Case JX Service Manual Abby PDF

CASE III
JX60 - JX70 - JX80 - JX90 - JX95

MODEL TRACTORS
SERVICE MANUAL
SECTIONS
GENERAL ........................................................................................................00
ENGINE ............................................................................................................ 10
C L U T C H ............................................................................................................ 18
G E A R B O X ........................................................................................................21
TRANSMISSION OF M O T IO N .......................................................................23
FRONT MECHANICAL TRANSMISSION ................................................... 25
REAR MECHANICAL TRANSMISSION....................................................... 27
POWER TA K E -O FF........................................................................................ 31
B R A K ES ............................................................................................................33
HYDRAULIC SYSTEMS ................................................................................ 35
S TE E R IN G ........................................................................................................41
AXLE AND W H E ELS...................................................................................... 44
AUXILIARY E Q U IP M E N T.............................................................................. 50
ELECTRICAL S Y S TE M .................................................................................. 55
C A B ................................................................................................................... 90
S E R V I C E
INTRODUCTION
◊ This m anual is divided into sections identified b y tw o-figure numbers. Each section has independent page
numbering.
For ease o f reference, these sections have the same numbers and nam es as the Repairs Rate Book sections.
◊ The different sections can easily be found b y consulting the table o f contents on the following pages.
◊ The docum ent num ber o f the m anual and the edition/update dates are given at the bottom o f each page.
◊ The information contained in this m anual was current on the date printed on each section. As CASE IH
constantly improves its product range, some information m ay be out o f date subsequent to modifications im
plem ented for technical o r commercial reasons o r to m eet legal requirem ents in different countries.
In the event o f conflicting information, consult the CASE IH Sales and Service Departments.
IMPORTANT WARNINGS
◊ A ll maintenance and repair work described in this m anual m ust be perform ed exclusively by CASE IH service
technicians in strict accordance with the instructions given and using any specific tools necessary.
◊ Anyone who perform s the operations described herein without strictly following the instructions is personally
responsible for resulting injury or damage to property.
◊ The M anufacturer and all organisations belonging to the M anufacturer’s distribution network, including but
not restricted to national, regional or local distributors, will accept no responsibility for personal injury or dam
age to property caused by abnorm al function o f parts and/or components not approved by the Manufacturer,
including those used for maintenance and/or repair o f the product m anufactured o r marketed b y the Manufac
turer.
In any case, the product m anufactured or m arketed by the Manufacturer is covered by no guarantee o f any
kind against personal injury or damage to property caused by abnormal function o f parts and/or components
not approved b y the Manufacturer.
TEXT AND ILLUSTRATIONS ARE THE PROPERTY

OF CNH ITALIA S.p.A.
•
No part of the text or illustrations
may be reproduced
PRINTED IN ?????
CNH ITALIA S.p.A. - Viale delle Nazioni, 55 - 41100 MODENA - Italy

Technical Support - Technical Information
Print No . ?????? - ?? - ????
Repair Manual - JX Series Tractors
CONTENTS
GENERAL SECTION 00
General Instructions and Health and Safety Chapter 1
Section Description Page
00 000 General in s tru c tio n s .........................................................................................................................1

Notes for spare parts ...................................................................................................................... 2
Notes for e q u ip m e n t........................................................................................................................ 2
Safety rules ...................................................................................................................................... 3
C onsum able s.................................................................................................................................... 6
ENGINE SECTION 10
Engine System Chapter 1

10 000 General specification ....................................................................................................................... 2

Injection pump calibration d a t a ...................................................................................................... 5
General specifications ............................................................................................................... 16
Tightening torques ..................................................................................................................... 24
Tools ............................................................................................................................................. 25
Cross-sectional v ie w s ............................................................................................................... 28
Lubrication and cooling system d ia g ra m s ............................................................................... 32
Fault diagnosis ........................................................................................................................... 35
10 001 10 Engine R em o val-Installa tion...................................................................................................... 39
10 001 54 Engine Bench o v e r h a u l.............................................................................................................. 53
Checks, measurements and repairs ....................................................................................... 78
10 406 10 Radiator R em oval-Installation ................................................................................................ 102
10 1 0 2 7 0 Crankshaft front oil seal rem oval installation ....................................................................... 106
10 402 10 Coolant pump rem oval in s ta lla tio n ......................................................................................... 112
10 402 30 Cooling system therm ostat ...................................................................................................... 115
10 206 14 Bosch injection pump rem oval installation ........................................................................... 118
Bosch injection pump tim in g ................................................................................................... 121
Bosch injection pump air b le e d in g ......................................................................................... 123
10 218 30 Injectors rem oval in s ta lla tio n .................................................................................................... 124
10 106 12 Valve clearance adjustment ................................................................................................... 126
10 402 28 Coolant pump overhaul ............................................................................................................ 129
10 001 30 Compression test ...................................................................................................................... 130
CLUTCH SECTION 18
Clutches Chapter 1
18 000 General specifications ...................................................................................................................... 1

