisional
clearance of approximately 0.10 mm to 0.15 mm, in
order to carry out definitive shimming (see further
on).
81. Place washer (27). Provisionally tighten bolt (28).
Fig. 24
Issue 1
May 2001
6B03.19
28
Fig. 26
27
26
25
16
13
Fig. 25
Issue 1
May 2001
J . Service tools
1. Tools available in the AGCO network
- 3376885M1 - Spacer (30) seal protector (Fig. 27).
- 3378151M1 - Cassette seal (3) insertion tool (Fig.
28).
Fig. 27
Fig. 28
Issue 1
May 2001
6B03.21
85
30
R10
47-0-0,3
51-0-0,2
32,6 +0,1
+0,3
18
R10
41
35
20
45
180
0,5 x 45
61
71
51,2 +0,3
+0,1
30
Fig. 29
Issue 1
May 2001
Issue 1
May 2001
6B04
6B04.1
Contents
-
General ________________________________________________
A.
B.
11
C.
14
D.
15
E.
16
F.
17
G.
19
Issue 1
May 2001
6B04.2
20
31
47
44
24
18
15
51
25
Fig. 1
Issue 1
May 2001
Construction
The axle shaft is supported by two bearings comprising
cups (8) (12) and bearing cones (7) (13) mounted in
opposition to each other. The input shafts (31) are of
different lengths ; the long shaft is fitted in the left hand
side trumpet. The crownwheels, spacer and brake plate
are positioned by pins (14). The pre-loading of the taper
roller bearings is provided by shim(s) (26) placed at the
end of the axle shaft. Shaft (2) and planetary carrier (25)
are held by washer (27) and bolt (28).
The oil tightness between the trumpet, crownwheels,
spacer and brake plate is provided by silicone seals
(Silicomet type).
The cassette seal (3) protects the outer bearing comprising cup (8) and cone (7).
The oil splash lubrication for the mechanical assemblies
is provided by transmission oil coming from the shared
oil tank formed by the intermediate housing and the
centre housing. The centre housing is linked to the lower
part of the trumpet by an external transfer pipe. The brake
plate contains a port "O" (Fig. 2) allowing lubrication and
cooling of the discs by a flow of oil coming from the
booster circuit. The transmission oil within the trumpet is
kept at the correct level via an oblique pipe (56). This pipe
is located in the drive unit compartment and communicates with the external transfer pipe.
The inner chamber of the trumpet is maintained at
atmospheric pressure by a breather pipe screwed onto
the left lift ram support. This breather pipe also ensures
the venting of the shared oil tank.
The input shaft (31) drives brake discs (35) via a splined
hub (32) held by snap ring (33).
6B04.3
Operation
Special point
- In order to maintain an operational clearance between
the planetary gears, the sun gears and crownwheels,
the secondary sun gear (51) floats on ball bearings (19)
(49).
Kinematics (Fig. 1)
Primary epicyclic gear train
- The primary planetary carrier (24) is integral via splines
with the secondary sun gear (51) and comprises three
planetary gears (20) that engage with crownwheel (47)
and primary sun gear (44) splined onto input shaft (31).
Secondary epicyclic gear train
- The secondary planetary carrier (25) integral via splines
with axle shaft (2) possesses six planetary gears (18)
in constant engagement with crownwheel (15) and
secondary sun gear (51). It receives movement coming
from the primary epicyclic gear train to then transmit it
to axle shaft (2).
Issue 1
May 2001
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
Bush
Straight shaft
Cassette seal
Thrust washer
Locating pin
Circlip
Bearing cone
Bearing cup
Washer
Trumpet
Nut
Bearing cup
Bearing cone
Pins
Secondary crownwheel
Tab washer
Stop ring
Secondary planetary gears
Ball bearing
Primary planetary gears
Circlip
Roller bearing
Roller bearing
Primary planetary carrier
Secondary planetary carrier
Shim(s)
Lock washer
Bolt
Circlip
Brake plate
Input shaft
Splined hub
Snap ring
Studs
Brake discs
Stud
Studs
Intermediary plate
Drilled stop pin
Bolt
Stop pin
Circlip
Magnetic drain plug
Primary sun gear
Circlip
Washer
Primary crownwheel
Spacer
Ball bearing
Issue 1
Washer
Secondary sun gear
Oring
Orings
Transfer tube
Cup plug
Oblique pipe
Locating pin
Fig. 2
Fig. 3
May 2001
14
6B04.5
Overall view
5
30
39
41
0
30
10
15
48
47
30
25
17
23
18
17
29
24
20
22
29
51
26
27
28
19
46
21
45
44
42
6
57
50
49
31
33
32
35
38
2
10
12
2
4
13
16
11
34
36
37
31
P1 = 0,02 / 0,12 mm
43 52
Issue 1
May 2001
Parts list
Fig. 3
Fig. 2
6B04.6
50
29
Exploded view
17
18
48
23
17
49
56
52
25
43
16
13
12
15
8
14
7
1
9
11
34
42
53
44
40
54
53
55
10
11
20
22
40
40
29
21
46
28
36
19
27
31
26
47
51
39
14
11
45
37
24
41
41
53
54
53
33
32
35
38
35
30
Issue 1
Parts list
May 2001
Fig. 2
Fig. 3
6B04.7
54
43
Fig. 4
15
48
47
30
35
32
31
11
40
9
P
40
38
39
41
1
30
Fig. 5
Issue 1
May 2001
2
Fig. 6
Important
- Take care not to press the brake pedal concerned, or fit
a piston retainer tool on the centre housing (see section
6E01).
9. Remove the transfer tube (54) and discard the Orings
(53).
2
Fig. 7
Fig. 8
Issue 1
May 2001
6B04.9
Refitting
Special points
- The studs (34) (36) (37), screwed into the centre
housing are of different lengths. Before fitting, their
threads must be lightly smeared with Loctite 270 or
equivalent (Fig. 9).
Important
Fig. 9
Fig. 10
Fig. 11
Issue 1
May 2001
Issue 1
May 2001
6B04.11
42
33
30
32
44
31
21
46
19
47
20
45
28
24
51
31
27
49
48
26
18
25
4
15
16
31
40
40
F
40
Fig. 12
Fig. 13
Issue 1
May 2001
33. Take out the secondary planetary carrier (25). Remove the planetary gears (18) (see D).
34. If necessary, extract bearing (19) from the input
shaft (31).
35. Unstick and remove the secondary crownwheel (15)
(see special points below).
Special points
- The reason for the secondary crownwheel (15) are
the large forces exerted, and its heat treatment is
different compared to that of the primary crownwheel
(47).
- In order to identify the crownwheels and avoid their
incorrect fitting, the perimeter of the secondary
crownwheel has two diametrically opposed machined flats "M" (Fig. 14).
- This crownwheel also possesses an additional
locating pin (57) (Fig. 2).
Refitting
36. Clean the components. Replace any parts found to
be defective. Remove all traces of previous sealing
compound in the internal angles of the trumpet, on
the crownwheels (15) (47), the spacer (48) and the
brake plate (30).
Special points
- If the replacement of the oblique pipe (56) is
necessary, lightly smear the end concerned with
Loctite 648 or its equivalent and introduce it into the
trumpet, the oblique profile turned towards bearing
(12) (13) (Fig. 15).
- The bearing cup plug (55) fitted at the end of the
channel (see exploded view) must likewise be
smeared with Loctite 542 or equivalent before insertion.
37. Check for the presence of the tab washer (16).
38. Refit the secondary planetary carrier (25).
39. Refit the thrust washer (4) as in the overall view.
Refit the secondary sun gear (51) comprising ball
bearing (49), washer (50) and circlip (6).
40. Place pin (14) and the locating pin (57) in their respective grooves located on the trumpet.
15
Fig. 14
56
12
13
Fig. 15
Issue 1
May 2001
6B04.13
30
E
48
A
C
15
B
10
Fig. 16
56. Coat the internal angle "E" of the brake plate (30) with
a silicone sealing compound (Silicomet type) (Fig.
16).
57. Position the brake plate on the primary crownwheel
(47).
58. Fit bolts (40) and tighten them to a torque of 90 - 120
Nm.
59. Slide hub (32) onto shaft (31). Using suitable pliers,
fit the snap ring (33).
60. Refit the trumpet assembly (see A).
Issue 1
May 2001
Preliminary operations
61. Partially drain the trumpet concerned.
62. Chock the front wheels. Remove the rear wheel (see
section 2G01). Place an axle stand beneath the
trumpet.
Removal
Special points
- Model 8260 to 8280 tractors are fitted with axle shaft
with a diameter of 110 mm. The shape of this shaft is
different from that of the same diameter fitted to 8240
tractors (depending on option) and the 8250 fitted with
composite drive unit.
- Bush (1) (Fig. 17) has a larger bore and is referenced in
the spare parts catalogue.
- The cassette seal (3) (Fig. 17) retains the same characteristics as that fitted to trumpets with composite drive
unit.
- The bore of the bush is smeared with Loctite 648 or
equivalent. The bush is placed on the shaft flush with
the thrust face of the bearing cone (7) (Fig. 18).
1
Fig. 17
3
1
63. Using a locally manufactured tool, extract the cassette seal (3) without leaving any marks on the
trumpet or external diameter of the bush (1) (Fig. 17).
Refitting
64. Clean the groove of the seal on the trumpet and the
bush (1).
65. Lightly smear the external diameter of the seal with
Loctite 648 or equivalent and moderately lubricate its
internal diameter with transmission oil.
66. Using service tool ref. 3378151M1 (see G), insert
the seal. Wipe away any remaining traces of Loctite.
Remark
- The design of the service tool determines the
position of the cassette seal in its groove in the
trumpet.
Final operations
67. Refit the wheel and tighten the wheel nuts or studs
to the correct torque depending on the version (see
section 2G01).
68. Top up the oil level in the housings and check it on
the transparent tube located on the left-hand side of
the centre housing.
69. Road test. Check the oil tightness of the cassette
seal.
Issue 1
May 2001
7
Fig. 18
6B04.15
18
Disassembly
70. Remove the trumpet assembly (see A) and the
epicyclic reducer gears (see B).
20
Primary planetary carrier (24) (Fig. 20)
71. Note visually the shape of the planetary gears (20)
and roller bearings (22) (Fig. 19). Take off the circlips
(29). Remove the three planetary gears.
Secondary planetary carrier (25) (Fig. 20).
72. Note visually the shape of the planetary gears (28)
and roller bearings (23) (Fig. 9). Take off the circlips
(29). Remore the six planetary gears.
23
D
D
22
Fig. 19
Reassembly
73. Check the components. Replace any parts found to
be defective.
74. Fit the planetary gears with their roller bearings and
respective snap rings. Refit the planetary gears on
the corresponding planetary carrier by turning the
clearance "D" on the bearings (Fig. 19) towards throat
"C" of the reducer gears (Fig. 20).
75. Fit the circlips (29) (Fig. 20)
76. Manually check the rotation of each planetary gear.
77. Refit the epicyclic reducer gears (see B) and the
trumpet assembly (see A).
25
24
29
C
18
20
29
Fig. 20
Issue 1
May 2001
Disassembly
80. Take off washer (16) and shaft assembly (2).
Remark
- The bearing cone (13) is free on the shaft.
81. Remove cone (13). Extract bearing cone (7).
82. Drive out the cassette seal (3).
83. Using an extractor or a locally manufactured tool,
remove the bearing cups (8) (12).
Reassembly
84. Clean and check the components. Replace any
parts found to be defective.
85. Lubricate the bores of the cups (8) (12) with transmission oil.
86. Insert the cups into their respective bores thrusting
against the shoulder.
87. Lubricate the bore of the bearing cone (7) and insert
it so as to mate with the shoulder on shaft (2).
88. Lubricate the bearing cup (8).
89. Introduce the prepared shaft into the trumpet fitted
with its cups.
90. Lubricate and fit the bearing cone (13) and the tab
washer (16).
Final operations
91. Refit the secondary planetary carrier (25), thrust
washer (4), secondary sun gear (51) comprising
bearing (49), washer (50) and the circlip (6).
92. Carry out shimming of the bearings (see F).
93. Complete the refitting of the epicyclic reducer gear,
spacer, crownwheels and brake plate (see B).
94. Refit the trumpet assembly (see A).
95. Insert a new cassette seal (see C).
96. Refit the wheel and tighten the wheel nuts or studs
to the correct torque depending on the version (see
section 2G01).
97. Top up the level of the housings and check the oil
level on the transparent tube located on the left hand
side of the centre housing.
Issue 1
May 2001
6B04.17
Remark
- The pre-loaded shimming of the taper roller bearings of
the axle shaft is carried out using shim(s) (26) placed
between the end of the shaft (2) and washer (27) (Fig.
22).
Reminder
Fig. 21
P1 =
0,02 / 0,12 mm
27
26
Fig. 22
Issue 1
May 2001
6B04.18
Preparation
98. Check for the presence of bearing cone (13), the tab
washer (16), the planetary carrier (25) and the
secondary sun gear (51) (Fig. 24).
Fig. 23
51
49
2
25
16
13
Fig. 24
Issue 1
May 2001
6B04.19
G . Service tools
- 3378151M1 - Fitting tools for rear shaft's cassette
seal ( 110) (Fig. 25)
Fig. 25
Issue 1
May 2001
Issue 1
May 2001
6C01
6C01.1
Contents
-
General ________________________________________________
Operation ______________________________________________
A.
B.
C.
Issue 1
May 2001
General
The mechanical control assembly of the handbrake is
fitted on drive pinion (9) located on the intermediate housing.
It consists of a mechanism (16) placed between six
discs (14) that are integral with the drive pinion and four
intermediary plates (6).
The mechanism housed in a unit (15) fixed to the rear
bearing carrier is composed of two cast-iron plates held
by springs and separated by ball bearings lodged in
raceways.
It is operated via a rod (23) fitted on relay pin (26) by
means of relay cam (22) which is in contact with rod (19),
itself thrusting against a second cam (31) integral via
splines with pin (11) controlled by link (3).
Remarks
- Depending on the type of tractor, the lubrication of the
handbrake discs is ensured by an oil mist coming from
a central channel and radial drilled holes machined into
the drive pinion (see section 6D01, 6D02 or 6D03
depending on the version).
- This centre oil channel also serves to lubricate a needle
bearing on those tractors fitted with a creeper unit (see
section 6H01 depending on the version).
Operation
When the handbrake lever is pulled upwards, the cable
acts upon link (3) integral with pin (11) via splines.
Pin (11) pivots and turns cam (31) that pushes rod (19) to
thrust against a relay cam (22) that turns freely on pin
(26), thus causing the spreading of mechanism (16) by
way of threaded link pin (23).
When the handbrake lever is in the off position, the link
(3) returns to its initial position by means of spring (32).
The adjuster nut of the mechanism is accessible via a
plug screwed on to the top of the intermediary housing.
The oil tightness of housing (7) is provided by seal (12)
and that of pin (11) by oring (1).
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
Oring
Bolt
Link
Holding plate
Bolt
Intermediate plates
Housing
Bolt
Drive pinion
Friction ring
Pin
Oil seal
Bearing carrier
Disks
Housing
Spreader mechanism
Bolt
Washer
Rod
Pin
Adjuster nut
Cam
Link
Clevis
Pin
Pin
Friction rings
Special bolt
Mecanindus pin
Set screw
Cam
Spring
Oring
Lever
Nuts
Grower washer
Cable
Ratchet
Quadrant
Clevis
Rod
Shouldered washer
Washer
Push-button
Spring
Fig. 1
Fig. 2
Issue 1
May 2001
Overall view
6C01.3
19
30
31
K-K
6
16
14
13
LOCTITE 510
15
9
2
17
32
3
18
19
11
27
22
33
28
12
21
22
7
29
26
10
M
31
20
23
24
25
M-M
Fig. 1
L-L
Parts list
Issue 1
May 2001
Fig. 2
Exploded view
6C01.4
34
8
13
6
14
16
35
14
15
36
35
21
20
37
23
25
24
33
29
28
27
22
5
27
26
38
39
17
18
1
3
32
40
12
41
42
11
45
43
44
7
10
31
30
30
19
Parts list
Issue 1
May 2001
Fig. 1
Fig. 2
6C01.5
15
Remark
- To carry out operations on the handbrake mechanism
comprising discs (14), intermediate plates (6) and
mechanism (16), it is necessary to uncouple the tractor
and remove the intermediate housing as well as the
drive pinion.
Preliminary operations
1. Uncouple the tractor between the gearbox and the
intermediate housing (see section 2C01).
2. Separate the intermediate housing from the centre
housing (see section 2D01).
3. Remove the creeper unit (if fitted) (see section 6H01).
If necessary, remove the sleeve and ratchet of the
Park Lock (depending on equipment) and the bearing
assembly / hydraulic pump drive pinion.
4. Remove the drive pinion and handbrake unit (see
section 6D01, 6D02 or 6D03 depending on the version).
T
14
C
5
16
13
6
8
Fig. 3
Disassembly
5. Remove circlip (5)
6. Loosen and remove bolts (8)
Separate the housings (13) (15).
7. Place the drive pinion on the workbench, the bevel
gear at the bottom.
8. Remove the discs, intermediate plates and the brake
mechanism.
Reassembly
9. Clean and check the components. Replace any parts
found to be defective or buckled.
Check that the central channel and radial drilled holes
of the drive pinion (depending on versions) are not
obstructed.
Check also, the oil discharge ports located at the base
of the handbrake unit housing.
Issue 1
May 2001
Final operations
15. Refit the drive pinion unit and handbrake (see
section 6D01, 6D02 or 6D03 depending on the version).
16. Turn and fit axle (25) to mechanism (16) so as to
clear it easily. Fit the washer and a new split pin.
Adjust the control (see B).
17. Refit the bearing / hydraulic pump drive pinion
assembly, the ratchet and the Park Lock sleeve
(depending on equipment). Fit the creeper unit (if
fitted).
18. Reassemble the intermediate housing and centre
housing (see section 2D01).
19. Couple the tractor between the gearbox and the
intermediate housing (see section 2C01).
20. Check the correct operation of all the controls.
21. Check all the functions (mechanical and electrical)
of the handbrake lever.
22. Road test.
23. Check the oil tightness of the mating faces and the
hydraulic unions.
Issue 1
May 2001
6C01.7
27
22
24. Remove the entire unit (7) and rod (19). If necessary,
take out each component in the unit.
Remark
Reassembly
25. Reverse the order of the previous operations and
respect the following special points.
Fig. 4
Special points
On unit (7)
- Insert friction bush (10) using a locally manufactured
drift.
- Insert oil seal (12) in contact with unit (7) using a
suitable fixture. After inserting, lubricate the seal.
- lightly smear with Loctite 241 the Philips head bolt (30)
of cam (31).
- lightly smear with Loctite 510 the mating face of unit (7)
and the intermediate housing.
- Tighten bolts (2) to a torque of 25 - 35 Nm and bolt (17)
to a torque of 14 - 20 Nm.
Note: During assembly, do not forget oring (1) that
provides oil tightness between pin (11) and the link
(3).
On cam (22)
- Insert the friction bush (27) flush with face F (Fig. 4).
- Lightly smear bolt (28) with Loctite 542 (solely on an
assembly without an oring) and tighten to a torque of
25 35 Nm.
On cam (31)
- Moderately tighten set screw (30) smeared with Loctite
241.
On the brake mechanism (16)
- Fit pin (25) in such a manner as to provide clearance.
- Lightly smear the thread of link rod (23) with Loctite 270
and tighten it in clevis (24).
Issue 1
May 2001
Adjustment
- With cam (31) in contact with unit (7) (Fig. 5) via the port
located above the intermediate housing, act on nut (21)
in order to obtain a clearance "J" of 1.2 mm to 1.3 mm
between the discs, intermediate plates and mechanism (Fig. 7).
26. Position link (3) on pin (11) to obtain a dimension of
225 mm to 250 mm between the centre of the cable
and cable holder (4) (position A - Fig. 6) by checking
that cam (31) is in contact with the housing (7).
27. Check that the travel of the link (3) falls between 30
mm and 45 mm with a force of 10 - 25 daN exerted
at the point where the cable is fixed (position B Fig. 6).
31
Remarks
Fig. 5
225 - 250 mm
30 - 45 mm
Reminder
- Tightening torque for wheel nuts or studs (see section
2G01).
11
3
Fig. 6
J = 1,2 / 1,3 mm
Fig. 7
Issue 1
May 2001
6C01.9
Reassembly
37
Fig. 8
42
44
39
43
45
41
40
38
Fig. 9
Issue 1
May 2001
6C01.10
Refitting
Note: If necessary, before refitting the new cable,
hold it vertically and inject a few drops of Vaseline
oil between the cable and sheath. Wait for several
moments for the oil to descend the length of the
cable.
36. Carry out the fitting of the cable on its respective
fixing points.
Remark
- Take care to place the lock washer (1) between
nuts (35) on cable holder (4) (Fig. 10) located above
the intermediate housing. This assembly avoids
any kinking of the cable during handbrake operation.
37. Check the following points to ensure correct operation of the handbrake lever:
- put the handbrake on, its initial travel should be
approximately 10 to 13 clicks of the ratchet with a
force of around 10 - 25 daN exerted at the point of
cable connection.
- the signal lamp on the dashboard should light.
- release the handbrake. The assembly should return
to the handbrake off position.
- the assembly should operate freely without any
"hard" points or sticking.
- in the handbrake off position, the dashboard light
must go out.
Reminder
- On tractors fitted with a Full Powershift gearbox, first
disengage the speed control of the Park Lock in order to
get the dashboard light to go out when the handbrake is
in the off position.
Issue 21
Issue
May 2002
2001
May
35
35
Fig. 10
6D01
6D01.1
Contents
-
General ________________________________________________
A.
C.
D.
11
E.
13
F.
15
G.
18
H.
21
I.
25
B.
Issue 1
May 2001
General
Reminder
The 8210 - 8220 - 8240 and 8250 tractors are equipped
with an identical centre housing. The intermediate housing differs depending on the type of gearbox.
Specifications
- Model 8210 8220 8240 and 8250 tractors
. Heavy Duty gearbox
. narrow intermediate housing
- Model 8210 8220 and 8240 tractors
. AG 150 Full Powershift gearbox
. wide intermediate housing
- Model 8250 tractors
. AG 250 Full Powershift gearbox
. wide intermediate housing (hypoid version)
Differential lock
Model 8210 - 8220 - 8240 and 8250 tractors are fitted with
a standard bevel gear and either a multidisc or hydromechanical differential lock (depending on version).
In this section, we shall limit our description to the hydromechanical version. For the multidisc version, see section 6D02.
Construction
The bevel gear, its rotation provided by the gearbox
output shaft, drives the rear axle.
The helical drive pinion is supported by two taper roller
bearings mounted in opposition.
The bearing cone (7) is force fitted on the drive pinion, and
cups (2) (10) are likewise force fitted into the intermediate housing (19) and bearing carrier (13). The bearing
cone (1), mounted free on the drive pinion, allows to fit
shims (3) required for shimming. The crownwheel is
fastened to the differential housing by rivets. The differential assembly rotates on two taper roller bearings
supported by two lateral carriers centred by bushes (25)
(40) and fixed by bolts to the housing.
Issue 1
May 2001
Overall view
6D01.3
A
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
Bearing cone
Bearing cup
Shim(s)
Thrust washer
Circlip
Intermediat plates (handbrake)
Bearing cone
Bolt
Drive pinion
Bearing cup
Bolt
Shim(s)
Bearing carrier
Discs
Handbrake unit
Mechanism
4 WD drive pinion (if fitted)
Nut
Intermediate housing
Deflector
Crownwheel
Differential half-housing
Rivets
Centring bush
Bolt
Right-hand carrier
Spherical washer
Planetary gear
Sun gear
Bearing cone
Bearing cup
Brace
Orings
Shouldered bush
Fixed coupler
Oring
Left-hand carrier
Bolt
Centring bush
Bolt
Transfer tube
Oring
Union
Centre housing
Fixed dog
Spring
Mobile dog
Friction washer
Oring
Oring
Circlip
(53)
(54)
(55)
(57)
(58)
(59)
(61)
Finger
Bearing cone
Deflector (shim)
Bearing cone
Piston
Shim(s)
Shouldered bush
55
46
50
57
59
52
58
Fig. 1
51
Fig. 2
19
20
6
49
Fig. 3
8
7
1
48
54
47
61
35
44
45
43
22
42
23
41
24
34
34
40
25
39
26
37
30
9
18
16
17
10
11
31
13
12
27
53
32
38
29
14
15
15
28
33
23
36
Parts list
Issue 1
Fig. 2
Fig. 3
Fig. 1
May 2001
Parts list
Fig. 1
Fig. 3
Fig. 2
6D01.4
Exploded view
33
30
35
28
22
23
20
23
59
32
61
31
34
29
9
24
25
4
7
27
3
10
26
11
1
13
12
18
44
57
54
41
46
43
38
34
42
50
58
37
51
52
49
48
39
47
55
40
53
Parts list
Issue 1
May 2001
Fig. 1
Fig. 2
Fig. 3
6D01.5
A . Removing and refitting the lefthand differential lock carrier, disassembling and reassembling the lock
assembly
Remark
It is possible to gain access to the following differential
lock components by removing only the left-hand trumpet
housing:
- differential lock carrier (38)
- piston (58)
- seals (50) (51)
- spring (47)
- mobile dog (48)
44
Fig. 4
42
Fig. 5
V
39
Issue 1
Fig. 6
May 2001
Refitting
6. Check for the presence of centring bush (40), the
correct positioning of deflector (55) (shim) and cup
(57) in accordance with Fig. 7.
7. Fit new orings (34) (37).
8. Place the friction washer (49) and spring (47) on the
mobile dog. Fit the assembly in the piston. Slide the
differential lock carrier onto the guide studs "G"
previously fitted into the housing (Fig. 6) by positioning the hydraulic port of the differential lock upwards
and holding the spring in position.
9. Alternately and uniformly tighten the four bolts (39)
to a torque of 100 - 130 Nm. Remove the guide studs.
Fit and tighten the other bolts to the same torque.
10. Fit transfer pipe (42) and connection (44).
11. Refit the brake piston (see section 6E01).
12. Check the oil tightness of seal (34) on differential
lock carrier (38) (see section 6E01).
13. Refit the left-hand trumpet (see section 6B01, 6B02
or 6B03 depending on the version).
57
55
40
Fig. 7
58
Fig. 8
Issue 1
May 2001
6D01.7
52
50
58
Reassembly
20. Check and clean the components. Replace any
parts found to be defective.
21. If finger (53) has been removed, lightly smear with
Loctite 221 then refit and tighten it in the differential
lock carrier (38).
22. Coat the orings (50) (51) with miscible grease, in
order to place them correctly in the bottom of their
respective grooves.
23. Using a plastic hammer, insert the piston (58) into
the differential lock carrier (38) (Fig. 10) while respecting the location of the finger (53).
24. Fit circlip (52), deflector (55) (shim) while respecting
its orientation (Fig. 7). Place bearing cup (57).
25. Refit the differential lock carrier on to the centre
housing (see A).
26. Test the oil tightness of the seals (50) (51) and
differential lock carrier (38) mounted on the locking
piston.
Reminder
- If the piston (58), seals (50) (51) or carrier (38) have
been disassembled, it is recommended to carry
out an hydraulic test of the whole hydraulic assembly and of the transfer tube after reassembly.
51
57
55
37
Fig. 9
58
38
Fig. 10
Issue 1
May 2001
Hydraulic test
- Use a pressure gauge that has previously been tested
for pressure tightness (Fig. 11).
- Supply the circuit with compressed air up to around 5
bar, in order to check the reaction of the piston. Adjust
the pressure to approximately 0.3 bar. Carry out the
hydraulic test.
- Close the valve. For approximately 1 minute, no drop in
pressure must be observed on the pressure gauge.
27. When the test is completed, remove the pressure
gauge and fit the original pressure pipe.
28. Refit the trumpet housing (see section 6B01, 6B02
or 6B03 depending on the version).
44
Fig. 11
Removal
25
34
Fig. 12
Refitting
31. Check for the presence of centring pin (25) and Oring
(34) (Fig. 12).
32. Uniformly and alternately, tighten the four bolts (26)
to a torque of 100 - 130 Nm. Take out the guide studs.
Fit and tighten the other bolts to the same torque.
33. Check the oil tightness of seal (34) on carrier (27)
(see section 6E01)
Issue 1
27
May 2001
6D01.9
Fig. 13
Refitting
Note: Since space is limited around the differential
unit, it is vital to fit the auxiliary spool valve and lift
control valve the oil return pipe in the housing (45)
before refitting the unit..
43. Using the sling, introduce the differential assembly
into the centre housing and hold it in the axis of the
trumpets.
44. Refit the left and right-hand side differential lock
carriers (see B and A).
45. After fitting the differential lock carriers, manually
check the rotation of the differential assembly.
Issue
Issue21
May 2002
December
2000
6D01.10
Special point
- If the carrier (1) of the ground speed sensor (2) has been
removed, position the carrier previously lightly smeared
with Loctite 510 or its equivalent, with the offset of the
sensor turned towards the longitudinal axis of the
centre housing as shown in Fig. 14. Tighten the bolts (3)
previously lightly smeared with Loctite 542 to a torque
of 25 - 35 Nm.
Remarks
- The end of the sensor must always be placed above the
teeth of the differential crownwheel.
- Fit and adjust the ground speed sensor lightly smeared
with Loctite 577 (Sensor Sealing or equivalent).
Fig. 14
Final operations
47. Refit the trumpet housings (see section 6B01, 6B02
or 6B03 depending on the version).
48. If the PTO housing has been removed, assemble it
with the centre housing (see section 2E01).
49. Couple the tractor between the intermediate housing
and the centre housing (see section 2D01).
50. Check the correct operation of all the controls (mechanical, hydraulic and electronic).
51. Carry out a road test. Check the oil tightness of the
mating faces and hydraulic unions.
Issue 1
December 2000
6D01.11
D . Removing and refitting the planetary gears and sun gears and disassembling and reassembling the
crownwheel
46
Preliminary operations
52. Remove the differential unit (see operations 34 to
42).
53. Remove the fixed dog (46) (Fig. 15).
Removal
54. Separate the differential half-housings (23) (Fig. 15).
Note: These components both bear the same
number. They must always be fitted as pairs.
55. Remove the sun gears (30), planetary gears (29),
washers (28) and the differential brace (33) (Fig.
15A).
56. If necessary, drive cup (32) off the differential halfhousing (23), recover the shim(s) (59). Extract and
discard the deflector (20).
23
Fig. 15
29
35
30
33
61
28
Fig. 15A
Issue 1
May 2001
24
Final operations
65. Finish the refitting of the different assemblies. Carry
out operations 47 to 51.
Issue 1
May 2001
Fig. 17
Disassembly
- Using an appropriate extractor, remove cup (32) and
discard the deflector (20).
6D01.13
Pre-adjustment
- The thickness of the shim(s) "E" required to obtain the
correct backlash is calculated as follows: E = Dc + 0.10
mm
E: thickness of shim(s) (59) to be fitted
Dc: crownwheel offset
Remark
- The Dc (example shown: -0.40) engraved on the external diameter of the crownwheel (Fig. 18) after the
pairing number and letter (39 K) may range between 0
and -0.60 mm.
Special point
- When calculating "E" do not take the negative sign preceding the Dc into consideration (Fig. 18).
59
32
20
39
40
K - 0,
23
Fig. 18
Issue 1
May 2001
Checking
- Couple and provisionally fix the intermediate housing to
the centre housing using several diametrically opposed
bolts tightened to a torque of 540 - 680 Nm.
- With the PTO housing taken off, through the rear
opening of the centre housing (45), place the index of a
dial gauge half way across the length of a tooth of the
crownwheel (Fig. 19).
- Check that the backlash is between 0.15 mm and 0.45
mm. Carry out this check at three points around the
crownwheel.
Important
- If the backlash is incorrect, the adjustment principle is
to reduce or increase the thickness of shim(s) (59).
- In this case, select and fit a different thickness of
shim(s). Carry out the shimming of the differential unit
again in order to obtain the pre-loading of bearings (31)
(32) and (54) (57).
- Check a second time, the backlash between the drive
pinion and the crownwheel.
- When the final adjustment has been obtained, go on
with the refitting operations.
Issue 1
May 2001
Fig. 19
6D01.15
Shimming preparation
68. Place the differential assembly previously fitted
with bearing cone (54) in the housing using sling ref.
3378116M1 (see I). Screw two diametrically opposed guide studs into the centre housing.
Fig. 20
- Insert the carrier (27) fitted with a new oring (34) using
four bolts (26). Remove the guide studs. Finish refitting
the four bolts and tighten to a torque of 100 - 130 Nm.
69. At the location of the left-hand side differential lock
carrier, place tool ref. 3378117M1 (see I), adapted
for the standard differential unit with hydromechanical
differential lock. Using two bolts, fix the tool onto the
housing (Fig. 20).
70. Tighten the centre bolt to 10 Nm (Fig. 20).
Note: Turn the crownwheel several times to seat
the cones correctly in the cups. Check the tightening torque of the centre bolt again.
Issue 1
May 2001
3378117 M1
57
Fig. 21
38
3378117M1
B
Y
57
57
45
38
Fig. 23
Issue 1
May 2001
Fig. 22
6D01.17
E
55
38
57
Final operations
75. Remove the tool and the bearing cup (57).
76. On differential lock carrier (38), check for the presence of centring bush (40) and place the deflector
(55) (shim) determined in operation 74 and cup (57)
in accordance with Figure 7.
77. Insert the carrier. Carry out operations 7 to 9.
78. After fitting the differential lock carriers, manually
check the rotation of the differential assembly.
P2 =
0,05 / 0,15 mm
Fig. 24
Reference
No. of punch
marks (dots)
E (mm)
57
187 689 M1
0,73
0,78
892 173 M1
0,864
0,914
892 172 M1
0,991
1,041
892 171 M1
1,118
1,168
892 170 M1
1,245
1,295
191 124 M1
1,37
1,42
191 125 M1
1,49
1,54
521 401 M1
0,61
0,66
Punch
marks
(dots)
Issue 1
May 2001
18
Preliminary operations
79. Uncouple the tractor between the intermediate housing and the centre housing (see section 2D01).
80. Remove the creeper unit (if fitted) (see section
6H01). Free the ratchet of the Park Lock transmission lock (if fitted) (see section 6F01).
81. Locate the position of and take out the sleeve linking
the drive pinion and the lower shaft.
82. Remove the hydraulic pump bearing / drive pinion
assembly.
3378119M1
3378118M1
Issue 1
May 2001
Fig. 25
11
G
13
V
11
Fig. 26
6D01.19
Issue 1
May 2001
Final operations
105. Refit the hydraulic pump bearing / drive pinion
assembly.
106. Refit the ratchet and locking sleeve of the Park
Lock transmission (if fitted). Refit the creeper
gearbox reducer gear (if fitted). Adjust the fork (see
section 6H01).
107. Re-couple the tractor between the intermediate
housing and the centre housing (see section 2D01).
Note: If the crownwheel and drive pinion have
been replaced, check the backlash (see E).
108. Check the operation of all the controls.
109. Carry out a road test.
110. Check the oil tightness of the mating surfaces.
111. Check the oil tightness of the hydraulic unions.
Issue 1
May 2001
6D01.21
Preliminary operations
112. Using a press, force fit cup (10) thrust against
bearing carrier (13).
Using a suitable fixture, insert cup (2) to thrust
against housing (19). Screw in two diametrically
opposed guide studs into the tapped bolt holes (11).
Fit the carrier alone without shims (12). Alternatively and progressively, tighten the four bolts (11)
to a torque of 100 - 130 Nm.
Check that carrier (13) is in contact with the
intermediate housing (19).
113. Using a press and an appropriate fixture, force fit
cone (7) to thrust against the drive pinion.
114. Lubricate the taper roller bearings (7) (10) with
transmission oil.
115. Temporarily fit the drive pinion without shims (3)
but with thrust washer (4) placed between the
bearing cone (1) and nut (18)
116. Pre-tighten the nut to a torque of 30 - 50 Nm using
wrench, ref. 3378118M1 and socket, ref.
3378119M1 (Figs. 33 -34, I) taking care to correctly position the torque wrench.
117. Turn the drive pinion several times to correctly seat
the bearing cones in the cups. Check again the
correct pre-tightening of nut (18).
Issue 1
May 2001
6D01.22
Z
X
19
18
39 K
22
39 K
11
13
19
12
Fig. 27
Issue 1
May 2001
6D01.23
Fig. 28
Fig. 29
Issue 1
May 2001
18
E
P1 0,04 / 0,10 mm
18
10
11
2
13
12
Fig. 30
Issue 1
May 2001
6D01.25
I . Service tools
Tools available in the AGCO network
- 3378116M1 Differential unit sling (Fig. 31)
- 3378117M1 Shimming tool (Fig. 32)
- 3378118M1 Locking wrench for drive pinion nut
(Fig. 33)
- 3378119M1 Drive pinion tightening socket (Fig.
34).
Fig. 31
Fig. 32
Fig. 33
Fig. 34
Issue 1
May 2001
6D02
6D02.1
Contents
-
General ________________________________________________
A.
B.
C.
10
D.
12
E.
14
F.
16
G.
18
H.
21
I.
24
Issue 1
May 2001
Specifications
Differential lock
General
Reminder
Model 8210 - 8220 - 8240 and 8250 tractors are fitted with
a standard bevel gear and either a multidisc or hydromechanical differential lock (depending on version).
In this section, we shall limit our description to the multidisc version. For the hydromechanical version, see
section 6D01.
Construction
The bevel gear, moved in rotation by the gearbox output
shaft, drives the rear axle.
The helical drive pinion is supported by two taper roller
bearings mounted in opposition.
The bearing cone (7) is force fitted on the drive pinion, and
cups (2) (10) are likewise force fitted into the intermediate housing (19) and bearing carrier (13). The bearing
cone (1), mounted free on the drive pinion, allows to fit
shims (3) required for shimming.
The crownwheel is fastened to the differential housing by
rivets. The differential assembly rotates on two taper
roller bearings supported by two lateral carriers centred
by bushes (25) (40) and fixed by bolts to the housing.
The differential assembly is formed by two halves
holding four planetary gears and two sun gears. The drive
pinion, which bears the 4 WD drive pinion (17) (if fitted),
is located in the intermediate housing. The adjustment of
its position is carried out by shims (12) fitted between the
differential lock carriers, the bearings (13) and the housing. The pre-loading of the bearings is obtained by
shim(s) (3) fitted between the bearing cone (1) and the
Issue 1
May 2001
Operation
Clutched position
When the differential lock solenoid valve is activated, the
pressure flows through the channels of carrier (38) and
cover (52) and enters piston chamber (58). The piston
compresses the intermediate plates (48) and discs (49)
integral respectively via stops and splines in lock unit
(46) and hub (53).
In this clutched position, the input sun gears of the righthand and left-hand trumpets turn at the same speeds.
Declutched position
When the pressure is cut, the piston returns, the discs
and intermediate plates are no longer compressed and
allow the sun gears and planetary gears to carry out their
differential function.
Overall view
6D02.3
A
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)
Bearing cone
Bearing cup
Shim(s)
Thrust washer
Circlip
Intermediate plates (handbrake)
Bearing cone
Bolt
Drive pinion
Bearing cup
Bolt
Shim(s)
Bearing carrier
Discs
Handbrake unit
Mechanism
4 WD drive pinion (if fitted)
Nut
Intermediate housing
Deflector
Crownwheel
Differential half-housing
Rivets
Centring bush
Bolt
Right-hand carrier
Spherical washer
Planetary gear
Sun gear
Bearing cone
Bearing cup
Brace
Orings
Shouldered bush
Fixed dog
Oring
Left-hand carrier
Bolt
Centring bush
Bolt
Transfer tube
Oring
Union
Centre housing
Differential lock disc unit
Bolt
Intermediate plates (differential lock)
Discs
Oring
Oring
Cover
Hub
(54)
(55)
(56)
(57)
(58)
(59)
(60)
(61)
Bearing cone
Shims
Seal ring
Bearing cup
Piston
Shim(s)
Rivet
Shouldered bush
Fig. 1
19
60
Fig. 2
2
21
Fig. 3
4
41
20
56
59
57
61
35
44
45
43
22
42
23
52
24
34
34
9
18
40
25
39
26
16
37
17
30
54
11
53
31
55
27
51
32
12
58
35
14
15
38
29
15
48
28
50
33
10
13
Fig. 2
Fig. 3
Fig. 1
Parts list
49
46
47
Parts list
Issue 1
May 2001
23
36
Fig. 1
Fig. 3
Fig. 2
6D02.4
Exploded view
33
30
35
28
22
23
20
23
59
32
61
31
34
29
9
24
25
4
7
27
3
10
26
2
11
1
13
12
53
18
48
49
44
41
46
43
47
42
56
37
54
39
50
58
38
51
40
34
55
Fig. 1
57
52
Parts list
Fig. 2
Fig. 3
Issue 1
May 2001
6D02.5
42
44
Fig. 4
36
52
G
Fig. 5
Fig. 6
Issue 1
May 2001
Refitting
6. Check for the presence of centring bush (40), the
correct positioning of shim(s) (55) and bearing cone
(54).
7. Check that the seal rings (56) are not damaged and
that they turn normally in their grooves. After this
check, remove the seal rings and coat them with
miscible grease, so that they remain at the bottom
of the groove when refitting the carrier.
8. Fit new Orings (34) (37).
9. Slide the carrier onto the guide studs "G" (Fig. 5) and
alternately and uniformly tighten the four bolts (39) to
a torque of 100 - 130 Nm. Remove the guide studs.
Fit and tighten the other bolts to the same torque.
10. Position the transfer tube (42) in carrier (38).
11. Screw in and position union (44).
12. Refit the brake piston (see section 6E01).
13. Check the oil tightness of seal (34) on carrier (38)
(see section 6E01).
14. Refit the left-hand trumpet housing (see section
6B01, 6B02 or 6B03 depending on the version).
Right-hand carrier
Note: The access to the right-hand carrier (27) is
similar to that of the left-hand carrier (38).
Removal
- Take out bolts (26) and place diametrically opposed
guide studs in the housing, their end resting against the
half-housing (23).
- Extract and remove the carriers by inserting the two
bolts "V" through the tapped holes and take it off.
Refitting
- Check for the presence of the centring pin (25) and
Oring (34).
- Tighten uniformly and alternately the four bolts (26) to
a torque of 100 - 130 Nm. Remove the guide studs. Fit
and tighten the other bolts to the same torque.
- Check the oil tightness of seal (34) on carrier (27) (see
section 6E01).
Issue 1
May 2001
6D02.7
36
Fig. 7
Issue 1
May 2001
25
Issue 1
May 2001
27
34
56
40
38
34
Fig. 8
6D02.9
Remarks
- The end of the sensor must always be placed above the
teeth of the crownwheel of the differential.
- Fit and adjust the ground speed sensor lightly smeared
with Loctite 577 (Sensor Sealing or equivalent).
Fig. 9
Final operations
33. Refit the trumpet housings (see section 6B01, 6B02
or 6B03 depending on the version).
34. If the PTO housing has been removed, assemble it
with the centre housing (see section 2E01).
35. Couple the tractor between the intermediate housing
and the centre housing (see section 2D01).
36. Check the correct operation of all controls (mechanical, hydraulic and electronic).
37. Carry out a road test. Check the oil tightness of the
mating faces and hydraulic unions.
Issue 1
May 2001
50
52
57
51
48
53
58
49
47
41
46
Preliminary operations
38. Remove the differential unit (see operations 15 to
23).
Reassembly
Note: If unit (46), cover (52) and carrier (38) have been
removed, it is mandatory to carry out shimming of
the differential unit (see F) and to check the
backlash between the drive pinion and the
crownwheel (see E).
46. Clean and check the components. Replace any
parts found to be defective.
47. Check that the hydraulic channels in cover (52) are
not obstructed.
48. Lubricate and fit new Orings (50) (51) on piston (58).
49. Insert the piston by tapping around its rim with a
plastic hammer. Check that there are no seal fragments after insertion.
50. Position unit (46). Lightly smear bolts (41) with
Loctite 270 and tighten them to a torque of 130 Nm.
51. Place hub (53). Assemble the intermediate plates
(48) and discs (49) as shown in Figure 10.
Issue 1
May 2001
Fig. 10
6D02.11
52. Position cover (52) fitted with piston (58). Fit bolts
(47) lightly smeared with Loctite 270 and tighten to
a torque of 90 - 120 Nm.
53. Manually check that the discs and intermediate
plates are not constrained in any way.
54. Refit the differential unit (see operations 24 to 31) and
the brake pistons (see section 6E01)
Fit and adjust the forward speed sensor lightly smeared
with Loctite 577 (Sensor Sealing or its equivalent).
Refit the transfer tube (42) and union (44).
Final operations
55. Complete the refitting of the various assemblies,
carry out operations 33 to 37.
Issue 1
May 2001
D . Removing and refitting the planetary gears and sun gears and disassemblying and reassembling the
crownwheel
46
23
30
29
33
30
61
35
Preliminary operations
56. Remove the differential unit (see operations 15 to
23).
57. Remove the locking system and unit (46) (see C).
Removal
58. Separate the half-housings (23) (Fig.11).
Note: These components both bear the same
number. They must be fitted as pairs.
59. Remove the sun gears (30) fitted with friction bushes
(35) (61), the planetary gears (29), washers (28) and
differential brace (33) (Fig. 11).
60. If necessary, drive cup (32) off the half-housing (23)
and recover the shim(s) (59). Extract and discard
deflector (20).
29
28
Fig. 11
24
Fig. 12
Fig. 13
Issue 1
May 2001
6D02.13
Final operations
69. Finish the refitting of the different assemblies. Carry
out operations 33 to 37.
Issue 1
May 2001
Disassembly
- Using an appropriate extractor, remove cup (32) and
discard the deflector (20).
Pre-adjustment
Fig. 14
59
32
20
39
40
K - 0,
23
Fig. 14A
Issue 1
May 2001
6D02.15
Remarks
- The deflector serves as a guide for centring the shims.
It is inserted using the cup and an appropriate locally
manufactured tool. This method allows the deflector to
rest against the cup both during and after its insertion.
- When the operation is completed, check that the cup is
thrusting on the shim(s) and in contact with the deflector.
71. Refit and shim the differential unit (see B and F).
Checking
- Couple and temporarily fix the intermediate housing to
the centre housing using several diametrically opposed
bolts tightened to a torque of 540 680 Nm.
- With the PTO housing taken off, through the rear
opening of the centre housing (45), place the index of a
dial gauge half way across the length of a tooth of the
crownwheel (Fig. 14).
- Check that the backlash is between 0.15 mm and 0.45
mm. Carry out this check at three points around the
crownwheel.
Important
- If the backlash is incorrect, the adjustment principle is
to reduce or increase the thickness of shim(s) (59).
In this case, select and fit a different thickness of
shim(s).
Carry out the shimming of the differential unit again in
order to obtain the pre-loading of bearings (31) (32) and
(54) (57).
Check a second time the backlash between the drive
pinion and the crownwheel.
- When the final adjustment has been obtained, go on
with the refitting operations.
Issue 1
May 2001
Shimming preparation
72. Place the differential assembly previously fitted
with bearing cone (54) in the housing using sling ref.
3378116M1 (see I). Screw two diametrically opposed guide studs into the centre housing. Insert
carrier (27) fitted with a new Oring (34) using four
bolts (26). Remove the guide studs. Complete the
refitting of the other bolts and tighten to a torque of
100 - 130 Nm.
73. Remove bearing cone (54) and shim(s) (55) from
carrier (38).
74. Slide bearing cone (54) on tool, ref. 3378117M1 (see
I), adapted for the standard differential unit with
multidisc lock. Using two bolts, fix the tool onto the
housing (Fig. 15).
75. Tighten the centre bolt to 10 Nm (Fig. 15).
Note: Turn the crownwheel several times to seat
the cones correctly in the cups. Check the tightening torque of the centre bolt again.
Fig. 15
3378117 M1
Fig. 16
38
57
C
B
54
3378117 M1
45
Fig. 17
Issue 1
May 2001
Final operations
54
6D02.17
38
45
Fig. 18
P2 = 0,05/0,15 mm
Fig. 19
Issue 1
May 2001
18
Preliminary operations
82. Uncouple the tractor between the intermediate housing and the centre housing (see section 2D01).
83. Remove the creeper unit (if fitted) (see section
6H01).
Free the ratchet of the Park Lock transmission lock
(if fitted) (see section 6F01).
84. Locate the position of and take out the sleeve linking
the drive pinion and the lower shaft.
85. Remove the hydraulic pump bearing / drive pinion
assembly.
3378119M1
3378118M1
Fig. 20
Issue 1
May 2001
11
G
13
V
11
Fig. 21
6D02.19
Issue 1
May 2001
Final operations
108. Refit the hydraulic pump bearing / drive pinion
assembly.
109. Refit the ratchet and locking sleeve of the Park
Lock transmission (if fitted). Refit the creeper unit
(if fitted). Adjust the fork (see section 6H01).
110. Re-couple the tractor between the intermediate
housing and the centre housing (see section 2D01).
Note: If the crownwheel and drive pinion have
been replaced, check the backlash (see E).
111. Check the operation of all the controls.
112. Carry out a road test.
113. Check the oil tightness of the mating surfaces.
114. Check the oil tightness of the hydraulic unions.
Issue 1
May 2001
6D02.21
Preliminary operations
115. Using a press, insert cup (10) thrust against bearing
carrier (13). Using a suitable fixture, insert cup (2)
to thrust against housing (19). Screw in two diametrically opposed guide studs into the tapped bolt
holes (11). Fit the carrier alone without shims (12).
Alternatively and progressively, tighten the four
bolts (11) to a torque of 100 - 130 Nm.
Check that carrier (13) is in contact with the
intermediate housing (19).
116. Using a press and an appropriate fixture, insert
cone (7) to thrust against the drive pinion.
117. Lubricate the taper roller bearings (7) (10) with
transmission oil.
Z
X
19
18
39 K
22
39 K
11
13
E
19
Issue 1
12
Fig. 22
May 2001
Fig. 22A
Fig. 23
Checks
- Temporarily refit the assembly fitted with the previously determined shims and measure dimension "X"
again. Check that X + Y does in fact equal Z.
123. Remove the drive pinion and bearing carrier (13).
124. On bearing carrier (13), refit the mechanism, the
intermediate plates, the discs and unit (15). Refit
the assembly on the intermediate housing (19).
Carry out operations 97 to 103.
Reminder
- Carry out shimming of the drive pinion taper roller
bearings.
Issue 1
May 2001
6D02.23
18
E
P1 =
0,04 / 0,10 mm
18
10
11
2
13
12
Fig. 24
Issue 1
May 2001
I . Service tools
Tools available in the AGCO network
- 3378116M1 Differential unit sling (Fig. 25)
- 3378117M1 Shimming tool (Fig. 26)
- 3378118M1 Locking wrench for drive pinion nut
(Fig. 27)
- 3378119M1 Drive pinion tightening socket (Fig.
28).
Fig. 25
Fig. 26
Fig. 27
Issue 1
May 2001
Fig. 28
6D03.1
Contents
-
General ________________________________________________
A.
B.
C.
10
D.
11
E.
13
F.
15
G.
17
H.
21
I.
25
Issue 1
May 2001
General
Reminder
The 8260 to 8280 tractors is equipped with a centre
housing identical to that mounted on the 8210, 8220,
8240 and 8250 tractors. They are fitted with an AG250
Full Powershift gearbox and have a wide intermediate
housing in which the axial position of the drive pinion has
been redesigned for the fitting of a hypoid bevel gear.
Construction
The bevel gear, moved in rotation by the gearbox output
shaft, drives the rear axle.
The helical drive pinion is supported by two taper roller
bearings mounted in opposition.
The bearing cone (7) is force fitted on the drive pinion, and
cups (2) (10) are likewise force fitted into the intermediate housing (19) and bearing support (13). The bearing
cone (1), mounted free on the drive pinion, allows to fit
the shims (3) required for shimming.
The crownwheel is fastened to the differential housing by
bolts. The differential assembly rotates on two taper
roller bearings supported by two lateral carriers centred
by bushes (23) and fixed by bolts to the housing.
The differential assembly is formed by two halves
holding four planetary gears (31) and two sun gears (32)
(33). The left-hand side sun gear also serves as the hub
for the differential lock discs (56). The planetary gears
turn on four half shafts (35) housed in the unit and the
differential yoke (34). They are held in place by pins and
bolts.
The lubrication of the planetary gears is carried out by
axial and radial channels drilled in the half shafts.
The sun gears, left-hand carrier (40), cover (50) and the
differential yoke contain drilled lubrication channels allowing transmission oil to reach bushes (36) (37), discs
(56) and the differential lock system. The drive pinion,
which bears the 4 WD drive pinion (17), is located in the
intermediate housing. The adjustment of its position is
carried out by shims (12) fitted between the bearing
carrier (13) and the housing. The pre-loading of the
bearings is obtained by shim(s) (3) fitted between the
bearing cone (1) and the thrust washer (4). The preloading via shimming of the differential assembly is
carried out via shim(s) (48) placed between bearing cone
(46) and the left-hand carrier (40).
Issue 1
May 2001
Differential lock
The multidisc lock system comprises:
- a unit (21) housing the discs (56) and intermediate
plates (55).
- a hub (33) integral via splines with the left-hand trumpet
input sun gear.
- a cover (50) made up by piston assembly (52) and
supported by taper roller bearings (46) (47).
The piston chamber lodged in the cover communicates
with a channel in the left-hand carrier (40), allowing (17
bar) low pressure to act upon the piston. Two seal rings
(49) ensure the oil tightness of the circuit.
Operation
Clutched position
When the differential lock solenoid valve is activated, the
pressure flows through the channels in left-hand carrier
(40) and cover (50) on unit (21) and enters piston chamber
(52). The piston compresses the intermediate plates (55)
and discs (56) integral respectively via stops and splines
in lock unit (21) and hub (33).
In this clutched position, the input sun gears of the righthand and left-hand trumpets turn at the same speeds.
Declutched position
When the pressure is cut, the piston returns, the discs
and intermediate plates are no longer compressed and
allow the sun gears and planetary gears to carry out their
differential function.
Bearing cone
Bearing cup
Shim(s)
Thrust washer
Circlip
Intermediate plates (handbrake)
Bearing cone
Bolt
Drive pinion
Bearing cup
Bolt
Shim(s)
Bearing carrier
Discs
Handbrake unit
Mechanism
4 WD drive pinion
Nut
Intermediate housing
Crownwheel
Unit
Bolts
Centring bushes
Bolts
Right-hand carrier
Orings
Bearing cone
Bearing cup
Shim(s)
Spherical washer
Planetary gear
Right sun gear
Left sun gear
Differential yoke
Planetary gear half shafts
Shouldered bush
Shouldered bush
Needle bearings
Bolt
Left-hand carrier
Transfer tube
Oring
Oring
Union
Centre housing
Bearing cone
Bearing cup
Shim(s)
Seal rings
Cover
Bolt
Piston
Overall view
A
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
6D03.3
(53)
(54)
(55)
(56)
(57)
(58)
(59)
58
Oring
Oring
Intermediate plates (differential lock)
Discs
Lubricating pipe
Rivet
Rivet
Fig. 1
Fig. 2
50
29
21
59
32
23
37
36
51
46
48
Fig. 3
49
20
45
50
19
14
12
44
43
41
22
51
21
26
26
23
23
24
24
42
29
47
32
57
46
13
11
36
A
49
34
37
27
48
28
18
16
17
10
25
54
8
6
31
40
30
15
35
52
53
Parts list
Fig. 2
Fig. 3
56
55
33
39
38
Fig. 2
Fig. 1
Parts list
Issue 1
May 2001
Fig. 1
Fig. 3
6D03.4
Exploded view
34
35
37
31
30
32
36
21
33
29
28
27
30
26
25
31
24
39
9
20
38
12
4
3
2
7
22
10
23
18
8
13
11
33
56
55
42
44
40
26
43
49
48
46
41
47
50
24
53
52
23
51
54
Parts list
Issue 1
Fig. 1
Fig. 2
Fig. 3
May 2001
6D03.5
Removal
1. Remove the left-hand trumpet housing (see section
6B04).
2. Take off union (44) (Fig. 4) and raise the transfer tube
(41) (Fig. 5).
3. Remove the brake piston (see section 6E01)
4. Remove bolts (24) on from the left-hand carrier. Place
two diametrically opposed guide studs "G" on the
housing as shown in Figure 6, their ends pushing
against cover (50) of the lock unit.
5. Extract the carrier by inserting two bolts "V" through
the tapped holes (Fig. 6); take it off and recover cone
(46) and shim(s) (48).
Note: The guide studs "G" hold and centre the
differential assembly in the housing (Fig. 7). Do
not unscrew the guide studs. This may throw off
centre the assembly and damage the seal rings
(49) during refitting of the carrier.
44
Fig. 4
41
Fig. 5
50
V
50
G
Fig. 7
Fig. 6
Issue 1
May 2001
Refitting
6. Check for the presence of centring bush (23) on the
housing, the shim(s) (48) and bearing cone (46).
7. Check that the seal rings (49) are not damaged and
that they turn normally in their grooves. After this
check, remove the seal rings and coat them with
miscible grease, so that they remain at the bottom
of the groove during refitting of the carrier.
8. Fit new Orings (26) (42).
9. Slide the carrier onto the guide studs"G" (Fig. 6) and
alternately and uniformly tighten the four bolts (24) to
a torque of 100 - 130 Nm. Remove the guide studs.
Fit and tighten the other bolts to the same torque.
10. Position the transfer tube (41) in carrier (40).
11. Screw in and position union (44).
12. Refit the brake piston (see section 6E01).
13. Check the oil tightness of seal (26) on carrier (40)
(see section 6E01).
14. Refit the left-hand trumpet housing (see section
6B04).
Right-hand carrier
Note: The access to the right-hand carrier (25) is
similar to that of the left-hand carrier (40).
Removal
- Take out bolts (24) and place diametrically opposed
guide studs "G" in the housing, their ends thrust against
the half-housing (21).
- Extract the carrier by inserting two bolts "V" through the
tapped holes and remove it.
Refitting
- Check for the presence of the centring pin (23) on the
housing and Oring (26).
- Tighten uniformly and alternately the four bolts (24) to
a torque of 100 - 130 Nm. Remove the guide studs. Fit
and tighten the other bolts to the same torque.
- Check the oil tightness of seal (26) on carrier (25) (see
section 6E01).
Issue 1
May 2001
6D03.7
Fig. 8
Refitting
Note: Since space is limited around the differential
unit, it is essential to fit the auxiliary spool valve and
lift control valve return pipe in the housing (45)
before refitting the unit.
In order not to damage the seal rings (49), it is
necessary to correctly align the differential assembly along the axis of the centre housing before
inserting carriers (25) (40).
24. Using the sling, introduce the differential assembly
into the centre housing and hold it in the axis of the
trumpet housings.
Issue 1
May 2001
25
23
Issue 1
May 2001
26
Fig. 9
49
40
23
26
Fig. 10
6D03.9
Special points
- If the carrier (1) of the ground speed sensor (2) has been
removed, position the carrier previously lightly smeared
with Loctite 510, with the offset of the sensor turned
towards the longitudinal axis of the centre housing as
shown in Fig. 11.
- Tighten the bolts (3) previously lightly smeared with
Loctite 542 to a torque of 25 - 35 Nm.
Remarks
- The end of the sensor must always be placed above the
teeth of the crownwheel of the differential.
- Fit and adjust the ground speed sensor lightly smeared
with Loctite 577 (Sensor Sealing or equivalent).
34. Refit transfer tube (41) and union (44).
Fig. 11
Final operations
35. Refit the trumpet housings (see section 6B04).
36. If the PTO housing has been removed, assemble it
with the centre housing (see section 2E01).
37. Couple the tractor between the intermediate housing
and the centre housing (see section 2D01).
38. Check the correct operation of all controls (mechanical, hydraulic and electronic).
39. Carry out a road test. Check the oil tightness of the
mating faces and hydraulic unions.
Issue 1
May 2001
47
51
Preliminary operations
40. Remove the differential unit (see operations 15 to
23).
50
52
53
54
56
33
55
Reassembly
Note: If unit (21), cover (50) and carrier (40) have been
replaced, it is mandatory to carry out shimming of
the differential unit (see F) and to check the
backlash between the drive pinion and the
crownwheel (see E).
48. Clean and check the components. Replace any
parts found to be defective.
49. Check that the hydraulic channel in cover (50) is not
obstructed.
50. Lubricate and fit new Orings (53) (54) on piston (52).
51. Insert the piston by tapping around its rim with a
plastic hammer.
52. Check that there are no seal fragments after insertion.
53. Assemble the intermediate plates (55) and discs
(56) as shown in the overall view.
54. Position cover (50) fitted with piston (52). Fit bolts
(51) lightly smeared with Loctite 270 and tighten to
a torque of 100 - 130 Nm.
55. Manually check that the discs and intermediate
plates are not constrained in any way.
Issue 1
May 2001
Fig. 12
56. Refit the differential unit assembly (see operations
24 to 31) and the brake pistons (see section 6E01)
57. Adjust the forward speed sensor (see special points
and remarks, B). Refit the transfer tube (41) and
union (44).
Final operation
58. Complete the refitting of the various assemblies,
carry out operations 35 to 39.
6D03.11
D . Removing and refitting the planetary gears and sun gears and disassembling and reassembling the
crownwheel
34
21
39
Preliminary operations
30
38
33
35
Removal
61. Remove the left-hand sun gear (33).
62. To remove the half shafts (35), it is necessary to
disassemble the crownwheel (see below).
63. Remove bolts (39).
64. Take out pins (38) from unit (21).
65. Push on a half shaft in the direction of the arrow to
drive out the opposite half shaft. Repeat the operation for the remaining half shafts. Recover the
spherical washers (30). Remove the planetary gears
(31).
66. Remove the differential yoke and the right-hand sun
gear (32).
67. If necessary, drive cup (28) off the unit (21) and
recover the shim(s) (29).
31
34
31
36
32
30
28
29
39
38
35
39
21
Fig. 13
22
Fig. 14
Issue 1
May 2001
Final operation
80. Finish the refitting of the different assemblies. Carry
out operations 35 to 39.
Issue 1
May 2001
6D03.13
Special point
When calculating E do not take the negative sign
preceding the Dc into consideration (Fig. 15).
81. Place the previously selected shim(s) in the bore of
the unit (21). Insert bearing cup (28) and check that
it is in contact with the shims.
82. Refit and shim the differential unit (see B and F
respectively).
Disassembly
Using an appropriate extractor, remove cup (28).
Pre-adjustment
The thickness of the shim(s) "E" required to obtain the
correct backlash is calculated as follows:
E = Dc + 0.10 mm
where:
E : thickness of shim(s) (29) to be fitted
Dc : crownwheel offset
Remark
- The Dc (example shown: -0.10) engraved on the external diameter of the crownwheel (Fig. 15) after the
pairing number and letter (31 A) may range between 0
and -0.60 mm.
29
28
21
31
10
A - 0,
Fig. 15
Issue 1
May 2001
Checks
- Couple and temporarily fix the intermediate housing to
the centre housing using several diametrically opposed
bolts tightened to a torque of 540 680 Nm.
- With the PTO housing taken off, through the rear
opening of the centre housing (45), place the index of a
dial gauge half way across the length of a tooth of the
crownwheel (Fig. 16).
- Check that the multidisc is between 0.15 mm and 0.45
mm. Carry out this check at three points around the
crownwheel.
- If the backlash is incorrect, the adjustment principle is
to reduce or increase the thickness of shim(s) (29).
- In this case, select and fit a different thickness of
shim(s). Carry out the shimming of the differential unit
again in order to obtain the pre-loading of bearings (27)
(28) and (46) (47).
- Check a second time the backlash between the drive
pinion and the crownwheel.
83. When the final adjustment has been obtained, go on
with the refitting operations.
Issue 1
May 2001
Fig. 16
6D03.15
3378117M1
Shimming preparation
84. Place the differential assembly in the housing using
sling ref. 3378116M1 (see I). Screw two diametrically opposed guide studs into the centre housing.
Insert carrier (25) fitted with a new Oring (26) using
four bolts (24). Remove the guide studs. Complete
the refitting of the other bolts and tighten to a torque
of 100 - 130 Nm.
85. Remove bearing cone (46) and shim(s) (48) from
carrier (40).
86. Slide bearing cone (46) on tool, ref. 3378117M1 (see
I), adapted for the hypoid differential unit with
multidisc lock. Using two bolts, fix the tool onto the
housing (Fig. 17).
87. Tighten the centre bolt to 10 Nm (Fig. 17).
Note: Turn the crownwheel several times to seat
the cones correctly in the cups. Check the tightening torque of the centre bolt again.
Fig. 17
Issue 1
May 2001
40
B
3378117M1
45
46
47
Fig. 18
3378117M1
Fig. 19
Issue 1
May 2001
45
6D03.17
40
46
Final operations
92. Remove the tool and bearing cup (46).
93. On carrier (40), place the shims determined in
operation 91. Centre the differential assembly, carry
out operations 26 and 27. Insert the carrier, carry out
operations 28 to 31.
Fig. 20
46
40
P2 = 0,05 / 0,15 mm
Fig. 21
Issue 1
May 2001
57
Fig. 22
18
3378118M1
3378119M1
Fig. 23
11
11
V
G
Fig. 24
Issue 1
May 2001
6D03.19
Issue 1
May 2001
18
337811
8M1
3378119M1
Fig. 25
Final operations
122. Refit the hydraulic pump bearing / drive pinion
assembly.
123. Refit the ratchet and locking sleeve of the Park
Lock transmission.
124. Refit the creeper unit (if fitted). Adjust the fork (see
section 6H01).
125. Couple the tractor between the intermediate housing and the centre housing (see section 2D01).
Note: If replacement of the crownwheel and
drive pinion has been carried out, check the
backlash (see E).
126. Check the operation of all the controls.
127. Carry out a road test.
128. Check the oil tightness of the mating surfaces.
129. Check the oil tightness of the hydraulic unions.
Issue 1
May 2001
6D03.21
Preliminary operations
130. Using a press, insert cup (10) thrust against bearing
carrier (13).
Using a suitable fixture, insert cup (2) to thrust
against housing (19). Screw in two diametrically
opposed guide studs into the tapped holes (11). Fit
the carrier alone without shims (12). Alternatively
and progressively, tighten the four bolts (11) to a
torque of 100 -130 Nm. Check that carrier (13) is in
contact with the intermediate housing (19).
131. Using a press and an appropriate fixture, insert
cone (7) to thrust against the drive pinion.
132. Lubricate the taper roller bearings (7) (10) with
transmission oil.
133. Temporarily fit the drive pinion without shims (3)
but with thrust washer (4) placed between the
bearing cone (1) and nut (18).
134. Pre-tighten the nut to a torque of 30 - 50 Nm using
wrench, ref. 3378118M1 and socket, ref.
3378119M1 (Figs. 33 - 34, I) taking care to correctly position the torque wrench.
135. Turn the drive pinion several times to correctly seat
the bearing cones in the cups. Check the correct
pre-tightening of nut (18) again.
Issue 2
1
May 2002
2001
6D03.22
19
X
Y
31 A
20
18
31 A
13
11
19
E
12
Fig. 26
Issue 1
May 2001
6D03.23
Fig. 27
Fig. 28
Issue 1
May 2001
18
E
P1 =
0,04 / 0,10 mm
18
10
11
2
13
12
Fig. 29
Fig. 30
Issue 1
May 2001
6D03.25
I . Service tools
Tools available in the AGCO network
- 3378116M1 Differential unit sling (Fig. 31)
- 3378117M1 Shimming tool (Fig. 32)
- 3378118M1 Locking wrench for drive pinion nut
(Fig. 33)
- 3378119M1 Drive pinion tightening socket (Fig.
34).
Fig. 31
Fig. 32
Fig. 33
Fig. 34
Issue 1
May 2001
6E01
6E01.1
Contents
-
General ________________________________________________
A.
Disassembly ____________________________________________
B.
Reassembly ____________________________________________
C.
11
Issue 1
May 2001
General
The brake pistons (2) are housed in two cavities formed
by the centre housing and the differential carrier, concentric with the thrust face of each trumpet housing. The
brake pistons are guided by three locating pins (6) force
fitted into the centre housing and have an annular face
that is submitted to pressure from the master cylinder.
The other face has a larger surface area and acts upon a
disc that is integral via splines with the input sun gear of
the trumpet housing and on the wall of a compartment
that also serves as the brake plate. This compartment is
centred by locating pins that are force fitted into the
trumpet housing which may or not be oil tight depending
on the type of assembly.
The oil tightness of the pistons is provided by Orings
fitted into the grooves of the centre housing and the
differential carriers. Two other seals placed in the angle
of each carrier stop the pressure in the piston chamber
from communicating with the interior of the centre
housing.
The shape of the pistons differs according to the options
and the type of trumpet housing.
Each piston is controlled by a master cylinder the oil level
of which is maintained by a residual oil flow from the
lubricating circuit.
When the brake is released, a minimum clearance is
provided between the piston and the disc. The brakes are
self-adjusting and maintain a constant brake pedal position.
When they are not in use, the discs are lubricated by an
oil flow from the lubricating circuit on the right-hand
cover. This oil also serves to cool the discs when they are
used.
Remark
On tractors fitted with trumpet housings with double
drive unit, the brake pistons (2) are fitted in the same
cylinders as previously mentioned. They are guided by
three stop pins (39) (41) mounted free in the housing. Pin
(39) fitted in the upper part of the housing has a drilled
central port to allow pressure venting from the trumpet
housing into the rear axle and breather pipe. The pistons
act upon a two-disc system (35) running in an oil bath and
integral via splines with hub (32) and the trumpet housing
input shaft. The discs are separated by an intermediate
plate (38) that is guided by the previously mentioned
pins.
During braking, the double-disc system is thrust against
the centre brake plate by pin (7) on the centre housing.
Issue 1
May 2001
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(32)
(35)
(38)
(39)
(41)
Centre housing
Piston
Oring
Oring
Oring
Stop pin
Pin
Hub
Disc(s)
Intermediate plate
Stop pin (drilled)
Stop pin
Identification of ports
O : Disc lubricating port
P : Pressure from master cylinders
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
6E01.3
Overall view
P
1
35
3
2
4
35
2
32
4
6
6
Parts list
Fig. 2
Fig. 3
Issue 1
Fig. 4
Fig. 5
Fig. 1
May 2001
Parts list
Fig. 1
Fig. 3
Fig. 4
Fig. 5
Fig. 2
Overall view
Assembly with trumpet housing fitted with composite drive unit
1
3
4
4
35
35
32
32
38
5
5
41
Parts list
Fig. 1
Fig. 2
Fig. 4
Fig. 5
Parts list
Fig. 3
Issue 1
Fig. 1
Fig. 2
May 2001
Fig. 3
Fig. 5
Fig. 4
6E01.5
Exploded view
Single disc
3
4
2
6
35
39
Double disc
3
4
2
41
32
35
38
35
Parts list
Fig. 1
Fig. 2
Issue 1
Fig. 3
Fig. 4
Fig. 5
May 2001
A . Disassembly
1. Remove the trumpet housing(s) concerned (see section 6B01, 6B02, 6B03 or 6B04 depending on the
version).
2. Remove the master cylinder brake supply pipe from
the union above the centre housing. Progressively
drive out piston (2) from housing (1) using a compressed air jet connected to the union (3) (Fig. 6).
Fig. 6
Issue 1
May 2001
6E01.7
Reminder
- If the spacer acting as the brake plate has to be replaced, consult the section concerning the relevant trumpet housing type (6B01, 6B02, 6B03 or 6B04).
3
Fig. 7
Issue 1
May 2001
B . Reassembly
5. Clean and check the components. Replace any parts
found to be defective.
6. If removed, refit the differential carrier(s) with a new
seal (see section 6D01, 6D02, or 6D03 depending on
the version).
V
1
6
V
6
V
39
41
41
Fig. 8
Issue 1
May 2001
6E01.9
6
6
39
41
41
3
Fig. 9
Issue 1
May 2001
Tests
- Pressurize the circuit again to a pressure of approximately 0.3 bar.
- Close the pressure relief-valve.
- Over a period of one minute, no drop in pressure should
be seen on the pressure gauge.
- After the test, remove the pressure gauge and take off
the retainer tool.
3
Final operations
9. Refit the trumpet housing(s) (see section 6B01,
6B02, 6B03 or 6B04 depending on the version).
10. Purge the main brake system (see section 9I01).
11. Carry out a road test of the brake circuit.
12. Check the oil tightness of:
- trumpet housing seals (silicone)
- brake lubricating pipes
Issue 1
May 2001
Fig. 10
6E01.11
C . Service tools
340
215
30
2 13
20
2 mini
a
Fig. 11
Issue 1
May 2001
6F01
6F01.1
Park lock
Contents
-
General ________________________________________________
A.
B.
C.
D.
Issue 1
May 2001
General
The Park lock system, fitted inside the centre housing,
comprises a ratchet (17) and a toothed sleeved (15),
integral via splines with the drive pinion and the lower
shaft connected to the gearbox.
This system is activated by a control unit (3) attached to
the right-hand side of the housing and through a springloaded control rod.
The Park lock is only fitted to transmissions equipped
with a Full Powershift gearbox.
Operation
Engaged position (speed control in position P)
- When the tractor is halted with the engine running, the
Park lock provides a mechanical locking of the transmission. In the engaged position, the solenoid valve (7)
is not activated and the system functions in a purely
mechanical manner.
- Spring (10) pushes piston (1) towards unit (3). The
control rod (11) screwed into the piston drives the links
(13) that engage ratchet (17) in the toothed sleeve (15),
thus locking the lower transmission shaftline.
- With the engine halted, the Park lock is engaged automatically.
Disengaged position (hydraulic activation)
- When the speed control is placed in the P or N position,
the electronic unit (TC) controls solenoid valve (7) that
supplies control unit (3) which disengages the Park
lock. The pressure in the piston chamber (1), acting
upon the front face of the piston, compresses spring
(10) and frees ratchet (17) from the toothed sleeve (15).
- The electronic unit (TC) is informed through the position
of switch (19) (see section 11).
Issue 1
May 2001
Overall view
Parts list
Key to letters
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(15)
(16)
(17)
(18)
(19)
(20)
(23)
D : Disengaged position
E : Engaged position
Piston
Oring
Control unit
Bolt
Oring
Special bolt
Solenoid valve
Oring
Nut
Spring
Control rod
Split pin bolt
Links
Toothed sleeve
Pin and washer
Ratchet
Seal(s)
Switch
Oring
Non-return valve
6F01.3
23
6
10
11
13
15
12
17
16
18
Fig. 1
Fig. 2
19
E
F
D
2
20
24
18
25
26
View along F
Parts list
Issue 1
May 2001
Fig. 2
Fig. 1
6F01.4
Exploded view
19
18
16
17
16
12
13
13
11
10
1
8
23
6
5
20
Parts list
Issue 1
May 2001
Fig. 1
Fig. 2
6F01.5
15
Unlocking
17
1. Take off nut (9) and turn the special bolt (6) (Fig. 3)
clockwise until piston (1) comes into contact with the
shoulder of the housing.
Action obtained
- During this operation, the control rod (11) is moved to
the right and compresses the spring (10) freeing ratchet
(17) from the toothed sleeve (15) (Figs. 3 - 4).
10
11
Fig. 4
Test
3. Check the correct operation of the transmission lock.
11
1
10
15
11
17
11
11
Fig. 3
Issue 1
May 2001
Removal
5. Disengage the Park lock system (see A) and remove the creeper drive unit (if fitted, see section 6H01).
6. Visually locate the position of the sleeve and remove
it.
If necessary, take out the snap ring located inside it.
Refitting
7. Clean and check the components. Replace any
defective parts.
8. If previously removed, replace the snap ring.
9. Check that the sleeve slides easily on the drive
pinion and on the lower shaft coming from the
gearbox. Place the sleeve in its final position on the
drive pinion, the long part turned towards the pinion.
Refit the creeper unit (if fitted, see section 6H01).
Final operations
10. Couple the tractor between the gearbox and the intermediate housing (see section 2C01).
11. Place the special bolt (6) in its initial position (see
A).
Issue 1
May 2001
6F01.7
Disassembly
9
Fig. 5
10
E
9
Fig. 6
Issue 1
May 2001
Final operations
35. Refit the right- and left-hand side covers (see section
9G01, 9G02 and 9H01).
36. Reconnect solenoid valve (7).
37. Remove the axle stands (if used) refit the wheels or
place them in their initial position. Carry out the
tightening of nuts and bolts to their indicated torque
(see section 2G01).38.
Check the correct operation of the dashboard indicator lamp and the
display of the letters P and N in relation to the speed
control.
39. Check the oil tightness of the control unit (3).
Issue 1
May 2001
R
1
11
Fig. 7
Torques
-
Switch (19): 20 Nm
Bolts (4): 10 - 14 Nm
Solenoid spool valve (7): 18 - 20 Nm
Knurled nut (solenoid valve): 3 - 4 Nm or manual tightening
Remark
- The letter "R" (Fig. 7) indicates the unit (3) oil return port.
6G01.1
CONTENTS
-
General ________________________________________________
A.
B.
C.
D.
10
E.
10
F.
11
Issue 1
May 2001
Issue 1
May 2001
6G01.3
Remarks
- In both assembly configurations, an Oring (19) between the housing and the support provides oil tightness for channel "C".
- Tractors also exist without hydraulic lift. In this case, a
plate covers the location of the supports (2) (16).
The lift shaft (7) fits into supports (2) (16) fitted to the
centre housing. The lift shaft is splined at its ends and
operates the arms (5) (15).
The arm (5) is positioned by locating pin (4) inserted into
cam (8), itself integral with the shaft via splines. The
shaft drives the cam that informs the ELC calculator of
the arm position via sensor (11).
Each support is positioned by two locating pins (13) force
fitted into the centre housing.
Oil tightness of the bearings including friction bushes (10)
is provided by seals (1) (3) inserted in both sides of the
support.
Special point
Tightening torques
- Bolts (4) on supports (1) (Fig. 1): 480 - 640 Nm, Loctite
270
- Bolts (5): 50 Nm, Loctite 270.
6
5
4
2
7
1
Fig. 1
Issue 1
May 2001
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(30)
(31)
(32)
Seal
Right-hand support
Seal
Locating pin
Right-hand side lift arm
Bolts and washers
Shaft
Cam
Bolts and washers
Friction bushes
Position sensor
Nut
Locating pins
Grease nipples
Left-hand side lift arm
Left-hand side support
Grooved spacer
Breather pipe
Oring
Plug
Oring
Oring
Fig. 2
Fig. 3
Issue 1
May 2001
6G01.5
Overall view
Right-hand support
14
6
10
7
B
11
13
12
Left-hand support
32
16
18
6
15
16
14
O
7
10
C
19
13
Assembly 1
9
17
30
31
C
Parts list
Fig. 3
Issue 1
Assembly 2
Fig. 2
May 2001
6G01.6
Exploded view
31
30
O
7
1
32
18
16
10
17
6
10
2
4
1
11
12
14
13
19
15
29
Parts list
Fig. 2
Fig. 3
Issue 1
May 2001
6G01.7
Upper pins
Retaining pins
Cylinders
Washers
Grease nipples
Snap rings
Washers
Lower pins
Circlips
Friction bushes
20
21
20
21
24
22
24
23
23
29
23
29
Fig. 4
22
24
22
26
27
26
28
28
25
27
24
25
Parts list
Issue 1
May 2001
Fig. 4
B . Preliminary operations
2
Fig. 5
Issue 1
May 2001
16
6G01.9
Removal
6. Take off breather pipe (18). Disconnect and remove
the union screwed into port "O" on support (16)
(depending on the assembly type, see Fig. 2).
7. Take out bolts (9) on each support. Using straps,
sling together the pin, supports and lifting arm and
remove them.
8. Recover the Oring (19).
9. Take out bolts (6). Remove the lift arms, noting their
direction for reassembly. If necessary, extract bushes
(29) (Fig. 3).
10. Remove the cam (8) and grooved spacer (17).
11. Note the position of the supports (2) (16) and separate them from the shaft.
Refitting
12. Clean and check the components. Replace any
parts found to be defective.
13. Use protector, ref. 3378123M1 (see F). Slide support (16) onto shaft (7) (Fig. 6) in the position previously noted in operation 11. Proceed in the same
way with support (2).
14. Check for the presence of locating pin (4) on cam (8).
15. On shaft (7), insert grooved spacer (17) and cam (8)
in contact with their respective supports (2) (16).
16. If necessary, replace friction bushes (29) using pin
(20) as an insertion tool.
17. Mark the position of locating pin (4) with a line of
paint on cam (8) and arm (5).
18. Lightly coat the splined ends of the shaft with Antiseize grease or its equivalent.
19. Refit the lift arms with the paint mark made previously on the arm (5) aligned with that on cam (8) and
side "A" of the arm flush with side "B" of the pin (see
Fig. 2).
20. Assemble the washers and bolts (6) the threads
lightly smeared with Loctite 270. Tighten to a torque
of 240 - 320 Nm.
21. Check for the presence of locating pins (13) inserted
into the centre housing at the location of each
support and Oring (19) on the left-hand side support.
22. Using straps, correctly sling the assembly of pin,
supports and lift arm and position them on locating
pins (13).
3378123M1
Fig. 6
23. Fit the washers on bolts (9) the threads lightly smeared with Loctite 270. Tighten to a torque of 240 -320
Nm.
24. Check that none of the channels in support (16) are
obstructed. In the case of an Assembly 2 type (Fig.
2), refit the plug (30) fitted with seal (31).
On an Assembly 1 type, fit the hydraulic union and
reconnect the pipe (see operation 6).
On each type of assembly, check the cleanliness of
breather pipe (18) and screw it fitted with Oring (32)
onto the left-hand side support.
25. Manually check the axial clearance and the rotation
of the shaft.
Issue 1
May 2001
Reassembly
27. Lightly smear the external diameter of seals (1) (3)
with Loctite 542 and insert them using service tool,
ref. 3378124M1, with the lip turned towards the
outside of the support (see F).
28. Fit the grease nipples (14).
E . Final operations
29. Refit the upper cylinder pins fitted with grease
nipples (24) respecting the location of washer (23).
30. Fit and adjust the position sensor (see section 11 Electronics).
31. Refit union (2) on the manifold and reconnect the high
pressure pipe (1) from the auxiliary and lift control
spool valves that was disassembled in operation 3.
32. If needed, place the cab on its rear supports. Tighten
the bolts previously lightly smeared with Loctite 270
to a torque of 200 - 260 Nm. Refit the wheels or place
them in their initial position. Remove the axle stands
(if used). Tighten all nuts and bolts to their correct
torque (see section 2G01).
33. Using a grease gun, grease the supports (2) (16), and
pins (20) (27).
34. Check the lift control operation. Check the oil tightness of pipe (1) and union (2) (Fig. 5).
Issue 1
May 2001
6G01.11
F . Service tools
Tools available in the AGCO network
- 3378123M1 Protector (Fig. 7)
- 3378124M1 Seal insertion tools (Fig. 8).
Fig. 7
Fig. 8
Issue 1
May 2001
6H01.1
6H01 Creeper
CONTENTS
-
General ________________________________________________
Operation ______________________________________________
A.
B.
11
12
C.
D.
Issue 1
May 2001
6H01.2
Operation (Fig. 1)
General
Lubrication
The lubrication of the mechanical components of the
epicyclical reducer gear is ensured by an oil splash. The
drive pinion and the layshaft (30) have an axial drilled
channel, this allows flow "D" from the right-hand side
hydraulic cover to lubricate needle bearing (34) (Fig. 1).
The bearing supports the layshaft and permits a difference in rotation of the shafts when in the "Creeper"
position.
20
19
22
30
29
24
34
Fig. 1
Issue 1
May 2001
6H01.3
Overall view
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
Snap ring
Connecting shaft
Bolts
26
28
27
36
37
Sleeve
Support
Snap ring
Bearing carrier
Circlip
Circlip
Ball bearing
Snap ring
Friction washer
Pin
Friction plates
Sun gears
Crownwheel
Spacers
Roller bearings
A
Intermediate housing
Planetary carrier
Snap ring
45
Coupler ring
Bolts
Planetary carrier assembly (reducer gear)
Locating pin
Nut
B
Fork
Guide rod
Coupler
Layshaft
Snap ring
Sleeve
19
40
38
41
39
Snap ring
Needle bearing
Locking stud
Spring
B
Plug
Pin
Finger
Fig. 2
Oring
Pin
Link
Fig. 3
Bolt
Housing
43
42
Fig. 4
Shim(s)
35
16
17
18
14
26
25
27
28
29
30
15
14
E
12
11
13
12
20
22
21
44
10
23
7
24
3
5
6
19
34
31
32
33
Parts list
Fig. 3
Fig. 2
Issue 1
Fig. 4
Parts list
May 2001
Fig. 2
Fig. 4
Fig. 3
6H01.4
Exploded view
3
5
10
7
2
11
12
16
25
20
45
42
12
44
26
23
43
38
40
18
28
41
35
17
36
39
37
14
15
27
14
13
19
21
22
29
31
34
30
32
33
Parts list
Issue 1
Fig. 2
Fig. 3
Fig. 4
May 2001
6H01.5
Removal
3. Remove bolts (3). Remove the shaft (2) and unit (24)
assembly.
Note: The locating pins (25) are force fitted into
the intermediate housing (19).
Refitting
4. Check for the presence of the locating pins on the
intermediate housing.
5. Screw two guide studs of suitable length in the place
of two bolts (3).
6. Place coupler (29) in contact with snap ring (31).
7. Refit shaft (2) and unit (24) assembly turning the
machined recess "E" on support (5) towards the
adjusting nut (26) on guide rod (28) (Fig. 3). Turn shaft
(2) several turns to engage the exterior splines of
coupler ring (22) in those of coupler (29).
8. Alternately and uniformly tighten bolts (3) lightly
smeared with Loctite 241 to a torque of 90 - 120 Nm.
9. Couple the tractor between the gearbox and the
intermediate housing (see section 2C01).
Issue 1
May 2001
6H01.6
26
28
27
36
37
35
26
27
28
29
30
31
19
34
A
45
B
B
40
38
41
39
43
42
Fig. 5
Issue 1
May 2001
Disassembly (Fig. 5)
12. Remove plug (37). Recover spring (36) and locking
stud (35).
13. Remove the Allen screw (43). Remove the link (42)
and pin (41) fitted with seal (40) and finger (39).
Recover the shim(s) (45). Drive out pin (38) linking
the pin and the finger.
14. Disengage the guide rod (28) from the fork (27) and
the intermediate housing (19).
15. If necessary, loosen, unscrew and discard nut (26).
16. Remove the fork, coupler and shaft (30) fitted with
needle bearing (34).
17. Remove snap ring (31).
18. If necessary, extract the bearing.
6H01.7
Final operations
25. Couple the tractor between the gearbox and the
intermediate housing (see section 2C01).
26. Connect the control cable and adjust it if necessary
(see D).
Refitting
19. Clean and check the components. Replace any
parts found to be defective.
20. If fitted, using an appropriate fixture, insert bearing
(34) thrust against the shoulder on layshaft (30) and
check that the needle bearing turns normally. Place
snap ring (31).
21. Lubricate a new seal (40) and fit it on pin (41). Enter
the pin through the chamfered port of the intermediate housing (19).
Reminder
- To limit axial clearance of the pin, it is recommended to carry out shimming with a tolerance of
0.1 mm to 0.6 mm.
Shimming
- On the pin, place an approximate thickness of
shim(s) (45). Fit finger (39) and partially fit pin (39).
Reassemble the link (42) and bolt (43).
- Manually evaluate the existing clearance.
Remark
- The adjustment principle consists in obtaining a
minimum clearance between the various parts.
Action
- If the clearance is outside the maximum stated
tolerance, determine a new thickness of shim(s).
After shimming, check for the correct orientation of
the finger and the link. Definitively insert pin (38), fit
and tighten Allen screw (43).
Issue 1
May 2001
6H01.8
B
A
27
37
35
36
B
X2
26
X1
19
28
F4
F3
G1
F2
29
2
F1
Fig. 6
Issue 1
May 2001
6H01.9
Adjustment (Fig. 6)
- Fit the locking stud (35), spring (36) and plug (38).
Partially tighten the plug.
- Position coupler (29) in accordance with F1, its forward
face thrust against shaft (2).
- Maintain the fork thrust against the coupler in accordance with F2. Turn the guide rod (28) in nut (25)
according to F3 so as to place in contact the oblique
face of groove G1 with locking stud (35) while simultaneously holding nut (26) against spot-faced face B of
the intermediate housing (19).
- Using a depth gauge, measure X1 between the forward
face of the guide rod and face A of the intermediate
housing (19).
- Hold the fork thrust against the coupler in accordance
with F2.
- Turn the guide rod in the nut in accordance with F4 so
as to place the other oblique face of groove G1 in
contact with the locking stud while holding nut (26) as
previously.
- Measure X2 in the same manner as X1.
- Determine the position of adjustment X using the
following formula:
X = (X1 + X2) : 2
- Provisionally position guide rod (28) to dimension X.
- Place coupler (29) in the "Creeper unit" position. Manually check for locking of the control and the clearance
between the fork and the coupler.
- If this check is satisfactory, remove unit (24), plug (37),
the spring and the locking stud.
- Grease the threads of the guide rod and the threads of
nut (26).
- Tighten the nut, previously lightly smeared with Loctite
frein filet faibe, and definitively position the guide rod
according to the previously calculated dimension X.
- Lock the nut by bending its collar into the machined
groove of the guide rod.