Tightening torques .......................................................................................................................... 2
Tools ...................................................................................................................................................3
Cross-sectional v ie w s .................................................................................................................... 4
Clutch Troubleshooting .................................................................................................................. 5
18 110 10 Removal - Installation .................................................................................................................... 6
O v e rh a u l....................................................................................................................................... 14
Minimum permissible dimensions after refacing ................................................................... 18
Adjustments ............................................................................................................................... 19
18 100 40 Adjustm ent of the main and PTO clutch control lin k a g e ...................................................... 21
GEARBOX SECTION 21
Mechanical Transmission (12x4) Chapter 1

21 000 Main d a t a ...........................................................................................................................................1

Tools ...................................................................................................................................................3
Section v ie w s ................................................................................................................................3&5
Description and operation .............................................................................................................. 8
Fault diagnosis ................................................................................................................................ 8
2 1110 Removal - Refitting see sect 27
Reverser (12x12) Chapter 2

21 000 Main d a t a ............................................................................................................................................ 1

Tools ...................................................................................................................................................3
Section v ie w s .................................................................................................................................... 3
Fault diagnosis ................................................................................................................................ 5
21 110 Removal--Refitting .......................................................................................................................... 6
Reverser and Creeper (20x12) Chapter 3

21 000 Main d a t a ............................................................................................................................................ 1

Tools ...................................................................................................................................................3
Section v ie w s .................................................................................................................................... 4
Fault diagnosis ........................................................................... .............. 6
21 110 Rem oval-Refitting ..................................................................... .............. 7
DRIVE LINES SECTION 23
Drive Lines Chapter 1

23 000 Main s p e c ific a tio n ....................................................................... .............. 1

Torque settings and Tools ........................................................ .............. 2
Cross-Sectional v ie w s .............................................................. .............. 3
23 101 26 Transmission shafts and guard (Disassembly - Assembly) . .............. 4
23 101 40 Drive gear housing (Removal - Installation).......................... .............. 5
23 101 42 Drive gear housing removed (Disassembly - Assembly) . . . .............. 7
FRONT AXLE MECHANICAL TRANSMISSION SECTION 25
Front Axle Mechanical Transmission Chapter 1

25 000 Main d a t a ............................................................................................................................................ 1

Tools .................................................................................................................................................. 6
25 100 30 Complete front axle. Removal - Installation .......................................................................... 10
25 100 38 Front axle. Removal - Installation ............................................................................................ 14
25 108 4 6 -4 7 Steering knuckle bearing pins. Replacement ....................................................................... 24
Stub axle adjustment ................................................................................................................. 25
Wheel hub bearing a d ju s tm e n t................................................................................................. 27
Bevel drive a d ju stm e n t............................................................................................................... 29
25 102 24 Front axle differential. O v e rh a u l................................................................................................ 36
25 100 27 Front axle differential with LIM-SLIP. O v e rh a u l...................................................................... 37
Front axle differential with NO SPIN. Overhaul ..................................................................... 39
44 511 80 Leading drive wheels to e -in check .......................................................................................... 42
REAR AXLE AND TRANSMISSION SECTION 27
Rear Axle And Transmission Chapter 1

27 000 Maind a t a ............................................................................................................................................ 1

Special tools .................................................................................................................................... 5
Description and operation and troubleshooting .......................................................................... 9
2 1 .1 1 8 .1 0 -1 2 Transm ission-gearbox casing Rem oval-Installation .......................................................... 10
21.118.85 Transm ission-gearbox casing Disassem bly-Overhaul ....................................................... 27
Gearbox driven shaft end float a d ju s tm e n t............................................................................. 35
Differential lock engagement sleeve a d ju s tm e n t................................................................... 36
Determining the bevel pinion positioning adjustment ring .................................................. 37
Adjusting the taper roller bearings for the bevel pinion s h a ft.............................................. 39
Adjusting the bearings and checking the backlash ............................................................. 40
Differential pinion and side gear backlash a d ju s tm e n t........................................................ 44
POWER TAKE-OFF SECTION 31
Mechanical Power Take - Off Chapter 1

31 000 Main s p e c ific a tio n ..............................................................................................................................1

Tools ...................................................................................................................................................3
Torque settings ................................................................................................................................ 4
Sectional d ra w in g s .......................................................................................................................... 5
T roubleshooting........................................................................................................................... 10
Removal - Refitting .......................................................................................................................11
31 101 Bench o v e rh a u l............................................................................................................................ 14
BRAKING SYSTEM SECTION 33
Braking System Chapter 1

33 000 Main d a t a ...........................................................................................................................................1

Description & O p e ra tio n .................................................................................................................. 9
Tools - T roublesho oting............................................................................................................. 10
33.206 Front brake assembly mod. JX60 and JX70 removal and refitting -
overhauling on the bench .............................................................................................................11
33.202.60 Service brake removal and refitting ......................................................................................... 14
33.202.50 Rem oval-Refitting of front brake p u m p s ................................................................................. 19
33.202.40 Bleeding air from the front braking s y s te m ............................................................................. 23
33.120.08 Adjusting service brake pedals travel ..................................................................................... 24
33.110.08 Parking brake travel a d ju s tm e n t............................................................................................... 24
HYDRAULIC SYSTEM SECTION 35
Rear Mechanical Hydraulic Lift Chapter 1

35 000 Main s p e c ific a tio n ............................................................................................................................1

Tightening torques ......................................................................................................................... 3
Tools ................................................................................................................................................. 6
Cross-sectional v ie w s ................................................................................................................... 7
Description & O p e ra tio n ................................................................................................................. 9
Hydraulic c irc u it............................................................................................................................... 9
Description and operation o f lift phases .................................................................................... 10
Fault diagnosis ............................................................................................................................. 13
35 110.30 Hydraulic lift - disassembly re a s s e m b ly ....................................................................................15
35.110.40-42-46 Hydraulic lift - bench overhaul ...................................................................................................21
Adjusting the l i f t ........................................................................................................................... 26
35.110.08 Linkage adjustment ......................................................................................................................32
35.110.30 Pressure relief valve - disassembly re a sse m b ly ..................................................................... 34
35.110.32 Pressure relief valve - s e ttin g ......................................................................................................34
35.110.14 Lift control valve - disassembly assembly and overhaul on bench ..................................... 36
35.0101.10 Lift p u m p .......................................................................................................................................... 41
Open Centre System Auxiliary Control Valves Chapter 2

S e ctio n D e s c rip tio n Page
35 000 Main data --Tools ............................................................................................................................ 1

Auxiliary control valves --sectional views ................................................................................... 2
Fault diagnosis .......................................................................................................... see chapter 1
35 204 46 Auxiliary control valves --Assembly--Disassembly ................................................................... 7
Spool binding t e s t ....................................................................................................................... 15
Spool leakage test ..................................................................................................................... 16
Adjustm ent of the automatic detent release p re s s u re .......................................................... 17
Trailer Brake Auxiliary Control Valve Chapter 3

35 000 Section v ie w s ....................................................................................................................................1
Hydraulic d ia g ra m ............................................................................................................................ 2
Description and operation of valve p h a s e s .................................................................................. 3
Trailer brake auxiliary control valve linkage a d ju s tm e n t............................................................6
STEERING SECTION 41
Steering Chapter 1
41 000 Principal d a ta .................................................................................................................................... 1

Section v ie w s .................................................................................................................................... 4
Hydraulic d ia g ra m ............................................................................................................................ 6
Operation ...........................................................................................................................................7
Fault diagnosis ................................................................................................................................ 9
Tools ............................................................................................................................................. 10
41 204 30 Hydrostatic steering control valve --Removal--Installation ....................................................... 11
41 204 34 Hydrostatic steering control valve - Disassem bly-Assem bly ............................................. 14
41 204 38 Hydrostatic steering control valve --Bench testing ............................................................... 28
Hydrostatic steering oil pump --Disassembly--Assembly .................................................... 30
41 216 20 Steering cylinder (tw o-w heel drive axle) - Rem oval-Refitting ........................................... 32
Steering cylinder (four wheel drive axle) - Rem oval-Refitting .......................................... 33
FRONT AXLE AND WHEELS SECTION 44