- Reassemble the locking mechanism. Tighten plug (37)
to a torque of 50 - 70 Nm. Refit unit (24) (see A).
Issue 1
May 2001
6H01.10
13
12
20
22
21
44
23
14
24
18
17
16
15
14
12
11
10
Fig. 7
Issue 1
May 2001
6H01.11
Final operations
42. If disassembled, insert bearing (10) on shaft (2)
using an appropriate fixture.
43. Fit circlips (8) (9) and snap ring (6).
44. Assemble supports (5) (7).
45. Engage reducer gear (20) on shaft (2).
46. Refit the crownwheel (16).
47. Position housing (44), with the cut out turned downward.
48. Assemble and tighten bolts (23) previously lightly
smeared with Loctite 241 and tighten to a torque of
10 - 14 Nm.
49. Refit unit (24) (see A).
Disassembly
32.
33.
34.
35.
Reassembly
36. Check and clean the components. Replace any
parts found to be defective.
37. Fit each sun gear (15) with both needle bearings (18)
and spacer (17) smeared with miscible grease.
38. Refit the sun gears and position the friction plates
(14). Refit pins (13) correctly turning the spot-face for
the fitting of snap ring (11).
39. Fit the snap ring.
40. Manually check the axial clearance and rotation of
each sun gear.
41. Lightly smear the faces of the reducer gear with
miscible grease and fit the friction washers (12),
with the tabs lodged in the appropriate grooves.
Issue 1
May 2001
6H01.12
D . Adjusting the control
1
7
6
4
2
3
5
Fig. 8
14
13
12
6
C
11
10
9
Fig. 9
Issue 1
May 2001
6I01
6I01.1
CONTENTS
-
General ________________________________________________
A.
B.
C.
Issue 1
May 2001
General
The 8200 tractors can be fitted either with an automatic
hook or a bracket according to the models shown in A
and depending upon the country and options.
Yokes
e : Lemoine standard yoke
f : Cramer automatic yoke
Swinging drawbars
g : standard swinging drawbars
h : swinging drawbar with roller
Hook
i
Issue 1
May 2001
6I01.3
2
2
2
4
1
2
1
i
3
2
2
d
Fig. 1
Issue 1
May 2001
Fig. 2
Fig. 3
Issue 1
May 2001
6I01.5
4
2
L
5
8
6
7
3
Fig. 4
5
8
6
7
2
4
3
B
1
Fig. 5
Issue 1
May 2001
Construction (Fig. 6)
- The automatic hook assembly comprises a main bracket
(1) fixed to the centre housing, a mobile plate (2) that
can be raised or lowered by the lift control and a
retractable hook (3) operated by a double acting hydraulic cylinder (4).
Operation (Fig. 8)
Plate lowered
- When the manual valve (1) is opened and the auxiliary
lever No. 1 (Fig. 7) located on the console is operated,
the high pressure passing through the unions (2) connected to quick-disconnect couplings A and B of the
spool valve concerned supplies the double acting cylinder (4) integral with the retractable hook (3).
- The hook can then extend and retract to connect a
trailer, depending on the position the auxiliary lever is
placed in.
Plate raised
- In this configuration, the locking safety of the retractable hook is provided when it is at maximum retraction,
with plate (2) (Fig. 6) previously raised and engaged.
- The principle is two mechanical locks located at the
rear of the main bracket. When the previously stated
conditions exist, the lock bolts enter their respective
recesses in the retractable hook and prohibit any further
movement.
On placing in the safety position, the locks must
produce a clack that is audible by the operator during
maximum retraction of the hook.
Note: During retraction of the hook, the operator in
the driving seat should check that the gear and
handbrake levers are in the neutral position. This
facilitates the coupling of a trailer.
3
Fig. 6
3
2
1
Fig. 7
Issue 1
May 2001
6I01.7
Reminder
- Periodically grease the safety lock mechanism and the
mobile plate control cable.
Fig. 8
Issue 1
May 2001
6J01.1
CONTENTS
A.
General ________________________________________________
B.
C.
Issue 1
May 2001
A . General
On 8200 tractors, the hitch comprises several components that are, depending on the options and the country:
- a hook or ball joint 3-point hitch
- two lower bars with ball joints, automatic hook or
telescopic links (depending on version)
- two levelling units
- two tube or thrust type blades
- a perforated bar
:
:
:
:
:
:
:
Special point
- For the adjustment of tube type blades, refer to Operator Instructions Book.
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Issue 1
May 2001
6J01.3
Parts list
Fig. 3
Fig. 5
Parts list
Parts list
Fig. 1
f
IMPORTANT
a
Improper positionning
of stabilizers may
cause damage. See
Operator Instruction
Book.
Fig. 2
Fig. 4
Parts list
Parts list
Fig. 6
Parts list
Issue 1
May 2001
Issue 1
May 2001
6J01.5
Remark
Preliminary operations
1. Run the engine and lower the lower bars to their
maximum using the ELC.
2. Disconnect the feed hose, remove the cylinder and
empty it of oil.
3
2
Disassembly (Fig. 7)
3. Remove the 90 union (1) fitted with its Oring.
4. Push the cylinder ram (5) until snap ring (4) is visible
in port O of the union.
5. Introduce a screwdriver in this port and while turning
the cylinder ram push the snap ring into the V-shaped
recess.
6. Remove the ram and seal (4). Drive off scraper seal
(2) and oil seal (3) (systematically discard these three
parts).
5
4
5
Reassembly
Special point
- Carefully clean all components. Replace any parts that
are scratched or bowed. In cases of seizing up or
serious scratching, replace the cylinder and ram.
7. Dry all components using compressed air.
8. Lubricate the assembly with clean transmission oil.
9. Proceed with assembly of the cylinder. Carry out
operations 3 to 6 in reverse order.
Special points
- New seals and snap rings must always be fitted.
- Use an appropriate fixture to force fit the parts
without damaging the seals.
- Fit the ram into the cylinder with care.
Fig. 7
Final operations
10. Lubricate the upper and lower pins with anti-seize
grease and refit them. Reconnect the feed hose.
11. Run the engine. Using the ELC, raise the lower hitch
bars into the high position and vice versa.
12. Check that the hitch is operating correctly and that
there are no oil leaks around either cylinder or ram.
Issue 1
May 2001
7 . POWER TAKE-OFF
Contents
7 A01
7 B01
7 C01
REMOVABLE SHAFT
7 D01
7 E01
7 F01
Issue 1
May 2001
7A01.1
CONTENTS
A.
General ________________________________________________
B.
Issue 1
May 2001
A . General
Description
The power take-off housing, fitted to the rear of the centre
housing, houses all mechanical components of the rear
power take-off on the 8200 series tractors.
The power take-off is independent of the transmission.
On tractors fitted with a Heavy Duty gearbox, the input
shaft is integral via splines with the vibration damper
fixed to the engine flywheel. It transmits the engine
speed to the power take-off multi-disc clutch via a
shaftline comprising two layshafts.
The first layshaft is linked by splines to the engine input
shaft and, at the front, to the hydraulic pump drive pinion.
The second layshaft is splined at the front on the
hydraulic pump drive pinion and at the rear on the power
take-off clutch.
On tractors fitted with an AG150 or AG250 Full Powershift
gearboxes, the engine speed is transmitted to the power
take-off clutch by a shaftline comprising four shafts.
The first shaft is likewise driven via the vibration damper
fitted to the engine flywheel. The second shaft, passing
through the gearbox, is linked to the third shaft by a
sleeve and drives the hydraulic pump drive pinion. As in
the version mentioned above, the last shaft is splined at
the front on the hydraulic pump drive pinion and at the rear
on the power take-off clutch.
Section EE
Fig. 1
Issue 1
May 2001
7A01.3
Construction
The clutch, located on the upper shaftline, is supported
by two taper roller bearings. The bearing cups are fitted
in two carriers fixed to the power take-off housing and the
bearing cones are positioned on two spans inside the
clutch housing.
The front bearing cone is force fitted on:
- the clutch unit (type "a" PTO)
- the 540 or 750 rpm pinion drive pinion (type "b" PTO)
- the spacer (type "c" PTO)
The rear bearing cone is mounted free on all types. The
bearing clearance is adjusted by means of shims placed
between the two carriers.
The lower shaftline comprises:
- A unit fixed by bolts on the rear of the centre housing,
in which a roller bearing (type "a" PTO) is fitted.
On the other types, this bearing is force fitted, preceded
by an oil deflector, in the centre housing.
- A rear bearing comprising two taper roller bearings;
their clearance is adjusted by shims placed between
the power take-off housing and the bearing.
On the type "a" power take-off, the previously stated
bearings are fitted on a sleeve integral with the power
take-off output shaft.
- A cassette seal provides oil tightness for the bearing.
Fig. 2
Issue 1
May 2001
7A01.4
B . Overall views
Type "a"
Fig. 3
Issue 1
May 2001
7A01.5
Type "b"
Fig. 4
Type "c"
Fig. 5
Issue 1
May 2001
7B01.1
CONTENTS
-
General ________________________________________________
A.
Shimming ______________________________________________
B.
Issue 1
May 2001
General
On tractors in the 8200 series, the layshaft, clutch,
bearings and driving pinion form the upper shaft line of the
rear power take-off.
The upper shaftline passes through the intermediate and
centre housings to then transmit the engine speed to the
driving pinions located in the rear housing.
The layshaft is supported at the front by a bearing block
mounted on two ball bearings housed in the bore of the
intermediate housing and at the rear by the clutch
assembly (15) in which the driving pinions are integral via
splines.
On unit (23), the cups (3) (8) are free mounted in their
respective bores. The bearing cone (7) is mounted free on
the splined part of the clutch. Depending on the type of
power take-off, the bearing cone (2) is force fitted on:
- the clutch unit (15)
- the pinion (9)
- the spacer (10)
Identification of the assemblies corresponding to the
types of power take-off available
"a" : removable shaft
"b" : jaw coupler
"c" : 1000 rpm
Issue 1
May 2001
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(27)
(28)
Circlip
Bearing cone
Bearing cup
Cover
Shims
Unit housing
Bearing cone
Bearing cup
Driving pinion
Spacer
Driving pinion(s)
Circlip
Bolt
Layshaft
Fig. 1
Fig. 2
7B01.3
Overall view
Front bearing with
Full Powershift gearbox
27
23
12
28
11
11
15
23
28
10
11
Parts list
Fig. 2
Issue 1
Fig. 1
May 2001
15
a
23
2
3
27
4
5
11
6
8
7
9
2
c
11
10
2
11
Parts list
Issue 1
May 2001
Fig. 1
Fig. 2
7B01.5
Remark
- Uncouple the power take-off housing from the centre
housing (see section 2E01) to carry out maintenance on
the following components:
- driving pinion(s)
- unit housing (6)
- cover (4)
- bearings (2) (3) and (7) (8)
11
27
Fig. 3
4
" D"
Removal
1. Remove and separate the clutch (15) and unit (23)
assembly (see section 7F01, B ).
Assembly "a" (Fig. 2 - 3)
2. Extract bearing cone (2) from the clutch unit and
remove it. Take off bolts (27), cover (4) and shim(s)
(5).
3. Take out the driving pinion (11) from unit (6).
4. Disassemble the cups (3) (8) (as required).
11
6
Fig. 4
Issue 1
May 2001
Refitting
Reminder
- If maintenance has been carried out on one of the
components stated at the beginning of this section, it is
important to carry out shimming of the bearings (2) (3)
and (7) (8) (see B).
Assembly "a"
8. If disassembled, place cups (3) and (8) in cover (4)
and unit (6) respectively.
9. Refit the driving pinion (11), the shim(s) (5) (if
adjustment is not necessary), the cover (4) and the
bolts (27) on unit (6).
10. Using a press and an appropriate fixture, insert
bearing cone (2) into the clutch housing.
Assembly "b"
11. If disassembled, place cups (3) and (8) in cover (4)
and unit (6) respectively.
12. Position pinion (11) in unit (6), the long offset "D"turned
to face cover (4) (Fig. 1 - 4).
13. Refit the shim(s) (5) (if adjustment is not necessary),
the cover (4) and bolts (27) on unit (6).
14. Using a press and an appropriate fixture, insert
bearing cone (2) in pinion (9).
Assembly "c"
- In this type of assembly, assemble the components
using the assembly principle used in the b type
assembly.
15. Reassemble and refit clutch (15) and unit (23) assembly (see section 7F01, B).
Issue 1
May 2001
7B01.7
B . Shimming
Preparation for shimming
J1 = 0 / 0,10mm
23
Shimming (Fig. 5 6)
J1 = 0 / 0,10mm
4
27
14
6
b
23
J1 = 0 / 0,10mm
14
10
14
23
27
Fig. 6
Fig. 5
Issue 1
May 2001
7C01.1
CONTENTS
-
General ________________________________________________
A.
B.
C.
D.
E.
Shimming ______________________________________________
F.
Issue 1
May 2001
General
On 8200 series tractors, the driven pinions (7) (18) are
fitted on the power take-off shaft located on the lower
rear housing.
These pinions are constantly engaged with the driving
pinion(s) (depending on version) and driven by the upper
shaftline where the engine speed is transmitted by the
power take-off clutch.
At the front, the removable shaft (12) turns on a roller
bearing (24) inserted into a fixed bearing block on the rear
of the centre housing.
At the rear, the shaft is supported by a splined sleeve (5)
that turns in taper roller bearings.
Washer (4) is integral via a tab with sleeve (5) which itself
is integral with shaft (12) via splines. The sleeve is
serrated all around its outside edge and transmits speed
information to the onboard electronic system via the
sensor located on the right-hand side of the rear housing.
An oil splash from the centre housing along with a central
port and radial channels drilled in the shaft provide
lubrication of the:
- friction washers (10)
- taper roller bearings.
In the 540 rpm or 750 rpm (optional) configurations, the
shaft (12) is integral with pinion (7) via splines. Pinion (18)
is an idling gear that runs on the hubs of pinion (7) and
sleeve (5).
In the 1000 rpm configuration, the shaft (12) is integral
with pinion (18) via splines. Pinion (7) is an idling gear that
runs on the hub of pinion (18) and the front bearing.
The oil tightness of the rear bearing is provided by
cassette seal (14) and Oring (15).
Bearing clearance is adjusted by shim(s) (23) placed
between the rear housing and bearing (22).
Issue 1
May 2001
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Front bearing
Bearing cup
Bearing cone
Castellated washer
Serrated sleeve
Snap ring
540 or 750 rpm driven pinion
Bearing cone
Protector
Friction washer
Bolt
Shaft
Bolt
Cassette seal
O'ring
Circlip
Circlip
1000 rpm driven pinion
O'ring
Friction washer
Bearing cup
Bearing
Shim(s)
Roller bearing
Fig. 1
Fig. 2
7C01.3
Overall view
10
2
3
4
11
23
22
21
8
12
24
20
10
18
17
16
15
14
13
19
540 / 750
1000
Parts list
Issue 1
Fig. 2
Fig. 1
May 2001
7C01.4
Exploded view
540 / 750
1
24
1000
7
10
18
10
11
20
17
2
3
4
8
21
16
14
23
15
22
13
12
6
Parts list
5
19
12
Fig. 1
Fig. 2
Issue 1
May 2001
Disassembly
1. Uncouple the power take-off housing from the centre
housing (see section 2E01).
2. Recover the friction washer (20).
3. Remove snap ring (6) and support driven pinions (7)
(18).
4. Pull shaft (12). Remove the pinions. Recover the
friction washer (10).
7C01.5
Reassembly
14. Clean and check the components. Replace any
parts found to be defective.
15. If disassembled, position bearing (24) using an
appropriate insertion drift, with the rounded cage
holding the rollers turned to face the forward end of
shaft (12).
16. Refit bearing block (1). Fit and tighten bolts (11) with
their threads lightly smeared with Loctite 241 and
tighten to a torque of 27 - 35 Nm. Carry out operation
9 A.
17. Couple the power take-off housing to the centre
housing (see section 2E01).
Reassembly
5. Clean and check the components. Replace any
parts found to be defective. Check that the oil
channels in shaft (12) are not obstructed. Check that
the interior of sleeve (5) is clean and free of burrs.
Lubricate and fit a new Oring (19).
6. Assemble driven pinions (7) (18) and friction washers (10) smeared with miscible grease and placed
according to the overall view. Maintain the pinions
inserted and thrust against sleeve (5).
7. Engage shaft (12) against the shoulder of the sleeve.
8. Fit snap ring (6).
9. Smear friction washer (20) with miscible grease and
apply it against bearing (24).
10. Couple the PTO housing to the centre housing (see
section 2E01).
Issue 1
May 2001
Reassembly
Special point
- If the power take-off housing, bearing block (22), taper
roller bearings (2) (3) (8) (21) or castellated washer (4)
had to be replaced, the bearings must be shimmed
again (see E).
23. Clean and check the components. Replace any
parts found to be defective. Check that the oil
channels in shaft (12) are not obstructed.
24. On sleeve (5), place circlip (16), bearing cones (3) (8)
separated by castellated washer (4). Fit circlip (17).
25. Refit cup (2), sleeve (5) assembled, cup (21), bearing
block (22) with shim(s) (23) according to the method
described in operations 39, 41 and 42 D, as well as,
after lubrication, Orings (15) (19). Fit and tighten
bolts (13) to a torque of 72 - 96 Nm.
26. Refit the 540 - 1000 rpm or 750 - 1000 rpm pinions
and shaft (12) (see A).
27. Couple the power take-off to the centre housing (see
section 2E01).
28. Refit the sensor, Oring and bolt
Issue 1
May 2001
7C01.7
Refitting
31. Check that the interior of sleeve (5) is clean and free
of burrs. Lubricate and fit a new Oring.
32. Check that the channel in the shaft is not obstructed.
Clean and then engage the shaft thrust up against the
shoulder on sleeve (5). Refit snap ring (6).
33. Remove the trolley jack.
Reassembly
37. Clean and check the components. Replace any
parts found to be defective.
38. If necessary, before fitting seal (14), see note E.
Lightly smear the external diameter of seal (14) with
Loctite 542. Using a press and tool ref. 3378115M1,
insert the cassette seal into the bearing block (22)
with its lip turned to face taper roller bearing (8) (21).
39. Screw two diametrically opposed threaded rods (
10 x 150, length approximately 50 mm) in place of
bolts (13). Check that sleeve (5) is free from burrs.
Lubricate the internal diameter of cassette seal (14)
with transmission oil. Refit the bearing block fitted
with lubricated seal (15) and the shims (23) removed
during disassembly.
Issue 1
May 2001
7C01.8
E . Shimming (Fig. 3 - 4)
Note: Carry out the shimming of bearings (2) (3) and
(8) (21) before fitting seal (14).
44. Using a depth gauge, measure dimension A on the
power take-off housing.
45. Place the sleeve prepared in operation 24, the bearing cups and bearing block (22) thrust against a
locally manufactured support.
46. With the help of an operator, apply strong continuous
pressure around the rim of the cup (2). At the same
time, alternately turn the sleeve left and right in order
to correctly seat the bearing cones in their cups.
Measure dimension B at two opposing points. Take
the average of the two measurements.
47. Apply the formula B - A. Place a thickness of shim(s)
(23) in order to provide a clearance of:
J1 = 0.05 mm to 0.15 mm.
2
B
22
Issue 1
21
21
J1 = 0,05
/ 0,15
23
Fig. 3
May 2001
Fig. 4
7C01.9
F . Service Tools
Tool available in the AGCO network
- 3378115M1 - Insertion tool for cassette seal (14) on
power take-off bearing block (Fig. 5).
Fig. 5
Issue 1
May 2001
7D01.1
SOMMAIRE
-
General ________________________________________________
A.
C.
Shimming ______________________________________________
D.
E.
F.
B.
Issue 1
May 2001
General
On tractors in the 8200 series, the driven pinions (7) (18)
are fitted on the power take-off shaft located at the lower
part of the rear housing.
These pinions are constantly engaged with the driving
pinions driven by the upper shaftline where the engine
speed is transmitted via the power take-off clutch.
The power take-off shaft is supported at the front by a
roller bearing (24) that is force fitted into the centre
housing. It is free fitted in bearing cones (3) and (8) of the
rear bearing block (22).
Hub (11) of the coupler is integral with shaft (12) via
splines. The pinions (7) (18) drive the shaft when coupler
(10) is moved either forwards (540 or 750 rpm), or
rearward (1000 rpm). When one of the pinions (7) (18)
transmits movement to the lower layshaft, the other
pinion is passive and idles on its shaft.
A fork (31) fitted on pin (28) allows selection of the
required speed (540 - 750 - or 1000 rpm). This fork may
be controlled by an external lever located on the righthand side of the housing or via a cable operated by a lever
placed inside the cab.
The oil tightness of the rear bearing block is ensured by
cassette seal (14) and Oring (15).
Bearing clearance is adjusted by shim(s) (23) inserted
between the rear housing and bearing block (22).
The castellated washer (4), via its rotation, transmits
information to the sensor (output speed of shaft (12)) and
equally serves as a spacer for bearing cones (3) (8).
Locking ring
Circlip
Bearing cone
Castellated washer
Interchangeable end piece (shaft with disc)
Bolt
540 or 750 rpm driven pinion
Bearing cone
Protector
Coupler
Hub
Shaft
Bolt
Cassette seal
Oring
Circlip
Circlip
1000 rpm driven pinion
Bearing cup
Splined washer
Bearing cup
Bearing block
Shim(s)
Roller bearing
Oil deflector
Locking ring
Oring
Pin
Pads
Set screw
Fork
Oring
Control link
Fig. 1
Bolt
Locating pin
Fig. 2
Plug
Issue 1
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
May 2001
A : External control
B : Internal control via cable and lever
7D01.3
Overall view
26
25
24
19
20
11
10
540 / 750
18
17
21
16
23
14
12
15
13
22
33
34
1000
A
FRONT
1000
REAR
540 / 750
1000
FRONT
540 / 750
REAR
33
B
34
27
28
29
30
31
29
32
33
Parts list
27
36
Fig. 2
Fig. 1
Issue 1
May 2001
7D01.4
Exploded view
33
32
25
28
24
2
31
20
30
27
29
10
7
26
11
540 / 750
36
1
18
1000
17
19
3
4
8
13
21
12
16
35
14
23
15
22
Parts list
Issue 1
May 2001
Fig. 1
Fig. 2
7D01.5
Special points
- The removal of the power take-off housing is necessary
for all maintenance concerning the lower layshaft line,
except for the disassembly of the interchangeable shaft
(5).
- The centre housing must be drained during maintenance and refilled afterwards.
7
18
Preliminary operation
Fig. 3
11. Lubricate the ring (1) of pinion (18) (Fig. 3). Slide the
pinion on to shaft (12).
12. Assemble the locking ring (1).
13. Assemble the hub assembly (11), coupler (10) and
fork (31) assembly with the pads (29) smeared with
miscible grease. Fit new Orings (27) (32) on pin (28)
and slide it through the bores of the power take-off
housing.
14. Position the fork. Fit and tighten the set screw (30)
previously lightly smeared with Loctite 241. Fit ring
(26).
15. Lubricate ring (1) of pinion (7) (Fig. 3).
16. Slide pinion (7) on to shaft (12). Refit the clutch (15)
and unit (23) assembly (see section 7F01 B).
Place washer (20) and fit circlip (2).
17. Manually check the rotation of the mechanical assemblies.
18. Assemble link (33). Tighten bolt (34).
19. Using either the external control or the control located inside the cab, check that coupler (10) engages correctly on the 540 - 1000 rpm or 750 - 1000
rpm pinions.
Final operation
20. Couple the power take-off housing to the centre
housing (see section 2E01).
Issue 1
May 2001
Reassembly
Special point
- If the power take-off housing, bearing block (22),
bearings (3) (19) (8) (21) or castellated washer (4) has
been replaced, carry out shimming of the bearings (see
C).
29. Clean and check the components. Replace any
parts found to be defective. Check that the oil
channels in shaft (12) are not obstructed.
30. Before assembly of seal (14), see note C.
Lightly smear the external diameter of the seal with
Loctite 542. Using a press and tool, ref. 3378115M1
(see F), insert the cassette seal into bearing block
(22) with the lip turned to face bearing cone (8).
Issue 1
May 2001
7D01.7
C . Shimming (Fig. 4 5)
Note: The shimming of bearings (3) (19) (8) (21) must
be carried out before fitting seal (14).
19
B
22
Fig. 4
J1 = 0,05
/ 0,15
23
35
12
Fig. 5
Fig. 6
Issue 1
May 2001
On link B (Fig. 8)
Fig. 7
48. Turn link B towards the front of the tractor in the 1000
rpm position.
49. Screw yoke (9) flush with the threaded part of cable
(6).
50. Fit yoke (9) on link B using clip (10). Tighten nut (11).
51. Adjust the threaded sheath end (12) on bracket (8)
using nut (13), taking care that link B does not move.
52. Tighten nut (14) while checking that the cable is not
constrained.
53. Check the operation of the control lever in the
position 540 or 750 rpm.
2
7
4
3
5
12
14
13
11
10
Fig. 8
Issue 1
May 2001
7D01.9
F . Service tools
Tool available in the AGCO network
- 3378115M1 Tool for fitting cassette seal (14) on
the power take-off bearing block (Fig. 9).
Fig. 9
Issue 1
May 2001
7E01.1
CONTENTS
-
General ________________________________________________
A.
C.
Shimming ______________________________________________
D.
E.
B.
Issue 1
May 2001
General
Certain types of tractors in the 8200 series may be fitted
with a 1000 rpm power take-off.
The driven pinion (18) is fitted on the power take-off shaft
located at the lower part of the rear housing.
This pinion is constantly engaged with the driving pinion
driven by the upper shaft line where the engine speed is
transmitted via the power take-off clutch.
The power take-off shaft is supported at the front by a
roller bearing (24) that is force fitted into the centre
housing. It is mounted free in the bearing cones (3) (8) of
the rear bearing block (22).
The hub (11) is integral with shaft (12) via splines.
Rotation is transmitted to the driven pinion (18) via the
coupler (10). This coupler is held in position permanently
by circlip (2).
The oil tightness of the rear block is provided by cassette
seal (14) and Oring (15).
The clearance of the bearings is adjusted by shim(s) (23)
inserted between the rear housing and bearing block (22).
During rotation, the serrated washer (4) transmits information to the output shaft speed sensor (12) and equally
serves as a spacer between bearing cones (3) and (8).
Lubrication
Lubrication is provided by the transmission oil. The
projected oil is held in deflector (25) and lubricates roller
bearing (24) and bearing cones (3) (19) (8) (21) via the
intermediary of shaft (12) that contains an axial channel
and radial drilled ports.
Issue 1
May 2001
(1)
(2)
(3)
(4)
(5)
(6)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(21)
(22)
(23)
(24)
(25)
(26)
(35)
(36)
Locking ring
Circlip
Bearing cone
Castellated washer
Interchangeable end-piece (shaft with disc)
Bolt
Bearing cone
Protector
Coupler
Hub
Shaft
Bolt
Cassette seal
Oring
Circlip
Circlip
1000 rpm driven pinion
Bearing cup
Bearing cup
Bearing block
Shim(s)
Roller bearing
Oil deflector
Locking ring
Locating pin
Plugs
Fig. 1
Fig. 2
7E01.3
Overall view
25
24
19
26
11
10
18
17
21
16
23
14
12
15
13
22
1000
36
Parts list
Issue 1
Fig. 2
Fig. 1
May 2001
7E01.4
Exploded view
25
24
2
26
11
10
1
18
1000
36
17
19
3
4
8
13
21
12
16
35
14
23
15
22
Parts list
Issue 1
May 2001
Fig. 1
Fig. 2
7E01.5
Special points
- The removal of the power take-off housing is necessary
for all maintenance operations on the lower shaftline,
apart from the disassembly of the interchangeable
shaft (5).
- The centre housing must be drained and then brought
back up to level after the maintenance operation.
18
Fig. 3
Preliminary operation
Final operation
13. Couple the power take-off housing to the centre
housing (see section 2E01).
Issue 1
May 2001
Reassembly
Special point
- If replacement is necessary of the power take-off
housing, bearing block (22), bearings (3) (19) (8) (21) or
castellated washer (4), carry out shimming of the
bearings (see C).
22. Clean and check the components. Replace any
parts found to be defective. Check that the oil
channels in shaft (12) are not obstructed.
23. Before fitting seal (14), see note C. Lightly smear
the external diameter of the seal with Loctite 542.
Using a press and tool, ref. 3378115M1 (see F),
insert the cassette seal in bearing block (22) with its
lip turned to face bearing cone (8).
Issue 1
May 2001
7E01.7
C . Shimming (Figs. 4 - 5)
Note: The shimming of bearings (3) (19) (8) (21) must
be carried out before fitting seal (14).
32. Using a depth gauge, measure dimension A on the
power take-off housing.
33. On shaft (12), fit: bearing block (22), circlip (16), cup
(21), cone (8), castellated washer (4), cone (3) and
circlip (17).
34. Place the shaft and bearing block assembly (22) to
thrust against a locally manufactured fixture. Using
another operator, apply strong pressure around the
rim of cup (19) in a sustained manner. At the same
time turn the shaft alternately left and right in order
to correctly seat the bearings in their cups. Measure
dimension B at two diametrically opposed points.
Calculate the average of the two measurements.
35. Use the formula: B - A.
Place a thickness of shims (23) to obtain a clearance of:
J1 = 0.05 mm to 0.15 mm
19
B
22
Fig. 4
J1 = 0,05 /
0, 15
23
35
12
Fig. 6
Fig. 5
Issue 1
May 2001
E . Service tools
Tool available in the AGCO network
- 3378115M1 - Tool for inserting cassette seal (14) on
the power take-off shaft (Fig. 7)
Fig. 7
Issue 1
May 2001
7F01.1
CONTENTS
A.
General ________________________________________________
B.
C.
D.
11
Issue 1
May 2001
Issue 1
May 2001
7F01.3
Operation
Clutched position
- The clutch is supplied via the power take-off proportional
solenoid valve by the 17 bar hydraulic circuit located on
the right-hand side cover and by an external pipe connected to the rear housing of the power take-off.
- Oil enters unit (6) via channels a, c and chamber b (Fig.
2). It pushes piston (19) that then compresses clutch
plates (4) against the intermediary plates (3). The latter
are integral with cover (2) via tabs and bolts (16). Clutch
plates (4) are integral with hub (1) via splines. The
movement is transmitted to driving pinions (11) (9) (Fig.
4 - 5), depending on the type of power take-off, via shaft
(28) housed in hub (1).
- In the clutched position, the brake piston (1) of the
power take-off located in the centre housing is at rest
and this frees clutch unit (6) (Fig. 1) allowing the 540rpm 1000 rpm pinions to turn freely. When the clutch
is engaged, oil from the lubricating circuit coming from
channel d cools and lubricates the clutch plates (Fig. 2).
1
8
19
6
Fig. 1
Issue 1
May 2001
Drive hub
Cover
Intermediate plates
Clutch plates
Progressivity washer
Clutch housing
Valve
Spring
Oring
Sleeve
Bolt
Chamfered washer
Ball bearing
Circlip
Clutch assembly
Bolt
Spring seat
Oring
Piston
Support
Oring
Seal rings
Intermediate shaft
Reducer
Threaded plug
Deflector
Fig. 2
Fig. 3
Issue 1
May 2001
7F01.5
Overall view
Exploded view
15
30
10
3
4
11
1
12
31
13
14
17
8
20
5
19
18
21
10
29
30
6
28
11
12
13
14
17
16
31
19
18
20
21
29
22
15
Parts list
Issue 1
Fig. 3
22
Fig. 2
May 2001
16
Parts list
Fig. 2
Fig. 3
7F01.6
16 0,1 mm
27
15
15
22
23
27
25
23
28
11
12
24
20
10
18
26
10
Fig. 4
15
23
27
Fig. 6
16 0,1mm
15
22
23
27
25
28
11
20
24
Fig. 5
26
Fig. 7
Issue 1
May 2001
7F01.7
Preliminary operation
1. Remove the power take-off housing (see section
2E01).
Remove the sensor located on the upper right-hand
side of the power take-off housing.
22
Removal
Power take-off with removable shaft (Fig. 4)
2. Recover the friction washer (20).
3. Take off snap ring (6), support the driven pinions
(7) (18).
Pull on shaft (12). Remove the pinions. Recover the
friction washers (10).
4. Take out bolts (27).
5. Remove the clutch (15) and unit (23) assembly.
Power take-off with jaw coupler (Fig. 5)
6. Take off circlip (2) and splined washer (20).
7. Remove bolts (27).
8. Disengage the clutch (15), unit (23) and pinion (7)
assembly.
Fig. 8
25
26
24
S
Fig. 9
Issue 1
May 2001
Special point
- If disassembled, using an appropriate insertion drift,
position ring (5) (Fig. 10) according to the dimension 16
mm 0.1 mm measured between the thrust face of the
power take-off housing and the end of ring (5) (Fig. 4 or
5) and in such a manner that the machined groove on
the outside of the ring matches the 17 bar channel of the
power take-off housing.
Reassembling assembly (15) (23)
13. Place bolts (27) on unit (23). Assemble clutch (15)
and unit (23) (Fig. 6 or 7).
14. Fit a new Belleville washer (24) respecting its assembly direction, then fit washer (25) turning the
countersinking towards snap ring (26).
15. Slide the new snap ring (a new snap ring must be
fitted) on sleeve (10) opening its diameter to the
minimum.
16. Compress the washer as in operation 10. Fit and
correctly position the snap ring in the countersunk
washer (25).
17. Place the seal rings (22) in their grooves and hook
their ends (Fig. 8). After assembly, check that they
rotate freely.
Refitting
Remark
- In order to facilitate the refitting of the clutch assembly,
tilt the power take-off housing, with the inside face
turned upwards.
18. Lubricate the seal rings with transmission oil
Power take-off with removable shaft (Fig. 4)
19. Lightly smear the threads of bolts (27) with Loctite
242 or equivalent and tighten them to a torque of 50
- 70 Nm. Assemble the clutch (15) and unit (23)
assembly.
20. Refit the driven pinions (7) (18) with friction washers
(10) lightly smeared with miscible grease.
21. Engage shaft (12) in the rear bearing block and
pinions (7) (18). Reassemble snap ring (6).
22. Position friction washer (20), previously lightly
smeared with miscible grease.
Issue 1
May 2001
Fig. 10
Power take-off with jaw coupler (Fig. 5)
23. With the help of another operator, refit the assembly
(clutch (15) and unit (23) accompanied by pinion (7)).
24. Tighten bolts (27) to a torque of 50 - 70 Nm.
25. Place washer (20) and assemble circlip (2). On each
type of power take-off, manually check the rotation
of the mechanical assembly.
Final operations
26. Lightly smear the threads of the upper sensor with
Loctite 577 (Sensor Sealing or equivalent). Assemble and adjust the sensor:
- screw the sensor fully home without forcing it until
it touches the driving pinion,
- unscrew the sensor by turn
- moderately tighten the lock nut.
27. Couple the power take-off housing to the centre
housing (see section 2E01).
Test the clutch and its brake.
7F01.9
28. Remove and separate the clutch (15) and unit (23)
(see B).
Disassembly
11
12
29. Tighten unit (6) in a vice fitted with soft jaw protectors.
30. Take out bolts (16). Separate the unit from the cover (2).
Remove clutch plates (4) and intermediate plates (3).
31. Using a locally manufactured tool (see D), hold the
hub (1). Take out bolts (11) and washer (12). Release
spring (8) (Fig. 11). Remove the tool.
32. Remove the drive hub (1), spring seat (17), spring (8),
support (20) and progressivity washer (5).
33. Where necessary, take off circlip (14) and extract
bearing (13).
34. Using a compressed air jet, drive out piston (19) and
take off the Orings (9) (18) (21).
Fig. 11
Reassembly
Remarks
- Valve (7) is crimped in unit (6). The restrictor (29) is
placed in sleeve (10). The bearing cone E is force fitted
(Fig. 2). The sleeve (10), previously lightly smeared
with Loctite 648, is fitted by press.
- If disassembly was necessary, on reassembly check
that the 17 bar and lubrication channels are not obstructed by Loctite. Threaded plug (30) is lightly smeared
with Loctite 542 or equivalent.
35. Clean and check the components. Replace any
parts found to be defective.
36. Replace and lubricate the Orings (9) (18) (21).
37. Lubricate sleeve (10) and piston (19) and insert it in
unit (6) by tapping it moderately around the rim with
a plastic hammer.
38. If disassembled, insert bearing (13) in hub (1). Fit
circlip (14).
39. Refit progressivity washer (5) in accordance with the
overall view, support (20), spring (8), spring seat (17)
and drive hub (1).
Issue 1
May 2001
V
Fig. 12
Final operations
44. Reconstitute and refit the clutch assembly (15) (23)
(see B).
45. Couple the power take-off housing to the centre
housing (see section 2E01).
Issue 1
May 2001
7F01.11
D . Service tools
Tool available in the AGCO network
- 3378135M1 - Belleville washer (24) compression
sleeve (Fig. 13).
Fig. 13
+ 0,2
146,25 -
21
170
25
= =
170
1 x 45
64
58
+ 0,5
0
92
M6
M6
Fig. 14
Issue 1
May 2001
8 . FRONT AXLE
Contents
8 A01
8 B01
8 B02
8 B03
8 C01
DANA DIFFERENTIAL
8 C02
ZF DIFFERENTIAL
8 C03
CARRARO DIFFERENTIAL
8 D01
2 WD FRONT AXLE
8 E01
STEERING COLUMN
8 F01
8 F02
8 F03
8 G01
4WD CLUTCH
8 G02
CARRARO SUSPENSION
8 I01
CARRARO TROUBLESHOOTING
Issue 2
May 2002
8A01.1
CONTENTS
A. General description _________________________________________
14
Issue 2
May 2002
8A01.2
A. General description
The axle described in this manual, designed and manufactured following the customers requests, consists of
a beam casing, housing the differential in the middle and
a wheel hub unit at each end.
The differential, type Limited Slip, is supported by two
bearings mounted on a suitable structure allowing the
bevel gear set to be adjusted.
The ring bevel gear is adjusted by means of two ring nuts
located opposite each other.
The position of the bevel pinion, supported by two
bearings, is adjusted by inserting adjusting shims.
The wheel hubs containing the epicyclic reduction gears
are supported by two tapered roller bearings and are
powered by a hydraulically-operated steering unit.
The axle is equipped with hydropneumatic shock-absorbing suspension system (Carraro patent), electronically controlled, ensuring the constant contact of the
tyres with the ground in any operating conditions.
Issue 2
May 2002
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Fig. 1
8A01.3
Issue 2
May 2002
Parts list
Fig. 1
Issue 2
May 2002
8A01.5
Overall dimensions
All values given in the following table are in millimeters.
A = 2145
F = 335
K = 260 45
B = 548
G = M22 x 1.5
L = 66
C = 380
H = 454
M = 160
D = 280.8
I = 90
N = 348
E = 1900
J = 183
O = 508
A
.
B
.
E
.
G
.3 1
8
9 9
0 9
1
.4 2
1 9
H
1 2
9 8
. 7
9
2
I
7 3
6
. 8
4
9
L
2 .3 7
1 1
2
K
J
I
.
6 .8 1
8 2
6
N
.
O
Fig. 2
Issue 2
May 2002
8A01.6
The product identification
Part list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Axle type
Carraro S/N
Carraro N
Customer reference
Total ratio
Input rotation
Differential type
Differential oil type
Differential oil quantity
Epicyclic reduction gear oil type
Epicyclic reduction gear oil quantity
10
11
Fig. 3
Issue 2
May 2002
8A01.7
Technical features
Axle model
20.29 S
20.43 S
Tractor
8210/40
8250
DESCRIPTION
Bevel gear reduction
Epicyclic reduction
Total reduction
Dry weight
Input rotation
Differential type
Steering angle
Toe in
Oil specification
VALUES
20.29 S
20.43 S
3,00 / 1
3,00 / 1
6,923 / 1
6,923 / 1
20,769 / 1
20,769 / 1
596 kg
616 kg
Reverse clock wise
With multidisc clutch in oil bath hydraulically
control
O
Maxi 55 -2
O
A -2
SAE 85W- 140 EP
To comply
API GL4 GL5
respectively
MIL-L-2105
and
MIL-L-2105D
8,5 Liters
1,3 + 1,3 liters
1,3 + 1,3 liters
20 bar
POLYMER 400/L
DIN = KHER1R
ISO-I-XMR-XM2
0,18+0,23 mm
P = 9,2 + 13,7 daN
T = (P+9,2) + (P+10,7) daN
Issue 2
May 2002
8A01.8
A1
B2
A1
B1
B1
B1
B1
Fig. 4
A1 = Loctite 510
B2 = Loctite 270
A2 = Loctite 573
C1 = Loctite 405
A3 = Loctite 518
C2 = Loctite 496
B1 = Loctite 542
C3 = Loctite 638
Issue 2
May 2002
8A01.9
Tightening torques
All tightening torques are referenced in the following
table.
Tightening torques for 20.29 Sand 20.43 S(Fig.5 - 6)
NR.
T HREAD
DESCRIPTION
Nm
M18x69
70
M10x50
79
M14x65
230
Magnetic plug
M30x2
60
M8x20
25
M10x25
10
M10x30
70
Oil breather
M10x1
10
M20x1.5
220
10
M14x35
190
11
M24x1.5
60
12
M16
150
13
M10x30
60
14
Greaser
M6x1
15
Ball joint
16
M12x45
120
17
M10x60
57
18
M24x10
250
19
M14x120
190
20
M4x12
21
M8x25
13
22
M14x75
266
23
M12x33
169
24
M10x35
60
25
M14x120
190
26
M14x100
190
27
Greaser
M6x1
28
M12x55
169
300
Issue 2
May 2002
8A01.10
2
3
4
5
B
7
6
11
10
12
13
14
F
15
18
16
17
Fig. 5
Issue 2
May 2002
8A01.11
22
19
20
21
Sez.A.A
24
Sez.B.B
23
Sez.C.C
25
26
Sez.D.D
28
Sez.F.F
Sez.E.E
27
Fig. 6
Issue 2
May 2002
8A01.12
Filling and checks
Routine checks
Specific description
Differential oil filling and plug
level
Oil breather
Fill/drain and level plug of
epicyclic reduction gear oil
Differential oil drain plug
Greasing points
Position
1
2
3
4
5
2
1
5
5
Fig. 7
Issue 2
May 2002
8A01.13
General checks
1. Before draining the oil, loosen the breather to release
possible internal pressure, then tighten the plug with
a torque wrench to the prescribed torque (see A)
(Fig.8)
Drain the oil from the appropriate plug, then tighten the
plug with a torque wrench to the prescribed torque
(see section A01 A).
2. Before draining the oil, always loosen the breather to
release possible internal pressure.
Check oil level and top up if necessary (Fig.9)
Tighten the plug with a torque wrench to the prescribed torque (see A).
3. Before draining the oil, position the wheel hub so that
the filer cap is in the highest point, then loosen the plug
to release possible internal pressure.
Position the wheel hub so that the filer cap is on the
centre line of the horizontal axis (Fig.10)
Check oil level and top up if necessary.
Tighten the plug with a torque wrench to the prescribed torque (see A).
Fig. 8
Fig. 9
Fig. 10
Issue 2
May 2002
8A01.14
B. Safety instructions
Important
Before proceeding with any operations please read this
chapter very carefully
Safety precautions
- Correct use and repair of axles and of their components
is very important for safety and reliability.
- Recommendations and all described procedures given
in this manual have been experimented and hence are
effective operational methods. Please follow every
procedure. Use the text as well as the illustrations.
- Certain procedures show use of special tools, designed
so that the operations can be carried out in a clear and
correct manner.
- Special tools must be used when a particular operation
is being carried out.
- It is impossible to advice every working method or
know all possible methodologies for carrying it out or to
predict risky consequences of each operation. Hence,
performing procedures or using instruments which
have not been advised could be dangerous for the
operator/mechanic as well as the vehicle.
Danger : Safety goggles must be worn while carrying out every assembling or disassembling operations.
Issue 2
May 2002
8A01.15
- Risk of fire due to the solvents used and to the oil in the
axle.
Warning :
- Keep off any heat sources from the working area.
- When solvents or paint removers are used, they
should be removed with soap and water, before
welding.
- Remove any containers of solvent, paint remover
or any other inflammable products from the working area.
Issue 2
May 2002
8B01.1
CONTENTS
-
General ________________________________________________
A.
B.
C.
D.
10
E.
12
F.
12
G.
15
H.
17
Issue 1
May 2001
General
Types of final drive unit available according
to tractor type:
- 8210 - 8220 tractors
. Dana final drive unit (AG 155H front axle)
- 8240 tractors
. Dana final drive unit (AG 155H front axle or optional AG
200H)
- 8250 and 8260 tractors
. Dana final drive unit (AG 200H front axle)
The 8270 and 8280 tractors are fitted with a ZF front axle
with final drive unit of the same type (see section 8B02).
A plate riveted on the axle housing indicates the type and
serial number.
The final drive unit assembly comprises a swivel housing (5) that is articulated on the front axle housing via two
swivel pins (21). The wheel hub (3) turns on two taper
roller bearings whose cups (25) are force fitted in the hub.
The bearing cones (24) are likewise force fitted.
The taper roller bearings (24) (25) are not adjustable. The
parts are produced with machined tolerances that require
neither shimming nor adjustment.
The movement from the differential is transmitted to the
wheel hub via the universal drive shaft assembly (14),
the sun gear (39), the planetary gears (42) and crownwheel
(31). The crownwheel is retained on the crownwheel
carrier (28) by two snap rings (29). The splined rear end
of the sun gear (39) is inserted in the universal drive shaft
(14). The crownwheel carrier is force fitted on the swivel
housing (5). It is integral with the splines of the housing
and locked by central nut (32).
For greater efficiency, the oil seals are fitted with double
lips.
Oil tightness is ensured at the hub / housing by cassette
seal (23) and at the universal drive shaft / axle housing
by seal (16) and protection bush (17). It is ensured at the
drive unit / swivel housing by seal (22) and at the swivel
bearings in the unit and by seals (18).
Issue 1
May 2001
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(48)
(49)
(50)
(51)
(52)
Wheel stud
Locating pin
Wheel hub
Circlip
Swivel housing
Cup plug
Threaded plug
Bolt
Shim(s)
Cover
Bearing cone
Bearing cup
Front axle housing
Universal drive shaft
Bush
Seal
Protection bush
Seal
Grease nipple
Cover
Swivel pin
Seal
Cassette seal
Bearing cone
Bearing cup
Plug
Seal
Crownwheel carrier
Snap ring
Bushes
Crownwheel
Nut
Stop
Washer
Circlip
Planetary carrier
Friction washers
Stop
Sun gear
Planetary gear pin
Needles
Planetary gear
Bolt
Set screw
Nut
Compound needle bearings
Oring
Countersunk screw
Fig. 1
Fig. 2
Fig. 3
Fig. 4
8B01.3
Overall view
AG155H
AG200H
10
11
12
13
14
15
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
40
42
50
26
27
51
52
43
42
41
40
39
37
38
36
35
34
33
32
31
Parts list
Fig. 2
Issue 1
Fig. 3
Fig. 4
Fig. 1
May 2001
Parts list
Fig. 1
Fig. 3
Fig. 4
Fig. 2
8B01.4
Exploded view
23
1
AG 155H
25
24
19
29
10
28
9
49
48
29
24
30
32
26
12
22
31
25
11
27
4
18
2
37
40
21
41
13
42
33
37
38
34
15
16
36
35
43
39
17
23
21
3
51
18
AG 200H
24
19
25
11
29
24
12
25
28
29
20
8
31
32
4
40
42
34
14
35
50
39
52
38
36
26
27
Fig. 3
Parts list
Fig. 1
Issue 1
Fig. 2
Fig. 4
May 2001
8B01.5
42
39
31
3
AG 155H
36
28
41
32
24
24
23
25
25
36
50
42
39
31
51
35
34
22
21
14
13
AG 200H
Parts list
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Issue 1
May 2001
Issue 1
May 2001
8B01.7
Preliminary operations
1. Chock the rear wheels. Put the handbrake on.
Reminder
- The 4 WD clutch is mechanically engaged when
the tractor is stationary and the engine turned off.
Raise both front wheels in order to freely turn the
hub of the wheel concerned.
2. Position axle stands.
3. Take off the wheel concerned.
4. Drain the final drive unit.
Fig. 5
32
Fig. 6
Issue 1
May 2001
28
31
Fig. 7
28
31
3
Fig. 8
40
42
36
42
Fig. 9
Issue 1
36
May 2001
Fig. 10
40
8B01.9
Final operations
41. Turn the hub of the wheel in order to place the filler
plug in the horizontal axis of the final drive unit. The
same port is used for both filling and checking the oil
level of the drive unit.
Screw in plug (26) fitted with its seal (27).
42. Refit the wheel. Remove the axle stands and the
trolley jack.
Reminder
Wheel nut tightening torque: 640 - 680 Nm.
43. Remove the wheel chocks and take off the handbrake.
44. Carry out a road test. Check the oil tightness of the
planetary carrier mating face and the filler plug.
Issue 1
May 2001
Fig. 11
B
28
Disassembly
45. Remove the planetary carrier (36), the wheel hub (3)
and the crownwheel carrier (28) (see B).
46. If necessary, extract bearing cones (24) and remove
bearing cups (25) from the hub. If the bearings are to
be re-used, take care to match the correct cones and
cups.
Reassembly
47. Clean and inspect the components. Replace any
parts found to be defective.
Assembling bearings (24) (25)
Cups and cones re-used
48. Insert the previously carefully matched cups and
cones on their respective shoulders machined on the
wheel hub, swivel housing and crownwheel carrier.
28
3
B
Fig. 12
49. To correctly guide hub (3) onto the cassette seal (23),
insert the crownwheel carrier (28) according to the
method described in operation 50.
Issue 1
May 2001
8B01.11
G
3
28
G
Fig. 13
28
D
Fig. 14
Issue 1
May 2001
Issue 1
May 2001
Fig. . 15
8B01.13
Reassembly
71. Clean and inspect the components. Replace any
parts found to be defective.
72. If disassembled, insert bush (15) and seal (16) so as
to thrust against the shoulder of housing (13). Lubricate seal (16). Refit the universal drive shaft. Introduce a guide into the filler hole in order to align the
left-hand side drive shaft with the differential.
73. If disassembled, insert bushes (30) and a new
lubricated seal (22) thrusting against the shoulder of
housing (5).
74. Replace seals (18) turning the lips as shown in
Fig. 16.
Remark
- The turning lock stops (Fig. 17) are adjusted by set
screw (48), depending on the amount of turning
lock required. Refer to the table below. After adjustment, lock by tightening nut (49).
Dimension X
Turning lock angle
77 mm
35
63 mm
40
34 mm
50
75. If disassembled, insert cones (11) thrusting against
swivel pins (21).
76. Refit housing (5). Position the upper swivel pin (21)
in order to align the unit assembly with housing (13).
Insert the swivel pin while checking that the lip of
seal (18) is correctly positioned.
77. Fit cup (12), shim(s) (9) removed during disassembly, and cover (10). Fit and tighten bolts (8) uniformly
and alternately.
78. Fit the lower pin (21) smeared with Anti-seize grease
while checking that the lip of seal (18) is correctly
positioned. Place cup (12) and cover (20). Fit and
tighten bolts (8) (115 - 140 Nm) in the same way as
described in operation 77.
Important
- Check that the swivel pins (21) are fully in contact
with the housing.
79. Once the pins have been inserted, provisionally
remove shim(s) (9). Refit cover (10) and tighten the
bolts to a torque of 115 - 140 Nm. Inspect and if
required carry out P1 shimming.
18
21
Fig. 16
AG 155H
49
48
AG 200H
Fig. 17
Issue 1
May 2001
Fig. 18
P1
Fig. 19
Fig. 20A
11,5
F
542
Fig. 20
Issue 1
May 2001
8B01.15
Removal
88. Remove the planetary carrier (see B).
89. Remove the sun gear (39), circlip (35) and washer
(34). Extract the steering ball-joint.
90. To remove the swivel housing (5) and hub (3)
assembly, apply the same procedure as that used
for removing the pins (21)and described in F.
91. Remove the universal drive shaft (14).
Fig. 21
Fig. 22
Issue 1
May 2001
102. Press the sleeve (1) into the yoke quite deeply and
hold the spider (Fig. 23) in order to fit the circlip.
103. Assemble the other sleeves and spider in the same
way.
Refitting
104. Refit the drive shaft. Introduce a guide through the
housing filler aperture (13) to align the left-hand
drive shaft with the differential while holding the
overhanging part.
105. Replace the seals (18). Turn the lips of seals as
shown in Fig. 16. Insert the cones (11) to thrust
against swivel pins (21). Refit the swivel housing
and wheel hub assembly. Position the upper swivel
pin (21) in order to align the housing assembly with
housing (13). Insert the pin while checking that the
lip of seal (18) is correctly positioned.
106. Fit cup (12), shims (9) and cover (10). Fit and tighten
bolts (8) uniformly and alternately to a torque of
115 - 140 Nm.
107. Fit the lower swivel pin (21) smeared with AntiSeize grease and while checking that the lip of seal
(18) is correctly positioned. Place cup (12) and
cover (20). Fit and tighten bolts (8) to a torque of
115 - 140 Nm in the same way as in operation 106.
Important
- Check that swivel pin (21) is fully in contact with
housing (13).
108. Using a grease gun, grease bearings (11) (12).
109. Reassemble the steering ball-joint. Tighten the nut
to a torque of 140 - 155 Nm and lock it using a new
pin.
110. Check for the presence of friction washer (33).
Place washer (34) and circlip (35). Fit the sun gear
(39).
Special point
- washer (33) is fixed on swivel housing (5) using
Loctite 270 or its equivalent.
111. Refit the planetary carrier (see C).
Issue 1
May 2001
Fig. 23
8B01.17
H . Service tools
Tools available in the AGCO network
- MF451B - Swivel pin extractor (Fig. 24)
- MF451B-3 - Adaptor for extractor M18 (Fig. 24)
- 3378028M1 - Socket for crownwheel carrier nut
(Fig. 25)
- 3378038M1 - Crownwheel carrier extractor (Fig. 26)
Fig. 24
Fig. 25
Fig. 26
AG 155H
AG 200H
Issue 1
May 2001
A
D
Fig. 27
Fig. 28
Fig. 29
Issue 1
May 2001
8B02.1
CONTENTS
-
General ________________________________________________
A.
B.
C.
D.
E.
10
F.
11
G.
14
H.
15
I.
16
J.
17
Issue 1
May 2001
General
The 8270 and 8280 tractors are fitted with an APL 5052
front axle. A plate riveted on the rear right-hand side of the
main housing indicates the serial number and type, as
well as certain front axle specifications.
The final drive unit assembly is fitted on a swivel housing
(13) that is articulated on the main housing (1) via two
swivel pins (16). Two taper roller bearings (33) (36) and
(37) (38) fitted in the wheel hub (34) ensure the rotation
of the latter.
The movement from the front differential is transmitted
to the wheel hub via universal drive shaft (12), sun gear
(45) and crownwheel (41). The latter is retained by snap
ring (39) on planetary carrier (40).
Oil tightness is ensured at the final drive unit by a lip seal
(32) and at the universal drive shaft / main housing by
seal (9).
Oil tightness is ensured at spindle (30) and universal
drive shaft (12) by seal (28) and at swivel bearings in
housing (13) by Oring (7).
Parts list
(1)
(2)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(27)
Axle housing
Breather
Bearing cone
Bearing cup
Deflectors
Oring
Bush
Seal
Dust cover
Universal drive shaft
Swivel housing
Steering lock adjustment screw
Nut
Swivel pin
Shims
Arm
Mecanindus pin dia. 12
Mecanindus pin dia. 20
Bolt
Grease nipple
Lower cover
Bolt
45 grease nipple
Dust cover
Issue 1
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
(58)
(59)
Seal
Bush
Spindle
Bolt
Seal
Bearing cone
Wheel hub
Stud
Bearing cup
Bearing cup
Bearing cone
Snap ring
Crownwheel carrier
Crownwheel
Castellated nuts
Stop
Tab washer
Sun gear
Snap ring
Tab washer
Shim
Planetary carrier
Bolt
Planetary gear pin
Snap ring
Bearing cup plug
Seal
Plug
Friction washer
Washer
Planetary gear
Needle bearing
Fig. 1
May 2001
8B02.3
Exploded view
12
27
2
28
29
6
31
4
30
32
36
10
33
34
21
1
37
38
39
19
35
40
20
41
18
42
22
44
45
17
46
47
16
48
49
13
14
50
15
43
55
56
23
16
17
24
25
57
54
58
59
53
57
56
51
Fig. 1
52
Parts list
Issue 1
May 2001
Issue 1
May 2001
8B02.5
T
50
Fig. 2
34
Removal
5. Remove bolts (50) and separate the planetary carrier
assembly from the hub using two extractor bolts V,
ref. 5870 204 016 (Fig. 2 and J).
6. Take off snap ring (46), sun gear (45) and tab washer
(44).
7. Correctly unlock the two castellated nuts (42) and
successively unscrew them using socket, ref.
5870 401 082 (see J). Discard the retainer (43).
8. Extract the wheel hub (34), crownwheel carrier (40)
and crownwheel (41). Remove the assembly using a
lifting device (Fig. 3). Where necessary, match and
keep together bearing cones (33) (38) and bearing
cups (36) (37).
Fig. 3
Danger
- Request the assistance of another operator and take
care when removing the hub.
9. If required, remove snap ring (39) and separate
crownwheel (41) from the crownwheel carrier (40).
Issue 1
May 2001
Refitting
Note: If the crownwheel has previously been separated from the crownwheel carrier, fit the two together and fit the snap ring (39).
10. If required, replace lip seal (32) that provides oil
tightness for the wheel hub (see C).
11. Refit the wheel hub, the crownwheel carrier and
crownwheel, using the same safety precautions and
method as when removing it.
12. Adjust the rotational torque of the wheel hub (see
D).
13. Check or carry out shimming of the planetary carrier
(see E).
14. Lightly smear the mating face of the planetary carrier
with the hub with Loctite 510 or its equivalent, taking
care that it does not enter the tapped holes.
15. Screw two diametrically opposed guide studs into
the hub.
16. Check for the presence of tab washer (47) in the
cavity in the planetary carrier.
17. Position the planetary carrier according to the paint
marks made during its removal.
18. Fit bolts (50) and tighten to a torque of 190 - 220 Nm.
Final operations
19. Turn the wheel hub in order to fit the oil filler plug in
the horizontal axis of the drive unit. Top up the oil
level using an oil with a viscosity grade of 80W/90
and check the oil level through the same port. Screw
in plug (55) fitted with its seal (54).
20. Refit the wheel. Remove the axle stands and trolley
jack. Tighten the wheel nuts to a torque of 575 Nm.
21. Remove the chocks and release the handbrake.
22. Carry out a road test. Check for the oil tightness of
the mating face of the planetary carrier and the drain
and filling plugs.
Issue 1
May 2001
8B02.7
51
Preliminary operation
23. Remove the planetary carrier (see A).
Disassembly
24. Place the planetary carrier in a press fitted with an
appropriate fixture.
25. Extract pins (51) from the planetary carrier (49),
pulling outwards as shown by P (Fig. 4)
Remark
- Each pin is fitted with a snap ring (52).
26. Recover the friction washers (56), washers (57) and
needle bearings (59) from each bearing.
49
Fig. 4
Reassembly
27. Clean and inspect the components. Replace any
parts found to be defective.
28. In the planetary gears (58), arrange the needle
bearings coated with bearing grease. Place a washer
(57) on either side of each planetary gear.
29. Position the friction washers (56), with each tab
located in the groove of the planetary carrier. Slide
the pre-assembled planetary gears between the
friction washers.
30. Check for the presence of snap ring (52) on the
planetary gear pins. Centre the planetary gears and
friction washers. Position and insert the pins (51)
thrusting against the planetary carrier via its external
face (Fig. 5) using the same equipment that was
used for their removal.
31. Manually check the axial clearance and the free
rotation of each planetary gear.
51
Fig. 5
Final operation
32. Refit the planetary carrier (see A).
Issue 1
May 2001
Final operations
42. Refit the wheel hub (see A).
43. Adjust the hub rotational torque (see D).
44. Check or carry out the shimming of the planetary
carrier (see E).
Issue 1
May 2001
8B02.9
Adjustment
45. Fit internal nut (42) and tighten it using socket, ref.
5870 401 082 (see J), so as to obtain a rotational
torque of:
- 7 to 13 Nm for new bearings
- 3.5 to 6.5 Nm for re-used bearings
Remark
- The rotational torque is checked using a spring
balance and a wire wrapped around the circumference of hub (34) (Fig. 6).
46. Place the retainer (43). Screw and lock the external
nut (42) using the socket applied in operation 45.
Special point
- Retainer (43) is fitted between two nuts (42). By
means of two tabs lodged in the grooves on spindle
(30) it stops any rotation of the internal adjusting nut
during the tightening of the external locking nut.
47. Using an appropriate tool, lock nut (42) by bending
the retainer (43), without breaking it, into one of the
six notches on each nut.
Fig. 6
Issue 1
May 2001
12
Remark
- The shimming of the planetary carrier consists of
obtaining a J1 clearance of 0.3 to 0.5 mm between the
end of the universal drive shaft (12) and the bottom of
the planetary carrier (49).
Preliminary operations
48. Fit the tab washer (44) with its tabs positioned in the
notches on spindle (30).
49. Slide the sun gear (45) on to the end of universal drive
shaft and fit snap ring (46).
Shimming
Fig. 7
Important
- Push hard on the universal drive shaft in order that the
sun gear thrusts against the spindle.
On the wheel hub (34) (Fig. 7)
50. Measure dimension A between the thrust face of the
planetary carrier on the hub and the end of the
universal drive shaft (12).
On the planetary carrier (49) (Fig. 8)
51. Measure dimension B between the thrust face of the
planetary carrier and the tab washer (47).
52. Determine J1 using the formula: B - A
Remark
- If J1 is between 0.30 and 0.50 mm, the shimming
is correct. Otherwise, extract cup plug (53). Release and drive off tab washer (47) to add or remove
shims (48) in order to obtain the correct J1 clearance.
Final operation
53. After carrying out the shimming, refit:
- the previously selected shims
- the thrust washer, its rim lightly smeared with
Loctite
- a new cup plug, its circumference lightly smeared
with Loctite 542 or its equivalent.
Issue 1
May 2001
49
47
Fig. 8
8B02.11
Preliminary operation
Disassembly
55. Remove pin (1). Unscrew nut (2) and extract the ball
joint (3) from swivel housing (13) (Fig. 9).
56. Unscrew the nut and extract the ram ball joint (see
section 9F02).
57. Take out bolts (31) and take off the spindle (30).
58. Remove the universal drive shaft (12).
59. Take off grease nipples (22) (25) located on the upper
and lower swivel pins (16).
60. Take out bolts (21) (24). Remove arm (18) and the
lower cover (23).
61. With the assistance of another operator, hold the
swivel housing.
62. Remove the swivel pins (16) from the housing (13)
using an inertia extractor (Fig. 10 - 11) beginning with
the lower swivel pin.
Note: If necessary, match shims (17) with their
respective swivel pin.
63. Separate the bearing cones (4), deflectors (6) and
Orings (7) from the swivel pins. If needed, extract
the bearing cups (5) inserted in axle housing (1) and
match them with their respective cones (4).
13
Fig. 9
16
13
Fig. 10
13
Fig. 11
Issue 1
May 2001
Reassembly
64. Clean and inspect the components. Replace any
parts found to be defective.
65. Insert bearing cups (5) in the axle housing (1) using
an appropriate fixture.
66. Assemble on each swivel pin (16):
- a new Oring (7)
- a correctly positioned deflector (6)
- a bearing cone (4)
67. With the assistance of another operator, refit the
swivel housing (13).
68. Position the pre-assembled upper swivel pin (16) in
order to align swivel housing (13) and axle housing
(1) (Fig. 12).
69. Replace the shim (17) removed during disassembly.
Check for the presence of the Mecanindus pins (19)
(20) and check that their slots are diametrically
opposed. Fit arm (18) by partially fixing it with two
bolts (21).
70. Assemble the pre-assembled lower swivel pin (16).
Place shim (17) removed during disassembly and fit
cover (23). Assemble and tighten bolts (24) to a
torque of 190 Nm.
71. Fit all the bolts (21) and tighten to a torque of 190 Nm.
72. Turn swivel housing (13) several times from one
stop to the other in order to seat the cones in their
cups (Fig. 13).
73. Using a torque wrench fitted with a dial and an
appropriate fixture that respects the axis of the
swivel pins (Fig. 13), check that the resistance of
bearings (4) (5) is between 21 and 28 Nm. Otherwise, carry out adjustments.
16
13
Fig. 12
13
Fig. 13
Issue 1
May 2001
8B02.13
Adjustment
- The adjustment principle consists of adding or removing shims (17) on the lower or upper swivel pins in order
to obtain the previously stated bearing resistance.
31
30
Fig. 14
Final operations
79. Refit the wheel hub (see A).
80. Adjust the steering lock stops.
Note: On the APL 5052 axle, the maximum allowed steering lock is 50.
Remark
- The steering lock stops are located on the upper
part of each swivel housing.
Issue 1
May 2001
Preliminary operations
81. Extract the steering ball joints and the coupling bar
(see F).
82. If only the dust covers (10), seal (9) or bush (8) on
axle housing (1) are to be replaced, integrally remove
swivel housing (13) and the final drive unit (Fig. 15).
Danger
8
9
13
10
Reminders
- For the replacement of the dust covers (27), seal (28)
and bush (29) on spindle (30), in addition remove the
planetary carrier and sun gear (see A) as well as the
universal drive shaft.
- Then use the same method as described in operations
84 and 85 for disassembly and then operations 86 to 89
for reassembly.
Final operation
Reminder
84. Locate the position of dust covers (10) and seal (9)
and drive them off the axle housing (1).
85. Carry out the same operation for bush (8).
Reassembly
86. Clean the components. Check that the seal and bush
carriers are free of scratches and dents.
87. Lightly smear the rim of the bush with Loctite 620 or
its equivalent and insert it into the axle housing using
the service tool made up from drift, ref. 5870 058 026
and handle, ref. 5870 260 002 (see J) in accordance with the position marked during disassembly.
88. Insert the seal and the dust covers using a service
tool made up from drift, ref. 5870 055 006 and handle,
ref. 5870 260 002 (see J).
89. Lubricate the lip of the seal.
Issue 1
May 2001
90. Refit the entire final drive unit assembly (Fig. 15 and
F) using the same safety precautions taken during
its removal.
8B02.15
H . Removing and refitting - disassembling and reassembling the universal drive shaft
12
Removal
91. To gain access to the universal drive shaft, it is
necessary to:
- remove the upper and lower swivel pins and
remove the housing assembled with the final drive
unit (see G).
- remove the planetary carrier and the sun gear (see
A).
1
2
1
Fig. 16
12
Fig. 17
Issue 1
May 2001
Fig. 18
Reassembling
104. Refit the universal drive shaft, carry out operation
91 in reverse order.
Issue 1
May 2001
Fig. 19
8B02.17
J . Service tools
Tools available in the AGCO network
- 5870 401 082 - Socket for crownwheel carrier nuts
(Fig. 20)
- 5870 204 016 - Crownwheel carrier extraction bolt
(Fig. 21)
- 5870 260 002 - Handle (Fig. 22)
Fig. 20
Fig. 21
Fig. 22
Issue 1
May 2001
Remarks
* Bush, ref. 5870 905 005 must be used with drift, ref.
5870 055 073
** Insertion drifts, ref. 5870 055 006, 5870 058 026
and 5870 055 073 must be used with handle, ref.
5870 260 002
Fig. 23
Fig. 24
Fig. 25
Issue 1
May 2001
8B03.1
CONTENTS
-
General _______________________________________________
F.
10
15
16
I.
18
19
Issue 1
May 2002
General
Some of the pictures of that manual may not show
exactly your axle, but the process is the same.
A. Steering
disassembly
cylinder
group
Fig. 1
Preliminary operations
1.
2.
3.
4.
Issue 1
May 2002
Fig. 2
8B03.3
Fig. 3
Fig. 4
20.29 S
20.43 S
Fig. 5
Issue 1
May 2002
Fig. 6A
Fig. 6B
Issue 1
May 2002
Fig. 6B
8B03.5
Danger
- Don't use these two screws for the assembly of
the wheel carrier.
Fig. 7
Fig. 8a
Issue 1
Fig. 8A
May 2002
Fig. 9
Fig. 10
B
B
Fig. 11
Issue 1
May 2002
8B03.7
Danger
- Before removing the king pins, secure the swivel
housing with a belt or a rope to a hoist or any other
supporting device.
Remove the king pins.
Note : Collect the belleville washers.
17. Remove the swivel housing from the axle beam and
from the short shaft of the U-Joint (Fig.13)
Position the swivel housing on a flat surface and
take the seal ring out with a lever (Fig.14)
Note : This is a destructive operation for the seal
ring.
18. Turn the swivel housing and take the bush out, using
a drift and a hammer (Fig.14A)
Fig. 12
Fig. 13
Fig. 14
Issue 1
Fig. 14A
May 2002
Fig. 15
C
D
B
E
C
Fig. 16
Fig. 17
Issue 1
May 2002
8B03.9
Fig. 18
Fig. 19
Fig. 20
Issue 1
May 2002
Fig. 21
Fig. 22
Fig. 23
Issue 1
May 2002
8B03.11
Fig. 24
Fig. 25
Fig. 26
Fig. 26A
Issue 1
May 2002
Danger
- Don't use the two screws you took to remove the
wheel carrier group from its housing (see operation
12).
34. Force all the hub dowel bushes completely with the
special tool code CA715027 (see J) and a hammer.
Assemble the wheel carrier fastening screws and
tighten to the requested torque (see section 8A01
A) (Fig.29).
X
Fig. 27
Fig. 28
Fig. 29
Issue 1
May 2002
8B03.13
Fig. 30
Fig. 31
Fig.31A
Issue 1
May 2002
Fig. 31B
Fig. 31C
Fig. 31D
Issue 1
May 2002
8B03.15
Fig. 32
Fig. 33
Fig. 34
Issue 1
May 2002
H . Toe-in adjustement
39. Put two equal one-meter-long linear bars on the
wheel sides and lock them with two nuts on the
wheel hub stud bolt (Fig. 35)
Warning : The two bars should be fixed on their
middle so that they are perpendicular to the
supporting surface and parallel to the pinion
shaft axis. Align the two bars.
40. Measure the distance in mm M between the bars
ends with a tapeline (Fig. 36)
Note : Keep the minimum value, swinging the
measurement point.
41. Check that the difference of the measurements E
between the wheel hubs diameters ends is within
the requested tolerance range (see Toe-in in sec.
8A01 A) (Fig. 37)
The prescribed value is referred to the external
diameter of the wheel hubs flange, therefore the
measured value M at the bars ends must be related
to the ratio between lenght of the bar and flange
diameter :
- toe-in (see section 8A01 A) = E 0-2
- measurement difference = M0-5
50 cm
50 cm
Fig. 35
Fig. 36
.
E0-2
A
.
M0-5
M
Fig. 37
Issue 1
May 2002
8B03.17
Fig. 38
Fig. 39
Issue 1
May 2002
Fig. 40
Fig. 41
Fig. 42
Issue 1
May 2002
8B03.19
K. Service tools
- CA 119055 - Bush driver (Fig. 43)
- CA 715097 - Oil seal driver (Fig. 44)
- CA 119143 - Oil seal driver (Fig. 45)
Fig. 43
Fig. 44
Fig. 45
Issue 1
May 2002
Fig. 46
Fig. 47
Fig. 48
Issue 1
May 2002
8B03.21
Fig. 49
Fig. 50
Issue 1
May 2002
8C01.1
CONTENTS
-
General ________________________________________________
A.
B.
C.
D.
E.
F.
G.
H.
12
I.
14
J.
14
K.
14
L.
14
M.
15
Issue 1
May 2001
General
Whatever the type of front axle installed on 8200 series
tractors (AG 155H or AG 200H), the operating principles
and maintenance procedures remain similar.
- 8210 - 8220 - 8240 tractors
. AG 155H type
- 8240 (optional) - 8250 - 8260 tractors
. AG 200H type
Note however that the splined end of the drive pinion is
different on AG 200H front axles. This amendment
allows for a semi-rigid link between plate (45) and the
drive shaft.
The 8270 and 8280 tractors have a ZF front axle fitted with
a bevel gear of the same type (see section 8C02).
The bevel gear assembly containing the differential lock
mechanism is fitted in a housing (35) that has two halfbearings held by bolts (42).
The drive pinion is placed at the rear of the housing on two
opposing taper roller bearings. Its adjustment is carried
out via shim(s) (28) located behind the leading bearing.
The preloading of the bearings is obtained via shim(s)
(34) placed between bearing cone (32) and the shoulder
of the drive pinion.
The oil tightness is provided by seal (31) and Oring (29)
fitted on the drive pinion.
The adjustment of the crownwheel / drive pinion is
obtained via shim(s) (11) placed behind bearing cup (12).
The preloading of the housing and crownwheel assembly
is carried out via splined nut (24).
A plate riveted on the right-hand side of the housing
indicates the type and serial number of the front axle.
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Washer
Shim(s)
Bearing cup
Bearing cone
Bolt
Cover
Half-housing
Planetary gear
Spherical washer
Planetary gear pins
Bolts
Sun gear
Bolt
Lock washer
Splined nut
Washer
Half-housing
Crownwheel
Shim(s)
Oring
Nut
Seal
Bearing cone
Bearing cup
Shim
Housing
Deflector
Bearing cup
Bearing cone
Drive pinion
Mobile coupler
Half-bearing
Bearing block bolt
Centring bush
Wear ring
Plate
Washer
Fig. 1
Fig. 2
Snap ring
Tab washer
Oring
Piston
Friction washer
Spring
Locating pin
Oring
Guiding washer
Issue 1
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
Fig. 3
May 2001
8C01.3
Overall view
AG 155H
5
10
11
12
AG200H
13
14
15
16
17
18
19
20
21
22
23
24
39
47
38
40
25
39
26
37
35
38
27
28
44
37
28
42
42
44
36
22
35
23
34
33
43
32
31
30
29
24
22
34
33
32
29
43
31
23
45
24
46
41
30
41
Fig. 1
Parts list
Issue 1
Fig. 2
Fig. 3
May 2001
Parts list
Fig. 1
Fig. 2
Fig. 3
8C01.4
Exploded view
31
32
33
36
44
30
35
46
45
29
36
30
31
29
32
24
33
12
44
13
41
35
23
34
28
20
22
37
43
38
42
13
34
12
28
AG 200H
37
38
26
39
3
2
11
25
21
27
1
10
9
6
AG 155H
40
18
19
5
8
16
17
4
15
7
14
Parts list
Issue 1
Fig. 1
Fig. 3
Fig. 2
May 2001
8C01.5
35
Danger
- With the help of another operator, carefully carry out the
removal operation while taking into account the risks of
any unexpected tilting of the housing with its consequent weight.
3. Extract the steering ball joints.
4. Using a suitable sling, hold, then remove the swivel
housing assembly (see section 8B01 F).
Issue 1
May 2001
8C01.6
24
42
35
23
Danger
27
12.
13.
14.
15.
16.
17.
41
22
Fig. 4
12
13
Fig. 5
20
25
21
19
16
15
14
26
18
17
Fig. 6
Issue 1
May 2001
8C01.7
40
10
3
Fig. 7
Issue 1
May 2001
C
F
Fig. 8
Fig. 8A
Fig. 9
Issue 1
May 2001
d
C
SP
35
28
37
38
Fig. 10
+
9-
13
0
0,1
38. Adjust the position of the drive pinion (Fig. 10). The
thickness of shims necessary to correctly position
the drive pinion is calculated using the following
formula:
SP = C - E - (d r)
SP : Thickness of shims necessary (28)
C : Distance measured between thrust face of cup
(37) on housing (35) and machined face F.
d : Nominal distance of positioning drive pinion on
axles:
- AG 155H= 133.5 0.10
- AG200H = 139 0.10
E : Thickness of bearing (37) (38).
r : Actual dimension marked on drive pinion
(Fig. 11). This value may be either positive or
negative (add or deduct from nominal dimension d).
8C01.9
Procedure
39. Measure dimensions C and E using a depth gauge.
Note: Take care to correctly seat cone (38) in cup
(37).
40. When the dimensions are measured, apply the
formula in order to determine the thickness of the
shims required.
41. Insert the cone thrusting against the shoulder on the
drive pinion using a press and a suitable fixture
(Fig. 12).
42. Place the previously calculated thickness of shim(s)
(28) in the housing.
43. Insert cup (37) using an appropriate fixture.
44. Carry out the shimming of bearings (32) (33) (37)
(38).
r
Fig. 11
39
38
Fig. 12
Issue 1
May 2001
Method
45. Place the prepared drive pinion in the housing (35)
thrusting against the cylindrical sleeve M as shown
in Fig. 13. Turn the housing several turns while
applying a strong pressure to correctly seat cone (38)
in cup (37).
46. Using an appropriate depth gauge, measure dimension F in accordance with the formula A - B (Fig. 13).
47. Press hard on cup (33) while turning it alternately left
and right in order to correctly seat cone (32). Measure dimension G (Fig. 13).
48. Determine thickness SP1 of shim (34) (Fig. 13) using
the formula:
(G + F) 0.05 (0.05 mm being the preload value).
49. Place cup (33) thrusting against the housing.
50. Slide the shim(s) (34) determined during operation 48
on to the drive pinion. Fit cone (32) and seal (29)
previously lubricated (Fig. 14).
51. Grease seal (31) and insert it home in the shoulder
using a locally manufactured tool (see M).
52. AG 155H front axles
- Assemble nut (30) lock it using wrench ref.
3378051M1. Using a special sleeve and a torque
wrench, turn the drive pinion then tighten to a torque
of 450 - 500 Nm (Fig. 15).
AG 200H front axles
- Assemble nut (30) and lock it with wrench ref.
3378275M1 and flange ref. 3378276M1, then tighten
to a torque of 450 - 500 Nm (Fig. 15).
53. Check the rotation torque of the drive pinion.
SP1
34
37
A
B
38
F
35
33
32
Fig. 13
29
32
34
Fig. 14
AG 155H
30
AG 200H
Fig. 15
Issue 1
May 2001
8C01.11
Method
54. On AG 155H front axles, turn the drive pinion several
turns using a dial torque wrench and the special
sleeve (Fig. 16) on AG 200H front axles use wrench
ref. 3378275M1. Check that the rotation torque of the
drive pinion is between 2 to 4 Nm.
Fig. 16
Issue 1
May 2001
Issue 1
May 2001
Fig. 17
13
26
8C01.13
24
27
Fig. 18
Fig. 19
27
Issue 1
May 2001
Issue 1
May 2001
8C01.15
M . Service tools
1. Tools available in the AGCO network
- MF 471 - Differential lock spring compression tool
(Fig. 20)
- 3378051M1 - AG 155H front axles - Drive pinion nut
wrench (Fig. 21)
- 3378275M1 - AG 200H front axles - C wrench for
drive pinion nut (Fig. 22)
- 3378276M1 - AG 200H front axles - B flange for
drive pinion plate (Fig. 22)
Fig. 20
Fig. 21
Fig. 22
Issue 1
May 2001
14
H M12
20
10
H M8
13
74
100
Fig. 23
H M18
H M8
3714416M2
Fig. 24
- Oil tightness bush insertion drift (Fig. 25)
+0,5
0
85
72
37,60
50
91,8
R=
30
22
25
1 x 45
94
107
Fig. 25
Issue 1
May 2001
8C02.1
8C02 ZF differential
CONTENTS
-
General ________________________________________________
A.
B.
C.
D.
11
13
G.
19
H.
19
I.
19
J.
20
E.
F.
Issue 1
May 2001
General
The 8270 and 8280 tractors are fitted with an APL 5052
front axle. This axle does not have a hydraulic differential
lock similar to the conventional front axles.
This front axle is fitted with an limited slippage system
which consists of friction disks (35) and intermediate
plates (36) integral with the left and right-hand side output
sun gears (34) and the half-housings of the differential
(17) (37).
This type of differential does not have a total self-locking
function.
The crownwheel / drive pinion assembly is fitted in
housing (7) and comprises two split bearings (18) held by
bolts. The drive pinion, located at the rear of the housing,
bears on two taper roller bearings. Its position is adjusted
by shim (23) inserted between the housing and the
bearing cup (21). The pre-loading of the bearings is
obtained by shim (9) placed between the shoulder of the
drive pinion and bearing cone (11).
Both the pre-loading of the differential housing assembly
and the drive pinion backlash is adjusted by castellated
nuts (4) fitted on either side of the differential housing.
The housing oil tightness is provided by a lip seal (12)
fitted in flange (13).
Axle housing
Breather
Split pin
Castellated nut
Bearing cup
Bearing cone
Housing
Bush
Shim
Bearing cup
Bearing cone
Lip seal
Flange
Bolt
Issue 1
May 2001
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
Ring
Bolt
Half-housing
Half-bearing
Crownwheel
Drive pinion
Bearing cup
Bearing cone
Shim (bevel gear)
Planetary gear pin
Planetary gear
Dust cover
Spherical washer
Plate
Washer
Nut
Level plug and seal
Drain plug and seal
Bolt
Sun gear
Friction disks
Intermediate plates
Half-housing
Washer
Bolt
Bolt
Tab washer
Bolt
Fig. 1
Exploded view
8C02.3
15
42
13
14
12
10
11
9
8
4
5
27
5
25
24
18
30
29
28
16
27
26
25
24
4
40
17
36
23
21
22
20
2
27
19
34
25
41
25
27
35
31
36
37
34
33
38
39
35
41
32
Fig. 1
Parts list
Issue 1
May 2001
Issue 1
May 2001
8C02.5
Fig. 2
3. Take off:
- the swivel pin grease nipples
- the arm on the upper swivel pin
- the cover on the lower swivel pin
Note: Visually note the location of the shims and
bearing cones.
1
Remark
- A 45 grease nipple is fitted on the lower swivel pin.
Reminder
- Take care not to damage the seals and dust covers
fitted on the axle housing when the removing the
universal drive shaft.
Fig. 3
Issue 1
May 2001
D . Removing and refitting - disassembling and reassembling the differential housing and crownwheel
Removal (Fig. 4)
5. Mark the position of the half-bearings (18) on the
housing (7) using two opposing paint marks T so
as to be able to replace them in their original
positions on reassembly.
6. Take off and discard the two split pins (3). Unscrew
the castellated nuts (4) using a suitable locally
manufactured tool.
7. Cut and remove the steel wire F that locks bolts
(40). Take out the bolts fitted with their washers.
8. Remove the half-bearings and bearing cups (5). Take
out the differential housing from the housing (7) (Fig.
5)
Remark
- If they are to be re-used, match the cups and cones
together.
1
1
F
T
40
40
18
Refitting
Reminder
- The bearing cups and cones must be lubricated with oil
having an 80W/90 viscosity grade before assembly.
9. Place the differential housing in the housing with the
bearing cones.
10. Position the half-bearings in accordance with the
previously made marks.
11. Fit bolts (40) equipped with their washers and tighten
them to a torque of 150 Nm.
12. Lock the bolts by tying them in pairs using new steel
wire. Twist the ends of the wire together correctly.
13. Carry out the shimming of the differential housing
bearing cones and cups (6) (5) (see E).
14. Adjust the crownwheel and drive pinion backlash
(see E).
7
1
1
4
Fig. 4
Fig. 5
Issue 1
May 2001
8C02.7
37
17
19
Fig. 6
34
Fig. 7
Fig. 9
35
36
25
41
34
Fig. 8
24
Issue 1
27
24
May 2001
16
Fig. 10
34
36
41
Issue 1
May 2001
Fig. 11
8C02.9
Fig. 12
25
24
36
27
24
17
35
41
34
Fig. 13
Issue 1
May 2001
41
37
Adjustment
Remark
- The adjustment is carried out on each sun gear.
34
Sun gear opposite the crownwheel
35. Place the index of a dial gauge on tab washer (41)
which is accessible via one of the four ports machined in the half-housing (37) (Fig. 14).
36. Set the needle of the dial gauge to zero.
37. Manually apply pressure from top to bottom or vice
versa on the sun gear (34) through the lateral recesses in the half-housing (Fig. 14) and calculate the
gap after reading the dial gauge.
Note: If the gap is between 0.1 mm and 0.2 mm
the adjustment is correct. Otherwise, replace
the intermediate plates (36) by thicker or thinner
plates in order to obtain the previously stated
clearance.
Remark
- There are three thicknesses of intermediate plates
referenced in the Spare Parts catalogue:
. 1.8 mm
. 1.9 mm
. 2 mm
38. Use the previously mentioned method for the sun
gear on the crownwheel side (Fig. 15)
Remark
- The half-housing (17) does not have lateral recesses. Manually access the sun gear via the central
bore.
39. When the adjustment phase is completed, take out
the four bolts and washers that were provisionally
tightened and then fit all the bolts (39), with their
threads lightly smeared with Loctite 242 or its
equivalent. Tighten the bolts to a torque of 120 Nm.
40. Manually check for the rotation of the sun gears
using a locally manufactured tool matching the
splines on the sun gears.
Issue 1
May 2001
Fig. 14
17
34
41
Fig. 15
8C02.11
17
Fig. 16
Issue 1
May 2001
Issue 1
May 2001
Fig. 17
291 / 0,18
291/0,18
Important
50. Carry out three measurements at three equidistant
points on the crownwheel and calculate the average
of the three readings, so as to obtain a backlash
corresponding to the decimal number stamped on
the rim of the crownwheel (Fig. 18) within a tolerance
of 10%.
Example: 291 / 0.18
- 291 = matching set number
- 0.18 = correct value of backlash
51. When the correct backlash has been obtained, fit
and bend the new pins (3) in order to immobilise the
castellated nuts (4).
Notes:
- If the notch of the nut is not aligned with the
hole of the half-bearing pin, continue tightening until the next notch.
- Manually check for the rotation of the differential housing.
19
Fig. 18
8C02.13
19
Fig. 19
Removal
Reminder
- Re-used bearing cups and cones must be matched
pairs.
55. Loosen and take off nut (30) using a standard socket
and holding clamp ref. 5870 240 002 (see J) from
plate (28).
56. Remove the plate and recover washer (29).
57. Take out bolts (14) and remove ring (15).
58. Take out bolts (42) and extract flange (13).
59. Force off the drive pinion fitted with bearing cone (22)
using a press and take it out through the rear of the
housing.
60. Recover shim (9) and extract bearing cone (22) using
a locally manufactured tool.
61. Extract the bearing cups (10) (21) from the housing
and recover shim (23) that positions the drive pinion.
62. Drive the lip seal (12) off the flange (13).
Issue 1
May 2001
8C02.14
18
b
SP
23
7
22
21
e
Fig. 22
18
18
Fig. 23
Issue 1
May 2001
8C02.15
Refitting
63. Clean the components. Replace any parts found to
be defective.
64. Lightly smear the external diameter of seal (12) with
Loctite 640 or its equivalent and insert it to within 8
mm from the external edge of flange (13) (Fig. 20)
using tool, ref. 5870 055 017 and handle, ref. 5870
260 002 (see J).
13
12
Fig. 20
Reminders
- As with the backlash, the adjustment of the bevel gear
distance is of firts importance. It ensures the reliability
and the correct operation of the drive / crownwheel
assembly.
- It is essential to first adjust the bevel gear distance and
then carry out the shimming of the drive pinion.
291
Remark
- The adjustment of the bevel gear distance is carried out
using a service tool made up from rod ref. 5870 500 001
and two bushes ref. 5870 500 010, held by the two halfbearings (18) (see Fig. 22 - 23 and J).
r
Fig. 21
Issue 1
May 2001
Special point
- In the given example, the negative r value is subtracted from the nominal dimension d.
Procedure
65. Measure dimension of A using tools, ref. 5870 500
001 and 5870 500 010 (see J) and in accordance
with Fig. 22 and 23.
66. Measure dimension e of bearing (21) (22) using a
depth gauge (Fig. 22).
Special point
- Take care to correctly seat bearing cone (22) in cup
(21).
67. After having taken the measurements, use the
previously stated formula to calculate the thickness
of shim(s) required.
68. Using a press and an appropriate fixture, insert
bearing cone (22) against the shoulder of the drive
pinion.
69. Place the previously calculated thickness of shim(s)
(23) in the housing. Insert the bearing cups (21) (10)
using a press and an appropriate fixture.
70. Lubricate the bearing cones and cups and carry out
the shimming of the drive pinion.
71. Install the pre-assembled drive pinion in the housing.
Issue 1
May 2001
8C02.17
30
12
Fig. 24
20
Fig. 25
Issue 1
May 2001
30
28
29
Fig. 26
Final operation
85. Refit the differential housing (see D) and the axle
nose (see G).
C
9
Fig. 27
Issue 1
May 2001
8C02.19
95. Assemble the front axle and bearings with the main
stand (see section 8F02).
96. Top up the oil level in the front axle housing and
check the oil level in drive units.
97. Carry out a road test of the front axle and the
differential lock with limited slippage.
98. Check for the oil lightness of the mating face of the
differential housing and plate. (28).
Issue 1
May 2001
J . Service tools
Tools available in the AGCO network
- 5870 055 017 - Insertion drift for lip seal (Fig. 28).
- 5870 240 002 - Holding clamp for the drive pinion
plate (Fig. 29).
- 5870 260 002 - Handle for the insertion drift for the
lip seal (Fig. 30).