Front Axle And Wheels Chapter 1
44 000 Principal d a ta ......................................................................................................................................1

Sectional v ie w s ................................................................................................................................ 3
Torque settings ................................................................................................................................ 4
Equipment - Fault d ia g n o s is .......................................................................................................... 5
44 101 30 R em oval-R efitting-O verhaul ......................................................................................................... 6
44 101 22 Wheel hub disassem bly-assem bly ............................................................................................... 9
44 101 46 Stub axle overhaul ...................................................................................................................... 16
44 101 80 Checking wheel alignment ........................................................................................................ 20
AUXILIARY UNITS SECTION 50
Auxiliary Units Chapter 1

50 000 Safety instructions ........................................................................................................................... 2
General characteristics .................................................................................................................. 3
Equipment ........................................................................................................................................ 4
Operating p rin c ip le s ........................................................................................................................ 5
Fault diagnosis ................................................................................................................................ 7
Cab c o n tro ls .....................................................................................................................................11
Use ............................................................................................................................................... 14
Main components of the cab air conditioning system ........................................................ 15
Refrigerant recovery-recycling and evacuation-charging stations .................................. 20
50 200 04 Drying recharging and checking c o o lin g .................................................................................. 22
50 200 03 Functional testing of air conditioning system .......................................................................... 27
Summary of the cab air-conditioning system charging operations .................................. 28
Checking for refrigerant leaks using an electronic leak d e te c to r........................................ 30
Summary of fault diagnosis and maintenance ..................................................................... 31
A ir conditioning and heating pipes - Replacement ............................................................. 33
50 200 0 4 -7 4 R eceiver-drier - Replacement ............................................................................................... 36
50 200 04 -7 2 Condenser - Replacement ..................................................................................................... 38
50 200 04 -2 6 Com pressor --Removal--Refitting ........................................................................................... 39
50 200 10 Com pressor drive belt tension adjustment ............................................................................ 41
ELECTRICAL SYSTEM SECTION 55
Instruments Chapter 1
Section D e s c rip tio n ............................................................................................................................. Page
Analogue instruments In tro d u c tio n ........................................................................................................................... 1

Transmitter and switch 4.
Components Chapter 2
Section D e s c rip tio n ............................................................................................................................ Page
55 500 Introduction .......................................................................................................................................1

Component description ...................................................................................................................1
Starting System Chapter 3

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

Tightening torques ...........................................................................................................................1
Starting circuit .................................................................................................................................. 3
System tests .................................................................................................................................... 5
55 201 Removal and re-installation of starter m o t o r .............................................................................. 8
S e rv ic in g .............................................................................................................................................9
Bench tests ................................................................................................................................. 10
Charging System Chapter 4


Tightening torques ...........................................................................................................................1
System testing and tro u b le -sh o o tin g ............................................................................................ 4
55 301 Removal, re-installation and servicing ................................................................................... 10
Battery Chapter 5

55.301.040 Removal and re-installation .......................................................................................................... 2
Battery checking and maintenance .............................................................................................. 3
Charging the b a tte ry ........................................................................................................................ 4
Battery problems - Frequent c a u s e s ............................................................................................ 7
Electrical Circuits Chapter 6

55 100 Contents .............. 1
Fuses (all versions) ......................................................................................................................... 2
Symbols used in electrical circuits ................................................................................................. 4
Electrical wire colour coding ........................................................................................................... 5
Ground lo c a tio n s ............................................................................................................................... 5
Electrical d ia g ra m s ............................
- General diagrams (W/Cab) 9

- General diagrams (W/Out Cab) ................................................................................15
- Analogue instrument circuit and connector overview ........................................... 19
- S tart-up circuit and connector o v e rv ie w ................................................................. 21
- Direction indicator & hazard warning light circuit and connector overview . . . . 25
- W indscreen and rear window wiper/washer circuit and connector overview . . . 31
- Brake light circuit and connector o v e rvie w ............................................................. 35
- Heating and air-conditioning system circuit and connector overview ...............41
- W ork lamp (without cab circuit and connector overview) .....................................45
- W ork lamp (without cab circuit and connector overview) .....................................49
- Side lights,main and dipped headlights, parking light circuit and connector
overview 53
BODYWORK AND DRIVER POSITION SECTION 90
Bodywork And Driver Position Chapter 1

Section D e s c rip tio n .............................................................................................................................Page
90 160 42 -4 3
90 120 10 Control levers, seat and electrical controls - disassembly and re a s s e m b ly ...........................2
90 156 52 Rear window, handle and lock - disassembly and reassembly .......................................... 10
90 154 30 Left-hand door exterior handle and lock - disassembly and re a s s e m b ly............................. 11
90 1 5 4 1 0 Left-hand door - disassembly and reassem bly...................................................................... 12
90 160 60
55 518 52 Windscreen w iper motor - disassembly and reassembly ................................................... 13
90154 24
90 156 10 - 14
90 156 28 Cab windows - re p la ce m e n t...................................................................................................... 15
SECTION 00 - GENERAL - CHAPTER 1 1
GENERAL INSTRUCTIONS
IMPORTANT NOTICE
All maintenance and repair operations described in this manual should be carried out exclusively by the CASE
IH authorised workshops. All instructions detailed should be carefully observed and special equipment indicated
should be used if necessary.
Everyone who carries out service operations described without carefully observing these prescriptions will be
directly responsible of deriving damages.
SHIMMING
At each adjustment, select adjusting shims, measure them individually using a micrometer and then sum up
recorded values. Do not rely on measuring the whole shimming set, which may be incorrect, or on rated value
indicated for each shim.
ROTATING SHAFT SEALS

To correctly install rotating shaft seals, observe the following instructions:
- Let the seal soak into the same oil as it will seal for at least half an hour before mounting;
- Thoroughly clean the shaft and ensure that the shaft working surface is not damaged;
- Place the sealing lip towards the fluid. In case of a hydrodynamic lip, consider the shaft rotation direction and
orient grooves in order that they deviate the fluid towards the inner side of the seal;
- Coat the sealing lip with a thin layer of lubricant (oil rather than grease) and fill with grease the gap between
the sealing lip and the dust lip of double lip seals;
- Insert the seal into its seat and press it down using a flat punch. Do no tap the seal with a hammer or a drift;
- Take care to insert the seal perpendicularly to its seat while you are pressing it. Once the seal is settled, ensure
that it contacts the thrust element if required.;
- To prevent damaging the sealing lip against the shaft, place a suitable protection during installation.
O RINGS
Lubricate the O rings before inserting them into their seats. This will prevent the O rings from rolling over and
twine during mounting which will jeopardise sealing.
SEALERS
Apply one of the following sealers: RTV SILMATE, RHODORSIL CAF 1, or LOCTITE PLASTIC GASKET over
the mating surfaces marked with an X.
Before applying the sealer, prepare the surface as follows:
- remove possible scales using a metal brush;
- thoroughly degrease the surfaces using one of the following cleaning agent: trichlorethylene, petrol or a water
and soda solution.
BEARINGS
It is advisable to heat the bearings to 80 to 90°C before mounting them on their shafts and cool them down before
inserting them into their seats with external tapping.
ROLL PINS
When fitting straight roll pins, ensure that the pin notch is oriented in the direction of the effort to stress the pin.
Coil roll pins can be installed in any position.
???
2 SECTION 00 - GENERAL - CHAPTER 1
NOTES FOR SPARE PARTS
Use exclusively genuine CASE IH spare parts, the only ones bearing this logo.
CASE
Only genuine parts guarantee same quality, life, safety as original components as they are the same as mounted
in production.
Only the CASE IH genuine spare parts can offer this guarantee.
All spare parts orders should be complete with the following data:
- tractor model (commercial name) and frame number;
- engine type and number;
- part number of the ordered part, which can be found on the “Microfiches” or the “Spare Parts Catalogue”,
which is the base for order processing.
NOTES FOR EQUIPMENT

Equipment which CASE IH proposes and shows in this manual are as follows:
- studied and designed expressly for use on CASE IH tractors;
- necessary to make a reliable repair;
- accurately built and strictly tested to offer efficient and long-lasting working means.
We also remind the Repair Personnel that having these equipment means:
- work in optimal technical conditions;
- obtain best results;
- save time and effort;
- work more safely.
NOTICES
W ear limits indicated for some details should be intended as advised, but not binding values. The words “front”,
“rear”, “right hand”, and “left hand” referred to the different parts should be intended as seen from the operator’s
seat oriented to the normal sense of movement of the tractor.
HOW TO MOVE THE TRACTOR WITH THE BATTERY REMOVED