Fig. 28
Fig. 29
Fig. 30
Issue 1
May 2001
8C02.21
Fig. 31
Fig. 32
Issue 1
May 2001
8C03.1
CONTENTS
-
General _______________________________________________
C.
F.
10
14
16
I.
22
Issue 1
May 2002
General
Some of the following pictures may not show exactly
your axle, but the process is the same.
Issue 1
May 2002
8C03.3
C
B
Fig. 1
Fig. 2
Fig. 3
Issue 1
May 2002
Fig. 4
Fig. 5
Fig. 6
Issue 1
May 2002
8C03.5
D
D
E
F
Fig. 7
G
Fig. 8
Issue 1
May 2002
Fig. 9
B
A
Fig. 10
E
D
Fig. 11
Issue 1
May 2002
8C03.7
Fig. 12
Fig. 13
Fig. 14
Issue 1
May 2002
Fig. 15
A
B
Fig. 16
Fig. 17
Issue 1
May 2002
8C03.9
22. Using a thin punch, pull out the three locking pins in
order to take out the short and the long pins (Fig. 18).
23. Disassemble the planetary carrier and collect all the
components inside the differential box: sun gears,
thrust washers, spider, planetary gear (Fig. 19).
Note: Check the operating and wear conditions
of all the components.
24. Take the bearings out of the differential half boxes
and from the cover, using a three-hold extractor (Fig.
20).
Fig. 18
Fig. 19
Fig. 20
Issue 1
May 2002
Fig. 21
Fig. 22
Fig. 23
Issue 1
May 2002
8C03.11
Fig. 24
SHIM RANGE
3.0
3.1
Q.ty
Fig. 25
Fig. 26
Issue 1
May 2002
32. Insert the bevel pinion unit into the differential housing (from the internal side) and install the assembly
(with the bevel pinion oriented downwards) on a
hydraulic press equipped with a pressure gauge in
order to read the press fit pressure.
Insert a suitable shim between the bevel pinion and
the press bench so as to exert an opposing force to
the bearing press fit pressure.
Insert the second bearing cone at the pinion end
(Fig. 27), then the tool CA715004 (see I).
Press fit the bearing until the load in the press jack
reaches 3 tons as a maximum.
Remove the press assembly.
33. Insert a ring nut washer and screw a new lock ring
nut on the pinion end (Fig. 28).
34. Screw the ring nut in, using the wrench for ring nut
(CA119099) (see I) and for pinion retainer CA715022
(see I) (Fig. 29).
Warning : The torque setting is given by the
preloading measurement on bearings. Tighten
the ring nut gradually.
Note :
- If the tightening is excessive, the elastic spacer
must be replaced and the procedure repeated.
- When you check the preloading, it is advisable
to beat slightly both pinion ends with a soft
hammer, so as to help setting the bearings.
Fig. 27
Fig. 28
Fig. 29
Issue 1
May 2002
8C03.13
Fig. 30
Fig. 31
Issue 1
May 2002
Fig. 32
Fig. 33
Fig. 34
Issue 1
May 2002
8C03.15
40. Position all the inner components into the box sun
gear, discs and counterdiscs (Fig. 35).
41. Position new O-Rings well lubricate in the relative
housings on the piston and on the differential box
cover.
Insert the piston and assemble the cover in the
differential box (Fig. 36).
42. Position the bevel crown gear on the cover, apply
Loctite 270 on the threads and fix the whole, tightening the screws to the requested torque (see
section 8A01 A) (Fig. 37).
Fig. 35
Fig. 36
Fig. 37
Issue 1
May 2002
Fig. 38
Fig. 39
Fig. 40
Issue 1
May 2002
8C03.17
Fig. 41
Fig. 42
Fig. 43
Issue 1
May 2002
Fig. 44
Fig. 45
Fig. 45
Issue 1
May 2002
8C03.19
Generic information
51. To test the marks of the bevel gear teeth, paint the
ring gear with red lead paint.
The marking test should be always carried out on the
ring bevel gear teeth and on both sides (Fig. 47).
52. OK = Correct contact
If the bevel gear is well adjusted, the mark on the
teeth surfaces will be regular.
- Z : Excessive contact on the tooth tip
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in
order to adjust the backlash.
- X : Excessive contact at the tooth base
Move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in
order to adjust the backlash (Fig. 48)
53. Movements to correct :
1 move the pinion for type X contact adjustment
2 move the pinion for type Z contact adjustment
(Fig. 49).
Fig. 47
Z
OK
Fig. 48
Fig. 49
Issue 1
May 2002
54. Once all the adjustment operations have been completed, fit the adjuster ring nut retainers and their
respective screws, tightening them to the requested
torque (see section 8A01 A) with a dynamometric
wrench (Fig. 50).
Warning : The ring nut and the relative locking
plate from the crown side are different from
them on the opposite differential box side; turn
the ring nuts slightly in order to align them to
the related retainer.
55. Tighten the bolts of both half collars to the requested
torque (see section 8A01 A) with a dynamometric
wrench (Fig. 51).
56. Before matching 2 surfaces, make sure they are
perfectly clean. Degrease and clean them with
appropriate detergents.
Spread a film of Loctite 510 on the contact surface
between the axle beam and the differential carrier.
Position the differential carrier on the axle housing,
and tighten the retaining screws to the requested
torque (see section 8A01 A) (Fig. 52).
Fig. 50
Fig. 51
Fig. 52
Issue 1
May 2002
8C03.21
C
B
Fig. 53
Issue 1
May 2002
I. Service tools
- CA 119030 - Ring nut wrench (Fig. 54)
- CA 119099 - Pinion lock nut wrench (Fig. 55)
- CA 119148 - Oil seal driver (Fig. 56)
Fig. 54
Fig. 55
Fig. 56
Issue 1
May 2002
8C03.23
Fig. 57
Fig. 58
Fig. 59
Issue 1
May 2002
Fig. 60
Fig. 61
Fig. 62
Issue 1
May 2002
8C03.25
Fig. 63
Fig. 64
Fig. 65
Issue 1
May 2002
8D01.1
CONTENTS
-
General _____________________________________________
A.
B.
C.
D.
E.
10
F.
10
G.
11
Issue 1
May 2001
General
Tractors in the 8200 series, except the 8270 and 8280,
may be fitted with a 2 WD front axle.
The front axle is made up by the following assemblies:
- a cast-iron support identical to the 4 WD version, its
lower rear part having a bearing supporting the 2nd
removable swivel pin,
- a front bearing fixed to the cast-iron support and holding
the 1st swivel pin,
- a swivel beam, holding the arms,
- two extending arms,
- two axle spindle assemblies mounted into the bores of
the extending arms,
- a double-acting hydraulic ram linked to the axle spindles by two links.
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
Nut
Washer
Bearing cone
Spindle
Bearing cup
Guard
Grease nipple
Nut
Axle
Steering arm
Bush
Extending arm
Seal
Bearing cone
Hub
Bearing cup
Cover
Rivet
Nut
Washer
Belleville washers
Sealing ring
Bearing cone
Bearing cup
Sealing ring
Lock washer
Spacers
Bolt
Hydraulic ram
Bolt
Issue 1
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)
(54)
(55)
Washers
Nuts
Sleeve
Bolt
Steering rod
Bolt
Nuts
Sleeve
Pin
Washer
Nut
Ball joint
Pin
Nut
Ball joint
Support
Bush
Thrust washer
Oring
Oring
Nut
Lock nut
Bushes
Grease nipple
Plug
Fig. 1
Fig. 2
May 2001
21
10
8D01.3
19
20
28
29
11
22
12
15
16
A
17
27
DETAIL A
27
55
18
12
24
26
25
13
14
23
45
46
47
53
51
54
50
52
1
DETAIL B
29
32
31
30
34
32
31
37
38
37
42
10
29
B
39
41
44
40
C
DETAIL C
19
28
Issue 1
33
35
36
May 2001
10
43
48
49
Parts list
Fig. 2
Fig. 1
8D01.4
Exploded view
53
52
50
8
48
47
39
41
9
40
24
54
28
23
51
19
27
20
10
49
29
21
25
46
45
22
30
44
11
43
6
31
7
12
32
4
34
37
13
33
35
26
14
36
18
15
38
16
3
2
17
42
Parts list
Issue 1
Fig. 1
Fig. 2
May 2001
Refitting
5. Clean and inspect the components. Replace any
parts found to be defective.
6. Fit the ball joint (42) into the steering arm (10).
7. Couple sleeve (38), steering rod (35) and ball joint
(42).
8. Place washer (40) and tighten nut (41) to a torque of
108 - 122 Nm, then lock it using a new pin (39).
9. Remove the jack.
10. Remove the chocks and take off the handbrake.
11. Adjust the wheel alignment (see E).
8D01.5
Issue 1
May 2001
Final operations
49. Refit the wheel and remove the axle stands. Tighten
the wheel nuts to a torque of 140 - 200 Nm. Grease
the extending arms (12).
50. Remove the chocks and release the handbrake.
51. Adjust the wheel alignment (see E).
Issue 1
May 2001
13
Fig. 3
8D01.7
Refitting
59. Clean and inspect the components. Replace any
parts found to be defective.
60. Assemble sleeves (33) fitted with steering rods (35)
on the ram. Fit bolts (30), washers (31) and tighten
nuts (32).
61. Screw ball joint (45) (if removed) on to the steering
ram.
62. Refit the ram assembly on to the support (46).
63. Tighten nut (44) of the ball joint to a torque of 100 120 Nm and fit pin (43).
64. Couple sleeves (38) to the steering rods (35) and ball
joints (42).
65. Remove the jack. Take away the chocks and release the handbrake.
67. Check the wheel alignment (see E).
68. Check the oil tightness of the hydraulic ram unions.
Issue 1
May 2001
Fig. 4
2
1
Fig. 5
Issue 1
May 2001
Refitting
82. Clean and inspect the components. Replace any
parts found to be defective.
83. If necessary, insert bushes (53) using a locally
manufactured drift (see G).
84. Check for the presence of bush (47) and thrust
washer (48). Replace Oring (49) and refit support
(46).
85. Tighten nut (51) fitted with Oring (50) on support
(46), then loosen it in order to obtain an axial
clearance of 0.05 mm to 0.25 mm.
86. Using a pin wrench, tighten lock nut (52) to a torque
of 120 - 150 Nm. Check that the support swivels
freely.
87. Place slings on the axle beam, position washer (6)
(the chamfer facing the axle) (Fig. 6). Insert the axle
in support (5).
88. Position washer (4) (the chamfer facing the axle)
(Fig. 6). Fit the front bearing (2) in order to obtain the
minimum clearance between washers and axle.
89. Smear bolts (1) with Loctite 270 (Fig. 6). Tighten to
a torque of 520 - 640 Nm. Remove the slings.
90. Fit grease nipples (3) and (7) (Fig. 6).
91. Refit the hydraulic ram assembly (29) on support
(46). Tighten nut (44) to a torque of 100 - 120 Nm and
fit the pin (43).
92. Grease the bearings (2) and (5) (Fig. 6) and support
(46).
93. Grease the steering rods (35) using molybdenum
sulphide grease. Refit assemblies (1) (Fig. 4). Fit
nuts (8) and bolts (28). Tighten to a torque of 400 600 Nm.
94. Fit bolts (30), washers (31) and nuts (32). Tighten to
a torque of 75 - 81 Nm.
95. Refit the front wheels, remove the axle stand.
Tighten the wheel nuts to a torque of 140 - 200 Nm.
96. Remove the chocks and release the handbrake.
97. Check the wheel alignment (see E).
8D01.9
1
2
3
5
7
Fig. 6
895
A
A'
A'
Issue 1
B'
Fig. 7
May 2001
28
34
32
Fig. 8
28
27
Fig. 9
Issue 1
May 2001
8D01.11
G . Service tools
Locally manufactured tools
- Bush insertion drift (Fig. 10)
(a) Knurling
(b) Chamfer
(a)
(b) 2 x 45
45
34,90
37,90
(b) 2 x 45
5
40
40
180
Fig. 10
Issue 1
May 2001
8E01.1
CONTENTS
-
General ___________________________________________________
Operation _________________________________________________
A.
B.
C.
D.
E.
F.
Issue 1
May 2001
General
The steering column assembly consists of two parts:
- a lower fixed part comprising a tube and fixing baseplate,
- an upper mobile part comprising a tube and a welded
yoke as well as a housing containing the steering wheel
height and tilt adjustment mechanisms.
Operation
Height adjustment
When the control lever (4) is moved upwards, the rod T
causes the elbowed lever (8) to swivel and lower arm
(15), which is hinged on pin (14). The lock plate (16), on
which presses the adjusting screw (5) integral with the
arm, is released and allows the upper part of the steering
column to move.
Spring (3) returns lever (4) to its initial position.
Stop (25) limits the movement of both parts.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
Retaining washer
Retaining washer
Spring
Control lever assembly
Adjusting screw
Bolt
Spring
Elbowed lever
Notched lever
Rack
Pin
Upper shaft
Retaining washer
Pin
Arm
Lock plate
Springs
Pin
Pin
Housing
Mobile column
Bearings
Circlip
Bolt
Stop
Bush
Bush
Fixed column
Lower shaft
Bushes
Circlip
Seal
Fig. 1
Tilt adjustment
When control lever (4) is moved downwards, it presses
against the rod T which in turn pushes against the end of
the notched lever (9) and frees it from the rack (10), thus
allowing tilt the housing (20).
The two return springs (17) facilitate the positioning of the
steering wheel.
Adjusting screw (5) allows the meshing of the teeth of
the rack (10) and notched lever (9) to be adjusted.
Issue 1
May 2001
Fig. 2
8E01.3
Overall view
12
23
32
17
22
20
17
19
18
20
10
11
10
27
15
24
28
25
26
21
16
13
28
28
14
21
15
30
31
26
29
Parts list
Issue 1
Fig. 2
Fig. 1
May 2001
8E01.4
Exploded view
Fig. 2
Parts list
Fig. 1
32
23
22
20
12
3
2
27
17
T
7
1
28
6
19
10
29
18
14
30
11
21
15
26
Issue 1
24
May 2001
25
16
13
8E01.5
Removal
2
2
Fig. 3
Refitting
6. Check the operation in all steering column positions.
7. Lightly smear the splines of shaft (29) with Loctite
Anti-Seize grease or its equivalent.
8. Carry out operations 2 to 5 in reverse order.
Note: Tighten the steering wheel nut to a torque
of 57 - 78 Nm.
9. Check the correct operation of the electrical equipment.
Reassembly
13. Refit the levers (4) (8) and spring (3). Replace the
retaining washers (1) (2).
14. Adjust lever (4), with the rod T in contact with the
notched lever (9), by using adjusting screw (5) (3
mm Allen key).
15. Reverse operation 11 and carry out operations 6 to 9.
Issue 1
May 2001
Removal
16. Remove the steering column. Carry out operations 1
to 5.
17. Take off the half-housings around the steering column.
18. Remove and discard the retaining washers (1) (2).
Remove spring (3) and lever (4) complete with its
dust cover.
19. Compress spring (7) by pressing notched lever (9).
Remove bolts (6). Take out bolts (6). Remove the
rack (10).
20. Drive out pin (11). Remove the notched lever (9) and
spring (7).
Refitting
21. Carry out operation 20 in reverse order.
22. Compress spring (7). Position rack (10) in accordance with Fig. 4 in order to avoid interference with
lever (4). Fit and tighten bolts (6) lightly smeared with
Loctite 241.
23. Refit lever (4), with the rod T and spring (3). Replace
the retaining washers (1) (2).
24. Adjust lever (4) with the rod T in contact with the
notched lever (9), using adjusting screw (5) (3 mm
Allen key).
25. Carry out operation 17 in reverse order and then carry
out operations 6 to 9.
Issue 1
May 2001
10
Fig. 4
Refitting
30. Carry out operation 29 in reverse order.
31. Place pin (14). Replace the retaining washer (13).
32. Fit and adjust screw (5), lever (4), the rod T in contact
with notched lever (9).
33. Carry out operation 27 in reverse order and then carry
out operations 6 to 9.
8E01.7
Disassembly
Disassembly
Reassembly
44. Insert bearings (22) in housing (20) using an appropriate fixture.
45. Assemble the upper shaft (12) on bearings (22). Fit
circlip (23).
46. Assemble the lower shaft (29) complete with bushes
(30) and circlip (31) on the fixed column (28).
Note: Deform the tube of the column using a
punch in order to lock bushes (30).
47. Assemble housing (20) and mobile column (21). Fit
pins (18) (19). Insert pin (18).
48. Refit springs (17).
49. Compress spring (7). Position rack (10) in accordance with Fig. 4 in order to avoid interference with
lever (4). Fit and tighten bolts (6) lightly smeared with
Loctite 241.
50. Adjust lever (4), with the rod T in contact with
notched lever (9) by using adjusting screw (5) (3 mm
Allen key).
51. Carry out operation 35 in reverse order and then carry
out operations 6 to 9.
Reassembly
59. Position bush (27).
60. Place stop (25) in the groove on fixed column (28).
61. Assemble the mobile column (21) with fixed column
(28).
62. Fit bolt (24) loose it in order to locate bush (26). When
the bush is correctly located, moderately tighten the
bolt. Check that the mobile column (21) slides freely.
63. Refit the lock plate (16). Adjust lever (4) and the rod
T in contact with notched lever (9) by using adjusting
screw (5).
64. Reverse the order of operation 53 and then carry out
operations 6 to 9.
Issue 1
May 2001
8F01.1
CONTENTS
General ________________________________________________
A.
B.
C.
10
Issue 1
May 2001
General
On 8200 series tractors, the bearings supporting the
AG155H front axle are attached on the frame the same
way as the AG200H front axles.
The transmission shaft (1) is housed in a guard (2)
located beneath the tractor (Fig. 1). Each of its ends is
respectively linked by sleeves (3) to the 4WD gearbox
and to the front axle housing. The central part of the
transmission shaft is supported in a bearing (6) contained
in a support (5) fixed on to the lower part of the engine.
Parts list
(1)
(2)
(4)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(52)
Bolt
Front bearing
Chamfered washer
Rear bearing
Chamfered washer
Seal
Seal
Bush
Seal
Bolt
Bolt
Bush
Main support
Axle housing
Fig. 1
Fig. 2
Fig. 3
Issue 1
May 2001
8F01.3
1
AG 155H
2
6
3
AG 200H
Parts list
Issue 1
Fig. 2
Fig. 3
Fig. 1
May 2001
15
AG 155H
1
A
10
11
13
12
14
A
4
9
2
4
52
AG 200H
8
A
Parts list
Issue 1
May 2001
Fig. 1
Fig. 3
Fig. 2
8F01.5
Exploded view
15
1
2
14
10
11
6
12
13
Parts list
Issue 1
Fig. 1
Fig. 2
Fig. 3
May 2001
Fig. 4
Fig. 5
Issue 1
May 2001
8F01.7
7. Take out bolts (12) (13). Remove the front axle with
bearing (6) (AG 155H front axle - Fig. 6 or AG 200H
front axle - Fig. 7).
8. Separate the front axle bearing. Remove washer (7)
and seal (8).
Refitting
9. Replace seal (8). Position washer (7), the chamfer
facing the axle housing (52) (Fig. 2). Assemble
bearing (6) on the front axle.
10. Sling the axle and bearing assembly and fit it in
place. Provisionally fit bolts (12) (13).
11. Replace seal (9). Position washer (4), the chamfer
facing housing (52) (Fig. 2). Refit bearing (2). Provisionally fit bolts (1).
12
13
Fig. 6
12
5
6
13
Fig. 7
Issue 1
May 2001
12. Remove and refit, one by one, bolts (12) (13), lightly
smeared with Loctite 270. Definitively tighten them
to a torque of:
- (12): 260 - 320 Nm
- (13): 560 - 640 Nm
13. Apply bearing (2) to washer (4) in order to obtain the
minimum clearance possible. Definitively tighten
bolts (1) previously lightly smeared with Loctite 270
and tighten to a torque of 520 - 640 Nm.
14. Fit the grease nipples to the bearings (2) (6).
15. Reconnect the steering ram hoses. Smear the two
transmission shaft sleeves with Anti-Seize grease
or its equivalent. Fit the dust covers. Refit the
transmission shaft and sleeves on to the 4WD unit
and front axle.
- AG 155H front axles
. fit the bolts with a seal and tighten them on to the
sleeves previously lightly smeared with Loctite
241 or its equivalent.
- AG 200H front axles
. lightly smear bolts (4) with Loctite 241 or its
equivalent and tighten them to a torque of 61 81 Nm (Fig. 7).
16. Refit the guard. Reconnect both the hoses located on
either side of the front differential lock supply pipe.
Refit the wheels and tighten the wheel nuts to a
torque of 640 - 680 Nm.
17. Using a grease gun, grease friction bushes (10) (14).
Issue 1
May 2001
8F01.9
Refitting
19. Clean the components. Using a press and an appropriate fixture, insert bushes (10) (14) in their respective holders, flush with face F (Fig. 8), and with orifice
O facing upward and aligned with the grease channel.
Using an appropriate fixture, insert seal (11) thrust
against the shoulder of the bearing (6). Refit the
bearings.
14
10
11
Fig. 8
O
O
Fig. 9
Fig. 10
Issue 1
May 2001
C . 2 WD version
On tractors equipped with the 2 WD version, the same
method as that used for the 4WD version is applied.
Special points
- Raise the front of the tractor using a jack positioned in
the axis of the front axle and position axle stands.
- Insert plug (55), its rim previously lightly smeared with
Loctite 542 (Fig. 11).
- The Oring (11) ensures oil tightness of the 2nd axle
pivot.
- Tightening torque for wheel nuts or studs:140 - 200 Nm.
- Using a grease gun, grease the friction bushes (10) (14).
12
13
11
10
14
55
Parts list
(3) - (5) Grease nipples
(11) Oring
(55) Plug
Issue 1
Fig. 11
May 2001
8F02.1
CONTENTS
General ________________________________________________
A.
B.
C.
10
Issue 1
May 2001
General
On 8270 and 8280 tractors, the front bearings, located on
the cast-iron stand, support the two pivots of the ZF axle.
The 4WD transmission shaftline comprises two shafts,
the straight shaft (1) and the universal shaft (1A) (Fig. 1).
They are linked to the 4WD and the front axle housing (52)
by splined sleeve (3) and the universal joint spiders (9).
This transmission line is supported by bearing (6) and
bearing block (5) fitted beneath the lower housing at the
rear of the engine.
Issue 1
May 2001
8F02.3
Overall view
2A
52
1A
8
9
7
5
8
Fig. 1
Parts list
Issue 1
May 2001
Fig. 2
Fig. 3
8F02.4
Parts list (Figs. 2 - 3)
(1)
(2)
(3)
(4)
(6)
(8)
(9)
(10)
(11)
(12)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(52)
Bolt
Front bearing
Mecanindus locating pin
Washer
Rear bearing
Seal
Seal
Bush
Seal
Bolt
Bush
Main bearing stand
Bolt
Grease nipples
Grease nipples
Cover
Stop washer
Locating pins
Washer
Nuts
Axle housing
Overall view
15
12
Fig. 1
21
Fig. 2
Fig. 3
2
22
18
17
52
23
8
Fig. 2
Parts list
Issue 1
Fig. 1
Fig. 3
May 2001
8F02.5
Exploded view
12
15
21
17
2
14
20
19
18
11
10
1
17
8
16
Parts list
Issue 1
Fig. 1
Fig. 2
Fig. 3
May 2001
1A
Fig. 4
4. Refit the shaft.
5. Raise the front wheels (optional). Fix the spiders on
sleeve (4) and plate (7) using bolts (8) previously
lightly smeared with Loctite 241 or its equivalent and
tightened to a torque of 61 - 81 Nm.
6. Using a grease gun, grease sleeve (4).
7. Refit the front guard (2A).
Issue 1
May 2001
8F02.7
Straight shaft
Disassembly (Fig. 1)
8. Remove the front guard and the universal shaft and
carry out operations 1 to 3.
9. Remove the rear guard (2).
10. Spread apart the rubber protectors on sleeve (3).
Take out the bolt located in the centre of the sleeve
and slide the latter along straight shaft (1) towards
the front of the tractor.
11. Uncouple and remove the shaft, sleeve (3) and
bearing (5) assembly.
Reassembly (Fig. 1)
12. Inspect the components. Replace any parts found to
be defective.
13. Refit the shaft and sleeve assembly. Assemble the
central bearing in accordance with Fig. 5.
14. Tighten the bolts of bearing (5) and the central bolt of
sleeve (3).
15. Position the straight shaft.
Remark
- The rotating shaft turns bearing (6) located in
bearing (5) by means of bolts V (Fig. 5).
16. Lightly smear bolts V with Loctite 542 or its equivalent and tighten them in order to obtain a space
between the rear end of the shaft and the central bolt
on sleeve (3) (Fig. 1, detail A).
17. Place the rubber protectors on the sleeve.
18. Using a grease gun, grease sleeve (3).
19. Refit guard (2).
20. Refit the universal shaft (1A) and refit the front guard
(2A). Carry out operations 4 to 7 again.
5
Fig. 5
Issue 1
May 2001
Removal
22. Remove the front guard and disassemble the universal shaft (1A) (see A).
23. Raise the front of the tractor using an appropriate
jack positioned in the axis of the axle housing. Take
off the wheels. Position an axle stand under the
lower part of the engine sump (Fig. 7).
24. Locate the hose unions and disconnect them from
the steering rams.
25. Sling the front axle using appropriate straps (Fig. 7).
17
Fig. 6
Fig. 7
Issue 1
May 2001
8F02.9
Refitting (Fig. 2)
30. Slide washer (4) on the axle pivot with the hole facing
the Mecanindus pin (3).
31. Position new seals (8) (9) on the axle pivots turning
the lip towards their respective stands.
32. Sling the front axle. Refit the front axle and stands
assembly.
33. Place the stands on the main stand.
Fit the bolts and washers and tighten the nuts (23)
lightly smeared with Loctite 270 or its equivalent to
a torque of 540 - 610 Nm.
34. Push bearing stand (2) towards axle housing (52) in
order to obtain the minimum clearance possible
between the bearing stands and housing.
35. Fit the washers and tighten bolts (1) previously
lightly smeared with Loctite 270 or its equivalent to
a torque of 480 - 640 Nm.
36. Check for the presence of grease nipples on cover
(19) and on each bearing.
37. Reconnect the hoses to the steering ram.
38. Refit the wheels. Remove the axle stand. Tighten
the wheel nuts to a torque of 640 - 680 Nm. Refit the
centre weight and front weights (depending on options).
39. Refit the universal shaft and guard (see A).
Fig. 8
22
23
Fig. 9
Final operations
40. Remove the chocks and take off the handbrake.
41. Using a grease gun, grease bushes (10) (14) in the
bearing stands.
Issue 1
May 2001
Preliminary operation
42. Remove the bearing stands (see B).
F
Disassembly
Front bearing (Fig. 10)
43. Take out bolts (16), remove cover (19) and stop
washer (20). Extract and discard bush (14) of bearing
stand (2).
Rear bearing (Fig. 11)
44. Mark the position of the dust seal (11). Extract and
discard the latter as well as bush (10).
14
Reassembly
45. Clean and inspect the components. Replace any
parts found to be defective. Check that the grease
channels are not obstructed.
16
19
Front bearing
Fig. 10
10
11
10
Rear bearing
Issue 1
May 2001
Fig. 11
8F02.11
10
Front bearing (Fig. 13)
48. Using a press and an appropriate fixture, insert bush
(14) flush with face F of bearing stand (2) (Fig. 10) and
with the oblong ports facing upwards and communicating with the lubricating channel of bearing stand
(2).
49. Refit the stop washer (20).
Remark
- The stop washer has ridges that allow the passage
of grease for the lubrication of the bearing block.
50. Fit cover (19) on bearing block holder (2) and tighten
bolts (16) to a torque of 90 - 120 Nm (Fig. 10).
11
Final operation
51. Refit the bearing stands (see B).
Front bearing
Fig. 12
20
2
Rear bearing
Issue 1
14
Fig. 13
May 2001
8 F03
8F03.1
CONTENTS
General ________________________________________________
A.
14
B.
C.
Issue 1
May 2002
8F03.2
General
8210 - 8220 - 8240 and 8250 series tractors are equipped
with a Carraro fixed or suspension front axle. It is fitted
on a new frame which integrates the second axle pivot
bearing. The first axle pivot bearing, of conventional type,
can therefore be disassembled.
This frame can also be fitted with a Dana front axle. In
this case, the front axle must be supported by two
specific bearings (front bearing (2) and rear bearing (6)) to
be attached under the frame (Fig. 1).
The 4 WD transmission line is constituted by two shafts:
- straight shaft
- universal drive shaft.
These shafts are linked respectively to the 4 WD arrangement on the centre housing and to the nose of the front axle,
via a splined sleeve and universal joint spiders (Fig. 2).
This transmission line is supported by the bearing and the
cast-iron unit fitted at the front under the axle housing.
The rotating assembly is protected by two guards (2) (2A)
(Fig. 2).
Straight shaft
Universal drive shaft
Rear guard
Front guard
Serrated shaft
Nut and bolt
Support
Ball bearing
Dust cover nut
Spiders
Yoke
Sleeve
Castellated locknut
Front frame
Flanges
Shoulder screw
Issue 1
Fig. 1
May 2002
8F03.3
Overall view
A : Full Powershift
B : Dynashift
15
20
19
1A
11
10
5
9
8
2
19
20
B
2A
Issue 1
Parts list
May 2002
Fig. 1
Bolt
Front bearing
Unions
Washers
Lubricating pipe
Rear bearing
Seal
Seal
Bush
Seal
Bolt
Bush
Main bearing stand
Bolt
Grease nipples
Grease nipple(s)
Flanges
Stop washer
Axle housing
8F03.4
Fig 3
15
Fig 4
Parts list
2
9
A
16
7
Version with suspension front axle
2
L1
7
2
A
10
6
1
L1
14
A
11
7
52
4
Fig 4
May 2002
52
19
20
Fig. 2
8F03.5
3
17
8
3
6
5
15
10
16
9
2
11
3
12
18
14
Parts list
Fig 1
Issue 1
May 2002
Reassembly
Check points
- If the universal joint spiders must be replaced, carefully
check the condition of the universal joint end yokes.
Remove any traces of impact or deformations. Clean
the groove of each circlip correctly. After assembly
check that the circlips are properly placed in their
respective grooves.
Remark
- If necessary, to facilitate the coupling of the universal
joint to the nose of the axle, raise the front wheels using
a jack having sufficient lifting capacity and positioned
along the axis of the axle housing.
6. Replace the dust cover nut (7) if necessary.
Note: Use a locally made conical tool to refit the
dust cover nut (7) on the shaft (1).
Issue 1
May 2002
1A
19
20
Fig. 5
7. Smear the front splines of the straight shaft with
molybdenum sulphide grease or its equivalent. Refit
the universal drive shaft (1A).
8. Fix the front universal joint spider (8) on the plate of
the axle nose using flanges (19) and shoulder screws
(20) lightly smeared with Loctite 241 or its equivalent
and tighten them to a torque of 34 - 41 Nm.
9. Moderately tighten the dust cover nut (7).
10. Using a grease gun, grease sleeve (10) and refit the
guards (2) (2A)(Fig.2).
8F03.7
Reassembly
1
Fig. 6
Issue 1
May 2002
1
11
Remark
- The belly weight (1) (where fitted) (Fig. 8) is attached
under the front frame and may hinder the removal of
bearing (2) support.
Danger
Fig. 7
Reminder
- Some tractors may be fitted with a front power take off.
In this case, it will be necessary to remove it in order
to uncouple the front axle from the frame.
1
2
Fig. 8
Issue 1
May 2002
Fig. 9
8F03.9
2
4
11
Fig. 10
Fig. 11
Fig. 12
1
2
Issue 1
May 2002
Danger
- Place a fixed axle stand under the lower engine
housing.
34. Locate the connections of the hoses for the steering
and separate them from the cylinder.
35. Disconnect the front differential lock hose.
36. Sling the front axle using suitable straps (Fig. 9).
37. Take out bolts (1) (Fig. 3).
38. Pull the front axle assembly complete with bearing
support (2) frontwards along the axis of the axle
(position 1) and remove the front axle (position 2)
(Fig. 3 - 9).
39. Note the characteristics, location and position of the
chamfered washers (4) (7) and remove them (Fig. 3).
Remark
- On 8210 to 8250 series tractors, which are equipped
with a fixed front axle, the two washers 3785074M1
(4 mm thick each) fitted on the first axle pivot now
are replaced by a single washer 3785924M1
(8 mm thick) from the serial number K179009 on.
Washers (4)
3785924M1
Inside
Outside
Inside
Outside
60 mm
90 mm
60 mm
110 mm
Outside
8210 - 8220
8240 - 8250
Issue 1
May 2002
70 mm
115 mm
8F03.11
Refitting
Check points
40. Clean all components and check the condition of:
- the pivot pin at each end
- the chamfered washers (4) (7)
- the friction rings (10) (16)
- the seal (9)
Issue 1
May 2002
F
1
Fig. 13
Issue 1
May 2002
8F03.13
Final operations
59. Remove the safety chocks and release the handbrake.
60. Using a grease gun, grease the friction rings (10) (16)
of the axle pivots.
Issue 1
May 2002
16
Reassembly
64. Clean and check the components. Replace any parts
found to be defective. Check that the grease channels in the support are not obstructed.
65. Using a press and a suitable fixture, insert a correctly
positioned seal (9) and ring (16) flush with face F of
support (2) (Fig. 14 - 15), the grease hole T in
communication with the channel (Fig. 16).
2
Fig. 14
2
16
Fig. 15
Fig. 16
9
Issue 1
May 2002
8F03.15
Disassembly
66. Drive out bush (10) using a locally-made tool.
Note: The circlip (6) and plug (8) are not considered as normally wearing parts, therefore their
replacement is unlikely.
Reassembly
67. Using a locally-made drift, insert bush (10) into the
frame (15) flush with chamfer C (Fig. 17 - 18).
10
15
Fig. 17
Remark
- Bush (10) does not have a grease port. The grease is
led inwards by an axial channel L1 and a radially drilled
hole at the rear end of the pivot axis (Fig. 3).
Fig. 18
10
C
15
15
Issue 1
May 2002
8G01.1
8G01 4 WD clutch
CONTENTS
-
General ________________________________________________
A.
B.
C.
D.
11
E.
11
Issue 1
May 2002
Issue 1
May 2002
8G01.3
Operation
Declutched position
- The 4 WD solenoid valve, fitted on the right-hand side
hydraulic cover and controlled by the tractors electronic system, supplies the interior of the shaft with 17bar pressure via channel A (Fig. 1). The pressure is
maintained by seal rings (32). Piston (39) moves in hub
(30) and draws clutch cover (23) thus compressing the
Belleville washers (26) and freeing the plates (36). The
bell-shaped gear (10) then idles on the shaft.
Clutched position
- When the pressure is cut-off, the Belleville washers
(26) push the clutch cover (23), mating the clutch plates
with the bell-shaped gear (10) and thus allowing for the
rotation of shaft (2).
Lubrication
- The oil from the lubricating circuit arrives via reducer
union (22) and lubricates the clutch plates (36) via the
transfer pipe (21) and channel B drilled in shaft (2)
(Fig. 1).
Issue 1
May 2002
Part list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
Lip seal
4 WD drive shaft
Circlip
Bearing cup
Circlip
Bush
Bush
Bearing cup
Bearing cone
Bell-shaped gear
Cover
Bolt
Plug
Seal
Clutch assembly
Bearing cone
Driving pinion
Shim(s)
Oring
Seal holder
Transfer pipe (lubrication)
Restrictor union and seal
Clutch cover
Oring
Oring
Belleville washers
Union and seal
Transfer pipe (17 bar)
Cover plate
Hub
Oring
Seal rings
Circlip
Circlip
Shim(s)
Clutch friction plates
Intermediate clutch plates
Circlip
Piston
Oring
Dust seal
Issue 1
Fig 1
Fig 2
May 2002
19
18
8G01.5
Overall view
16
17
41
20
21
22
23
F-F
30
27
28
29
13
14
33
15
11
12
31
40
34
39
9
38
35
24
25
26
36
37
10
32
8
Parts list
Fig 2
Issue 1
May 2002
Fig. 1
8G01.6
Exploded view
5
17
7
33
8
6
11
29
37
12
28
13
31
9
14
10
25
34
35
36
38
32
23
2
26
16
30
19
39
1
24
20
40
Parts list
41
21
4
18
Fig 1
3
Fig. 2
Issue 1
May 2002
8G01.7
Removal
5. Take off circlip (3).
6. Wrap the splined section of shaft (2) with a flexible
protective tape. Take out dust seal (41). Extract the
seal holder (20) fitted with its seal (1) using two
locally manufactured hooks placed in internal groove
"G" of the seal holder (Fig. 1). Extract seal (1).
7. Take out Oring (19).
8. Remove the shim(s) (18) and bearing cup (4).
9. Take out the shaft assembly (2) fitted with bearing
cone (16) while holding the clutch (15) and the bellshaped gear (10) assembly.
10. Remove the clutch assembly, the bell-shaped gear
and bearing cone (9).
11. Extract cup (8). Remove circlip (33).
Note: To carry out maintenance on driving pinion (17), remove the entire unit assembly with
drive pinion (see section 6D01, 6D02 or 6D03
according to the version).
12. Remove the 4 WD clutch 17 bar supply pipe, union
(27) and transfer pipe (28) using circlip pliers. Take
off bush (7). Remove Oring (31).
Issue 1
May 2002
Issue 1
May 2002
8G01.9
34
35
26
Fig. 3
Reassembly
39. Inspect and clean the components. Replace any
parts found to be defective. Check that channels "A"
and "B" (Fig. 1) are not obstructed.
40. Position the Belleville washers (26) in the clutch
cover (23) (Fig. 4).
41. Lubricate and fit Oring (25) on hub (30).
42. Position hub (30) in clutch cover (23) and thrusting
against the Belleville washers.
43. Place the clutch friction plates (36) aligning the tabs,
the intermediate plates (37) and fit the cover plate
(29).
Reminder
- Depending upon the options, cover (29), the number
of clutch plates and intermediate plates differ.
26
23
Fig. 4
Issue 1
May 2002
26
Fig. 5
J1 = 0,9 / 1,1 mm
34
35
34
29
X
Fig. 6
Issue 1
May 2002
8G01.11
J2 = 0 / 0,10 mm
Action
- To carry out J2 shimming, provisionally fit bearing cone
(9), shaft (2) fitted with taper roller bearing (16) without
fitting the clutch (15), bell-shaped gear (10) and shim(s)
(18) assembly. Fit bearing cup (4), seal holder (20) and
circlip (3).
J2 shimming
53. Place the index of a dial gauge on the end of shaft (2)
(Fig. 7).
54. Since access is limited around the shaft, pull hard
using vice grip pliers, and alternatively turning it left
and right in order to correctly seat the cones and
cups.
55. Set the dial gauge to zero.
56. Repeat operation 54, this time while pushing.
57. In relation to the clearance measured, select a shim
(18) thickness to provide a clearance of:
J2 = 0 mm to 0.1 mm (Fig. 7)
58. Remove circlip (3), seal holder (20), shaft (2) and the
bearings.
59. Definitively fit the clutch (15), bell-shaped gear (10)
and shaft (2) assembly. Carry out operations 21 to 28
B.
Fig. 7
64. Refit the transmission shaft.
65. On tractors fitted with an AG 155H or AG 200H front
axle, reconnect the differential lock control piping.
66. Remove the chocks from the wheels. Carry out a
road test the 4 WD clutch.
67. Check the oil tightness of:
- the cover (11) mating face beneath the intermediate housing
- the hydraulic unions
E . Final operations
60. Clean cover (11) and its mating face on the housing.
61. Smear the cover mating face with Loctite 510 or its
equivalent.
62. Refit the inspection cover. Tighten the bolts (12) to a
torque of 70 - 90 Nm.
63. Refill the housings and check the oil level on the
transparent tube on the left-hand side of the centre
housing.
Issue 1
May 2002
8G02.1
CONTENTS
A. Arms unit disassembly _________________________________
14
Issue 1
May 2002
8G02.2
A
B
Danger
Fig. 1
H
D
F
G
Danger
- if the upper and lower arms arent correctly
supported, they could move harming the operator.
Fig. 2
J
I
Fig. 3
Issue 1
May 2002
8G02.3
Danger
- the lower arms could rotate harming the operator.
Collect the seal rings and the shims, where they are
present.
If needed replace the shock-absorber pads K removing the relative screws.
5. Remove the lower arms pin covers and the sensor
plate E, unsrewing the relative fastening screws F
(Fig. 5). Collect the rubber washer on the sensor side
(see section 11G01 B).
6. Remove the bearings fastening screws L from the
arms pin, collecting the relative thrust washer M and
the shims N, where they are present.
Note : The thrust washer on the sensor pin has a
particular shape and it could not be confused with
the other ones.
To reach the fastening screw on the sensor side,
positioning ring needs to be removed from the thrust
washer (see section 11G01 B).
Note : This is a destructive operation for the seals.
Remove the bearings O and the seal rings P.
Fig. 4
Fig. 5
P
L
Fig. 6
Issue 1
May 2002
8G02.4
Fig. 7
R
S
U
T
Fig. 8
Issue 1
May 2002
8G02.5
Fig. 9
Fig. 10
Fig. 11
Issue 1
May 2002
12. Assemble the seal ring (I) on every pin in the lower
arms housings using the special tool CA715352 (see
C) code with a hammer.
Insert the conical bearing (J) using the special tool
CA715349 (see C).
Assemble a reference spacer R (on the pinion side)
of appropriate dimension (shim R= 1 mm) and the
thrust washer K with the fastening screw L (Fig.12).
Warning : The spacer must have the outer diameter lower than the inner one of the bearing.
Note : The thrust washer on the sensor pin has
a particular shape and it must not be confused
with the other pins ones.
Adjust the conical bearings moving the arms and
tighten the fastening screws with a dynamometric
wrench to the requested torque (see section 8A01
A).
13. Warning : verify the bearings assembly position
on the pins arms.
On the lower pins : the bearing must be inserted
with the cup on the inner side (in the arm housing)
and the cone on the outer one (on the pin).
On the upper pins : the bearing must be inserted
with the cone in the inner side (on the pin) and the cup
on the outer one (on the arm housing) (Fig.13).
14. Position a magnetic-base dial gauge on the axle
beam so that the feeler touches the lower arm side
surface and then zero the gauge.
Position a lever between the arm and the axle beam,
drive the arm till end of stroke from both side and
measure the backlash with the dial gauge. Repeat
this operation several times, so to find an average
value X (Fig.13).
15. In order to determine the necessary thickness S to
give preloading to the bearing, substract the measured value X and the prescribed one from the known
reference shim value R
S = (R - X) - V
V = 0.05 to 0.15 mm
Choose among the available shims a quantity in a
way to reach the previously determinated value S.
Thickness
Quantity
Shim range
0.1
0.2
-
I
L
Fig. 12
Fig. 13
0.5
-
R
X
Fig. 14
Issue 1
May 2002
8G02.7
L
S
Danger
Fig. 15
P
P
Fig. 16
Issue 1
May 2002
U
T
U
Fig. 17
ZV
Fig. 18
F
E
Fig. 19
Issue 1
May 2002
Thickness
Quantity
Shim range
0.1
0.2
-
8G02.9
H
K
Fig. 20
0.5
-
Fig. 21
I
J
L
Fig. 22
Issue 1
May 2002
A
Fig. 23
A
Fig. 23A
Issue 1
May 2002
Shim range
Thickness
0.1
Quantity
-
0.3
-
8G02.11
W
D
Fig. 24
Fig. 24A
Danger
- if the upper and lower arms arent correctly
supported, they could move harming the operator.
32. Remove the fastening screws of all the lower arms
pins and erassamble then applying Loctite 542 on
the threads, then ligthen them with a dynanometric
wrench to the requested torque (see section 8A01
A).
Fig. 25
Fig. 26
Issue 1
May 2002
33. Insert the seal ring M on the sensor pin thrust washer
with the special tool CA715345 (see C) and new ORings in the relative housing on the pins arms covers
O and on the sensor plate N.
Assemble arms pin covers and the sensor plate,
filling their housing in excess with grease, then
screw the relative fastening screws to the requested
torque (see section 8A01A) (Fig. 27).
34. Measure the distance Xac in the Closed Axle position from the pin centre to the differential support,
choosing a well precise datum-point P (Fig. 28).
35. Lift completly the arms and measure the distance
Xaa in the Opened Axle position, from the pivot pin
centre to the chosen datum-point P (Fig. 29).
Warning : Lift gradually the arms untill the end
of strokes is reached, surpasse this position
damage suspension cylinder.
Check that the suspension cylinder stroke C fall
within the prescribed range, substracting between
C = Xaa - Xac
C = 88 to 89 mm
M
N
O
Fig. 27
Xac
P
Fig. 28
Xaa
P
Fig. 29
Issue 1
May 2002
Thickness
Quantity
Shim range
0.05
0.10
-
0.20
-
8G02.13
2.00
Fig. 30
Fig. 31
Issue 1
May 2002
C. Service tools
- CA 715382 - Driver rod (Fig. 32)
- CA 715345 - Oil seal driver (Fig. 33)
- CA 715383 - Oil seal driver (Fig. 34)
Fig. 32
Fig. 33
Fig. 34
Issue 1
May 2002
8G02.15
Fig. 35
Fig. 36
Fig. 37
Issue 1
May 2002
Fig. 38
Fig. 39
Fig. 40
Issue 1
May 2002
8G02.17
Fig. 41
Fig. 42
Fig.43
Issue 1
May 2002
8I01
8I01.1
Carraro troubleshooting
CONTENTS
-
Generality __________________________________________________
A. Troubleshooting ____________________________________________
Issue 1
May 2002
8I01.2
Generality
The following table presents you some possible problems
and their causes. Refer you to the number of the cause
to know its remedy.
Possible causes
Problems
Friction noise
10
11
Issue 1
May 2002
8I01.3
5. Bent halfshaft
Replace halfshaft.
6. Blocked differential
Abnormal functioning of the differential or breakage/
blockage of command device. Verify assembly and
all components.
Vehicles with wide steering angle may proceed with
kicks, have steering difficulty or cause pneumatic
wearing at sharp turns. Reduce the steering angle to
minimum and decelerate when the vehicle begins to
kick.
7. Incorrect wheel adjustment
Verify group integrity and wheel side bearings.
Adjusting according.
8. Spoiled or worn out axle parts
Check the condition of ring gear, pinion gear, bearings etc. Replace when ever necessary.
9. Contamination in the axle box or incorrect assembly of parts
Look for foreign particles. Check assembly of the
various parts of the axle.
10. Incorrect adjustment of bevel gear set: Parts of
the transmission worn out (transmission gears, U
joints, etc.)
Replace or adjust as required.
11. Incorrect use of the product
See the vehicle producers instructions once again.
Issue 1
May 2002
A. Troubleshooting
PROBLEM
CAUSE
REMEDY
1. Load bump
2. Incorrect gear adjustment
(insufficient backlash)
3. Pinion nut loosened
1. Insufficient lubrication
2. Contaminated oil
3. Incorrect lubrication or
depleted additives
4. Worn out pinion bearings
that cause an incorrect pinion
axle backlash and wrong
contact between pinion and
ring.
1. Prolong ed functioning at
high temperatures
2. Incorrect lubrication
3. Low oil level
4. Contaminated oil
1. Excessive use
2. Insufficient lubrication
1. Insufficient lubrication
2. Contaminated oil
3. Excessive use
4. Normal wear out
5. Pinion nut loosened
Replace bearings.
Use correct lubrication fill up,
to the right level and replace at
recommended intervals
Issue 1
May 2002
1. Prolonged functioning at
high temperature of the oil
2. Oil gasket assembled
incorrectly
3. Seal lip damaged
4. Contaminated oil
1. Exhaustive use
2. Continuos overload
Excessive use
1. Insufficient lubrication
2. Incorrect lubrication
3. Contaminated oil
Replace bearing.
Check pinion axial backlash.
Use proper lubrication, fill up to
right level and replace at
recommended intervals.
Replace
Replace
Check that wheel support is
not worn out or wrongly
adjusted.
Issue 1
8I01.5
May 2002
8I01.6
CAUSE
RECOMMENDED REPAIR
1. Adjust
Intermittent noise
Constant noise
1. Replace
2. Replace
Issue 1
May 2002
2. Replace
3. Replace
4. Adjust
5. Adjust
6. Replace
7. Adjust
8. Replace
9. Oil level
10. Replace
11. Replace
2. Replace
3. Adjust
2. Replace
3. Replace
4. Replace
3. Replace
4. Replace
9 . HYDRAULICS
Contents
9 A01
9 A02
9 B01
9 C01
9 D01
9 E01
9 F01
9 F02
9 G01
9 G02
9H01
9 I01
9 J01
9 K01
9 K02
9 L01
DYNASHIFT CONTROL
9 M01
OIL DECONTAMINATION
9 N01
HYDRAULIC TESTS
Issue 2
May 2002
9A01.1
CONTENTS
A.
General ________________________________________________
B.
Principle _______________________________________________
C.
D.
Diagrams _______________________________________________
20
E.
Issue 1
2
December
May 2000
2002
Issue 1
December 2000
9A01.3
The controller takes into account the pilot signal corresponding to the function requiring the highest pressure.
Component characteristics
Suction strainer (37)
- Type ....................................
- Filtration threshold ................
cartridge
150
Rexroth Sigma
60 cm3 per revolution
165 l/min at 2200 rpm
15
3,5 bar
2,4 bar
5 bar
supplies booster pump
5 bar (clogging indicator placed on main
filter)
3 bar
2 bar
Opens ..................................
Closes .................................
Fitted in parallel to filter
Linked to signal lamp on dashboard
All the pilot signals from the various high pressure valves
are directed to the priority block(s) to then be retransmitted
to the variable displacement pump controller.
Issue 1
May 2001
B . Principle
The purpose of the closed centre hydraulic system is to
limit the power absorbed by the engine. If no hydraulic
slave device is actuated, no flow is discharged by the
variable displacement pump.
When a function is activated, the pump only supplies the
output required for that function.
:
:
:
:
:
:
Issue 1
May 2001
9A01.5
B
C
D
G
Fig. 1
Issue 12
Issue
May 2000
2002
December
Issue 1
December 2000
(53)
(54)
(55)
(62)
(63)
(64)
(65)
Fig. 2
Fig. 3
High pressure
Low pressure
Lubrication
Suction
Return
Brakes
Pilot flow
9A01.7
52
51
50
49
3
4
47
58
46
15
45
13
44
54
53
14
43
16
38
18
12
55
17
21
37
40
22
23
65
39
24
29
30
42
48
32
27
41
25
26
28
36
33
35
34
33
Parts list
Issue 1
32
31
Fig. 3
Fig. 2
May 2001
52
51
51
1
2
49
3
4
12
47
58
46
15
45
13
44
54
53
14
43
16
17
38
22
23
37
62
63
40
18
39
24
42
48
32
27
41
25
36
33
35
34
33
64
Parts list
Issue 1
May 2001
32
55
65
21
29
30
26
28
31
Fig. 2
Fig. 3
9A01.9
Right-hand side
14
(A)
(B)
(C)
(D)
Issue 1
2
December
May 2000
2002
12
45
15
52
44
46
49
Fig. 5
Issue 1
December 2000
9A01.11
(1)
(2)
(3)
(4)
(4)
(5)
(5)
(6)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
to
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)
(51)
Tank
Brake master cylinders
Servo brake
Engine clutch
Power shuttle
Control valve (clutch and Dynashift)
Control unit with Power shuttle
Clutch diagnostics connector
Front and rear clutch diagnostics connector
Dynashift diagnostics connectors
Accumulator for low pressure components
Hare/Tortoise solenoid valve
Oil cooler
Load Sensing diagnostics connector
Variable displacement pump controller
Main filter (15 )
Solenoid valves: PTO, PTO brake, differential lock
(front, rear)
and 4WD
Steering priority spool valve
17 bar pressure spool valve
High pressure diagnostic connector
Booster pressure / lubricating diagnostics connector
Low pressure diagnostics connector
Priority blocks without trailer braking
Right-hand side cover
5 bar safety valve
22 bar safety valve
Pressure limiter
Lift rams
Couplers
PTO brake
PTO clutch
Auxiliary spool valves
Lift control valve
Rear differential lock
Centre housing lubricating manifold
4WD clutch
Suction strainer (150 )
Booster pump
Left-hand side cover
Pump drive pinion bearing
Suction strainer and pipe (clutch(es))
Left and right-hand side brakes
Dynashift unit
Hydrostatic steering spool valve (Orbitrol)
Clutch master cylinder
Front differential lock
Steering ram
Variable displacement pump
Braking assistance accumulator
Fig. 6
Fig. 7
Fig. 7A
Issue 21
with mechanical
reverse shuttle
(Fig. 7)
with Power
shuttle
(Fig. 7A)
December
2000
May 2002
9A01.12
Parts list
with mechanical
reverse shuttle
(Fig. 6)
with Power
shuttle
(Fig. 6)
High pressure
Low pressure
Lubrication
Version with trailer braking
Suction
Return
Brakes
Pilot flow
2
3
Parts list
Fig. 7
Fig. 7A
55
56
57
Fig. 6
Issue 12
May 2000
2002
December
9A01.13
Parts list
Fig. 6
Fig. 7A
10
47
46
1
2
3
4
45
44
51
43
42
41
13
40
11
39
14
38
18
19
37
20
21
22
36
48
35
23
34
24
25
26
28
27
33
32
29
31
29
30
12
17
28
Fig. 7
2
Issue 1
May 2000
2002
December
4
5
Parts list
Issue 12
December
May 2000
2002
Fig. 6
Fig. 7
Fig. 7A
9A01.15
51
Fig. 8
41
Fig. 9
Issue 21
May 2002
December
2000
Booster circuit
Cooling
- The transmission oil of the rear axle housing is cooled
by two cooling elements located in the grille at the front
of the tractor and linked to the main 15 micron filter
element via a set of pipes and hoses.
Issue 21
May 2002
December
2000
9A01.17
51
B
Fig. 8A
41
Fig. 9A
Issue 1
2
December
May 2000
2002
Issue 2
1
May 2002
December
2000
9A01.19
Issue 12
Issue
May 2000
2002
December
E . Diagrams
Full Powershift gearbox (Fig. 10)
Parts list
(1) Oil tank (gearbox and centre housing)
(2) Brake master cylinders
(3) Servo brake
(4)
to Gearbox proportional solenoid valves
(12)
(13) Main filter (15 )
(14) Suction strainer (250 )
(15) Pump
(16) Variable displacement pump controller
(17) Load Sensing diagnostic connector
(18) Solenoid valves: PTO brake, differential lock
to (front, rear)
(21) and 4WD
(22) Steering priority spool valve
(23) 17 bar pressure spool valve
(24) High pressure diagnostic connector
(25) 5 bar safety valve
(26) 22 bar safety valve
(27) Priority block without trailer braking
(28) Right-hand cover
(29) Booster pump pressure diagnostic connector
(30) Low pressure diagnostics connector
(31) Dsicharge pressure limiter
(32) Lift rams
(33) Couplers
(34) PTO brake
(35) PTO clutch
(36) Auxiliary spool valve
(37) Suction strainer (150 )
(38) Booster pump
(39) Centre housing lubricating manifold
(40) 4WD clutch
(41) Lift control valve
(43) Left cover
(44) 3-way filter
(46) Gearbox pressure regulating valve (17 bar)
(47) Hydrostatic steering spool valve (Orbitrol)
(48) Variable displacement pump
(49) Thermostatic valve
(51) Steering rams
(52) Oil cooler
(54) Park Lock control
(55) Park Lock solenoid valve
(56) Dual Control or front PTO (if fitted) 17 bar hydraulic
line
(57) Braking assistance non-return valve
(58) Braking assistance accumulator
(59) Load Sensing connector (provision for)
Issue 12
December
May 2000
2002
(60)
(61)
(62)
(63)
(64)
(65)
Legend
A : Differential lock
B : (17 bar) low pressure switch
C : 4WD
D : rear PTO
E : rear PTO brake
F : 4WD clutch
G : Pump bearing lubrication
H : Rear PTO lubrication
I : Trumpets lubrication
J : Creeper unit and handbrake mechanism lubrication
Fig. 10
- Load sensing 110 l/min and Dana front axle mounted in series.
9A01.21
27
Yft
41
32
T0
63
150
bar
23
17
bar
Xdlr
Pbf
Pdlr
Pbn
Parts list
62
22
61
65
Xbf
Xbf
P
Paux
26
64
31
22 bar
155 bar
17
LS
A2
B2
Pl
Pfr
51
Xaux
24
A
B
16
24
20
230 bar
47
XLS
21
22 bar
44
200 bar
15
29
48
250 microns
15>200
17 bar
6 bar
LS
19
30
49
52
2,4 bar
87/73
45 cc/tr
14
18
46
25
3,5 bar
36
A1
B1
60
58
5 bar
LS
59
15>200
12
2,4 bar
3,5 bar
28
G
13
56
J
I
2,8 bar
38
87/70
60 cc/tr 7
37
150
microns
39
4,4
4,4
Issue
Issue 2
1
May 2002
December
2000
55
54
57
43
Fig. 10
Issue 1
May 2000
2002
December
(59)
(60)
(61)
(62)
(63)
(64)
(65)
Legend
A : Differential lock
B : (17 bar) low pressure switch
C : 4WD
D : rear PTO
E : rear PTO brake
F : 4WD clutch
G : Pump bearing lubrication
H : Rear PTO lubrication
I : Trumpets lubrication
J : Creeper unit and handbrake mechanism lubrication
Fig 11
9A01.23
27
Yft
41
32
T0
63
150
bar
23
17
bar
Xdlr
Pbf
Pdlr
Parts list
62
Pbn
22
61
65
Xbf
Xbf
P
Paux
26
64
31
24
22 bar
155 bar
17
LS
A2
B2
Pl
Pfr
51
Xaux
A
B
16
24
20
230 bar
47
XLS
21
22 bar
44
200 bar
15
29
48
250 microns
15>200
17 bar
6 bar
60
58
5 bar
LS
59
15>200
2,4 bar
12
3,5 bar
28
13
J
I
56
2,8 bar
38
87/70
60 cc/tr
37
150
microns
39
4,4
Issue 1
30
LS
19
49
52
2,4 bar
87/73
45 cc/tr
14
18
46
25
3,5 bar
36
A1
B1
4,4
December
2000
May 2002
55
54
57
43
Fig. 11
with mechanical
reverse shuttle
(Fig. 12)
with Power
shuttle
(Fig. 13)
Fig 12
Fig 13
with mechanical
reverse shuttle
(Fig. 12)
Issue 1
December 2000
with Power
shuttle
(Fig. 13)
9A01.25
23
33
28
T0
19
17
bar
Pbn
Fig 13
Parts list
54
18
Xbf
LS
A2
B2
Paux
26
27
Xaux
20
22 bar
11
32
A1
B1
Pl
A
B
12
150 bar
47
24
16
230 bar
XLS
17
25
K
21
14
48
22
15
LS
52
50
51
53
45
D
87/73
45 cc/tr
LS
200 bar
44
22 bar
8
5 bar
G
11 2,8 bar
38
I
4,4
Issue 1
24
49
13
4,4
37
N
2,4 bar
15>200
35
3,4 bar
87/70
60 cc/tr
150
microns
May 2000
2002
December
3,4 bar
10
6
7
39
Q
5
Fig. 12
Issue
Issue11
May 2002
December
2000
9A01.27
23
Yft
T
T0
19
62
17 bar
32A
150 bar
Xdir
32
Pdir
28
54
18
U
Paux
26
Xaux
27
20
22 bar
12
P1
Pfr
60 microns
33
B
11
50 bar
47
16
230 bar
17
XLS
22 bar
52
14
25
21
22
200 bar
48
V
S
50
44
76/65
45cc/tr
15
51
Fig 12
59
5 bar
Parts list
L
F
58
3,4 bar
13
G
H
2,8 bar
35
24
15>200
2,4 bar
3,4 bar
38
39
37
150 nicrons
49
13b
10
76/61
50cc/tr
6A
O
5
Q
1
7
Issue 1
December
2000
May 2002
Fig. 13
9A02.1
CONTENTS
A.
General ________________________________________________
B.
Principle _______________________________________________
C.
D.
Diagram ________________________________________________
10
E.
Issue 1
May 2001
A . General
All tractors in the 8200 series are fitted with a closed
centre hydraulic circuit with controlled pressure and
flowrate.
Only tractors with a Full Powershift gearbox can be fitted,
depending on options, with a 150 l/min flowrate circuit.
48
Issue 1
May 2001
Fig. 1
The first block supplies:
Component characteristics
Suction strainer (37)
- Type: cartridge
- Filtration threshold: 150
9A02.3
B . Principle
The purpose of the closed centre hydraulic system is to
limit the power absorbed by the engine. If no hydraulic
slave device is actuated, no flow is discharged by the
variable displacement pump.
When a function is activated, the pump only supplies the
output required for that function.
Note: If the housing is drained, or if the main filter is
replaced or any servicing operation carried results in
the air intake into the system, it is essential to prime
the hydraulic circuit. Disconnect the connector to
the fuel injection pump. Activate the engine starter
motor in consecutive bursts until the (red) booster
pressure signal lamp on the dashboard goes out.
Issue 1
May 2001
B
C
D
G
A:
B:
C:
D:
E:
F :
Issue 1
May 2001
9A02.5
Tank
Brake master cylinders
Servo brake
Proportional solenoid valves of gearbox
Main filter (15 )
Suction strainer (250 )
Pump
Variable displacement pump controller
Load Sensing diagnostic connector
Solenoid valves: PTO brake, differential lock
(front, rear)
and 4WD
Steering priority spool valve
17 bar pressure spool valve
High pressure diagnostic connector
5 bar safety valve
22 bar safety valve
Priority block without trailer braking
Right-hand cover
Booster pump pressure diagnostic connector
Low pressure diagnostics connector
Discharge pressure limiter
Lift rams
Couplers
PTO brake
PTO clutch
Auxiliary spool valve
Suction strainer (150 )
Booster pump
Centre housing lubricating manifold
4WD clutch
Lift control valve
Rear differential lock
Left-hand.t cover
3-way filter (15 )
Temperature probe
Gearbox pressure regulating valve (17 bar)
Hydrostatic steering spool valve (Orbitrol)
Variable displacement pump
Thermostatic valve
Front differential lock
Steering rams
Oil cooler
Pump drive pinion bearing
27
Fig. 3
Version without trailer braking
(54)
(55)
(58)
(62)
(63)
(64)
(65)
Remark
High pressure
Low pressure
Lubrification
Suction
Return
Brakes
Pilot flow
Fig. 4
Issue 1
Fig. 5
May 2001
52
51
50
49
3
4
12
47
58
46
15
45
62
63
44
22
23
53
54
55
43
24
25
38
27
37
28
40
18
39
14
42
30
32
13
48
41
16
17
36
33
35
34
33
64
Parts list
Issue 1
May 2001
32
65
26
31
21
29
Fig. 5
Fig. 4
9A02.7
52
51
51
1
2
49
3
4
12
47
58
46
15
45
62
63
44
22
23
53
54
55
43
24
25
38
27
37
28
40
18
39
14
42
30
32
13
48
41
16
17
36
33
35
34
33
64
Parts list
Issue 1
32
65
26
31
21
29
Fig. 4
Fig. 5
May 2001
9A02.8
Right-hand side
14
(A)
(B)
(C)
(D)
Issue 1
May 2001
9A02.9
Left-hand side
4
12
45
15
52
44
46
49
Fig. 7
Issue 1
May 2001
E . Diagram
Parts list
(1)
(2)
(3)
(4)
to
(12)
(13)
(14)
(15)
(16)
(17)
(18)
to
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(36)
(37)
(38)
(39)
(41)
(43)
(44)
(46)
(47)
(48)
(49)
(51)
(52)
(54)
(55)
(56)
Tank
Brake master cylinders
Servo brake
Gearbox proportional solenoid valves
Main filter (15 )
Suction strainer (250 )
Pump
Variable displacement pump controller
Load Sensing diagnostic connector
Solenoid valves: PTO, PTO brake, differential lock
(front, rear)
and 4WD
Steering priority spool valve
17 bar pressure spool valve
High pressure diagnostic connector
5 bar safety valve
22 bar safety valve
Priority block without trailer braking
Right-hand cover
Booster pump pressure diagnostic connector
Low pressure diagnostics connector
Discharge pressure limiter
Lift rams
Auxiliary spool valve
Suction strainer (150 )
Booster pump
Centre housing lubricating manifold
Lift control valve
Left cover
3-way filter (15 )
Gearbox pressure regulating valve (17 bar)
Hydrostatic steering spool valve (Orbitrol)
Variable displacement pump
Thermostatic valve
Steering ram(s)
Oil cooler
Park Lock control
Park Lock solenoid valve
Dual Control or front PTO (if fitted)17 bar hydraulic
line
Issue 1
May 2001
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
(65)
(66)
Fig. 8
9A02.11
62
27
Yft
41
32
T0
63
150
bar
Xdir
23
17
bar
Xdir
Pdir
Pbf
Pdir
Pbn
22
61
65
Xbf
Xbf
P
Paux
26
47
64
31
22 bar
B
155 bar
17
16
Manocontact
BP
XLS
21
A
22 bar
200 bar
15
25
29
48
66
250 microns
17 bar
6 bar
2,4 bar
30
Frein PDF
52
60
58
5 bar
LS
59
15>200
Pump
bearing lub.
2,4 bar
PTO lub.
3,5 bar
28
13
56
Trumpets lub.
2,8 bar
38
87/70
80 cc/tr 7
37
150
microns
39
4,4
LS
19
49
4 WD
clutch
12
87/77
60 cc/tr
14
15>200
18
46
3,5 bar
36
A1
B1
4 RM
44
Diff.lock
24
20
230 bar
LS
A2
B2
Pl
Pfr
51
Xaux
24
4,4
55
54
57
43
Fig. 8
Parts list
Issue 1
May 2001
9B01.1
CONTENTS
-
General ________________________________________________
A.
B.
Issue 1
May 2001
General
Depending on options, the 8200 Load Sensing series
tractors fitted with the 110 l/min or 160 l/min variable
displacement pump, may be fitted with a trailer brake
mechanism.
The hydraulic unit attached on the right-hand side cover
has two priority blocks mounted in series.
The internal block (1) (Fig. 1) ensures priority for the 17 bar
circuit and manifold that supplies the auxiliary spool
valves and lift control valve (see respective sections
9D01 and 9E01).
The external block (4) (Fig. 1) shares priority between the
steering function and trailer braking.
To facilitate access to the trailer-braking device, either
remove the rear wheel or place it in its wide track position
(see section 2G01).
Tightening torques
- Bolts V: 25 - 35 Nm. Loctite 542 (Fig. 2 - 3)
- Wheel studs or nuts: see section 2G01
Special points
- Check the oil tightness of the unions and Orings on
priority blocks fitted against the hydraulic cover.
- If the priority blocks have been replaced, carry out
hydraulic tests (see section 9N01) and check the
operation of the controls.
- Carry out a road test.
Issue 1
May 2001
Fig. 1
9B01.3
Fig. 2
Issue 1
May 2001
G F
Fig. 3
Issue 1
May 2001
9B01.5
I : 17 bar output
J : Plugs
K : Pilot flow from brake master cylinders
P.dir (St.pr) : Tiroir priorit direction
BP (LP)
: low pressure spool valve
HP
: high pressure spool valve
:
:
:
:
:
Bottom view
Bottom view
2
K
K
F
E
Front view
A
Front view
P.dir
HP
BP
BP
HP
P.dir
2
I
A
Top view
Top view
Fig. 4
Issue 1
May 2001
Issue 1
May 2001
(4)
(17)
(20)
(21)
(31)
Priority block
Lift control valve
Auxiliary spool valves
Manifold
LS signal
P : High pressure
R : Return below oil level
LS : Signal to pump controller via the priority blocks
Fig. 5
9B01.7
4
B
A
150 bar
17 bar
D
A
R
G
E
B
17
20
1A
1B
31
21
7
P
LS
LS
P R
R
P
P
Fig. 5
Parts list
Issue 1
May 2001
9C01.1
CONTENTS
-
General ________________________________________________
A.
B.
Operation ______________________________________________
Issue 1
May 2001
General
The priority block (1) (Fig. 1) comprises two spool valves
(Fig. 5) and is fitted on the right-hand side hydraulic cover
(2) (Fig. 2). It receives the oil flow coming from the
variable displacement pump. It ensures priority for the
steering circuit and the low-pressure circuit (17 bar). The
oil is then directed to the manifold for use by the auxiliary
spool valves and lift control valve (see respective sections 9D01 and 9E01).
To facilitate access to the priority block, remove the rear
wheel or place it in its wide track position (see section
2G01).
Tightening torques
- Bolts V: 25 - 35 Nm. Loctite 542 (Figs. 2 to 4).
- Wheel nuts or studs: see section 2G01.
Special points
- Check the oil tightness of all unions and Orings fitted
between the priority block and the hydraulic cover.
- If the priority block has been replaced, carry out hydraulic tests (see section 9N01) and check the operation of
the controls.
- Carry out a road test.
Issue 1
May 2001
Fig. 1
9C01.3
Fig. 2
Fig. 3
Fig. 4
2
Bottom view
B
Bottom view
J
V
HP
BP
BP
HP
V
Front view
Front view
F
G
Top view
Top view
Parts list
Issue 21
Fig. 4
Fig. 2
Fig. 3
May 2002
2001
9C01.4
HP
BP
Parts list
Issue 1
May 2001
Fig. 2
Fig. 4
Fig. 3
9C01.5
G F
Parts list
2
Issue 1
Fig. 2
Fig. 3
Fig. 4
2002
May 2001
B . Operation (Fig. 5)
1 priority: Steering
st
The spool valve (2) moves to the left under the action of
spring (3).
The oil flow coming from the variable displacement
pump via channel B (Fig. 2) is by priority directed towards
the Orbitrol spool valve via channel A.
- Steering in neutral position: The steering spool valve
(Orbitrol) is closed. The pump pressure moves spool
valve (2) to the right and the oil flow is directed into
channel H.
- Steering wheel turned: A pilot pressure from the
Orbitrol arrives at port D and pushes the spool valve (2)
to the left, allowing the oil flow to enter into port A and
supply the Orbitrol.
Note: An oil flow of approximately 0.5 l/min flows
through port A towards port D via a drilled hole and
restrictor in spool valve (2). This flowrate causes a
pressure of approximately 6 bars at port D. The line
LS directs this pressure to the pump controller
which is adjusted to 22 bar in order to obtain a
standby pressure of 28 bar.
Issue 1
May 2001
(1)
(17)
(20)
(21)
(31)
Priority block
Lift control valve
Auxiliary spool valves
Manifold
LS signal
P : High pressure
R : Return below oil level
LS : Signal to pump controller via the priority block
9C01.7
1
HP
I
F
D
BP
B
20
17
1A
1B
21
P
31
LS
LS
P R
R
P
G
4
Fig. 5
Issue 1
May 2001
9D01.1
CONTENTS
-
General ________________________________________________
Operation ______________________________________________
A.
B.
Diagram ________________________________________________
10
C.
11
Issue 1
May 2001
General
The Rexroth MP18 type auxiliary spool valves are fitted
on the high flowrate, high-pressure circuit. They are
supplied by oil coming from the priority block(s) (depending on options).
If no function is activated, the entire flowrate is sent to
the spool valves. If certain priorities are being supplied,
the remaining flowrate is then available to the auxiliary
spool valves.
3
3
3
3
4
4
4
4
4
spool valves: e c c
spool valves: a d c
spool valves: c c c
spool valves: b a d
spool valves: a d c c
spool valves: e c c c
spool valves: c c c c
spool valves: b a d c
spool valves: b - e c c
Fig. 1
Issue 1
May 2001
9D01.3
F
5
3
3
F
Fig. 1A
Issue 1
May 2001
Operation (Fig. 5 to 7)
Adjusting the compensated pressure flow
This system comprises:
- the flow control tube (6)
- the compensating spool (7)
- the rod (5)
- the compensator spring (10)
The role of this system is to provide a constant pressure
drop of 4.5 bar (65 psi) in the flow control tube and outlet
port and to limit the flowrate of 9.5 to 114 l/min.
The pressure supplied by the variable displacement
pump arrives via chamber D and enters inside the tube.
This pressure then passes to the right-hand side end of
the spool via a central drilled hole. The pressure in the
inlet chamber E becomes greater by 4.5 bar than the XLS
pilot pressure acting upon the spring. The compensating
spool moves to the left and closes the inlet, thus dropping
the pressure in chamber E and causing movement of the
spool to the right.
This regulation of the compensating spool ensures a
constant drop in pressure in the control tube and the work
port. This pressure drop allows the flowrate to remain
constant whatever the load.
Slot F in the control tube limits the maximum flowrate.
This slot opens or closes the oil flow to the body of the
spool valve when rod (5) is turned. When the tube is in
the minimum position, a slightly open space is formed
and a greater percentage of 4.5 bar pressure acts on the
flowrate control tube. The remainder of the pressure drop
acts upon the main spool. The result of this is to create
a flowrate of 9.5 l/min at the work port. When rod (5) is
turned in the other direction, the opening increases,
generating a lower pressure in the flow control tube and
a greater pressure at the main spool, permitting an
increase in the flowrate in the work port.
Issue 1
May 2001
9D01.5
Position A
The main spool is pushed 9.50 mm (0.375 inch) and held
in position by the trigger mechanism (automatic return to
neutral version only (Fig. 6 7)). It places port B and
control chamber J in communication with the tank. The
main spool closes chamber J and places port A in
communication with the primary shuttle valve linked to
the spring side of the compensating spool. The primary
shuttle valve is also linked to a secondary shuttle valve
(13) and to the pressure-relief housing (22). The secondary valve (13) closes to transmit the XLS pilot pressure
to the pump regulator. The main spool permits the flow
to pass from chamber H to outlet port A.
Automatic return to neutral (Figs. 6 7)
The pilot pressure acts on valve (25) in the pressure-relief
housing. When the pressure is sufficient, the valve
raises and the pressure moves the piston (26) which
relieves the relief spring and allows the centring spring to
return the spool to the neutral position. When the spool
is in the neutral position, the piston relief pressure flows
to the tank via port K of the pressure relief housing. The
spring then returns the piston to its original position. The
return pressure can be adjusted using screw (27).
The more the spring is compressed, the greater the return
pressure.
Issue 1
May 2001
Description (Fig. 2)
(2)
(3)
(20)
(22)
Main spool
Compensating valve
Spool valve
Return to neutral device housing (automatic or by
spring)
22
20
Fig. 2
Special points
- Check for the presence of plugs on manifold (21). If
necessary, lightly smear them with Loctite 542 before
fitting.
- The oil tightness of the auxiliary spool valve return pipe
and the lift control manifold is provided by two Orings
placed at each end of the collar held in place by manifold
(21). The tube is positioned by a stud lodged in a cavity
in the centre housing.
30
21
30
15
31
1
30
31
RL
30
15
20
A
21
Fig. 4
Issue 1
May 2001
15
Fig. 3
9D01.7
22
23
J
20
LS
10
Fig. 6-7
Issue 1
Fig. 8
Fig. 5
May 2001
9D01.8
26
20
22
10
11
LS
Fig. 6
4-position spool valve - Automatic return to neutral
(Kick-out) zero leak
27
25
23
13
22
20
G
A
26
10
LS
Fig. 7
Fig. 5
Issue 1
May 2001
Fig. 8
9D01.9
26
20
22
10
27
25
11
13
Fig. 5
Fig. 6-7
Fig. 8
Issue 1
May 2001
B . Diagram
20
17
LS
21
31
LS
P
R
1
P
(1)
(17)
(20)
(21)
(31)
P
R
LS
Priority block(s)
Lift control spool valve
Auxiliary spool valves
Manifold
LS signal
High pressure
Return beneath oil level
Signal to pump regulator via the priority block(s)
LS
P
Fig. 9
Issue 1
May 2001
9D01.11
Important:
When removing the control cables from spool valves,
it is essential not to turn the main spool of the valve
by half a turn in order to avoid any communication
between the control and pressure channels.
The seals (1) are maintained in the spot faced ports
of manifold (21) by a "RL" wide washer and rings "C"
(depending on channels) (Fig. 3) in order to ensure
the oil tightness of the mating face, when the spool
valve is in operation.
6
2
4
3
1
21
2
Removal
1. On each spool valve, disconnect the control cables (2)
and the hose pipes fitted to the spool valve rods (5)
(Fig. 10).
2. Take off the LS hose pipe (9) (Fig. 10). Mark the
position of the hose pipes connected to the couplers
(Fig. 11).
3. Remove the auxiliary spool valves separately and
disconnect the hose pipes one by one as they are
removed.
4. Note the colour of the connectors and disconnect the
solenoid valves on the lift control spool valve.
Note: The brown connector is connected to the
MoveDown solenoid valve.
5. Take off or move to one side the lift control spool valve
from its mating face.
6. Take out bolts (10), remove the support (11) (Fig. 10),
the seals, the wide "RL" washer and rings "C" (Fig. 3).
10
11
9
21
11
10
Refitting
7. Clean the mating faces of the manifold (21) and the
support (11) (Fig. 10).
8. Position new seals (1) with the wide "RL" washer and
rings "C" on the relevant channels of the manifold (21)
(Fig. 3).
9. Refit support (11). Tighten bolts (10) to a torque of 25
- 35 Nm (Fig. 10).
Before refitting the lift control spool valve, check for
the presence of the Orings and washer "R" and rings
"B" (see section 9E01). Tighten the bolts to a torque of
25 - 35 Nm.
A-A
M
+- 5
A
M
A
2
Fig. 10
Issue 1
May 2001
10. Check for the presence of new Orings (1) (Fig. 3) and
shims (2) (see assembly procedure). Refit the spool
valves. Reconnect:
- the hose pipes of the couplers, respecting their
correct locations
- the LS signal hose on the spool valve block.
11. Check that the flats provided for the fitting of the yoke
on the end of the main spool are parallel to the mating
face of the spool valve.
If this is not so, it is essential to position the flats "M"
of the spool according to Figure 10 and without turning them a half turn, in order to avoid any abnor-mal
operation of the spool valve.
12. Loosen nut (3) on control cable (2) (Fig. 10). Position
the cable and the yoke (1) on the spool. Fit pin (4) (Fig.
10). Hold the yoke and tighten the nut without turning
the spool. Check that the yoke pin is not constrained
in any way. Adjust the position of the levers in the
cab by acting upon the covers (8) (Fig. 10). After
adjustment, tighten bolts (6) and nut (7) (Fig. 10).
13. Check the operation of the spool valve controls, in
three or four positions, as well as the lift control spool
valve.
14. Check the oil tightness of the seals and hydraulic
unions.
3B
3A
2B
2A
1B
1A
3A
3B
2B
2A
1A
1B
Fig. 11
Issue 1
May 2001
9D01.13
Assembly procedure
To correctly fit the Orings (1) (Fig. 3) and shims (2) (Fig.
12), the reassembly of each spool valve must be carried
out in a vertical position on the tractor or workbench, in
accordance with Fig. 12.
Important: Shims (2) allow the tightening load to be
distributed among the three studs and not the entire
contact surface of the spool valves. To avoid jamming the spools, it is important to respect the fitting
of the shims and to tighten nuts (3) to a torque of 27
Nm (Fig. 12).
Special point
Tighten studs (1), smeared with Loctite 241, on support
(11) (Fig. 12).
20
11
11
11
Fig. 12
Issue 1
May 2001
9D02.1
CONTENTS
-
General ________________________________________________
Operation ______________________________________________
A.
B.
Diagram ________________________________________________
C.
D.
13
E.
14
Issue 1
May 2002
General
The Bosch SB23 LS proportional auxiliary spool valves
are fitted on the high pressure, high flowrate circuit. As
for the Rexroth auxiliary spool valves, they are fitted to
8200 series tractors. They are juxtaposed at the rear of
the tractor each side of the oil manifold and may form a
unit of two, three or four spool valves (depending on the
option).
The auxiliary spool valve unit also integrates the lift
control spool valve.
The auxiliary spool valves comprise spools and valves.
Certain parts cannot be repaired or replaced by spare
parts.
The spool valves are supplied by oil coming from the
priority block(s). When no other function is engaged, the
entire flowrate is directed to the spool valve. If certain
priorities are being supplied, the remaining flowrate is
then made available to the auxiliary spool valves.
Each spool valve has a flowrate regulation system
controlled by a black, red, green or yellow button (depending on the option) fitted directly to the shaft of the
regulating valve.
The main spool is activated by a cable linked to a lever
located in the cab. The spool directs oil to one or other of
the outlet ports.
Each outlet port is connected to the LS pilot flow line of
the variable displacement pump regulator via the priority
block(s).
Issue 1
May 2002
9D02.3
Couplers (Fig. 1)
- When the auxiliary spool valve is at rest, a lever system
(1) allows the pressure to be relieved in the hydraulic
hoses (2). These hose pipes link the spool valves to the
couplings concerned (3). By acting on this system, the
clean oil under pressure is directed to the return via a
pipe and hose assembly (4) connected to the upper part
of the intermediate housing.
- This drop in pressure facilitates the connecting of the
male coupler to the female coupler.
- The oil, which may be polluted, coming from the
separation of the couplers, drains into a flexible transparent plastic tank (5) that is located beneath the
coupling unit.
F
5
3
3
F
Fig. 1
Issue 1
May 2002
Operation (Fig. 2 - 3)
When the spool (1) is pulled, oil penetrates into channel
P, passes through restrictor C and grooves D. It is then
directed to channel E, pushes the ball (2) and enters into
chamber F.
Simultaneously, the ramp on the spool lifts valve (3) and
oil flows via port B.
The supply of port A is obtained by pushing spool (1).
Flow regulation is ensured by rod (4) and control spool (5).
E
D
C
R
P
A
LS
F
N
Main spool
Valve
One-way valve
Flowrate regulation control rod
Flowrate regulation control spool
Unit(s) and locking system.
Fig. 2
:
:
:
:
:
:
:
P2
R
R2
LS
:
:
:
:
Outlet to coupler
Outlet to coupler
Restrictor
Grooves
Channels
Chamber
High pressure supply from variable displacement
pump via the priority block(s) (according to version)
High pressure port - Not yet available
Auxiliary spool valves return
Return port - Not yet available
Load Sensing signal to variable displacement pump
regulator via the priority block(s) (according to
version).
R
3
1
542
Issue 1
May 2002
Fig. 4
9D02.5
3
1
A
5
N-N
Fig. 3
Issue 1
May 2002
9D02.6
14
241
17
P
21
LS
1
1
1
6
R2
P2
241
R
P
LS
R
A
1
B
Fig. 5
Issue 1
May 2002
9D02.7
B . Diagram
B A
B A
1.2
F
2
0
1
F
2
0
1
B A
1.2
1.2
F
2
0
1
20
P
LS
R
B A
21
1.2
F
2
0
1
17
P2
20
P
(1)
(17)
(20)
(21)
P
P2
R
LS
Priority block(s)
Lift control spool valve
Auxiliary spool valves
Manifold
High pressure
High pressure port - Not yet available
Return below the oil level
Signal to the pump regulator via the priority block(s)
LS
Fig. 6
Issue 1
May 2002
14
Reminder
- On the mechanically-operated spool valves, disconnect the linkage cables while avoiding turning the main
spools a half-turn. This precaution avoids any possible
hydraulic leaks between the pilot flow and pressure
channels.
17
21
Remark (Fig. 7)
- The lift control spool valve (17) is integral with the
auxiliary spool valve unit. It is located between the oil
manifold (21) and the right-hand side end plate (14) or
4th spool valve (1) (if fitted).
Preliminary operations
17
21
Fig. 7
2
A-A
7
8
5
3
A
4
1
4
6
Issue 1
May 2002
1
Fig. 8
9D02.9
30
16
9
Fig. 9
3B
3A
2B
2A
1B
1A
14
17
13
Fig. 10
3A
2A
1A
3B
2B
1B
Fig. 12
Issue 1
May 2002
3
21
21
Fig. 11
Issue 1
May 2002
9D02.11
1
Fig. 13
5
4
21
21
1
5
1
1
2
3
3
Fig. 14
Fig. 15
Issue 1
May 2002
Final operations
14. Fit the hose pipes linking the spool valves to the
couplers.
15. Reconnect the high pressure pipes (30) and the
supply to the lift rams (16) as well as the LS hose
pipe (9) (Fig. 9).
16. Fit and adjust the control cables, see E.
17. Start the engine.
18. At each spool position, check the operation of:
- the hydraulic system (see section 9N01 - Hydraulic
tests)
- the electronic system (see section 11H01 - Tests).
19. Check the oil tightness of spool valves and hydraulic
unions.
Issue 1
May 2002
270
Fig. 16
9D02.13
D . Assembly procedure
Remark
- To obtain a correct fitting of seals (3) (4) (5) (6)
(Figs. 13 - 14), the assembling of each spool valve (1)
on the manifold (21) must be carried out in a vertical
position on a clean workbench (Fig. 17).
Special points
- Adhesive shims, known as inserts, allow a spreading
of tightening forces around the three long studs but not
across the whole contact surface of the various parts.
- To avoid any warping that may lead to a jamming of the
spools, it is important to check for the presence of these
shims and to respect the tightening torque of the nuts:
30 - 33 Nm.
21
Fig. 17
30/33 Nm
Fig. 18
Issue 1
May 2002
2
3
2
1
6
5
8
3
2
23. Pass the cable through the flange plate (9) located at
the rear right-hand side of the cab and then into
stirrup (8).
Note: The hole in stirrup (8) is offset (Fig. 20). To
assemble a spool valve control having floating
position, the hole must be turned upwards in
order to ensure a correct alignment of the cable
and its attachment.
24. Screw clevis (4) flush with the threaded cable end of
the cable sheath (7) and mount it on linkage A or B
of the lever concerned. Position clip (5).
Tighten the nut on the clevis while checking that the
cable is not constrained in any way.
4
9
Fig. 19
Issue 1
May 2002
9D02.15
6
Fig. 20
8
6
Fig. 21
Issue 1
May 2002
9 D03
9D03.1
CONTENTS
General ________________________________________________
A.
B.
Diagram ________________________________________________
C.
10
D.
13
E.
14
Issue 1
May 2002
General
Description of the components
The SB23LS - EHS BOSCH type spool valves that control
the supply to the hydraulic couplers comprise two parts:
A hydraulic part:
- See operation below.
Issue 1
May 2002
Available assemblies
-
3
3
4
4
spool valves : a + a + c
spool valves : a + a + b
spool valves : a + a + c + c
spool valves : a + a + b + c
9D03.3
Exploded view
M
A
P
LS
14
R
17
A : 3 spool valves
B : 4 spool valves
P
21
M
LS
1
1
P2
R2
241
R
Parts list
Issue 1
Fig. 1
May 2002
9D03.4
Fig. 2
Remark
- Figures 1 to 4 indicate the assembly order of the
auxiliary spool valves.
Legend
. M : black, mechanical spool valve
. X : red, Joystick
. Y : green, Joystick
. DC : black, Dual Control
. VR : lift control spool valve
(5) Support
(6) Joystick lever
VR
M
Y
DC
VR
X
DC
Fig. 3
VR
Y
X
5
Fig. 4
Issue 1
May 2002
9D03.5
18
X3
3
DMV
FP
X3
XNA
18
Remark
- Channels P and R are linked to the auxiliary spool
valve.
Fig. 5
FP : Filter
X3 plug 12 x 1.50 : Location of diagnostics
connector.Presence of fuel tank limits access.
3
4
Issue 1
Fig. 6
May 2002
Main spool
Valve
Non-return valve
Pressure balancing valve
Cover
LS
21
Fig. 8
P
21
P
LS
R
R
LS
R
1
2
3
R
Issue 1
May 2002
Fig. 9
9D03.7
A
5
3
B
Fig. 10
Issue 1
May 2002
A
B
A
B
A
B
Fig. 11
E
P
R
C
A
LS
F
Fig. 13
Issue 1
May 2002
Fig. 12
9D03.9
B . Diagram
B A
B A
B A
F
2
0
1
F
2
0
1
F
2
0
1
DMV FP
XNA
1.2
20
P
LS
R
B A
21
1.2
F
2
0
1
17
P2
20
P
Priority block(s)
Lift control valve
Auxiliary spool valves
High pressure
Hight pressure port (not yet available)
Return beneath the oil level
Signal to the pump regulator via the priority
block(s)
LS
Fig. 14
Issue 1
May 2002
Fig. 15
Reminder
- On tractors where one or more elements of the auxiliary spool valves are operated mechanically, take care
to disconnect the link cable(s) without turning the main
spool of the valve a half turn (see section 9D02).
Preliminary operations
Remark
- The lift control valve (17) is integral with the spool valve
assembly.
1. On the lift control valve (Fig. 16), locate and disconnect the solenoid valve harnesses:
- moveUp E1
- moveDown E2 (brown connector)
2. Disconnect:
- the following: high pressure pipe, lift rams feed pipe
and LS hose
on mechanically operated spool valves
- control cable (2) (Fig. 15) taking into account the
previous reminder.
on Joystick or lever (Dual Control) operated spool
valves (Fig. 16)
- solenoid valve (18) located on the left-hand end
plate (6)
- connector(s) "C" linked to the electro-hydraulic unit(s)
of the spool valve(s), carefully marking their
position(s).
Removal
18
E1
Remark
- The spool valve assembly must be removed in full.
- Any operations carried out on the spool valves require
scrupulous cleanliness.
- First correctly clean the spool valves (lift control and
auxiliary), and the areas around them on the tractor,
before removing them.
3. Locate the hose pipe(s) between spool valves and
couplers and disconnect them.
4. Remove the spool valve assembly.
Issue 1
E2
May 2002
Fig. 16
9D03.11
Fig. 17
5
4
21
21
1
1
3
Fig. 18
Issue 1
May 2002
270
Final operations
12. Assemble the hose pipes between the spool valves
and couplers, according to the marks.
13. Reconnect the pipes (high pressure pipe, lift rams
feed pipe and LS hose.
14. Reconnect the MoveUp and MoveDown solenoid
valve connectors in accordance with marks made
during removal.
15. Reconnect:
On the mechanically operated spool valves
- the control cable(s) taking into account the reminder in C
On the Joystick or lever operated spool valves
(Dual Control)
- the connector(s) connected to the electro-hydraulic housing(s) in accordance with marks made
during removal.
- the ON - OFF solenoid valve located on the lefthand end plate.
16. Start the engine.
17. For each spool valve position, check the operation of:
- hydraulic devices (see section 9N01 - tests)
- electronic devices (see section 11)
18. Check the oil tightness of the spool valves and
hydraulic unions.
Issue 1
May 2002
Fig. 19
9D03.13
D . Assembly procedure
Remark
- To obtain the correct assembly of seals (3) (4) (5) (6)
(Fig. 17 - 18), the reassembly of each spool valve (1)
on the oil manifold (21) must be carried out vertically
on a clean workbench (Fig. 20).
1
Special point
- Adhesive shims also known as inserts allow the
tightening load to be distributed among the three studs
and not on the entire contact surface of the spool
valves. To avoid jamming the spools, it is important to
respect the fitting of the shims and to tighten nuts to
a torque of 30 - 33 Nm.
21
Fig. 20
30/33 Nm
Fig. 21
Issue 1
May 2002
Fig. 22
Issue 1
May 2002
9D03.15
1
1
Reminder
- For the design and operation of the Dual Control lever,
see chapter 11 - Electronics
3
A
4
5
8
9
Fig. 23
Issue 1
May 2002
5
6
Fig. 24
Issue 1
May 2002
9E01.1
CONTENTS
-
General ________________________________________________
A.
Diagrams _______________________________________________
B.
C.
D.
E.
10
Issue 2
May 2002
General
21
30
15
31
30
Fig. 1
14
30
31
17
13
Remarks
- The number of hydraulic ports on the Bosch lift control
spool valve varies depending on whether it is assembled with:
. a manifold (21) and Rexroth auxiliary spool valves
(Fig. 1)
. a manifold (21) and Bosch auxiliary spool valves (Fig.
4)
- In all cases, the operating principle remains identical.
- Note the different location on the tractor.
15
16
Fig. 2
17
Fig. 3
Issue 2
May 2002
9E01.3
15
30
21
31
15
Fig. 4
14
30
31
17
13
16
Fig. 5
15
Special points
- The return oil from the lift control spool valve is
directed to the centre housing at the manifold (21)
outlet by a large section pipe the end of which is
beneath the oil level.
- This pipe is also used for the return from the auxiliary
spool valves (see section 9D01 and 9D02).
17
Fig. 6
Issue 2
May 2002
9E01.4
A . Diagrams
17
LS
21
31
20
LS
31
R
P
R
P
P
LS
LS
(1)
(17)
(20)
(21)
(31)
P :
R :
V :
Priority block(s)
Lift control spool valve
Auxiliary spool valves
Manifold
LS signal to pump regulator via the priority block(s)
High pressure
Return beneath the oil level
Lift rams
Fig. 7
Issue 2
May 2002
9E01.5
20
P
LS
R
V
21
20
31
P2
17
P
(1)
(17)
(20)
(21)
(31)
P :
P2 :
R :
V :
Priority block(s)
Lift control spool valve
Auxiliary spool valves
Manifold
LS signal to pump regulator via the priority block(s)
High pressure
Secondary high pressure port
Return beneath the oil level
Lift rams
LS
Fig. 8
Issue 2
May 2002
21
Removal
30
Refitting
6. Clean the mating faces of the cover and the spool
valve.
7. Position new seals (1) with washer "R" and rings "B"
on the channels concerned of the manifold (21)
(Fig. 9).
Replace the seals (1) between the spool valve (17)
and the cover (2) (Figs. 3 - 10).
8. Fit and tighten bolts (1) to a torque of 25 - 35 Nm
(Fig. 10).
9. Definitively tighten union (16) on the ram feed pipes.
10. Reconnect the solenoid valves (according to their
markings) and refit the auxiliary spool valves (see
C, section 9D01).
11. Start the engine.
12. Check the operation of the lift control system and the
auxiliary spool valves, the oil tightness of all seals
and hydraulic unions.
30
15
31
Fig. 9
13
17
16
14
Fig. 10
Issue 2
May 2002
9E01.7
Fig. 11
14
17
21
Issue 2
May 2002
9E01.8
C . Neutral position
When the engine is not running and the spool valve is in
the neutral position, the control spool (4) and the other
spools (2) are maintained in position by springs (10) and
(11).
11
9
10
P
R
LS
Fig. 12
Issue 2
May 2002
9E01.9
R
P
LS
16
5
12
4
13
Fig. 13
Issue 2
1
May 2002
E . Lower position
When the MoveDown solenoid valve (14) is activated to
lower the lift control arms, the spool assembly (2) allows
the flow coming from the rams to enter the return. The LS
pressure information is transmitted to the side of the
flowrate regulating spool (5) (spring (9) side) and to the
variable displacement pump.
14
P
R
LS
Fig. 14
Issue
Issue 12
May 2002
2002
9F01.1
CONTENTS
-
General ________________________________________________
A.
B.
C.
Diagram ________________________________________________
D.
E.
10
F.
12
G.
14
16
H.
Issue 2
May 2002
General
Issue 2
May 2002
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
Bolt
Bolt
O-ring
Cover plate
O-ring
Stator
Pin
O-ring
Rotor
Spacer
Link shaft
Washer
Centring springs
Needle bearing
Bush
Washer
O'ring
Relief-valve
Seal
Shock valve
Orbitrol unit (distribution valve)
Non-return valve
Suction valve
Bush
Spool valve
Non-return valve
Sleeve
O'ring
Distributor plate
Fig 1
Fig 2
9F01.3
Overall view
20
14
16
17
15
13
19
21
27
12
24
25
11
26
29
22
28
8
5
4
3
10
18
23
Fig 2
Parts list
Fig. 1
Issue 2
May 2002
9F01.4
Exploded view
DANFOSS
OSPC XXX
XXXXXX
2
XXXX
3
4
1
5
6
8
9
10
29
7
11
28
27
26
25
13
24
12
14
16
15
17
18
21
22
19
23
20
Fig 1
Issue 2
May 2002
Parts list
Fig. 2
A
B
L
LS
9F01.5
R
T
Steering ram
Location of steering column
Supply to left-hand side union of the steering ram
Signal to variable displacement pump via the priority
block(s)
High flow rate supply from the variable displacement pump
Supply to right-hand side union of the steering ram
Return to the housing via the selection cover or the
gearbox (depending on transmission version)
(1)
(2)
(3)
(4)
2WD axle
Dana front axle
Carraro fixed front axle
Carraro suspended front axle
L
T
B
T
LS
P
R
A
A
R
3
L
R
L
P
LS
R
1
A
A
L
4
R
L
Fig. 3
Issue 2
May 2002
Issue 2
May 2002
9F01.7
C .Diagram
A
Mechanical links
LS
BP
BP Priority block(s)
Fig. 4
Issue 2
May 2002
Issue 2
May 2002
9F01.9
R
20
23
25
27
P1
13
P
12
BP
LS
Inlet channel
BP Priority block(s)
P1 Supply to the metering device
Fig. 5
Issue 2
May 2002
Issue 2
May 2002
9F01.11
13
25
27
9
(R) D
T
T
(L) G
26
18
Inlet channel
Delivery channel
Return channel
Pilot flow channel
Fig. 6
Issue 2
May 2002
Issue 2
May 2002
9F01.13
13
25
27
(R) D
(L) G
13
22
T
P
BP
LS
Inlet channel
Delivery channel
Return channel
Fig. 7
Issue 2
May 2002
Disassembly
1. Remove the distribution valve from the tractor.
2. Place the distribution valve in a vice fitted with
plastic jaws
3. Take out the bolts (1). Carefully mark the location of
the bolt (2) and then remove it.
4. Remove the cover plate (4), the O'ring (5), the stator
(6) and O'ring (8).
5. Remove the spacer (10), the rotor (9), the distribution
plate (29) and the O'ring (28).
6. Take out the splined link shaft (11).
7. Unscrew the threaded bush and take out the valve
ball from the non-return valve (22).
8. Take out the two axle pins and valve balls from the
suction valves (23) of the distribution valves.
9. Extract the sleeve (27) and spool valve (25) assembly
by pushing it out while checking that the pin (7) lies
along the horizontal axis.
10. Remove the washers (12) (16), the needle bearing
(14) as well as the bush (24) from the sleeve and
spool valve assembly. Remove the pin (7), and the
centring springs (13) by pressing on their ends.
Separate the sleeve (27) from the spool valve (25).
11. Unscrew the plug from the relief-valve (18). Using an
8 mm Allen key, disassemble the threaded bush and
remove the seal, the spring and the valve (the
crimped seat cannot be removed).
12. Unscrew the two plugs from the shock valves (20)
and remove the seals. Using a 6 mm Allen key,
remove the threaded bushes and take out the springs,
the valve balls and their seats (the crimped seats
cannot be removed).
13. Extract the seal (19), the bush (15) and the O'ring (17).
14. Disassemble the non-return valve (26).
Issue 2
May 2002
9F01.15
Reassembly
15. Check and clean all components, replace those
defective. Lubricate with clean transmission oil
before reassembly.
16. Reassemble the non-return valve (26).
17. Fit the seal (19), the O'ring (17) and the bush (15).
18. Place the valve balls and springs in the recesses of
the shock valve (20). Screw in the threaded bushes,
fit the seals and tighten the plugs.
19. Fit the valve and spring in the recesses of the reliefvalve (18), screw in the threaded bush. Fit the seal
and tighten the plug to a torque of 40 - 60 Nm.
20. Insert the spool valve (25) into the sleeve (27).
Position the centring springs (13) according to Fig. 8
and insert the pin (7).
21. Position the bush (24) on the sleeve and spool valve
assembly so that the chamfer facilitates assembly
in the steering unit.
22. Place the washers (12) (16), the chamfer of washer
(12) towards the centring springs (13), by inserting
the needle bearing (14) between them.
23. Fit the sleeve and spool valve assembly in the
steering unit by oscillating it slightly. Check that the
pin (7) is held horizontally.
24. Place the two valve balls and the two pins in the
recesses of the suction valves (23).
25. Fit the valve ball in the recess of the non-return valve
(22) and screw in the threaded bush.
26. Position the splined link shaft (11).
27. Fit the O'ring (28), the distributor plate (29).
28. Fit the rotor (9) so that the two concave depressions
"C" lie along the axis of the slot in the splined link
shaft (11) (Fig. 9). Refit the spacer (10).
29. Place the O'rings (5) (8) on the stator (6).
30. While avoiding moving the rotor (9), fit the stator (6).
Then move it so that its fixing holes match with
those of the steering unit.
Note: The rotor (9) and the pin (7) must be in the
position shown in Figure 10.
31. Refit the cover plate (4).
32. Refit the bolt (2) (in the same location as marked
during disassembly) and the bolts (1) fitted with their
seals (3). Tighten opposing bolts to a torque of 30 35 Nm.
33. Using a test-bench or a suitable fixture, check the
adjustment and correct operation of the steering unit.
34. Refit the steering unit on the tractor.
35. Check the oil tightness of the unions.
Fig. 8
11
C
Fig. 9
7
Fig. 10
Issue 2
May 2002
9F01.16
Remark
- If access to the ram fixing bolt (2) in the Dana front axle
seems difficult (Fig. 11):
. lift the front of the tractor with a trolley jack positioned
in the centre of the front axle,
. remove the front wheels,
. place an appropriate axle stand beneath the lower
engine housing,
. swing the front axle at maximum to high and low
positions in order to access the bolts.
Preliminary operation
36. Immobilise the tractor. Chock the rear wheels. Put
on the handbrake.
Fig. 11
1
4
5
7
2
Fig. 11A
Issue 2
May 2002
9F01.17
Refitting
Dana or Carraro front axle
40. Refit the ram. Fit and tighten bolts (2) :
- Dana front axle: to a torque of 180 - 200 Nm, the
threads previously smeared with Loctite 270 or
equivalent.
- Carraro axle: to a torque of 120 Nm.
41. Fix the steering ball joints. Tighten bolts (4) :
- Dana front axle: to a torque of 115 - 130 Nm and
block them with new pins (Fig. 11)
- Carraro front axle: to a torque of 220 Nm (Fig. 11A)
42. Reconnect the feed hoses in the positions identified
during disassembly.
43. Mount the wheel(s) and tighten the bolts to a torque
of 640 - 680 Nm.
Refit the mudguard (Carraro front axle).
Issue 21
May 2002
9F01.18
Description
Dana
(Fig. 12)
Carraro
(Fig. 12A)
(1)
Ram assembly
(2)
Pack of seals
(3)
Guide bushes
(4)
Cylinder
(5)
Lock ring
(6)
Piston rod
(7)
Cover
2
3
2
4
5
Remarks
- The Dana or Carraro front axles are fitted with a doubleacting cylinder, which receives pressure from the
Orbitrol spool valve proportional to the rotation of the
steering wheel.
- When one side of the ram is fed, the other is connected
to the return pipes and vice versa.
- Each component can be replaced and is listed in the
spare parts catalogue.
- A pack provides all the seals necessary for carrying out
service operations.
2
3
2
Fig. 12
2
4
Fig. 12A
Issue 2
1
May 2002
9F01.19
45. Release and remove the spherical joints (7) (Fig. 11).
46. Take off the lock rings (5) using an appropriate locally
manufactured tool, while simultaneously turning the
guide bushes (3).
47. Take out the piston rod (6) from cylinder (4).
48. Discard all the seals (sealing ring, Orings, dust
guards and lock rings).
Reassembly
Dana or Carraro front axle
53. Clean the components. Replace any parts to be found
defective.
Remark
- Check the condition of the internal bore of the
cylinder and the operational parts of the piston rod.
Systematically discard all scratched components
that may compromise the oil tightness of the
steering mechanism.
Final operation
66. Carry out a road test on the steering system.
2
Issue 1
May 2002
9F02.1
CONTENTS
-
General ________________________________________________
A.
B.
C.
D.
11
E.
13
16
18
F.
G.
Issue 1
May 2001
Issue 1
May 2001
9F02.3
General
The steering system on 8270 and 8280 is of the dynamic
type (constant flowrate of 0.5 l/min, standby pressure of
6 bar) (see section 9B01 or 9C01 depending on the
version). There is no mechanical linkage between the
steering wheel and the steering rams.
Its control principle is of the Load Sensing type. The main
components of the circuit are:
- pressurised oil feed from the priority block(s) (depending on version) supplied by the variable displacement
pump,
- an Orbitrol steering distribution valve of the closed
centre OSPD.LS 100 - 260 type with twin stator rotors
mounted in by-pass.
- two double acting steering rams connected in parallel
and mounted on the front 4WD axle.
Operation
The Orbitrol is supplied via the priority block(s) by the high
flowrate circuit that equally supplies the integrated spool
(18) and the twin stator rotors (27) (28) and (30) (31).
When the steering wheel is turned, the necessary oil flow
is directed to the corresponding side of the steering rams.
The excess flow not required by the rams is directed via
the return ports to the right-hand side of the gearbox.
In the case of an engine breakdown or a variable
displacement pump failure, only stator rotor (27) (28) is
active and acts as a hand pump allowing the steering to
still be used.
Issue 1
May 2001
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
Lip seal
Centring springs
Bush
Oring
Pin
Sleeve
Spool valve
Oring
Linkage shaft
Oring
Plate
Oring
Plate
Oring
Spacer
Oring
Oring
Integrated spool
Spool body
Seals
Oring
Washer
Needle bearings
Washer
Discharge valve
Block
Rotor (100 cm3)
Stator (100 cm3)
Oring
Stator (160 cm3)
Rotor (160 cm3)
Plate
Spring
Oring
Closing plate
Bolts
Shock valves
Non-return valve
Spacers
One-way valve
Suction valve
Pin
Issue 1
Fig. 1
Fig. 2
May 2001
9F02.5
Overall view
21
22
23
24
5
6
25
7
8
9
26
10
27
11
28
12
29
13
30
14
31
15
32
16
33
17
34
18
35
19
36
20
Parts list
Issue 1
Fig. 2
Fig. 1
May 2001
9F02.6
Exploded view
37
37
1
41
39
4
22
23
24
3
25
5
26
6
40
38
15
8
12
7
28
29
10
11
27
14
13
31
30
33
16
32
17
19
18
42
Parts list
34
35
Fig. 1
20
36
Issue 1
May 2001
Fig. 2
9F02.7
Two shock valves (37) and two suction valves (41) are
placed in the L and R ports of the distribution valve. The
shock valves (37) protect the circuit between the steering ram and the spool valve from eventual pressure
overloads caused by shocks to the wheels.
The suction valves allow the oil released by the shock
valves to pass from the right-hand channel into the lefthand channel and vice versa, depending on the movement of the piston in the steering ram.
37
2
6
41
L
P1
27
25
28
31
30
40
38
T
12
LS
B
L
LS
P
Priority block(s)
Supply to steering rams (left-hand lock)
Pilot flow
High flowrate supply from variable displacement
pump
P1
R
T
Issue 1
May 2001
9F02.8
27
31
(R) D
T
T
25
(L) G
30
40
T
28
18
LS
Fig. 4
Issue 1
May 2001
9F02.9
Issue 1
May 2001
9F02.10
27
31
L
(R) D
T
28
25
(L) G
40
38
LS
Fig. 5
Issue 1
May 2001
9F02.11
Issue 1
May 2001
9F02.12
LS
A
A-A
A
40
LS
B
LS
L
P
R
T
Issue 1
May 2001
Priority block(s)
Pilot flow
Supply to the steering rams (left-hand lock)
P High flowrate supply from the variable
displacement pump
Supply to the steering rams (right-hand lock)
Return to housing
Fig. 6
9F02.13
Issue 1
May 2001
Reassembly
18. Check and clean all components, replace any parts
found to be defective. Lubricate the components
with clean transmission oil before reassembly.
19. Refit the check valve (40).
20. Fit seal (1), Oring (21) and the bush.
21. Fit the balls and springs in the housings of the shock
valves (37). Screw in the threaded bushes, place the
seals and tighten the plugs.
22. In the housing of the discharge valve (25), place the
valve and spring, screw in the threaded bush. Fit the
seal and tighten the plug to a torque of 40 - 60 Nm.
23. Introduce the spool valve (6) in sleeve (7). Position
the centring springs (2) according to Figure 7 and fit
pin (5).
24. Position bush (3) on the sleeve and spool valve
assembly so that the chamfer facilitates assembly
in the spool valve.
25. Place washers (22) (24), with the chamfer of washer
(24) turned towards the centring springs (2) and
placing needle bearing (23) in between them.
26. Assemble the sleeve and spool valve assembly in
the spool valve using a slight oscillatory movement.
Take care that pin (5) is held horizontally.
27. In the suction valve housings (41), place the two
balls and the two pins.
28. In the non-return valve housing (38), place the ball
and screw in the threaded bush.
29. Position the splined linkage shaft (9).
30. Place the Oring (10), and the distributor plate (11).
31. Fit rotor (27) so that the two cavities "C" lie in the axis
of the slot of splined shaft (9) (Fig. 8).
32. Place the Orings (12) (29) on the stator (28).
33. While avoiding moving the rotor (27), fit the stator
(28). Then turn it so that its fixing holes match those
in the spool valve. Position spacer (15) and plate
(13).
Note: Rotor (27) and pin (5) must be in the
position shown in Figure 9.
34. Refit rotor (31) on the spacer (15) so that the two
cavities "C" lie in the axis of the slot of splined shaft
(9) (Fig. 8).
Issue 1
May 2001
2
Fig. 7
27
31
C
Fig. 8
9F02.15
27
31
5
Fig. 9
Issue 1
May 2001
Fig. 10
10
3
Issue 1
May 2001
Fig. 11
9F02.17
3
2
4
5
6
7
8
9
10
11
12
13
14
15
Fig. 12
Issue 1
May 2001
9F02.18
T
LS
A
LS
A
B
LS
L
R
P
T
Steering rams
Location of the steering column
Pilot pressure from the priority block(s)
Supply to steering rams
Issue 1
May 2001
A-A
9G01.1
CONTENTS
General ________________________________________________
A.
13
B.
17
C.
20
D.
21
E.
22
Issue 1
May 2001
General
The right-hand cover is mounted on the intermediate
housing. It acts as a support for numerous components
and contains the different booster, lubricating and low
flowrate channels and circuits.
39
Description
- The movement transmitted to pinion (1) by the engine,
via shaft (2), drives pinion (39) of the variable displacement pump (41) (Fig. 1).
- The oil coming from the booster pump, located on the
left-hand cover (see section 9H01) is directed towards
the priority blocks through pipe (54) (Fig. 2) via the
variable displacement pump (41), in order to supply the
function requested.
- The pipe (55) (Fig. 2) directs oil coming from the 5 bar
safety valve (44) to the suction manifold fitted on the
booster pump (see section 9H01).
Issue 1
May 2001
Fig. 1
9G01.3
A
53
22
55
VS
52
52
54
22
53
PCV
54
(22)
(52)
(53)
(54)
(55)
55
Mecanindus pin
Oring
Oring
Booster pipe
Safety valve pipe (44)
A :
PCV :
VS :
C :
Suction
To variable displacement pump
5 bar safety valve (44)
Intermediate housing compartment
Fig. 2
Issue 1
May 2001
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
to
(18)
(19)
(20)
(21)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
Bolt
Pressure relief-valve
Supply to Orbitrol
Bolt
LS pilot flow from the Orbitrol
LS pilot flow to the pump regulator
Priority block(s)
Cover
LS diagnostics connector
Plugs (depending on version)
HP diagnostic connector
Pump regulator
Union (LS)
LP switch (17 bar)
Solenoid valves (PTO, PTO brake,
differential lock (front and rear if fitted)
and 4WD
Plugs
Park Lock union or plug (depending on assembly)
PTO clutch union
PTO brake union
2WD or 4WD differential lock union
Plug or speed sensor (Heavy Duty gearbox)
4WD union
15 micron main filter
LP union
Diagnostic connector for booster and lubricating
pressure
Supply to lift control valve manifold and auxiliary
spool valves
LS pilot flow from auxiliary spool valves and lift
control valve
Bolt
Trailer brake valve pilot line
Clogging indicator
Centring pins
Nut
Washer
Pinion
Key
Variable displacement pump
Booster and lubricating pressure switch
Union and pipe to manifold and lubrication (depending on assembly)
5 bar safety valve
Issue 1
May 2001
(45)
(46)
(47)
(48)
(49)
(50)
Fig. 3
Fig. 3A
Fig. 4
Fig. 5
Fig. 5A
9G01.5
11
12
13
14
19
15
16
17
18
21
20
23
HP
24
BP
24
28
26
34
31
32
30
47
29
19
48
28
27
25
F
F
Parts list
Fig. 3A
Fig. 4
Fig. 5
Issue 1
Fig. 5A
Fig. 3
May 2001
9G01.6
33
11
12
13
14
19
15
16
17
18
21
20
23
HP
24
BP
28
26
34
50
31
32
30
47
29
19
48
28
27
25
F
F
Parts list
Issue 1
Fig. 3
Fig. 4
May 2001
Fig. 5
Fig. 5A
Fig. 3A
9G01.7
36
10
49
37
39
38
40
41
36
45
49
10
44
34
Heavy Duty
gearbox
43
42
46
Full Powershift
gearbox
Parts list
Fig. 3
Fig. 3A
Issue 1
Fig. 5
Fig. 5A
Fig. 4
May 2001
9G01.8
53
55
52
7
4
54
41
40
39
36
8
12
1
47
38
44
37
34
32
25
42
11
34
27
29
48
15
16
17
Parts list
Fig. 3
Issue 1
46
18
May 2001
Fig. 3A
Fig. 4
Fig. 5A
Fig. 5
9G01.9
53
55
52
7
4
54
41
40
39
36
8
1
47
9
25
38
12
44
37
34
32
46
11
27
29
48
42
15
16
17
Fig. 3
18
Parts list
Fig. 3A
Issue 1
Fig. 4
Fig. 5
Fig. 5A
May 2001
9G01.10
HP
GAV
Fig. 7
9
P
C
F
12
C
D
P
R
S
:
:
:
:
:
Issue 1
May 2001
9G01.11
G
S1
G
G
R
Fig. 9
45
2
G
G
G
44
F
G
L
P
R
S
S1
:
:
:
:
:
:
:
Issue 1
May 2001
9G01.12
12
14
19
15 16 17 18
2
21
20
23
HP
24
BP
26
28
48
27
"O"
34
31
32
30
47
41
28
43
Issue 1
May 2001
42
46
Fig. 10
9G01.13
6.
7.
8.
Special points
- One upper bolt holding the cover may be masked by the
union screwed into regulator (12). Take off the regulator
in order to facilitate the removal of the cover.
- To disassemble the safety valve (45) of the LP circuit,
compress spring (3) using a screwdriver and remove
circlip (1). Remove parts (2) to (4) (Fig. 12). Check that
valve (4) slides freely in its housing.
54
Fig. 11
Fig. 12
1
2
45
3
4
44
Issue 1
May 2001
Refitting
Note: Check for the presence of the rivets on the
channels provided on the external face of the cover,
as well for those (45) on the internal face (Fig. 4).
Also check for the fitting of plugs (10).
9. Clean the mating faces of the housing and the cover.
10. Check for the presence of the two pins (36) (Fig. 13).
11. If it has been removed, insert pipe (55) of the 5 bar
safety valve. Position its end fitted with seal (53) in
the Mecanindus pin (22) located on compartment "C"
of the intermediate housing (Fig. 2).
Place booster pipe (54) fitted with Oring (52) (Fig. 2),
its slot held by pin (1) (Fig. 11). Lightly smear seal (4)
with miscible grease and position it on the collar of
pipe (54) (Fig. 11).
12. Smear the mating face of the housing with a sealing
product (Loctite 510 or equivalent). Place the guide
studs "G" (Fig. 11).
13. Fill pump (41) with transmission oil via port "O"
(Fig. 10).
14. Slide the cover on the guide studs "G" (Fig. 11). Using
a bronze hammer, tap the rim of the cover to engage
pins (36) in the housing. Between the mating faces
of the cover and housing, check that pipe (55)
(Fig. 2) is correctly positioned on the 5 bar valve (44).
15. Tighten bolts (1) to a torque of 120 - 160 Nm.
Note: If resistance is felt during tightening, do
not continue. Move the cover away from the
housing and check the position of pipe (55) on
the 5 bar valve (44) (Fig. 2). Also check for the
rotation of pinion (39).
16. Replace seals (3) to (5) (Fig. 14) and refit the priority
block(s). Tighten bolts (4) smeared with Loctite 542
(Fig. 10) to a torque of 25 - 35 Nm.
17. Reconnect the engine speed sensor (see following
special points). Reconnect the switches, the harnesses of the solenoid valves and the hydraulic
pipes.
18. Raise the tractor, refit the wheel or place it in its initial
position. Remove the axle stands where necessary
and tighten the wheel nuts or studs to the torque
shown in section 2G01.
19. Top up the oil level in the housings.
20. Check the operation of the electrical circuits, LP
switches (14), booster (lubrication) switches (42),
clogging switch (34) and the solenoid valves.
21. Check the oil tightness of the cover, the mating
faces and the hydraulic unions.
36
36
Fig. 13
Fig. 14
Issue 1
May 2001
9G01.15
Special points
- The engine speed sensor (25) is only fitted on 8200
tractors with a Heavy Duty transmission. Before fitting
it, see D.
- Lightly smear the threads of the booster (lubrication)
switch (42) and low pressure switch (14) with Loctite
542 or its equivalent before fitting them.
Reminder: If replacement of the pump is necessary
(see C), carry out hydraulic tests (see section 9N01).
Tightening torques
- Solenoid valve spools (15) to (18): 18 - 20 Nm.
- Hexagonal nut (PTO differential solenoid valve) moderate tightening.
- 5 bar valve (44): smear threads with Loctite 241 and
tighten to a torque of 10 - 20 Nm using a locally
manufactured tool.
- Sensor nut (25) (depending on options, Heavy Duty
gearbox only): 10 - 15 Nm.
- Pressure relief-valve (2): 150 Nm.
- Knurled nuts: 4 - 5 Nm.
Issue 1
May 2001
9G01.16
10
F
a
+
-
41
10
b
P
13
12
4
G
F
R
P
11
6
7
Fig. 15
Issue 1
May 2001
9G01.17
Issue 1
May 2001
9G01.18
12
S
R
LS
P
10
20
20
21
(1)
(10)
(12)
(17)
(20)
(21)
Issue 1
17
Priority blocks
Piston
Variable displacement pump regulator
Lift control spool valve
Auxiliary spool valves
Spool valves (17) (20) manifold
Fig. 16
May 2001
12
9G01.19
XLS
D
Fig. 17
R
F
1
P
F
Fig. 18
Issue 1
May 2001
Removal
Refitting
25. Clean all components. Replace any parts found to be
defective. Check that none of the channels in the
cover are obstructed.
26. Check for the presence of the locating pins (4) (Fig.
19).
27. Remplace O'ring (1) to (3) (Fig. 19).
28. Carry out the removal operations in reverse order.
Tighten bolts and nuts to the indicated torque.
Note: Inside the cover, apply a small continuous
bead of Loctite 574 or its equivalent around the
bolt holes (47). Use the same method as used
with the left-hand cover (see section 9H01 B).
Final operation
29. Refit the right-hand cover (see A).
Tightening torques
-
Issue 1
May 2001
Fig. 19
9G01.21
Special point
- The threads of the sensor must be lightly smeared with
Loctite 577 or its equivalent before adjustment.
Adjustment
30. Screw the sensor fully home without forcing it. The
end must be in contact with pinion (39) of the variable
displacement pump.
Then unscrew the sensor by three quarters of a turn,
in order to obtain a clearance of 1 mm approximately
between the sensor and the pinion. Tighten the nut
to a torque of 10 - 15 Nm.
Issue 1
May 2001
Issue 1
May 2001
Reassembly
41. Clean and check the parts. Replace any components found to be defective.
42. Using a press and an appropriate fixture, insert
bearings (6) separated by spacer (5).
43. Place circlip (10).
44. Refit the bearing block.
45. Fix the pinion on the bearing block using bolts (4)
lightly smeared with Loctite 241 and tighten to a
torque of 72 - 96 Nm.
Special point
- The union (9) has a calibrated port R to provide a
metered lubrication of the bearings (6).
9G01.23
9
AA
5
A
10
12
11
A
Fig. 20
Issue 1
May 2001
Final operations
If fitted, refit the ratchet and sleeve of the Park Lock. The
long part of the sleeve must be turned towards the drive
pinion.
- Refit and adjust the elements of the creeper gearbox if
fitted (see section 6H01).
- Couple the tractor between the gearbox and the intermediate housing (see section 2C01).
- Replace the rear wheels in their original position.
Tighten wheel nuts or studs to the torque shown in
section 2G01.
- Check the correct operation of all controls.
- Road test.
- Check the oil tightness of the mating faces and hydraulic unions.
11
Fig. 21
Special points
- On tractors fitted with the Heavy Duty gearbox, the
profile of the drive bearing block (11) (Figs. 21 22) is
different from that fitted to tractors with a Full Powershift
gearbox (Fig. 20). The repair and maintenance operations however remain the same for both versions.
- If necessary, see section 5K01, creeper unit.
- A sleeve (14) held in position against bush (76) by a
spring (12) and a tab washer (3) provides oil tightness
of the upper shaft line between the gearbox and the
intermediate housing (Fig. 22).
Issue 1
May 2001
9G01.25
14
12
3
12
13
11
76
13
(2) Collar
(3) Tab washer
(12) Spring
19
(13) Rivets
(14) Sleeve
(19) Intermediate housing
Issue 1
10
May 2001
9G02.1
CONTENTS
-
General ________________________________________________
A.
13
B.
16
C.
20
D.
22
25
E.
Issue 1
May 2001
Issue 1
May 2001
9G02.3
Hydraulic routing
- The oil coming from the booster pump located on the
left-hand cover (see section 9H01) flows into the priority
block(s) (7) (depending on version) via the main filter
(27) and the variable displacement pump (41) (Fig. 2).
- The tube (55) (Fig. 3) sends the oil coming from the 5 bar
safety-valve into the suction manifold of the booster
pump (see section 9H01) when no hydraulic slave
device is used.
Description
- The engine movement transmitted to pinion (1) by shaft
(2) drives the variable displacement pump pinion via the
"relay" pinion (82) (Fig. 1).
82
Fig. 1
Issue 1
May 2001
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
to
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
Bolt
High pressure relief-valve
Orbitrol spool valve supply port
Bolt
Load Sensing control port from Orbitrol spool valve
Load Sensing control port to pump regulator
Priority block(s)
Cover
Load Sensing diagnostics connector
Return pipe
High pressure diagnostic connector
Pump regulator
Load Sensing union
Low pressure (17 bar) switch
Solenoid valves: power take off, power take off
brake, differential lock front and rear if fitted and
4WD
Hydraulic cover assembly
Park Lock union
Power take off clutch port
Mecanindus pin
Power take off brake
2WD or 4WD differential lock port
Oring
Port for 4WD union
15 micron main filter
Low pressure port
Booster pressure and lubricating diagnostic connector
Supply port for lift control valve and auxiliary spool
valves via the manifold
Load Sensing control port from auxiliary spool
valves and lift control valve
Bolt
Control port of trailer brake valve
Clogging indicator
Oring
Centring pins
Nut
Washer
Pump pinion
Key
Variable displacement pump
Pressure switch (booster and lubrication)
Port to lubricating manifold located above centre
housing
5 bar safety valve
22 bar safety valve
Plug
Bolt
Issue 1
May 2001
(48)
(49)
(50)
(51)
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
(65)
(66)
(67)
(68)
(69)
(70)
(71)
(72)
(73)
(74)
(75)
(76)
(77)
(78)
(79)
(80)
(81)
(82)
(83)
(84)
Fig. 9
Fig. 10
9G02.5
41
BP
27
HP
7
Fig. 2
Issue 1
May 2001
A
53
22
55
VS
52
52
54
22
53
PCV
54
(22)
(52)
(53)
(54)
(55)
A
PCV
VS
C
Mecanindus pin
Oring
Oring
Booster pipe
Safety valve (44) pipe
:
:
:
:
55
Suction
To variable displacement pump (41)
5 bar safety valve (44)
Intermediate housing compartment
Fig. 3
Issue 1
May 2001
9G02.7
F
F1
16
17
15
18
F.PDF
4RM D.LOCK
PDF
21
48
42
29
43
10
47
23
24
26
28
31
14
30
F1
67
68
BP
7
13
HP
12
56
57
72
51
41
62
61
11
3
Fig. 4
Issue 1
May 2001
9G02.8
F
F1
16
17
15
18
F.PDF
4RM D.LOCK
PDF
21
48
42
29
43
10
47
23
24
26
28
31
30
14
50
67
F
F1
68
33
BP
13
HP
12
56
57
72
51
41
62
61
11
5
Fig. 5
Issue 1
May 2001
9G02.9
24
26
31
28
P aux
X aux
23
50
66
21
30
33
17B
Frein Rem
20
Xdir
Pdir
XLS
69
67
68
65
67
Fig. 6
67
68
70
68
32
71
34
27
Fig. 7
Issue 1
May 2001
36
45
36
2
44
84
41
37
74
38
40
39
68
36
67
82
77
78
80
79
80
81
78
77
83
76
75
Fig. 8
Issue 1
May 2001
75
76
77
78
80
81
82
80
19
79
52
58
63
78
39
77
83
54
46
38
42
37
53
48
60
55
14
59
67
49
47
25
44
68
40
41
1
45
49
35
49
84
12
62
64
70
61
56
57
51
34
32
27
72
73
11
74
68
67
36
Fig. 10
Fig. 9
Parts list
Issue 1
71
Fig. 10
May 2001
Parts list
Fig. 9
Issue 1
May 2001
9G02.13
8
Fig. 11
Issue 1
May 2001
Danger
- The cover and pump together are extremely heavy.
Their removal must be carried out with care using a
locally manufactured support that replaces the head of
a trolley jack.
10. After removing the cover, take out pipes (54) (55)
(optional).
Reminder
- The 22 bar safety valve (45) comprises (Fig. 13):
. a circlip (1)
. a stop (2)
. a spring (3)
. a valve (4)
Fig. 12
36
36
Fig. 13
Issue 1
May 2001
Fig. 14
9G02.15
Fig. 15
Final operations
23. Refit the rear wheel. Remove the axle stand. Tighten
the wheel nuts or studs (depending on version) to the
torque shown in section 2G01.
24. Top up the oil levels in the housings and check the
transparent tube on the left-hand side of the centre
housing.
25. Remove the chocks. Start the engine and check:
- the operation of the hydraulic and electrical components
- the oil tightness of the mating faces, pipes and
hoses.
Remark
- If the variable displacement pump has been replaced, carry out hydraulic tests (see section 9N01).
26. Carry out a road test.
Issue 1
May 2001
9G02.16
a
41
10
b
P
11
13
G
8
-
10
R1
S
12
P1
F
F
Fig. 16
Issue 1
May 2001
:
:
:
:
:
:
:
(1)
(10)
(12)
(17)
(20)
Priority block(s)
Piston
Variable displacement pump regulator
Lift control spool valve
Auxiliary spool valves
(21)
Manifold for spool valves (17) (20)
Important
- Screws C and D are factor set.
- Do not modify these settings.
20
P
9G02.17
21
17
LS
LS
PR
1
P
P1
12
R1
S
R1
C
10
D
P1
S
F
Fig. 17
Issue 1
May 2001
P1
12
R1
a
b
O
S
Issue 1
May 2001
XLS
D
Fig. 18
:
:
:
:
:
:
:
Important:
- The adjusting screws C and D are factory set.
- Do not modify these settings.
9G02.19
2
Fig. 19
Issue 1
May 2001
47
84
41
51
Fig. 20
82
39
40
38
37
74
Fig. 21
Issue 1
May 2001
9G02.21
Refitting
36. Clean and inspect all the parts. Replace any components found to be defective.
37. Degrease the threads of the pump shaft.
38. Place an new Oring (84) in the bore of the pump
housing and position key (40) in its slot at the end of
the shaft.
39. Position the pump on the cover by checking the
alignment of the key in the slot on the pinion. Tighten
bolts (47), lightly smeared with Loctite 542 or its
equivalent, to a torque of 200 - 260 Nm.
40. Slide washer (38) onto the shaft.
41. Degrease the threads of nut (37) and lightly smear
them with Loctite 241 or its equivalent, then tighten
to a torque of 80 - 100 Nm.
42. Manually check the rotation of the pump and check
the pinion backlash.
43. Fit the obturator with a new seal and refit the
assembly in the port in the cover.
44. Replace the hydraulic manifolds and the transfer
pipe fitted with new seals. Fit spacer (72). Tighten
the bolts (Fig. 20) using the torques shown below:
- manifold A : 90 - 120 Nm
- manifold R : 50 - 70 Nm
- spacer (51) : 50 - 70 Nm
41
Fig. 22
Final operation
45. Refit the right-hand side cover (see A).
Important
- Fill the variable displacement pump (41) with transmission oil via the port of pipe (1) (Fig. 22) before
starting the engine.
Issue 1
May 2001
79
80
81
78
77
Reassembly
50. Place the bearing cups (78) thrust against the previously fitted circlips.
51. Reassemble the turning hub of the idler pinion (82) by
assembling the bearing cones (77), spacer (81), the
shim(s) and pin (83).
Reminder
- If required, carry out the shimming of the idler
pinion (see operations 56 to 64). Otherwise continue the reassembly operations.
52. Assemble the pinion and pin on the cover.
53. Degrease the threads of bolt (75) and lightly smear
it with Loctite 241 or its equivalent.
54. Fit washer (76) and tighten the bolt to a torque of 100
- 130 Nm.
55. Manually check the rotation of the pinion.
83
82
75
76
Fig. 23
Issue 1
May 2001
9G02.23
77
78
80
81
Remark
- The clearance of the taper roller bearings is adjusted by
shim(s) (79) placed between the front cone (77) and
spacer (81). (Fig. 24).
77
Reminder
- To carry out the correct shimming of the bearings, place
the cover in a vice with the pump pinion (39) protruding
as shown in Figure 25.
78
82
83
80
79
Fig. 24
J1 = 0,03 / 0,13mm
81
39
75
79
76
82
Fig. 25
Issue 1
May 2001
Shimming
56. Place the index of the dial gauge on the pinion (82)
(Fig. 25).
57. Push the pinion strongly downwards, alternatively
turning the pinion left and right in order to correctly
seat the cone in the bearing cup.
58. Reset the dial gauge to zero.
59. Repeat the operation, this time pulling on the pinion
instead of pushing.
60. Depending on clearance measured, select a thickness of shim(s) in order to provide a clearance of:
J1 = 0.03 to 0.13 mm (Fig. 25)
Remark:
Wherever possible, shim the bearings to the minimum clearance.
61. Fit the definitive shim(s) selected in operation 60.
62. Degrease the threads of bolt (75) and lightly smear
the threads with Loctite 241 or its equivalent.
63. Fit washer (76) and tighten the bolt to a torque of 100
- 130 Nm.
64. Manually check the rotation of the pinion.
Issue 1
May 2001
82
9G02.25
Preliminary operations
- Place the rear wheels in the wide track position.
- Uncouple the tractor between the gearbox and the
intermediate housing (see section 2C01).
- Remove the creeper unit components (if fitted, see
section 6H01).
- Free the ratchet of the Park Lock (if fitted, see section
6F01). Take out the toothed sleeve after carefully noting
its position.
Removal
Fig. 26
Refitting
68. Check that the hydraulic channels and ports of the
spacer are not obstructed.
69. Refit the bearing block. Carry out operation 67 in
reverse order.
70. Place the groove of the spacer in the axis of the port
provided for the plug (8) (Fig. 27).
71. Fit the locating pin, with the flats lodged in the groove
in the spacer. Tighten the plug.
72. Check that the bearing block assembly is correctly
positioned and that it turns normally.
73. Fit pinion (1). Tighten bolts (4) previously smeared
with Loctite 241 or its equivalent to a torque of 72 96 Nm (Fig. 26).
Issue 1
May 2001
Disassembly
74. Remove the bearing block.
75. Take off circlip (10). Extract bearings (6) and recover
spacer (5) (Fig. 27).
Reassembly
76. Clean and check the components. Replace any
parts found to be defective.
77. Using a press and an appropriate fixture insert
bearings (6), placing spacer (5) between them.
78. Fit circlip (10).
79. Check for the presence of circlip (12) on the upper
shaft of the power take off (Fig. 27).
80. Refit the bearing block and fit the pinion. Tighten the
bolts to the torque shown in operation 73.
Special point
- The union (9) has a calibrated port for the lubrication of
bearings (6).
Final operations
- If fitted, unclamp the ratchet and position the sleeve of
the Park Lock.
Remark
- The long part of the ratchet must face the drive pinion.
- Refit and adjust the creeper unit components (if fitted,
see section 6H01).
- Couple the tractor between the gearbox and the
intermediate housing (see section 2C01).
- Replace the wheels in their initial positions. Tighten
the wheel nuts or studs to the torque shown in section
2G01.
- Check the operation of all the controls.
- Carry out a road test.
- Check the oil tightness of the mating faces and
hydraulic unions.
Issue 1
May 2001
9G02.27
9
AA
6
1
10
12
11
A
Fig. 27
Issue 1
May 2001
9H01.1
CONTENTS
General ________________________________________________
A.
B.
10
C.
11
Issue 1
May 2001
9H01.2
General
12
1
2
Load Sensing hydraulic circuit
Booster pump
Variable displacement
pump (*)
60 cm3/rpm
0 45 cm3/rpm
80 cm3/rpm
0 60 cm3/rpm
Remarks
- The figures given in this section are for the 60 cm3 pump
and its surrounding elements. The construction of the
80 cm3 pump is identical in principle to the former.
- It should be noted however, that the internal pinions as
well as the body of the pump have slightly different
profiles.
Description
Pinion (1) taking its rotation from shaft (2), drives pinion
(12) of the booster pump (Fig. 1). The oil is sucked into
the intermediate housing via the manifold (4). It is then
directed towards the strainer (6) and the booster pump (2)
(Fig. 2) through an internal channel in the cover.
The oil is then discharged towards the variable displacement pump by the booster pipes (3) (54) held by compartment C of the intermediate housing (Fig. 2).
The pipe (55) directs the oil coming from the 5 bar safetyvalve towards the suction manifold (4).
Issue 1
May 2001
Fig. 1
9H01.3
A
5
C
4
55
25
2
VS
6
54
17
3
26
25
PCV
26
(25)
(26)
(54)
(55)
A
PCV
VS
C
Oring
Mecanindus pin
Booster pipe
Safety-valve pipe (see section 9G01 or 9G02 depending on hydraulic characteristics)
Suction
To the variable displacement pump (see section 9G01 or 9G02 depending on hydraulic characteristics)
5 bar safety-valve
Fig. 2
Compartment of the intermediate housing
Issue 1
May 2001
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Nut
Booster pump
Booster pipe
Suction manifold
Oring
Strainer
Studs
Plug
Seal
Bolt
Washer
Pinion
Key
Cover
Nut
Centring pins
Oring
Gasket
Bolt
Bowl
Oring
Bolt
Oring
Locating pins
Fig. 3
Fig. 4
Issue 1
May 2001
9H01.5
Vue
densemble
Overal
view
17
14
13
12
11
16
17
10
9
8
1
7
15
5
4
18
16
20
24
23
21
19
20
22
18
Parts list
Issue 1
Fig. 4
Fig. 3
May 2001
9H01.6
Exploded view
16
3
17
2
24
23
12
10
14
9
8
22
24
19
11
13
15
10
6
21
20
18
7
1
Parts list
Issue 1
May 2001
Fig. 3
Fig. 4
9H01.7
12
23
24
Fig. 5
16
16
Fig. 6
Issue 1
May 2001
Refitting
6. Clean the mating faces of the housing and the cover.
Smear the mating face of the housing with Loctite
510 or its equivalent.
7. Replace the Oring (17) and position the seal (5) on
the suction manifold (4) (Fig. 3).
8. Refit manifold (4), the end fitted with seal (5) inserted
into compartment C of the intermediate housing
(Fig. 2).
9. Lightly smear the face of the gasket (18) on the
suction manifold (4) with Silicomet type silicone.
Spool the gasket over the studs (7), the adhesive
facing the cover. Screw two diametrically opposed
guide studs G on to the intermediate housing (Fig. 8).
10. Check for the presence of the two centring pins (16)
(Fig. 6).
11. Place a new Oring (25) on the booster pipe (3). Insert
the pipe, its end positioned in the Mecanindus pin
(26) (Fig. 2).
14
19
10
14
20
20
Fig. 7
Issue 1
May 2001
9H01.9
7
G
18
Fig. 8
Tightening torques
-
Issue 1
May 2001
24
23
Remark
- The removal and refitting procedures are the same for
a 60 cm3 or 80 cm3 pump.
Preliminary operation
18. Take off the cover (see A).
Removal
19. Remove bolts (22) and pump (2) (Fig. 3). If necessary, remove pinion (12) from the pump. Recover
key (13).
Refitting
20. Clean the mating faces of the pump and cover.
21. Check for the presence of the locating pins (24) (Fig.
9).
22. Inside the cover, apply a bead C of Loctite 574 or
its equivalent around the bolt holes (Fig. 9). The diameter of the bead should be small in section so as
to not touch the groove of seal (23). Fit a new seal.
23. If disassembled, replace key (23) and refit pinion
(12). Tighten nut (15) to the torque indicated below.
Position the pump on the centring pins.
24. Fit bolts (22) smeared with Loctite 241 or its equivalent and tighten to a torque of 40 - 50 Nm.
25. Manually check the rotation of the pump.
Final operation
26. Refit the cover (see A).
Tightening torques
- Nut (15): 50 - 60 Nm (Loctite 241)
- Bolt (22): 40 - 50 Nm (Loctite 241)
Issue 1
May 2001
Fig. 9
9H01.11
Preliminary operation
27. Remove the left-hand side cover (see A) and the
booster pump (see B).
13
17
5
7
Fig. 10
Issue 1
May 2001
Disassembly
28. Tighten the pump in a vice fitted with plastic jaw
protectors.
29. Remove bolt (1) and cover (7) (Fig. 11).
30. Take off circlip (3), seal (4) (Fig. 12) and Orings (5)
(6) (Fig. 13).
Refitting
Final operation
35. Refit the booster pump (see B) and the left-hand
cover (see A).
Fig. 12
Fig. 13
Issue 1
May 2001
Fig. 14
9I01.1
CONTENTS
General ________________________________________________
A.
B.
C.
10
D.
12
E.
12
F.
13
14
H.
15
I.
17
J.
18
G.
2
Issue 1
May 2000
2002
December
Issue 1
December 2000
9I01.3
General
Brake master cylinders
The tank (4) (Fig. 1 - 2) maintains a constant level in the
brake master cylinders through a residual flow of oil
coming from:
- either, the output line of the oil cooler via the thermostatic valve (on tractors with Full Powershift transmission)
- or, the lubrication line (booster) of the right-hand hydraulic cover (on tractors with Heavy Duty transmission).
The servobrakes are supplied from the 17 bar lowpressure circuit (Fig. 3 - 3A or 4 depending on the
version).
Fig. 2
Issue 1
May 2001
9I01.4
Characteristics
Servobrake
1
Fig. 4
Issue 1
May 2001
9I01.5
2
3
Issue 1
May 2001
9I01.6
Parts list (Fig. 5 to 7)
11
13
12
14
10
Fig. 5
Issue 1
May 2001
9I01.7
11
12
14
13
A
D
10
C : To gearbox lubrication
D : Oil cooler return
Fig. 6
11
12
14
13
16
18
17
15
1
D C
A : Supply to thermostatic valve from the gearbox
B : To oil cooler
10
C : To gearbox lubrication
D : Oil cooler return
Fig. 7
Issue 1
May 2001
9I01.8
D
B
Fig. 8
4
D
Fig. 8A
16
17
11
10
8
Fig. 9
Issue 1
May 2001
9I01.9
2
Issue 1
May 2000
2002
December
Issue 1
December 2000
9I01.11
Trailer braking
- The action on piston (4) also produces a movement of
piston (6) and the closing of valve F. The oil contained
in chamber E is directed to chamber E of the passive
master cylinder and towards port B via the intermediary of the open valve F. The valve F and piston (6)
assembly rapidly abuts against the bottom of the
active master cylinder.
- In this position, only the tractor brake is activated, the
trailer is not braked.
Issue 1
May 2001
J = 0,5 +- 0,25
16
10
A
17
Fig. 10
5
8
1
Issue 1
May 2001
4
Y
Fig. 11
9I01.13
1
A
B
(1)
(2)
Fig. 12
Issue 12
Issue
May 2000
2002
December
Remark
Adjustment
Special point
- Tractors equipped with Full Powershift transmission
are fitted with a pedal known as a manoeuvring pedal.
To adjust it, see section 11 - Electronics.
Issue 2
1
May 2000
2002
December
C
Fig. 13
9I01.15
Remark
- Some hose pipes may be difficult to pinch shut due to
their rigid sheath. Consequently, it will be necessary to
disconnect the hose pipe from union (2) and temporarily
replace it with a plug.
110 l/min
1
150 l/min
Fig. 14
Issue 1
May 2001
Bleeding procedure
19. Run the engine at approximately 1300 rpm.
20. Open the bleed screws by one turn and wait 5 minutes
Latched pedals
- Press and slowly release the latched brake pedal eight
times over its full travel, until the oil that is released
contains no air bubbles.
Unlatched pedals
- Press and slowly release each unlatched brake pedals
eight times over their full travel, until the oil that is
released contains no air bubbles.
- First close the left bleed screw, then the right-hand one.
- Press hard (60 - 80 kg approximately) on each pedal in
order to position the brake pistons. Check the hardness
and the force required on each pedal. The travel of the
latched pedals must be less than 120 mm using the
previously stated force.
- Stop the engine.
- Remove the hose and unions (3) assembly (Fig. 16) and
the clip fitted to hose (5), see remark in operation 18.
Fig. 15
Special point
- If any functional problem appears, carry out the bleeding operation again.
- If the problem persists, check the oil tightness of:
. the circuit
. the master cylinders
. the piston seals.
Fig. 16
Issue 1
May 2001
9I01.17
110 l/min
1
Special point
- Open the three bleed screws (main brake (1) (Fig. 15),
trailer brake (1) (Fig. 17 or 19)).
- When the bleeding has been completed, tighten the
bleed screws in the following order: left bleed screw,
right bleed screw and trailer brake bleed screw.
- Check the pressure of trailer braking system (see
section 9N01 - Hydraulic Tests) at the quick-disconnect
(17) (Fig. 18) at the rear of the tractor.
Fig. 17
17
Fig. 18
150 l/min
Fig. 19
Issue 1
December 2000
Issue 2
1
May 2000
2002
December
Fig. 20
9I02.1
CONTENTS
General ________________________________________________
A.
B.
C.
D.
10
E.
11
Issue 1
May 2002
General
The MT645 to MT665 tractors are equipped, in their
standard version, with Meritor brake master cylinders (1)
(Fig. 1 - 2) and provide hydraulic power assistance.
The MT535 model may be fitted with the Meritor master
cylinders as an option.
On the version with trailer braking, the system is completed by a FTE valve (2) (Fig. 2) providing control of the
trailer brake valve. The latter is incorporated into the
priority blocks (see section 9B01) and a quick-disconnect coupling located at the rear of the tractor.
Fig. 1
Fig. 2
Issue 1
May 2002
9I02.3
Characteristics
(1) Accumulator (Fig. 3 - 3A - 4)
- Manufacturer ................................
Olaer
- Type ..............................................
1/20
- Capacity ........................................
1 litre
- Gas ...............................................
Nitrogen
- Inflation pressure ..........................
9 1bar
To be checked every
six months with
the engine stopped
(2) Non-return valve (Fig. 3 - 3A - 4)
- Manufacturer .................................
Parker
Special point
- During refitting, turn the arrow engraved on the
valve body to match the direction of the fluid flow
(3) Main accumulator (Fig. 3 - 3A) for Dynashift integrated into Heavy Duty transmission
(4) Brake hydraulic power assistance
4
1
Fig. 4
2
3
Issue 1
May 2002
9I02.4
Parts list (Figs. 5 to 7)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Master cylinder
FTE valve
Brake power assistance return and bleed connector
Brake pistons supply
Brake power assistance supply
Hydraulic link
Trailer brake quick-disconnect coupling
Priority blocks with trailer brake
Bleed screw
Fig. 5
Issue 1
May 2002
9I02.5
Fig. 6
Full Powershift transmission and trailer braking
12
13
9
Fig. 7
Issue 1
May 2002
Issue 1
May 2002
9I02.7
D
2
1
7
9
D
11
12
10
Parts list
Issue 1
Fig. 8
May 2002
9I02.8
C.
(1)
(2)
(3)
(4)
A:
B:
C:
D:
E:
Spool
Ball
Plunger
Spring
Fig. 9
Issue 1
May 2002
9I02.9
Fig. 10
Fig. 11
Issue 1
May 2002
Issue 1
May 2002
5
8
1
4
Y
Fig. 12
9I02.11
Remark
- Some hose pipes may be difficult to pinch shut due to
their rigid sheath. Consequently, it will be necessary to
disconnect the hose pipe from union (2) and temporarily
replace it with a plug.
110 l/min
1
150 l/min
Fig. 13
Fig. 14
Issue 1
May 2002
Bleeding procedure
11. Run the engine at approximately 1300 rpm.
12. Open the three bleed screws by single turn:
- right-hand brake
- left-hand brake
- trailer braking valve (if fitted)
13. Slowly depress the brake pedals several times
14. Continue until bubble free oil is discharged from both
the left- and right-hand bleeds.
15. With the brake pedals fully released, close the leftand right- hand brake bleeds.
16. If trailer braking is fitted, slowly depress the brake
pedals several times until bubble free oil is discharged from the trailer braking valve bleed.
17. With the brake pedals fully released, close the trailer
braking valve bleed.
18. Remove the clip from the booster return hose.
19. Remove the 5 bar pressure connector.
20. The bleeding procedure is now completed.
Fig. 15
110 l/min
1
Fig. 16
Issue 1
May 2002
9I02.13
Special points
- If a there is a problem when operating the brakes, carry
out the bleed sequence a second time.
- If the problem still persists:
. check the oil tightness of the circuit and the unions
. check the trailer braking pressure (see section 9L01
or 9L02) on the quick-disconnect coupling (17) (Fig.
17) at the rear of the tractor.
17
Fig. 17
150 l/min
Fig. 18
Issue 1
May 2002
9J01.1
CONTENTS
-
General ________________________________________________
A.
B.
C.
11
Issue 1
December 2000
General
On 8210 - 8220 - 8240 and 8250 tractors fitted with a
Heavy Duty gearbox, with a mechanical reverse shuttle,
the distribution block (1) (Fig. 1) mounted on the front
right-hand side of the gearbox is formed of two distinct
parts that ensure the control of the clutch and the four
Dynashift ratios.
- The clutch part comprises a series of spools, seals,
a valve and piston. These can be replaced by a kit (Fig.
10) that is found in the Spare Parts catalogue.
- The Dynashift part (see section 9L01).
Issue
Issue 21
May 2002
December
2000
9J01.3
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Distribution block
17 bar supply
Accumulator on 17 bar line
Master cylinder hose pipe
Clutch supply pipe
Clutch diagnostics connector
Dynashift front piston diagnostics connector
Dynashift rear piston diagnostics connector
Accumulator for brake assistance
Fig. 1
Issue 1
May 2001
Description
- The valve comprises two spools. The upper spool is
controlled by pressure from the clutch master cylinder
and controls the clutch supply.
- The lower spool, controlled by the inlet pressure,
provides hydraulic safety for the system.
Issue 1
May 2001
9J01.5
P = 17 bar
R = Return
E = Clutch
Fig. 2
P = 17 bar
R = Return
E = Clutch
19
4
Fig. 3
Issue 1
May 2001
P = 17 bar
R = Return
E = Clutch
5
4
Fig. 4
P = 17 bar
R = Return
E = Clutch
16
Fig. 5
P = 17 bar
R = Return
E = Clutch
Fig. 6
Issue 1
May 2001
9J01.7
Issue 1
May 2001
9J01.8
Overall view
13
14
15
18
16
19
20
21
11
17
18
10
22
11
10
9
4
6
12
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Plug
Spring
Non-return valve
Safety-valve spool
Main spool
Safety-valve sleeve
Valve body
Main spool sleeve
Plugs
Oring
Circlip
Spring
Push rod
Circlip
Spring
Modulation spring
Seal quadring
Guide segments
Piston
Calibrated union
Modulation limit stop
Main spool limit stop
Fig. 7
Issue 1
May 2001
9J01.9
Exploded view
8
3
22
20
13
16
21
18
12
17
18
11
10
15
9
14
10
11
19
Fig. 8
Disassembly
1. Using a locally manufactured tool, C, remove circlip
(11) and take out plug (9) (Fig. 9) from the A assembly.
Using the same method for the B assembly. Remove
the A and B assemblies while visually noting their
positions.
2. Unscrew plug (1) and remove the C assembly as in
the previous operation.
11
Fig. 9
Issue 1
May 2001
9J01.10
Reassembly
Final operations
5. Refit and bleed the clutch control valve (see sections
4A01 and 9I01 respectively).
6. Check the modulation pressure of the valve (see
section 9N01 - Hydraulic Tests).
A
20
11
11
10
7
18
8
10
5
B
Issue 1
May 2001
Fig. 10
9J01.11
C . Service tools
Tool to be manufactured locally
- Spring compression tool
100
HM8
35
17
M8
45
60
75
100
Fig. 11
Issue 1
May 2001
9K01.1
CONTENTS
.
General ________________________________________________
A.
B.
C.
Issue 1
May 2002
General
The control unit is fixed on the right-hand side at the front
of the gearbox. Its role is to supply:
- the power shuttle proportional solenoid valves with oil
- the Dynashift (see section 5B04).
A filter element (6) (Fig. 1) is located underneath the righthand hydraulic cover, upstream of the control unit, to
provide additional filtering of oil going to the proportional
solenoid valves.
Control unit
17 bar line - Front clutch
17 bar line - Rear clutch
Accumulator (Nitrogen)
Main supply line (17 bar)
60 micron filter element
17 bar line - Dynashift to clutch A - B
17 bar line - Dynashift to clutch C - D
Cover for separate return to gearbox for oil coming
from pipes (2) (2A)
Issue 1
May 2002
9K01.3
2A
12
F
7
2A
Gas
Issue 1
Fig. 1
May 2002
Removal
Danger
- If you work on the 17 bar hydraulic circuit immediately
after stopping the engine, release the pressure stored in
the accumulator or wait a while before working on the
circuit.
1. Mark and disconnect the connectors on EV1 and EV2
solenoid valves of the Dynashift (see section 9L01) as
well as those of the proportional solenoid valves of the
front and rear clutch of the power shuttle (Fig. 2).
2. Disconnect and remove pipes (2) (2A) (4) connected
respectively to the gearbox and accumulator.
3. Remove the solenoid from the solenoid valve of the
Dynashift rear clutch. Unscrew, release and take off
cover (12) and the control unit. Discard the Oring (13)
(Fig. 2).
4. If necessary, empty the internal pipes supplying the
A - B - and C - D clutches of the Dynashift.
Remark:
- The lower pipe has a swan neck.
Refitting
5. Remove all traces of Loctite from the mating surfaces
of the unit and gearbox housing.
6. If removed, position the internal pipes of the Dynashift
clutches in the ports of the input unit.
7. On the unit, replace the Orings of the previously
mentioned pipes.
8. Lightly smear the mating surface of the unit that
mates with the housing with Loctite 510 or equivalent.
9. Turn the internal pipes of the Dynashift in such a way
that they correctly penetrate the ports of the unit. Refit
the unit.
Issue 1
May 2002
9K01.5
12
13
12
F
F1
F
2
Loctite 510
F1
F2
8
11
10
F2
10
11
10
11
Fig. 2
Issue 1
May 2002
10
11
Remark
- Each hydraulic return line from the proportional solenoid
valves is channeled separately, this is done so as to
avoid back pressure between one solenoid valve and
another.
Tightening torques
- Body of solenoid valves: 15 to 20 Nm maximum
- Nut on solenoids: 5.4 to 8.1 Nm maximum.
Important: It is imperative to respect the indicated
tightening torques in order to avoid any risk of
deforming the valves and leading to the blocking of
the spool.
Issue 1
May 2002
F
Fig. 3
9K02.1
A.
B.
C.
D.
Issue 1
Mai 2002
A. Technical Features
DESCRIPTION
Nominal pressure
Hydraulic oil type
Ambient temperature
VALUES
250 bar
DIN 51524
Min -30 C
Max +90 C
Min -30 C
Max +70 C
M18x1.5 (ISO6149-1)
M14x1.5 (ISO6149-1)
NAS 1638 class 10
25 Nm
200 Nm
12 V DC
LS pilot flow
Accumulator KSP1
Accumulator KSP2
Accumulator RSP1
Bleed screw
Solenoid valve WV1
Solenoid valve WV2
Return line
Supply from the pump
Top cylinder supply
Bottom cylinder supply
2
4
Fig. 1
RSP 1
KSP 1
KSP 2
20.19
0,75 litres
140 bar
1,4 litres
40 bar
0,75 litres
40 bar
20.22
0,75 litres
140 bar
1,4 litres
40 bar
0,75 litres
40 bar
20.29
0,75 litres
140 bar
1,4 litres
40 bar
1,4 litres
40 bar
20.43
0,75 litres
140 bar
1,4 litres
40 bar
1,4 litres
40 bar
Issue 1
Mai 2002
9K02.3
10
3
11
6
9
5
Fig. 2
Issue 1
Mai 2002
9K02.4
Neutral position
D
C
E
5
12
11
6
250 + 20
bar
14
Fig. 3
Issue 1
Mai 2002
9K02.5
A
B
D
E
C
5
12
11
6
250 + 20
bar
14
Fig. 3A
Issue 1
Mai 2002
9K02.6
Lowering position (Fig. 3B)
1
2
A
B
D
E
C
5
11
12
250 + 20
bar
14
Fig. 3B
Issue 1
Mai 2002
9K02.7
AV
Fig. 4
Fig. 5
B
C
Fig. 6
Issue 1
Mai 2002
B
C
Fig. 7
Fig. 8
Issue 1
Mai 2002
9K02.9
Fig. 9
Fig. 10
E
A
B
Fig. 11
Fig. 12
Issue 1
Mai 2002
Fig.13
Fig. 14
Fig. 15
Issue 1
Mai 2002
9K02.11
Fig. 16
Fig. 17
NON
Fig. 18
Issue 1
Mai 2002
9L01.1
CONTENTS
-
General ________________________________________________
A.
B.
Issue 1
May 2001
General
The Dynashift control assembly fitted to 8210 - 8240 and
8250 tractors equipped with the Heavy Duty gearbox
comprises the following three components (Figs. 1 - 1B):
- The control unit (1) mounted on the right-hand side of
the gearbox, constituted by two separate parts
. the first part controls the engine clutch control (Pressure Loaded version) or the front and rear clutches
(Power Shuttle)
. the second part controls the four Dynashift ratios. The
Dynashift part contains two internal channels, A and
B (Fig. 2 - 2A) allowing oil to circulate from one
solenoid valve to another.
- The solenoid valves (2) screwed into the control unit
comprise:
. a lower solenoid valve EV1 with four ports and two
positions
. an upper solenoid valve EV2 with three ports and two
positions.
- The accumulator (3) fitted on the supply line, allows
the oil flow rate to be accelerated to fill the piston
chambers of the Dynashift unit when necessary. The
reaction of the pistons is consequently faster.
Trademark
: Olaer
Type
: 1/20
Capacity
: 1 litre
Gas
: Nitrogen
Inflation pressure
: 9 1 bar (to be checked with
specific tools every 6 months,
engine stopped).
Note: When the engine is stopped, the accumulator maintains a pressure of 17 bar for a short while.
If an immediate maintenance intervention is necessary, release the pressure or acts on the circuit
with caution.
Issue 1
May 2001
Fig. 1A
On the version with a Mechanical Reverse Shuttle, two
diagnostics connectors (7) (8) (Fig. 1B) can be provisionally fitted to replace the plugs and in order to check the
pressure in the piston chambers (see section 9N01 Hydraulic tests).
On tractors fitted with a reverse shuttle, the diagnostic
connectors are fitted during manufacture.
The tube (4) supplies the control unit. The oil return
allowing the piston chambers to be emptied passes
through the gearbox.
Special point
- The cross-shaped union (6) is fitted with a restrictorvalve. During reassembly, turn the restrictor to face the
17 bar supply coming from tube (4) (Fig. 1B).
9L01.3
Fig. 1B
F
4
Gas
D : Non-return valve
Issue 1
Fig. 1
May 2001
9L01.4
R
A
P
A
C
F
EV2
D
P
A
E /T
EV1
Tightening torques
- bodies of solenoid valves EV1 and EV2 : 20 Nm
maximum
- nuts of solenoid valves: 3 to 4 Nm maximum
Fig. 2
Issue 1
May 2001
9L01.5
P
A
B
EV2
R
D
B
P
A
EV1
Tightening torques
- bodies of solenoid valves EV1 and EV2 : 20 Nm
maximum
- nuts of solenoid valves: 3 to 4 Nm maximum
Issue 1
May 2001
A . Explanation of ratios
- For a theoretical and mechanical explanation of the
ratios, see section 5B03 or 5B04 (depending on the
version).
EV1+
A ratio (Fig. 2 - 2A - 3)
The solenoid valve EV1 is supplied, thus allowing oil
under pressure to reach channel A. This channel directs
the oil towards the front piston via port E and also
towards solenoid valve EV2. The latter being in the
neutral position, the oil can pass through the slide and
port F towards the rear piston chamber. Both pistons are
therefore under pressure.
A
E
EV2
F
Front
B ratio (Fig. 2 - 2A - 4)
Rear
Fig. 3
EV1+
B
EV2+
Front
Issue 1
May 2001
Rear
Fig. 4
9L01.7
C ratio (Fig. 2 - 2A - 5)
The changing of speeds from B to C is obtained by cutting
off the electrical supply to solenoid valve EV1, while
solenoid valve EV2 is still maintained under voltage. The
channel A is no longer under pressure but linked to the
housing. Consequently, the front piston can return to its
neutral position. Channel B is under pressure. The oil
flows to the rear piston via solenoid valve EV2.
EV1
B
EV2+
Front
Rear
Fig. 5
D ratio (Fig. 2 - 2A - 6)
The D ratio is obtained by cutting off the electrical supply
of EV2. Both pistons are linked to the housing via channel
A.
EV1
EV2
Front
Issue 1
Rear
Fig. 6
May 2001
Remark
- If the pressures are incorrect, check that the spool
valve is actually moving in the solenoid valve concerned or consult the section on electrical tests.
Issue 1
May 2001
9M01.1
CONTENTS
A.
General ________________________________________________
B.
C.
Diagrams _______________________________________________
Issue 1
May 2001
A . General
The correct operation and performance of the hydraulics
system is closely linked to the use of clean transmission
oil.
When maintenance is carried out on the gearbox / axle
assembly (e.g. brake or transmission repairs) this contaminates virtually the whole hydraulic circuit.
It is therefore essential to carry out a decontamination
operation after repairs in order to avoid the rapid deterioration of other components in the circuit caused by the
movement of particles carried by the oil.
The contamination of oil can result in:
- seizure or leaks in the steering spool valve (Orbitrol)
- seizure of the spool valves in the solenoid valves
- excessive wear in the hydraulic pump(s).
The aim of oil decontamination is to restore the hydraulic
circuit to a state of cleanliness higher than that before the
repair operation. The particles that cause the greatest
damage are not the largest ones, for these are rapidly
caught in the filter, it is the repeated circulation of small
non-filtered particles that has the greatest abrasive
effect.
Issue 1
May 2001
9M01.3
B . Decontamination procedure
Special point
- The decontamination is carried out in two distinct
phases.
Fig. 1
Issue 1
May 2001
Decontamination
Remark
- The oil temperature must be above 10 C to avoid the
opening of the by-pass.
4. Start the engine and run it at 1200 rpm.
5. Allow the engine to run for 15 minutes minimum in
order to filter out the particles in the oil.
Important: Check that the clogging indicator
lamp on the dashboard does not light during the
decontamination operation. If this does happen,
replace the 15-micron filter element and check or
change the suction strainer.
6. After having let the engine run for 15 minutes, stop
the engine and replace the 15-micron filter by a 6micron filter.
7. Procure a hose pipe of appropriate strength, fitted at
each end with a male quick-disconnect coupling for
connection to the auxiliary spool valves (Fig. 2).
8. Connect the connectors of the flexible to ports A and
B of the same spool valve (Fig. 2).
9. Start the engine and run it at 1200 rpm.
10. While the engine is running, turn the knurled knob of
the spool valve to maximum flow and alternate the
direction of oil circulation in the spool valve for
approximately 5 minutes (Fig. 2) using the control
lever.
Repeat the operation on the two or three other spool
valves (depending on options).
Reminder
- If the clogging indicator lamp lights on the dashboard,
replace the 6-micron filter element by another of the
same type.
Issue 1
May 2001
Fig. 2
9M01.5
Dynamic phase
Remark
- Contrary to the static phase, the dynamic phase uses
all the hydraulic functions of the tractor for 15 minutes
with the engine running:
. lift control
. steering
. power take off
. brakes
. etc.
Procedure
Reminder
- During decontamination, carefully monitor the dashboard clogging indicator. If necessary, immediately
replace the 6-micron filter and the suction strainer.
12. Raise and lower the lift arm over the entire travel of
the rams and carry out a rapid alternating raise and
lower cycle.
13. Turn the steering wheel to full lock in both directions
several times.
14. Declutch and allow the clutch in and out 5 or 6 times
using the full travel of the pedal (tractors with Heavy
Duty transmission).
Repeat the same operation again more quickly.
15. Press and release each of the unlatched brake
pedals several times.
16. Repeat the same operation more quickly.
17. Slowly press and release the latched pedals several
times.
18. Repeat the same operation again more quickly.
19. Activate the Dynashift control, located on the left
beneath the steering wheel, moving it from A to D
and vice versa several times.
20. Operate and halt the power take off 4 or 5 times, one
after another.
21. Reconnect the temperature switch.
Issue 1
May 2001
Test
22. Carry out a road test the tractor using various engine
speeds, changing up and down through the ratios for
approximately 15 minutes.
23. When the road test is completed, let the engine run
at 1200 rpm for approximately 15 minutes with the
tractor stationary, in order to eliminate any remaining
particles in the circuit.
Issue 1
May 2001
9M01.7
C . Diagrams
Parts list
(1)
(2)
(3)
(4)
(5)
Fig. 3
B
2
5
4
3
Parts list
Issue 1
May 2001
Fig. 3
Issue 1
May 2001
9M01.9
R
Parts list
(1) Decontamination connectors (low pressure)
(4) Oil decontamination replaceable oil filter element (6 micron)
(5) Clogging indicator
Fig. 4
4
Fig. 4
Parts list
Issue 1
May 2001
9N01.1
CONTENTS
A.
General ________________________________________________
B.
C.
D.
21
E.
30
F.
31
2
Issue 1
May 2000
2002
December
A . General
The 8200 series tractors are fitted with a closed centre
hydraulic system that provides a flowrate of 110 l/min,
depending upon the characteristics of the booster pump
and the variable displacement pump.
The 150 l/min hydraulic system is only fitted as an option
on tractors with a Full Powershift transmission.
The hydraulic system comprises two separate circuits:
low and high pressure.
Preliminary operations
Before beginning the tests, run the engine in order to bring
the oil temperature up to 80 C minimum (176 F).
To facilitate the increase in oil temperature:
- run the engine at 2000 rpm
- connect a flowmeter to an auxiliary spool valve
- maintain the spool valve activated
- limit the flow through the flowmeter
- as soon as the oil temperature is above 80 C, release
the spool valve and open the flowmeter valve to the
maximum.
Issue 2
1
May 2002
December
2000
Always check the oil flow direction to avoid damaging the flowmeter. In addition, select pressure
gauges, hose piping and unions of sufficient capacity and strength.
Values measured during the tests :
- maxi flowrate .................. 105 115 l/min
or 150 l/min (depending on option)
- mini flowrate ................... 5 l/min
- maxi pressure ................. 200 bar
- mini pressure .................. 0,4 bar
9N01.3
P1
The high pressure, 110 l/min circuit supplies the following functions:
- steering
- auxiliary spool valves
- lift control
- trailer braking
11 bar
maxi
Fig. 1
Engine speed
(rpm)
P1
(bar)
1000
5.2 1
2200
6.3 1
P2
Engine speed
(rpm)
P2
(bar)
P3
(bar)
1000
26 1
2200
26 1
30 bar
11 bar
maxi
P3
Fig. 2
P3
P2
HP
P1
BP
Fig. 3
Issue 1
May 2001
9N01.4
Q1
P2
P3
(l/min)
(bar)
(bar)
2200
10010
110
2200
10010
130
2200
10010
2200
10010
170
2200
10010
180
2200
P2 = P3 - 221
190
150
190
P2
270 b
270 b
P3
Fig. 5
Issue 1
May 2001
9N01.5
Fig. 6
Engine
speed
(rpm)
P2
P3
(bar)
(bar)
Q2
mini
(l/min)
Maxi
2200
P2 = P3
-221 bar
130
10010
Mini
2200
P2 = P3
-221 bar
35
51
P2
HP
P3
BP
Fig. 7
P2
270 b
Fig. 8
Issue 1
May 2001
6. Lift control
Maximum pressure
- Connect a pressure gauge to each diagnostics connector (Fig. 9 - 11) located:
on the pump controller: XLS pressure = P2
on the right-hand side hydraulic cover: pump pressure
= P3
- Run the engine at 1000 rpm.
- Use the external lift control buttons to reach the maximum lift position
P2 and P3 = 190 bar.
Shock valve
- With the engine stopped, disconnect hose supply
piping to the ram (Fig. 10 - 11).
- Inject a pressure in the circuit using a calibration pump
(note the opening pressure):
P4 = 220 240 bar.
P2
270 b
270 b
P3
Fig. 9
High pressure
7. Steering
Maximum steering
- Connect a pressure gauge to each diagnostics connector (see 6 and Fig. 9 to 11) and run the engine at 1000
rpm.
- Slowly turn the steering and make sure that P2 and P3
gradually increase:
P2 = 149 + 2 bar
P3 = 170 + 2 bar
Shock valve
- With the engine stopped, connect a hand calibration
pump to one of the two supply pipes of the steering ram
(Fig 10 - 11).
- Inject a pressure using a calibration pump (note the
opening pressure).
P5 = 225 - 250 bar.
- Apply the same procedure to the second steering ram
supply.
Steering circuit leak
- Run the engine at 1000 rpm.
- Place the front wheels on full lock and apply a torque of
4 Nm, measured along the axis of the steering column,
to the steering wheel. The steering wheel must not turn
more than 2 rpm. If it rotates at more than 2 rpm,
disconnect the piping supplying the rams and block off
both ports.
- Apply the same torque to the steering wheel, if it turns
less than 2 rpm, this indicates a leak from the hydraulic
ram.
Issue 1
May 2001
Low pressure
Lubrication
Full Powershift gearbox lubrication (filter
clogged)
Suction
Booster
Return
Brakes
Pilot flow
9N01.7
P5
P5
P3
P3
P2
P2
HP
BP
HP
BP
P4
P4
P4
P4
Fig. 10
Issue 1
May 2001
Fig. 11
9N01.8
High pressure 110 l/min circuit (Full Powershift gearbox)
P6
(bar)
Q3
(l/min mini)
1000
47 1
2200
53 1
P6
(bar)
Q3
(l/min mini)
1000
90
25 1
2200
90
26 1
HP
BP
R
Q3
Fig. 13
Issue 1
May 2001
P6
Fig. 12
9N01.9
P7
30bar
Fig. 14
1. 17 bar circuit
P1
11 bar
maxi
Fig. 15
Engine speed
(rpm)
P1
(bar)
1000
5.2 1
2200
6.3 1
2
Issue 1
May 2000
2002
December
9N01.10
P8
P9
P10
HP
BP
P1
Issue 1
December 2000
P7
Fig. 16
9N01.11
Engine speed
(rpm)
P8
(bar)
P9
(bar)
1000
2 0.5
1.9 0.5
2200
2.3 0.5
2 0.5
Issue 1
May 2001
9N01.12
Q4
P11 P12
Fig. 18
Issue 1
May 2001
9N01.13
3
30bar
b) Flowrate test
- Connect a flowmeter to the lubricating circuit as shown
in Fig. 18, in order to read Q4 (the union on the box is still
accessible despite the tank being fitted).
Important: The flowmeter valve must remain in the
maximum open position until the end of the test in
order not to cut off lubrication to the transmission.
Engine speed
(rpm)
Q4 mini
(l/min)
1000
17.8 1
2200
19.9 1
Important:
- If an auxiliary spool valve is activated (a flowmeter
or slave device must be connected to it), the
pressure must not drop more than 2 l/min.
P11
30bar
2
P12
Fig. 17
- Check that the pressures are correct according to the
following table:
Ratio
Front
piston
connector (2)
P11 (bar)
Rear
piston
connector (3)
P12 (bar)
EV1
voltage
en
Volt
EV2
voltage
en
Volt
171
171
12
171
12
12
171
12
Issue 1
May 2001
Q5
P13
P14
Fig. 21
Issue 1
May 2001
9N01.15
b) Clutch
Control circuit
- Connect a pressure gauge to the clutch valve diagnostics connector located on the right-hand side of the
gearbox (Fig. 19 - 21) in order to check P13.
- Operate the pedal to disengage and engage the clutch.
17 bar
Engine speed
(rpm)
P13
P13
disengaged engaged
(bar)
(bar)
1000
17 1
2200
17 1
150
25
Modulation position
- The clutch valve modulates between 11 bar and 0 bar.
This modulation corresponds to a pedal travel of between 32 mm 1 mm from the high stop position and
25 mm 1 mm before the lower stop position of the
pedal (the total travel is 150 mm).
- If the modulation travel is offset in relation to the pedal
travel, it is necessary to bleed the system using the
bleed-valve located on the end of the valve (see section
9I01).
0 bar
(rpm)
30bar
P14
P14
disengaged engaged
(bar)
(bar)
1000
2 0,1
0,4 0,1
2200
3 0,1
1,2 0,1
11 bar
P13
32
Fig. 19
P14
11bar
Engine speed
(rpm)
1000
Q5
Q5
declutched clutch in
(l/min)
(l/min)
0
3 maxi
Fig. 20
Issue 1
December 2000
Power shuttle
Remark
All 8200 tractors with a Heavy Duty gearbox can be fitted
with a power shuttle.
The rear axle 17 bar low pressure supplies the following
functions:
- Dynashift
- Power shuttle
- Rear PTO clutch
- Power take-off brake
- 4 WD clutch
- front and rear differential lock
- Hare / Tortoise range
- Power braking assistance
- front clutch PTO (if fitted)
2
Front view
6. 17 bar circuit
- Connect a pressure gauge to the diagnostics connector
(Fig. 14) located at the front of the right-hand side
hydraulic cover in order to check P7.
- Run the engine at 1000 rpm.
- Deactivate all the low pressure components.
- Place the multiple position lever, located to the left
beneath the steering wheel, in neutral position.
- The front axle must be engaged, the pressure is only
used when de-clutching.
- Place the range lever in the Tortoise position and the
Dynashift lever in position D.
- Engage each function, the pressure must not drop
below 14 bar and must restore its initial position after
each disengagement.
P7 = 17 + 1 bar
Reminder
- The booster, transmission oil cooler safety and transmission lubricating circuits are similar for the Power
shuttle and mechanical reverse shuttle. If necessary,
refer to C (2 - 3 and 4).
P11
2
P12
Fig. 23
Issue 2
1
May 2002
December
2000
9N01.17
P18
P12
P11
P15
P16 - P17
Fig. 22
2
Issue 1
May 2000
2002
December
9N01.18
Front
Rear
EV1
EV2
piston
piston
voltage voltage
connector
connector (in volts) (in volts)
(2) P11 (bar) (3) P12 (bar)
171
171
12
171
12
12
171
12
P15
Fig. 24
Engine speed
(rpm)
P15
(bar)
1000
18 1
2200
18 1
Issue 2
1
May 2002
December
2000
9N01.19
Remark
- The clutch diagnostics connectors (1) (forward ratio)
and (2) (reverse ratio) can be accessed through the
control unit located to the right-hand sode in front of the
gearbox as shown in Fig. 25.
Reminder
The multiple position lever is located on the left-hand
side, beneath the steering wheel:
- lever in upward position (forward): green light is on
- lever in downward position (reverse): red light is on
Lever
position
1
P16
Clutch (1)
Clutch (2)
P16 (bar)
P17 (bar)
Clutch
Clutch
Clutch
Clutch
engaged disengaged engaged disengaged
Forward
gear
181
Neutral
Reverse
gear
181
P17
2
Fig. 25
2
Issue 1
May 2000
2002
December
9N01.20
Reminders
- The clutches are lubricated by a gear pump, independent from the one used for the standard lubricating
system.
- When the front clutch is under load, its internal components are lubricated.
- Two valves, mounted on the reverse shuttle front
cover, enable lubrication of the reverse gear system,
when selected.
- Connect a hose fitted with a 11 bar capacity pressure
gauge on the diagnostics connector (1) located to the
right-hand side on the front of the gearbox housing (Fig.
22 and 26).
- Check the test results against the table below.
Ratio
Ratio
engine (rpm)
P18 (bar)
disengaged
P18
P18 (bar)
engaged
Pedal or lever
Forward
(green
light on)
Reverse
(red
light on)
1000
1,5 0,1
0,5 0,1
2200
2 0,1
0,9 0,1
1000
1,5 0,1
0,4 0,1
2200
2 0,1
0,8 0,1
Fig. 26
Issue 2
1
May 2002
December
2000
9N01.21
P1
P1
(bar)
1000
5,2 1
Fig. 27
Fig. 28
P2
2200
6,3 1
P2
(bar)
P3
(bar)
1000
26 1
2200
26 1
P3
P1
P2
P3
Fig. 29
2
Issue 1
May 2000
2002
December
Fig. 30
P3
P2
Fig. 31
Issue 2
1
May 2002
December
2000
Engine
speed
(rpm)
Q1
P2
P3
(l/min)
(bar)
(bar)
2200
145 10
110
2200
145 10
130
2200
145 10
2200
145 10
170
2200
145 10
180
2200
P2 = P3 - 221
190
9N01.23
Fig. 32
1
150
190
2
Issue 1
May 2000
2002
December
P2
P3
Fig. 33
P2
Fig. 34
Issue 2
1
May 2002
December
2000
9N01.25
6. Lift control
Maximum pressure
- Connect a pressure gauge on each diagnostics connector (Fig. 35 - 37) located:
. on the pump controller: XLS pressure = P2
. on the right-hand side hydraulic cover: pump pressure
= P3
- Run the engine at 1000 rpm.
- Utilise the external lift control buttons to reach the
maximum high position:
P2 and P3 = 190 bar
Shock valve
- With the engine stopped, disconnect the hose piping
supplying the rams (Fig. 36 - 37).
- Inject a pressure in the circuit using a calibration pump
(note the opening pressure):
P4 = 220 - 240 bar
P3
P2
Fig. 35
Issue
Issue 12
December
May 2000
2002
7. Steering
Maximum pressure
- Connect a pressure gauge to each diagnostics connector (see 6, Fig. 35 - 37) and run the engine at 1000 rpm.
- Slowly turn the steering and ensure that P2 and P3
gradually increase:
P2 = 149 2 bar
P3 = 170 2 bar
Shock valve
- With the engine stopped, connect a hand calibration
pump to one of the two supply pipes of the steering ram
(Fig. 36 - 37).
- Inject a pressure using the calibration pump (note the
opening pressure):
P5 = 225 - 250 bar
- Carry out the same procedure with the second ram
supply.
Steering circuit leakage
- Run the engine at 1000 rpm.
- Place the front wheels on full lock and apply a torque of
4 Nm to the steering wheel axis. The steering wheel
must not turn more than 2 rpm. If the steering wheel
rotates faster than 2 rpm, disconnect the piping supplying the rams and block off both pipe ports.
- Apply the same torque to the steering wheel, if it rotates
less than 2 rpm, there is a leak from the steering ram.
Issue 2
1
May 2002
December
2000
9N01.27
ZF front axle - High pressure 150 l/min circuit
(Full Powershift gearbox)
P5
P5
P2
P3
P2
P4
P4
P4
P4
R
Q3
Q3
Fig. 31
Issue 2
P3
May 2002
Fig. 32
Issue 2
May 2002
9N01.29
P6
Flowrate
- Connect a flowmeter, with its load valve open to the
maximum, on to the trailer brake quick-disconnect
coupling (Fig. 36 - 37).
- Connect the return to the manifold union that supports
the auxiliary spool valves.
- Carry out a reading of Q3.
Engine speed
(rpm)
P6
(bar)
Q3
(l/min mini)
1000
47 1
2200
53 1
Fig. 38
P6
(bar)
Q3
(l/min mini)
1000
90
25 1
2200
90
26 1
Issue 21
May 2002
December
2000
9N01.30
P7
1. 17 bar circuit
Fig. 39
P1
2. Booster circuit of the variable displacement pump and rear axle lubricating circuit
- The oil used for boosting the variable displacement
pump is also used to lubricate the following functions:
. power take off clutch
. the trumpets (depending on model)
. the handbrake system and mainly the creeper gearbox (if fitted)
. the 4WD unit
. the hydraulic pump drive bearing block
- Connect a pressure gauge to the diagnostics connector
located on the booster manifold above the right-hand
side hydraulic cover (Fig. 40) in order to check P1.
Engine speed
(rpm)
Issue 11
Issue
P1
(bar)
1000
5,2 1
2200
6,3 1
May 2000
2002
December
Fig. 40
9N01.31
Top view
12
13
Preliminary operations
- In order not to eliminate the operation of the pressure
switch (17 bar) during the pressure tests, provisionally
screw the pressure switch (13) (red dot) and its reliefvalve at the location of the large plug (12) (Fig. 41).
Reconnect the wiring loom to the pressure switch.
- Fit in the port previously used by the pressure switch,
the diagnostics connector and reducer found in kit, ref.
3378174M1, in order to test P1 (Fig. 41).
- Remove the 7/16 plugs. Screw the diagnostic hose
piping provided with kit, ref. 3378174M1, into the
corresponding ports (1) (2) (A) (B) (C) and (R) (Fig. 41)
and the diagnostics connectors into the ports (L) (H) and
(M) (Fig. 42).
P1
A
Fig. 41
Bottom view
AG 250
AG 150
Fig. 42
Issue 1
December
2000
May 2002
9N01.32
- Take out the 9/16 plug (14) located on the upper left-side
of the gearbox (Fig. 43). Fit a diagnostic connector in its
location.