Cables from the external power supply should be connected exclusively to the respective terminals of the tractor
positive and negative cables using pliers in good condition which allow proper and steady contact.
Disconnect all services (lights, w ind-shield wipers, etc.) before starting the tractor.
If it is necessary to check the tractor electrical system, check it only with the power supply connected. At check
end, disconnect all services and switch the power supply off before disconnecting the cables.
????
SAFETY RULES
PAY ATTENTION TO THIS SYMBOL
A
This warning symbol points out im portant messages involving personal safety.
Carefully read the safety rules contained herein and follow advised precautions to
avoid potential hazards and safeguard your safety and personal integrity.
In this m anual you will find this symbol together with the following key-w ords:
WARNING - it gives warning about improper repair operations and deriving potential
consequences affecting the service technician’s personal safety.
DANGER - it gives specific warning about potential dangers for personal safety o f the
operator or other persons directly o r indirectly involved.
TO PREVENT ACCIDENTS if they are certified operators to assist in the

operation to be carried out.
Most accidents and personal injuries taking place in
workshops are due from non-observance of some 0 Never operate the machine or use attachments
simple and essential prudential rule and safety pre from a place other than sitting at the operator’s
cautions. For this reason, IN MOST CASES THEY seat.
CAN BE AVOIDED. It suffices to foresee possible
causes and act consequently with necessary caution 0 Never carry out any operation on the machine
and care. when the engine is running, except when specifi
The possibility that an accident might occur with any cally indicated.
type of machines should not be disregarded, no mat
0 Stop the engine and ensure that all pressure is
ter how well the machine in question was designed
relieved from hydraulic circuits before removing
and built.
caps, covers, valves, etc.
A wise and careful service technician is the best pre
cautions against accidents. 0 All repair and maintenance operations should be
Careful observance of this only basic precaution carried out with the greatest care and attention.
would be enough to avoid many severe accidents.
0 Service stairs and platforms used in a workshop
DANGER: Never carry out any cleaning, lubrication or in the field should be built in compliance with
or maintenance operations when the engine is run the safety rules in force.
ning.
0 Disconnect the batteries and label all controls to
warn that the tractor is being serviced. Block the
SAFETY RULES machine and all equipment which should be
raised.
GENERALITIES
0 Never check or fill fuel tanks and accumulator
0 Carefully follow specified repair and mainte batteries, nor use starting liquid if you are smok
nance procedures. ing or near open flames as such fluids are flam
mable.
0 Do not w ear rings, wristwatches, jewels, unbut
toned or flapping clothing such as ties, torn 0 Brakes are inoperative when they are manually
clothes, scarves, open jackets or shirts with open released for maintenance purposes. In such
zips which could get hold into moving parts. We cases, the machine should be kept constantly
advise to use approved safety clothing such as under control using blocks or similar devices.
anti-slipping footwear, gloves, safety goggles,
helmets, etc. 0 The fuel filling gun should remain always in con
tact with the filler neck. Maintain this contact until
0 Never carry out any repair on the machine if the fuel stops flowing into the tank to avoid pos
someone is sitting on the operator’s seat, except sible sparks due to static electricity buildup.
???
0 Use exclusively specified towing points for tow 0 In case of operations outside the workshop, drive
ing the tractor. Connect parts carefully. Ensure the tractor to a flat area and block it. If working on
that foreseen pins and/or locks are steadily fixed an incline cannot be avoided, first block the trac
before applying traction. Do not stop near towing tor carefully. Move it to a flat area as soon as pos
bars, cables or chains working under load. sible with a certain extent of safety.
0 To transfer a failed tractor, use a trailer or a low 0 Ruined or plied cables and chains are unreliable.
loading platform trolley if available. Do not use them for lifting or trailing. Always han
0 To load and unload the machine from the trans dle them wearing gloves of proper thickness.
portation mean, select a flat area providing a firm
0 Chains should always be safely fastened.
support to the trailer or truck wheels. Firmly tie
Ensure that fastening device is strong enough to
the machine to the truck or trailer platform and
hold the load foreseen. No persons should stop
block wheels as required by the forwarder.
near the fastening point, trailing chains or cables.
0 For electrical heaters, battery-chargers and sim
ilar equipment use exclusive auxiliary power 0 The working area should be always kept CLEAN
supplies with a efficient ground to avoid electrical and DRY. Immediately clean any spillage of
shock hazard. water or oil.
0 Always use lifting equipment and sim ilar of 0 Do not pile up grease or oil soaked rags, as they
appropriate capacity to lift or move heavy compo constitute a great fire hazard. Always place them
nents. into a metal container.
Before starting the tractor or its attachments,
0 Pay special attention to bystanders. check, adjust and block the operator’s seat. Also
0 Never pour gasoline or diesel oil into open, wide ensure that there are no persons within the trac
and low containers. tor or attachment operating range.
0 Never use gasoline, diesel oil or other flammable 0 Do not keep into your pockets any object which
liquids as cleaning agents. Use non-flam m able might fall unobserved into the tractor’s inner
non-toxic proprietary solvents. compartments.
0 W ear protection goggles with side guards when 0 Whenever there is the possibility of being
cleaning parts using compressed air. reached by ejected metal parts or similar, use
protection eye mask or goggles with side guards,
0 Do not exceed a pressure of 2.1 bar, in accor
helmets, special footwear and heavy gloves.
dance with local regulations.
0 Do not run the engine in a closed building without 0 Wear suitable protection such as tinted eye
proper ventilation. protection, helmets, special clothing, gloves and
footwear whenever it is necessary to carry out
0 Do not smoke, use open flames, cause sparks in welding procedures. All persons standing in the
the nearby area when filling fuel or handling vicinity of the welding process should wear tinted
highly flammable liquids. eye protection. NEVER LOOK AT THE WELD
ING ARC IF YOUR EYES ARE NOT SUITABLY
0 Do not use flames as light sources when working
PROTECTED.
on a machine or checking for leaks.
0 Move with caution when working under a tractor, 0 Metal cables with the use get frayed. Always
and also on or near a tractor. Wear proper safety wear adequate protections (heavy gloves, eye
accessories: helmets, goggles and special foot protection, etc.)
wear.
0 Handle all parts with the greatest caution. Keep
0 During checks which should be carried out with your hands and fingers far from gaps, moving
the engine running, ask an assistant to seat at the gears and similar. Always use approved protec
operator’s seat and keep the service technician tive equipment, such as eye protection, heavy
under visual control at any moment. gloves and protective footwear.
????
START UP HYDRAULIC SYSTEMS