- Run the engine to bring the oil up to a temperature of
80 C minimum (176 F) (see A).
- Before checking the clutch pressure (see paragraph 3),
check the pump pressure, the operation of the 17 bar
valve and the lubrication pressure in the clutches.
P2
14
P1
(bar)
1000
18 1
2200
18 1
Fig. 43
P2
(bar)
1000
0,6 0,2
2200
1,8 0,2
Issue 1
May 2002
December
2000
9N01.33
Clutches
engaged
F1
1-A-L
F2
2 - A- L
F3
1-B-L
F4
1-A-M
F5
2-B-L
F6
2-A-M
F7
1-C-L
F8
1-B-M
F9
2-C-L
F10
2-B-M
F11
1-A-H
F12
1-C-M
F13
2-A-H
F14
2-C-M
F15
1-B-H
F16
2-B-H
F17
1-C-H
F18
2-C-H
R1
R-A-L
R2
R-B-L
R3
R-A-M
R4
R-C-L
R5
R-B-M
R6
R-A-H
R7
R-C-M
R8
R-B-H
Issue 1
May 2000
2002
December
9N01.34
Pressure
P3 = 17 1
P4 = 17 1
P5 = 17 1
P6 = 17 1
P7 = 17 1
P8 = 17 1
P9 = 17 1
P10 = 17 1
P11 = 17 1
Final operations
- After carrying out the tests, restore the tractor to the
state prior to the tests (17 bar pressure switch is refitted
in its initial location - all connectors and hose piping
removed).
Fig. 44
Top view
R
1
Bottom view
of AG250 gearbox
M
Bottom view
of AG150 gearbox
Issue 11
Issue
May 2000
2002
December
10 . ELECTRICAL EQUIPMENT
Contents
Issue 2
May 2002
Electrical equipment
10A01.1
CONTENTS
A.
General ________________________________________________
B.
C.
22
D.
24
E.
26
F.
28
G.
30
H.
32
I.
34
J.
36
K.
37
L.
38
M.
39
Issue 1
May 2001
Issue 1
Electrical equipment
May 2001
Electrical equipment
A . General
The 8200 series of tractors are fitted with a 12-volt
negative ground electrical circuit, charged by a 120 A
alternator (70 A for platform versions).
The alternator has an integrated rectifier and a charging
regulator. An additional terminal is provided to supply the
electronic tachometer (for Autotronic 2 versions only).
The alternator fitted on the right-hand side of the engine
is driven by a belt from the crankshaft pulley.
The starter motor, fitted on the right-hand side of the
engine, is of the pre-engaged type.
The safety switch, placed under the clutch pedal, supplies
the starter solenoid when the clutch pedal is fully pressed.
The batteries are mounted on a fixed or pivoting carrier
(depending on the model), behind the right-hand side
footstep.
10A01.3
Regulator voltage
Starter
8210 to 8260
Make
Model
Voltage
Type
14.2 V
Magneti Marelli
2.8 kW
12 V
pre-engaged
8270 8280
Make
Model
Voltage
Type
Magneti Marelli
3.6 kW
12 V
pre-engaged
+P
: + Permanent
+ AC : + After contact
Ah
: Amp hours
Designation of harnesses
Characteristics
Batteries
8210 - 8220
Quantity
Type
Cold start performance
Reserve capacity at 25 A
Voltage
Capacity
2
Maintenance free
420 A (- 18 C)
120 minutes
12 V
66 Ah
8240 to 8280
Quantity
Type
Cold start performance
Reserve capacity at 25 A
Voltage
Capacity
2
Maintenance free
420 A (- 18 C)
180 minutes
12 V
105 Ah
Alternator
Cab
Make
Max. output amperage
Regulator
Regulator voltage
Valeo
120 A
integral
14.2 V
Platform
Make
Type
Max. output amperage
Regulator
Magneti - Marelli
A127
70 A
integral
a
b
c
g
h
i
j
k
l
m
n
o
p
r
s
t
u
v
w
x
y
z
aa
ab
ak
: Dashboard harness
: Engine harness
: Console harness
: Roof harness
: Battery cut out harness
: Rear wiper harness
: Lead for battery cut out (radio, clock and roof light
supply)
: Additional tank harness
: Door switch harness for roof light
: Windscreen washer pump lead
: Thermostart lead
: Batteries harness
: Interior power socket harness
: Roof dashboard lighting harness
: Roof headlights harness
: Roof dashboard harness (lower part)
: Roof dashboard harness (upper part)
: Front work lights harness
: Front and rear lighting harness
: Roof lighting harness
: Registration plate light harness
: Interior 25 A power socket harness
: Cigarette lighter harness
: Parking brake buzzer harness
: Ground lead (tractor without radiator water level
sensor)
Issue 1
May 2001
Electrical equipment
10A01.4
Connectors
Number
of ways
Connector
colour
Lead colour
C1
9 (Ritz) or 16
(Deutsch kit)
Black circle
M - M - M - M - VI - G - G - N
C2
9 (Ritz) or 16
(Deutsch kit)
Black circle
with red mark
RO - M - M - B - R - VI O - BLF
C3
Black
J - R - M emb. R - R - VI - MC
Dynashift
C3
10
Black
V-R-N-R-R-N-J-J
M emb. R - MC
Full
Powershift
C4
Black
VC - VI - B - VF - MC - N
Dynashift
C4
Black
J-N
Full
Powershift
C5
10
Black
M-R-J-R-N-O-M-R
Dynashift
C5
10
Black
RO - S - R - V - M - B - VI
Full
Powershift
C6
Black
B - O - O - G - VI - R - RO - BL
C7
13
Transparent
G - BLF - MF - O - VC - J G - VI - B - BL - R - M - RO
C8
Black
BLC - BLF
Dynashift
Except
North America
C8
Black
BLF
Dynashift
North America
C8
Black
Full
Powershift
C9
9 (Ritz) or 16
(Deutsch kit)
Black circle
with green mark
M-M-M-M-V-J-G
C10
Transparent
VF - BE - BLF - VF - R - BLF
Except
North America
C10
Transparent
North America
C11
10
Grey
BL/G - G - S - R - B RO - R - VI
Full
Powershift
C12
Transparent
M emb. R - N
C13
Black
C14
Transparent
R - R - R - N - VI
Issue 1
May 2001
Tractor
Electrical equipment
Connectors
Number
of ways
10A01.5
Connector
colour
Lead colour
Tractor
Full
Powershift
C15
10
Black
J - R - V - O - BLF - B - R R - VI - N
C16
Transparent
R - G - BE - N
C17
Black
VI - O - R
Standard roof
C17
Brown
O - O - N - VI
High visibility
roof
C18
Black
G - BL - B - O - N
C19
Black
O - N - R - RO
Except
North America
C19
Black
O-N
North America
C21
Black
O - RO - RO
Except
North America
C21
Black
VF - VF - VF - M - RO - VI
North America
C22
Black
N-R
C24
Black
VI - O - RO - R
C25
Black
RO
C26
Black
RO
C27
Black
Dynashift
Except
North America
C27
Black
BLC
Dynashift
North America
C28
Black
M-R-V
C29
Black
O-O-N-N-R
Except
North America
C29
Black
R-N-O
North America
C30
13
Transparent
G - VF - O - R - G - J - M - R
M - B emb. N - J - M - N
Dynashift
C31
13
Transparent
O - BLF - J - R - G - B - VI RO - O - B emb. B
Dynashift
C33
Black
N-J
C34
Black
R-N
C37
Black
R - B - M - G - M - BL
Issue 1
Full
May 2001
Electrical equipment
10A01.6
Connectors
Number
of ways
Connector
colour
Lead colour
Tractor
C42
Black
VI
Except
North America
C43
Black
M-R
Except
North America
C45
Black
G - VF - J
Full
Powershift
C46
Transparent
B-N
Except
North America
C47
Transparent
M-R-N
C48
Black
N-N
C50
10
Black
R-N-O-M-V-R
B - O - RO
Dynashift
C50
10
Grey
R - B - RO - R - V
BL - O - RO
Full
Powershift
C51
Black
J-R-M
Dynashift
C51
10
Black
O - BLF - R - J - R - V
BLG - RO - S - N
Full
Powershift
C52
Black
V - BL - O - R
Dynashift
C52
Black
B - VI - V - BL - O - RO
Full
Powershift
C53
V-M-B
Full
Powershift
C60
Black
O - R - R - M - I - B - RO - R
Except
North America
C60
Transparent
G - RO - R - O - R - R - M - BE
North America
C62
Transparent
VF - VF - BLF - BLF - BE - R
Except
North America
C62
Black
North America
C63
Black
G - V - BL - BL - V - R
Except
North America
C63
Black
BL - BL - BL - M - G - RO
North America
C64
Transparent
RO - R
Except
North America
C64
Transparent
RO
North America
C65
Transparent
M-R
Except
North America
Issue 1
May 2001
Electrical equipment
10A01.7
Connectors
Number
of ways
Connector
colour
Lead colour
Tractor
C65
Transparent
RO
North America
C66
Black
R - RO - B - N
Except
North America
C66
Black
N - RO - R/M
North America
C67
Black
N-M-R-B
Except
North America
C67
Black
N-M-R
North America
C68
2x2
Black
BL - BL - N - N
C69
2x2
Black
BL - BL - N - N
C70
Black
VF - V
Except
North America
C70
Black
BLF - B
North America
C71
Black
VF - V
Except
North America
C71
Black
BLF - B
North America
C72
Black
N-R
C73
Black
N-R
C74
Round terminal
C75
Black
R - R - VI - O - RO - N
C76
Black
O - VI - R - RO - N - R
C78
Black
VF - VF
C79
Black with
green adhesive tape
VF - VF
C80
Black
VF
C81
Transparent
VF - N
C82
Black
C83
Black
C84
Black
N-J-V
Issue 1
May 2001
Electrical equipment
10A01.8
B . Dynashift - Cab accessories and
engine equipment (Fig. 1 to 7)
Parts list
1.
2.
3.
4.
5.
5a.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Starter switch
Air filter
Temperature probe
Water temperature gauge
Water level detector
Ground to be connected (if no water level detector)
Engine oil pressure switch
Thermostart
Injection pump control solenoid
Temperature switch
Thermostart solenoid valve
Dashboard supply
Alternator
Lighting switch
Cab relay
Air conditioned compressor pressure switch
Ventilation unit harness connector
Clock
Roof light
Door switch
Radio harness connector
Starter
Batteries
Power socket
Cigarette lighter connector
Windscreen washer pump
Front windscreen wiper switch
Time delay relay
Front windscreen wiper motor
Rear wiper switch
Rear wiper motor
Indicator lamps
T5 : Alternator charge lamp
T8 : Air filter clogging lamp
T10: Engine oil pressure lamp
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
Identification of connectors
Connectors
Number of ways /
colour
C1
9 (Ritz) or 16
(Deutsch kit) / black circle
Under bonnet
C2
Under bonnet
C3
6 / Black
C6
8 / Black
C10
6 / Transparent
C : Light
F : Dark
Except
North America
C10
8 / Transparent
North America
C12
2 / Transparent
C13
1 / Black
C14
5 / Transparent
To ELC calculator
C16
4 / Transparent
In heating compartment
C17
3 / Black
In heating compartment
Standard roof
C17
7 / Marron
In heating compartment
C18
6 / Black
C24
4 / Black
C25
1 / Black
Under dashboard
C28
3 / Black
In heating compartment
C29
6 / Black
Except
North America
C29
3 / Black
North America
C47
3 / Transparent
To ELC calculator
C62
6 / Transparent
Except
North America
C62
8 / Black
North America
Issue 1
Location
Tractor
Dynashift
Behind starter
May 2001
Electrical equipment
10A01.9
T8
Temperature probe
5a
T10
Fig. 1
Issue 1
May 2001
Electrical equipment
10A01.10
B . Dynashift - Cab accessories and
engine equipment (Fig. 1 to 7)
Parts list
1.
2.
3.
4.
5.
5a.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Starter switch
Air filter
Temperature probe
Water temperature gauge
Water level detector
Ground to be connected (if no water level detector)
Engine oil pressure switch
Thermostart
Injection pump control solenoid
Temperature switch
Thermostart solenoid valve
Dashboard supply
Alternator
Lighting switch
Cab relay
Air conditioned compressor pressure switch
Ventilation unit harness connector
Clock
Roof light
Door switch
Radio harness connector
Starter
Batteries
Power socket
Cigarette lighter connector
Windscreen washer pump
Front windscreen wiper switch
Time delay relay
Front windscreen wiper motor
Rear wiper switch
Rear wiper motor
Indicator lamps
T5 : Alternator charge lamp
T8 : Air filter clogging lamp
T10: Engine oil pressure lamp
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
C : Light
F : Dark
Emb.: end fitting
Identification of connectors
Connectors
Number of ways /
colour
C1
9 (Ritz) or 16
(Deutsch kit) / Black circle
Under bonnet
C2
Under bonnet
C3
6 / Black
C6
8 / Black
C10
6 / Transparent
Except
North America
C10
8 / Transparent
North America
C12
2 / Transparent
C13
1 / Black
C14
5 / Transparent
To ELC calculator
C16
4 / Transparent
In heating compartment
C17
3 / Black
In heating compartment
Standard roof
C17
7 / Brown
In heating compartment
C18
6 / Black
C24
4 / Black
C25
1/ Black
Under dashboard
C28
3 / Black
In heating compartment
C29
6 / Black
Except
North America
C29
3 / Black
North America
C47
3 / Transparent
To ELC calculator
C62
6 / Transparent
Except
North America
C62
8 /Black
North America
Issue 1
Location
Tractor
Dynashift
Behind starter
May 2001
Electrical equipment
10A01.11
Thermostart
1
N
R
R
8
1
R
9
11
10
Fig. 2
Issue 1
May 2001
Electrical equipment
10A01.12
B . Dynashift - Cab accessories and
engine equipment (Fig. 1 to 7)
Parts list
1.
2.
3.
4.
5.
5a.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Starter switch
Air filter
Temperature probe
Water temperature gauge
Water level detector
Ground to be connected (if no water level detector)
Engine oil pressure switch
Thermostart
Injection pump control solenoid
Temperature switch
Thermostart solenoid valve
Dashboard supply
Alternator
Lighting switch
Cab relay
Air conditioned compressor pressure switch
Ventilation unit harness connector
Clock
Roof light
Door switch
Radio harness connector
Starter
Batteries
Power socket
Cigarette lighter connector
Windscreen washer pump
Front windscreen wiper switch
Time delay relay
Front windscreen wiper motor
Rear wiper switch
Rear wiper motor
Indicator lamps
T5 : Alternator charge lamp
T8 : Air filter clogging lamp
T10: Engine oil pressure lamp
Colour codes
A :
B :
BL :
BE :
G :
I :
J :
M :
N :
O :
R :
RO :
S :
V :
VI :
Silver
White
Blue
Beige
Grey
Ivory
Yellow
Brown
Black
Orange
Red
Pink
Salmon
Green
Violet
C : Light
F : Dark
Emb.: end fitting
Identification of connectors
Connectors
Number of ways /
colour
C1
9 (Ritz) or 16
(Deutsch kit) / Black circle
Under bonnet
C2
Under bonnet
C3
6 / Black
C6
8 / Black
C10
6 / Transparent
Except
North America
C10
8 / Transparent
North America
C12
2 / Transparent
C13
1 / Black
C14
5 / Transparent
To ELC calculator
C16
4 / Transparent
In heating compartment
C17
3 / Black
In heating compartment
Standard roof
C17
7 / Brown
In heating compartment
C18
6 / Black
C24
4 / Black
C25
1/ Black
Under dashboard
C28
3 / Black
In heating compartment
C29
6 / Black
Except
North America
C29
3 / Black
North America
C47
3 / Transparent
To ELC calculator
C62
6 / Transparent
Except
North America
C62
8 /Black
North America
Issue 1
Location
Tractor
Dynashift
Behind starter
May 2001
Electrical equipment
10A01.13
Battery charging
12
T5
1
N
13
14
15
16
Fig. 3
Issue 1
May 2001
Electrical equipment
10A01.14
B . Dynashift - Cab accessories and
engine equipment (Fig. 1 to 7)
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
Identification of connectors
Connectors
Number of ways /
colour
C1
9 (Ritz) or 16
(Deutsch kit) / Black circle
Under bonnet
C2
Under bonnet
C3
6 / Black
C6
8 / Black
C10
6 / Transparent
Except
North America
C10
8 / Transparent
North America
C12
2 / Transparent
C13
1 / Black
C14
5 / Transparent
To ELC calculator
C16
4 / Transparent
In heating compartment
C17
3 / Black
In heating compartment
Standard roof
C17
7 / Brown
In heating compartment
C18
6 / Black
C24
4 / Black
C25
1/ Black
Under dashboard
C28
3 / Black
In heating compartment
Indicator lamps
C29
6 / Black
Except
North America
C29
3 / Black
North America
C47
3 / Transparent
To ELC calculator
C62
6 / Transparent
Except
North America
C62
8 /Black
North America
Parts list
1.
2.
3.
4.
5.
5a.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Starter switch
Air filter
Temperature probe
Water temperature gauge
Water level detector
Ground to be connected (if no water level detector)
Engine oil pressure switch
Thermostart
Injection pump control solenoid
Temperature switch
Thermostart solenoid valve
Dashboard supply
Alternator
Lighting switch
Cab relay
Air conditioned compressor pressure switch
Ventilation unit harness connector
Clock
Roof light
Door switch
Radio harness connector
Starter
Batteries
Power socket
Cigarette lighter connector
Windscreen washer pump
Front windscreen wiper switch
Time delay relay
Front windscreen wiper motor
Rear wiper switch
Rear wiper motor
C : Light
F : Dark
Emb.: end fitting
Issue 1
Location
Tractor
Dynashift
Behind starter
May 2001
Electrical equipment
10A01.15
Accessories
1
N
13
14
20
17
18
19
Fig. 4
Issue 1
May 2001
Electrical equipment
10A01.16
B . Dynashift - Cab accessories and
engine equipment (Fig. 1 to 7)
Parts list
1.
2.
3.
4.
5.
5a.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Starter switch
Air filter
Temperature probe
Water temperature gauge
Water level detector
Ground to be connected (if no water level detector)
Engine oil pressure switch
Thermostart
Injection pump control solenoid
Temperature switch
Thermostart solenoid valve
Dashboard supply
Alternator
Lighting switch
Cab relay
Air conditioned compressor pressure switch
Ventilation unit harness connector
Clock
Roof light
Door switch
Radio harness connector
Starter
Batteries
Power socket
Cigarette lighter connector
Windscreen washer pump
Front windscreen wiper switch
Time delay relay
Front windscreen wiper motor
Rear wiper switch
Rear wiper motor
Indicator lamps
T5 : Alternator charge lamp
T8 : Air filter clogging lamp
T10: Engine oil pressure lamp
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
C : Light
F : Dark
Emb.: end fitting
Identification of connectors
Connectors
Number of ways /
colour
C1
9 (Ritz) or 16
(Deutsch kit) / Black circle
Under bonnet
C2
Under bonnet
C3
6 / Black
C6
8 / Black
C10
6 / Transparent
Except
North America
C10
8 / Transparent
North America.
C12
2 / Transparent
C13
1 / Black
C14
5 / Transparent
To ELC calculator
C16
4 / Transparent
In heating compartment
C17
3 / Black
In heating compartment
Standard roof
C17
7 / Brown
In heating compartment
C18
6 / Black
C24
4 / Black
C25
1/ Black
Under dashboard
C28
3 / Black
In heating compartment
C29
6 / Black
Except
North America
C29
3 / Black
North America
C47
3 / Transparent
To ELC calculator
C62
6 / Transparent
Except
North America
C62
8 /Black
North America
Issue 1
Location
Tractor
Dynashift
Behind starter
May 2001
Electrical equipment
10A01.17
21
23
30 Amp
22
13
24
Cigarette lighter
Fig. 5
Issue 1
May 2001
Electrical equipment
10A01.18
B . Dynashift - Cab accessories and
engine equipment (Fig. 1 to 7)
Colour codes
A :
B :
BL :
BE :
G :
I :
J :
M :
N :
O :
R :
RO :
S :
V :
VI :
Silver
White
Blue
Beige
Grey
Ivory
Yellow
Brown
Black
Orange
Red
Pink
Salmon
Green
Violet
Identification of connectors
Connectors
Number of ways /
colour
C1
9 (Ritz) or 16
(Deutsch kit) / Black circle
Under bonnet
C2
Under bonnet
C3
6 / Black
C6
8 / Black
C10
6 / Transparent
Except
North America
C10
8 / Transparent
North America.
C12
2 / Transparent
C13
1 / Black
C14
5 / Transparent
To ELC calculator
C16
4 / Transparent
In heating compartment
C17
3 / Black
In heating compartment
Standard roof
C17
7 / Brown
In heating compartment
C18
6 / Black
C24
4 / Black
C25
1/ Black
Under dashboard
C28
3 / Black
In heating compartment
Indicator lamps
C29
6 / Black
Except
North America
C29
3 / Black
North America
C47
3 / Transparent
To ELC calculator
C62
6 / Transparent
Except
North America
C62
8 /Black
North America
Parts list
1.
2.
3.
4.
5.
5a.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Starter switch
Air filter
Temperature probe
Water temperature gauge
Water level detector
Ground to be connected (if no water level detector)
Engine oil pressure switch
Thermostart
Injection pump control solenoid
Temperature switch
Thermostart solenoid valve
Dashboard supply
Alternator
Lighting switch
Cab relay
Air conditioned compressor pressure switch
Ventilation unit harness connector
Clock
Roof light
Door switch
Radio harness connector
Starter
Batteries
Power socket
Cigarette lighter connector
Windscreen washer pump
Front windscreen wiper switch
Time delay relay
Front windscreen wiper motor
Rear wiper switch
Rear wiper motor
C : Light
F : Dark
Emb.: end fitting
Issue 1
Location
Tractor
Dynashift
Behind starter
May 2001
Electrical equipment
10A01.19
14
27
25
26
28
Fig. 6
Issue 1
May 2001
Electrical equipment
10A01.20
B . Dynashift - Cab accessories and
engine equipment (Fig. 1 to 7)
Parts list
1.
2.
3.
4.
5.
5a.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Starter switch
Air filter
Temperature probe
Water temperature gauge
Water level detector
Ground to be connected (if no water level detector)
Engine oil pressure switch
Thermostart
Injection pump control solenoid
Temperature switch
Thermostart solenoid valve
Dashboard supply
Alternator
Lighting switch
Cab relay
Air conditioned compressor pressure switch
Ventilation unit harness connector
Clock
Roof light
Door switch
Radio harness connector
Starter
Batteries
Power socket
Cigarette lighter connector
Windscreen washer pump
Front windscreen wiper switch
Time delay relay
Front windscreen wiper motor
Rear wiper switch
Rear wiper motor
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
Identification of connectors
Connectors
Number of ways /
colour
C1
9 (Ritz) or 16
(Deutsch kit) / Black circle
Under bonnet
C2
Under bonnet
C3
6 / Black
C6
8 / Black
C10
6 / Transparent
Except
North America
C10
8 / Transparent
North America.
C12
2 / Transparent
C13
1 / Black
C14
5 / Transparent
To ELC calculator
C16
4 / Transparent
In heating compartment
C17
3 / Black
In heating compartment
Standard roof
C17
7 / Brown
In heating compartment
C18
6 / Black
C24
4 / Black
C25
1/ Black
Under dashboard
C28
3 / Black
In heating compartment
C29
6 / Black
Except
North America
C29
3 / Black
North America
C47
3 / Transparent
To ELC calculator
C62
6 / Transparent
Except
North America
C62
8 /Black
North America
C : Light
F : Dark
Emb : end fitting
Indicator lamps
T5 : Alternator charge lamp
T8 : Air filter clogging lamp
T10: Engine oil pressure lamp
Issue 1
Location
Tractor
Dynashift
Behind starter
May 2001
Electrical equipment
10A01.21
Rear wiper
14
13
29
30
Fig. 7
Issue 1
May 2001
Electrical equipment
10A01.22
C . Full Powershift Engine equipment (Fig. 8)
Parts list
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
45.
Starter switch
Safety switch
Batteries
Injection pump solenoid
Starter
Alternator
Starter relay
Fuel gauge
Engine oil pressure gauge
Water temperature gauge
Tachometer and hourmeter
Air filter vacuum sensor
Water level sensor
Engine oil pressure sensor
Temperature probe
Fuel level sensor
Fuel level sensor (additional tank)
Diode and resistor located behind fuse box
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
Identification of connectors
Connectors
Number of ways /
colour
Location
C1
9 (Ritz) or
16 (Deutsch kit) / Black circle
Under bonnet
C2
Under bonnet
C60
8 / Black
Except
North America
C60
8 / Transparent
North America
C : Light
F : Dark
Emb.: end fitting
Indicator lamps
T5
T8
T10
T23
T28
:
:
:
:
:
Designation of harnesses
a
b
k
w
: Dashboard harness
: Engine harness
: Additional tank harness
: Front and rear lighting harness
Issue 1
May 2001
Tractor
Electrical equipment
10A01.23
Fig. 8
Issue 1
May 2001
Electrical equipment
10A01.24
D . Full Powershift - Cab equipment
(Fig. 9)
Parts list
1.
2.
3.
6.
13.
18.
19.
20.
21.
22.
22b
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
Starter switch
Safety switch
Batteries
Alternator
Lighting switch
Air conditioned pressure switch
Air conditioned compressor
Cab relay
Radio
Digital clock
Digital clock supply with battery cut out
Roof light
Door switch
Water pump
Water pump switch
Ventilation switch
Blower motor
Air conditioned temperature switch
Battery cut out
Front windscreen wiper motor
Interior power socket
Console, armrest lighting (roof)
Windscreen washer pump
Parking brake switch
Rear wiper switch
Cigarette lighter
Windscreen wiper time delay
Windscreen wiper switch
Rear wiper motor
Parking brake sound signal
Autotronic2 or DCC / TC batteries supply
Abbreviations
Designation of harnesses
a
b
c
h
i
j
: Dashboard harness
: Engine harness
: Console harness
: Battery cut out harness
: Rear wiper harness
: Lead for battery cut out (radio, clock and roof light
supply)
: Door switch harness for roof light
: Windscreen washer pump lead
: Batteries harness
: Interior power socket harness
: Roof dashboard harness (lower part)
: Roof dashboard harness (upper part)
: Interior 25 A power socket harness
: Cigarette lighter harness
Identification of connectors
Connectors
Number of ways /
colour
C1
9 (Ritz) or 16
(Deutsch kit) / Black circle
Under bonnet
C2
Under bonnet
C3
6 / Black
C4
2 / Black
C6
8 / Black
C8
1 / Black
Under bonnet
C12
2 / Transparent
C13
1 / Black
C14
5 / Transparent
To ELC calculator
C16
4 / Transparent
In heating compartment
C17
3 / Black
In heating compartment
Standard roof
C17
7 / Brown
In heating compartment
C18
6 / Black
C19
8 / Black
Except
North America
C19
2 / Black
North America
C : Light
F : Dark
C22
2 / Black
C24
4 / Black
C25
1/ Black
Under dashboard
C26
1 / Black
Under dashboard
C28
3 / Black
In heating compartment
C29
6 / Black
Except
North America
C29
3 / Black
North America
C33
2 / Black
Under Autotronic2 or TC
C34
2 / Black
Under Autotronic2 or TC
l
m
o
p
t
u
z
aa
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
Issue 1
Location
Tractor
Dynashift
May 2001
Connectors
Electrical equipment
Ro.
emb.R
Location
Tractor
C47
3 / Transparent
To ELC calculator
C48
2 / Black
On roof light
C60
8 / Black
Except
North America
C60
8 / Transparent
North America
22
24
23
+AC
MF
21
25
10A01.25
Number of ways /
colour
3
G
20
13
26
2
27
RE
30
5
CB
28
19
29
18
CE
31
13
32
22b
39
33
42
M
34
PS
RE
RE
37
38
41
RE
35
40
GY
36
Fig. 9
Issue 1
May 2001
Electrical equipment
10A01.26
E . Lighting layout (except North
America) (Fig. 10)
Parts list
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
23.
43.
Starter switch
Horn
Front left headlight
Front right headlight
Right rear tail light / stop light
Left rear tail light / stop light
Stop light switch
Lighting controller
Roof mounted front left headlight
Roof mounted front right headlight
Registration plate light
Roof mounted headlights switch
Lighting switch
Front right sidelight
Front left sidelight
Trailer lighting socket
Lighting control unit
Indicator lamps
Colour codes
A :
B :
BL :
BE :
G :
I :
J :
M :
N :
O :
R :
RO :
S :
V :
VI :
Silver
White
Blue
Beige
Grey
Ivory
Yellow
Brown
Black
Orange
Red
Pink
Salmon
Green
Violet
C : Light
F : Dark
Emb.: end fitting
Identification of connectors
Connectors
Number of ways /
colour
Location
C1
9 (Ritz) or 16
(Deutsch kit) / Black circle
Under bonnet
C2
Under bonnet
C7
13 / Transparent
C9
C10
6 / Transparent
C60
Tractor
Under dashboard
Under bonnet
Except
North America
8 / Black
Except
North America
C62
6 / Transparent
Except
North America
C63
6 / Black
Except
North America
C64
2 / Transparent
Except
North America
C65
2 / Transparent
Except
North America
C66
4 / Black
Except
North America
C67
4 / Black
Except
North America
C72
2 / Black
C73
2 / Black
C75
6 / Black
C76
6 / Black
Issue 1
May 2001
Except
North America
Electrical equipment
10A01.27
Fig. 10
Issue 1
May 2001
Electrical equipment
10A01.28
F . Direction indicator lamps (except
North America) (Fig. 11)
Parts list
1.
16.
17.
18.
19.
20.
21.
23.
43.
Starter switch
Rear right indicator lamp
Rear left indicator lamp
Front right indicator lamp
Front left indicator lamp
Flasher unit
Emergency lights switch
Trailer lights socket
Lighting control unit
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
Identification of connectors
Connectors
Number of ways /
colour
C1
9 (Ritz) or
16 (Deutsch kit) / Black circle
Under bonnet
C2
Under bonnet
C60
8 / Black
C64
C : Light
F : Dark
Indicator lamps
T16 : Direction indicator lamp
T18 : Direction indicator lamp for second trailer
T19 : Direction indicator lamp for first trailer
Issue 1
Location
Tractor
Except
North America
2 / Transparent
Except
North America
C65
2 / Transparent
Except
North America
C66
4 / Black
Except
North America
C67
4 / Black
Except
North America
May 2001
Electrical equipment
10A01.29
T16
T16
T19
T18
21
20
43
16
18
23
17
19
Fig. 11
Issue 1
May 2001
Electrical equipment
10A01.30
G . Work lights and flashing beacons
(except North America) (Fig. 12)
Parts list
13.
22.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
34.
44.
Lighting switch
Rear right wing work light
Rear left wing work light
Rear roof work lights
Front work light on right-hand rail
Front roof work lights
Front work light on left-hand rail
Front work light on right-hand footstep
Front work light on left-hand footstep
Front and rear work lights switch
Flashing beacons
Flashing beacon(s) switch
Wing and rail work lights switch
Footstep work lights switch
To console lighting
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
C : Light
F : Dark
Identification of connectors
Connectors
Number of ways /
colour
Location
C1
9 (Ritz) or
16 (Deutsch kit) / Black circle
Under bonnet
C2
Under bonnet
C9
Under bonnet
C10
6 / Transparent
C16
4 / Transparent
In heating compartment
C21
3 / Black
Except
North America
C62
6 / Transparent
Except
North America
C63
6 / Black
Except
North America
C68
2 x 2 / Black
C69
2 x 2 / Black
C70
2 / Black
Except
North America
C71
2 / Black
Except
North America
C74
1 / Round terminal
C79
C80
1 / Black
C81
2 / Transparent
C82
1 / Black
C83
1 / Black
Issue 1
May 2001
Tractor
Except
North America
Electrical equipment
10A01.31
13
29
26
35
34
31
31
22
27
25
28
24
30
32
32
44
33
Fig. 12
Issue 1
May 2001
Electrical equipment
10A01.32
H . Dynashift - Full lighting system
(North America) (Fig. 13)
Abbreviations
EA : To rear windscreen wiper switch
JC : To fuel gauge
TB : To dashboard
Identification of connectors
Connectors
Number of ways /
colour
C1
9 (Ritz) or
16 (Deutsch kit) / Black circle
Under bonnet
C2
Under bonnet
C3
6 / Black
C6
8 / Black
C7
13 / Transparent
C9
C10
8 / Transparent
C16
4 / Transparent
In heating compartment
Parts list
1.
2.
3.
7.
8.
9.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
43.
44.
Starter switch
Horn
Front left headlight
Stop light switch
Lighting controller
Roof mounted front left headlight
Right rear direction indicator lamp
Left rear direction indicator lamp
Front right direction indicator lamp
Front left direction indicator lamp
Flasher unit
Emergency lights switch
Rear right wing work light
Power socket
Rear left wing work light
Rear roof work light
Front right rail light
Front roof work light
Front left rail light
Front right footstep work light
Front left footstep work light
Front and rear roof work lights switch
Flashing beacon
Flashing beacon switch
Rear low work lights switch
Front rail and footstep work lights switch
Rear right tail light and direction indicator lamp
Rear left tail light and direction indicator lamp
Lighting control unit
To console lighting
Indicator lamps
T16 : Direction indicator lamp
T17 : Headlights lamp
T18 : Second trailer direction indicator lamp
Colour codes
A :
B :
BL :
BE :
G :
I :
J :
M :
N :
O :
R :
RO :
S :
V :
VI :
Silver
White
Blue
Beige
Grey
Ivory
Yellow
Brown
Black
Orange
Red
Pink
Salmon
Green
Violet
Location
Tractor
Dynashift
Under dashboard
Under bonnet
North America
C21
6 / Black
North America
C : Light
F : Dark
C60
8 / Transparent
North America
C62
8 / Black
North America
C63
6 / Black
North America
C64
1/ Transparent
North America
C65
1 / Transparent
North America
C66
3 / Black
North America
C67
3 / Black
North America
C68
2 x 2 / Black
C69
2 x 2 / Black
C70
2 / Black
North America
C71
2 / Black
North America
C74
1 / Round terminal
C78
2 / Black
C79
C80
1 / Black
Designation of harnesses
a :
b:
g:
t :
u:
w:
x :
Dashboard harness
Engine harness
Roof harness
Roof dashboard harness (lower part)
Roof dashboard harness (upper part)
Front and rear lighting harness
Roof lighting harness
Issue 1
May 2001
North America
Electrical equipment
Connectors
Number of ways /
colour
Location
C81
2 / Transparent
C82
1 / Black
C83
1 / Black
Tractor
10A01.33
13
32
33
43
EA
21
20
35
31
34
1
44
Auto 2
7
16
18
36
25
29
22
26
27
23
28
24
TB
JC
30
25
37
19
17
Fig. 13
Issue 1
May 2001
Electrical equipment
10A01.34
I . Full lighting system - Full
Powershift (North America) (Fig. 14)
Parts list
1.
2.
3.
4.
7.
8.
13.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
43.
44.
Starter switch
Horn
Front left headlight
Front right headlight
Stop light switch
Lighting controller
Lighting switch
Right rear direction indicator lamp
Left rear direction indicator lamp
Front right direction indicator lamp
Front left direction indicator lamp
Flasher unit
Emergency lights switch
Rear right wing work light
Power socket
Rear left wing work light
Rear roof work light
Front right rail light
Front roof work light
Front left rail light
Front right footstep work light
Front left footstep work light
Front and rear roof work lights switch
Flashing beacon
Flashing beacon switch
Rear low work lights switch
Front rail and footstep work lights switch
Rear right tail light and direction indicator lamp
Rear left tail light and direction indicator lamp
Lighting control unit
To console lighting
Indicator lamps
T16 : Direction indicator lamp
T17 : Headlights lamp
T18 : Second trailer direction indicator lamp
Abbreviations
EA : To rear wiper switch
JC : To fuel gauge
TB : To dashboard
Identification of connectors
Connectors
Number of ways /
colour
C1
9 (Ritz) or
16 (Deutsch kit) / Black circle
Under bonnet
C2
Under bonnet
C6
8 / Black
C7
13 / Transparent
C9
C10
8 / Transparent
C16
4 / Transparent
In heating compartment
C21
6 / Black
North America
C60
8 / Transparent
North America
C62
8 / Black
North America
C63
6 / Black
North America
C64
1 / Transparent
North America
C65
1 / Transparent
North America
C66
3 / Black
North America
C67
3 / Black
North America
C68
2 x 2 / Black
C69
2 x 2 / Black
C70
2 / Black
North America
C71
2 / Black
North America
C74
1 / Round terminal
C78
2 / Black
C79
C80
1 / Black
C81
2 / Transparent
Colour codes
A
B
BL
BE
G
I
J
M
N
O
R
RO
S
V
VI
: Silver
: White
: Blue
: Beige
: Grey
: Ivory
: Yellow
: Brown
: Black
: Orange
: Red
: Pink
: Salmon
: Green
: Violet
C
F
: Light
: Dark
Location
Tractor
North America
Designation of harnesses
a :
b:
g:
t :
u:
w:
x :
Dashboard harness
Engine harness
Roof harness
Roof dashboard harness (lower part)
Roof dashboard harness (upper part)
Front and rear lighting harness
Roof lighting harness
Issue 1
May 2001
Electrical equipment
32
33
Number of ways /
colour
Location
C82
1 / Black
C83
1 / Black
Tractor
10A01.35
13
EA
Connectors
43
21
8
20
T18
35
31
34
1
44
7
18
16
36
25
29
22
26
27
23
28
24
TB
JC
30
25
37
19
17
Issue 1
May 2001
Fig. 14
15
25
7.5
7.5
16
17
18
10
11
15
10
15
25
15
12
15
(+P)
(+P)
14
30
(+P)
25
25
10
15
25
15
25
7.5
F19
F20
F21
F22
F23
F24
10
(+AC)
(+AC)
(+AC)
(+AC)
13
25
15
30
10
7,5
7,5
7,5
10
F13
F14
F15
F16
F17
F18
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
24
7.5
(+P)
(+P)
(+P)
(+AC)
(+AC)
(+AC)
23
30
25
3
30
25
30
15
10
5
7,5
10
15
25
22
30
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
21
Functions protected
20
Amperage
15
Fuse
reference
19
10
25
Electrical equipment
25
10A01.36
Fig.15
+P
=
+AC =
Permanent
+ after contact
Note :
- Fuse F7 : If no fuse, the pneumatic seat function is protected by fuse F12
- Fuse F11: Depending on assembly, it may be 15, 20 or 30 A
- Fuse F21: Depending on assembly, it may be 7.5 or 15 A
Issue 1
May 2001
+P
=
+AC =
(+P)
(+P)
Permanent
+ after contact
Note :
- Depending on assembly, the functions of the Datatronic, ELC and power take off are protected by fuse F10
or fuse F12.
- Fuse F21: Depending on assembly, it may be 7.5 or 15 A
Issue 1
May 2001
15
30
7.5
7.5
14
15
16
17
18
10
11
12
30
25
30
15
(+P)
25
30
10
7,5
25
15
30
7.5
F19
F20
F21
F22
F23
F24
10
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
13
25
15
30
10
7,5
7,5
7,5
7,5
F13
F14
F15
F16
F17
F18
10
(+AC)
(+AC)
(+AC)
24
15
10
30
25
23
30
F10
F11
F12
10
(+P)
(+P)
(+P)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
22
30
30
3
30
25
30
15
15
3
15
21
F1
F2
F3
F4
F5
F6
F7
F8
F9
Functions protected
20
Amperage
15
Fuse
reference
19
15
30
30
Electrical equipment
Fig.16
15
15
7.5
7.5
15
16
17
18
10
11
10
20
14
25
25
15
12
30
(+P)
(+P)
25
(+P)
7.5
30
20
10
25
15
15
10
F19
F20
F21
F22
F23
F24
13
25
(+AC)
(+AC)
(+AC)
(+AC)
10
15
3
10
7,5
7,5
7,5
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
24
7.5
F13
F14
F15
F16
F17
F18
(+P)
(+P)
(+AC)
(+AC)
(+AC)
23
30
30
3
30
25
30
15
10
5
7,5
10
25
25
22
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
21
Functions protected
20
Amperage
15
Fuse
reference
19
10
30
Electrical equipment
30
10A01.38
Fig.17
+P
=
+AC =
Permanent
+ after contact
Note :
- Fuse F7 : If no fuse, the pneumatic seat function is protected by fuse F12
- Fuse F11: Depending on assembly, it may be 15, 20 or 30 A
- Fuse F21: Depending on assembly, it may be 7.5 or 15 A
Issue 1
May 2001
(+P)
(+P)
Permanent
+ after contact
Note :
- Depending on assembly, the functions of the Datatronic, ELC and power take off are protected by fuse F10
or fuse F12.
- Fuse F21: Depending on assembly, it may be 7.5 or 15 A
Issue 1
May 2001
15
15
7.5
16
17
18
10
11
12
25
15
(+P)
7.5
30
20
10
25
15
30
15
30
F19
F20
F21
F22
F23
F24
14
30
(+AC)
(+AC)
(+AC)
(+AC)
25
10
7,5
7,5
7,5
7.5
F15
F16
F17
F18
10
(+AC)
(+AC)
13
25
15
3
10
F13
F14
24
10
(+AC)
(+AC)
(+AC)
23
15
10
30
25
22
30
F10
F11
F12
21
20
(+P)
(+P)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
20
30
3
30
25
30
15
15
3
15
19
F1
F2
F3
F4
F5
F6
F7
F8
F9
+P
=
+AC =
Functions protected
Amperage
30
Fuse
reference
15
15
30
Electrical equipment
Fig.18
Electricity
10A02.1
CONTENTS
A.
General ________________________________________________
B.
12
C.
30
D.
50
E.
56
F.
62
G.
63
H.
64
I.
65
Issue 1
May 2002
Issue 1
Electricity
May 2002
Electricity
A . General
The 8200 Z1 series tractors are equipped with a 12-volt
negative ground electrical circuit. The charging is provided by an 120 amp alternator (80 amp for platform
tractors).
The alternator contains an integrated rectifier and charge
regulator. The alternator fitted on the right-hand side of
the engine is driven by a belt from the crankshaft pulley.
The starter, fitted on the right-hand side of the motor, is
of the pre-engaged type.
The starter safety switch, placed beneath the clutch
pedal, allows the starter solenoid to be activated only
when the clutch pedal is fully pressed.
The batteries are mounted on a stable or rotating base
(depending on option) behind the right-hand side footstep.
10A02.3
Fig. 1
Issue 1
May 2002
Electricity
Characteristics
Colour codes
Battery
8210 and 8220
Quantity
Type
Cold start efficiency
Reserve capacity at 25 A
Voltage
Capacity
2
Maintenance free
420 A (-18 C)
120 min
12 V
66 Ah
8240 to 8280
Quantity
Type
Cold start efficiency
Reserve capacity at 25 A
Voltage
Capacity
2
Maintenance free
505 A (-18 C)
180 min
12 V
105 Ah
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
C : Light
F : Dark
Alternator
Cab
Make
Type
Maximum output
Regulator
Regulator voltage
Iskra
AAK
120 A
built-in
14.2 V
Iskra
AAK
80 A
built-in
14.2 V
Starter
8210 to 8280
Make
Model
Voltage
Type
Issue 1
Iskra
(3 kW)
12 V
Pre-engaged
May 2002
Emb.: end
Electricity
Identification of connectors
Note: One connector may have a different number of
wires in relation to the number of channels.
Example: Connector C3: 6 channels and 5 wires
CD1 M - Engine harness / dashboard harness junction
- channels: 31
- colour: Black
- wires: B - B - B - B - B - B - B - B - B - B - B - B - B
-B- B-B- B-B- B-B- R-M-R
- location: front of the cab
- for: Tractors 8210 - 8220
10A02.5
Issue 1
May 2002
Electricity
10A02.6
C3 - Console / dashboard harness junction
- channels: 10
- colour: Black
- wires: VI - V - J - R - R - R- R - J - M
- location: under dashboard, left-hand side
- for: Full powershift tractors all countries
Issue 1
May 2002
Electricity
10A02.7
C25 - Junction
- channels: 1
- colour: Black
- wires: RO
- location: under dashboard
- for: tractors all countries
Issue 1
May 2002
Electricity
Issue 1
May 2002
Electricity
10A02.9
Issue 1
May 2002
Electricity
Issue 1
May 2002
Electricity
10A02.11
Issue 1
May 2002
Starter switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Injection pump control solenoid
To electronic linkage
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Ventilation harness junction
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Trailer socket reversing light
Reversing light junction
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
CD2
- Lighting harness / dashboard harness
junction
CD3
- Autotronic 3 harness / dashboard harness
junction
C : Light
F : Dark
Emb.: end
C3
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Indicator lights
T5 : Alternator charge indicator light
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.13
CD1 M/C
Air filter vacuum sensor
P8
P8
Ro
Tb-C01
Tb-B05
T8
7
N
Temperature probe
B
10
P1
P1
CD1 M/C
Tb-B03
87
P7
P7
BL.F
88
CD1 M/C
Engine oil pressure
B
11
P5
P5
Tb-A05
T10
Fig. 2
Issue 1
May 2002
Starter switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Injection pump control solenoid
To electronic linkage
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Ventilation harness junction
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Trailer socket reversing light
Reversing light junction
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
CD2
- Lighting harness / dashboard harness
junction
CD3
- Autotronic 3 harness / dashboard harness
junction
C : Light
F : Dark
Emb.: end
C3
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Indicator lights
T5 : Alternator charge indicator light
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.15
1
CD1 M/C
Thermostart
+P
2
P2
P2
89
94
P3
P3
30
F5
Injection control
CD1 M/C
B
P9
P9
P10
P10
1
R
14
+P
1
94
2
3
+AC
5
R
B
90
91
Fig. 3
Issue 1
May 2002
Starter switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Injection pump control solenoid
To electronic linkage
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Ventilation harness junction
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Trailer socket reversing light
Reversing light junction
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
CD2
- Lighting harness / dashboard harness
junction
CD3
- Autotronic 3 harness / dashboard harness
junction
C : Light
F : Dark
Emb.: end
C3
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Indicator lights
T5 : Alternator charge indicator light
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.17
F18
7.5
Battery charging
Vi
Vi
CD1 M/C
B
12
6-D+ ALT
Vi
P6
C14-04
C3-03
Vi
Vi
Tb-C03
T5
C3-03
16
10
F12
30
F9
R
6
M
+P
20
Ro
3
4
M.F
10
53
+ACC
94
5
F25
M.F
N Ro
M.F
22
92
C17-03 C17-02
C17-01
Issue 1
Vi
O R
P4
P4
C24-01
C24-04
C24-02
May 2002
Vi
O
Vi
Ventilation
CD1 M/C
C24-01
C24-04
C24-02
Fig. 4
Starter switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Injection pump control solenoid
To electronic linkage
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Ventilation harness junction
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Trailer socket reversing light
Reversing light junction
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
CD2
- Lighting harness / dashboard harness
junction
CD3
- Autotronic 3 harness / dashboard harness
junction
C : Light
F : Dark
Emb.: end
C3
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Indicator lights
T5 : Alternator charge indicator light
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.19
10
15
10
F25
96
97
P3 P1 P8
P1A P2A
R
6
53
5
P2 P7
P1B P2B
N
R
93
M
+P
2
+AC
4
5
1
R
P1 P2
CD1 M/C
P3
P24
M
P4
95
P5
P7
P8
P6
P24
26
P26
27
B
29
M
P25
25
R
V
P27
28
P28
G
O
P29
Fig. 5
Issue 1
May 2002
Starter switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Injection pump control solenoid
To electronic linkage
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Ventilation harness junction
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Trailer socket reversing light
Reversing light junction
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
CD2
- Lighting harness / dashboard harness
junction
CD3
- Autotronic 3 harness / dashboard harness
junction
C : Light
F : Dark
Emb.: end
C3
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Indicator lights
T5 : Alternator charge indicator light
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.21
F9
10
30
F12
10
30
F17
Accessories
F25
94
1
R
M
+P
2
53
Ro
+AC
20
M.F
M.F
M.F
N Ro
M.F
Ro
C25
C25
Ro
Ro
C24-03
Ro
O
C24-03
C24-04
C24-02
C24-02
18
19
ONR R
C24-04
49
Ro
Ro
50
N
Fig. 6
Issue 1
May 2002
Starter switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Injection pump control solenoid
To electronic linkage
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Ventilation harness junction
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Trailer socket reversing light
Reversing light junction
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
CD2
- Lighting harness / dashboard harness
junction
CD3
- Autotronic 3 harness / dashboard harness
junction
C : Light
F : Dark
Emb.: end
C3
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Indicator lights
T5 : Alternator charge indicator light
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.23
30
F1
P-04
40
P-04
10
O
F20
R
N
N
N
C03-04
C03-04
+P
94
2
1
3
4
+AC
30
10
Cigarette lighter
F17
R
6
94
+P
2
53
F24
3
4
M.F
M.F
R
31
C47-01
C47-02
C47-03
C03-02
C03-02
C03-06
C03-06
Issue 1
Fig. 7
May 2002
Starter switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Injection pump control solenoid
To electronic linkage
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Ventilation harness junction
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Trailer socket reversing light
Reversing light junction
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
CD2
- Lighting harness / dashboard harness
junction
CD3
- Autotronic 3 harness / dashboard harness
junction
C : Light
F : Dark
Emb.: end
C3
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Indicator lights
T5 : Alternator charge indicator light
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.25
10
F3
CD1 M/C
P12
99
P12
94
M
+P
+AC
1
R
P-01
P-01
98
N
F4
CD2
Reversing light
PIN A
BL
PIN A
BL
94
+P
+AC
1
R
BL
100
CD3
P40
101
N
Issue 1
May 2002
Fig. 8
Starter switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Injection pump control solenoid
To electronic linkage
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Ventilation harness junction
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Trailer socket reversing light
Reversing light junction
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
CD2
- Lighting harness / dashboard harness
junction
CD3
- Autotronic 3 harness / dashboard harness
junction
C : Light
F : Dark
Emb.: end
C3
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Indicator lights
T5 : Alternator charge indicator light
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
F9
25
F10
10
Electricity
Windscreen wiper
1
94
M
+P
2
1
Ro
+AC
20
M.F
N Ro
M.F
G
BL
B
M
Vi
93
CD1 M/C
38
22
C8
P22
BL
27
43
C18-01
C18-02
C18-03
C18-04
C18-06
B
BL
O
G
Fig. 9
Issue 1
May 2002
Starter switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Injection pump control solenoid
To electronic linkage
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Ventilation harness junction
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Trailer socket reversing light
Reversing light junction
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
CD2
- Lighting harness / dashboard harness
junction
CD3
- Autotronic 3 harness / dashboard harness
junction
C : Light
F : Dark
Emb.: end
C3
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Indicator lights
T5 : Alternator charge indicator light
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.29
F9
10
Rear wiper
10
15
F11
F25
94
M
+P
2
1
Ro
53
+AC
3
4
20
M.F
M.F
N Ro
M.F
C10-02
C10-02
M EMB R
R
C16-02
C16-03
C12
C12
C16-02
C16-03
36
M V
C12
C12
C28-02
C28-03
C28-01
C28-03
C28-02
M
C28-01
N
V
R
J
P4
P3
P2
P1
28
Fig. 10
Issue 1
May 2002
Starter switch
Safety switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Starter
Injection pump control solenoid
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Start relay
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
C : Light
F : Dark
C3
C4
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Emb.: end
Indicator lights
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.31
P8
Ro
Tb-F.f
T8
7
CD1 M/C
Temperature probe
10
P1
Tb-C.f
Tb-B03
87
CD1 M/C
P1
BL.F
P5
88
11
Tb-B.g
T10
CD1 M/C
Fig. 11
Issue 1
May 2002
Starter switch
Safety switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Starter
Injection pump control solenoid
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Start relay
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
C : Light
F : Dark
C3
C4
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Emb.: end
Indicator lights
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.33
Thermostart
M
+P
2
1
89
P2
P3
94
4
5
CD1 M/C
30
F5
Injection control
14
P9
R
10
P10
M
+P
2
1
5
CD1 M/C
94
+ AC
90
91
Fig. 12
Issue 1
May 2002
Starter switch
Safety switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Starter
Injection pump control solenoid
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Start relay
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
C : Light
F : Dark
C3
C4
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Emb.: end
Indicator lights
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.35
7,5
F18
Battery charging
R
12
6-D+ ALT
P6
Vi
CD1 M/C
1
+P
2
1
+ ACC
3
4
5
F9
Ventilation
F12
M
+P
2
1
R0
+ ACC
94
53
4
5
7
N
M.F
F25
20
M.F
Ro
N
O
M.F
92
C17-03
C17-03
C17-02
Vi
O
Vi
CD1 M/C
22
P4
C24-01
R
Issue 1
C24-02
C24-01
C24-04
C24-02
C24-04
Vi
O
Fig. 13
May 2002
Starter switch
Safety switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Starter
Injection pump control solenoid
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Start relay
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
C : Light
F : Dark
C3
C4
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Emb.: end
Indicator lights
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.37
F14
15
10
15
F27
F25
96
97
P3 P1 P8
P1A P2A
53
5
P2 P7
7
N
P1B P2B
M
N
R
+P
2
1
94
+ AC
1
R
P1 - P2
P3
95
P4
P5
P6
25
B
B
P26
28
B
P8
P24
26
27
P7
P24
P25
P27
V
O
P28
P29
29
CD1 M/C
Fig. 14
Issue 1
May 2002
Starter switch
Safety switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Starter
Injection pump control solenoid
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Start relay
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
C : Light
F : Dark
C3
C4
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Emb.: end
Indicator lights
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.39
10
F3
99
12
P12
CD1 M/C
+P
2
94
4
5
+ AC
1
R
P-01
P-01
98
N
Fig. 15
Issue 1
May 2002
Starter switch
Safety switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Starter
Injection pump control solenoid
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Start relay
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
C : Light
F : Dark
C3
C4
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Emb.: end
Indicator lights
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.41
F9
10
30
F12
Accessories
30
10
F17
F25
94
53
6
+P
1
R0
M.F
20
+ AC
M.F
7
N
M.F
N R0
M.F
D
R0
C25
C25
R0
R0
C24-03
R0
C24-03
R
C24-04
C24-04
C24-02
C24-02
19
O NR R
R
D
18
49
R0
R0
50
N
Issue 1
May 2002
Fig. 16
Starter switch
Safety switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Starter
Injection pump control solenoid
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Start relay
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
C : Light
F : Dark
C3
C4
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Emb.: end
Indicator lights
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.43
F1
P-04
P-04
10
30
O
O
40
F20
N
N
M
N
C03-04
C03-04
+P
94
2
1
4
5
3
+ AC
1
R
94
+P
30
10
Cigarette lighter
F17
2
1
5
F24
53
7
N
M.F
M.F
31
C47-01
C47-02
C03-02
C03-02
C03-06
C03-06
C47-03
Fig. 17
Issue 1
May 2002
Starter switch
Safety switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Starter
Injection pump control solenoid
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Start relay
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
C : Light
F : Dark
C3
C4
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Emb.: end
Indicator lights
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.45
10
F9
25
F10
Windscreen wiper
M
+P
Ro
2
1
94
+ ACC
3
4
5
20
M.F
Ro
N
M.F
O
G
BL
B
M
VI
3
93
CD1 M/C
N
C8
22
P22
27
38
43
C18-01
C18-02
B
BL
C18-03
C18-04
C18-06
O
G
Fig. 18
Issue 1
May 2002
Starter switch
Safety switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Starter
Injection pump control solenoid
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Start relay
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
C : Light
F : Dark
C3
C4
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Emb.: end
Indicator lights
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.47
10
10
F9
15
F11
Rear wiper
F25
53
M
+P
2
1
Ro
M.F
94
+ ACC
1
5
7
N
M.F
20
N Ro
M.F
C10-02
C10-02
R
M EMB R
C16-02
C16-03
C16-02
C16-03
C12
C12
36
V
C12
C12
C28-03
C28-02
Issue 1
May 2002
C28-01
C28-03
C28-01
C28-02
V
J
P4
P2
P3
P1
28
Fig. 19
Starter switch
Safety switch
Water temperature indicator
Air filter vacuum sensor
Water temperature sensor
Engine oil pressure switch
Alternator
Starter
Injection pump control solenoid
Clock
Radio
Cab relay
Air conditioning pressure switch
Windscreen wiper switch
Rear wiper motor
Cigarette lighter
Rear wiper switch
Windscreen washer pump
Interior power socket
Windscreen wiper motor
Roof light
Door switch
Lighting switch
Water level sensor
To ground if no water level sensor
Thermostart
Temperature switch
Cold start solenoid valve
Wiper time delay relay
Front of the cab (+) terminal
Front axle connector
Front axle switch
Front axle LED
Pneumatic seat
Fuel heater
Start relay
Electricity
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
A)
CD1 M/C - Engine harness / dashboard harness
junction
C : Light
F : Dark
C3
C4
C8
C10
C12
C14
C16
C17
C18
C24
C25
C28
C47
Emb.: end
Indicator lights
T8 : Clogging indicator light
T10 : Engine oil filter clogging indicator light
Issue 1
May 2002
Electricity
10A02.49
F7
Start
C4-03
C4-03
C4-04
C4-04
C4
13
O
122
N
94
M
+P
2
1
+ ACC
5
Conn 14
Conn 14
CD1 M/C
Fig. 20
Issue 1
May 2002
Starter switch
To TCU
Windscreen wiper switch
Flashing beacon switch
Console lighting
Roof console lighting
Lighting switch
Rear right work light on roof
Lower rear right work light
Trailer power socket
Lower rear left work light
Rear left work light on roof
Horn
Front left direction indicator
Front left work light on footstep
Front left work light on rail
Front left work light on roof
Front right work light on roof
Front right work light on rail
Front right work light on footstep
Front left headlight
Front right headlight
Front right direction indicator
Flashing beacon
Central direction indicator
Hazard warning switch
Front work lights on rail and footstep switch
Front and rear work lights on roof switch
Front of the cab (+) terminal
Registration plate light
Right travelling / stop light
Left travelling / stop light
Front left parking light
Front right parking light
Left stop light switch
Right stop light switch
Front left roof mounted headlight
Front right roof mounted headlight
Roof headlights switch
Roof mounted headlights option
Option without roof mounted headlights
Rear right direction indicator
115.
116.
117.
118.
119.
120.
121.
Indicator lights
T16 : Parking lights indicator light
T17 : Headlight beam indicator light
T19 : 1st trailer parking light indicator light
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
Electricity
C : Light
F : Dark
Emb.: end
Issue 1
May 2002
Electricity
10A02.51
112
10
R
N O Vi
7.5
20
15
F19
15
Ro
F32
Vi
O
R-C75-P6
N-C75-P5 Ro-C75-P4
R-C75-P3 Vi-C75-P2
O-C75-P1
R-C75-P6
Ro-C75-P4
Vi-C75-P2
N-C75-P5
R-C75-P3
O-C75-P1
R-C72
94
109
R-C73
Horn
F26
10
111
110
7.5
F25
102
N
G
2
A1
M.F
O-C7
+AC
J-A1
T17
53
39
A12
94
+P
R-A12
27
R-C63-P6
R-C63-P6
R-C10-P2
R-C10-P2
V
J
G
108
107
Ro
B emb N
V
J
TCU
17
113
Vi
R-C75
106
B emb N
D47 V
D47 V
N
J
R
B emb N
V.C-C7
J-C7
Ro-C75-P4
N-C67-P4
B-C67-P3
R-C67-P2
103
O
J
N
J
V
79
B
B EMB N
B EMB N
CD1 M/C
N J V
P18
P19
P20
P18
P19
P20
78
V
J
G
R-C64
P-M
P-N
P-J
P-H
P-M
P-N
P-J
P-H
L
54
54g
58L
R EMB N
65
58R
31
R
CD2
N
R
N-C66-P4
R-C66-P2
B-C66-P3
104
105
G
70
Fig. 21
Issue 1
May 2002
Starter switch
To TCU
Windscreen wiper switch
Flashing beacon switch
Console lighting
Roof console lighting
Lighting switch
Rear right work light on roof
Lower rear right work light
Trailer power socket
Lower rear left work light
Rear left work light on roof
Horn
Front left direction indicator
Front left work light on footstep
Front left work light on rail
Front left work light on roof
Front right work light on roof
Front right work light on rail
Front right work light on footstep
Front left headlight
Front right headlight
Front right direction indicator
Flashing beacon
Central direction indicator
Hazard warning switch
Front work lights on rail and footstep switch
Front and rear work lights on roof switch
Front of the cab (+) terminal
Registration plate light
Right travelling / stop light
Left travelling / stop light
Front left parking light
Front right parking light
Left stop light switch
Right stop light switch
Front left roof mounted headlight
Front right roof mounted headlight
Roof headlights switch
Roof mounted headlights option
Option without roof mounted headlights
Rear right direction indicator
115.
116.
117.
118.
119.
120.
121.
Indicator lights
T16 : Parking lights indicator light
T17 : Headlight beam indicator light
T19 : 1st trailer parking light indicator light
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
Electricity
C : Light
F : Dark
Emb.: end
Issue 1
May 2002
Electricity
10A02.53
30
F21
82
83
BL
B
Ro
A2
A14
C3
A8
C1
A6
+P
49L
V.F
Ro
V.F
V.F
B-A14
27
N-A6
BL-A2
49
Ro-A8
31
94
+AC
B
M
Ro
BL
B
B
P-L
P-K
P-L
P-K
CD2
N-C67-P4
114
M-C67-P1
80
M-C65
Ro
54g
54
58L
58R
31
N
M
N-C66-P4
Ro-C64
71
65
115
Ro-C66-P1
Fig. 22
Issue 1
May 2002
Starter switch
To TCU
Windscreen wiper switch
Flashing beacon switch
Console lighting
Roof console lighting
Lighting switch
Rear right work light on roof
Lower rear right work light
Trailer power socket
Lower rear left work light
Rear left work light on roof
Horn
Front left direction indicator
Front left work light on footstep
Front left work light on rail
Front left work light on roof
Front right work light on roof
Front right work light on rail
Front right work light on footstep
Front left headlight
Front right headlight
Front right direction indicator
Flashing beacon
Central direction indicator
Hazard warning switch
Front work lights on rail and footstep switch
Front and rear work lights on roof switch
Front of the cab (+) terminal
Registration plate light
Right travelling / stop light
Left travelling / stop light
Front left parking light
Front right parking light
Left stop light switch
Right stop light switch
Front left roof mounted headlight
Front right roof mounted headlight
Roof headlights switch
Roof mounted headlights option
Option without roof mounted headlights
Rear right direction indicator
115.
116.
117.
118.
119.
120.
121.
Indicator lights
T16 : Parking lights indicator light
T17 : Headlight beam indicator light
T19 : 1st trailer parking light indicator light
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
Electricity
C : Light
F : Dark
Emb.: end
Issue 1
May 2002
Electricity
10A02.55
Vi
M.F
15
F28
Vi
25
53
F13
7.5
94
25
25
25
Flashing beacon
F16
F25
F27
M.F
F26
F29
M.F
R
R
Vi
P3
77
O-C81
116
P2
117
118
119
76
Ro-C79
N
P1
BL-C69
N-C69
75
N.C
V.C
N
BL.C
P1
P5
BL-C69
N-C69
Vi
Vi
Vi
Ro-C83
64
N
P4
P1
V.F-C71
G
BL-C68
N-C68
G
O
74
P1
63
V.F-C71
N
Ro
P-G
P-E
P-D
P-B
P-G
P-E
P-D
P-B
BL-C68
N-C68
V.F-C70
67
V.F-C70
N
C2
P2
73
P5
Ro-C79
Ro
N
P3
O-C80
72
V.F-C63-P1
G-C63-P2
BL.F-C63-P3
BL.F-C63P4
V.F-C63-P5
V.F-C63-P1
G-C63-P2
BL.F-C63-P3
BL.F-C63P4
V.F-C63-P5
V.F-C10-P1
R-C10-P2
BL.F-C10-P3
BL.F-C10-P4
V.F-C10-P5
Be-C10-P6
Ro-C82
V.F-C10-P1
R-C10-P2
BL.F-C10-P3
BL.F-C10-P4
V.F-C10-P5
Be-C10-P6
66
N
V.F
V.F
81
81
Be-C16-P1
N-C16-P2
R-C16-P3
G-C16-P4
N
Be-C16-P1
N-C16-P2
R-C16-P3
G-C16-P4
42
R
32
Be N
G-C74
G-C74
Fig. 23
Issue 1
May 2002
Starter switch
To TCU
Windscreen wiper switch
Flashing beacon switch
Console lighting
Roof console lighting
Lighting switch
Rear right work light on roof
Lower Rear right work light
Trailer power socket
Lower Rear left work light
Rear left work light on roof
Horn
Front left direction indicator
Front left work light on footstep
Front left work light on rail
Front left work light on roof
Front right work light on roof
Front right work light on rail
Front right work light on footstep
Front left headlight
Front right headlight
Front right direction indicator
Flashing beacon
Central direction indicator
Hazard warning switch
Front work lights on rail and footstep switch
Front and rear work lights on roof switch
Front of the cab (+) terminal
Registration plate light
Front right travelling / stop light
Left travelling / stop light
Front left parking light
Front right parking light
Left stop light switch
Right stop light switch
Front left roof mounted headlight
Front right roof mounted headlight
Roof headlights switch
Roof mounted headlights option
Option without roof mounted headlights
Rear right direction indicator
115.
116.
117.
118.
119.
120.
121.
Indicator lights
T16 : Parking lights indicator light
T17 : Headlight beam indicator light
T19 : 1st trailer parking light indicator light
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
Electricity
C : Light
F : Dark
Emb.: end
Issue 1
May 2002
Electricity
10A02.57
94
F25
+P
F19
F26
10
2
1
3
F32
M.F
15
1
+AC
94
7.5
10
53
7.5
39
O-C7
F31
F22
T17
V
N
A12
A1
J-A1
R-A12
27
V.C-C7
J-C7
R
R
108
107
B emb N
B emb N
B emb N
D47 V
D47 V
TCU
65
17
J
79
N-C67-P3
P-J
P-H
N J V
P18
P19
P20
P18
P19
P20
V
J
G
CD1 M/C
P-J
P-H
CD2
120
R-C67-P1
N-C66-P3
121
R-C66-P1
78
N
70
Fig. 24
Issue 1
May 2002
Starter switch
To TCU
Windscreen wiper switch
Flashing beacon switch
Console lighting
Roof console lighting
Lighting switch
Rear right work light on roof
Lower Rear right work light
Trailer power socket
Lower Rear left work light
Rear left work light on roof
Horn
Front left direction indicator
Front left work light on footstep
Front left work light on rail
Front left work light on roof
Front right work light on roof
Front right work light on rail
Front right work light on footstep
Front left headlight
Front right headlight
Front right direction indicator
Flashing beacon
Central direction indicator
Hazard warning switch
Front work lights on rail and footstep switch
Front and rear work lights on roof switch
Front of the cab (+) terminal
Registration plate light
Front right travelling / stop light
Left travelling / stop light
Front left parking light
Front right parking light
Left stop light switch
Right stop light switch
Front left roof mounted headlight
Front right roof mounted headlight
Roof headlights switch
Roof mounted headlights option
Option without roof mounted headlights
Rear right direction indicator
115.
116.
117.
118.
119.
120.
121.
Indicator lights
T16 : Parking lights indicator light
T17 : Headlight beam indicator light
T19 : 1st trailer parking light indicator light
Colour codes
A : Silver
B : White
BL : Blue
BE : Beige
G : Grey
I : Ivory
J : Yellow
M : Brown
N : Black
O : Orange
R : Red
RO : Pink
S : Salmon
V : Green
VI : Violet
Electricity
C : Light
F : Dark
Emb.: end
Issue 1
May 2002
Electricity
10A02.59
82
27
BL
B
83
10
F28
25
(SAE standard)
R
F21
Ro
3
4
49a
Ro
+AC
B-A14
BL-A2
V.F
B
R V.F
N-A6
Ro-A8
49
94
M
31
+P
A14
A2
C3
A8
C2
A6
B
M
Ro
BL
B
M
B
Ro
M
Ro
R
V.F
B
1
6
2
7
65
3
4
V
M
CD2
N-C67-P3
114
M-C67-P2
M-C65
80
N
N
N-C66-P3
Ro-C64
71
115
Ro-C66-P2
Fig. 25
Issue 1
May 2002
Starter switch
To TCU
Windscreen wiper switch
Flashing beacon switch
Console lighting
Roof console lighting
Lighting switch
Rear right work light on roof
Lower Rear right work light
Trailer power socket
Lower Rear left work light
Rear left work light on roof
Horn
Front left direction indicator
Front left work light on footstep
Front left work light on rail
Front left work light on roof
Front right work light on roof
Front right work light on rail
Front right work light on footstep
Front left headlight
Front right headlight
Front right direction indicator
Flashing beacon
Central direction indicator
Hazard warning switch
Front work lights on rail and footstep switch
Front and rear work lights on roof switch
Front of the cab (+) terminal
Registration plate light
Front right travelling / stop light
Left travelling / stop light
Front left parking light
Front right parking light
Left stop light switch
Right stop light switch
Front left roof mounted headlight
Front right roof mounted headlight
Roof headlights switch
Roof mounted headlights option
Option without roof mounted headlights
Rear right direction indicator
115.
116.
117.
118.
119.
120.
121.
Indicator lights
T16 : Parking lights indicator light
T17 : Headlight beam indicator light
T19 : 1st trailer parking light indicator light
Colour codes
A :
B :
BL :
BE :
G :
I :
J :
M :
N :
O :
R :
RO :
S :
V :
VI :
Silver
White
Blue
Beige
Grey
Ivory
Yellow
Brown
Black
Orange
Red
Pink
Salmon
Green
Violet
Electricity
C : Light
F : Dark
Emb.: end
Issue 1
May 2002
Electricity
10A02.61
BL
Vi
94
53
M.F
F16
15
25
F21
F28
15
F27
M.F
F13
10
10
Flashing beacon
15
94
25
F25
M.F
30
F30 F29
R
+P
Vi
2
3
+AC
V-C81
77
Vi
BI
R
49d
V-C79
76
V-C79
84
30
30b
15
49
83
117
R
R
BL-C69
N-C69
75
BL-C69
N-C69
N.C
P5
64
G-C83
N
85
P4
V.F-C71
BL-C68
N-C68
63
V.F-C71
N
P-G
P-E
P-D
P-B
P-G
P-E
P-D
P-B
74
BL-C68
N-C68
CD2
P4
V.F-C70
67
V.F-C70
N
V-C79
73
V-C79
G-C82
V-C80
72
V.F-C63-P1
G-C63-P2
BL.F-C63-P3
BL.F-C63P4
V.F-C63-P5
V.F-C63-P1
G-C63-P2
BL.F-C63-P3
BL.F-C63P4
V.F-C63-P5
81
V.F-C10-P1
R-C10-P2
BL.F-C10-P3
BL.F-C10-P4
V.F-C10-P5
Be-C10-P6
Be-C16-P1
N-C16-P2
R-C16-P3
G-C16-P4
81
N
66
BL-C10-P1
R-C10-P2
BL.F-C10-P3
BL.F-C10-P4
V.F-C10-P5
Be-C10-P6
Be-C16-P1
N-C16-P2
R-C16-P3
G-C16-P4
N
R
32
Be N
G-C74
G-C74
Fig. 26
Issue 1
May 2002
Electricity
10A02.62
F . Location of fuses - Dynashift (Europe) (Fig. 27)
Note: Always replace fuses by fuses of the same amperage
F7
(+AC)
F8
F9
7,5
10
(+AC)
(+AC)
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
F30
F31
F32
25
15
30
25
15
0
25
30
7,5
7,5
10
10
20
7,5
15
10
7,5
15
25
25
15
15
10
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+P)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+P)
(+P)
(+P)
(+AC)
(+P)
(+P)
(+P)
(+AC)
(+AC)
(+AC)
F 15
F 31
F 25
F 24
F 9
F 8
F 23
F 7
F 22
F 6
F 21
F 14
(+P)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
F 11
F 10
F 20
F 19
F 5
F 4
F 3
F 13
30
7,5
10
5
30
10
Functions protected
F 30
F1
F2
F3
F4
F5
F6
Amperage
F 27
F 26
F 29
Fuse
reference
F 12
F 16
F 32
F 28
F 18
F 17
F 2
F 1
F1 - 30A
F2 - 7,5A
F3 - 10A
F4 - 15A
5A
F5 - 30A
F6 - 10A
F7 - 5A
F8 - 7,5A
F9 - 10A
F10 - 25A
F11 - 15A
F12 - 30A
25A
F13 - 15A
F14 - 15A
F15 -
25A
F16 - 30A
F17 - 30A
F18 - 7,5A
F19 - 7,5A
F20 - 10A
F21 - 10A
F22 - 20A
F23 - 7,5A
F24 - 15A
F25 - 10A
AUTO III
F26 - 7,5A
F27 - 15A
F28 - 25A
F29 - 30A
25A
F30 - 15A
HAND
+P
=
+AC =
Permanent
+ after contact
STOP
F31 - 15A
F32 - 10A
REF: 3785765M1
A 5 A fuse located on the battery cut out (if fitted) protects the clock.
Fig.27
Issue 1
May 2002
Electricity
10A02.63
(+P)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
F7
(+AC)
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
F30
F31
F32
7,5
10
25
15
30
15
15
0
25
30
7,5
7,5
10
15
3
7,5
15
10
7,5
15
25
30
15
15
10
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+P)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+P)
(+P)
(+P)
(+AC)
(+P)
(+P)
(+P)
(+AC)
(+AC)
(+AC)
+P
=
+AC =
F 16
F 9
F 24
F 8
F 23
F 7
F 22
F 6
F 21
F 5
F 20
F 19
F 4
F 3
F 18
F 17
F 2
F 1
F1 - 30A
F2 - 7,5A
F3 - 10A
F4 - 15A
F5 - 30A
F6 - 10A
F7 - 5A
F8 - 7,5A
F9 - 10A
F10 - 25A
F11 - 15A
F12 - 30A
F13 - 15A
F14 - 15A
F15 -
25A
F16 - 30A
F17 - 30A
F18 - 7,5A
F19 - 7,5A
F20 - 10A
F21 - 15A
F22 - 20A
3A
F23 - 7,5A
F24 - 15A
F25 - 10A
AUTO III
F26 - 7,5A
Permanent
+ after contact
F 10
F 25
F 13
30
7,5
10
0
30
10
F 11
F 26
F 15
F 31
Functions protected
F 30
F1
F2
F3
F4
F5
F6
Amperage
F 29
Fuse
reference
F 12
F 27
F 14
F 32
F 28
F27 - 15A
F28 - 25A
F29 - 30A
F30 - 15A
HAND
A 5 A fuse located on the battery cut out (if fitted) protects the clock.
F31 - 15A
F32 - 10A
REF: 3785917M1
Fig.28
Issue 1
May 2002
Electricity
10A02.64
H . Location of fuses - Powershift (Europe) (Fig. 29)
Note: Always replace fuses by fuses of the same amperage
(+P)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
F30
F31
F32
7,5
10
25
15
30
25
15
0
25
30
7,5
7,5
10
10
20
7,5
15
10
7,5
15
25
25
15
15
10
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+P)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+P)
(+P)
(+P)
(+AC)
(+P)
(+P)
(+P)
(+AC)
(+AC)
(+AC)
+P
=
+AC =
F 15
F 7
F 22
F 6
F 21
F 20
F 19
F1 - 30A
F 18
F 17
F2 - 7,5A
F 9
F 8
F 23
F 14
30
7,5
10
15
30
10
5
F 24
F 11
F 10
F 5
F 4
F 3
F 13
F1
F2
F3
F4
F5
F6
F7
F 25
F 31
Functions protected
F 30
Amperage
F 26
F 29
Fuse
reference
F 27
F 12
F 16
F 32
F 28
F3 - 10A
F 2
F 1
F4 - 15A
F5 - 30A
Permanent
+ after contact
F6 - 10A
F7 - 5A
F8 - 7,5A
F9 - 10A
F10 - 25A
F11 - 15A
F12 - 30A
25A
F13 - 15A
F14 - 15A
F15 -
F16 - 25A
30A
F17 - 30A
F18 - 7,5A
F19 - 7,5A
F20 - 10A
F21 - 10A
F22 - 20A
F23 - 7,5A
F24 - 15A
F25 - 10A
F26 - 7,5A
F27 - 15A
F28 - 25A
F29 - 30A
25A
F30 - 15A
HAND
A 5 A fuse located on the battery cut out (if fitted) protects the clock.
STOP
F31 - 15A
F32 - 10A
REF: 3785919M1
3785918M1
Fig.29
Issue 1
May 2002
Electricity
10A02.65
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
F30
F31
F32
+P
=
+AC =
7,5
10
25
15
30
15
15
0
30
30
7,5
7,5
10
15
20
7,5
15
10
7,5
15
25
30
15
15
10
(+P)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+P)
(+AC)
(+AC)
(+AC)
(+AC)
(+AC)
(+P)
(+P)
(+P)
(+AC)
(+P)
(+P)
(+P)
(+AC)
(+AC)
(+AC)
Permanent
+ after contact
F 16
F 10
F 25
F 9
F 24
F 7
F 22
F 6
F 21
F 5
F 20
F 18
F 17
F2 - 7,5A
F 8
F 23
F 19
F1 - 30A
F 11
F 26
F 4
F 3
F 13
30
7,5
10
15
30
10
5
F 12
F 15
F 31
Functions protected
F 30
F1
F2
F3
F4
F5
F6
F7
Amperage
F 29
Fuse
reference
F 27
F 14
F 32
F 28
F3 - 10A
F 2
F 1
F4 - 15A
F5 - 30A
F6 - 10A
F7 - 5A
F8 - 7,5A
F9 - 10A
F10 - 25A
F11 - 15A
F12 - 30A
F13 - 15A
F14 - 15A
F15 -
F16 - 30A
F17 - 30A
F18 - 7,5A
F19 - 7,5A
F20 - 10A
F21 - 15A
F22 - 20A
F23 - 7,5A
F24 - 15A
F25 - 10A
F26 - 7,5A
F27 - 15A
F28 - 25A
F29 - 30A
F30 - 15A
HAND
A 5 A fuse located on the battery cut out (if fitted) protects the clock.
F31 - 15A
F32 - 10A
REF: 3785919M1
Fig.30
Issue 1
May 2002
11 . ELECTRONICS
Contents
11 A01 AUTOTRONIC 2 - DESCRIPTION
11 A02 AUTOTRONIC 2 - CHECKING WITHOUT TESTER
11 A03 11 A03 AUTOTRONIC 3 - DESCRIPTION
11 B01 DCC / TC - DESCRIPTION
11 B02 DCC / TC - CALIBRATION
11 B03 DCC / TC - ERROR CODES
11 C01 ELECTRONIC LINKAGE - DESCRIPTION - TRACTOR WITH CAB
11 C02 ELECTRONIC LINKAGE - AUTODIAGNOSTICS - TRACTOR WITH CAB
11 C03 PREVISIONAL
11 C04 PREVISIONAL
11 D01 DATATRONIC 2 - DESCRIPTION
11 D02 DATATRONIC 2 - FRONT DUAL CONTROL
11 D03 DATATRONIC 2 - DUAL CONTROL FOR SEMIMOUNTED IMPLEMENT
11 D04 DATATRONIC 2 - TIC FOR SEMIMOUNTED IMPLEMENT
11 E01 PREVISIONAL
11 E02 PREVISIONAL
11 E03 PREVISIONAL
11 F01 WINTEST - GENERAL
11 F02 AUTOTRONIC 2 WITH WINTEST
11 F03 AUTOTRONIC 3 WITH WINTEST
11 F04 TC / DCC WITH WINTEST
11 F05 ELECTRONIC LINKAGE WITH WINTEST
11 F06 DATATRONIC WITH WINTEST
11 F07 JOYSTICK WITH WINTEST
11 F08 AUTOTRONIC 3 TO KIT AUTOTRONIC
11 F09 KIT AUTOTRONIC TO AUTOTRONIC 3
11 G01 CARRARO FRONT AXLE
11 H01 SMS SYSTEM - DESCRIPTION
Issue 2
May 2002
Autotronic 2 - Description
11A01.1
11 A01 Description
CONTENTS
A.
General _____________________________________
B.
C.
D.
Diagrams ___________________________________
10
Issue 1
May 2001
Issue 1
Autotronic 2 - Description
May 2001
Autotronic 2 - Description
A . General
The Autotronic 2 also known as the TCU (Transmission
Control Unit) is fitted to all 8200 series tractors with a
Mechanical Reverse Shuttle.
On 8200 series tractors fitted with a Power Shuttle, the
Autotronic 2 has been replaced by a new calculator
known as the Autotronic 3.
The Autotronic 2 is fitted outside beneath the right-hand
flooring on tractors with cab, and inside on the right wing
on tractors without a cab.
Only Autotronic units with reference numbers equal to
or greater than 3792092H92 can be fitted to 8200 series
tractors.
11A01.3
Phoenix PN :
3792094 M1
PHOENIX
OP Software PN :
BOOTROM Software PN :
PN :
Serial Number :
1-91-127671 Issue D
1-91-123234 Issue E
3792093 H94
99 00 000
INTERNATIONAL
Assembled in USA
IIIIIIIIIIIIIIIII
Issue 1
May 2001
Autotronic 2 - Description
>
ALARM MODE
>
>
Clutch switch
signal
Low pressure
< 9 bar
Engine speed
< 200 rpm
Low pressure
= 17 bar
Engine speed
> 200 rpm
STANDBY MODE
>
Engine stopped
No hydraulic pressure
TCU OFF
Low pressure
< 9 bar
Engine speed
< 200 rpm
>
WORKING MODE
All functions OK
TCU 4
>
Issue 1
May 2001
Low pressure
= 17 bar
Engine speed
< 200 rpm
Autotronic 2 - Description
11A01.5
C . Flowchart of functions
AUTOTRONIC 2
(T . C. U .)
Automatically acts on
Hare / Tortoise
shifting
Power take-off
(PTO)
Differential
lock
Front axle
4WD
Dynashift
or
Speedshift
Issue 1
May 2001
Autotronic 2 - Description
11A01.6
POWER TAKE-OFF
2
Issue 1
May 2001
Autotronic 2 - Description
11A01.7
DIFFERENTIAL LOCKING
3
Unlocks when
brakes are applied
- indicator lights
Unlocks if the
forward speed
exceeds 14 kph
- Does not re-engage when
speed drops below 14 kph
(indicator not lit).
Issue 1
May 2001
Autotronic 2 - Description
11A01.8
FRONT AXLE
4
4 WD status
Tractor stopped
Engine running
If parameter
B=3 and I =2
1. If the front axle is
engaged, the 4 WD
indicator lamp is lit,
pressing the 4 WD
switch disengages
it. The 4WD solenoid valve is supplied.
2. If the 4 WD indicator
lamp is not lit, the
front axle is disengaged, pressing the
4 WD switch engages 4 WD. The 4
WD solenoid valve
is no longer supplied.
Note: The front
axle is engaged
mechanically and
disengaged hydraulically.
Disengages if speed
exceeds 14 kph
Remains engaged
whatever the speed
Engages
if hydraulic pressure
drops
Issue 1
Remains engaged
whatever the speed
May 2001
Autotronic 2 - Description
11A01.9
DYNASHIFT
5
On starting the
engine
Progressiveness
Drop in hydraulic
pressure
- If parameter G = 1, the
range engaged corresponds to the lever position.
- If parameter G = 2, 3 or 4,
the range engaged corresponds to the last position memorised before
stopping the engine.
- Automatic shifting to D
ratio, if hydraulic pressure < 9.5 1 bar.
Low temperature
Maximum engine
speed
Speed limitation
Issue 1
May 2001
Autotronic 2 - Description
D . Diagrams
Dynashift
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
46
47
48
53
54
55
Autotronic unit
Differential lock solenoid valve
Dynashift EV2 (3 x 2) solenoid valve
Hare / Tortoise solenoid valve
Rear PTO solenoid valve
4 WD solenoid valve
Dynashift EV1 (4 x 2) solenoid valve
F18 + lighting fuse
Cab ground
Battery
Temperature sensor
Alternator
PTO 540 / 1000 rpm switch
Starter motor
PTO 540 rpm indicator lamp
PTO 1000 rpm indicator lamp
Low pressure indicator lamp
Hare / Tortoise indicator lamp
Differential lock indicator lamp
4 WD indicator lamp
PTO and speed digital display
To + AC cab relay
+ AC (start switch)
Left brake switch
Right brake switch
Clutch safety switch
Start switch
Dynashift ratio indicator lamps
To hydraulic filter clogging indicator lamp
Economic PTO indicator lamp
Low hydraulic pressure switch
Engine speed sensor
Forward speed sensor
Rear PTO sensor
4 WD and differential lock sensor
Start relay
Rear PTO brake solenoid valve
Rear PTO, power take-off selector
PTO stop switch
Economic PTO switch
Rev counter - hourmeter
Dynashift control lever
Hare / Tortoise switch
High pressure filter clogging indicator lamp
Temperature switch
Low pressure 3 bar pressure switch
Selector cover ground
To linkage control harness
To Lifting / Neutral / Lowering, linkage control
switch
Issue 1
May 2001
56
57
58
59
60
61
Abbreviations
Example: TB.A4: terminal 4 of connector A on the
dashboard
Fig. 1
Autotronic 2 - Description
11A01.11
36
14
61
44
4
45
13
12
11
15
c49
10
Fus.
7,5A
57
16
17
Fus.
15A
53
18
19
9
54
20
C31
62
21
56
43
22
C30
F
25
53
D
C
B
A
B.emb.B
B.emb.N
C31
14
58
13
41
C30
25
24
D
7
VI
42
59
26
40
23
23
56
27
F7
O
55
D
8
C60
C
28
B
35
50
51
37
38
60
34
C42
VI
33
31
32
VI
C4
VI
TBA17
30
29
18
46
49
52
47
Issue 1
May 2001
48
Parts list
Fig. 1
CONTENTS
A.
B.
Issue 1
May 2001
A . Test procedure
This procedure allows to check for the proper operation
of the Autotronic 2 unit as well as solving the most
straightforward failures.
The tester or Wintest software shall be used for more
complex cases.
Issue 1
May 2001
3 . Differential lock
Engine idling
With the 4 WD indicator lamp lit.
- Press the differential lock button, the differential lock
indicator lamp lights.
- Press the differential lock button again, the differential
lock indicator lamp goes out.
- Disengage the front axle.
- Drive at 4 kph and engage the differential lock. The 4
WD engages.
- Place the Linkage Control switch in high position, then
in lowering position (not in Neutral), the differential
lock indicator lamp goes out, then re-lights.
- Turn the tractor in a tight circle, engage the differential
lock, you can feel the jerk as it engages and disengages
and the rear tyres skid.
- Check that the differential lock disengages when the
forward speed exceeds 14 kph.
- The differential lock disengages but does not engage
again when right or left braking is applied.
These tests show that:
- the supply to the switches is correct.
- the differential lock button is working correctly.
- the differential lock indicator lamp is working correctly.
- the solenoid valve is correctly wired and operating.
- the differential lock is also functioning.
- the speed sensor is functioning and the Autotronic
unit is correctly reacting.
5 . 4 WD
Engine idling
4 WD indicator lamp lit
- Press the 4 WD button: the 4 WD indicator lamp
should go out.
- Press the differential lock button: the 4 WD and
differential lock indicator lamps light up at the same
time.
- Successively disengage the 4 WD and the differential
lock, the two indicator lamps should go out.
- Drive the tractor at approximately 4 kph. Turn in a
circle using maximum steering lock.
Engage and disengage the 4 WD several times. When
the 4 WD is engaged you should see the front wheels
skid and feel a jerk with the engagement and
disengagement.
- With the front axle disengaged, when braking using
both pedals the front axle should engage.
- With the front axle disengaged, when braking using
one or other of the pedals the front axle should not
engage.
- Drive at less than 14kph. Press the 4WD button more
than 2seconds. The 4 WD remains engaged regardless
of the speed
- Drive at less than 14 kph. Press the 4 WD button
shortly. The front axle should be:
. engaged below 14 kph
. disengaged above 14 kph.
- Drive above 14 kph. Press the 4 WD button shortly.
The 4 WD remains engaged regardless of the speed.
11A02.3
Issue 1
May 2001
8 . Power take-off
Engine idling
Using the 540/1000 rpm or 750 / 1000 rpm control in the
cab.
- Place the PTO lever in the 1000 rpm position.
- Engage the PTO.
- The PTO 1000 rpm indicator lamp lights up on the
dashboard.
- The PTO shaft should begin turning.
- Stop the PTO.
- Place the PTO lever in the 540 rpm or 750 rpm position.
- Engage the PTO.
- The PTO 540 rpm or 750 rpm indicator lamp lights up
on the dashboard.
- Also check that at 1900 rpm, the economic PTO is
triggered.
- If the engine is stopped with the PTO engaged, the PTO
indicator lamp flashes on start-up and the PTO is not
engaged.
- Engage the PTO and press the "Stop PTO" switch
located on the rear wings. The PTO should stop.
These tests show that :
- the PTO switches are correctly wired
- the PTO indicator lamps are correctly wired
- the PTO solenoid valve is correctly wired
- the engine speed sensor and the TCU are operating
- the "Stop PTO" switch is operating.
Issue 1
May 2001
11 . Dynashift
Engine idling, tractor stopped, temperature above
0 C
- Move the Dynashift lever from A to D.
- Check that the four Dynashift indicator lamps light in
each corresponding position of the lever.
Tractor moving
- Select each Dynashift ratio one by one and check that
the speed increases or decreases.
These tests show that :
- the lever is correctly wired and that its supply is correct
- the indicator lamps are connected correctly
- the temperature sensor is connected
- the solenoid valves are correctly connected and that
the Autotronic unit is reacting correctly.
If only the D ratio can be obtained, check the supply to
the lever.
11A02.5
Issue 1
May 2001
11A02.6
Supply (1)
Igni- Engition
ne
switch runon ning
No
No
Disconnect connector F
(black)
Connect a 55W lamp
between:
Hydraulic
pressure
(2)
No
No
Yes
No
Disconnect connector A
(black)
D7 and ground, R =
D7 and ground, R = 0
No
Yes
No
No
Disconnect connector C
(green)
Switch
Yes
No
Disconnect connector B
(grey)
Solenoid
valve
Yes
Yes
U = 0 V, switch released
U = 12 V, switch pressed
Stop
light switch
(4)
Yes
No
Issue 1
If value incorrect
check 15A fuse
(battery)
No
No
Differential
lock
(3)
Indicator
lamp
Remarks
pedals connector A
(black) and F (black)
If value incorrect
check fuse F10
May 2001
Igni- Engition
ne
switch runon
ning
4 WD (5)
Indicator
lamp
No
No
Disconnect connector A
(black)
A5 and + battery = 4 WD
indicator lamp lights
Switch
Yes
No
Disconnect connector B
(grey)
Solenoid
valve
Yes
Yes
Disconnect solenoid ,
valve, connect 55 W
to the connector.
Engage and disengage
the 4 WD
Lifting
/ Lowering
linkage
control
switch (6)
Yes
Yes
Disconnect connector B
(grey)
No
No
Disconnect connector C
(green)
Switch
Yes
No
Disconnect connector C
(green)
Solenoid
valve
Yes
Yes
No
No
Disconnect connector A
(black)
Yes
No
Disconnect connector B
(grey)
Hare/
Tortoise(7)
Indicator
lamp
Power takeoff(8)
Indicator
lamp
Switch
Issue 1
11A02.7
Remarks
If value incorrect,
check fuse F10
If value incorrect
check fuse F12
If value incorrect
check fuse F12
May 2001
11A02.8
Functions
Power
take-off (8)
PTO Stop
switch
Igni- Engition
ne
switch runon
ning
Yes
No
Disconnect connector B
(grey)
B3 and ground, U = 12 V
switch released
B3 and ground, U = 0 V,
switch pressed
Yes
Yes
U = 0 V, PTO de-clutched
U = 12 V, PTO engaged
No
No
Disconnect connector D
(maroon)
Forward
speed
No
No
Disconnect connector D
(maroon)
Engine
No
No
Disconnect connector D
(maroon)
No
No
Disconnect connector A
(black)
Yes
No
Disconnect connector A
(black)
Place lever in range to be
checked and check voltage
between A19 then A21
and ground
Electrovalve
Speed
sensor (9)
Power
take-off
Dynashift
(10)
Indicator
lamp
Lever
Solenoid
valve
Yes
Tempe
rature
sensor
No
Issue 1
Yes
No
Disconnect connector F
(black)
May 2001
Remarks
A
B
C
D
A19
0V
12 V
12 V
12 V
A20
12 V
12 V
0V
0V
A
B
C
D
EV1
12 V
12 V
0V
0V
EV2
0V
12 V
12 V
0V
A21
0V
12 V
12 V
0V
between F2 & F3 :
- R < 10 K if temp > 0C
- R < 10 K if temp < 0C
If voltage = 0V
in all lever positions,
check power supply
to lever (orange wire,
fuse F8)
Autotronic 3 - Description
11A03.1
11 A03 Description
CONTENTS
A.
General ________________________________________
B.
C.
D.
14
E.
18
F.
19
G.
21
H.
25
I.
29
J.
31
K.
32
Issue 1
May 2002
Autotronic 3 - Description
A . General
Parst list
(1)
(2)
(3)
(4)
1
2
3
P/N : 3791899F91
N/Y : 3 7M 700 FM
S/Y : 3 7M 701 FM
SERIAL N : 10000001
TESTER
B4 397
MADE IN UK
Fig. 1
Issue 1
May 2002
Note : Whatever the mode, if the battery tension is upper than 16 V, the Autotronic 3 functions are lock,
only the power shuttle is working.
Autotronic 3 - Description
11A03.3
AUTOTRONIC 3 OFF
+ AC = 0
- + AC = 0
- engine speed = 0
- low pressure = 0
<
TCU 6
+ AC = 12 V wrong parameters
<
STANDBY MODE
Indicator lamps
AC / BD
flash alternately
<
+ AC = 12 V
clutch pedal low
switch signal
<
<
+AC = 12 V
and parameters
OK
<
TCU 1
<
ALARM MODE
<
Alarm delay
of
6 seconds
PTO Alarm
all functions
locked except
Power Shuttle
TCU 0
TCU 5
<
<
<
<
WORKING MODE
<
<
<
TCU 3
Issue 1
<
Work delay
of
4 seconds
May 2002
TCU 4
Issue 1
Autotronic 3 - Description
May 2002
Autotronic 3 - Description
11A03.5
Functions
Driver action
Creeper unit
Issue 1
May 2002
Autotronic 3 - Description
Driver action
4 WD
Presses both
simultaneously.
brake
pedals
Issue 1
May 2002
Autotronic 3 - Description
Functions
Driver action
11A03.7
Differential lock
Issue 1
May 2002
Autotronic 3 - Description
Driver action
Dynashift
Normale
version
Lamp
12 V
12 V
12 V
12 V
EV1
12 V
12 V
0V
0V
EV2
0V
12 V
12 V
0V
Issue 1
May 2002
Autotronic 3 - Description
Functions
Dynashift (continued)
Normale
version
Driver action
11A03.9
Issue 1
May 2002
Autotronic 3 - Description
Driver
actions
Automatic response
of Autotronic 3
Problems and
possible causes
Dynashift (continued)
Speed Matching
version
Switch in OFF
position
Switch in ON
position
Issue 1
Select a Dynashift
speed
The Autotronic 3
operates in normal
Dynashift
Autotronic Dynashift
deactived (operation in
Normal mode
May 2002
Autotronic 3 - Description
Functions
Driver
actions
Automatic response
of Autotronic 3
11A03.11
Problems and
possible causes
Dynashift (continued)
Autodrive version
Switch in OFF
position
Switch in ON 1
Power Mode
position
Switch in ON 2
Eco Mode
postion
Selects a Dynashift
speed
Selects a creeper
speed
Automatic Dynashift
deactivated (operation in
Normal mode)
Issue 1
May 2002
Autotronic 3 - Description
Functions
Driver action
Issue 1
May 2002
Autotronic 3 - Description
Functions
Power Shuttle
11A03.13
Driver action
Issue 1
May 2002
Autotronic 3 - Description
11A03.14
Block diagram
9
10
5
1
7
Parts list
(6)
(7)
(8)
(9)
(10)
(1) Switch
- two position for Speed Matching
- three position for Autodrive
(2) Accelerator pedal potentiometer
(3) Dashboard indicator lamps
(4) Autotronic 3
(5) Speed sensors:
. progressive speed
. forward speed
. effective engine speed
Issue 1
Fig. 2
May 2002
Autotronic 3 - Description
11A03.15
AUTO
Parts list
(1) Indicator lamps
(2) OFF position: no automation, both indicator lamps
are out. The Dynashift operates in Normal mode.
(3) ON position: the Dynashift operates in Speed
Matching mode, both indicator lamps are lit.
1
2
Fig. 3
User action
Autotronic 3 control
parameter
Autotronic 3 action
on the Dynashift ratio
R1<R2
R1>R2
Speed Vr
decrease
Speed Vr
stable
Speed Vr
increase
Or
Speed Vr
decrease
Speed Vr
stable
Speed Vr
increase
Or
Issue 1
May 2002
Autotronic 3 - Description
Operation of Autodrive
The Autodrive version of the Autotronic 3 handles the
automatic changing of Dynashift speeds during engine
gear shifts. Two operating modes are available: the
Power mode and the Eco mode. In Eco mode the
changing of Dynashift speeds is carried out at engine
speeds lower than those of the Power mode.
The Autodrive version is controlled by the three-position
switch located on the right-hand armrest (Fig. 4)
5
2
AUTO
Parts list
(1) Indicator lamp 1 (Autodrive Power mode)
(2) Indicator lamp 2 (Autodrive Eco mode)
(3) OFF position: Speed Matching operation, both indicator lamps are out.
(4) ON 1 position: Autodrive Power mode, indicator
lamp 1 is lit
(5) ON 2 position: Autodrive Eco mode, indicator lamp
2 is lit
The Autodrive operates with information from:
- the real engine speed sensor located on the right-hand
side hydraulic cover
- the potentiometer located beneath the acceleration
pedal, its data permits a calculation of the design
engine speed.
Note. In Autodrive mode, the Speed Matching function is always active and overrides the Autodrive
function as soon as a mechanical gear change is
made.
Issue 1
May 2002
1
3
Fig. 4
Autotronic 3 - Description
Increase in
Dynashift
ratios
+
Decrease in
Dynashift
ratios
-
11A03.17
Decrease in
Dynashift
ratios
Vmr < 0,8 Vmt
1200 < Vmt
Vmt > 2100
< 2100
Vmr < 1680
Vmr
1000
Increase in
Dynashift
ratios
+
1200
1400
1600
1800
Decrease in
Dynashift
ratios
-
2000
2200
2400
Decrease in
Dynashift
ratios
-
2400
2200
2000
1800
1600
1400
1200
1000
800
800
Vmr
1000
1200
1400
1600
1800
Issue 1
2000
2200
2400
May 2002
Autotronic 3 - Description
Preliminary operations
1. Start the engine. Put on the handbrake.
2. Place the gear and reverse shuttle levers in neutral
position.
3. The power take off must be disengaged.
Calibration
The calibration is carried out in two successive steps so
as to determine the minimum and maximum engine
speeds in relation to the pedal.
4. Set the engine speed to 1200 rpm 100 rpm using the
hand throttle.
5. Press and hold down the differential lock switch.
The buzzer sounds (after approximately 2 seconds)
indicating the end of the first calibration phase. Release the differential lock switch.
6. Increase the engine speed to 2100 rpm 100 rpm
using the hand throttle.
7. Press and hold down the differential lock switch.
The buzzer sounds (after approximately 2 seconds)
indicating the end of the second calibration phase.
Release the differential lock switch.
Issue 1
May 2002
Potentiometer errors
In the case of a potentiometer fault, short circuit or open
circuit, the Autotronic 3 locks the operation of the AutoDrive and flashes the Dynashift indicator lamp.
If the engine speed is less than 1200 rpm :
- the Dynashift indicator lamp corresponding to the ratio
lower than the one engaged flashes (example: B range
engaged, indicator lamp B is lit and indicator lamp A
flashes).
If the engine speed is greater than 2100 rpm :
- the Dynashift indicator lamp corresponding to the ratio
higher than the one engaged flashes (example: B range
engaged, indicator lamp B is lit and indicator lamp C
flashes).
Autotronic 3 - Description
11A03.19
4
Fig. 5
Parts list
(1)
(2)
(3)
(4)
(5)
Issue 1
May 2002
Autotronic 3 - Description
USE
- Start-up
and / or
- Power Shuttle shifting
OPERATING CONDITIONS
- Speed below 2 kph
AUTOTRONIC 3 ACTIONS
Without pedal signal
- Automatic pressure increase in clutch limited to 3
bar
Issue 1
May 2002
Autotronic 3 - Description
G . Calibration of the Power Shuttle
Note: The calibration of the Power Shuttle is essential
where the following components are changed:
- a Power Shuttle solenoid valve or its terminals
- the Power Shuttle hydraulic control unit
- the Power Shuttle unit or one of its components
- the Autotronic 3 unit
11A03.21
Legend
A
Indicator lamp on
Preliminary operations
Note: To authorise entry into calibration mode, the
transmission oil temperature must be:
- 35 C / 45 C: the temperature is measured by the
gearbox cover sensor and can be read using Wintest or
by a direct reading of a specific dashboard display.
The direct display of the temperature on the dashboard is
carried out by reading a code from the A, B, C and D
indicator lamps of the Dynashift or Speedshift.
To enter direct read mode:
- start the engine
- place the Power Shuttle lever in neutral
- Simultaneously move the gear lever (to activate the
Hare / Tortoise switch) and the differential lock switch
- The A, B, C, D indicator lamps show the temperature
as shown in the following table.
Exiting direct read mode is only completed after the
complete shut down of the engine accompanied by the
subsequent drop of the 17 bar low pressure, or by entry
into calibration mode.
Issue 1
May 2002
Autotronic 3 - Description
11A03.22
Temperature displayed by
Wintest
D
10 C
17 C
22 C
27 C
31 C
36 C
Calibration authorised
39 C
Optimal calibration
44 C
Calibration authorised
46 C
51 C
54 C
57 C
60 C
63 C
Issue 1
May 2002
Autotronic 3 - Description
1. Bring the tractor up to temperature
Tractor stationary
- Run the engine, gear lever and Power Shuttle levers
in neutral, PTO clutch in.
- Then, move the Power Shuttle lever 10 times in
each direction, leaving the lever 5 to 10 seconds in
each position in order to bring the control unit and
solenoid valves up to the temperature of the
transmission.
- Measure and note the temperature.
Tractor moving
- Carry out Power Shuttle maneuvers every 5 to 10
seconds, in Hare range 2nd gear.
- Measure and note the temperature.
2. Place the tractor on a hard even surface, free of
obstacles for at least 3 metres.
3. The tractor must be free of any implements.
4. Stop the PTO, disengage the front axle.
5. Stop the engine.
6. Extinguish any work lights / road lights.
7. Put the gear lever and Power Shuttle lever into
neutral.
11A03.23
Automatic calibration
Note : A manual calibration may be carried out using
Wintest (see section 11F03).
8.
9.
10.
11.
12.
13.
14.
15.
16.
Issue 1
May 2002
Autotronic 3 - Description
Validation
Immediate validation after calibration
18. Without stopping the engine, set the engine speed to
1500 rpm, engage 4th gear in the Tortoise range,
Dynashift in range A or Speedshift in range C.
19. Carry out 10 Power Shuttle maneuvers, forwards /
reverse.
20. Carry out 10 Power Shuttle maneuvers, neutral to
forward and neutral to reverse.
21. Judge the quality of the shuttling which should be
deft and smooth.
Validation of an already calibrated tractor
Note: The transmission temperature must be above
20 C.
22. Put the gear lever in neutral, the power take-off must
be de-clutched, the front axle disengaged.
22. Start the engine.
23. Put the Power Shuttle lever in Forward for at least 1
minute, then at least 1 minute in the Reverse
position.
24. Put the Power Shuttle lever back into neutral.
25. Engage 4th Tortoise, Dynashift in A or Speedshift in
C, with an engine speed of 1500 rpm.
26. Carry out 10 Power Shuttle forward / reverse
maneuvers.
27. Carry out 10 Power Shuttle neutral /forward and
neutral / reverse maneuvers.
28. Judge the quality of the shuttling which should be
deft and smooth.
Note: An abrupt reaction on the 1st maneuver is
normal.
Calibration faults
Note: A fault due to the non-compliance of the
conditions required to access to or to maintain the
calibration mode is signalled by an alternate flashing
of the A, B, C, D indicator lamps.
Access to calibration mode is not provided if:
- The transmission temperature is not correct
- The engine speed is other than 1500 rpm 100
- The Tortoise range has not been engaged before
accessing calibration mode
- The Power Shuttle lever has not been positioned in the
Forward position.
29. Check that the access to calibration conditions in
operation 1 to 13 have been met.
30. Check the connections of the solenoid valves and
the tightness of the coils (tightening torque 5.4 - 8.1
Nm).
31. Check that TOC (top clutch pedal switch) is connected and correctly adjusted (see H).
Issue 1
May 2002
Autotronic 3 - Description
11A03.25
Issue 1
May 2002
Autotronic 3 - Description
11A03.26
Fault
class
Error
code
number
Autotronic 3
action on the
transmission
Forward /
Reverse
indicator
lamp
Diagnostic
indicator
lamp
Buzzer
Power Shuttle
reset after the
fault has been
cancelled
Class I
1-2
Out
Out
Lit and
remains
Sounds
Class II
7-8-910 - 23*
Forward or
Flashes
Reverse lit
rapidly
depending
on direction
selected.
Out if Power
Shuttle is in
neutral
Sounds
De-clutch
Stops
Place lever in
neutral
* Non direct
in Neutral
Class III
Issue 1
3 - 4 - 5 - Forward or Reverse
6 - 15 - 16 depending on direction
17 - 18 19 - 20 21 - 22
Forward or
Reverse
depending
on direction
selected.
May 2002
Flashes
slowly
Autotronic 3 - Description
11A03.27
Errors code
Class
Error number
displayed by
Wintest
Fault
II
107
II
108
II
109
II
110
II
123
III
203
III
204
III
205
III
206
III
215
III
216
III
217
Open circuit or short circuit to ground on bottom clutch pedal switch (BOC)
III
218
III
219
Open circuit or short circuit to ground on top clutch pedal switch (TOC)
III
220
III
221
III
222
Issue 1
May 2002
Issue 1
Autotronic 3 - Description
May 2002
Signal
Lever position
Autotronic 3 - Description
11A03.29
Cap
Circlip
Washer
Housing
Bearing
Upper spindle
Compression spring
Pin 4 x 28
Magnet support
Left torsion spring
Right torsion spring
Sliding part
Compression spring
Ferrule
Neutral switch
Printed circuit
Rubber shim
Bottom cover
M4 x 14 bolt
Washer dia. 4
Water tight cap
Plastic washer
Screw 2 x 0.5
Lever
Screw HN 4
Grower washer dia. 4
Bolt CHC H4 x 18
Pin 3 x 15
O-ring and washer
Knob
1KOhm
1KOhm
S1
24KOhm
Signal
voltage (Volts)
Up (de-clutched)
Aucun
2,5
Forward +
S1 + S2 + S3
Forward
S1 + S2
3,5
Forward -
S1 + S2 + S4
Neutral
S7
0,5
Reverse -
S5 + S6 + S4
Reverse
S5 + S6
1,5
Reverse +
S5 + S6 + S3
S2
36KOhm
2.55KOhm
10KOhm
2.4KOhm
2KOhm
S3
5
15,8KOhm
2
100KOhm
S7
2KOhm
S4
560Ohm
10KOhm
2.55KOhm
S5
2.4KOhm
1.5KOhm
12
10
11
16
13
17
14
24KOhm
34KOhm
S6
1KOhm
18
15
20
5
6
6 5 4 3 2 1
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
Switch
1
2
3
4
5
6
Connector functions
Terminal
19
28
30
21
+ 5 Volts
Signal
Ground
22
29
23
25
26
27
24
Designation
switch
5
Issue 1
May 2002
Issue 1
Autotronic 3 - Description
May 2002
Autotronic 3 - Description
11A03.31
0,7/1,2 mm
10,9
(1)
(2)
(3)
(4)
(5)
2,6/3,6 mm
3
4
5
0,3/1,0 mm
BOC adjustment
- Screw the switch so that the end of its threaded cylinder
is recessed 0.3 mm to 1 mm in its support (Fig. 7).
- Tighten the lock nut to a torque of 6 - 9 Nm.
150
130
Fig. 7
Issue 1
May 2002
K . Electrical diagram
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
Autotronic 3
Temperature sensor
Engine speed sensor
Forward speed sensor
Gearbox input speed sensor
Power take off speed sensor
Hare / Tortoise range switch
Low-pressure pressure switch (17 bar green dot)
Not used
Left stop light switch
Right stop light switch
4WD switch (connected to rep. 15)
Eco power take off switch
Power take off stop
Differential lock switch (connected to rep. 12)
Creeper unit switch
Power take off switch
Analog shuttle and Dynashift or SpeedShift switch
(depending on options)
Top of clutch switch (TOC) (connected to rep. 22)
Bottom of clutch switch (BOC)
Engine start safety switch
Clutch pedal potentiometer (connected to rep. 19)
Proportional PTO shunt
Power shuttle buzzer
Power take off solenoid valve
Differential lock solenoid valve
Reverse solenoid valve
4 WD solenoid valve
Hare/Tortoise solenoid valve
EV1 Dynashift solenoid valve
EV2 Dynashift or SpeedShift solenoid valve
(depending on option)
Forward solenoid valve
Reverse indicator lamp
Forward indicator lamp
Ratio A indicator lamp
Ratio B indicator lamp
Ratio C indicator lamp
Ratio D indicator lamp
4 WD indicator lamp
Creeper unit indicator lamp
Low pressure indicator lamp
Self-diagnostics indicator lamp
Differential lock indicator lamp
Hare range indicator lamp
540 or 1000 rpm power take off indicator lamp
(46) Hourmeter
1 clock hour = 1 hour of hourmeter from reception
of engine speed signal on
(47) Dashboard displays
(48) Speed signals to lift control harness
(49) Battery
(50) Starter motor
(51) Ignition key switch
(52) Power take off brake switch
(53) Power take off brake solenoid valve
(54) Gear lever neutral sensor
(55) Parking brake lever switch
(56) Parking brake indicator lamp
(57) Temperature switch
(58) 15 micron filter clogging switch
(59) 150 micron strainer clogging switch (open centre)
5 bar booster pressure switch (closed centre)
(60) Filter clogging or low pressure switch
(61) 540 or 1000 rpm power take off dashboard display
selector (fitted if (62) and (63) are absent)
(62) 540 or 1000 rpm power take off
and dashboard display
(63) switch (fitted with selector lever in cab)
(64) CAN connector to lift control, 16-way plug
(65) Alternator
(66) Starter relay
(67) Supply switch (12) and (15)
(68) Dynashift armrest lever (North American version
only)
(69) Ignition switch
(70) Lighting switch
(71) Throttle pedal switch
(72) Autodrive or Speed Matching switch (according
to option)
(73) Dasboard power supply
Autotronic 3 - Description
Designation of connectors
CD1C :
CD1M :
CD2 :
CD3 :
CD4A :
CD4T :
Colour codes
B
BL
BE
G
J
M
N
O
R
RO
V
Vi
:
:
:
:
:
:
:
:
:
:
:
:
Black
Blue
Beige
Grey
Yellow
Brown
Black
Orange
Red
Pink
Green
Violet
C
F
: Light
: Dark
Issue 1
May 2002
Autotronic 3 - Description
11A03.33
52
R
CD4A
CD4T
23
32
31
30
29
28
27
26
25
53
Fig. 8
Issue 1
May 2002
K . Electrical diagram
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
Autotronic 3
Temperature sensor
Engine speed sensor
Forward speed sensor
Gearbox input speed sensor
Power take off speed sensor
Hare / Tortoise range switch
Low-pressure pressure switch (17 bar green dot)
Not used
Left stop light switch
Right stop light switch
4WD switch (connected to rep. 15)
Eco power take off switch
Power take off stop
Differential lock switch (connected to rep. 12)
Creeper unit switch
Power take off switch
Analog shuttle and Dynashift or SpeedShift switch
(depending on options)
Top of clutch switch (TOC) (connected to rep. 22)
Bottom of clutch switch (BOC)
Engine start safety switch
Clutch pedal potentiometer (connected to rep. 19)
Proportional PTO shunt
Power shuttle buzzer
Power take off solenoid valve
Differential lock solenoid valve
Reverse solenoid valve
4 WD solenoid valve
Hare/Tortoise solenoid valve
EV1 Dynashift solenoid valve
EV2 Dynashift or SpeedShift solenoid valve
(depending on option)
Forward solenoid valve
Reverse indicator lamp
Forward indicator lamp
Ratio A indicator lamp
Ratio B indicator lamp
Ratio C indicator lamp
Ratio D indicator lamp
4 WD indicator lamp
Creeper unit indicator lamp
Low pressure indicator lamp
Self-diagnostics indicator lamp
Differential lock indicator lamp
Hare range indicator lamp
540 or 1000 rpm power take off indicator lamp
(46) Hourmeter
1 clock hour = 1 hour of hourmeter from reception
of engine speed signal on
(47) Dashboard displays
(48) Speed signals to lift control harness
(49) Battery
(50) Starter motor
(51) Ignition key switch
(52) Power take off brake switch
(53) Power take off brake solenoid valve
(54) Gear lever neutral sensor
(55) Parking brake lever switch
(56) Parking brake indicator lamp
(57) Temperature switch
(58) 15 micron filter clogging switch
(59) 150 micron strainer clogging switch (open centre)
5 bar booster pressure switch (closed centre)
(60) Filter clogging or low pressure switch
(61) 540 or 1000 rpm power take off dashboard display
selector (fitted if (62) and (63) are absent)
(62) 540 or 1000 rpm power take off
and dashboard display
(63) switch (fitted with selector lever in cab)
(64) CAN connector to lift control, 16-way plug
(65) Alternator
(66) Starter relay
(67) Supply switch (12) and (15)
(68) Dynashift armrest lever (North American version
only)
(69) Ignition switch
(70) Lighting switch
(71) Throttle pedal switch
(72) Autodrive or Speed Matching switch (according
to option)
(73) Dasboard power supply
Autotronic 3 - Description
Designation of connectors
CD1C :
CD1M :
CD2 :
CD3 :
CD4A :
CD4T :
Colour codes
B
BL
BE
G
J
M
N
O
R
RO
V
Vi
:
:
:
:
:
:
:
:
:
:
:
:
Black
Blue
Beige
Grey
Yellow
Brown
Black
Orange
Red
Pink
Green
Violet
C
F
: Light
: Dark
Issue 1
May 2002
Autotronic 3 - Description
11A03.35
51
1
CD4A
CD3
CD4T
6
Fig. 9
Issue 1
May 2002
K . Electrical diagram
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
Autotronic 3
Temperature sensor
Engine speed sensor
Forward speed sensor
Gearbox input speed sensor
Power take off speed sensor
Hare / Tortoise range switch
Low-pressure pressure switch (17 bar green dot)
Not used
Left stop light switch
Right stop light switch
4WD switch (connected to rep. 15)
Eco power take off switch
Power take off stop
Differential lock switch (connected to rep. 12)
Creeper unit switch
Power take off switch
Analog shuttle and Dynashift or SpeedShift switch
(depending on options)
Top of clutch switch (TOC) (connected to rep. 22)
Bottom of clutch switch (BOC)
Engine start safety switch
Clutch pedal potentiometer (connected to rep. 19)
Proportional PTO shunt
Power shuttle buzzer
Power take off solenoid valve
Differential lock solenoid valve
Reverse solenoid valve
4 WD solenoid valve
Hare/Tortoise solenoid valve
EV1 Dynashift solenoid valve
EV2 Dynashift or SpeedShift solenoid valve
(depending on option)
Forward solenoid valve
Reverse indicator lamp
Forward indicator lamp
Ratio A indicator lamp
Ratio B indicator lamp
Ratio C indicator lamp
Ratio D indicator lamp
4 WD indicator lamp
Creeper unit indicator lamp
Low pressure indicator lamp
Self-diagnostics indicator lamp
Differential lock indicator lamp
Hare range indicator lamp
540 or 1000 rpm power take off indicator lamp
(46) Hourmeter
1 clock hour = 1 hour of hourmeter from reception
of engine speed signal on
(47) Dashboard displays
(48) Speed signals to lift control harness
(49) Battery
(50) Starter motor
(51) Ignition key switch
(52) Power take off brake switch
(53) Power take off brake solenoid valve
(54) Gear lever neutral sensor
(55) Parking brake lever switch
(56) Parking brake indicator lamp
(57) Temperature switch
(58) 15 micron filter clogging switch
(59) 150 micron strainer clogging switch (open centre)
5 bar booster pressure switch (closed centre)
(60) Filter clogging or low pressure switch
(61) 540 or 1000 rpm power take off dashboard display
selector (fitted if (62) and (63) are absent)
(62) 540 or 1000 rpm power take off
and dashboard display
(63) switch (fitted with selector lever in cab)
(64) CAN connector to lift control, 16-way plug
(65) Alternator
(66) Starter relay
(67) Supply switch (12) and (15)
(68) Dynashift armrest lever (North American version
only)
(69) Ignition switch
(70) Lighting switch
(71) Throttle pedal switch
(72) Autodrive or Speed Matching switch (according
to option)
(73) Dasboard power supply
Autotronic 3 - Description
Designation of connectors
CD1C :
CD1M :
CD2 :
CD3 :
CD4A :
CD4T :
Colour codes
B
BL
BE
G
J
M
N
O
R
RO
V
Vi
:
:
:
:
:
:
:
:
:
:
:
:
Black
Blue
Beige
Grey
Yellow
Brown
Black
Orange
Red
Pink
Green
Violet
C
F
: Light
: Dark
Issue 1
May 2002
Autotronic 3 - Description
11A03.37
CD4T
CD4A
51
54
56
55
CD3
CD4A
60
CD3
57
58
59
Issue 1
Fig. 10
May 2002
K . Electrical diagram
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
Autotronic 3
Temperature sensor
Engine speed sensor
Forward speed sensor
Gearbox input speed sensor
Power take off speed sensor
Hare / Tortoise range switch
Low-pressure pressure switch (17 bar green dot)
Not used
Left stop light switch
Right stop light switch
4WD switch (connected to rep. 15)
Eco power take off switch
Power take off stop
Differential lock switch (connected to rep. 12)
Creeper unit switch
Power take off switch
Analog shuttle and Dynashift or SpeedShift switch
(depending on options)
Top of clutch switch (TOC) (connected to rep. 22)
Bottom of clutch switch (BOC)
Engine start safety switch
Clutch pedal potentiometer (connected to rep. 19)
Proportional PTO shunt
Power shuttle buzzer
Power take off solenoid valve
Differential lock solenoid valve
Reverse solenoid valve
4 WD solenoid valve
Hare/Tortoise solenoid valve
EV1 Dynashift solenoid valve
EV2 Dynashift or SpeedShift solenoid valve
(depending on option)
Forward solenoid valve
Reverse indicator lamp
Forward indicator lamp
Ratio A indicator lamp
Ratio B indicator lamp
Ratio C indicator lamp
Ratio D indicator lamp
4 WD indicator lamp
Creeper unit indicator lamp
Low pressure indicator lamp
Self-diagnostics indicator lamp
Differential lock indicator lamp
Hare range indicator lamp
540 or 1000 rpm power take off indicator lamp
(46) Hourmeter
1 clock hour = 1 hour of hourmeter from reception
of engine speed signal on
(47) Dashboard displays
(48) Speed signals to lift control harness
(49) Battery
(50) Starter motor
(51) Ignition key switch
(52) Power take off brake switch
(53) Power take off brake solenoid valve
(54) Gear lever neutral sensor
(55) Parking brake lever switch
(56) Parking brake indicator lamp
(57) Temperature switch
(58) 15 micron filter clogging switch
(59) 150 micron strainer clogging switch (open centre)
5 bar booster pressure switch (closed centre)
(60) Filter clogging or low pressure switch
(61) 540 or 1000 rpm power take off dashboard display
selector (fitted if (62) and (63) are absent)
(62) 540 or 1000 rpm power take off
and dashboard display
(63) switch (fitted with selector lever in cab)
(64) CAN connector to lift control, 16-way plug
(65) Alternator
(66) Starter relay
(67) Supply switch (12) and (15)
(68) Dynashift armrest lever (North American version
only)
(69) Ignition switch
(70) Lighting switch
(71) Throttle pedal switch
(72) Autodrive or Speed Matching switch (according
to option)
(73) Dasboard power supply
Autotronic 3 - Description
Designation of connectors
CD1C :
CD1M :
CD2 :
CD3 :
CD4A :
CD4T :
Colour codes
B
BL
BE
G
J
M
N
O
R
RO
V
Vi
:
:
:
:
:
:
:
:
:
:
:
:
Black
Blue
Beige
Grey
Yellow
Brown
Black
Orange
Red
Pink
Green
Violet
C
F
: Light
: Dark
Issue 1
May 2002
Autotronic 3 - Description
11A03.39
62
63
61
CD3
45
45
1000
44
43
42
41
40
39
38
R
37
36
35
34
33
24
CD3
Fig. 11
Issue 1
May 2002
K . Electrical diagram
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
Autotronic 3
Temperature sensor
Engine speed sensor
Forward speed sensor
Gearbox input speed sensor
Power take off speed sensor
Hare / Tortoise range switch
Low-pressure pressure switch (17 bar green dot)
Not used
Left stop light switch
Right stop light switch
4WD switch (connected to rep. 15)
Eco power take off switch
Power take off stop
Differential lock switch (connected to rep. 12)
Creeper unit switch
Power take off switch
Analog shuttle and Dynashift or SpeedShift switch
(depending on options)
Top of clutch switch (TOC) (connected to rep. 22)
Bottom of clutch switch (BOC)
Engine start safety switch
Clutch pedal potentiometer (connected to rep. 19)
Proportional PTO shunt
Power shuttle buzzer
Power take off solenoid valve
Differential lock solenoid valve
Reverse solenoid valve
4 WD solenoid valve
Hare/Tortoise solenoid valve
EV1 Dynashift solenoid valve
EV2 Dynashift or SpeedShift solenoid valve
(depending on option)
Forward solenoid valve
Reverse indicator lamp
Forward indicator lamp
Ratio A indicator lamp
Ratio B indicator lamp
Ratio C indicator lamp
Ratio D indicator lamp
4 WD indicator lamp
Creeper unit indicator lamp
Low pressure indicator lamp
Self-diagnostics indicator lamp
Differential lock indicator lamp
Hare range indicator lamp
540 or 1000 rpm power take off indicator lamp
(46) Hourmeter
1 clock hour = 1 hour of hourmeter from reception
of engine speed signal on
(47) Dashboard displays
(48) Speed signals to lift control harness
(49) Battery
(50) Starter motor
(51) Ignition key switch
(52) Power take off brake switch
(53) Power take off brake solenoid valve
(54) Gear lever neutral sensor
(55) Parking brake lever switch
(56) Parking brake indicator lamp
(57) Temperature switch
(58) 15 micron filter clogging switch
(59) 150 micron strainer clogging switch (open centre)
5 bar booster pressure switch (closed centre)
(60) Filter clogging or low pressure switch
(61) 540 or 1000 rpm power take off dashboard display
selector (fitted if (62) and (63) are absent)
(62) 540 or 1000 rpm power take off
and dashboard display
(63) switch (fitted with selector lever in cab)
(64) CAN connector to lift control, 16-way plug
(65) Alternator
(66) Starter relay
(67) Supply switch (12) and (15)
(68) Dynashift armrest lever (North American version
only)
(69) Ignition switch
(70) Lighting switch
(71) Throttle pedal switch
(72) Autodrive or Speed Matching switch (according
to option)
(73) Dasboard power supply
Autotronic 3 - Description
Designation of connectors
CD1C :
CD1M :
CD2 :
CD3 :
CD4A :
CD4T :
Colour codes
B
BL
BE
G
J
M
N
O
R
RO
V
Vi
:
:
:
:
:
:
:
:
:
:
:
:
Black
Blue
Beige
Grey
Yellow
Brown
Black
Orange
Red
Pink
Green
Violet
C
F
: Light
: Dark
Issue 1
May 2002
Autotronic 3 - Description
11A03.41
Dashboard information
R
46
CD3
47
48
Power supply
51
73
CD3
R
Fig. 12
Issue 1
May 2002
K . Electrical diagram
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
Autotronic 3
Temperature sensor
Engine speed sensor
Forward speed sensor
Gearbox input speed sensor
Power take off speed sensor
Hare / Tortoise range switch
Low-pressure pressure switch (17 bar green dot)
Not used
Left stop light switch
Right stop light switch
4WD switch (connected to rep. 15)
Eco power take off switch
Power take off stop
Differential lock switch (connected to rep. 12)
Creeper unit switch
Power take off switch
Analog shuttle and Dynashift or SpeedShift switch
(depending on options)
Top of clutch switch (TOC) (connected to rep. 22)
Bottom of clutch switch (BOC)
Engine start safety switch
Clutch pedal potentiometer (connected to rep. 19)
Proportional PTO shunt
Power shuttle buzzer
Power take off solenoid valve
Differential lock solenoid valve
Reverse solenoid valve
4 WD solenoid valve
Hare/Tortoise solenoid valve
EV1 Dynashift solenoid valve
EV2 Dynashift or SpeedShift solenoid valve
(depending on option)
Forward solenoid valve
Reverse indicator lamp
Forward indicator lamp
Ratio A indicator lamp
Ratio B indicator lamp
Ratio C indicator lamp
Ratio D indicator lamp
4 WD indicator lamp
Creeper unit indicator lamp
Low pressure indicator lamp
Self-diagnostics indicator lamp
Differential lock indicator lamp
Hare range indicator lamp
540 or 1000 rpm power take off indicator lamp
(46) Hourmeter
1 clock hour = 1 hour of hourmeter from reception
of engine speed signal on
(47) Dashboard displays
(48) Speed signals to lift control harness
(49) Battery
(50) Starter motor
(51) Ignition key switch
(52) Power take off brake switch
(53) Power take off brake solenoid valve
(54) Gear lever neutral sensor
(55) Parking brake lever switch
(56) Parking brake indicator lamp
(57) Temperature switch
(58) 15 micron filter clogging switch
(59) 150 micron strainer clogging switch (open centre)
5 bar booster pressure switch (closed centre)
(60) Filter clogging or low pressure switch
(61) 540 or 1000 rpm power take off dashboard display
selector (fitted if (62) and (63) are absent)
(62) 540 or 1000 rpm power take off
and dashboard display
(63) switch (fitted with selector lever in cab)
(64) CAN connector to lift control, 16-way plug
(65) Alternator
(66) Starter relay
(67) Supply switch (12) and (15)
(68) Dynashift armrest lever (North American version
only)
(69) Ignition switch
(70) Lighting switch
(71) Throttle pedal switch
(72) Autodrive or Speed Matching switch (according
to option)
(73) Dasboard power supply
Autotronic 3 - Description
Designation of connectors
CD1C :
CD1M :
CD2 :
CD3 :
CD4A :
CD4T :
Colour codes
B
BL
BE
G
J
M
N
O
R
RO
V
Vi
:
:
:
:
:
:
:
:
:
:
:
:
Black
Blue
Beige
Grey
Yellow
Brown
Black
Orange
Red
Pink
Green
Violet
C
F
: Light
: Dark
Issue 1
May 2002
Autotronic 3 - Description
11A03.43
CAN
V
M
B
P09
P10
P08
J1-36
J1-34
EHR-C
J1-35
64
J1-04
J1-01
J1-03
BL.F
M
R
P07
P03
P24
P07
P03
P24
BL.F
M
R
P03
P25
P24
M
B
R
Cnc-B
Cnc-C
Cnc-A
22
J1-01
J1-03
J1-02
P03
P25
P24
Issue 1
May 2002
Cnc-3
Cnc-2
Cnc-1
18
Fig. 13
K . Electrical diagram
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
Autotronic 3
Temperature sensor
Engine speed sensor
Forward speed sensor
Gearbox input speed sensor
Power take off speed sensor
Hare / Tortoise range switch
Low-pressure pressure switch (17 bar green dot)
Not used
Left stop light switch
Right stop light switch
4WD switch (connected to rep. 15)
Eco power take off switch
Power take off stop
Differential lock switch (connected to rep. 12)
Creeper unit switch
Power take off switch
Analog shuttle and Dynashift or SpeedShift switch
(depending on options)
Top of clutch switch (TOC) (connected to rep. 22)
Bottom of clutch switch (BOC)
Engine start safety switch
Clutch pedal potentiometer (connected to rep. 19)
Proportional PTO shunt
Power shuttle buzzer
Power take off solenoid valve
Differential lock solenoid valve
Reverse solenoid valve
4 WD solenoid valve
Hare/Tortoise solenoid valve
EV1 Dynashift solenoid valve
EV2 Dynashift or SpeedShift solenoid valve
(depending on option)
Forward solenoid valve
Reverse indicator lamp
Forward indicator lamp
Ratio A indicator lamp
Ratio B indicator lamp
Ratio C indicator lamp
Ratio D indicator lamp
4 WD indicator lamp
Creeper unit indicator lamp
Low pressure indicator lamp
Self-diagnostics indicator lamp
Differential lock indicator lamp
Hare range indicator lamp
540 or 1000 rpm power take off indicator lamp
(46) Hourmeter
1 clock hour = 1 hour of hourmeter from reception
of engine speed signal on
(47) Dashboard displays
(48) Speed signals to lift control harness
(49) Battery
(50) Starter motor
(51) Ignition key switch
(52) Power take off brake switch
(53) Power take off brake solenoid valve
(54) Gear lever neutral sensor
(55) Parking brake lever switch
(56) Parking brake indicator lamp
(57) Temperature switch
(58) 15 micron filter clogging switch
(59) 150 micron strainer clogging switch (open centre)
5 bar booster pressure switch (closed centre)
(60) Filter clogging or low pressure switch
(61) 540 or 1000 rpm power take off dashboard display
selector (fitted if (62) and (63) are absent)
(62) 540 or 1000 rpm power take off
and dashboard display
(63) switch (fitted with selector lever in cab)
(64) CAN connector to lift control, 16-way plug
(65) Alternator
(66) Starter relay
(67) Supply switch (12) and (15)
(68) Dynashift armrest lever (North American version
only)
(69) Ignition switch
(70) Lighting switch
(71) Throttle pedal switch
(72) Autodrive or Speed Matching switch (according
to option)
(73) Dasboard power supply
Autotronic 3 - Description
Designation of connectors
CD1C :
CD1M :
CD2 :
CD3 :
CD4A :
CD4T :
Colour codes
B
BL
BE
G
J
M
N
O
R
RO
V
Vi
:
:
:
:
:
:
:
:
:
:
:
:
Black
Blue
Beige
Grey
Yellow
Brown
Black
Orange
Red
Pink
Green
Violet
C
F
: Light
: Dark
Issue 1
May 2002
Autotronic 3 - Description
11A03.45
20
73
51
R
CD3
Starting
N
CD1C
66
CD1M
50
69
51
49
65
Issue 1
Fig. 14
May 2002
K . Electrical diagram
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
Autotronic 3
Temperature sensor
Engine speed sensor
Forward speed sensor
Gearbox input speed sensor
Power take off speed sensor
Hare / Tortoise range switch
Low-pressure pressure switch (17 bar green dot)
Not used
Left stop light switch
Right stop light switch
4WD switch (connected to rep. 15)
Eco power take off switch
Power take off stop
Differential lock switch (connected to rep. 12)
Creeper unit switch
Power take off switch
Analog shuttle and Dynashift or SpeedShift switch
(depending on options)
Top of clutch switch (TOC) (connected to rep. 22)
Bottom of clutch switch (BOC)
Engine start safety switch
Clutch pedal potentiometer (connected to rep. 19)
Proportional PTO shunt
Power shuttle buzzer
Power take off solenoid valve
Differential lock solenoid valve
Reverse solenoid valve
4 WD solenoid valve
Hare/Tortoise solenoid valve
EV1 Dynashift solenoid valve
EV2 Dynashift or SpeedShift solenoid valve
(depending on option)
Forward solenoid valve
Reverse indicator lamp
Forward indicator lamp
Ratio A indicator lamp
Ratio B indicator lamp
Ratio C indicator lamp
Ratio D indicator lamp
4 WD indicator lamp
Creeper unit indicator lamp
Low pressure indicator lamp
Self-diagnostics indicator lamp
Differential lock indicator lamp
Hare range indicator lamp
540 or 1000 rpm power take off indicator lamp
(46) Hourmeter
1 clock hour = 1 hour of hourmeter from reception
of engine speed signal on
(47) Dashboard displays
(48) Speed signals to lift control harness
(49) Battery
(50) Starter motor
(51) Ignition key switch
(52) Power take off brake switch
(53) Power take off brake solenoid valve
(54) Gear lever neutral sensor
(55) Parking brake lever switch
(56) Parking brake indicator lamp
(57) Temperature switch
(58) 15 micron filter clogging switch
(59) 150 micron strainer clogging switch (open centre)
5 bar booster pressure switch (closed centre)
(60) Filter clogging or low pressure switch
(61) 540 or 1000 rpm power take off dashboard display
selector (fitted if (62) and (63) are absent)
(62) 540 or 1000 rpm power take off
and dashboard display
(63) switch (fitted with selector lever in cab)
(64) CAN connector to lift control, 16-way plug
(65) Alternator
(66) Starter relay
(67) Supply switch (12) and (15)
(68) Dynashift armrest lever (North American version
only)
(69) Ignition switch
(70) Lighting switch
(71) Throttle pedal switch
(72) Autodrive or Speed Matching switch (according
to option)
(73) Dasboard power supply
Autotronic 3 - Description
Designation of connectors
CD1C :
CD1M :
CD2 :
CD3 :
CD4A :
CD4T :
Colour codes
B
BL
BE
G
J
M
N
O
R
RO
V
Vi
:
:
:
:
:
:
:
:
:
:
:
:
Black
Blue
Beige
Grey
Yellow
Brown
Black
Orange
Red
Pink
Green
Violet
C
F
: Light
: Dark
Issue 1
May 2002
Autotronic 3 - Description
11A03.47
Cab switch
12 / 15
70
51
61
13
16
CD3
17
Fig. 15
Issue 1
May 2002
K . Electrical diagram
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
Autotronic 3
Temperature sensor
Engine speed sensor
Forward speed sensor
Gearbox input speed sensor
Power take off speed sensor
Hare / Tortoise range switch
Low-pressure pressure switch (17 bar green dot)
Not used
Left stop light switch
Right stop light switch
4WD switch (connected to rep. 15)
Eco power take off switch
Power take off stop
Differential lock switch (connected to rep. 12)
Creeper unit switch
Power take off switch
Analog shuttle and Dynashift or SpeedShift switch
(depending on options)
Top of clutch switch (TOC) (connected to rep. 22)
Bottom of clutch switch (BOC)
Engine start safety switch
Clutch pedal potentiometer (connected to rep. 19)
Proportional PTO shunt
Power shuttle buzzer
Power take off solenoid valve
Differential lock solenoid valve
Reverse solenoid valve
4 WD solenoid valve
Hare/Tortoise solenoid valve
EV1 Dynashift solenoid valve
EV2 Dynashift or SpeedShift solenoid valve
(depending on option)
Forward solenoid valve
Reverse indicator lamp
Forward indicator lamp
Ratio A indicator lamp
Ratio B indicator lamp
Ratio C indicator lamp
Ratio D indicator lamp
4 WD indicator lamp
Creeper unit indicator lamp
Low pressure indicator lamp
Self-diagnostics indicator lamp
Differential lock indicator lamp
Hare range indicator lamp
540 or 1000 rpm power take off indicator lamp
(46) Hourmeter
1 clock hour = 1 hour of hourmeter from reception
of engine speed signal on
(47) Dashboard displays
(48) Speed signals to lift control harness
(49) Battery
(50) Starter motor
(51) Ignition key switch
(52) Power take off brake switch
(53) Power take off brake solenoid valve
(54) Gear lever neutral sensor
(55) Parking brake lever switch
(56) Parking brake indicator lamp
(57) Temperature switch
(58) 15 micron filter clogging switch
(59) 150 micron strainer clogging switch (open centre)
5 bar booster pressure switch (closed centre)
(60) Filter clogging or low pressure switch
(61) 540 or 1000 rpm power take off dashboard display
selector (fitted if (62) and (63) are absent)
(62) 540 or 1000 rpm power take off
and dashboard display
(63) switch (fitted with selector lever in cab)
(64) CAN connector to lift control, 16-way plug
(65) Alternator
(66) Starter relay
(67) Supply switch (12) and (15)
(68) Dynashift armrest lever (North American version
only)
(69) Ignition switch
(70) Lighting switch
(71) Throttle pedal switch
(72) Autodrive or Speed Matching switch (according
to option)
(73) Dasboard power supply
Autotronic 3 - Description
Designation of connectors
CD1C :
CD1M :
CD2 :
CD3 :
CD4A :
CD4T :
Colour codes
B
BL
BE
G
J
M
N
O
R
RO
V
Vi
:
:
:
:
:
:
:
:
:
:
:
:
Black
Blue
Beige
Grey
Yellow
Brown
Black
Orange
Red
Pink
Green
Violet
C
F
: Light
: Dark
Issue 1
May 2002
Autotronic 3 - Description
11A03.49
68
51
71
CD3
Brake information
51
11
10
Fig. 16
CD3
Issue 1
May 2002
K . Electrical diagram
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
Autotronic 3
Temperature sensor
Engine speed sensor
Forward speed sensor
Gearbox input speed sensor
Power take off speed sensor
Hare / Tortoise range switch
Low-pressure pressure switch (17 bar green dot)
Not used
Left stop light switch
Right stop light switch
4WD switch (connected to rep. 15)
Eco power take off switch
Power take off stop
Differential lock switch (connected to rep. 12)
Creeper unit switch
Power take off switch
Analog shuttle and Dynashift or SpeedShift switch
(depending on options)
Top of clutch switch (TOC) (connected to rep. 22)
Bottom of clutch switch (BOC)
Engine start safety switch
Clutch pedal potentiometer (connected to rep. 19)
Proportional PTO shunt
Power shuttle buzzer
Power take off solenoid valve
Differential lock solenoid valve
Reverse solenoid valve
4 WD solenoid valve
Hare/Tortoise solenoid valve
EV1 Dynashift solenoid valve
EV2 Dynashift or SpeedShift solenoid valve
(depending on option)
Forward solenoid valve
Reverse indicator lamp
Forward indicator lamp
Ratio A indicator lamp
Ratio B indicator lamp
Ratio C indicator lamp
Ratio D indicator lamp
4 WD indicator lamp
Creeper unit indicator lamp
Low pressure indicator lamp
Self-diagnostics indicator lamp
Differential lock indicator lamp
Hare range indicator lamp
540 or 1000 rpm power take off indicator lamp
(46) Hourmeter
1 clock hour = 1 hour of hourmeter from reception
of engine speed signal on
(47) Dashboard displays
(48) Speed signals to lift control harness
(49) Battery
(50) Starter motor
(51) Ignition key switch
(52) Power take off brake switch
(53) Power take off brake solenoid valve
(54) Gear lever neutral sensor
(55) Parking brake lever switch
(56) Parking brake indicator lamp
(57) Temperature switch
(58) 15 micron filter clogging switch
(59) 150 micron strainer clogging switch (open centre)
5 bar booster pressure switch (closed centre)
(60) Filter clogging or low pressure switch
(61) 540 or 1000 rpm power take off dashboard display
selector (fitted if (62) and (63) are absent)
(62) 540 or 1000 rpm power take off
and dashboard display
(63) switch (fitted with selector lever in cab)
(64) CAN connector to lift control, 16-way plug
(65) Alternator
(66) Starter relay
(67) Supply switch (12) and (15)
(68) Dynashift armrest lever (North American version
only)
(69) Ignition switch
(70) Lighting switch
(71) Throttle pedal switch
(72) Autodrive or Speed Matching switch (according
to option)
(73) Dasboard power supply
Autotronic 3 - Description
Designation of connectors
CD1C :
CD1M :
CD2 :
CD3 :
CD4A :
CD4T :
Colour codes
B
BL
BE
G
J
M
N
O
R
RO
V
Vi
:
:
:
:
:
:
:
:
:
:
:
:
Black
Blue
Beige
Grey
Yellow
Brown
Black
Orange
Red
Pink
Green
Violet
C
F
: Light
: Dark
Issue 1
May 2002
Autotronic 3 - Description
11A03.51
TOC information
51
N
19
CD3
51
CD3
CD 2
Fig. 17
14
Issue 1
May 2002
K . Electrical diagram
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
Autotronic 3
Temperature sensor
Engine speed sensor
Forward speed sensor
Gearbox input speed sensor
Power take off speed sensor
Hare / Tortoise range switch
Low-pressure pressure switch (17 bar green dot)
Not used
Left stop light switch
Right stop light switch
4WD switch (connected to rep. 15)
Eco power take off switch
Power take off stop
Differential lock switch (connected to rep. 12)
Creeper unit switch
Power take off switch
Analog shuttle and Dynashift or SpeedShift switch
(depending on options)
Top of clutch switch (TOC) (connected to rep. 22)
Bottom of clutch switch (BOC)
Engine start safety switch
Clutch pedal potentiometer (connected to rep. 19)
Proportional PTO shunt
Power shuttle buzzer
Power take off solenoid valve
Differential lock solenoid valve
Reverse solenoid valve
4 WD solenoid valve
Hare/Tortoise solenoid valve
EV1 Dynashift solenoid valve
EV2 Dynashift or SpeedShift solenoid valve
(depending on option)
Forward solenoid valve
Reverse indicator lamp
Forward indicator lamp
Ratio A indicator lamp
Ratio B indicator lamp
Ratio C indicator lamp
Ratio D indicator lamp
4 WD indicator lamp
Creeper unit indicator lamp
Low pressure indicator lamp
Self-diagnostics indicator lamp
Differential lock indicator lamp
Hare range indicator lamp
540 or 1000 rpm power take off indicator lamp
(46) Hourmeter
1 clock hour = 1 hour of hourmeter from reception
of engine speed signal on
(47) Dashboard displays
(48) Speed signals to lift control harness
(49) Battery
(50) Starter motor
(51) Ignition key switch
(52) Power take off brake switch
(53) Power take off brake solenoid valve
(54) Gear lever neutral sensor
(55) Parking brake lever switch
(56) Parking brake indicator lamp
(57) Temperature switch
(58) 15 micron filter clogging switch
(59) 150 micron strainer clogging switch (open centre)
5 bar booster pressure switch (closed centre)
(60) Filter clogging or low pressure switch
(61) 540 or 1000 rpm power take off dashboard display
selector (fitted if (62) and (63) are absent)
(62) 540 or 1000 rpm power take off
and dashboard display
(63) switch (fitted with selector lever in cab)
(64) CAN connector to lift control, 16-way plug
(65) Alternator
(66) Starter relay
(67) Supply switch (12) and (15)
(68) Dynashift armrest lever (North American version
only)
(69) Ignition switch
(70) Lighting switch
(71) Throttle pedal switch
(72) Autodrive or Speed Matching switch (according
to option)
(73) Dasboard power supply
Autotronic 3 - Description
Designation of connectors
CD1C :
CD1M :
CD2 :
CD3 :
CD4A :
CD4T :
Colour codes
B
BL
BE
G
J
M
N
O
R
RO
V
Vi
:
:
:
:
:
:
:
:
:
:
:
:
Black
Blue
Beige
Grey
Yellow
Brown
Black
Orange
Red
Pink
Green
Violet
C
F
: Light
: Dark
Issue 1
May 2002
Autotronic 3 - Description
11A03.53
F7
51
74
D
J1
N
C5
J1-14
J1-16J1-15
B
A
N
M
R
P26
P27
P28
P26
P27
P28
N
M
R
CD3
Fig. 18
Issue 1
May 2002
DCC / TC - Description
11B01.1
CONTENTS
A.
Description ___________________________________
B.
C.
14
D.
18
E.
21
F.
35
G.
36
H.
41
I.
42
J.
43
K.
45
L.
46
Issue 1
May 2001
DCC / TC - Description
11B01.2
11
12
13
10
14
15
10 15
8
5
20
16
25
17
RPM x 100
KPH
% RPM
MPH
1/MIN
18
GNO
SL IP
PTO
ENG
ENG
FIELD
SPO
RPM
RPM
HRS
AREA
19
20
21
22
3
23
24
38
39
40
25
37
26
A
36
35
27
28
34
29
C
33
32
30
31
Fig. 1
Issue 1
May 2001
DCC / TC - Description
A . Description
The transmission control circuit is made up of three main
components. A digital dashboard display (Display Cab
Controller, DCC), a transmission controller (Transmission Controller, TC) and a CAN network (Communications Area Network). These components are connected
via harnesses, switches, potentiometers, sensors and
solenoid valves.
Manoeuvring pedal
Gear shift lever
Turbocharging sensor
Membrane key switches
Parking brake
Front axle switch (4WD)
Differential lock switch
Power take off switch
Fuel gauge
Coolant liquid sensors
Brake switches
Engine oil pressure
Radar
Instrument status
Headlights
11B01.3
Engine speed
Shaft speed / power take off clutch
Forward speed
Transmission temperature
Gearbox hydraulic pressure
Lubricating pressure
Hydraulic pressure (17 bar)
Hydraulic filter
Calibration speed
Park Lock switch
35)
Creeper unit switch
TC output signals
(36)
(37)
(38)
(39)
(40)
Issue 1
May 2001
DCC / TC - Description
Issue 1
May 2001
DCC / TC - Description
11B01.5
10 15
5
20
25
RPM x 100
KPH
% RPM
MPH
1/MIN
4
GNO
SL IP
PTO
ENG
ENG
FIELD
SPO
RPM
RPM
HRS
AREA
1
2
SELECT WIDTH
SET
6
Fig. 2
B . DCC dashboard
Dashboard (Fig. 2)
(1)
(2)
(3)
(4)
(5)
(6)
Gauges
Liquid crystal display
Tachometer
Membrane keys
Signal lamps
Fixing screws
Issue 2
May 2002
DCC / TC - Description
K
J
H
G
F
K
J
H
G
F
A
B
C
D
E
Connector "A"
Connector "B"
Connector "C"
Connector "D"
Connector "E"
Connector "F"
A
B
C
D
E
K
J
H
G
F
A
B
C
D
E
K
J
H
G
F
(1)
(2)
(3)
(4)
(5)
(6)
A
B
C
D
E
A
B
C
D
E
F
1
K
J
H
G
F
A
B
C
D
E
K
J
H
G
F
Fig. 3
A
B
C
D
E
K
J
H
G
F
Fig. 4
Issue 2
May 2002
DCC / TC - Description
Connector A
Pin
A
B
C
D
E
F
G
H
J
K
Connector C
Description
Battery ground
+ 12 V after contact
Signal to coolant level sensor (depending on options)
Turbocharging pressure sensor ground
Turbocharging pressure sensor + 5 V supply
Turbocharging pressure sensor input signal 0.8 V - 4.2 V
Not used
Not used
Not used
+ 12 V battery
F
G
H
J
K
Pin
A
B
C
D
E
F
G
H
J
K
Connector E
Description
Not used
Not used
12 V left brake switch input
12 V right brake switch input
Input signal to fuel level sensor, 0 V - 12 V
Input signal to coolant liquid temperature, 0 V - 12 V
Rear power take off switch input, 12 V
Rear power take off brake switch input, 12 V
Wing-mounted power take off emergency stop switch input, 12 V
Not used
Connector D
Connector B
Pin
A
B
C
D
E
11B01.7
Description
5 V supply to clutch potentiometer
Input signal to clutch potentiometer, 0.8 V - 4.2 V
5 V supply to armrest speed Up / Down potentiometer
5 V supply to steering wheel lever potentiometer
Input signal to steering wheel gear shift lever potentiometer
(0.8 V - 4.2 V)
Ground for steering wheel gear shift lever potentiometer
Pressure switch (0 V - 12 V)
Input signal to armrest speed Up / Down potentiometer (0.8 V
- 4.2 V)
Ground for armrest speed Up / Down potentiometer
Ground for top-of-clutch (TOC) potentiometer
Pin
A
B
C
D
E
F
G
H
J
K
Description
12 V differential lock switch input
12V 4WD switch momentary input
12 V parking brake switch input
Buzzer output signal, 12 V
Not used
Not used
Not used
Input to N.C. terminal of steering wheel Neutral lever switch
Input to N.O. terminal of steering wheel Neutral lever switch
Input to headlight selector, 12 V
Connector F
Description
CAN signal (Hi)
CAN network ground
Input to N.O. terminal of armrest Neutral switch, 12 V
Input to top-of-clutch switch (TOC) 12 V
Radar input signal
Input to N.O. terminal of bottom-of-clutch switch (BOC) 12 V
Input to N.C. terminal of bottom-of-clutch switch (BOC) 12 V
Not used
Input to N.C. terminal of armrest Neutral switch, 12 V
CAN signal (Low)
Note :
- N.O. = Normally open
- N.C. = Normally closed
Issue 1
Pin
A
B
C
D
E
F
G
H
J
K
May 2001
Pin
A
B
C
D
E
F
G
H
J
K
Description
12 V main beam switch input
12 V left direction indicator switch input
12 V right direction indicator switch input
12 V 1st trailer switch input V
12 V 2nd trailer switch input
open / grounded air filter switch input
Not used
Not used
12 V linkage position switch input
12 V linkage position switch input
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
Battery
Electronic linkage supply
Steering wheel Neutral switch
To alternator
Starter
Cab relay
To cab harness
Electronic linkage - Supply
Armrest Neutral switch
Park Lock switch
Not used
Linkage harness connector
Power take off emergency stop switch (on rear
wing)
Creeper unit switch
4WD and differential lock switch
Armrest lighting
Speeds Up / Down armrest potentiometer
To water temperature sensor
Rear power take off switch
Engine oil pressure switch
Turbocharging pressure sensor
DCC dashboard
Radiator water level sensor (8270 - 8280)
Fuel gauge
Lighting signal lamps
Air filter vacuum sensor
Lighting switch
To main beam / dipped beam toggle
To connector C60
To dashboard switch
To work lights relay
To connector C2
Buzzer
- continuous: parking brake on
- intermittent: warning / fault
Parking brake switch
CAN network plug
Top of clutch switch (TOC) and potentiometer
Forward / Reverse potentiometer on steering wheel
Safety switch
Starter switch
Not used
Right brake switch
Left brake switch
BOC clutch switch
To stop lights
Time delay relay (if not fitted is replaced by 15 A
fuse)
Electronic transmission control unit (TC)
DCC / TC - Description
Colour code
(47)
(48)
(49)
(50)
(53)
B
BE
BL
G
J
M
N
R
Ro
S
V
VI
=
=
=
=
=
=
=
=
=
=
=
=
C
F
= Light
= Dark
(54)
(55)
(56)
(57)
(58)
(59)
(61)
(62)
(63)
(64)
(65)
(66)
(67)
(68)
Solenoid valves
(79)
(80)
(81)
(82)
(83)
(84)
(85)
(86)
(87)
(88)
(89)
(90)
(91)
(92)
Issue 1
May 2001
White
Beige
Blue
Grey
Yellow
Brown
Black
Red
Pink
Salmon
Green
Violet
emb. = End
DCC / TC - Description
10
11B01.9
16
9
14
17
15
5
2
18
4
11
19
12
47
48
49
50
20
13
21
53
54
23
55
56
57
58
59
36
44
41
45
37
42
35
24
61
62
22
63
64
65
66
67
43
34
25
68
33
26
38
31
30
29
39
40
28
27
32
Fig. 5
46
Issue 1
May 2001
Issue 1
DCC / TC - Description
May 2001
DCC / TC - Description
11B01.11
1
2
10
11
12
13
14
Fig. 6
Issue 2
May 2002
DCC / TC - Description
Ratio selected
Creeper unit signal lamp
Pre-selected ratios
Automatic 4WD signal lamp
Direction of movement:
F : Forward
R : Reverse
N : Neutral
P : Park Lock
(6) Display of DCC / TC information (program versions,
error codes)
(7) Display of:
- forward speed
- wheel slippage
- power take off speed
- engine speed
- total engine hours
- worked area
- diagnostics functions
The DCC digital display comprises two parts. The upper
part displays the data relating to the changing of speeds,
error data / parameters / diagnostics, 4WD and creeper
unit status.
The lower part displays the engine speed, the power take
off, the percentage of wheel slip, the forward speed, total
engine hours, the worked area and error data / diagnostics / parameters. The digital display cannot be repaired
and must be replaced as an entire unit along with the
DCC.
Issue 2
May 2002
KPH
RPM
% MPH
1/MIN
Fig. 7
DCC / TC - Description
11B01.13
Fuel gauge
Engine oil pressure
Engine temperature
Tachometer
10 15
5
20
25
RPM x 100
KPH
% RPM
MPH
L/MIN
GNO
SL IP
PTO
ENG
ENG
FIELD
SPO
RPM
RPM
HRS
AREA
Warning buzzer
SELECT WIDTH
SET
Fig. 8
Issue 2
May 2002
DCC / TC - Description
The bottom of clutch switch (BOC)
Issue 2
May 2002
DCC / TC - Description
11B01.15
1
NF
NO
NF
NO
Fig. 8A
TC : B/B
DCC : D/J
DCC : D/C
DCC : E/H
DCC : D/G
DCC : E/J
BOC
NO NF
+ 12 V
Note: When the clutch pedal is fully pressed (disengaged position), the power supply to the Neutral
switches is cut and the DCC D/G input is 0 V.
Issue 1
May 2001
DCC / TC - Description
engine air intake pipe between the air filter and the inlet
manifold. It is a normally closed type switch that opens
when air filter clogging creates a vacuum of 635 mm of
water, this lights the air filter clogging signal lamp.
Issue 1
May 2001
DCC / TC - Description
The DCC is equipped with six membrane keys. Three of
them are used by the operator to select the different
display modes and the three others allow qualified
personnel to carry out calibration and diagnostics operations.
Key (3)
- Select total engine hours or worked area
- Modify a selected number
- Delete the worked area data
Key (4)
- Select the different calibration values available
Key (5)
- Display the current calibration value
- Select Diagnostics mode
Key (6)
- Decrement one level in the current calculator value
- Exit the calibration level
GNO
SL IP
PTO
ENG
ENG
FIELD
SPO
RPM
RPM
HRS
AREA
SELECT WIDTH
11B01.17
SET
Fig. 9
Keys (4) and (5)
- Enter level 1 calibration
. transmission calibration
. turbocharging pressure calibration
Keys (5) and (6)
- Enter level 2 calibration
. gear shift lever calibration
. display DCC / TC constants
. delete saved error codes
Keys (4) and (6)
- Enter level 3 calibration
. modify DCC / TC constants.
Issue 1
May 2001
DCC / TC - Description
11B01.18
Oil pressure
0
1 bar (15 psi)
3 bar (45 psi)
5 bar (75 psi)
Resistance
10 3
47 4
116.5 5
183 7
Lower tank
sensor
Resistance in position
High
Low
Resistance in position
High
Low
1-16
220-240
1-16
110-130
Bottom resistance
340-360
Issue 1
May 2001
DCC / TC - Description
The right-hand side speed lever
potentiometer is located in the armrest. It controls
the changing up and changing down of the ratios. Its
resistance varies between 5.40 and 3.70 from
terminal E and G of the black connector, 10 wires,
located in the armrest.
11B01.19
Resistance
282 5 %
180 2.5 %
89 3 %
Issue 1
May 2001
DCC / TC - Description
Turbocharger check
The DCC controls and handles the turbocharging pressure inputs in order to calculate the degree of
turbocharging. The turbocharging pressure is detected by
the relevant sensor mounted on the engine inlet manifold. The DCC uses the signal from the sensor along with
engine speed to determine the engine charging, this is
based on a three dimensional torque table stored in
memory via the DCC program.
Each type of engine has different turbo charging characteristics. It is therefore essential that calibration of the
engine and turbocharger parameters are correctly carried
out in order to guarantee a continuous quality of gear
shifting. For parameterisation and calibration procedures,
see section 11B02.
Issue 1
May 2001
DCC / TC - Description
11B01.21
F
G
H
J
K
E
D
C
B
A
K
J
H
G
F
K
J
H
G
F
A
B
C
D
E
A
B
C
D
E
K
J
H
G
F
E
D
C
B
A
C
F
G
H
J
K
A
B
C
D
E
Fig. 10
The status of these switches and sensors it transmitted
to the DCC via the CAN network and used by the TC to
activate the gearbox, 4WD, power take off, Park Lock
and differential lock solenoid valves. The TC compensates for changes in hydraulic temperature, engine load
and engine speed in order to guarantee gear shifting of
continuous quality.
A
B
C
D
E
K
J
H
G
F
Fig. 11
Issue 1
May 2001
Issue 1
DCC / TC - Description
May 2001
DCC / TC - Description
Description of connectors
Connector A
Pin
A
B
C
D
E
F
G
H
J
K
Connector E
Connector C
Description
Solenoid valve C (+ 12 V) supply
Solenoid valve A (+ 12 V) supply
Solenoid valve B (+ 12 V) supply
Differential lock solenoid valve (+ 12 V) supply
Solenoid valve H (+ 12 V) supply
Solenoid valve L (+ 12 V) supply
Solenoid valve M (+ 12 V) supply
Solenoid valve 1 (+ 12 V) supply
Solenoid valve 2 (+ 12 V) supply
Solenoid valve R (+ 12 V) supply
Pin
A
B
C
D
E
F
G
H
J
K
Connector B
Pin
A
B
C
D
E
F
G
H
J
K
11B01.23
Description
Solenoid valve C ( - ) ground return
Solenoid valve A ( - ) ground return
Solenoid valve B ( - ) ground return
Solenoid valve 1 ( - ) ground return
Solenoid valve H ( - ) ground return
Solenoid valve L ( - ) ground return
Solenoid valve M ( - )ground return
Solenoid valve 2 ( - ) ground return
Solenoid valve R ( - ) ground return
Differential solenoid valve ( - ) ground return
Connector D
Description
Ground ( - )
+ 12 V Neutral and BOC switches return supply
Park Lock solenoid valve (+ 12 V) supply
Rear power take off solenoid valve ( - ) ground return
Park Lock solenoid valve ( - ) ground return
Power take off brake solenoid valve (+ 12 V) supply
Rear power take off solenoid valve (+ 12 V) supply
4WD solenoid valve (+ 12 V) supply
+ after contact
Ground ( - )
Issue 1
Pin
A
B
C
D
E
F
G
H
J
K
Description
CAN signal (Hi)
Not used
Not used
Not used
Not used
Park Lock switch input on rear axle
Transmission temperature and CAN (ground)
Not used
Transmission temperature input signal
CAN signal (Low)
May 2001
Pin
A
B
C
D
E
F
G
H
J
K
Description
Rear axle 17 bar pressure
Gearbox 17 bar pressure
Creeper unit switch input
Input to calibration or rear PTO clutch output
Engine speed input
Forward speed input
Not used
Speed sensors common ground
15 micron filter clogging pressure switch on rear axle input
5 bar booster pressure switch input
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
Battery
Electronic linkage supply
Steering wheel Neutral switch
To alternator
Starter
Cab relay
To cab harness
Electronic linkage - Supply
Armrest Neutral switch
Park Lock switch
Not used
Linkage harness connector
Power take off emergency stop switch (on rear
wing)
Creeper unit switch
4WD and differential lock switch
Armrest lighting
Speeds Up / Down armrest potentiometer
To water temperature sensor
Rear power take off switch
Engine oil pressure switch
Turbo charger pressure sensor
DCC dashboard
Radiator water level sensor (8270 8280)
Fuel gauge
Lighting signal lamps
Air filter vacuum sensor
Lighting switch
To main beam / dipped beam toggle
To connector C60
To dashboard switch
To work lights relay
To connector C2
Buzzer
- continuous: parking brake on
- intermittent: warning / fault
Parking brake switch
CAN network plug
Top of clutch switch (TOC) and potentiometer
Forward / Reverse potentiometer on steering wheel
Safety switch
Starter switch
Not used
Right brake switch
Left brake switch
BOC clutch switch
To stop lights
Time delay relay (if not fitted is replaced by 15 A
fuse)
Electronic transmission control unit (TC)
DCC / TC - Description
Colour code
Solenoid valves
(79)
(80)
(81)
(82)
(83)
(84)
(85)
(86)
(87)
(88)
(89)
(90)
(91)
(92)
Issue 1
May 2001
B
BE
BL
G
J
M
N
R
Ro
S
V
VI
=
=
=
=
=
=
=
=
=
=
=
=
White
Beige
Blue
Grey
Yellow
Brown
Black
Red
Pink
Salmon
Green
Violet
C
F
= Light
= Dark
emb. = End
DCC / TC - Description
79
80
81
82
83
84
85
11B01.25
86
87
88
90
89
91
92
A
B
C
D
E
F
G
H
93
94
10
46
104
103
102
101
100
99
98
97
96
95
Fig. 12
Issue 1
May 2001
Issue 1
DCC / TC - Description
May 2001
DCC / TC - Description
11B01.27
Calculator Neutral
The TC places itself in calculator Neutral and displays an
error code when certain faults are detected. This action
is designed to protect the tractor and its driver from the
consequences of certain breakdown conditions. The
following conditions lead to the TC activating calculator
Neutral:
1. Open circuit or short circuit to ground of the solenoid
valves of gearbox clutches
2. Power supply short circuit of the solenoid valves of
gearbox clutches
3. Error between the presumed current and the measured current on a gearbox clutch
4. Failure of the CAN network communications between the DCC and TC
5. Attempted re-programming while the engine is running
6. Problem in an internal circuit (protection transistor
remains open)
7. Short circuit to + 12 V on the power take off solenoid
valve
8. Park Lock engagement error
9. Problem with electrical signals from steering wheel
or armrest shuttle lever
10. Short circuit to + 12 V in lower clutch pedal switch
(BOC)
11. Fault in the parameter table
12. Neutral lever switch fault on the analog shuttle lever
13. Neutral switch fault on the armrest lever
Fig. 13
Pulse modulation diagram (Fig. 13)
V = Voltage
T = Time
A = Average voltage
Note:
- The details of each error code is explained in
section 11B03.
- To remove calculator Neutral, first correct the fault.
Then place the gear shift levers in neutral and fully
press the clutch pedal.
Issue 1
May 2001
DCC / TC - Description
Issue 1
May 2001
DCC / TC - Description
11B01.29
F2
F3
F4
F6
X
X
F8
F10
F12
F14
F18
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
R2
R3
R4
R5
R6
* R7
* R8
R1
X
X
F17
F13
F16
X
X
F9
F11
X
X
F7
F5
F15
X
X
X
X
X
X
X
X
X
X
X
X
Issue 1
May 2001
DCC / TC - Description
Fig. 14
AG 150
(1) Clutch solenoid valve "A"
(2) Clutch solenoid valve "2"
(3) Clutch solenoid valve "M"
(4) Clutch solenoid valve "H"
AG 250
(1) Clutch solenoid valve "A"
(2) Clutch solenoid valve "2"
(3) Clutch solenoid valve "M"
(4) Clutch solenoid valve "H"
2
4
Tightening torque
- Nut holding solenoid on the spool valves: 1.7 - 2.8 Nm
- Spool valve on housing: 15 - 20 Nm
Issue 1
May 2001
Fig. 15
DCC / TC - Description
Power take off control
On request from the operator the TC engages and
disengages the power take off via the DCC and the CAN
network. It also controls the engagement of the power
take off and transmits this information to the DCC which
then displays the speed and lights the power take off
signal lamp.
The TC handles the progressive engagement of the
power take off, regardless of engine speed and the load
on the output shaft. It controls a proportional solenoid
valve via pulse width modulation (PWM) in order to
obtain a linear speeding-up and down ramp right up until
full engagement.
The TC detects two power take off speed inputs, one
represents the input speed of the power take off clutch
(engine speed) and the other corresponds to the power
take off clutch output speed. These speeds are used to
determine faults in the power take off circuit.
The safety functions aimed at protecting the tractor and
the implement are as follows:
1. If the main power take off switch is active when the
engine starts, the power take off is not engaged and
the power take off signal lamp on the DCC flashes. No
error code is transmitted or displayed. To start up the
power take off, the power take off switch must first be
turned to the Off position, then placed in the On
position.
2. Protection against excessive power take off clutch
slip.
If excessive clutch slip takes place, the TC cuts the
power supply to the power take off solenoid valve and
transmits an error code 93 via the CAN network. This
leads to a flashing of the power take off signal lamp
on the DCC. Maximum permitted clutch slip is 2% for
a period of 5 minutes.
11B01.31
Issue 2
May 2002
DCC / TC - Description
KPH
RPM
% MPH
L/MIN
Fig. 16
The 4WD can be activated either automatically or manually. These modes are as follows:
Automatic mode
- On starting up the tractor, the 4WD is in automatic
mode. "A" is displayed in the upper right-hand corner of
the display. If the speed exceeds 14 kph when 4WD is
engaged then the TC disengages it. It re-engages it
when the speed drops below 13.5 kph.
Manual mode
- To leave automatic mode and enter manual mode
when the speed is less than the above described limit,
press the 4WD switch and maintain it pressed for a
period of at least 2 seconds. If the forward speed is
greater than the 4WD speed limit, pressing the 4WD
switch temporarily places the circuit in manual mode.
- When the 4WD is in manual mode it is then permanently engaged regardless of the forward speed. Simply pressing on the 4WD switch disengages the 4WD
and re-pressing it engages the 4WD again.
US mode (depending on the country)
- When the 4WD switch is pressed for a long time (15
seconds), the front axle switches to US mode. In this
case, the front axle symbol (1) on the DCC flashes.
- In this mode, the front axle only disengages when a
brake pedal is pressed. It reengages when the pedal is
released.
Issue 2
May 2002
DCC / TC - Description
11B01.33
Warning: The tractor cannot be towed unless the Park Lock solenoid valve is activated and supplied with hydraulic pressure or towed
without the Park Lock being manually removed.
Issue 1
May 2001
DCC / TC - Description
Issue 1
May 2001
DCC / TC - Description
F . Operation of solenoid valves and
test procedures
Gearbox clutch and power take off clutch
solenoid valves
The solenoids of the nine solenoid valves on the Full
Powershift gearbox and that on the power take off clutch
are identical.
These solenoids operate the proportional valves that
supply hydraulic pressure to the gearbox and the power
take off clutch in response to the supply current.
The proportional valves of the gearbox and power take off
are different.
11B01.35
Issue 1
May 2001
DCC / TC - Description
1
Fig. 17
Issue 1
May 2001
Fig. 18
DCC / TC - Description
11B01.37
2
Fig. 19
This sensor cannot be adjusted. It is held by a single bolt
and oil tightness is provided by an Oring.
This sensor can be checked using a digital multimeter.
The resistance values across the terminals of the sensor
must correspond to the values indicated in the table
below:
Digital
multimeter
connection
+
Sensor
terminal
1
value
Digital
multimeter
connection
+
Sensor
terminal
value
0.L
0.L
0.L
4.1M
14.3M
0.L
Issue 1
May 2001
DCC / TC - Description
Issue 1
May 2001
DCC / TC - Description
11B01.39
Temperature
25 C (77F)
100 C (212F)
125 C (257F)
Resistance
2820 5 %
180 2.5 %
89 3 %
Fig. 20
Issue 1
May 2001
DCC / TC - Description
11B01.40
0,7/1,2 mm
10,9
2,6/3,6 mm
2
3
4
5
0,3/1,0 mm
150
130
Fig. 21
Issue 1
May 2001
DCC / TC - Description
11B01.41
BOC adjustment
- Screw the switch so that the end of its threaded cylinder
is recessed 0.3 mm to 1 mm in its support (Fig. 21).
- Tighten the lock nut to a torque of 6 - 9 Nm.
Issue 1
May 2001
DCC / TC - Description
11B01.42
- The selector switch assembly is fitted with a mechanical locking device beneath the control button. This must
be held in position in order to move the switch from the
Park Lock position into Neutral or from Neutral into On.
- The gear shift selector switch assembly comprises:
. a selection mechanism that operates the Park Lock
. a Neutral switch
. a selection potentiometer
- It also incorporates the differential lock / 4WD switch
and the electronic linkage controls.
- If the gear shift selector switch assembly must be
disassembled, it is necessary to carry out a new
calibration of the selection potentiometer after
reassembly.
Fig. 22
Issue 1
May 2001
Signal
Lever position
DCC / TC - Description
11B01.43
1KOhm
1KOhm
S1
24KOhm
S2
36KOhm
2.55KOhm
10KOhm
Signal
voltage
(Volts)
High (declutched)
Non
2,5
Forward +
S1 + S2 + S3
Forward
S1 + S2
3,5
Forward -
S1 + S2 + S4 + S7
Neutral
S7
0,5
Reverse -
S5 + S6 +S4
Reverse
S5 + S6
1,5
Reverse +
S5 + S6 + S3
2.4KOhm
2KOhm
S3
15,8KOhm
2
100KOhm
Parts list
S7
2KOhm
S4
560Ohm
Cap
Circlips
Washer
Top cover
Bearing
Upper pin
Compression spring
4 x 28 pin
Magnet support
Left torsion spring
Right torsion spring
Moulding
Compression spring
Cups
Neutral switch
Printed circuit
Rubber wedge
Bottom cover
M4 x 14 bolt
Washer dia. 4
Water tight cap
Plastic washer
Bolt No. 2 x 0.5
Lever
Nut HN 4
Grower washer dia. 4
Bolt CHC H 4 x 18
Oring and washer
Pommel
10KOhm
2.55KOhm
S5
2.4KOhm
1.5KOhm
24KOhm
34KOhm
S6
1KOhm
4
5
6
6 5 4 3 2 1
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(29)
(30)
Switch
1
2
3
4
5
6
Connector functions
Terminal
Designation
+ 5 Volts
Signal
Ground
Fig. 22A
Issue 1
May 2001
Issue 1
DCC / TC - Description
May 2001
DCC / TC - Description
11B01.45
Fig. 23
Fig. 24
Issue 1
May 2001
DCC / TC - Description
Issue 1
May 2001
DCC / TC - Description
11B01.47
21
10
11
20
19
18
17
16
15
14
13
12
Fig. 25
Issue 1
May 2001
DCC / TC - Description
Parts list
(1) Linkage position sensor
(2) Forward speed sensor on crownwheel (fitted with
Datatronic option only)
(3) Rear axle 17 bar pressure switch (red sticker,
black / beige leads)
(4) PTO solenoid valve (black / green)
(5) PTO brake solenoid valve (black / white)
(6) Differential lock solenoid valve (black / blue)
(7) TC transmission calculator
(8) Gearbox 17 bar pressure switch (red sticker, black
/ pink leads)
(9) Clutch A solenoid valve (black / beige)
(10) Clutch 2 solenoid valve (black / green)
(11) Clutch M solenoid valve - AG 150 gearbox (black
/ brown)
Clutch H solenoid valve - AG 250 gearbox
(12) Clutch H solenoid valve - AG 150 gearbox (black
/ red)
Clutch M solenoid valve - AG 250 gearbox
(13) Forward speed sensor (black / grey)
(14) Temperature switch (black)
(15) 5-bar booster pressure switch (white / black)
(16) Park Lock solenoid valve (black / grey)
(17) Front axle solenoid valve (black / yellow)
(18) 15 micron filter clogging pressure switch (black /
blue)
(19) Linkage draft sensor
(20) PTO output shaft speed sensor (black / green / red)
(21) PTO clutch output speed sensor (black / brown)
(22) Clutch 1 solenoid valve (black / salmon)
(23) Clutch C solenoid valve (black / blue)
(24) Clutch R solenoid valve (black / violet)
(25) Clutch B solenoid valve (black / white)
(26) Intermediate speed sensor (black / red)
(27) Engine speed sensor (black / yellow)
(28) Park Lock switch (black / pink)
(29) Clutch L solenoid valve (black / pink)
(30)
Transmission oil temperature sensor
Issue 1
May 2001
DCC / TC - Description
24
25
26
11B01.49
27
23
22
30
29
19
28
Fig. 26
Issue 1
May 2001
DCC / TC - Calibration
11B02.1
11B02 Calibration
CONTENTS
A.
General ________________________________________________
B.
Level 0 _________________________________________________
C.
Level 1 _________________________________________________
D.
Level 2 _________________________________________________
E.
Level 3 _________________________________________________
17
F.
18
G.
19
Issue 1
May 2001
DCC / TC - Calibration
General
Each time an electrical component is removed or replaced, this component must be recalibrated. If this
calibration is not carried out the DCC may display an error
message indicating a condition that falls outside the
tolerances or indicating that the component has not been
calibrated. The elements that particularly require calibration are the DCC and the TC, the turbo boost pressure, the
gearbox, the gear shift potentiometers, the forward
speed sensor and the implement width.
The procedures for calibrating the DCC and TC are
divided into 4 maintenance levels numbered from 0 to 3.
6
Level 0
These calibration functions are designed for use by the
operator during normal functioning of the vehicle. They
use the membrane keys 1, 2 and 3. The 0 level calibrations include the following: forward speed, wheel slip
ratio, engine speed, PTO speed, area worked, total
engine hours, calibration of the forward speed, adjustment of the implement width and deleting of the worked
area.
Level 1
These calculation functions are designed to be used by
the operator during normal maintenance operations.
Level 1 includes calibration of the gearbox and turbo
boost pressure.
Level 2
These calibration functions are used by qualified personnel during maintenance and repairs. The level 2 calibrations include the display of DCC and TC constants, and
calibration of the armrest gear shift lever.
Level 3
These calibration functions concern factory calibration.
They are used by qualified personnel when replacing the
DCC or TC. These calibration functions include the type
of engine, gear locking, the choice of the measurement
units system, the selection of the type of gear shift lever
and modification of constants of the DCC and TC.
Issue 1
May 2001
Fig. 1
DCC / TC - Calibration
B . Level 0
11B02.3
2
SL IP
SPO
- Press
ENG
RPM
RPM
ENG
FIELD
HRS
AREA
- Press
- Press
SL IP
SPO
6
4
Fig. 1
for 4 seconds.
ENG
RPM
RPM
5. Press
FIELD
HRS
AREA
6. Press
Fig. 2
Issue 1
May 2001
DCC / TC - Calibration
11B02.4
Implement width setting
ENG
RPM
RPM
for 4 seconds.
FIELD
HRS
AREA
GNO
SL IP
SPO
PTO
ENG
RPM
RPM
9. Press
10. Press
11. press
FIELD
HRS
AREA
for 4 seconds.
Fig. 4
Issue 1
May 2001
DCC / TC - Calibration
11B02.5
C . Level 1
Condition to enter calibration level 1
GNO
SL IP
PTO
ENG
ENG
FIELD
SPO
RPM
RPM
HRS
AREA
SELECT WIDTH
SET
6
Fig. 5
Fig. 6
Fig. 7
Issue 1
May 2001
DCC / TC - Calibration
Clutches
activated
St0
St1
R-C
St2
2-C
St3
2-B
St4
1-R-C
St5
2-R-C
St6
2-R-C
St7
2-A-C
St8
B-2-C
St9
B-2-C
St10
L-2-C
St11
M-2-C
St12
H-2-C
St13
H-1-C
St14
H-2-C
St15
H-R-C
St16
H-2-A
St17
H-B-2
St18
H-2-C
St19
L-B-2
St20
M-B-2
St21
H-B-2
Issue 1
May 2001
DCC / TC - Calibration
11B02.7
Note :
- Wait 30 seconds, due to the park lock relay, before
starting the engine again. If not waiting, error code
could appear.
- If an error code 101 to 109 and 111 to 119 appear
during the calibration, you should restart it.
Fig. 8
Issue 1
May 2001
DCC / TC - Calibration
11B02.8
Turbo boost calibration
Fig. 9
Fig. 10
Issue 1
May 2001
DCC / TC - Calibration
11B02.9
D . Level 2
33. Put the ignition on. Do not start the engine.
6 for 5
seconds
35. "CAL2" will be apprear on the lower display (Fig. 11)
36. Press 4
ErS
dcon
tcon
Display TC constants
CLEd
CLEt
Fig. 11
bration
Fig. 12
to start calibration.
SL IP
SPO
before 10
seconds
Issue 1
May 2001
DCC / TC - Calibration
11B02.10
43. "FOr" will be appear in the middle screen (Fig. 13) put
the armrest lever in forward position before 10
seconds
GNO
SL IP
SPO
before 10
seconds.
The calibration is finish, the normal display appear.
Note : If an error appear during the calibration,
"CAL" will be appear and the error code is
display on the lower screen.
Fig. 13
to start calibration
49. "nEU" will appear in the middle screen (Fig. 12) and
the lever should be put in neutral position before 5
seconds
Note : If the lever is not in neutral position, the
buzzer is activate and the DCC cleared the calibration mode after 10 seconds.
GNO
SL IP
SPO
before 10
seconds
51. "FOr" will be appear in the middle screen (Fig. 15) put
the lever in forward position before 10 seconds
GNO
SL IP
SPO
before 10
seconds
53. "rEu" will be appear in the middle screen (Fig. 14) put
the lever in reverse position before 10 seconds
GNO
Fig. 14
SL IP
before 10
SPO
seconds.
The calibration is finish, the normal display appear.
Note : If an error appear during the calibration,
"CAL" will be appear and the error code is
display on the lower screen.
Issue 1
May 2001
DCC / TC - Calibration
Display DCC constants
57. Press 5
11B02.11
Parameter
Parameter Options
Default
Value
trAc
55
tESt
Tester code
trAn
Transmission Type
1 = AG 150
2 = AG 250
cntr
Control type
ShUt
Shuttle type
4 = Powershuttle
PLOt
0 = None
2 = Electrohydraulic
3 = Electrohydraulc and park brake
3Pth
0 = None
1 = EHRC
2 = EHRB
bStS
0 = None
1 = Lucas 92VB
EtSt
0 = None
1 = Funk temperature sensor
PPSt
0 = None
3 = Bourns 1
rAdr
Radar Horn
273
unit
Units
0 = without
base = 273 Hertz per 10 kph
0 = USA
1 = English
2 = Metric
Issue 21
December
2000
May 2002
DCC / TC - Calibration
11B02.12
Display
Code
Parameter
Default
Value
EOSP
Engine overspeed
protection
En9S
Engine overspeed
parameter
2600
9rPr
Gear preselection
memorization
0 = Disabled
1 = Enable
Forward speed
selection
13
HSGF
PF9S
Pr9S
Parameter Options
0 = Disabled
1 = Enabled
Maximun engine speed value
StLL
Not used
StrL
Not used
ASFC
719
ASnC
496
ASrC
282
PPUC
980
PPLC
30
9SPd
Ground speed
constant
6100
ESnC
ES9C
FSPd
Maximum forward
speed allowed.