0 Never run the engine in confined spaces which 0 Some fluid slowly coming out from a very small
are not equipped with adequate ventilation for port can be almost invisible and be strong enough
exhaust gas extraction. to penetrate the skin. For this reason, NEVER
USE YOUR HANDS TO CHECK FOR LEAKS,
but use a piece of cardboard or a piece o f wood
0 Never bring your head, body, arms, legs, feet, to this purpose. If any fluid is injected into the skin,
hands, fingers near fans or rotating belts. seek medical aid immediately. Lack of immediate
medical attention, serious infections or dermato
sis may result.
ENGINE
0 Always take system pressure readings using the
0 Always loosen the radiator cap very slowly before appropriate gauges.
removing it to allow pressure in the system to dis
sipate. Coolant should be topped up only when WHEELS AND TYRES
the engine is stopped or idle if hot.
0 Check that the tyres are correctly inflated at the
pressure specified by the manufacturer. Periodi
cally check possible damages to the rims and
0 Do not fill up fuel tank when the engine is running,
tyres.
mainly if it is hot, to avoid ignition of fires in case
of fuel spilling.
0 Keep off and stay at the tyre side when correcting
the inflation pressure.
0 Never check or adjust the fan belt tension when
the engine is running. 0 Check the pressure only when the tractor is
Never adjust the fuel injection pump when the unloaded and tyres are cold to avoid wrong read
tractor is moving. ings due to over-pressure. Do not reuse parts of
recovered wheels as improper welding, brazing
or heating may weaken the wheel and make it fail.
0 Never lubricate the tractor when the engine is run
ning. 0 Never cut, nor weld a rim with the inflated tyre
assembled.
0 To remove the wheels, block both front and rear