18
FPt0
Issue 2
1
May 2002
December
DCC / TC - Calibration
Parameter Options
Display
Code
Parameter
Default
Value
Eur9
0 = R6 USA
1 = R8 Europe
PtLt
LOAd
Always 0
tb14
Turbo calibration at
1400 rpm
Turbo calibration at
2000 rpm
PtLd
tb20
11B02.13
Issue21
Issue
December
2000
May 2002
DCC / TC - Calibration
11B02.14
Display TC constants
Display
Code
Parameter
Default
Value
Parameter Options
50 = White 8810 / DT225
51 = Allis 9785
52 = MF 8180 / 8280
53 = White 8710 / DT200
54 = Allis 9775
55 = MF 8170 / 8270
56 = White 8610 / DT 180
57 = Allis 9765
58 = MF 8260 up to K066009
59 = White 8510 / DT 160
60 = Allis 9755
61 = MF 8250
62 = White 8410 /RT145
63 = Allis 9745
64 = MF 8220
65 = White 8310
66 = Allis 9735
67 = MF 8210
68 = MF 8240
70 = MF 8245
71 = MF 8260 from K066010
77 = RT130
trAc
55
tESt
Tester code
trAn
Transmission Type
1 = AG 150
2 = AG 250
cntr
Control type
ShUt
Shuttle type
4 = Powershuttle
ttSt
Transmission
temperature sensor
PFA
Front axle
0 = 2 WD
1 = 4 WD
dloc
Differential lock
0 = None
1 = installed
rPto
Rear PTOr
0 = None
1 = 8170, White and Allis type
2 = 8200 Type
PLCt
0 = None
2 = Electrical command
rPPr
44
Issue 21
Issue
December
2002
May 2002
DCC / TC - Calibration
Display
Code
FPPr
Parameter
Number of pulses for
rear PTO output shaft
Default
Value
11B02.15
Parameter Options
18
LPtO
EPPr
32
32 = AG 150
38 = AG 250
TPPr
72
72 = AG 150
81 = AG 250
CrPr
Creeper ratio
Creeper ratio
Pto1
PTO parameter 1
PTO parameter 1
Pto2
PTO parameter 2
PTO parameter 2
Pto3
PTO parameter 3
24
PTO parameter 3
Pto4
PTO parameter 4
200
PTO parameter 4
FP1
Clutch 1 base
128
FP2
Clutch 2 base
128
FP3
Clutch R base
128
FP4
Clutch A base
128
FP5
Clutch B base
128
FP6
Clutch C base
128
FP7
Clutch L base
128
FP8
Clutch M base
128
FP9
Clutch H base
128
FP10
Clutch 1 fill
19
FP11
Clutch 2 fill
19
FP12
Clutch R fill
19
FP13
Clutch A fill
19
FP14
Clutch B fill
19
FP15
Clutch C fill
19
FP16
Clutch L fill
19
FP17
Clutch M fill
19
FP18
Clutch H fill
19
Issue 1
May 2001
DCC / TC - Calibration
11B02.16
Clear DCC stored code
63. Repeat operation 33 to 36
64. Select "CLEd"
65. Press
FIELD
HRS
AREA
66. Press
during 10 seconds.
67. Press one time
70. Press
FIELD
HRS
AREA
71. Press
during 10 seconds.
72. Press one time
Fig. 16
Issue 1
May 2001
DCC / TC - Calibration
11B02.17
E . Level 3
With level 3 calibration, the qualified personnel can
modify the DCC and TC parameters.
73. Put the ignition on.
Note : You must not press the clutch pedal
74. Before 20 seconds, press and hold 4
6 for 5
seconds
75. "CAL3" will be apprear on the lower display (Fig. 17)
5
76. Press
Fig. 17
Calibration function
dCnt
tCnt
Edit TC constants
SL IP
SPO
FIELD
HRS
AREA
PTO
ENG
RPM
RPM
79. Press
80. Press
81. Press
Issue 1
May 2001
DCC / TC - Calibration
Issue 1
May 2001
Examples
- If the torque on the PTO shaft is high and the wheel
torque is low (stone crusher, rotary cultivator), enter a
high PtLd value. Example: during use of a Rotary
cultivator to prepare potatoes or rice, the values read
and entered to obtain the correct gear shifting for the
customer are:
. LoAd ......... 358
. PtLt ........... 178
. PtLd ........... 248
- If the torque on the PTO shaft is low and the wheel torque
is high, enter a low PtLd value. Example: during use of
a combined implement, seeder plus rotary harrow, the
values read and entered to obtain the correct gear
shifting for the customer are:
. LoAd .......... 500
. PtLt ............ 250
. PtLd ........... 138
DCC / TC - Calibration
11B02.19
G . Diagnostic modes
The diagnostic functions are used by service personnel
to test and monitor the functions of the tractor electronics. The diagnostics system uses the same type of
menu system as calibration levels 1 through 3.
The diagnostic menu may be entered at any time using
the following process.
92. Press and hold switch
for 5 seconds.
Fig. 18
of diagnostic functions.
95. To start the diagnostic function currently displayed
press switch
5 .
to
Upper display
Lower display
Diagnostic function
dAtA
trAc
dbin
dcc
dAdc
dcc
dErr
dcc
dLPS
dcc
9AU9
dcc
tbin
tad
TC switch states
tAdc
tad
tErr
tad
Issue 1
May 2001
DCC / TC - Calibration
6 .
Fig. 19
Display code
Issue 1
Parameters
Units
E9tP
Engine temperature
50 - 120 C
122 - 248 F
LoAd
Engine torque
Ft / lbs
trtP
Transmission temperature
0 - 120 C
32 - 248 F
CPPS
0 - 100 %
bStP
0 - 1,72 bar
0 - 25 psi
bAtF
0 - 16 volts
OILP
0 - 6,2 bar
0 - 92 psi
FUEL
0 - 100 %
ACCL
Not used
rAdr
Radar frequency
Hz
May 2001
DCC / TC - Calibration
11B02.21
5 . To leave it press
6 .
Fig. 20
Display code
Parameters
PFA
4 WD switch
LbrA
rbrA
rPtO
FPtO
SPtO
dIFF
IPS
L9ht
Headlights
AUtS
Not used
Prbr
LinS
Not used
bclt
tclt
RlnO
RInC
StOp
Not used
NErr
Not used
LLnC
LLnO
Brlu
Not used
Airl
Not used
Issue 1
May 2001
DCC / TC - Calibration
11B02.22
6 .
Fig. 21
Display code
Issue 1
Parameters
A / D value
ShrL
Armrest shifter
Forward +
Forward
Forward Neutral
Reverse Reverse
Reverse +
=
=
=
=
=
=
=
802
731
666
525
370 As a reminder
295 NAO type lever
208 8170 / 8180
SFnr
Forward +
Forward
Forward Neutral
Reverse Reverse
Reverse +
Declutch
=
=
=
=
=
=
=
=
800
693
604
100
415
312
221
486
StEr
Not used
bAtr
11 V
15,5 V
=
=
314
442
FUEL
Empty
Full
=
=
890
25
OILP
37 to 610
bAtF
12 V
350
May 2001
DCC / TC - Calibration
11B02.23
5 . To
6 .
Fig. 22
Display code
Parameters
Err1
tEr1
......
Err16
tEr16
Issue 1
May 2001
DCC / TC - Calibration
11B02.24
DCC lamp check "dLPS"
6 .
Fig. 23
position.
115. Press
position
116. To leave this diagnostic function, press
6 .
Fig. 24
Display code
Issue 1
Parameters
CEnt
Middle position
HI9H
Maximum position
LO
Minimum position
May 2001
DCC / TC - Calibration
11B02.25
5 . To
6 .
Fig. 25
Display code
Parameters
hPrS
hFLt
tPrS
LUbE
CrEP
Not used
PrLc
Issue 1
May 2001
DCC / TC - Calibration
11B02.26
5 . To
6 .
Fig. 26
Code affich
Issue 1
Parameters
En9S
trnS
FPtO
rPtO
May 2001
DCC / TC - Calibration
11B02.27
5 . To
6 .
Fig. 27
Display code
Parameters
Err1
tEr1
......
Err20
tEr20
Issue 1
May 2001
11B03.1
CONTENTS
A.
General ___________________________________________
B.
C.
Issue 1
May 2001
A . General
These 2 electronic units control all the automatic functions of the transmission according to the driver's actions and the information received from various sensors.
Issue 1
May 2001
11B03.3
TC error codes
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Not used
Not used
Clutch L electrical fault (open circuit or short circuit to earth)
Clutch L electrical fault (short circuit on + 12 AC)
Clutch M electrical fault (open circuit or short circuit to earth)
Clutch M electrical fault (short circuit on + 12 AC)
Clutch H electrical fault (open circuit or short circuit to earth)
Clutch H electrical fault (short circuit on + 12 AC)
Clutch 1 electrical fault (open circuit or short circuit to earth)
Clutch 1 electrical fault (short circuit on + 12 AC)
Clutch 2 electrical fault (open circuit or short circuit to earth)
Clutch 2 electrical fault (short circuit on + 12 AC)
Clutch R electrical fault (open circuit or short circuit to earth)
Clutch R electrical fault (short circuit on + 12 AC)
Clutch A electrical fault (open circuit or short circuit to earth)
Clutch A electrical fault (short circuit on + 12 AC)
Clutch B electrical fault (open circuit or short circuit to earth)
Clutch B electrical fault (short circuit on + 12 AC)
Clutch C electrical fault (open circuit or short circuit to earth)
Clutch C electrical fault (short circuit on + 12 AC)
Incorrect gear requested by DCC
Temperature of transmission oil for calibration less than 50C
Engine speed above the calibration limit (1800 rpm)
Engine speed below the calibration limit (1250 rpm)
Gearbox output speed above calibration limit
Default calibration values used
Wrong parameter for number of pulses per PTO rev
No speed sensor signal at calibration
Incorrect Forward speed sensor signal at calibration
Incorrect Reverse speed sensor signal at calibration
Speed sensor signal at calibration does not drop
31
32
33
34
35
36
37
38
39
40
41
42
Issue
Issue 2
1
May 2002
December
2000
Not used
Not used
High alternator regulator voltage (filtered battery signal)
Low alternator regulator voltage (filtered battery signal)
Not used
Not used
High transmission temperature sensor signal
Low transmission temperature sensor signal
Not used
Not used
High PTO solenoid valve current
Low PTO solenoid valve current
High PTO brake solenoid valve current
Low PTO brake solenoid valve current
High clutch C solenoid valve current
Low clutch C solenoid valve current
High clutch R solenoid valve current
Low clutch R solenoid valve current
High clutch A solenoid valve current
Low clutch A solenoid valve current
High clutch 2 solenoid valve current
Low clutch 2 solenoid valve current
High clutch B solenoid valve current
Low clutch B solenoid valve current
High clutch 1 solenoid valve current
Low clutch 1 solenoid valve current
High differential lock solenoid valve current
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
72
73
74
75
76
77
78
79
80
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Not Stored
Error Stored
Error Stored C.N. Special
Error Stored
81
82
83
84
85
86
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Issue
Issue 12
December
May 2000
2002
Issue 12
11B03.5
Error Stored
Error Not Stored C.N.
Error Stored C.N.
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored C.N.
Error Stored
Error Stored C.N.
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored C.N.
Error Stored C.N.
Error Stored C.N.
Error Stored C.N.
Error Stored C.N.
Error Stored C.N.
Error Stored C.N.
Error Stored C.N.
Error Stored C.N.
May 2000
2002
December
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Stored
Error Not Stored
Error Not Stored
Error Not Stored
Error Not Stored
Error Stored
Error Stored
147 NAO shuttle lever neutral switch normally closed failed - low
148 Attempt to reprogram with engine running
Error Stored
Error Not Stored C.N.
149
150
151
152
153
154
155
156
157
Error Stored
Error Stored
Error Not Stored
Error Stored
Error Not Stored C.N.
Error Stored C.N. Special
Error Not Stored
Error Stored
Error Stored
158
159
160
161
162
Issue
Issue 12
December
May 2000
2002
11B03.7
Error Code 22
Engine speed above the calibration limit (1800-rpm).
- Possible causes: The calibration of the transmission
has been undertaken with the engine speed above 1800
rpm. Calibration must be carried out at 1300-rpm +/-50.
Speed sensor or wiring defective.
- Tests : Reduce the engine speed and carry out calibration again. Check the speed sensor and test the wiring
for any open circuit or short circuit.
Error Code 23
Engine speed below the calibration limit (1250 rpm).
- Possible causes: The calibration of the transmission
was undertaken with an engine speed of less than 1150
rpm. Speed sensor or wiring defective.
- Tests: Increase engine speed and recalibrate. Check
the speed sensor and test wiring for any open circuit.
Error Code 24
Gearbox output speed above the calibration limit.
- Possible causes: The calibration of the transmission
was undertaken at an output speed greater than 100
rpm. The tractor has moved because the parking brake
was not on. Output speed sensor or wiring defective.
- Tests : Check that the parking brake is on. Check the
output speed sensor and test the circuit for any open
circuit or a short circuit in the wiring.
Error Code 20
Incorrect gear requested by DCC
- Possible cause: The TC has received a request for a
gear change from the DCC which is not defined in the
programming of the TC.
- Test: Check DCC/TC constants and calibration of the
gear lever.
Error Code 25
Default calibration values used.
- Possible causes: The TC is using the default values for
the calibration. The transmission has not been calibrated. The TC memory is damaged or the TC is
defective.
- Tests: Calibrate the transmission. Replace the TC.
Error Code 21
Temperature of transmission oil for calibration less than
50C.
- Possible cause: The calibration of the transmission has
been undertaken with the transmission oil below the
specified calibration temperature of 50C (120F).
- Tests: Heat the transmission oil. Then check the
correct operation of the temperature sensors and the
wiring.
Error Code 26
Wrong parameter for number of pulses per PTO rev.
- Possible causes: Incorrect parameter input, enter new
parameters for the tractor.
Issue 1
May 2001
Error Code 27
No speed sensor signal at calibration
- Possible causes: The speed of the shaft (gearbox 5th
stage) was zero during calibration phases 1, 2 or 3 due
to an incorrect conversion parameter in the TC; wiring
defect on the calibration speed sensor; partial failure of
the TC; low clutch pressure; defective solenoid valve or
mechanical failure in the transmission.
- Tests: Check that the calibration speed sensor is
connected and test the wiring to detect any open circuit
or short circuit. Check the pressure in the clutch circuit
and the correct operation of the solenoid valves
(clutches R, C, 2 and B). Replace the TC.
Error Code 31
Engaging pressure greater than 5.1 bar.
- Possible causes: A pressure in the clutch engaging
was greater than 5.1 bar (75 psi) during one of the calibration steps (4 to 12) due to high pressure in the circuit;
failure of a solenoid valve; failure in the transmission or
failure of the TC.
- Tests: Check the pressure in the clutch circuit, check
whether a solenoid valve corresponding to the stage
being calibrated is stuck or defective. Check whether
there is a mechanical failure in the transmission or in
the TC.
Error Code 28
Incorrect Forward speed sensor signal at calibration
- Possible causes: The speed of the shaft (gearbox 5th
stage) was not within admissible limits during phases
2 or 3 of the calibration due to an incorrect conversion
parameter in the TC; calibration speed sensor wiring
fault; partial failure of the TC; low clutch pressure;
defective solenoid valve or mechanical failure in the
transmission.
- Tests: Check that the calibration speed sensor is
connected and test the wiring for any open circuit or
short circuit. Check the pressure in the clutch circuit
and the correct operation of the solenoid valves
(clutches 2, C and B). Replace the TC.
Error Codes 32, 33, 34, 35, 36, 37, 38, 39, 40
Clutch filling fault (above 300 ms)
- Possible causes: Clutch filling time too slow (greater
than 300 milliseconds) due to low circuit pressure;
failure of a solenoid valve; partial failure of the TC or a
mechanical failure in the gearbox.
- Tests: Check clutch circuit pressure. Check whether a
stuck or defective solenoid valve is linked to the error
code. Check for mechanical failure in the gearbox or a
failure in the TC.
Error Code 29
Incorrect Reverse speed sensor calibration signal
- Possible causes: The speed of the shaft (gearbox 5th
stage) was not within admissible limits during phase 1
of the calibration due to an incorrect conversion parameter in the TC; a wiring fault on the calibration speed
sensor; partial failure of the TC; low clutch pressure;
defective solenoid valve or mechanical failure in the
transmission.
- Tests: Check that the calibration speed sensor is
connected and test the wiring for any open circuit or
short circuit. Check the pressure in the clutch circuit
and the correct operation of the solenoid valves
(clutches R and C). Replace the TC.
Error Code 30
Speed sensor signal at calibration doesnt drop.
- Possible causes: The speed of the shaft (gearbox 5th
stage) did not drop during one of the pressure maintenance calibration phases (4 to 12) due to a solenoid
valve failure; partial failure of the TC or mechanical
failure in the transmission.
- Tests: Check whether the solenoid valve corresponding to the stage being calibrated is stuck or defective;
or whether there is a failure in the transmission or the
TC.
Issue 1
May 2001
Error Code 41
Detection of transmission slip
- Possible causes: The engaging of the gearbox clutches
remained 10% below total engagement for a period of
10 seconds with the clutch pedal positioned at more
than 40% of its total travel; or during 30 seconds with
the pedal at less than 40% of its travel. This may be due
to prolonged overuse of the clutch pedal; starting in too
high a gear for the load; low pressure in the circuit;
failure of a solenoid valve or a mechanical failure in the
transmission.
- Tests: Start in a lower gear. Check pressure in the
clutch circuit. Check if one of the solenoid valves linked
to the gear indicating the fault is stuck or defective; or
whether there is a mechanical failure in the transmission. Avoid slipping the clutch with the clutch pedal.
Error Code 45
High alternator regulator voltage (filtered battery signal).
- Possible causes: The filtered battery voltage, terminal
B - J, at the TC is higher than 16.5 V. The alternator is
providing too high a charge.
- Tests: Check voltage at terminal B - J and the alternator
output current.
11B03.9
Error Code 55
High PTO brake solenoid valve current.
- Possible causes: The fine control circuit of the PTO
brake solenoid valve is defective following a short
circuit to 12 V in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal B - E of the
TC and the PTO brake solenoid valve to detect any short
circuit to 12 V. Replace the TC.
Error Code 56
Low PTO brake solenoid valve current.
- Possible causes: The fine control circuit of the PTO
brake solenoid valve is defective following a short
circuit to earth in the return circuit, or due to a TC failure
- Tests: Check the circuit between terminal B - E of the
TC and the PTO brake solenoid valve to detect any short
circuit to earth. Replace the TC.
Error Code 57
High clutch "C" solenoid valve current.
- Possible causes: The fine control circuit of the solenoid
valve of clutch "C" is defective due to a short circuit to
12 V in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal C - A of the
TC and the solenoid valve of clutch 'C' to detect any
short circuit to 12 V. Replace the TC.
Error Code 58
Low clutch "C" solenoid valve current.
- Possible causes: The fine control circuit of the solenoid
valve of clutch "C" is defective due to a short circuit to
earth in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal C-A of the TC
and the solenoid valve of clutch "C" to detect any short
circuit to earth. Replace the TC.
Error Code 59
High clutch "R" solenoid valve current.
- Possible causes: The fine control circuit of the solenoid
valve of clutch "R" is defective due to a short circuit to
12 V in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal C - J of the
TC and the solenoid valve of clutch "R" to detect any
short circuit to 12 V. Replace the TC.
Issue 1
May 2001
Error Code 60
Low clutch "R" solenoid valve current.
- Possible causes: The fine control circuit of the solenoid
valve of clutch "R" is defective due to a short circuit to
earth in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal C - J of the
TC and the solenoid valve of clutch "R" to detect any
short circuit to earth. Replace the TC.
Error Code 66
Low clutch "B" solenoid valve current.
- Possible causes: The fine control circuit of the solenoid
valve of clutch "B" is defective due to a short circuit to
earth in the return circuit or due to a TC failure.
- Tests: Check the circuit between terminal C - C of the
TC and the solenoid valve of clutch "B" to detect any
short circuit to earth. Replace the TC.
Error Code 61
High clutch "A" solenoid valve current.
- Possible causes: The fine control circuit of the solenoid
valve of clutch "A" is defective due to a short circuit to
12 V in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal C - B of the
TC and the solenoid valve of clutch "A" to detect any
short circuit to 12 V. Replace the TC.
Error Code 67
High clutch "1" solenoid valve current.
- Possible causes: The fine control circuit of the solenoid
valve of clutch "1" is defective due to a short circuit to
12 V in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal C-D of the TC
and the solenoid valve of clutch "1" to detect any short
circuit to 12 V. Replace the TC.
Error Code 62
Low clutch "A" solenoid valve current.
- Possible causes: The fine control circuit of the solenoid
valve of clutch "A" is defective due to a short circuit to
earth in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal C - B of the
TC and the solenoid valve of clutch "A" to detect any
short circuit to earth. Replace the TC.
Error Code 68
Low clutch "1" solenoid valve current.
- Possible causes: The fine control circuit of the solenoid
valve of clutch "1" is defective due to a short circuit to
earth in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal C - D of the
TC and the solenoid valve of clutch "1" to detect any
short circuit to earth. Replace the TC.
Error Code 63
High clutch "2" solenoid valve current.
- Possible causes: The fine control circuit of the solenoid
valve of clutch 2 is defective due to a short circuit to
12 V in the return circuit, or due to a TC failure.
Tests: Check the circuit between terminal C-H of the TC
and the solenoid valve of clutch 2 to detect any short
circuit to 12 V. Replace the TC.
Error Code 69
High differential lock solenoid valve current.
- Possible causes: The fine control circuit of the differential lock solenoid valve is defective due to a short circuit
to 12 V in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal C - K of the
TC and the differential lock solenoid valve to detect any
short circuit to 12 V. Replace the TC.
Error Code 64
Low clutch 2 solenoid valve current.
- Possible causes: The fine control circuit of the solenoid
valve of clutch "2" is defective due to a short circuit to
earth in the return circuit or due to a TC failure.
- Tests: Check the circuit between terminal C-H of the TC
and the solenoid valve of clutch "2" to detect any short
circuit to earth. Replace the TC.
Error Code 70
Low differential lock solenoid valve current.
- Possible causes: The fine control circuit of the differential lock solenoid valve is defective due to a short circuit
to earth in the return circuit, or due to a TC failure..
- Tests: Check the circuit between terminal C - K of the
TC and the differential lock solenoid valve to detect any
short circuit to earth. Replace the TC.
Error Code 65
High clutch "B" solenoid valve current.
- Possible causes: The fine control circuit of the solenoid
valve of clutch "B" is defective due to a short circuit to
12 V in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal C - C of the
TC and the solenoid valve of clutch "B" to detect any
short circuit to 12 V. Replace the TC.
Error Code 71
High clutch "M" solenoid valve current
- Possible causes: The fine control circuit of the solenoid
valve of clutch "M" is defective due to a short circuit to
12 V in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal C - G of the
TC and the solenoid valve of clutch "M" to detect any
short circuit to 12 V. Replace the TC.
Issue 1
May 2001
11B03.11
Error Code 72
Low clutch "M" solenoid valve current
- Possible causes: The fine control circuit of the solenoid
valve of clutch "M" is defective due to a short circuit to
earth in the return circuit, or due to a TC failure.
- Tests: Check the circuit between terminal C - G of the
TC and the solenoid valve of clutch "M" to detect any
short circuit to earth. Replace the TC.
Error Code 78
CAN network deactivated
- Possible causes: Hardware failure either in the DCC or
in the 3 CAN network cables linking the systems.
- Tests: Check the continuity of the 3 CAN cables
between terminals D - A, D - B and D - K of the DCC and
terminals D - A, D - G and D - K of the TC. Replace the
DCC.
Error Code 73
High clutch "H" solenoid valve current
- Possible causes: The fine control circuit of the solenoid
valve of clutch "H" is defective due to a short circuit to
12 V in the return circuit or due to a TC failure.
- Tests: Check the circuit between terminal C - E of the
TC and the solenoid valve of clutch "H" to detect any
short circuit to 12 V. Replace the TC.
Error Code 79
No CAN message from the DCC
- Possible causes: Open circuit or short circuit in the 3
CAN network cables linking the DCC and TC.
- Tests: Check the continuity of the 3 CAN cables
between terminals D - A, D - B and D - K of the DCC and
terminals D - A, D - G and D - K of the TC.
Note: Computer Neutral Special = gearbox will not
go any more to neutral but PTO will be shut off,
4WD will be engaged and Diff.lock will be disengaged. The error code 79 will be displayed on the
DCC but the tractor can still move in the selected
gear until the clutch pedal is depressed (BOC
switch activated) or one of the gear lever is moved
to neutral position (neutral switch activated).
Error Code 74
Low clutch "H" solenoid valve current.
- Possible causes: The fine control circuit of the solenoid
valve of clutch "H" is defective due to a short circuit to
earth in the return circuit or due to a TC failure.
- Tests: Check the circuit between terminal C - E of the
TC and the solenoid valve of clutch "H" to detect any
short circuit to earth. Replace the TC.
Error Code 75
High L clutch solenoid valve current
- Possible causes: The fine control circuit of the solenoid
valve of clutch "L" is defective due to a short circuit to
12 V in the return circuit or due to a TC failure.
- Tests: Check the circuit between terminal C - F of the
TC and the solenoid valve of clutch "L" to detect any
short circuit to 12 V. Replace the TC.
Error Code 76
Low L clutch solenoid valve current.
- Possible causes: The fine control circuit of the solenoid
valve of clutch "L" is defective due to a short circuit to
earth in the return circuit or due to a TC failure.
- Tests: Check the circuit between terminal C - F of the
TC and the solenoid valve of clutch "L" to detect any
short circuit to earth. Replace the TC.
Error Code 80
Minor Checksum Error in serial EEPROM (Table Of
Contents)
- Possible cause: An error was generated while saving
the parameter in the TC. The system will delete the error
after one or two ignition cycles, but the parameter may
not have been saved and the default parameters will be
used.
- Tests: Check the "dcon" and "tcon" parameters.
Error Code 81
Fatal Checksum Error in serial EEPROM (resets default
values)
- Possible cause: The operating parameters have been
lost.
- Tests: Check and re-enter the correct parameters for
the tractor.
Error Code 77
Loss of CAN message
- Possible causes: Hardware failure either in the DCC or
in the 3 CAN network cables linking the systems.
- Tests: Check the continuity of the 3 CAN cables
between terminals D - A, D - B and D - K of the DCC and
terminals D - A, D - G and D - K of the TC. Replace the
DCC.
Issue 1
May 2001
Error Code 82
Minor fault in transmission service hours counter (internal to TC)
- Possible cause: The transmission service hours are
stored in 3 different places. If one of the values differs
from the other two, these two values will be copied to
replace the wrong value. If the three values are different, there is no majority and the real number of transmission service hours are lost. To delete this error, turn
the key to OFF position, then to ON again.
Error Code 83
Major fault in transmission service hours counter (internal to TC)
- Possible cause: The transmission service hours are
stored in 3 different places. If the three places contain
different values, the real number of transmission service hours are lost. Certain figures will be stored as hours
but they will not be correct. To delete this error, turn the
key to OFF position, then to ON again.
Error Code 84
Minor fault in transmission tenths of service hours
counter (internal to TC)
- Possible cause: The tenths of transmission service
hours are stored in 3 different places. If one of the
values differs from the other two, these two values will
be copied to replace the wrong value. If the three values
are different, there is no majority and the real number of
tenths of transmission service hours are lost. To delete
this error, turn the key to OFF position, then to ON again.
Error Code 85
Major fault in transmission tenths of service hours
counter (internal to TC)
- Possible cause: The tenths of transmission service
hours are stored in 3 different places. If the three places
contain different values, the real number of tenths of
transmission service hours are lost. Certain figures will
be stored as tenths of hours but they will not be correct.
To delete this error, turn the key to OFF position, then
to ON again.
Error Code 86
Gearbox 17 bar pressure switch fault
- Possible causes: The circuit between the oil pressure
switch and terminal E - B of the TC is short-circuited to
earth. The oil pressure switch contacts are shorted
together. The transmission oil pressure is not reaching
the minimum required pressure.
- Tests: Check that the transmission oil pressure is
above the specified minimum. Test the circuit between
the oil pressure switch and terminal E - B of the TC to
detect any short circuit to earth. Check that the oil
pressure switch itself is not short-circuited.
Issue 1
May 2001
Error Code 87
Lubrication 3 bar pressure switch fault
- Possible causes: The circuit between the oil pressure
switch and terminal E - A of the TC is short-circuited to
earth. The contacts of the oil pressure switch are
shorting together. The hydraulic pressure has not
reached the minimum required.
- Tests: Check that the hydraulic oil pressure is above the
specified minimum. Test the circuit between the oil
pressure switch and terminal E - A of the TC to detect
any short circuit to earth. Check that the oil pressure
switch itself is not short-circuiting.
Error Code 88
Attempt to reprogram with engine running
- Possible cause: An attempt has been made to
download new software while the engine was running.
- Tests: To download new software, the ignition key
switch must be on but the engine must be stopped.
Note: This is an additional safety as Wintest
system normally does not allow reprogramming
with engine running.
Error Code 89
TC internal circuit (protection transistor stuck open)
- Possible cause: TC failure
- Tests: Replace the TC
Error Code 90
No electrical signal from PTO speed sensor
- Possible causes: The PTO operates but the TC is
receiving no input from the sensor. The sensor is
defective or one of the two sensor wires is short
circuited or broken.
- Tests: Check for breaks in the two wires running from
the sensor to the TC. Test the wiring from terminal E H of the TC to detect any short circuit to 12 V. Test the
wiring from terminal E - D of the TC to detect any short
circuit to 12 V or earth. Replace the sensor.
Note: After a gearbox calibration, if the PTO speed
sensor has not been reconnected (brown wire on
brown wire near the TC) this error code can occur
when using PTO.
11B03.13
Error Code 94
PTO brake failure
- Possible causes: The TC has deactivated the PTO and
activated the PTO brake but detects that the PTO shaft
is still turning. Mechanical failure of the PTO brake.
- Tests: Check pressure in the PTO clutch and PTO
brake. If the pressure is correct, there is a mechanical
failure in the brake itself. If the pressure is not within
specified limits, check whether the PTO brake or clutch
solenoid valves are jammed.
Error Code 95
No hydraulic pressure
- Possible cause: Hydraulic pressure was lower than 12
bar (176 psi) for more than 2 seconds. This puts all
transmission and rear axle solenoid valves out of
service.
- Tests: Connect a pressure-gauge and check the lowpressure hydraulic circuit. Check the correct operation
of the low-pressure switch. Check the wiring between
the pressure switch and terminal E - A of the TC.
Error Code 96
Short circuit on +12V AC of PTO clutch solenoid valve
- Possible cause: The current still reaches the PTO
solenoid valve when the TC has deactivated the PTO.
Due to a short circuit to +12 V AC in the wiring harness
or a TC failure.
- Tests: Disconnect connector B of the TC and check for
the presence of voltage on terminal C towards the earth
and on terminal G towards the earth. With the ignition
key switch on, if a voltage is present, the harness is
faulty. Repair the harness. If no voltage is measured,
replace the TC.
Error Code 97
Over voltage detected on PTO clutch solenoid valve
- Possible causes: The filtered battery voltage is above
16.5 V. This may be due to an alternator failure.
- Tests: Check that the output of the alternator is correct.
Issue 1
May 2001
Error Code 98
Park lock engagement error.
- Possible cause: The Park lock switch on the left-hand
side of the transmission / axle unit is signalling that the
Park lock is engaged although the TC has disengaged
the Park lock.
- Tests: Check the correct operation of the Park lock
switch on the left-hand side of the transmission / axle
unit. Test the wiring from the Park lock switch to the TC
to detect any open circuit or short circuit (terminals D F of the TC). Check the solenoid valve wiring. Check the
solenoid valve itself.
Error Code 99
Park-lock movement error
- Possible cause: The status of the Park-lock switch on
the left-hand side of the transmission / axle unit does
not change during the disengagement of the Park-lock
or the handbrake is still engaged.
- Tests: Check the correct operation of the Park-lock
switch on the left-hand side of the transmission / axle
unit. Test the wiring from the Park-lock switch to the
TC to detect any open circuit or short circuit (terminals
D - F of the TC). Disengage the handbrake.
Error Code 100
Front axle solenoid valve failure
- Possible causes: The 4WD actuator has detected an
error. Perhaps a short circuit or a break in the 4WD
solenoid valve circuit.
- Tests: Check the 4WD solenoid valve circuit to detect
any open circuit or short circuit. Check the wiring
harness between the solenoid valve connector and
terminals B - H and C - K of the TC to detect any short
circuit, short to earth or 12 V.
Error Codes 101, 102, 103, 104, 105, 106, 107, 108, and
109
Clutch engaging pressure calibration fa ult
- Possible causes: The calibration has failed due to low
pressure in the circuit; a solenoid valve failure; partial
failure of the TC or a mechanical failure in the transmission.
- Tests: Check the circuit pressure. Check whether the
solenoid valve corresponding to the Error Code is
jammed, has failed or has defective O-rings. Check for
a mechanical failure in the transmission.
Issue 1
May 2001
11B03.15
Issue 1
December 2000
Issue
Issue 12
December
May 2000
2002
11B03.17
Issue 1
May 2001
Issue 1
May 2001
11B03.19
Issue 1
May 2001
Issue 1
May 2001
11B03.21
Issue 1
May 2001
11C01.1
CONTENTS
A.
Description _________________________________
B.
Console _____________________________________
C.
Diagram ____________________________________
Issue 1
May 2001
A . Description
The electronic linkage system (Fig. 1) is composed of
the following components:
- A control console (1)
- A digital or electronic calculator (2)
- A position sensor (3)
- A depth button (4)
- A Lifting / Working selector with neutral position (5)
- Two draft sensors (6)
- A wiring harness (7)
- An electro-hydraulic proportional control solenoid
valve (8)
- Four or six external control switches depending on
option (9)
- A 3 A fuse (10) fitted beneath the right-hand side of the
linkage control console
- A button for quick soil engagement (11) fitted on the
right-hand side of the control armrest.
Issue 2
1
May 2002
2001
11C01.3
10
3
11
B
E
A
F
Fig. 1
Issue 1
May 2001
(5) Selector
Issue 2
1
May 2002
2001
11C01.5
(10) Fuses
7.5 Amp fuse for battery + 12 V
- it is located above the batteries and protects battery
+ 12 V to the ELC
25 Amp fuse for battery + 12 V AC
- it is located in the fuse box and protects all tractor +
12 V AC supplies
3 Amp fuse for battery + 12 V AC (10)
- it is located under the linkage control console and
protects the + 12 V AC supply to the ELC.
Issue 1
May 2001
11C01.6
JA
Fig. 2
B . Console
List of controls
(A)
(B)
(C)
(D)
(E)
(F)
Issue 1
May 2001
(G)
(H)
(I)
(J)
(K)
(L)
11C01.7
Issue 1
May 2001
Issue 1
May 2001
11C01.9
C . Diagram
Description
The electrical circuit is made up of the following elements:
1. Ignition switch
2. Linkage control console lighting
3. Battery
4. Radar (if fitted)
5. Onboard computer (if fitted)
6. Engine speed sensor (Autotronic or TC speed
output)
7. Forward speed sensor (Autotronic or TC speed
output)
8. Lift control valve
9. Left draft sensor
10. Right draft sensor
11. Position sensor
12. External control buttons
13. External control buttons
14. 3rd set of external controls for automatic coupling
15. Linkage control console
16. Lifting / Working selector with Neutral position
17. Quick soil engagement button
18. Electronic linkage calculator
19. Depth / height potentiometer
Issue 1
May 2001
Connector colour
Wires
Description
Pins
Wire colour
White
General supply to
connector C14
1. + battery
2. battery
3. + 12 V lighting
4. not used
5. + 12 V AC
Red
Black
Orange
Violet
Red
Black
CAN network
1. CAN lo
2. CAN hi
3. CAN ground
Brown
Green
Red
Black
Signals to 16-pin
diagnostics connector
1. CAN lo
2. CAN hi
3. CAN ground
4. drawn implement
signal
5. + 12 V AC
6. battery ground
7. not used
Brown
Green
White
Violet
Violet
Orange
Brown
White
Grey
Violet
Brown
White
Grey
Black
Black
Speed signals
Black
Black
Not used
Not used
Pink
Pink
Brown
1. + 6 V for control
2. Ground
Red
Red / White
Black
1. + 6 V for control
2. Ground
Light green
Red / White
Grey
1. Ground
2. Sensor signal
3. + 9.5 V from calculator
Black / White
Yellow
Brown /
Yellow
Grey
1. Ground
2. Sensor signal
3. + 9.5 V from calculator
Black / White
Yellow
Brown /
Yellow
Issue 1
May 2001
Connector colour
Wires
Description
Pins
11C01.11
Wire colour
Black
Position sensor
1. Ground
2. Sensor signal
3. + 9 V from calculator
Black / White
Dark green
Brown / Yellow
Black
External controls
Yellow
Dark blue
Yellow
Dark blue
K1
Black
External controls
Orange
Orange
Yellow
K2
K3
K4
K5
Black
Black
Black
Black
Round black
16
External controls
External controls
External controls
External controls
Issue 1
Dark blue
Orange
Yellow
Dark blue
Yellow
Dark blue
Yellow
Dark blue
1. Intermix signal
2. + 9.5 V from calculator
3. Ground from calculator
4. Lowering speed signal
Yellow
Grey / Red
Black / Grey
Grey
Orange
Orange
Orange
May 2001
Item
L
Issue 1
Connector colour
Round black
Black
Black
Wires
16
10
Description
Linkage control console
Right armrest
Right armrest
May 2001
Pins
5. High position signal
6. Diagnostic LED supply
7. Automatic lowering
LED supply
8. Transport damper LED
supply
9. Transport damper ON /
OFF signal
10. Lift solenoid valve
supply
11. Lower solenoid valve
supply
12. Battery ground
13. D+ alternator
14. External linkage control
supply
15. External control signal
16. External lower control
supply
Wire colour
Dark green
Pink
Dark green
Brown
Dark green
Light green
Red
Black
Violet
Yellow
Dark blue
Orange
1. Radar signal
2. Drawn implement
signal
3. Lifting / Neutral /
Working toggle switch
4. Ground
5. + 9.5 V from calculator
6. Depth control
7. Not used
White
Violet
Green
Blue
Orange
Pink
Green
Blue
Orange
White
Not used
55
Description
ELC connector
Issue 1
11C01.13
Pins
1. Sensors ground
2. Sensors supply 9.5 V
3. Engine speed signal
4. Slippage control signal
5. Not used
6. + 12 V AC
7. Position sensor signal
8. Depth potentiometer
signal
9. Battery ground
10. Battery + 12 V
11. Not used
12. Lighting + 12 V
13. Automatic lowering
indicator lamp
14. CAN H (linked to 15)
15. CAN H
16. Engine running signal
17. Not used
18. Not used
19. Lower coil supply
20. Linkage console
ground
21. Signal for mounting
Load Sensing
22. Ground
23. Radar speed signal
24. Theoretical forward
speed signal
25. Right force signal
26. Intermix
27. Lowering speed
28. External Lift / Lower
controls
29. Not used
30. Not used
31. Not used
32. Transport damper
indicator lamp
33. CAN L (linked to 34)
34. CAN L
35. CAN network ground
36. Not used
37. Not used
38. Not used
39. Console 9.5 V supply
Wire colour
-
May 2001
Item
P
Issue 1
Black
55
Description
ELC connector
May 2001
Pins
40. Not used
41. Ground
42. Ground
43. Left draft signal
44. High position signal
45. Battery ground
46. Lifting / Neutral /
Lowering selector
47. Battery + 12 V
48. Not used
49. Diagnostics indicator
lamp
50. Not used
51. Transport damper
switch
52. Not used
53. Coils ground
54. Not used
55. Lift coil supply
1. Ground
2. Signal or lack of signal
of the presence of the
closed centre lift
control valve
Wire colour
-
Orange
Grey / Black
Electronics Linkage
Tractor with cab
11C01.15
14
16
K4
K2
13
55
K3
12
17
15
K1
19
L
11
I
10
H
9
G
P
E
18
7
6
D
5
4
C
B
B
Q
A
2
1
Issue 1
May 2001
Fig. 3
11C02.1
CONTENTS
A.
Operation ___________________________________
Issue 1
May 2001
11C02.2
A . Operation
The electronic linkage calculator is capable of detecting
certain faults in the wiring harness or lifting components.
Code
Fault
Action required
1-1
1-2
Idem
Idem
1-3
Idem
Idem
1-5
Idem
Idem
1-6
Supply exceeds 18 V
Idem
Idem
1-7
Idem
Idem
1-8
Idem
Idem
2-2
2-3
Idem
Idem
2-4
Idem
Idem
Issue 1
May 2001
Fault
11C02.3
Action required
2-7
Idem
Idem
3-1
Idem
3-2
Idem
Idem
3-3
Idem
Idem
3-4
Idem
3-6
Idem
3-8
Selection of defaut AA
parameters pertaining to
the transmission calculator.
The electronic linkage
control operates with the
wrong parameters. The
diagnostic lamp flashes.
Issue 21
2001
May 2002
Datatronic 2 - Description
11D01.1
11 D01 Datatronic
CONTENTS
A.
General ________________________________________________
B.
C.
D.
10
E.
10
F.
11
G.
12
H.
16
I.
18
J.
Diagram ________________________________________________
24
Issue 1
May 2001
Datatronic 2 - Description
11D01.2
A . General
The Datatronic is a measurement instrument that permits the optimisation of tractor functions. It is located on
the right-hand side upright in the cab.
(10)
(11)
(12)
(13)
(14)
4 . PLOUGH
1
1000
9 8 0
A
n/min
RP/M
1 8 5 0
2
3
6
10
7
11
8
B
12
14
13
Fig. 1
Issue 1
May 2001
Datatronic 2 - Description
Description of menu functions and symbols
n/min
11D01.3
Issue 1
May 2001
Datatronic 2 - Description
COST/L: local cost of one litre of fuel;
stored in memory
Issue 1
May 2001
Datatronic 2 - Description
MENU
UNITS
Metric
USA
English
FUNCTION
11D01.5
RESET
OR
ADJUST
WORKING
POSITION
REQUIRED
DISPLAY
INCREMENT
MINIMUM
VALUE
DISPLAYED
COMPARE
MODE
Engine speed
Engine speed
rpm
no
no
10 rpm
100 rpm
yes
PTO
PTO speed
rpm
no
no
5 rpm
50 rpm
yes
SPEED
Forward speed
kph or mph
no
no
0.1 kph
1 km/h
yes
WHEEL SLIP
no
no
1%
0%
yes
yes
1%
0%
no
AREA/HR
Instantaneous area
worked per hour
hect/h or acre/h
no
yes
yes
FUEL/HR
Instantaneous hourly
consumption
l/hr or gal/hr
no
no
yes
FUEL/HECT
Instantaneous hourly
consumption per unit
of worked area
l/hr or gal/hr
no
yes
yes
COST/HECT
currency unit
no
yes
0.01
yes
FUEL
Fuel consumed
litre
yes or adjust
no
1 litre
no
AREA
Area worked
hect or acre
yes
yes
no
DISTANCE
Distance covered
metre or mile
yes
yes
1 metre or 1 mile
no
HOURS WORKED
Hours worked
hour
yes
yes
0.1 hour
no
COUNTER
Counter
none
yes
yes
no
COMPARE
Comparative mode
TEMPERATURE
Temperature
C ou F
no
no
1 C or 1 F
-35 C or -31 F
no
Issue 1
May 2001
MENU
FUNCTION
UNITS
Metric
USA
English
RESET
OR
ADJUST
Datatronic 2 - Description
WORKING
POSITION
REQUIRED
DISPLAY
INCREMENT
MINIMUM
VALUE
DISPLAYED
COMPARE
MODE
HOUR
Hour
H.min.sec
yes
no
1 second
00.00.00
no
DATE
Date
J,M,A
yes
no
1 day
00.00.00
no
SERVICE
Service
Hour
no
1 hour
no
COST/L
Cost of fuel
currency unit
adjust
no
0.01
no
COST/HR
Hourly cost
currency unit
adjust
no
0.01
no
UNITS
Choice of units
DUAL CTRL
Work screen
ADJUST DUAL
Adjustment of
semi-mounted implements
TOWED IMPLEMENT
Work screen
Adjustment of towed
implements
ICON
Implement width
adjust
no
no
Metric, USA or UK
Metre or yard
Issue 1
May 2001
Datatronic 2 - Description
11D01.7
FUEL USED
AREAWORKED
DISTANCE
HRS WORKED
COUNTER
COMP.MODE
EXT.TEMP.
TIME
DATE
SERVICE
FUEL/COST
COST/HOUR
METRIC/IMP
2 1 0 2 9 5
H
1 6 1 3 2 5
14
Fig. 2
Issue 1
May 2001
Datatronic 2 - Description
FUEL USED
AREAWORKED
DISTANCE
HRS WORKED
COUNTER
COMP.MODE
EXT.TEMP.
TIME
DATE
SERVICE
FUEL/COST
COST/HOUR
METRIC/IMP
4 . PLOUGH
/HR
200.00
H
1 6 1 3 2 5
Servicing (Fig. 2)
Adjustment of service to a period other than 250
hours:
. Proceed in the same way as with the hourly cost but by
first selecting the SERVICE function.
-The default servicing period is 250 hours:
. Press key (2) or (3) to display the list of functions
. Select SERVICE and press key (2) or (3) so that it
appears in the selected window with indicator lamp
(4) or (5) lit.
.Press and hold down the "Reset" key
. 250 hours is automatically displayed on screen.
Issue 1
May 2001
14
Fig. 3
Datatronic 2 - Description
11D01.9
1000
9 8 0
M
2.5
11
15
The "Working" position acts upon the following functions
even when they are not displayed on the screen:
- AREA/HR
- FUEL/HECT
- COST/HECT
- AREA
- DISTANCE
- HOURS WORKED
- COUNTER
Fig. 4
Issue 1
May 2001
Datatronic 2 - Description
4 . PLOUGH
1000
9 8 0
14
2.5
6
7
Fig. 5
4 . PLOUGH
n/min
RP/M
1 8 5 0
n/min
RP/M
1 5 0 0
9
Fig. 6
Issue 1
May 2001
Datatronic 2 - Description
F . The "Wheel Slip Control" key
(Fig. 7)
Principle
- This mode of operation allows optimisation of the
tractors performance by avoiding excessive wheel
slip.
- In relation to the actual wheel slip, calculated by the
difference between the design speed provided by the
forward speed sensor and the actual speed provided by
the radar, the operator determines and displays the
limit of wheel slip that should not be exceeded during
the working session.
- As soon as actual wheel slip exceeds the wheel slip
limit determined by the operator, the Datatronic acts
upon the linkage and raises the implement as long as
the wheel slip exceeds this limit.
11D01.11
- Press any of the keys (6) to modify the digits and turn
knob (14) to increase or decrease the selected digit.
Carry out the same operation with the other digits to be
modified.
The wheel slip value must be greater than 5% of the
actual wheel slip in order to obtain efficient control.
- Press key (2) or (3) again to return to the original screen.
4 . PLOUGH
ENGINE RPM
PTO
FWD SPEED
WHEEL SLIP
SLIP LIMIT
AREA/HOUR
FUEL/HOUR
FUEL/AREA
COST/AREA
FUEL USED
AREAWORKED
DISTANCE
n/min
RP/M
1 8 5 0
2 5
5
6
12
14
13
Fig. 7
Issue 1
May 2001
Datatronic 2 - Description
Fonctionnement
- When the actual percentage of slippage exceeds the
limit of slip fixed by the operator, LED (13) corresponding to the ACTIVE SLIP CONTROL button, lights.
- At the same time, the linkage rises and the LED lights.
- As the traction load reduces, the slip value drops until
it reaches the limit set by the operator.
- As soon as the actual wheel slip is less than the slip
limit, LED (13) and the MoveUp LED go off, the
MoveDown LED lights and the linkage lowers until the
implement reaches its initial position.
- The wheel slippage control acts in exactly the same
manner as an operator who is constantly modifying the
adjustment of the height / depth control on the linkage
console.
1 . SEED DRILL
2 . SEMOIR.
3 . SEMOIR.
41.8 HA
4 . SEMOIR.
41.8 HA
132.3 L
HA
41.8132.3
L H
L 6.0
132.3 6.0
H KM
123.7
H
6.0123.5
KM
KM2.5 M M
123.5 2.5
5 >999<
2.5 5 M
>999<
5 >999<
ON1ON21 321432 43 4
ON
ON 1 2 3 4
Fig. 8
G . "Memory" keys
The Datatronic allows working with four independent
memories (Fig. 8)
The functions taken into account are:
. the total worked area
. the quantity of fuel consumed
. the total work time
. the total distance run
. the implement width
. the counter
These four memories can be used at any time.
Issue 1
May 2001
Datatronic 2 - Description
11D01.13
1 . SEED DRILL
41.8
132.3
6.0
123.7
2.5
5
4 . PLOUGH
HA
L
H
KM
M
41.8
132.3
6.0
123.7
2.5
5
>999<
ON 1 2 3 4
HA
L
H
KM
M
>999<
14
ON 1 2 3 4
10
Fig. 9
Issue 1
May 2001
Datatronic 2 - Description
11D01.14
41.8
132.3
6.0
123.7
2.5
5
HA
L
H
KM
M
>999<
OFF 1 2 3 4
16
10
Fig. 11
1 . SEED DRILL
1000
9 8 0
n/min
RP/M
1 8 5 0
4 . PLOUGH
4 . PLOUGH
41.8
132.3
6.0
123.7
2.5
5
HA
L
H
KM
M
1000
9 8 0
n/min
>999<
ON 1 2 3 4
10
RP/M
1 8 5 0
10
Fig. 10
Issue 1
May 2001
Datatronic 2 - Description
11D01.15
4 . PLOUGH
41.8
132.3
6.0
123.7
2.5
5
HA
L
H
KM
M
>999<
ON 1 2 3 4
8
Fig. 12
Issue 1
May 2001
Datatronic 2 - Description
H . Comparative mode
This mode of operation allows the tractors performance
to be optimised by comparing reference working values
to the new values that the operator varies and acts upon
while driving the tractor.
In relation to the new values obtained, the operator can
judge whether or not they improve the economic performance of the tractor.
If the new adjustments correspond to the operators
economic performance criteria, they can be retained.
The variables in this mode of operation are:
- engine speed
- PTO speed
- forward speed
- wheel slip
- cost / hectare
- fuel / hour
- fuel / hectare
FUEL USED
AREAWORKED
DISTANCE
HRS WORKED
COUNTER
COMP.MODE
EXT.TEMP.
TIME
DATE
SERVICE
FUEL/COST
COST/HOUR
METRIC/IMP
ENGINE RPM
PTO
FWD SPEED
WHEEL SLIP
SLIP LIMIT
AREA/HOUR
FUEL/HOUR
FUEL/AREA
COST/AREA
FUEL USED
AREAWORKED
DISTANCE
2
3
14
4 . PLOUGH
Issue 1
May 2001
n/min
RP/M
1 8 5 0
n/min
RP/M
1 5 0 0
10
Fig. 13
Datatronic 2 - Description
11D01.17
ENGINE RPM
PTO
FWD SPEED
WHEEL SLIP
SLIP LIMIT
AREA/HOUR
FUEL/HOUR
FUEL/AREA
COST/AREA
FIN
14
Fig. 14
Issue 1
May 2001
Datatronic 2 - Description
11D01.18
(4)
(5)
(6)
(7)
(8)
(9)
Injectors
Filters
Injection pump
Tank return
Tank inlet
Cooler
8
2
Fig. 15
Issue 1
May 2001
Datatronic 2 - Description
Parts list
(4)
(5)
(6)
(7)
(8)
(9)
(1) Flowmeter
- inlets: . EA: decanting device inlet
. EA: leak return
- outlets: . A: to feed pump
. R: to tank
11D01.19
Injectors
Filters
Injection pump
Tank return
Tank inlet
Cooler
8
2
Fig. 16
Issue 1
May 2001
Datatronic 2 - Description
11D01.20
Parts list
(4)
(5)
(6)
(7)
(8)
(9)
(1) Flowmeter
- inlets:
Injectors
Filters
Injection pump
Tank return
Tank inlet
Cooler
8240 Dynashift
8
2
3
7
Issue 1
Fig. 17
May 2001
Datatronic 2 - Description
Parts list
(4)
(5)
(6)
(7)
(8)
(9)
(1) Flowmeter
- inlets:
11D01.21
Injectors
Filters
Injection pump
Tank return
Tank inlet
Cooler
9
1
8
2
Fig. 18
Issue 1
May 2001
Datatronic 2 - Description
Parts list
(4)
(5)
(6)
(7)
(8)
(9)
(1) Flowmeter
- inlets:
Injectors
Filters
Injection pump
Tank return
Tank inlet
Cooler
8250 Dynashift
8
2
Fig. 19
Issue 1
May 2001
Datatronic 2 - Description
Parts list
(1) Flowmeter
- inlets:
(4)
(5)
(6)
(7)
(8)
(9)
11D01.23
Injectors
Filters
Injection pump
Tank return
Tank inlet
Cooler
1
8
2
Fig. 20
Issue 1
May 2001
Datatronic 2 - Description
J . Diagram
(1) Datatronic 2
(2) Connectors on Datatronic 2
1. Engine / radar programmable frequency output
2. PTO / design forward speed programmable
frequency output
3. Max. wheel slip frequency output
4. CAN network ground
5. CAN network ground
6. PTO input speed
7. Fuel output flowrate frequency input
8. Fuel return flowrate frequency input
9. Ground
10. + 9.5 V sensor supply
11. CAN network (low)
12. Not used
13. Not used
14. Design forward speed input
15. Ground
16. Towed implement working position information
input
17. Counter information input
18. Analog signal input
19. Not used
20. CAN network (high)
21. Not used
22. Not used
23. Ground
24. Radar signal input
25. Not used
26. Linkage position signal input
27. + 12 V after contact
28. Not used
29. Air temperature sensor
(3)
(4)
(5)
(6)
Issue 1
May 2001
Colour code
B
BE
BL
G
J
M
N
R
Ro
S
V
Vi
=
=
=
=
=
=
=
=
=
=
=
=
White
Beige
Blue
Grey
Yellow
Brown
Black
Red
Pink
Salmon
Green
Violet
C
F
= Light
= Dark
Fig. 21
Datatronic 2 - Description
11D01.25
10
20
29
19
11
3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
1
2
3
4
5
6
7
1
2
3
4
5
6
7
1
3
7
11
15
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
2
6
10
14
16
6
7
1
3 4
7
1
4
3
5
1
2
3
1
2
3
4
5
4
5
3
5
1
4
Parts list
Issue 1
May 2001
Fig. 21
11D02.1
CONTENTS
A.
General ________________________________________________
B.
C.
D.
Adjustments ____________________________________________
E.
Use ____________________________________________________
F.
G.
Issue 1
May 2002
A . General
In addition to the basic electronic linkage functions, the
ELC calculator is allocated new functions such as Dual
Control.
With this system, when the front plough is to be used, it
is possible to lower the front plough in relation to the rear
and vice versa, depending on the selected mode (Furrow
start or Furrow end).
Since mid January 2001, this system is available on the
6200 and 8200 series with at least two electro-hydraulic
spool valves and the Joystick. It is however possible to
have a third electro-hydraulic spool valve controlled by an
additional lever.
The Dual Control can be used either manually via the
Joystick or additional lever, or automatically after having
entered data into the Datatronic.
The ELC calculator serves as an interface between the
control switches, the potentiometers, sensors,
Datatronic, solenoid valves, etc.
All this information transits via the BUS CAN, which cuts
out the need for a great deal of wiring.
Note:
- The calculator is the same model on all tractors
and can operate Rear Dual Control, Front Dual
Control and the TIC, but only one of these functions may be used at any one time. It is however
possible to have all three functions on the same
tractor.
Dual Control is available with the Joystick and therefore
two electro-hydraulic spool valves. In this case, one of
the two spool valves is used for the Dual function. The
manual control is carried out through action on the
Joystick along the red coloured Y axis.
If there is Front Dual Control then there is also Rear Dual
Control.
Issue 1
May 2002
11D02.3
B . Block diagram
With the front Dual Control, the rear implement enters the
earth at the precise spot where the forward implement
entered the ground.
To do this, the system needs to take into account all the
functions and parameters shown below, in order to
provide optimum operation.
+ 9,5 V
Lever
or Joystick
+ 9,5 V
Position sensor on
front lift control
system
E
BATTERY
L
C
+ 12 V
Solenoid valve
control system
+ 12 V
Spool valve
control valve
Ground
LED diagnostic on
solenoid valve
12 V +AC
CAN BUS
Engine speed
and forward speed,
Auto 3 to Dynashift
or TC to PowerShift
FRONT
DUAL
CONTROL
A
L
C
U
ACTIVATION
BUTTON
L
A
T
O
R
Potentiometers
and lift control switch
+ 9,5 V
CAN BUS
Issue 1
Datatronic
May 2002
11D02.4
ELC calculator
- the calculator is the same on all models, only one
reference is available.
- this calculator allows parameterisation, see section
11C01 - Operation of the calculator.
Components of the Front Dual Control
- 12 V supply to the calculator.
Note:
- If the front external control button is pushed, the
Spool valve Management System (SMS) and the
rear lift are secured. To unlock them, press on the
Joystick activation switch and the lift control
switch (in lift raise position).
- If the rear external control button is pushed, only
the rear lift will be secured.
5
3
10
7
11
8
12
14
13
Fig. 1
Issue 1
May 2002
11D02.5
2
9
3
CAN
8
4
5
7
Fig. 2
Issue 1
May 2002
11D02.6
:
:
:
:
:
EXT.TEMP.
TIME
DATE
SERVICE
FUEL/COST
COST/HOUR
METRIC/IMP
JOYSTICK
MAX FLOW
KICK OUT
TRAILED
TRAIL. ADJ
DUAL CTRL
REAR ADJ
REAR CTRL
FRONT ADJ
FRONT CTRL
3
14
Fig. 3
A
B
C
D
E
F
G
H
I
J
M
N
5
2
6
1
50
50
ON
10
5
Fig. 5
Issue 1
May 2002
Fig. 4
11D02.7
A
B
C
D
E
F
G
H
I
J
M
N
5
2
10
Fig. 6
Issue 1
May 2002
E . Use
- The screen shown in Fig. 7 is displayed to the driver
when he uses the Front Dual Control.
- To activate the Front Dual Control, press key 6 - 5 (OFF/
ON transition on Datatronic).
- To remove the padlock symbol on the Datatronic
screen, move the lift control switch to the Raise
position.
Safety delay
Working mode
- When Front Dual Control is in Working mode, the front
lift reproduces the movements of the rear lift.
- In this mode, the position of the front lift can be
corrected by manual action on the Joystick or the
additional lever.
- This correction is stored in this mode as long as the
function is ON and the mode has not been changed.
Example:
Value
. Furrow start mode
25
. Working mode (action on lever)
35
. Headland furrow mode
235
. then Furrow start mode again
25
In this case, the Datatronic will not have stored the
Working mode height, only the height pre-programmed
in the Datatronic (the above values are the values given
by the Datatronic to the driver).
Furrow end
- In Working mode, if the system detects a Work /
Transport transition, the system goes into Furrow end
mode.
- The sequence that is then carried out is:
. The front lift raises to the pre-adjusted height
. When the distance travelled by the tractor is identical to
the programmed distance between front implement
and rear implement, the rear lift raises to the preadjusted height set in the Datatronic.
Note: When the front implement is raised, the rear
implement can continue to work normally with the
pre-defined settings.
50
50
ON
6
Fig. 7
Issue 1
May 2002
11D02.9
F . Error codes
Front Dual Control errors that may appear
on the Datatronic screen
E-60 :
E-61 :
E-62 :
E-63 :
E-65 :
E-66 :
E-67 :
E-68 :
E-69 :
Issue 1
May 2002
11D03.1
CONTENTS
A.
General ________________________________________________
B.
C.
D.
Adjustments ____________________________________________
E.
Use ____________________________________________________
F.
11
G.
11
Issue 1
May 2002
A . General
In addition to the basic electronic linkage functions, the
ELC calculator is allocated new functions such as
handling Rear Dual Control.
With this system, when the driver uses a semi-mounted
plough, he only has to operate the lift.
For example, during the Furrow start phase, press on the
lift control switch:
the lift lowers and the wheel partially lowers
then the wheel support completely lowers when it
reaches the level of the furrow start of the first plough
share (automatically).
Since mid January 2001, this system is available on the
6200 and 8200 series with at least two electro-hydraulic
spool valves and the Joystick. It is however possible to
have a third electro-hydraulic spool valve controlled by an
additional lever.
Before January 2001, the Rear Dual Control was offered
with:
- an additional electric lever
- an electro-hydraulic spool valve controlled by 17 bar
pressure. Nowadays, the spool valves use 22 bar
pressure.
The Dual Control can be used either manually via the
Joystick or additional lever, or automatically after having
entered data into the Datatronic.
The calculator serves as an interface between the control
switches, potentiometers, sensors, Datatronic, spool
valves, etc.
All this information is transmitted via a CAN BUS which
cuts off the need for a great deal of wiring.
Issue 1
May 2002
11D03.3
B . Block diagram
The Rear Dual Control is generally used on Semi-mounted
ploughs in order to enter both parts of the plough on the
same line, to produce headland furrows that are as short
as possible.
Lever
or Joystick
+ 9,5 V
+ 9,5 V
Position sensor on
semi-mounted plough
E
BATTERY
L
C
+ 12 V
Solenoid valve
control system
+ 12 V
Spool valve
control valve
Ground
LED diagnostic on
solenoid valve
12 V +AC
CAN BUS
Engine speed
and forward speed,
Auto 3 to Dynashift
or TC to PowerShift
REAR
DUAL
CONTROL
A
L
C
U
ACTIVATION
BUTTON
L
A
T
O
R
Potentiometers
and lift control
switch
+ 9,5 V
CAN BUS
Issue 1
Datatronic
May 2002
11D03.4
Note:
- If the front external control button is pushed, the
Spool valve Management System (SMS) and the
rear lift are secured. To unlock them, press on the
activation switch on the Joystick and the lift control switch (in lift raise position).
- If the rear external control button is pushed, only
the rear lift will be secured
5
3
10
7
11
8
12
14
13
Fig. 1
Issue 1
May 2002
11D03.5
2
9
3
BUS CAN
8
4
5
7
6
Fig. 2
Issue 1
May 2002
EXT.TEMP.
TIME
DATE
SERVICE
FUEL/COST
COST/HOUR
METRIC/IMP
JOYSTICK
MAX FLOW
KICK OUT
TRAILED
TRAIL. ADJ
DUAL CTRL
REAR ADJJ
REAR CTRL
FRONT ADJ
FRONT CTRL
3
14
Fig. 3
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Fig. 4
4 . CHARRUE
D MY
2 1 0 2 9 5
25
-10
-10
ON
4
5
14
Fig. 5
Issue 1
May 2002
11D03.7
A = 11 mm
B = 04 mm
Fig. 6
1234
Fig. 7
Issue 1
May 2002
Note:
- The adjustment phases I to P are extremely important and affect the performance of the system.
- The values I, J, K and L between 0 and 100 are points
and each point equals 25 cm, therefore the distance
may be between 0 cm and 250 m.
Issue 1
May 2002
-15
-15
-0
-0
16
17
+15
ON
2
14
Fig. 8
11D03.9
E . Use
4 - PLOUGH
D MY
2 1 0 2 9 5
25
Working mode
-10
-10
ON
Fig. 9
20
21
22
23
25
26
24
X
Fig. 10
Issue 1
May 2002
Plough length
- This data represents a value from the distance of the
tractor rear wheel axis to the plough wheel support axis.
- This adjustment affects the time delay for the partial
lowering or raising of the plough wheel support.
Optimum adjustment
- Adjustment obtained by search for best plough length
values providing entry into the earth of the first and last
share on a same furrow start line.
Issue 1
May 2002
11D03.11
F . Error codes
Dual Control error codes that may appear
on the Datatronic screen
E-60 :
E-61 :
E-62 :
E-63 :
E-65 :
E-66 :
E-67 :
E-68 :
E-69 :
Issue 1
May 2002
Datatronic 2 - TIC
11D04.1
CONTENTS
A.
General ________________________________________________
B.
C.
D.
Adjustments ____________________________________________
E.
Using __________________________________________________
12
F.
12
G.
13
Issue 1
May 2002
Issue 1
Datatronic 2 - TIC
May 2002
Datatronic 2 - TIC
11D04.3
A . General
The TIC (Trailed Implement Control) is a digital control
system ensuring the automatic steering of trailed implements through the ELC console. The information required
for system operation is gathered by the sensors. This
information is processed by Datatronic. The ELC calculator ensures the control of the trailed implement through
an electro-hydraulic spool valve.
Since January 2001, this system is available for 6200
and 8200 tractors with at least two electro-hydraulic
spool valves and a joystick. However, it is possible to
have a third electro-hydraulic spool valve controlled by an
extra lever. The wheel slip control comes with the basic
equipment, the drawbar draft control is an option available on 8200 tractors but not on 6200.
Before January 2001, the TIC was already proposed
(only on 8200) with:
- an extra electronic lever
- an electro-hydraulic spool valve controlled with 17 bar
pressure whereas today the spool valve is controlled
under 22 bar pressure.
Electronic information circulates through a CAN bus
system, which helps reduce the number of wires.
Issue 1
May 2002
Datatronic 2 - TIC
11D04.4
B . Block Diagram
To allow the control of the trailed implement according to
the effort provided by the tractor, different protection
components and sensors should be taken into account,
so that an optimal operation of the system is achieved.
+ 9,5 V
+ 9,5 V
E
BATTERY
Lever or
Joystick
Position sensor on
Semi-mounted
implement
+ 12 V
Solenoid valve
management system
+ 12 V
Control valve of
spool valve
L
C
TIC
C
+ 9, 5 V
Draft sensor on
the drawbar
A
L
Masse
C
ACTIVATION
BUTTON
12 V +AC
External linkage
button
BUS CAN
+ 9,5 V
Potentiometers and
ELC switch
L
A
T
O
R
BUS CAN
Issue 1
May 2002
Datatronic
Datatronic 2 - TIC
Description of the TIC System
ELC calculator
- The calculator is the same for all, only one reference is
available.
- This calculator allows parameter setting. See section
11F05 for calculator operation.
TIC components
- The extra lever fed with +9.5V supply
- The position sensor fitted on the implement
Note:
- If the Front linkage external control button is
pressed, the SMS and the rear linkage are blocked.
To release it, press the activation switch of the
Joystick and the ELC switch (in raise position).
- If the rear linkage controls are pressed, only the
rear linkage will be blocked.
11D04.5
Issue 1
May 2002
Datatronic 2 - TIC
11D04.6
5
3
10
7
11
8
12
14
13
Parts list
Issue 1
May 2002
Fig. 1
Datatronic 2 - TIC
Datatronic
The ELC calculator is connected with Datatronic through
the CAN bus.
Datatronic receives information from the TIC system
(error codes, position sensor on the extra implement lever)
and sends radar speed, wheel slip required value. Datatronic
allows to adjust the implement height to its maximum and
minimum, and to activate the TIC function.
11D04.7
2
9
3
CAN
4
6
8
7
Fig. 2
Issue 1
May 2002
Datatronic 2 - TIC
COST / HOUR
UNITS
TRAILED
TRAIL. ADJ
.... DUAL ....
FRONT CTRL
REAR CTRL
FRONT ADJ
REAR ADJ
.. JOYSTICK ..
Once the parameters have been set (see D), press (2)
or (3) and another window appears; it will be used for
work (Fig.5) settings.
(1) indicates (Transport or Work) function
(2) indicates position of the implement in %:
- Low position = 0 %
- High position = 99 %
(3) indicates whether the implement is raised or lowered
(4) the padlock indicates whether the ELC console is
locked or open
(5) indicates whether the TIC function is ON or OFF
Fig. 3
0
0
0
0
C
D
5
Fig. 4
Fig. 5
1
2
50
5
ON
5
4
Issue 1
May 2002
Datatronic 2 - TIC
D . Settings
11D04.9
A = 11 mm
B = 04 mm
Fig. 6
Sensor
disconnected
Sensor
adjustment
limit
Sensor
in low
position
Sensor
in raise
position
Sensor
adjustment
limit
23
215
250
255
217
217
37
37
A : Programmed height
B : Present height
C : Programmed depth
D : Present depth
A
B
C
D
Fig. 7
Issue 1
May 2002
Datatronic 2 - TIC
Bar
Pin
Screw
Pin
Ring
Bearing
Screw
Plate
Retainer
Shackle
Washer
Pin
Lever
Cotter pin
Clevis
Bar
Screw
Ring
Lock plate
Screw
Washer
Draft sensor
Connector
Screw
Plate
Guard
Screw
Guard
Clevis
Washer
Issue 1
May 2002
Datatronic 2 - TIC
11D04.11
25
2
23
24
21
22
18
3
27
28
29
30
12
26
5
13
7
8
19
4
9
1
21
14
15
20
16
10
11
17
Parts list
Issue 1
Fig. 8
May 2002
Datatronic 2 - TIC
E . Using
The user interface consists of a Datatronic half-screen.
Each time the tractor is stopped, the TIC function is
disabled for safety reasons, and OFF is displayed on the
screen.
To activate the function, press the ELC switch to raise
position, then on TIC user screen press the 6-5 key (Fig.
9).
50
ON
Working mode
- when the TIC is in this mode, the height of the
implement can be adjusted with the lift height adjustment potentiometer situated beside the armrest.
- To change the implement from the working mode to
headland furrow mode, press the lift button.
F . Error codes
TIC errors that may be displayed on the
Datatronic screen
E-60 : Position sensor disconnected
E-61 : Upper limit of implement position sensor
ceeded
E-62 : Lower limit of implement position sensor
ceeded
E-63 : Spool valve control sensor disconnected
E-64 : Upper limit of spool valve control sensor
ceeded
E-65 : Lower limit of spool valve control sensor
ceeded
E-66 : Raise solenoid valve disconnected
E-67 : Lower solenoid valve disconnected
E-68 : Raise solenoid valve short-circuited
Issue 1
Fig. 9
exex-
exex-
May 2002
Datatronic 2 - TIC
11D04.13
3
2
23
1 . Lever assembly
19
DUAL
30
11
13
31
7
12
6
35
14
51
50
16
33
47
10
34
42
11
46
28
27
10
12
45
46
49
4
48
44
52
38
43
Note: The electro-hydraulic spool valves are different for the periods before and after February 2001
(see below)
- Rexroth MP18 type before January 2001, current
adjustments to be carried out with Wintest (see
section11F05)
- Bosch SB23 type after January 2001, valve parameter settings to be carried out with Wintest (see
section 11F07)
21
24
32
25
53
22
41
25
17
37
26
36
18
17
15
29
39
40
Issue 1
May 2002
27
Fig. 10
3
2
23
19
DUAL
Datatronic 2 - TIC
30
35
11
13
31
1
12
14
6
8
46
16
51
50
33
47
10
34
42
11
12
28
27
10
31
13
46
45
12
4
44
48
49
52
38
21
24
32
25
53
28
27
43
22
41
25
17
37
26
36
18
17
15
29
39
40
27
Fig. 11
Fig. 12
Issue 1
May 2002
Datatronic 2 - TIC
2. Assembly of the Dual Control electrohydraulic spool valves before January 2001
- Rexroth MP18
11D04.15
Fig. 13
Parts list
(1) Priority block
(2) Electro-hydraulic spool valve
(3) T union
Issue 1
May 2002
Datatronic 2 - TIC
11D04.16
x3
3
6
7
11
12
16
15
14
13
17
5
10
Issue 1
May 2002
Fig. 14
Datatronic 2 - TIC
18
17
19
20
11D04.17
14
15
16
11
3
18
1
2
23
22
21
12
9
6
12
13
10
8
7
7
21
22
23
15
12
10
12
10
19
18
16
20
17
21
26
13
11
25
24
7
10
12
10
13
6
8
9
13
10
9
13
14
Issue 1
13
Fig. 15
May 2002
Issue 1
Datatronic 2 - TIC
May 2002
Datatronic 2 - TIC
3. Assembly of the spool valves since January 2001 - Bosch SB23
- The differences compared to Rexroth are the following:
. a different electrical diagram (Fig. 16 and 17), different
connections, use of the CAN bus
. spool valve control hydraulic supply is now 22 bar
instead of 17 bar. To obtain this pressure it was
necessary to install an end plate containing a pressure
reducing valve, which by dividing the main hydraulic
flow allows to obtain a 22 bar pressure to control
electro-hydraulic spool valves. This end plate also
contains a solenoid valve that blocks oil flow in case
a problem is detected by the ELC and the internal
management system of the spool valves.
Parts list of the electrical diagram SB 23 (Fig. 16)
(20) SB23 Dual Control spool valve
(21) Manual control lever
(22) Position sensor fitted on the implement
(23) TIC draft sensor
(24) Position sensor
(25) Front linkage external controls
11D04.19
Issue 1
May 2002
Datatronic 2 - TIC
May 2002
Datatronic 2 - TIC
11D04.21
14
16
N
BF
K3
15
K5
19
13
12
K1
17
L
M/J
N
VF
11
N/B
Ro
10
H
G
9
G
VC
F
J
R/B
E
Vi
7
M
Ro
D
5
Vi
O
M
B
4
C
Q
23
B
N/G
O
A
N
R
O
21
S
N
N
R
M
R bis
R
Issue 1
22
20
Vi
R
2
1
Fig. 16
May 2002
Electronics - Wintest
11F01.1
CONTENTS
A.
B.
C.
D.
Connections _______________________________________
E.
F.
13
Issue 2
May 2002
Issue 2
Electronics - Wintest
May 2002
Electronics - Wintest
A . General - Description
Wintest software allows to:
- program Autotronic 2, Autotronic 3, TC, DCC and
Datatronic during part replacement, or following the
issue of a new and improved program
- change the parameters of Autotronic 2, Autotronic 3,
TC, DCC, ELC, SMS system and Datatronic according
to the options fitted to the tractor and its features
- display the operation of Autotronic 2, Autotronic 3, TC,
DCC and Datatronic and linkage and to detect any
malfunction.
Its use with each device is described in the following
sections:
- Autotronic 2 ................................................. 11 F02
- Autotronic 3 ................................................. 11 F03
- TC / DCC ..................................................... 11 F04
- Electronic linkage ........................................ 11 F05
- Datatronic .................................................... 11 F06
- SMS ............................................................ 11 F07
- Autotronic 3 towards Autotronic Kit ............. 11 F08
- Autotronic kit towards Autotronic 3 .............. 11 F09
11F01.3
Tested PCs
- Toshiba Satellite 2520 CDT
. AMD K6 microprocessor
. 300 MHz
. 64 MB SDRAM
. 4.1 GB hard drive
. CD-ROM and floppy drive
. 12.1 inch colour monitor
. Windows 98 OS
. Optional: 12V cigar lighter power supply
- Dell Latitude Cpi
. Pentium II microprocessor
. 233 MHz
. 32 MB SDRAM, extendable to 128 MB
. 4.1 GB hard drive
. 12.1 inch colour monitor
. Windows 95 or Windows 98 OS
. Optional: 12V cigar lighter power supply
Both these PCs have been tested with the Wintest
software. It is recommended that you check the guarantee and breakdown service conditions with your local
dealer.
Issue 2
May 2002
Electronics - Wintest
Installation procedure
- Boot the PC so that the desktop is displayed.
Windows 3.11
. Click on the "File" menu
. Click on "Run"
Windows 95 or 98
. Click on the "Start" menu
. Click on "Run"
Issue 2
May 2002
Electronics - Wintest
11F01.5
Wintest
Test
Options
Update
Help
GO!
Help
WGE-1
The following screen is displayed:
Update
Insert update disk in drive A
OK
Yes
Cancel
WGE-2
Issue 2
May 2002
Electronics - Wintest
11F01.6
D. Connections
Important :
- Never directly connect the PC to the 16-pin connector without the CAN BOX interface
- Battery voltage must be 12.5V minimum.
Fig. 2
Fig. 3
Auto 2
Programing
Setting
Test
Setting parameters
Test
Setting parameters
Test
Auto 3
TC/DCC
Connectors used
Programming
Program
Setting parameters Setting parameter
Test
Test
Power Shuttle
manal calibration
Cab 16 pin
connector
Connection
Linkage
Data 2
SMS
Connectors used
Fig. 1
Fig. 2
Setting parameters
Test
Fig. 3
Test
Issue 2
Programming
Joystick
calibration
Setting parameters Setting valve
Test
parameters
Test
-
May 2002
Cab 16 pin
connector
Electronics - Wintest
11F01.7
AGCO
E
3378244M1
3714779M1
C33
Fig. 1
CAN BOX
AGCO
Fig. 2
Issue 2
May 2002
Electronics - Wintest
11F01.8
3378246M1
3378243M1
CAN BOX
AGCO
3378245M1
C35
3715767M1
C33
3714779M1
3378244M1
Fig. 3
Issue 2
May 2002
Electronics - Wintest
11F01.9
Edit
Display
WIN
TEST
Wintest
1 objects
652 octets
bytes
WGE-3
Wintest
Test
Options
Help
GO!
Help
WinTest V1.10.06
B00AA03001456
M. ROCHEFOUCAULT
AGCO
TC
D CC
TCU 0 92
TCU 0 93
D ATA 2
AUTO3
KIT AUT OTRO NIC
:
:
:
:
:
:
:
2.14
2.14
R
C
D 001208
B11
X32
WGE-4
- Click on
to return to the Windows desktop and exit Wintest
- Click on "Help" to access the Wintest Help files.
Issue 2
May 2002
Electronics - Wintest
Setup
Auto
Auto 32Kit Autotronic
Auto 3
OK
Autotronic 2
TC-DCC
Cancel
Autotronic 3
Help
Datatronic 2
Linkage
Joystick
WGE-5
Issue 2
May 2002
Electronics - Wintest
11F01.11
Programming TC
Check the connections
Turn the ignition key
Retry
Cancel
CAN error
Initialization of CAN BOX not
possible
OK
WGE-7
- Check the connections between the PC and the 16-pin
connector, then click on "OK".
Issue 2
May 2002
Electronics - Wintest
11F01.12
Wintest
Test
Options
GO!
Help
Help
Wintest
Tester
OK
Help
DATA : D960500
TCU : R
9:25
NUM
WGE-8
Issue 2
Datatronic ..............
Autotronic 2 ...........
DATA: D960500
TCU: R
May 2002
Electronics - Wintest
11F01.13
F . Wintest version
- Click on "Help", then "About Wintest" to display the
software version and the programmes in the various
electronic devices.
Wintest
Test
Options
GO!
Help
Index
How to use Help
About Wintest...
Help
WGE-9
The following screen is displayed:
Wintest
Option
Tester
Aide
GO!
H elp
Abou t teste
r
WinTest
WinTest Version 18016
C opyright ' 1995. A llR ights R eserved
TC
D CC
D A TA 2
TC U 092
TC U 093
A U TO 3
:
:
:
:
:
:
2.08
2.13
D 001208
R
C
B 09
M . R O C H EFO U C A U LT.
A G C O FR A N C E B eauvais
B 00AA 03001456
OK
WGE-10
-
V1.10.06
2.14
2.14
D001208
R or C
B11
Issue 2
May 2002
Electronics - Wintest
11F02.1
CONTENTS
A.
B.
C.
19
D.
31
33
37
40
43
Issue 2
May 2002
Electronics - Wintest
11F02.2
Autotronic 2 status
Wintest
Test
GO!
Help
Autotronic
1064
4.1
0.0 Amps
Off
0.0 Amps
Off
100 %
280
280
Range
switch
Err : 0
Connector: J1-32
Colour: White
Off
OK
TCU 2
EV1
On
EV2
Off
OK
Help
WA2-1
Issue 2
May 2002
Electronics - Wintest
11F02.3
Wintest
Test
Options
GO!
Help
Help
Tractor code
19
OK
WA2-2
Issue 2
May 2002
Electronics - Wintest
Programming / Reprogramming
The software of Autotronic 2 will be incorrect for
tractor where it should be fitted.
To modify the Autotronic 2 software:
1. Connect the PC with Wintest to the tractor fitted
with the Autotronic 2 (Fig. 1).
2. Disconnect the "E" CAN harness between the
Autotronic 2 and the testing equipment (Fig. 1).
3378246M1
3378243M1
3378245M1
CAN BOX
AGCO
E
3378244M1
3714779M1
C33
Fig. 1
Issue 2
May 2002
Electronics - Wintest
11F02.5
3. Start Wintest.
4. Click on "GO" to access the main menu.
Wintest
Test
Options
GO!
Help
Help
WA2-3
Setup
Auto 2
Auto 3
OK
Autotronic 2
TC-DCC
Cancel
Autotronic 3
Help
Datatronic 2
Linkage
Joystick
WA2-4
Issue 2
May 2002
Electronics - Wintest
11F02.6
6. The following screen is display.
Click on "Cancel".
Retry
Cancel
WA2-5
Wintest
Test
Options
GO!
Help
Help
Tractor code
19
OK
WA2-6
Issue 2
May 2002
Electronics - Wintest
11F02.7
Winest
Options
Test
Help
GO!
H elp
Wintest
Parameters ......
Autotronic 2 parameters
Programming Autotronic 2
OK
Help
TCU : O FF
9:25
NUM
WA2-7
Nota :
- The software version "R" or "C" is automatically
selected by Wintest according to the "AA" code
entered at the operation 9 or read when you start
Wintest.
- To program, put the ignition on and start the
engine. The voltage must be at least 12,5 V.
Issue 2
May 2002
Electronics - Wintest
11F02.8
The following screen is displayed:
Wintest
Test
Options
GO!
Help
Help
Wintest
Programming Autotronic 2
Yes
No
OK
Help
WA2-4
Issue 2
May 2002
Electronics - Wintest
During programming, several error messages
may be displayed:
1. Stop the engine
2. Battery voltage too low
3. Unable to enter Programming mode
4. Unable to begin Boot programming
5. Unable to leave Programming mode
6. Unable to delete program
7. Unable to change page
8. Unable to program line
9. Cannot program a byte
10. Programming impossible
11. Unable to open source file
11F02.9
Correction method
Message 1: Stop the engine
Message 2: Check battery voltage
Messages 3 - 4 - 5: Check connection of the CAN BOX
interface and turn the ignition key off
Messages 6 - 7 - 8 - 9 - 10: The Autotronic 2 is defective
Message 11: Hard drive problem. Re-install the
WINTEST software on your PC.
Wintest
Test
Options
GO!
Help
Help
Wintest
Error message
OK
Help
Retry
Cancel
WA2-5
Issue 2
May 2002
Electronics - Wintest
11F02.10
Wintest
Test
Options
GO!
Help
Help
Wintest
Programming Autotronic 2
OK
Help
OK
WA2-6
- Start the engine.
- Click on OK
Issue 2
May 2002
Electronics - Wintest
11F02.11
Wintest
Test
Options
Help
GO!
Help
Wintest
Programming Autotronic 2
Remove connector F
OK
OK
Help
WA2-7
- Remove connector F
- Click on OK
Issue 2
May 2002
Electronics - Wintest
11F02.12
The following screen is displayed:
Wintest
Test
Options
Help
GO!
Help
Wintest
Programming Autotronic 2
Connect connector F
OK
OK
Help
WA2-8
- Connect connector F
- Click on OK
Issue 2
May 2002
Electronics - Wintest
11F02.13
Wintest
Test
Options
GO!
Help
Help
Wintest
Programming Autotronic 2
OK
OK
Help
WA2-9
- Fully depress the clutch pedal, then release it
- Click on OK
Issue 2
May 2002
Electronics - Wintest
11F02.14
The following screen is displayed:
Wintest
Test
Options
GO!
Help
Help
Wintest
100 %
OK
Help
WA2-10
Issue 2
May 2002
Electronics - Wintest
11F02.15
Wintest
Test
Options
GO!
Help
Help
Wintest
Programming Autotronic 2
Programming completed
Programming
Autotronic
2 2
Programmation
Autotronic
100 %
OK
Yes
No
Help
WA2-11
- Click on OK
Issue 2
May 2002
Electronics - Wintest
11F02.16
The following screen is displayed:
Wintest
Test
Options
Help
GO!
Help
Wintest
Programming Autotronic 2
Remove connector F
OK
OK
Help
WA2-12
- Disconnect connector F
- Click on "OK"
Issue 2
May 2002
Electronics - Wintest
11F02.17
Wintest
Test
Options
Help
GO!
Help
Wintest
Programming Autotronic 2
Connect connector F
OK
OK
Help
WA2-13
- Connect connector F
- Click on OK
Issue 2
May 2002
Electronics - Wintest
11F02.18
The following screen is displayed:
Wintest
Test
Options
GO!
Help
Help
Wintest
Programming Autotronic 2
OK
OK
Help
WA2-14
Note: It is necessary to set the Autotronic2 parameters again after programming (see C)
Issue 2
May 2002
Electronics - Wintest
11F02.19
Setting parameters
- Turn the ignition key on to carry out this operation. The
voltage must be 12.5 V minimum.
- It is necessary to change the parameters:
. if the Autotronic 2 has been replaced by a new device
. if improvements have been made to one or more
functions by changing the parameters
. if programming has been carried out
The parameter code is found on a label on the left hand
side dashboard support near the fuse box. This code
has 12 figures and corresponds to the 11 parameters
whose meaning is shown below.
Parameter code
AA
Example of setting
72
Issue 2
May 2002
Electronics - Wintest
11F02.20
CODE AA
MODEL
with
AUTOTRONIC 2
VERSION R
References
3715631M1
3792092M92
Speedshift
tractors with
30 Kph
mechanical
limitation or
Dynashift
Speedshift
tractors with
30 Kph
electronic speed
limitation from
No.G083035
onwards
Speedshift
tractors with
30 Kph
mechanical
limitation or
Dynashift
Speedshift
tractors with
30 Kph
electronic speed
limitation from
No.G083035
onwards
19
30
25
32
6110 - 6120
6130 - 6140
3050 - 3055
3060 - 3065
3065S
00
3070
01
6150 - 6160
6170
3075 - 3080
3085 - 3090
3095
02
20
31
26
33
6180
3115 - 3120
03
21
27
6190
3125 - 3140
04
22
28
Issue 2
May 2002
Electronics - Wintest
11F02.21
MODEL
with AUTOTRONIC 2
Version R
References
3715631M1 / 3792092M92
05
12
06
13
07
14
08
15
09
16
10
17
11
18
23
24
Issue 2
May 2002
Electronics - Wintest
11F02.22
Code B
Front axle
1 = 2WD
2 = 4WD (a)
3 = 4WD memory (b)
Code C
Hare / Tortoise
0 = Non synchronised
1 = Synchronised
Code F: Speedshift
0 = No Speedshift
1 = Speedshift with button
control
2 = Speedshift with steering
wheel lever
Code D
Gearbox type
Code E
Maximum speed
0= 4x2
(without AB range)
2= 4x4
(with AB range)
1 = 30 kph
2 = 40 kph except 8160
Heavy Duty
Reinforced
3 = 33 kph (Japan)
4 = 40 kph for 8160 with
Heavy Duty
reinforced gearbox
Code G: Dynashift
0 = No Dynashift
1 = Dynashift with steering wheel
lever
2 = Dynashift with gear lever
button
3 = for AGCO Allis or White
(a) Each time the engine is started, the 4WD indicator lamp is lit and the front axle engaged.
To disengage 4WD:
- press the brake pedal,
- press the 4WD switch.
The indicator lamp goes out.
The front axle is actually disengaged when the Autotronic receives a speed signal greater than 1 kph.
(b) Each time the engine is started, the 4WD is in the position stored when the engine was stopped. The 4WD
function may different according to the code (see (d)).
Issue 2
May 2002
Electronics - Wintest
Code I: Factory
0 = AGCO MF with Autotronic 371563M1 (c)
1 = Not used
2 = AGCO MF with Autotronic 3792092M92 (d)
11F02.23
0 = None
Code K: PTO
0 = with PTO
(c) Code I = 0
- changing from 4WD to 2WD is actually carried out when the speed sensor sends a signal
- the 4WD engages if there is action on one of the two brake pedals above 5 kph
(d) Code I = 2
- changing from 4WD to 2WD when stopped is actually carried out without any received speed sensor signal
- 4WD engages if there is action on one of the two brake pedals above 5 kph
Issue 2
May 2002
Electronics - Wintest
11F02.24
Open centre
hydraulic circuit
Closed centre
hydraulic circuit
6235 - 6245
70
74
71
75
6280
72
76
6290
73
77
Issue 2
8210 - 8220
Heavy Duty
34
79
8210 - 8220
Heavy Duty sealed
35
80
8240
Heavy Duty sealed
82
83
8240 - 8250
Double drive unit
36
81
May 2002
Electronics - Wintest
Code B
Front axle
1 = 2WD
2 = 4WD (a)
3 = 4WD with memory
(b)
Code C
Hare / Tortoise
0 = Non synchronised
1 = Synchronised
Code D
Gearbox type
1=4x2
(without AB range)
2=4x4
(with AB range)
11F02.25
Code E
Max. speed
1 = 30 kph
2 = 40 kph except 8160
Heavy Duty
Reinforced
3 = 33 kph (Japan)
4 = 40 kph for 8160 with
Heavy Duty
reinforced gearbox
(a) Each time the engine is started, the 4WD indicator lamp is lit and the front axle engaged.
To disengage 4WD:
- press the brake pedal,
- press the 4WD switch.
The indicator lamp goes out.
The front axle is actually disengaged when the Autotronic receives a speed signal greater than 1 kph.
(b) Each time the engine is started, the 4WD is in the position memorised when the engine was stopped. The 4WD
function may differ according to the code I (see (d)).
Issue 2
May 2002
Electronics - Wintest
11F02.26
Code F: Speedshift
0 = No Speedshift
1 = Speedshift with button
control
2 = Speedshift with steering
wheel lever
Code G: Dynashift
0 = No Dynashift
1 = Dynashift with steering
wheel lever
2 = Dynashift with gear lever
button
3 = for AGCO Allis or White
Code I: Factory
0 = None
1 = With
Code K: PTO
0 = with PTO
Issue 2
May 2002
Electronics - Wintest
11F02.27
Wintest
Test
Options
Help
GO!
H elp
Wintest
Parameter
Autotronic2 parameter...
Programming Autotronic2...
OK
Help
WA2-19
Issue 2
May 2002
Electronics - Wintest
11F02.28
The following screen is displayed:
Wintest
Test
Help
Options
GO!
Help
Wintest
Autotronic 2 parameters
AA
7272 3
OK
Cancel
OK
Help
WA2-16
- Using the Tab key, select the code to modify, then
type in the new parameter.
- Confirm the code by clicking on OK
Issue 2
May 2002
Electronics - Wintest
11F02.29
Wintest
Test
Options
GO!
Help
H elp
Wintest
Parameter
Paramtrer
Autotronic 2 parameter ....
Programming Autotronic2...
OK
Help
WA2-20A
Issue 2
May 2002
Electronics - Wintest
Autotronic 2 parameters
Tractor code
Display all
Parameter
Parameter value
Synchro type
Front axle
Tester code
Pulse/10 kph
RPTO pulse/rev
PTO ECO ratio
Engine pulse/rev
Eng. Nominal speed
Max. PFA & Diff speed
Hi -> Lo max speed
Lo -> Hi max speed
Trans type
Dynashift
Speedshift
Shuttle type
Speed limit
C ratio (eng./Fwd *8)
D ratio (eng./Fwd *8)
Synchro
With front axle stored
!0
115
28
12917
77
2200
14
! 10
8
4*2 Transmission
Telma
None
Preselect Reverse Shuttle lever
0
112
128
OK
Cancel
Help
WA2-20B
- Select "Display all" to display all the parameters.
- The "Parameter" column defines the parameter.
- The "Parameter value" column gives the characteristics
of the parameter.
Issue 2
May 2002
Electronics - Wintest
11F02.31
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WA2-21
Issue 2
May 2002
Electronics - Wintest
11F02.32
The following screen is displayed:
Wintest
Test
GO!
Help
Autotronic
1064
14,3
OK
Help
TCU 4
WA2-22
1064
Issue 2
May 2002
TCU 4
Autotronic 2 status.
Electronics - Wintest
11F02.33
"Gearbox" function
- Start the engine.
- Click on the "Gearbox" icon
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WA2-19
Issue 2
May 2002
Electronics - Wintest
11F02.34
The following screen is displayed:
Wintest
Test
GO!
Help
Autotronic
Off
1064
Off
155
On
180
EV1
On
EV2
Off
OK
Help
TCU 4
WA2-20
1064
- error at 255
Design forward speed indicated by forward
ground speed sensor in tenths of kph
0
155
- forward maximum: 160 points
- reverse maximum: 40 points
- difference between forward and reverse to be
between 70 and 110 points
Issue 2
May 2002
Electronics - Wintest
- Forward
- Reverse
Dynashift range
11F02.35
OFF
ON
ON
ON
Hare range indicator lamp
OFF
OFF
ON
ON
OFF
OFF
OFF
ON
- ON = reverse video
- OFF = normal video
-A-B-C-D
TCU 4
Autotronic 2 status
Off
OFF = solenoid valve deactivated
ON = solenoid valve activated
Issue 2
May 2002
Electronics - Wintest
11F02.36
Warning buzzer
EV1
EV2
Solenoid valve EV 1
ON
ON
OFF
OFF
Solenoid valve EV 2
OFF
ON
ON
OFF
Speedshift range
ON
OFF
Issue 2
May 2002
Electronics - Wintest
11F02.37
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WA2-25
Issue 2
May 2002
Electronics - Wintest
11F02.38
The following screen is displayed:
Wintest
Test
GO!
Help
Autotronic
1064
PFA
Off
OK
TCU 4
Help
WA2-22
1064
Issue 2
May 2002
Electronics - Wintest
11F02.39
PFA
Front axle ON / OFF solenoid valve
Off
- ON = 2WD
- OFF = 4WD
TCU 4
Autotronic 2 status
Issue 2
May 2002
Electronics - Wintest
11F02.40
Differential Lock function
- Start the engine.
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WA2-23
Issue 2
May 2002
Electronics - Wintest
11F02.41
Wintest
Test
GO!
Help
Autotronic
1064
Diff
Off
OK
Help
TCU 4
WA2-24
Issue 2
May 2002
Electronics - Wintest
Diff
Off
ON = Differential lock engaged
OFF = 4WD differential lock disengaged
TCU 4
Issue 2
May 2002
Electronics - Wintest
11F02.43
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WA2-29
Issue 2
May 2002
Electronics - Wintest
11F02.44
The following screen is displayed:
Wintest
Test
GO!
Help
Autotronic
1064
PTO
Off
OK
Help
TCU 4
WA2-30
Issue 2
May 2002
Electronics - Wintest
11F02.45
PTO
Off
ON = engaged
OFF = disengaged
TCU 4
Autotronic 2 status
Issue 2
May 2002
Electronics - Wintest
11F03.1
CONTENTS
A.
General ___________________________________________
B.
C.
Programming ______________________________________
D.
E.
15
18
23
26
29
F.
32
G.
37
Issue 2
May 2002
Electronics - Wintest
A . General
Note: There are now several configurations for installing the Autotronic 3:
- Tractor with basic Autotronic 3 (CAN network
speed: 250 Kbits)
- Tractor with basic Autotronic 2 and now equipped
with an Autotronic Kit (CAN speed: 100 Kbits) (see
section 11F08)
- Tractor with basic Autotronic 1 and now equipped
with an Autotronic Kit (no CAN network) (see
section 11F08).
It is imperative to program an Autotronic 3 used as an
Autotronic Kit (CAN network speed 100 Kbits) to obtain
a 250 Kbit CAN network speed, when the Autotronic 3 is
to be installed on a tractor equipped with a basic
Autotronic 3.
For the above, refer to section 11F09 (Kit Autotronic
towards Autotronic 3).
Issue 2
May 2002
Electronics - Wintest
11F03.3
Autotronic 3 status
Description
The Wintest software allows to program and set the
parameters of Autotronic 2 as well as to display and
detect faults within its various functions.
To carry out testing with Wintest, the status of a
function on the tractor is modified and compared with
status displayed on the screen of the PC.
- If the icon corresponding to the function is displayed
in reverse video, this indicates that 12V is present.
- If the icon corresponding to the function is displayed
in normal video, this indicates that 12V is absent.
- If no there is no change whatsoever, check the connectors, the ignition switch and test the wiring corresponding to the relevant function.
Where the function being tested seems defective, click
on the icon that represents it:
- a window is displayed showing the identity of the
connector terminals and the colour of the corresponding wires.
Example: The icon corresponding to the Hare / Tortoise range switch has been selected. Information
concerning it is displayed in a window:
J1 - 32 = Switch J1 of Autotronic 3, terminal No. 32,
wire colour white.
List of statuses
- TCU 0: ignition key turned on and parameters correct
or 17 bar pressure drop for more than
4 seconds
- TCU 1: 17 bar pressure lower than 9.5 bar and engine
speed lower than 200 rpm
- TCU 2: 17 bar pressure correct and engine speed
higher than 200 rpm
- TCU 3: 17 bar pressure drop for less than 4 seconds
- TCU 4: engine speed down for less than 0.5 seconds
- TCU 5: engine speed down for greater than
0.5 seconds
- TCU 6: 17 bar pressure lower than 9.5 bar and engine
speed lower than 200 rpm for at least
6 seconds
- TCU 7: ignition key turned on and incorrect parameters
- TCU 8: not used
- TCU 9: battery voltage above 16 V
Wintest
Test
GO!
Help
Autotronic
1064
4.1
0.0 Amps
Off
0.0 Amps
Off
100 %
280
280
Range
switch
Err : 0
Connector: J1-32
Colour: White
Off
OK
EV1
On
EV2
Off
OK
Help
TCU 2
WA3-1
Issue 2
May 2002
Electronics - Wintest
11F03.4
C . Programming
Wintest
Test
Options
Help
GO!
H elp
Wintest
Parameter ......
Auto 3 parameter
Programming Autotronic 3
List of error codes
OK
Help
WA3-2
Issue 2
May 2002
Electronics - Wintest
11F03.5
Wintest
Test
Options
GO!
Help
Help
Wintest
Programming Autotronic 3
Yes
No
OK
Help
WA3-3
Issue 2
May 2002
Electronics - Wintest
11F03.6
Correction method
Message 1: Stop the engine
Message 2: Check battery voltage
Messages 3 - 4 - 5: Check connection of the CAN BOX
interface and turn the ignition key off
Messages 6 - 7 - 8 - 9 - 10: The Autotronic 3 is defective
Message 11: Hard drive problem. Re-install the
WINTEST software on your PC.
Wintest
Test
Options
GO!
Help
Help
Wintest
Error message
OK
Help
Retry
Cancel
WA3-4
Issue 2
May 2002
Electronics - Wintest
11F03.7
D . Setting parameters
Setting parameters
- Turn the ignition key on to carry out this operation. The
voltage must be 12.5 V minimum.
- It is necessary to change the parameters:
. if the Autotronic 3 has been replaced by a new device
. if improvements have been made to one or more
functions by changing the parameters
. if programming has been carried out.
The parameter code is found on a label on the left hand
side of the dashboard near the fuse box. This code has
12 figures and corresponds to the 11 parameters
whose meaning is shown below.
Parameter code
AA
setting
39
Code AA = 39 = 6280
Code
B = 3 = 4 WD memory
Code
C = 1 = with Hare / Tortoise synchro
Code
D = 1 = with 4 x 2 gearbox
Code
E = 2 = forward speed not limited
Code
F = 0 = without Speedshift
Code
G = 4 = Dynashift with power shuttle type lever control
Code
H = 5 = Power shuttle
Code
I = 2 = for 6200 / 8200
Code
J = 1 = with creeper unit
Code
K = 2 = 6200 PTO
Issue 2
May 2002
Electronics - Wintest
11F03.8
Models with
Autotronic 3
AGCO
model
Hydraulic
pump
Open centre
Hydraulic
pump
Load sensing
RT 95
RT 115
540 rpm
PTO
RT 130
RT 145
750 rpm
PTO
RT 130
RT 145
MF
model
Type of
final drive unit
Control panel
switch N0 (*)
1 - 2 - 3 - 4 -5 - 6 - 7
AA Code
6235 -6245
1-1-1-0-1-0-0
37
6255 - 6260
6265 - 6270
0-1-1-0-1-0-0
38
6280
0-0-0-1-1-0-0
39
6290
1-1-1-0-1-0-0
40
6235 -6245
1-1-1-0-1-0-0
41
6255 - 6260
6265 - 6270
0-1-1-0-1-0-0
42
6280
0-0-0-1-1-0-0
43
6290
1-1-1-0-1-0-0
44
8210 - 8220
Heavy Duty
1-0-1-1-1-1-1
45
8210 - 8220
0-0-1-1-1-1-1
46
8240 - 8250
0-0-1-1-1-1-1
47
8240 - 8250
Composite
1-0-1-1-1-1-1
48
8210 - 8220
Heavy Duty
1-0-1-1-1-1-1
84
8210 - 8220
0-0-1-1-1-1-1
85
8240 - 8250
0-0-1-1-1-1-1
86
8240 - 8250
Composite
1-0-1-1-1-1-1
87
Issue 2
May 2002
Electronics - Wintest
Code B
Front axle
1 = 2WD
2 = 4WD (a)
3 = 4WD with memory
(b)
5 = 4WD US mode (c)
Code C
Hare / Tortoise
0 = Non synchronised
1 = Synchronised
operated by
gear shift lever
2 = Synchronised
controlled by button
Code F: Speedshift
0 = No Speedshift
1 = Speedshift with button control
2 = Speedshift with steering
wheel lever
3 = Not used
4 = Speedshift with power shuttle
type lever
11F03.9
Code D
Gearbox type
Code E
Max. speed
1=4x2
(without AB range)
Code G: Dynashift
0 = No Dynashift
1 = Dynashift with steering wheel
lever
2 = Dynashift with gear lever
button
3 = for AGCO Allis or White
4 = Dynashift with power shuttle
type lever
5 = Dynashift with Power Shuttle
and DynashiftAuto2 (Autodrive)
6 = Dynashift with Power Shuttle
and DynashiftAuto1 (Speed
matching)
Code I: Factory
1 = 30 Kph
2 = 40 Kph except 8160
Heavy Duty reinforced
3 = 33 Kph (Japan)
4 = 40 kph for 8160
with Heavy Duty rein
forced gearbox
0 = Mechanical
5 = Power shuttle
0 = None (f)
1 = With (f)
Code K : PTO
0 = without PTO
1 = PTO with ON / OFF solenoid valve
2 = PTO with proportional solenoid valve on MF 6200 and AGCO RT 95 - RT 115
3 = PTO with proportional solenoid valve on MF 8200 and AGCO RT 130 - RT 145
Issue 2
May 2002
Electronics - Wintest
(a) Each time the engine is started, the 4WD indicator lamp is lit and the front axle engaged.
To disengage 4WD:
- press the brake pedal
- press the 4WD switch
The indicator lamp goes out.
The front axle is actually disengaged when the Autotronic receives a speed signal greater than 1 kph.
(b) Each time the engine is started, the 4WD is in the position stored when the engine was stopped. The 4WD function
may different according to the code I (see (e)).
(d) Code I = 0
- 4WD is engaged if there is action on one of the two brake pedals above 5 kph
- changing from 4WD to 2WD is actually carried out when the forward ground speed sensor sends a signal
- the differential lock is disengaged and re-engaged by action on a brake pedal.
Issue 2
May 2002
Electronics - Wintest
11F03.11
Wintest
Test
Options
Help
GO!
H elp
Wintest
Parameters ......
Auto 3 parameters
Programming Autotronic 3
List of error codes
OK
Help
WA3-5
Issue 2
May 2002
Electronics - Wintest
11F03.12
The following screen is displayed:
Wintest
Test
Options
Help
GO!
Help
Wintest
Autotronic 3 Parameters
AA
39
OK
Cancel
OK
Help
WA3-6
- Using the tab key, select the code to modify and then
type in the new parameter.
- Confirm your modifications by clicking on "OK".
Issue 2
May 2002
Electronics - Wintest
11F03.13
Wintest
Tester
Option
Help
GO!
H elp
Wintest
Parameters....
Auto 3 parameters
Programming Autotronic 3
List of error codes
OK
Help
WA3-6A
Issue 2
May 2002
Electronics - Wintest
Autotronic 3 parameters
Tractor code
Display all
Parameter
Parameter value
With synchro
With Front axle stored
0
146
44
10000
82
36
22
14
6
10
4*2 transmission
Analog with Power shuttle
None
Power shuttle analog lever
0
No creeper
Synchro
Front axle
Tester code
Wheel pulse ratio/10 kph
PTOPPR
LSPTO ratio
Pulse/engine rev
PPR Intermediate speed
Engine nominal speed/100
Max PFA and Diff speed
Hi -> Lo limit speed
Lo -> Hi limit speed
Trans type
Dynashift lever
Speedshift
Shuttle type
Speed limit
Creeper type
OK
Cancel
Help
WA3-6B
- Select "Display all" to display all parameters.
- The "Parameter" column defines the parameter.
- The "Parameter value" column gives the parameter
characteristics or the value entered during calibration.
Issue 2
May 2002
Electronics - Wintest
11F03.15
Safety functions
- Start the engine.
- Click on the "Safety" icon
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WA3-7
Issue 2
May 2002
Electronics - Wintest
11F03.16
The following screen is displayed:
Wintest
Test
GO!
Help
Autotronic
1064
14.3
Err : 0
OK
Help
TCU 2
WA3-8
1064
- pedal up: normal video
- pedal down: reverse video
Battery voltage in volts. Value between 11V
and 15V.
14,3
Power shuttle neutral switch
Issue 2
May 2002
Electronics - Wintest
11F03.17
Power present for Autotronic 3 internal electronic relays controlling shuttle solenoid
valves.
- If the shuttle lever is in de-clutched position and
bottom clutch pedal switch open: reverse video (relays powered).
- If the shuttle lever is in forward or reverse and the
bottom clutch pedal switch is open: reverse video
(relays powered).
- If the shuttle lever is in neutral and whatever the
position of the clutch pedal: normal video (relays not
powered).
- If the bottom clutch pedal switch is closed and whatever the position of the shuttle lever: normal video
(relays not powered).
Err : 0
TCU 2
Autotronic 3 status
Issue 2
May 2002
Electronics - Wintest
11F03.18
"Gearbox" function
- Start the engine.
- Click on the "Gearbox" icon
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WA3-9
Issue 2
May 2002
Electronics - Wintest
11F03.19
Calib
Autotronic
AUTO
0
0.0
0.0 Amps
Off
0.0 Amps
Off
0%
0.0
0
Err : 109
0.0
Off
-25.6
TCU 6
EV1
On
EV2
Off
OK
Help
WA3-10
1064
2,5 V
4V
3,5 V
3V
0,5 V
2V
1,5 V
1V
Issue 2
May 2002
Electronics - Wintest
AUTO
- clutch engaged
- mid way
- de-clutched
= 100% = 4.5V
= 50% = 2.3V
= 0% = 0.5V
0.0
- the value in volts must vary between 0 and 5 V.
Note: For calibrating the potentiometer, see section
11B01.
Issue 2
May 2002
Electronics - Wintest
11F03.21
100 %
-A-B-C-D
Reverse proportional solenoid valve
current
lever in Neutral ............................
0.0A
lever in Reverse ..........................
0.2 to 1.2A
lever in de-clutched position ........
0A
lever in Forward ........................... 0.1A if Forward
gear engaged
0.0 Amps
-
TCU 2
Autotronic 3 status
Off
OFF = solenoid valve at rest
ON = solenoid valve open or fully open
Issue 2
May 2002
Electronics - Wintest
11F03.22
ERR : 0
- Tortoise =
- Hare
=
EV1
OFF =
ON =
EV2
Solenoid valve EV 1
ON
ON
OFF
OFF
Solenoid valve EV 2
OFF
ON
ON
OFF
Speedshift range
ON
OFF
Issue 2
May 2002
Electronics - Wintest
11F03.23
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WA3-11
Issue 2
May 2002
Electronics - Wintest
11F03.24
The following screen is displayed:
Wintest
Test
GO!
Help
Autotronic
1064
PFA
On
0
Err : 0
OK
TCU 2
Help
WA3-12
1064
Issue 2
May 2002
Electronics - Wintest
11F03.25
PFA
On
- ON = 2WD
- OFF = 4WD
Err : 0
TCU 2
Autotronic 3 status
Issue 2
May 2002
Electronics - Wintest
11F03.26
"Differential Lock" function
- Start the engine.
- Click on the "Differential Lock" icon
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WA3-13
Issue 2
May 2002
Electronics - Wintest
11F03.27
Wintest
Test
GO!
Help
Autotronic
1064
Diff
Off
0
Err : 0
OK
TCU 2
Help
WA3-14
Issue 2
May 2002
Electronics - Wintest
Diff
Off
ON = Differential lock engaged
OFF = Differential lock disengaged
Err : 0
TCU 2
Autotronic 3 status
Issue 2
May 2002
Electronics - Wintest
11F03.29
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WA3-15
Issue 2
May 2002
Electronics - Wintest
11F03.30
The following screen is displayed:
Wintest
Test
GO!
Help
Autotronic
1064
PTO
Off
Err : 0
OK
Help
TCU 2
WA3-16
1064
- if pressure is correct displayed in reverse video.
- if pressure below 9 bar 1, displayed in normal video
Power take-off clutch speed sensor in rpm
0
Issue 2
May 2002
Electronics - Wintest
PTO emergency stop switch (fitted on rear
wing according to options)
Err : 0
TCU 2
Autotronic 3 status
11F03.31
PTO
Off
ON = engaged
OFF = disengaged
Issue 2
May 2002
Electronics - Wintest
Preliminary operations
Note: To authorize entering into calibration mode,
the transmission oil temperature must be:
- 35/45C: temperature measured by the gearbox cover
probe and that can be read using Wintest or by
following the procedure for direct display of temperature
on the instrument panel.
Direct display of the temperature on the instrument panel
is through a light code provided by the Dynashift or
Speedshift A, B, C, D indicator lights.
Input in reading mode:
- start the engine
- place shuttle lever in neutral
- simultaneously activate the gear shift lever for at least
4 seconds in order to activate the Hare/Tortoise switch
and the differential lock switch.
- the A, B, C, D indicator lights show the temperature
according to the table below.
Exit from reading mode only takes place after the engine
has been stopped and the pressure in the 17 bar low
pressure circuit has dropped or if there is a shift to
calibration mode.
Issue 2
May 2002
Legend
A
Light off
Flashing light
Electronics - Wintest
11F03.33
Temperature displayed by
Wintest
D
10 C
17 C
22 C
27 C
31 C
36 C
Calibration authorized
39 C
Calibration can be
launched
Optimal calibration
44 C
Calibration authorized
46 C
51 C
54 C
57 C
60 C
63 C
Issue 2
May 2002
Electronics - Wintest
Manual calibration
- Start the engine.
- Start Wintest and select Autotronic 3.
- Click on
Issue 2
May 2002
Electronics - Wintest
- Click on the
CALIB
11F03.35
icon
- Click on icon
OK
Issue 2
May 2002
Electronics - Wintest
Validation
Immediate validation after calibration
1. Without stopping the engine, set the engine speed at
1500 rpm, engage Tortoise range 4th gear, Dynashift
in range A or Speedshift in C.
2. Carry out ten forward/reverse shuttle maneuvers
3. Carry out ten neutral to forward and neutral to reverse
shuttle maneuvers
4. Assess shuttle quality, it should be a smooth reaction
without any jerks.
Validation of a tractor that has already been calibrated
Note: Transmission temperature must be higher
than 20C
5. Put the gear shift lever in neutral, the power take-off
must be de-clutched, the front axle disengaged.
6. Start the engine.
7. Put the Power Shuttle lever in Forward for at least 1
minute, then at least 1 minute in the Reverse
position.
8. Put the Power Shuttle lever back into neutral.
9. Engage 4th Tortoise, Dynashift in A or Speedshift in
C, with an engine speed of 1500 rpm.
10. Carry out 10 Power Shuttle forward / reverse
maneuvers.
11. Carry out 10 Power Shuttle neutral / forward and
neutral / reverse maneuvers.
12. Assess shuttle quality, it should be a smooth reaction
without any jerks.
Note: An abrupt reaction on the 1st maneuver is
normal.
Calibration anomalies
Note: a defect due to the non-compliance of the
calibration input mode conditions or to failure to
maintain the calibration mode is indicated by
alternate flashing of the A, B, C and D indicator
lights.
Switching to calibration input mode does not occur if:
- transmission temperature is not correct,
- engine speed is other than 1500 rpm + 100
- the Tortoise range was not engaged before switching to
calibration input mode
- shuttle lever was not placed in forward mode
13. Check that operations 1 to 7 for calibration input
mode have been correctly carried out.
14. Check solenoid valve coil tightness and connections
(torque values 5.4 to 8.1 Nm).
15. Check that the TOC (Top Of Clutch pedal switch) is
correctly adjusted and connected.
Issue 2
May 2002
Electronics - Wintest
11F03.37
Wintest
Test
Options
Help
GO!
H elp
Wintest
Parameters ......
Auto 3 parameters
Programming Autotronic 3
List of error codes
OK
Help
WA3-17
Issue 2
May 2002
Electronics - Wintest
11F03.38
The following screen is displayed :
Errors stored
215
109
OK
Help
Erase
WA3-18
- It enables display of all the error codes stored in the
memory.
- If you click on "Erase", all error codes will be deleted
from Autotronic 3 memory.
Issue 2
May 2002
Electronics - Wintest
11F03.39
Fault
class
Error
code
number
Autotronic 3
action on the
transmission
Forward /
Reverse
indicator
light
Diagnostic
indicator
light
Lit and
Sounds
remains on
Class I
1-2
Forced de-clutching,
power shuttle locked
Off
Class II
7-8-910 - 23*
Forward or
Light
Reverse lit
flashes
depending
rapidly
on direction
selected.
Out if Power
Shuttle is in
neutral
Buzzer
Shuttle reset
after the fault
has been
cancelled.
Stop the engine
and wait
Autotronic 3
standby mode (17
bar pressure
equals 0) (engine
speed equals 0).
Restard the
engine
Sounds
De-clutch
Stops
Place lever in
neutral
* Non direct
in Neutral
Class III
3 - 4 - 5 - None, normal
6 - 15 - 16 operation
17 - 18 19 - 20 21 - 22
Forward or
Reverse
depending
on direction
selected.
Issue 2
Light
flashes
slowly
May 2002
Electronics - Wintest
11F03.40
Errors code
Class
Error No.
displayed on
Wintest
Fault
II
107
II
108
II
109
II
110
II
123
III
203
III
204
III
205
III
206
III
215
III
216
III
217
III
218
III
219
III
220
III
221
III
222
12 V open circuit on solenoids due to BOC and/or Neutral lever switches being
jammed in closed position.
Issue 2
May 2002
Electronics - Wintest
11F04.1
CONTENTS
A.
General ___________________________________________
B.
Programming ______________________________________
C.
D.
16
D.
17
21
26
29
32
36
E.
Issue 2
May 2002
Electronics - Wintest
11F04.2
A . General
Wintest
Test
GO!
DCC
Help
TC
892
0
Engine Speed Sensor
Connector: Ee-TC Eh-TC
Colour: Yellow Black
P-Lck
OFF
OK
Error : 0
Error : 0
CAN
Request: No request
OK
Help
Response: No response
WTD-1
Issue 2
May 2002
Electronics - Wintest
11F04.3
B . Programming
Programming the TC unit
- Turn the ignition key on to carry out this operation. The
voltage must be at least 12.5 V.
- Programming of the TC is necessary:
. when the former TC unit has been replaced by a new
one
. when a new program becomes available to improve
the product
Note: The version of the TC program is shown
alternately with the DCC program on the dashboard.
- Click on the "Tools" icon and then on "Programming TC".
Wintest
Test
Options
Help
GO!
H elp
Wintest
Parameter...
TC parameters
DCC parameters
Programming TC
Programming DCC
List of error codes
OK
Help
WTD-2
Issue 2
May 2002
Electronics - Wintest
11F04.4
The following screen is displayed:
Wintest
Test
Options
GO!
Help
Help
Wintest
Programming TC
YES
No
OK
Help
WTD-3
- Click on "YES".
- A gauge indicates the progress of the programming.
Issue 2
May 2002
Electronics - Wintest
11F04.5
Wintest
Test
Options
GO!
Help
Help
Wintest
Programming TC
Help
Retry
Cancel
WTD-4
Messages:
1. Stop the engine
2. Battery voltage too low
3. Unable to enter Programming mode
4. Unable to begin Boot programming
5. Unable to leave Programming mode
6. Unable to delete the program
7. Unable to change page
8. Unable to program the line
9. Unable to program a byte
10. Programming impossible
11. Unable to open the source file
Correction method
Message 1: Stop the engine
Message 2: Check battery voltage
Messages 3 4 5: Check connection of the CAN BOX
interface and turn the ignition key off.
Messages 6 7 8 9 10: The TC unit is defective
Message 11: Hard drive problem. Re-install the
WINTEST software on your PC.
Issue 2
May 2002
Electronics - Wintest
11F04.6
Programming the DCC
Wintest
Test
Options
Help
GO!
H elp
Wintest
Parameter...
TC parameters
DCC parameters
Programming TC
Programming DCC
List of error codes
OK
Help
WTD-5
Issue 2
May 2002
Electronics - Wintest
11F04.7
Options
GO!
Help
Help
Wintest
Programming DCC
YES
No
OK
Help
WTD-6
- Click on "YES"
- A gauge indicates the progression of the programming.
Several error messages may be displayed:
1. Stop the engine
2. Battery voltage too low
3. Unable to access Programming mode
4. Unable to begin Boot programming
5. Unable to leave Programming mode
6. Unable to delete the program
7. Unable to change page
8. Unable to program the line
9. Unable to program a byte
10. Programming impossible
11. Unable to open the source file
Correction method
Message 1: Stop the engine
Message 2: Check battery voltage
Messages 3 4 5: Check connection of the CAN BOX
interface and turn the ignition key off.
Messages 6 7 8 9 10: The DCC unit is defective
Message 11: Hard drive problem. Re-install the
WINTEST software on your PC.
Issue 2
May 2002
Electronics - Wintest
C . Setting parameters
- Turn the ignition key on to carry out this operation. The
voltage must be 12.5 V minimum.
- Parameterisation is necessary:
. if the TC or DCC has been replaced by a new device
. if improvements have been made to one or more
functions via the parameterisation
. if programming has been carried out.
The parameter code is found on a label on the left hand
side dashboard support near the fuse box. This code has
12 figures and corresponds to the 11 parameters whose
meaning is shown below.
Parameter code
AA
Example of setting
68
Code AA = 68 = 8240
Code B = 3 = 4 WD memory
Code C = 1 = with creeper unit
Code D = 3 = with Full Powershift gearbox
Code
E = 2 = forward speed not limited
Code
F = 2 = with Park Lock
Code G = 2 = metric units
Code H = 1 = with radar
Code
I = 2 = PTO stop on the fender
Code
J = 1 = with pre-selection memory
Code
K = 2 = with Europe type analog lever
Issue 2
May 2002
Electronics - Wintest
11F04.9
Code parameters
Models
Code AA
Perkins
Cummins engine
Navistar
Valmet
MF 8210
67
MF 8220
64
MF 8240
68
MF 8250
61
MF 8260
58
MF 8170 / 8270
55
MF 8180 / 8280
52
50
Allis 9785
51
53
Allis 9775
54
56
Allis 9765
57
59
Allis 9755
60
62
Allis 9745
63
White 8310
65
Allis 9735
66
RT130
77
MF 8245
70
Issue 2
May 2002
Electronics - Wintest
11F04.10
Code B
Front axle
Code C
Creeper unit
1 = 2WD
3 = 4WD memory (a)
5 = 4RM mode US (b)
0 = None
Code E
Max. speed
1 = 30 kph
2 = 40 kph
Code F
Park Lock
0 = None
2 = With Park Lock
Code I
Issue 2
Code D
Gearbox
3 = Full Powershift
1 = With
Code G
Type of units
0 = U.S.
2 = Metric
Code J
Gear pre-selection
memory
0 = None
1 = With
May 2002
Code H
Radar
0 = None
1 = With
Code K
Type of lever
Electronics - Wintest
11F04.11
Issue 2
May 2002
Electronics - Wintest
11F04.12
Wintest
Test
Help
Options
GO!
H elp
Wintest
Parameters...
TC parameters
DCC parameters
Programming TC
Programming DCC
List of error codes
OK
Help
WTD-7
Issue 2
May 2002
Electronics - Wintest
11F04.13
Wintest
Test
Options
Help
GO!
Help
Wintest
Autotronic 3 Parameters
AA
68
OK
Cancel
OK
Help
WTD-8
Issue 2
May 2002
Electronics - Wintest
11F04.14
- The following screen is displayed :
Wintest
Test
Options
Help
GO!
H elp
Wintest
Parameters...
TC parameters
DCC parameters
Programming TC
Programming DCC
List of error codes
OK
Help
Issue 2
May 2002
WTD-8A
Electronics - Wintest
11F04.15
TC parameters
Tractor code
Display all
Parameter
Parameter value
! - 17493
AG150
EUR dual type lever
Power Shuttle
Current sensor
4RM with Memo
Type1
Type2
Electrohydraulic
2
2
44
18
0
32
72
0
5
Tester
Transmission type
Lever type
Shuttle type
Temperature sensor
Front axle
Differential lock
Rear PTO
Park Lock type
Hi Lo limit speed range
Hi Hi limit speed range
RPTO inter Pulse/rev
RPTO output Pulse/rev
Eco PTO ratio (*10000)
Engine Pulse/rev
Pulse/rev at unit output
Creeper speed ratio
PTO para 1
OK
Cancel
Help
WTD-8B
Issue 2
May 2002
Electronics - Wintest
Issue 2
May 2002
Electronics - Wintest
11F04.17
"Safety" function
- Start the engine
- Click on the "Safety" icon
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WTD-9
Issue 2
May 2002
Electronics - Wintest
11F04.18
The following screen is displayed:
Wintest
Test
GO!
DCC
Help
TC
892
0
N
P-Lck
OFF
Error: 0
Error: 0
CAN
Request: No request
OK
Help
Response: No response
WTD-10
Faulty switch
Issue 2
May 2002
Electronics - Wintest
11F04.19
Faulty switch
Fault
Transmission mechanism Park Lock switch
Error: O
P-Lck
OFF
Request: No request
Not used in the safety tests
Fault
Issue 2
May 2002
Electronics - Wintest
11F04.20
Error: 0
Response: No response
Not used in the safety tests
CAN
Issue 2
May 2002
Electronics - Wintest
11F04.21
"Gearbox" function
- Start the engine.
- Click on the "Gearbox" icon
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WTD-11
Issue 2
May 2002
Electronics - Wintest
11F04.22
Wintest
Test
GO!
DCC
Help
TC
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
897
0.5
0
1: 0.00 Amps
2: 0.00 Amps
-2
1.41
R: 0.00 Amps
24
A: 0.00 Amps
B: 0.00 Amps
16
C: 0.00 Amps
L: 0.00 Amps
100 %
M: 0.00 Amps
H: 0.00 Amps
0.49
0.74
Error: 0
2.41
Error: 0
CAN
OK
Request: Neutral
Issue 2
Help
May 2002
WTD-12
- not active
Electronics - Wintest
11F04.23
Error : 0
100 %
- value between 0% = de-clutched
100% = clutch engaged
Fault
Issue 2
May 2002
Electronics - Wintest
Signal from gearbox oil pressure switch
(17 bar)
- left side
2.5 V
4V
3,5 V
3V
0,5 V
2V
1,5 V
1V
2,2 to 2,8 V
3,8 to 4,4 V
0,6 to 1,6 V
H : 0.00 Amps
897
Fault
Gearbox output speed in 100th of kph
- if this icon is in reverse video with the N flashing on the
dashboard a fault has occurred. Click on the icon to
learn the nature of the fault.
24
Issue 2
May 2002
Electronics - Wintest
11F04.25
CAN
OFF
OFF
Issue 2
May 2002
Electronics - Wintest
11F04.26
"Front Axle" function
- Start the engine.
- Click on the "Front Axle" icon
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WTD-13
Issue 2
May 2002
Electronics - Wintest
11F04.27
GO!
DCC
Help
TC
1.2
PFA
Error: 0
ON
Error: 0
CAN
Request: No request
OK
Help
WTD-14
Fault
Error: 0
Issue 2
May 2002
Electronics - Wintest
Error: 0
0.0
CAN
PFA
ON
- ON = solenoid valve activated 4WD disengaged
- OFF = solenoid valve deactivated 4WD engaged
Fault
Issue 2
May 2002
Electronics - Wintest
11F04.29
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WTD-15
Issue 2
May 2002
Electronics - Wintest
11F04.30
The following screen is displayed:
Wintest
Test
GO!
DCC
Help
TC
0.0
Error: 0
Diff
OFF
Error: 0
CAN
OK
Request: No request
Help
WTD-16
Fault
Error: 0
Issue 2
May 2002
Electronics - Wintest
Actual ground speed given by radar
Error: 0
11F04.31
0.0
Diff
OFF
- ON = Differential lock engaged
- OFF = Differential lock disengaged
Request: No request
Gearbox 15 filter clogging switch
or
Lift control 3-position switch. Shows Work or Up position
Fault
Issue 2
May 2002
Electronics - Wintest
11F04.32
"Power Take-Off" function
- Start the engine.
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WTD-17
Issue 2
May 2002
Electronics - Wintest
11F04.33
Wintest
Test
GO!
DCC
Help
TC
1102
0
PTO: 0.00 A
PTO
OFF
Stop
OFF
Stop: 0.00 A
Error: 0
Error: 0
CAN
Request: No request
OK
Help
WTD-18
PTO switch
Issue 2
May 2002
Electronics - Wintest
11F04.34
Fault
PTO: 0.00 A
Fejl: 0
1102
0.0A = solenoid valve deactivated
- 0.5A to 1.2A = solenoid valve activated
PTO clutch output sensor value. The PTO
speed = engine speed
Fault
0
- Comparison of the two speeds permits detection of
PTO clutch slip.
Error: 0
0
- This value must correspond to that displayed by the
DCC
PTO
Low pressure hydraulic circuit pressure
switch pressure, in bar
OFF
- ON = solenoid valve activated, PTO engaged
- OFF = solenoid valve deactivated, PTO disengaged.
Issue 2
May 2002
Electronics - Wintest
STOP
11F04.35
OFF
- ON = solenoid valve activated, brake on
- OFF = solenoid valve deactivated, brake off.
CAN
Request: No request
Indicates the requests of the DCC to TC
Issue 2
May 2002
Electronics - Wintest
11F04.36
E . List of error codes
Wintest
Test
Options
Help
GO!
H elp
Wintest
Parameters...
TC parameters
DCC parameters
Programming TC
Programming DCC
List of error codes
OK
Help
WTD-19
Issue 2
May 2002
Electronics - Wintest
11F04.37
Stored errors
81
80
136
138
140
156
x
x
x
x
x
x
00001
00001
00052
00052
00052
00032
OK
Help
Erase
WA3-20
- It enables you to see all the error codes that have been
stored and the number of times they have appeared.
- If you click on "Erase", all the error codes will be deleted
from the TC and DCC memory.
Issue 2
May 2002
Electronics - Wintest
11F05.1
CONTENTS
A.
B.
C.
D.
10
E.
12
F.
19
Issue 2
May 2002
Electronics - Wintest
11F05.2
Wintest
GO!
Help
Autotronic
1064
4.1
0.0 Amps
Off
0.0 Amps
Off
100 %
280
280
Range
switch
Err : 0
Connector: J1-32
Colour: White
Off
OK
TCU 2
EV1
On
EV2
Off
OK
Help
WRE-1
Issue 2
May 2002
Electronics - Wintest
11F05.3
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WRE-2
Issue 2
May 2002
Electronics - Wintest
11F05.4
The following screen is displayed:
Wintest
Test
Options
Help
GO!
Help
Wintest
Testing the Electronic Linkage Control
215
240
18
159
159
41
140
--
1098
0.0
99
OK
Help
OK
Help
WRE-3
Issue 2
May 2002
Electronics - Wintest
- -
11F05.5
0
- pure draft = 0
- pure position = 250
- error at 255
159
- no load approximately 165
- error at 255
140
18
-
Error indicator
Issue 2
May 2002
Electronics - Wintest
1098
0.0
Autotronic 2 only
+ power supply engine running
- + present with engine running: reverse video
- + absent with engine running: normal video
Frequency
to be read
on ELC
0% slip
100 Hz
5% slip
150 Hz
10% slip
200 Hz
15% slip
250 Hz
20% slip
300 Hz
etc.
Issue 2
May 2002
Electronics - Wintest
11F05.7
C. Error codes
- The electronic linkage control computer is able to detect certain faults in the wiring harness or lift control components.
- When a fault is identified:
. the auto-diagnostic lamp on the lift control console flashes according to the error
. in Wintest, the error code is displayed
- The first figure of the error code denotes the gravity of the failure:
. 1 = serious
. 2 = medium
. 3 = minor
- The second figure of the error code indicates the fault.
Code
Fault
Effect
Action
1-1
Stop the
engine. Correct
the fault.
Restart the
engine. Reset
the console
1-2
Stop the
engine. Correct
the fault.
Restart the
engine. Reset
the console
1-3
Stop the
engine. Correct
the fault.
Restart the
engine. Reset
the console
1-5
Stop the
engine. Correct
the fault.
Restart the
engine. Reset
the console
1-6
Stop the
engine. Correct
the fault.
Restart the
engine. Reset
the console
Issue 2
May 2002
Electronics - Wintest
11F05.8
Code
Fault
Effect
Action
1-7
Stop the
engine.
Correct the
fault. Restart
the engine.
Reset the
console
1-8
Stop the
engine. Correct
the fault.
Restart the
engine. Reset
the console
2-2
Repair fault.
Reset ELC
2-3
Repair fault.
Reset ELC
2-4
Repair fault.
Reset ELC
2-7
Repair fault.
Reset ELC
3-1
Repair fault.
Reset ELC
3-2
Repair fault.
Reset ELC
Issue 2
May 2002
Electronics - Wintest
Code
Fault
Effect
11F05.9
Action
3-4
Repair fault.
Reset ELC
3-6
Repair fault.
Reset ELC
3-8
Reset calculator
parameters. If
problem persists, replace
the calculator.
Issue 2
May 2002
Electronics - Wintest
11F05.10
Wintest
Linkage Diagnostics
204
249
174
158
191
- -
00
184
170
130
118
255
OK
Help
OK
Help
Position sensor
Linkage .....
Linkage diagnostics
Linkage parameters
WRE-4
Issue 2
May 2002
Electronics - Wintest
11F05.11
Tester
Aide
GO!
Help
Wintest
Linkage Diagnostics
252
240
16
162
163
46
140
Linkage Parameters
46
853
OK
Help
OK
Help
OK
Help
WRE-5
Issue 2
May 2002
Electronics - Wintest
Issue 2
May 2002
Electronics - Wintest
11F05.13
Parameter codes
Models
Hydraulic circuit
lift ram
AA Code
6235 to 6270
Open centre
66 mm
01
Open centre
75 mm
02
6235 / 6245
CCLS 90 l
66 mm
05
6245
CCLS 90 l
75 mm
19
6255 6270
CCLS 105 l
66 mm
09
CCLS 105 l
75 mm
10
CCLS 110 l
95 mm
11
CCLS 150 l
95 mm
13
8210 to 8250
Full Powershift
CCLS 110 l
95 mm
15
8260 to 8280
Full Powershift
CCLS 110 l
105 mm
16
8210 to 8250
Full Powershift
CCLS 150 l
95 mm
17
8260 to 8280
Full Powershift
CCLS 150 l
105 mm
18
Issue 2
May 2002
Electronics - Wintest
Parameter codes
Models
Hydraulic circuit
lift ram
AA Code
RT 95
CCLS 105 l
66 mm
09
RT 115
CCLS 105 l
75 mm
10
CCLS 110 l
95 mm
11
CCLS 150 l
95 mm
13
AGCO DT
CCLS 110 l
95 mm
15
AGCO DT
CCLS 110 l
105 mm
16
AGCO DT
CCLS 150 l
95 mm
17
Issue 2
May 2002
Electronics - Wintest
11F05.15
No. of
electro
-hydraulic
spool valves
Joystick
Front
Dual
control
Rear
Dual
control
Front
linkage
capacity
Trailed
implement
control (TIC)
BB
code
01
02
04
05
With
Drawbar sensor
08
09
With
Drawbar sensor
10
11
13
14
With
Drawbar sensor
17
18
Issue 2
May 2002
Electronics - Wintest
11F05.16
No. of
electro
-hydraulic
spool valves
Joystick
Front
Dual
control
Rear
Dual
control
Front
linkage
capacity
Trailed
implement
control (TIC)
BB
code
3,5 t
With
Drawbar sensor
25
5t
With
Drawbar sensor
26
2,2 t
27
3,5 t
28
5t
29
Issue 2
May 2002
Electronics - Wintest
11F05.17
Linkage Diagnostics
Tractor code
Display all
Parameter
Parameter value
P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
P14
P15
P16
P17
P18
100
100
100
100
0
0
0
0
16683
7
4
6
5
200
51
8
8
7
OK
Cancel
Help
Linkage Diagnostics
Tractor code
Display all
Parameter
Parameter value
P 55
P 56
P 57
P 58
P 59
P 60
P 61
P 62
P 63
P 64
P 65
P 66
P 67
P 68
P 69
DeadBandJoystick
K.O.
Seuilthreshold
K.O.
Pin sensing
9
10
5
74
34
64
20
14
7
2
4
5
6
2
1
10
80
60kN
OK
Cancel
Issue 2
Help
May 2002
Electronics - Wintest
11F05.18
Linkage Diagnostics
Tractor code
Extended display.
Display all
Parameter
Parameter value
Pin sensing
Drawbar
Trans. controller type
Position sensor type
Panel type
EH Dual valve
Dual pos. sensor
Front linkage pos. sensor
Ram type
Joystick
Front linkage
TIC
Dual
Lift control valve
Hydraulic pump
P 90
P 91
Programme version
60kN
150kN
TC
BOSCH
6200/8200
None
With
With
Diameter 95
Without
Without Front linkage
With TIC
With dual Ctrl
LS 110L
EHR23 LS100L
0
0
18
OK
Issue 2
May 2002
Cancel
Help
Electronics - Wintest
11F05.19
F . Dual Control/TIC
1. Test
The Dual Control icons and parameters can be
accessed to via the "Testing the Electronic Linkage
Control" screen.
Wintest
Linkage Diagnostics
Test du Relevage
204
249
174
158
191
- -
00
184
170
130
118
255
OK
Help
OK
Help
WRE-6
lower limit: 20
neutral adjustment: 144
upper limit: 250
error at 255
Issue 2
May 2002
Electronics - Wintest
11F05.20
2. Dual Control Parameters
Wintest
Linkage Diagnostics
Test du Relevage
204
249
174
158
191
- -
00
184
170
130
118
255
OK
Help
OK
Help
Position sensor
Linkage .....
Linkage diagnostics
Linkage parameters
WRE-7
Issue 2
May 2002
Electronics - Wintest
11F05.21
Wintest
Test
GO!
Options
Help
Help
ParaDual
Move Up
63
No Move
59
Move Down
OK
Cancel
WRE-8
63
t
- The aim of the parameter setting is to adjust the
beginning of the opening of the solenoid valves of the
electro hydraulic spool valves.
- Connect a 0 - 300 bar pressure gauge to the hydraulic
pump output connector.
- Bring the oil temperature up to between 50C and 60C.
- Nothing must be connected to the auxiliary spool
valves.
- On the ParaDual screen click on "Move Up". Increase
or reduce the value of the current by clicking on s or t
to obtain a pressure of 200 bar. Stop the control by
clicking on "No move".
- Click on "Move Down". Increase or reduce the value of
the current by clicking on s or t to obtain a pressure of
200 bar. Stop the control by clicking on "No Move".
59
t
- Disconnect the pressure gauge.
The adjustment is correct if the tool reacts at the same
time as the ELC. If the reactions are too abrupt, reduce
the value of the current. On the other hand, if they are too
slow, increase the current value.
Note:
- A value of 40 points corresponds to a slight opening and therefore a slight flow rate.
- A value of 100 points corresponds to full opening
and therefore the full flow rate.
Issue 2
May 2002
Electronics - Wintest
11F06.1
CONTENTS
A.
B.
3
3
Issue 2
May 2002
Electronics - Wintest
11F06.2
GO!
Help
Autotronic
1064
4.1
0.0 Amps
Off
0.0 Amps
Off
100 %
280
280
Range
switch
Err : 0
Connector: J1-32
Colour: White
Off
OK
TCU 2
EV1
On
EV2
Off
OK
Help
WDA-1
Issue 2
May 2002
Electronics - Wintest
11F06.3
Wintest
Test
Options
GO!
Help
Help
Wintest
OK
Help
WDA-2
Issue 2
May 2002
Electronics - Wintest
11F06.4
The following screen is displayed:
Wintest
Test
Options
GO!
Help
Help
Wintest
273
113
0
1
21
188
166
OK
OK
Help
Help
WDA-3
273
0
- less than 1 kph = value is not reliable
113
Issue 2
May 2002
Electronics - Wintest
1
11F06.5
Value of one cubic centimetre per flow meter turbine revolution (fixed value)
21
- value displayed equals difference between flow meter input and output
"Tools" icon for programming, setting parameters and selecting the language.
Issue 2
May 2002
Electronics - Wintest
11F06.6
Wintest
Test
Options
GO!
Help
Help
Wintest
273
115
0
17
192
176
OK
OK
Help
Help
Parameters
Programming Datatronic 2
WDA-4
Issue 2
May 2002
Electronics - Wintest
11F06.7
Option
GO!
Help
Help
Wintest
273
115Datatronic
Testing the
0
17
192
176
OK
Yes
No
OK
Help
Help
WDA-5
Issue 2
May 2002
Electronics - Wintest
11F06.8
PARAMETERS
- Turn the ignition key on and restart the engine.
- Click on the "Tools" icon and on "Parameters", then on
"Programming Datatronic 2".
Wintest
Test
Options
GO!
Help
Help
Wintest
273
113
0
20
188
168
OK
OK
Help
Help
Parameters
Datatronic 2 Parameters
Programming Datatronic 2
Translate Datatronic 2
WDA-6
Issue 2
May 2002
Electronics - Wintest
11F06.9
Option
GO!
Help
Help
Wintest
273
Datatronic 2 Parameters
115
Dual Control
0 Imp.
Trailed
39
0
0
10
1
9
17
192
100
176
OK
40
Help
Help
OK
OK
Cancel
Help
Trailed Imp.
Option not available
WDA-7
Setting the Datatronic parameters
The Datatronic parameter code is composed of 2 figures corresponding to the tractor code or AA code.
Dual Control
s
39
t
- using the up or down arrow select the correct code
Issue 2
May 2002
Electronics - Wintest
Trailed Imp.
- if the tractor is fitted with the TIC function, tick the box.
- if the tractor is not fitted with the TIC function, click on
box to remove tick.
Joystick
- if the tractor is fitted with the Joystick function, tick
the box.
- if the tractor is not fitted with the Joystick function, click
on box to remove tick.
40
Issue 2
Example:
An implement manufacturer needs a 130 Hz m/s output
frequency in order to operate his electronic device from
the tractors radar.
1 m/s = 3.6 kph therefore 130 Hz / m/s =
130 Hz / 3.6 kph
100
May 2002
Electronics - Wintest
11F06.11
Wintest
Test
Options
GO!
Help
Help
Wintest
273
113
0
20
188
168
OK
OK
Help
Help
Parameters
Datatronic 2 Parameters
Programming Datatronic 2
WDA-8
Issue 2
May 2002
Electronics - Wintest
11F06.12
The following screen is displayed:
Wintest
Test
Options
GO!
Help
Help
Wintest
273
115
0
FRANCAIS
ENGLISH UK
ENGLISH US
FUOMI
PORTUGUES
ITALIANO
17
192
SVENSKA
DEUTSCH
ESPAGNOL
OK
174
DANSK
NORGE
OK
HOLLANDS
Help
Help
Parameters
Datatronic 2 Parameters
Programming Datatronic 2
WDA-9
-
Issue 2
May 2002
Electronics - Wintest
11F07.1
SOMMAIRE
A.
B.
C.
D.
Issue 2
May 2002
Electronics - Wintest
Spool valve screen
Description
The Joystick and SMS (Spool valve Management System) could be tested and the default functions could be
detected with Wintest software.
A self-diagnostics system generates error codes that are
displayed on the Wintest Test screen of the Datatronic (if
installed) and lights the indicator lamp located on the ON/
OFF switch (see GUF71).
To carry out testing with Wintest, the status of a function
on the tractor is modified and compared with status
displayed on the screen of the portable PC.
- If the icon corresponding to the function is displayed in
reverse video, this indicates that 12V is present.
- If the icon corresponding to the function is displayed in
normal video, this indicates that 12V is absent.
- If no there is no change whatsoever, check the connectors, the ignition switch and test the wiring corresponding to the relevant function.
Issue 2
May 2002
Electronics - Wintest
11F07.3
Wintest
OK
Help
WJO-1
Issue 2
May 2002
Electronics - Wintest
11F07.4
The following screen is displayed :
Joystick
Joystick
EHRC
Valve SB23
On
Up
Neutral
Down
M
X+:100%
X-:100%
Y+:100%
Y-:100%
CAN
CAN
1: -47 %
2:
0 %
47 %
Float
Err : 0
Up
Neutral
Down
0 %
Float
Err : 0
Ver :
2. 1
OK
Help
WJO-2
X+:100%
X-:100%
Y+:100%
Y-:100%
On
SMS ON / OFF switch
Joystick positioning
M
Flowrate memory switch
Issue 2
May 2002
Electronics - Wintest
1:0%
2:0%
11F07.5
Up
Neutra
Down
Float
Err : 0
47 %
CAN
Issue 2
May 2002
Electronics - Wintest
11F07.6
C . Joystick calibration
Joystick
Joystick
EHRC
On
Up
Neutral
D own
M
X+:100%
X-:100%
Y+:100%
Y-:100%
CAN
1:
2:
CAN
0 %
0 %
0 %
Float
Err : 0
Up
Neutral
D own
0 %
Float
Err : 0
Ver :
2. 1
OK
Help
Joystick calibration
Valve parameters
WJO-3
Issue 2
May 2002
Electronics - Wintest
11F07.7
Joystick calibration
Joystick
EHRC
C AN
1:
2:
C AN
0 %
0 %
2. 1
OK
Help
WJO-4
Issue 2
May 2002
Electronics - Wintest
11F07.8
D . Valve parameters
- Click on the "Valve parameters"
The following screen is displayed :
Valve parameters
Valve Type
DUAL
CONTROL
Longitudinal Joystick
OK
Valve
Retry
Cancel
Help
WJO-5
Green valve
Tick the box for setting Y valve
parameters
Red valve
Black valve
- valve configured for Dual Control / TIC
Issue 2
May 2002
DUAL
CONTROL
Electronics - Wintest
11F07.9
Issue 2
May 2002
Electronics - Wintest
11F07.10
Valve parameter
Valve Type
DUAL
CONTROL
Longitudinal Joystick
Valve
OK
Retry
Cancel
Help
WJO-6
Issue 2
May 2002
Electronics - Wintest
11F07.11
Starting parameter
- Once the spool valve has been detected and selected,
press "OK" to start the parametering.
- The software is sending instructions to the spool valve.
A few seconds is needed to send the parameters.
During this time, the message "Parametering" is written
in the bottom left corner of the screen.
- When done, another message appears, that can be
different depending of the results:
When the parametering is done right
- the message "Parameters OK" appears a few seconds.
When the parametering is not done right
. the valve keeps the original parameters (same state as
before the operation).
- In both cases, the software stops automatically the
function Parametering.
- Some error messages could be displayed:
. Selection = Detection: the selected spool valve is
the same as the detected spool valve.
. No Detection, valve 100Khz or 29 bits: no spool
valve detected (see Detection of the type of valve ).
. No Selection: No valve type selected (see Selection of
type of spool valve).
. Parameter error: The valve doesnt accepted the
parameters and kept the original ones.
Issue 2
May 2002
Electronics - Wintest
11F08.1
CONTENTS
A.
B.
C.
Parameters ________________________________________
Issue 1
May 2002
Electronics - Wintest
11F08.2
A . Programming Autotronic 3
- Programming Autotronic 3 in Autotronic Kit is required
to :
. change the CAN network from 250 Kbits (Autotronic
3) over to 100 Kbits (Autotronic 2 type)
. integrate the X32 program in Autotronic 3
- Switch on the ignition key to carry out this operation. The
minimum voltage should be 12.5 Volts.
Wintest
Test
Options
Help
WinTest V1.10.06
B00003001456
M. ROCHEFOUCAULT
AGCO
TC
DCC
TCU 092
TCU 093
DATA2
AUTO3
KIT AUTOTRONIC
Issue 1
:
:
:
:
:
:
:
2.14
2.14
R
C
D001208
B11
X32
May 2002
Important
- When programming Autotronic 3 as a replacement
to Autotronic 2, only the CAN network between the
PC and Autotronic 3 should be left connected
(disconnect the ELC calculator and Datatronic 2, if
installed).
- Use the harness ref. 3378244 M1.
Electronics - Wintest
11F08.3
Wintest
Test
Options
GO!
Help
Help
Wintest
Programming Autotronic 3
Yes
No
OK
Help
Issue 1
May 2002
Electronics - Wintest
11F08.4
The following screen is displayed:
Wintest
Tester
Option
Aide
GO!
Help
WinTest V1.10.06
B00003001456
M. ROCHEFOUCAULT
AGCO
TC
DCC
TCU 092
TCU 093
DATA2
AUTO3
KIT AUTOTRONIC
:
:
:
:
:
:
:
2.14
2.14
R
C
D001208
B11
X32
AUTO3_100K
Issue 1
May 2002
Electronics - Wintest
During programming, several error messages may
be displayed:
1. Stop the engine
2. Battery voltage too low
3. Unable to enter Programming mode
4. Unable to begin Boot programming
5. Unable to leave Programming mode
6. Unable to delete the program
7. Unable to change page
8. Unable to program the line
9. Unable to program data
10. Programming impossible
11. Unable to open the source file
11F08.5
Correction method
Message 1: Stop the engine
Message 2: Check battery voltage
Message 3 : Autotronic 3 is already programmed in
Autotronic Kit
Messages 4 - 5: Check connection of the CAN BOX
interface and turn the ignition key off
Messages 6 - 7 - 8 - 9 - 10: The Autotronic 3 is defective
Message 11: Hard drive problem. Re-install the
WINTEST software on your PC.
Wintest
Test
Options
Help
GO!
Help
WinTest V1.10.06
B00003001456
M. ROCHEFOUCAULT
AGCO
TC
DCC
TCU 092
TCU 093
DATA2
AUTO3
KIT AUTOTRONIC
:
:
:
:
:
:
:
2.14
2.14
R
C
D001208
B11
X32
AUTO3_100K
Impossible to enter in
programming mode
Retry
Issue 1
Cancel
May 2002
Electronics - Wintest
11F08.6
Wintest
Test
Options
Help
GO!
Help
WinTest V1.10.06
B00003001456
M. ROCHEFOUCAULT
AGCO
TC
DCC
TCU 092
TCU 093
DATA2
AUTO3
KIT AUTOTRONIC
:
:
:
:
:
:
:
2.14
2.14
R
C
D001208
B11
X32
Setup
Kit Autotronic
OK
Autotronic 2
TC-DCC
Cancel
Autotronic 3
Help
Datatronic 2
Linkage
Joystick
Issue 1
May 2002
Electronics - Wintest
11F08.7
C . Parameters
- Turn the ignition key on to carry out this operation. The
voltage must be 12.5 V minimum.
The parameter code is found on a label on the left hand
side of the dashboard near the fuse box. This code has
12 figures and corresponds to the 11 parameters whose
meaning is shown below.
Parameter code
AA
Setting
27
Issue 1
May 2002
Electronics - Wintest
11F08.8
Parameter codes for Autotronic 1 and basic Autotronic 2 : 6100 - 3000 - 3100
CODE AA
MODEL
WITH
Non modified
flow rate
AUTOTRONIC 1 hydraulic pump
up to
OR
No.D125026
BASIC
AUTOTRONIC 2
Speedshift
tractors with
30 Kph
mechanical
limitation or
Dynashift
Speedshift
tractors with
30 Kph
electronic speed
limitation from
No.G083035
onwards
Speedshift
tractors with
30 Kph
mechanical
limitation or
Dynashift
Speedshift
tractors with
30 Kph
electronic speed
limitation from
No.G083035
onwards
19
30
25
32
6110 - 6120
6130 - 6140
3050 - 3055
3060 - 3065
3065S
00
3070
01
6150 - 6160
6170
3075 - 3080
3085 - 3090
3095
02
20
31
26
33
6180
3115 - 3120
03
21
27
6190
3125 - 3140
04
22
28
Issue 1
May 2002
Electronics - Wintest
11F08.9
05
12
06
13
07
14
08
15
09
16
10
17
11
18
23
24
6235 - 6245
70
74
71
75
6280
72
76
6290
73
77
Issue 1
May 2002
Electronics - Wintest
11F08.10
8210 - 8220
Heavy Duty
34
79
8210 - 8220
Heavy Duty with sealed
35
80
8240
Heavy Duty with seales
82
83
8240 - 8250
Double reduction
36
81
Issue 1
PTO ON / OFF
solenoid valve
PTO proportional
solenoid valve
29
Allis 8775
White 6710
26
75
Allis 8785
White 6810
28
77
May 2002
Electronics - Wintest
Code B
Pont avant
Code C
Livre / Tortue
1 = 2 RM
0 = Non synchronis
2 = 4 RM (a)
1 = Synchronis
3 = 4 RM " mmoire" (b)
Code D
Type bote de vitesses
1=4x2
(sans gammeAB)
2=4x4
(avec gamme AB)
Code I : Usine
0 = MF 3000 / 3100 / 3600 / 6100 / 8100 (c)
1 = Non utilis
2 = MF 6200 / 8200 / AGCO Allis / White (d)
11F08.11
Code E
Vitesse maxi
1 = 30 Km/h
2 = 40 Km/h sauf 8160
Heavy Duty
renforce
3 = 33 Km/h (Japon)
4 = 40 Km/h pour
8160 avec bote de
vitesses Heavy Duty
renforce
Code K : PDF
0 = sans PDF
1 = PDF avec lectrovalve ON / OFF
2 = PDF avec lectrovalve proportionnelle sur MF 6200 / AGCO White - Allis (6810/6710/8775/8785)
3 = PDF avec lectrovalve proportionnelle sur MF 8200 / AGCO White - Allis (8310/8410/9735/9745)
Issue 1
May 2002
Electronics - Wintest
(a) A chaque dmarrage du moteur, le tmoin de 4 RM est allum et le pont avant engag.
Pour dsengager le 4 RM :
- appuyer sur les freins,
- appuyer sur le contacteur de 4 RM.
Le tmoin s'teint.
Le pont avant est rellement dsengag lorsque le botier Autotronic reoit un signal de vitesse d'avancement
suprieur 1 km/h.
(b) A chaque dmarrage du moteur, le 4 RM se trouve dans la position mmorise lors de l'arrt du moteur.
La fonction 4 RM peut tre diffrente en fonction du code I (voir (d))
(c) Code I = 0
- le 4 RM sengage si action sur une des deux pdales de freins au dessus de 5 Km/h
- le passage de 4 RM en 2 RM seffectue rellement quand le capteur vitesse davancement envoie un signal
- le blocage diffrentiel se dsengage et se rengage aprs action sur une pdale de frein.
(d) 6200 / 8200 / White / Allis
Code I = 2
- le 4 RM sengage uniquement si action des deux pdales de freins quelque soit la vitesse
- le passage de 4 RM en 2 RM larrt seffectue rellement sans avoir le signal du capteur vitesse davancement
- le blocage diffrentiel se dsengage dfinitivement si action sur une pdale de frein
- contacteur d'arrt durgence PDF situ sur les ailes (si mont).
(e) Pour les tracteurs avec Autotronic 1 d'origine, mettre les codes F et G zro quelque soit le type de transmission.
Issue 1
May 2002
Electronics - Wintest
11F09.1
CONTENTS
Issue 1
A.
General ___________________________________________
B.
May 2002
Electronics - Wintest
A . General
It is necessary to reprogramm an Autotronic 3 to fit on a
tractor with Autotronic 3 in base (250 Kbits), when the
Autotronic was fitted on a tractor with a kit Autotronic
(software X32 and CAN 100 Kbits).
Issue 1
May 2002
Electronics - Wintest
11F09.3
B . Reprogramming Autotronic 3
- Switch on the ignition key to carry out this operation. The
minimum voltage should be 12.5 Volts.
Wintest
Test
Options
Help
WinTest V1.10.06
B00003001456
M. ROCHEFOUCAULT
AGCO
TC
DCC
TCU 092
TCU 093
DATA2
AUTO3
KIT AUTOTRONIC
Issue 1
:
:
:
:
:
:
:
2.14
2.14
R
C
D001208
B11
X32
May 2002
Electronics - Wintest
11F09.4
The following screen is displayed:
Wintest
Test
Options
GO!
Help
Help
Wintest
Programming Autotronic 3
Yes
No
OK
Help
Issue 1
May 2002
Electronics - Wintest
11F09.5
The following screen is displayed:
Wintest
Test
Options
Help
GO!
Help
WinTest V1.10.06
B00003001456
M. ROCHEFOUCAULT
AGCO
TC
DCC
TCU 092
TCU 093
DATA2
AUTO3
KIT AUTOTRONIC
:
:
:
:
:
:
:
2.14
2.14
R
C
D001208
B11
X32
AUTO3
Issue 1
May 2002
Electronics - Wintest
11F09.6
Correction method
Message 1: Stop the engine
Message 2: Check battery voltage
Message 3 : Autotronic 3 is already programmed in
Autotronic 3
Messages 4 - 5: Check connection of the CAN BOX
interface and turn the ignition key off
Messages 6 - 7 - 8 - 9 - 10: The Autotronic 3 is defective
Message 11: Hard drive problem. Re-install the
WINTEST software on your PC.
Wintest
Test
Help
Options
GO!
Help
WinTest V1.10.06
B00003001456
M. ROCHEFOUCAULT
AGCO
TC
DCC
TCU 092
TCU 093
DATA2
AUTO3
KIT AUTOTRONIC
:
:
:
:
:
:
:
2.14
2.14
R
C
D001208
B11
X32
AUTO3
Impossible to enter in
programming mode
Retry
Issue 1
May 2002
Cancel
11G01.1
CONTENTS
-
General ____________________________________________________
10
Issue 1
May 2002
General
Some of the following pictures may not show exactly
your axle, but the process is the same.
Position sensor
Suspension ram
Electro-hydraulic control unit
Electronics connecting plug
Hydraulic connection unit
3
2
A
LS
1
Fig. 1
Issue 1
May 2002
11G01.3
Fig. 2
Fig. 3
H
Fig. 4
Issue 1
May 2002
90
Fig. 5
Fig. 6
Issue 1
May 2002
Fig. 7
11G01.5
7. In order to adjust the sensor position let down completely the axle arms, in a way that the pads leaned
on the axle body (Closed Axle) (Fig.8).
Note : If the axle is already assembled to the
vehicle, this position is reached putting down the
vehicle till the end of stroke is reached.
8. If the axle has been installed on the vehicle with all
accessories including the battery, disconnect the
connector between the sensor and the suspension
control unit, and use service tool ref. 3378322M1 to
connect up a milliammeter in order to measure the
intensity of the current absorbed (Fig. 9).
9. If the axle is on a workbench with equipment consisting of 12 V battery and a milliammeter connected to
the angle sensor measure the absorbed electric current intensity (Fig.10).
Fig. 8
Amp.
BATTERY 12V
Fig. 9
Amp.
-VB
+VB
BATTERY 12V
Fig. 10
Issue 1
May 2002
Fig. 11
Fig. 12
Fig. 13
Issue 1
May 2002
Definitions
Two different operation modes and one calibration mode
can be chosen.
- Blocked position : the suspension cylinder space is
emptied (Closed Axle) and the axle operates without
suspension.
- Automatic operation : the axle is automatically controlled in accordance with a set value (middle position)
independent of the load.
- Calibration : the end stops are calibrated in the control
unit.
11G01.7
Operational modes
When the system is started a sensor scans the axle
position. Depending upon the scanned actual value, the
electronics will assign an operation mode, which will
then be displayed with the help of the respective signal
lamp.
The possible operational modes are the following:
1. Axle is within the tolerance band of active suspension
level : Automatic Operation
2. Axle is within the tolerance band of the lower stop :
Blocked position
3. Axle is not in previous states : (L1) and (L2) (Fig.14)
flash, that is operational mode has to be selected by
mean of toggle key (valves are not activated)
- Blocked position
As soon as the toggle key for the operational mode
Blocked Position T1 is activated, the vehicle lowers,
the lamp L2 (Fig.14) shines.
By pressing the key Blocked Position T1 the valve WV2
(Fig.14) is activated for 15 seconds in order to release
pressure from the cylinder and from the accumulators.
- Automatic Operation
As soon as the toggle key is pressed in Automatic
Operation, signal lamp L1 (Fig.14) starts to shine and
the the axle to middle position.
In after 30 seconds the desired value has not been
reached, the control is deactivated for 30 seconds.
After 30 seconds the procedure is repeated for 30
seconds.
If three attempts fail, the control switches to the
operation mode Overload that is L1 and L2 (Fig.14)
flash and an operation mode has to be selected by
mean of the toggle key.
The operation mode Automatic Operation can be quit by
activating the operation mode Blocked Position.
Issue 1
May 2002
- Calibration
Calibration consists in determining the values of the
upper and lower cylinder stops.
If no calibration value has been recorded, the control
system automatically selects the Calibration mode
when the system is activated.
To manually select the Calibration mode, press on T2
Automatic Operation mode toggle key for 10 seconds.
Wait till the system changes to Calibration mode to
release the toggle key. This makes the suspension
manual control functions available.
Press on T1 key to manually lower the cylinders or on
T2 key to raise them.
When the cylinder stops have been adjusted, activate
the toggle key to leave the Calibration mode. The system immediately changes to Automatic Operation
mode.
If required, the cylinder stop adjustment can be modified. When a change is made the new values replace
the old ones.
If the stop values exceed the allowed limit values or
the cylinder travel is lower than the minimum fixed
value, the system remains in Calibration mode.
Calibration tolerances
- lower stop (axle closed) : 5 mA
- upper stop (axle open) : 19 mA
- minimum travel : 9.35 mA
- Error modes
The system recognizes the following error modes:
- position sensor error (position lower than 4 mA or
higher than 20 mA)
- overload or cable breaking at the level of the solenoid
valve.
When one of these error modes occurs, the L1 indicator light gets on with the relevant error code and the
solenoid valve is disabled. To validate the error mode,
switch off the system.
Error codes
21 WS1 angle sensor
31 VW1 and/or VW2 solenoid valve raised
32 VW2 solenoid valve lowered
33 No movement of the axle: overload or circuit breaking
41 T1 and T2 short-circuited
Issue 1
May 2002
11G01.9
UZ UB
T1
T2
L2
L1
8
1
GND
LGND
WV1
Green
WS1
S
J
WV2
Black
Carraro electronic box
Fig. 14
Issue 1
May 2002
D. Service tools
- CA 715362 - Sensor rubber positioning ring driver
(Fig.15).
- 3378322 M1 - front axle position sensor adjustment harness (Fig. 16)
Fig. 15
1
2
3
1
2
3
Fig. 16
Issue 1
May 2002
11H01.1
11H01 Description
CONTENTS
A.
General ___________________________________________________
B.
C.
10
D.
12
E.
17
F.
17
G.
18
Issue 1
May 2002
Issue 1
May 2002
11H01.3
Parts list
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
7
Y- Y+
X- X+
5
4
1
+
+
8
3
Issue 1
Fig. 1
May 2002
Issue 1
May 2002
11H01.5
5
3
1
4
6
ON
M
AUT
UTO
11
10
9
7
C52
C5
Fig. 2
Issue 1
May 2002
(1) Joystick
A
B
C
F
D
Fig. 3
Q
100%
50%
Note:
- Any replacement or disassembly of the Joystick
requires calibration using Wintest
- This operation allows the 100% travel of the lever
across the X and Y-axes to be defined.
0
100%
50%
+ +
+ -+
Dp
++ -
Fig. 4
XX-/Y-
Y+/X%
127
%
100
+ +
Y+
X+/Y+
Y-/X+
X+
Issue 1
May 2002
Y-
Fig. 5
11H01.7
Issue 1
May 2002
1
2
100
75
50
11
15
5
6
10
ON
5 4 3 2 1
3
7
8
(10) Datatronic
- If fitted, the Datatronic displays the precise flowrates
memorised for each valve and allows the adjustment
of the spool valve opening time (Time Delay function).
It also displays the possible error codes (see D).
Note: To display the SMS windows, the Datatronic
parameters must be correctly set (see section
11F06)
Parts list (Fig. 6)
(1) Adjustment of oil flowrates
(2) Upper screen selection key
(3) Bottom screen selection key
(4) SMS activation indicator lamp
(5) ON / OFF time delay
(6) Floating mode
(7) Activation of Time Delay mode
(8) Selection keys
(9) Selection knob
(10) Y- and Y+ valves
(11) X- and X+ valves
Issue 1
May 2002
Fig. 6
The SMS is active when the padlock symbol (4) is absent
from the MAX FLOWRATE and TIME windows.
11H01.9
Issue 1
May 2002
Reaction of SMS
SMS is
activated
Indicator lamp
Conditions :
of ON / OFF
- Engine has run
switch gets out
for more than
Padlocks on
2 seconds.
Datatronic TIME
- Joystick is in
and MAX
neutral
FLOWRATE
disappear
Safety valve
opens the
hydraulic circuit
Changing of
1. Operate the joystick Memorises the
maximum
to reach desired
new maximum
flowrate
flowrate
flowrate
2. Press Memory
switch for 1 second
3. Return Joystick to
neutral position
With Datatronic: :
Vary desired percentage
up to the flowrate
desired
Reinitialisation
1. Operate joystick in
Reinitialises
of a valve
desired direction
maximum
flowrate
2. Press for at least 3
flowrate of all
seconds on the
valves
Memory switch
ON / OFF
switch indicator
lamp flashes
once
With Datatronic:
vary desired flowrate up
to 100%
Reinitialisation
1. Joystick in neutral
- Reinitialises
of flowrate of all 2. Press for at least 3
maximum
valves
seconds on the
flowrate of all
Memory switch
valves
- ON / OFF
switch indicator
lamp flashes
once
With Datatronic:
vary all flowrates up to
100%
Issue 1
User actions
Press ON / OFF switch
with the joystick in
neutral
May 2002
Problem
No activation
Possible causes
Using Wintest
check:
ON / OFF switch
engine speed
sensor
ELC calculator
safety valve
reference of ELC
calculator
parameters of
ELC calculator
Maximum
flowrate
doesnt vary
Using Wintest,
check:
Memory switch
ELC calculator
Joystick
calibration
Set spool valves
parameters
User actions
Reaction of SMS
Problem
Push the Joystick
No transition
Transition to
beyond 100% position in
to Floating
Floating mode: 2
X- or Yspool valves (X or Y mode
depending on
choice) are linked
with return to
housing
~ displayed on
Datatronic TIME
screen
11H01.11
Possible causes
Using Wintest
check ELC
calculator
check operation of
spool valves
check valves
parameters
Recalibrate the
Joystick
Time delay
Clock symbol
screen)
displayed during
2. Select spool valve
time delay
3. Select time (0 to 60
seconds or infinity )
4. Push Joystick
beyond 80% position
1. Operate the Joystick Time delay stops
at least 10% in
opposite control
direction
Issue 1
May 2002
11H01.12
1s
5s
2s
5s
2s
1s
5s
2s
2s
5s
Issue 1
May 2002
100
75
50
15
OFF
E231
Fig. 7
1-1
1-2
1-3
1-4
1-5
1-6
1-7
2-1
2-2
2-3
2-4
2-5
Flash on ON / OFF
0-1
0-2
0-3
0-4
0-5
0-6
0-7
0-8
8-8-8
1-3-3
2-3-3
3-3-3
1-1-1
2-1-1
3-1-1
1-1-2
2-1-2
3-1-2
1-1-3
2-1-3
3-1-3
1-1-4
2-1-4
3-1-4
1-1-5
2-1-5
3-1-5
1-1-6
2-1-6
3-1-6
1-1-7
2-1-7
3-1-7
1-2-1
2-2-1
3-2-1
1-2-2
2-2-2
3-2-2
1-2-3
2-2-3
3-2-3
1-2-4
2-2-4
3-2-4
1-2-5
2-2-5
3-2-5
11H01.13
Datatronic display
E1
E2
E3
E4
E5
E6
E7
E8
E9
E 10
1-1
E 111
E 211
1-2
E 112
E 212
1-3
E 113
E 213
1-4
E 114
E 214
1-5
E 115
E 215
1-6
E 116
E 216
1-7
E 117
E 217
2-1
E 121
E 221
2-2
E 122
E 222
2-3
E 123
E 223
2-4
E 124
E 224
2-5
E 125
E 225
Issue 1
May 2002
11H01.14
Error code
2-6
3-1
3-2
4-1
4-2
4-3
8-1
8-2
Issue 1
Flash on ON / OFF
1-2-6
2-2-6
3-2-6
1-3-1
2-3-1
3-3-1
1-3-2
2-3-2
3-3-2
1-4-1
2-4-1
3-4-1
1-4-2
2-4-2
3-4-2
1-4-3
2-4-3
3-4-3
1-8-1
2-8-1
3-8-1
1-8-2
2-8-2
3-8-2
May 2002
Datatronic display
E 126
E 226
3-1
E 131
E 231
3-2
E 132
E 232
4-1
E 141
E 241
4-2
E 142
E 242
4-3
E 143
E 243
8-1
E 181
E 281
8-2
E 182
E 282
11H01.15
Error code
0-1
0-2
Detected by
ELC
calculator
0-3
0-4
0-5
0-6
Fault
Reaction of the
System
Analog input error 1
Function jammed, spool
(X+ position sensor)
valves in neutral
Analog input error 2 (X- Function jammed, spool
position sensor)
valves in neutral
Analog input error 3 (Y+ Function jammed, spool
position sensor)
valves in neutral
Analog input error 4 (Y- Function jammed, spool
position sensor)
valves in neutral
Joystick internal
Function jammed, spool
calculator error
valves in neutral
EPROM error.
Function jammed, spool
Too little difference
valves in neutral
between each position
X+ / centre / X- or Y+ /
centre / Y- of joystick
during calibration
0-7
Safety message on
CAN
0-8
0-9
No joystick detected
1-0
No valve detected
Action required
Test with Wintest and
replace joystick
Test with Wintest and
replace joystick
Test with Wintest and
replace joystick
Test with Wintest and
replace joystick
Test with Wintest and
replace joystick
Recalibrate or replace
joystick
Issue 1
May 2002
11H01.16
Error code
CAN
1-1
errors
1-2
1-3
1-4
1-5
Fault
CAN message missing
CAN message missing
Wrong CAN message
Wrong CAN message
Spool valve internal
signal error (PWM)
Issue 1
Minor
errors
Major
errors
May 2002
Action required
Repair fault and / or
move control to neutral
to reinitialise.
Repair fault
Repair fault
Move control to neutral
to reinitialise.
Repair fault
11H01.17
Disassembly of Joystick
1. Disassemble the armrest by unscrewing the 6 bolts
linking the upper and lower parts.
2. Loosen the 3 bolts holding the Joystick support and
the internal armrest support.
3. Remove the plastic washer linking the Joystick dust
cover to the upper part of the armrest.
4. Remove the Joystick (Fig. 8).
Fig. 8
F . Replacement of ON / OFF or
Memory switches
If it is necessary to replace the ON / OFF or Memory
switches, separate the pin connector. During reassembly,
take care to respect the following connections:
Fig. 9
Wire colour
Blue
Brown
ON
Wire colour
Brown
White
Green
Yellow
1
2
Issue 1
Fig. 10
May 2002
11H01.18
Item
AA
AB
AC
Colour
Grey
Black
Ways
7
Parts list
(26) Joystick
(27) Joystick function multiplier switch
(28) ON / OFF switch
(29) Memory switch
Description
Joystick / AE connector 1
2
Switch connected to
Joystick terminals
3
4
5
6
7
1
2
1
2
AD
AE
10
3
4
Zero reset and Memory 1
switches
2
Calculator armrest
K
connection
J
B
F
E
D
AF
Issue 1
10
Dashboard armrest
connection
May 2002
A
H
C
G
A
B
C
D
E
F
G
H
J
K
Pins
12 V after contact
Signal to solenoid
valve
CAN high
CAN low
+9.5V
Ground
Not used
12 V after contact
Signal to solenoid
valve
12 V after contact
Joystick activation
signal
LED ON/OFF
Ground
12 V after contact
Signal for calculator
Towed implement
signal
Radar speed signal
Multiplier solenoid
valve control
Joystick LED
Joystick activation
signal
Memory
Zero reset signal.
+9.5V
Depth control
Ground
Raise / lower toggle
Not used
Not used
Not used
Radar speed
Not used
12 V after contact
CAN low
CAN high
CAN low
CAN high
Wires
Orange
Grey
Green
Brown
Red
Black
Blue
White
Orange
Blue
Green
Black
Orange
Yellow
Violet
White
Grey
Green
Blue
Yellow
Red
Green
Black
Pink
White
Orange
Brown
Green
Brown
Green
28
AC
26
27
11H01.19
AD
N
BF
AB
B
V
AA
G
M/J
R
VF
N/B
AF
AE
RO
M
V
VC
R
R/B
M
R
V
V
20
23
Ro
31
30
Vi
25
B
R
N/B
24
M/J
21
M
N
B
22
N
R
Fig. 11
Issue 1
May 2002
CHAPTER
UNDER
CONSTRUCTION
CHAPTER
UNDER
CONSTRUCTION
14 . SERVICE TOOLS
Contents
Issue 1
May 2001
Service tools
14A01.1
Designation
Reference
CONTENTS
Splitting the tractor ____________________________________________
Clutch ________________________________________________________
19
Gearbox ______________________________________________________
20
23
25
26
Hydraulics ____________________________________________________
32
34
41
Issue 1
May 2001
Service tools
14A01.2
Designation
Reference
Air conditioning plugs kit
3378152 M11
N
O
T
AV
AI
LA
BL
E
3376935 M1
Issue 1
May 2001
Service tools
14A01.3
Designation
Reference
MS.76 - 73B
PD.1D
PD.1D-1A
PD.1C-6
Adaptor for inlet valve for use with PD.1D and PD.1D-1A
PD.41D
Indicator gauge for measuring piston height, valve depth cylinder liner
collar: for use with PD.208
Issue 1
May 2001
Service tools
14A01.4
Designation
Reference
PD.145D
PD.150B
PD.150B-17 A
PD.155C
Universal extractor
PD.155C-5
Issue 1
May 2001
Service tools
Designation
Reference
PD.170
14A01.5
Fitting tool for timing gear housing cover lip seal (main tool)
PD.170-1
PD.170-2
PD.170-3
PD.170-4
Issue 1
May 2001
Service tools
14A01.6
Designation
Reference
PD.206
PD.208
PD.221A
PD.248
Adaptor for exhaust valve, for use with PD.1D and PD.1D-1A
PD.6118-7
Issue 1
May 2001
Service tools
14A01.7
Designation
Reference
PD.6118-8
6118B
3378242 M1
Perkins green engine timing tool for Lucas and Stanadyne pump
Issue 1
May 2001
Service tools
14A01.8
Designation
Reference
9020 01100
9024 55800
Socket for crankshaft nut for 612 / 620 DS and 645 engines
9025 79200
9025 87400
9025 98700
Issue 1
May 2001
Service tools
14A01.9
Designation
Reference
9025 98800
9025 98900
9025 99000
9030 15200
9051 71300
Issue 1
May 2001
Service tools
Designation
Reference
9051 73100
9051 79300
9052 46300
9052 46400
9052 46620
Bearing cup plug mandrel ( 40 mm) for 620 DS and 645 engine
Issue 1
May 2001
Service tools
14A01.11
Designation
Reference
9052 46650
Bearing cup plug mandrel ( 16 mm) for 612 / 620 DS and 645 engines
9052 46660
Bearing cup plug mandrel ( 36 mm) for 612 / 620 DS and 645 engines
9052 46900
9052 47200
Nut for valve spring compression lever for 612 / 620 DS and 645 engines
9052 47600
Issue 1
May 2001
Service tools
Designation
Reference
9052 47800
Test pressure gauge for injection pump valve for 612 / 620 DS engines
9052 48800
9052 48900
Water pump hub and injection pump pinion extractor for 612 / 620 DS
and 645 engines
9101 65502
9101 65503
Issue 1
May 2001
Service tools
14A01.13
Designation
Reference
9101 65505
9101 65506
9101 65600
9101 65700
9101 65800
Issue 1
May 2001
Service tools
Designation
Reference
9101 65900
9101 66000
9101 66100
9101 66200
9101 66300
Issue 1
May 2001
Service tools
14A01.15
Designation
Reference
9101 71100
Mill for exhaust valve seat for 620 DS and 645 engines
9101 75800
Mill for inlet valve seat for 620 DS and 645 engines
9101 93200
9103 41000
9103 41100
Issue 1
May 2001
Service tools
Designation
Reference
9103 41300
9103 94600
9103 94700
9103 94800
9103 94900
Issue 1
May 2001
Service tools
14A01.17
Designation
Reference
9104 05800
9104 34600
9104 51500
9104 52000
9104 52600
Issue 1
May 2001
Service tools
Designation
Reference
9104 52700
9104 52800
9104 53300
9104 53700
Issue 1
May 2001
Service tools
14A01.19
Designation
Reference
3378004 M1
3378012M2
3378262 M1
Issue 1
May 2001
Service tools
Designation
Reference
MF 391
MF 459
MF 460
MF 462 A
3376883 M1
Issue 1
May 2001
Service tools
,
,
,
,
,
,
,
,,,,,,,,,
,, ,,
14A01.21
Designation
Reference
3376887 M1
3376888 M1
3376920 M2
3378013 M1
3378059M1
Issue 1
May 2001
Service tools
Designation
Reference
3378263 M1
ATP.3002
Clutch spring compression tool for Full Powershift gearbox (AG 150 /
AG 250)
ATP.3015
ATP.3030
Issue 1
May 2001
Service tools
14A01.23
Designation
Reference
MS 550
Universal sleeve
3376885 M1
3378116 M1
3378117 M1
3378118 M1
Issue 1
May 2001
Service tools
Designation
Reference
3378119 M1
3378123 M1
3378124 M1
Insertion tool for lift control shaft support seal, used with MS550
3378151 M1
Issue 1
May 2001
Service tools
14A01.25
Designation
Reference
3378115 M1
3378135 M1
Issue 1
May 2001
Service tools
Designation
Reference
MF 195 C
MF 451 B
MF 471.A
Issue 1
May 2001
Service tools
14A01.27
Designation
Reference
3378028 M1
3378038M1
AG 155H
AG 200H
3378039 M1
Fitting tool for Cassette seal and crownwheel (AG 125 - 155 - 200 axles)
A
D
3378051M1
3378056M1
Issue 1
May 2001
Service tools
Designation
Reference
3378057M1
3378122 M1
3378275 M1
3378276 M1
Insertion tool for ZF APL 5052 front axle final drive unit seal, used with
5870 260 00024
Issue 1
May 2001
Service tools
14A01.29
Designation
Reference
5870 055 019
Ring for lip seal insertion tool - ZF APL 5052 front axle
Insertion tool used with 5870 905 004 and 5870 260 002 - ZF APL 5052
front axle
Insertion tool for final drive unit ring, used with 5870 260 002 - ZF APL
5052 front axle
Issue 1
May 2001
Service tools
Designation
Reference
5870 260 002
Conical distance adjustment tool, used with 5870 500 101 - ZF APL
5052 front axle
ZF APL 5052 front axle - rings for conical distance adjustment tool used
with 5870 500 101
Issue 1
May 2001
Service tools
Designation
Reference
5870 905 004
14A01.31
ZF APL 5052 front axle - centering ring used with 5870 055 073 and
5870 260 002
Issue 1
May 2001
Service tools
Designation
Reference
MF 3001
MF 3016
Hydraulic flowmeter
Q = 4 - 160 l/min
MF 3017
3376882 M91
Depollution kit
3378174 M1
Issue 1
May 2001
Service tools
14A01.33
Designation
Reference
3378272 M1
3378273 M1
3378274 M1
3582045 M1
3583550 M91
Issue 1
May 2001
Service tools
14A01.34
Designation
Reference
MF 3005
3378077 M1
Adaptor
3378207 M91
207
M91
3378
3378234 M1
78
23
4M
3378243 M1
WINTEST
CAN BOX
AGCO
Issue 1
Ref : 3378243 M1
May 2001
Service tools
Designation
Reference
3378244 M1
14A01.35
Wintest type B harness with CAN 16-way connector for cab upright
socket
3378245 M1
379
072
8H
Supersedes 3790728 H1
3378246 M1
3378281 M1
1
2
3378282 M1
Issue 1
May 2001
Service tools
14A01.36
Designation
Reference
3378283 M1
1
2 3
3378284 M1
1
2
3
3378285 M1
1 2 3 4
5
3378286 M1
3378287 M1
1 2 3 4 5 6 7
Issue 1
May 2001
Service tools
14A01.37
Designation
Reference
3378288 M1
3378290 M1
3378289 M1
3378291 M1
3378292 M1
Issue 1
May 2001
Service tools
14A01.38
Designation
Reference
3378293 M1
3378296 M1
3378302 M12
3378304 M11
3580817M1
Issue 1
May 2001
Service tools
14A01.39
Designation
Reference
3580818 M1
Clip extractor
3580820 M1
3712723 M1
3714779M1
3715767 M1
Issue 1
May 2001
Service tools
Designation
Reference
114 010
0411-204-1605
0411-204-2005
Issue 1
May 2001
Service tools
Designation
Reference
3376935 M1
14A01.41
Issue 1
May 2001