ELECTRICAL SYSTEMS
tractor wheels. Raise the tractor and install safe
0 If it is necessary to use auxiliary batteries, cables and stable supports under the tractor in accor
must be connected at both sides as follows: (+) to dance with regulations in force.
(+) and (-) to (-). Avoid short-circuiting the termi
nals. GAS RELEASED FROM BATTERIES IS 0 Deflate the tyre before removing any object
HIGHLY FLAMMABLE. During charging, leave caught into the tyre tread.
the battery compartment uncovered to improve
ventilation. Avoid checking the battery charge by 0 Never inflate tyres using flammable gases as they
means of “jum pers” made by placing metallic may originate explosions and cause injuries to
objects across the terminals. Avoid sparks or bystanders.
flames near the battery area. Do no smoke to pre
vent explosion hazards.
REMOVAL AND INSTALLATION
0 Lift and handle all heavy components using lifting
0 Prior to any service, check for fuel or current equipment of adequate capacity. Ensure that
leaks. Remove these leaks before going on with parts are supported by appropriate slings and
the work. hooks. Use lifting eyes provided to this purpose.
Take care of the persons near the loads to be
lifted.
0 Do not charge batteries in confined spaces. En
sure that ventilation is appropriate to prevent acci 0 Handle all parts with great care. Do not place your
dental explosion hazard due to build-up of gases hands or fingers between two parts. W ear
releaved during charging. approved protective clothing such as safety
goggles, gloves and footwear.
0 Always disconnect the batteries before perform 0 Do not twine chains or metal cables. Always wear
ing any type of service on the electrical system. protection gloves to handle cables or chains.
???
CONSUMABLES
QUANTITY CASE IH
COMPONENT TO BE FILLED OR INTERNATIONAL
RECOMMENDED
TOPPED UP litres/dm3 US gal IMP gal SPECIFICATION
PRODUCTS
Cooling system:
JX60, JX70 models 12 3.2 2.64 Water & liquid
JX80, JX90, JX95 models 14 3.7 3.08 AKCELA PREMIUM
-
with cab : ANTI-FREEZE
JX60, JX70 models 14 3.7 3.1 50% + 50%
JX80, JX90, JX95 models 16 4.2 3.5
Water & cleaning
Windscreen washer bottle .................. 2 0.53 0.44 -
liquid
Fuel tank 90 23.8 19.8 Decanted and filtered -
Additional fuel tank (Optional) ............ 27 7.1 5.94 diesel fuel -
Engine sump:
without filter :
AKCELA No.1
JX60, JX70 models 7.6 1.98 1.67 API C F-4/SG
ENGINE OIL
JX80, JX90, JX95 models 10.5 2.77 2.31 CCMC D4
with filter : API C H -4 * ACEA M IL-L-2104E
JX60, JX70 models 8.3 2.19 1.83 E5 * MB 228.3 *
CUMMINS CES
JX80, JX90, JX95 models 11.2 2.96 2.46
200072/20076/20077
AKCELA LHM
Brake control c irc u it.............................. 0.4 0.1 0.09 ISO 7308
FLUID Oil
Hydrostatic steering c ir c u it.................. 2.0 0.5 0.44
Front axle:
- axle housing : 4.5 1.2 0.99
JX60, JX70 models
7.0 1.8 1.54
JX80, JX90, JX95 models
- final drives (each) :
JX60, JX70 HP models 0.8 0.2 0.18
JX80, JX90, JX95 models 1.25 0.3 0.28
Rear transmission (bevel drive and API GL4
Oil
brakes), gearbox, hydraulic lift and
PTO AKCELA ISO 32/46
NEXPLORE SAE 10W -30
JX60, JX70, JX80, JX90, 12.15 10.12
46
JX95 models ..................................
- with synchro-reverser:
JX60, JX70, JX80, JX90, 12.15 10.12
46
JX95 models ..................................
Rear final drives (each) :
JX60, JX70 HP models 3.9 1.03 0.86
JX80, JX90, JX95 models 5.3 1.40 1.17
Grease
Front wheel h u b s .................................. - - -
AKCELA
MULTI PURPOSE NLGI 2
Grease fittings ...................................... GREASE
- - -
(251H EP)
????
SECTION 10 - ENGINE - CHAPTER 1 1
SECTION 10 - ENGINE
Chapter 1 - Engine
CONTENTS
10 000 General specification ................................................................................................................... 2

Injection pump calibration d a t a ................................................................................................... 5
General specifications ............................................................................................................... 16
Tightening torques ..................................................................................................................... 24
Tools ............................................................................................................................................. 25
C ross-sectional views ............................................................................................................... 28
Lubrication and cooling system d ia g ra m s ............................................................................... 32
Fault diagnosis ........................................................................................................................... 35
10 001 10 Engine R e m o va l-In stalla tio n...................................................................................................... 39
10 001 54 Engine Bench overhaul .............................................................................................................. 53
Checks, measurements and repairs ....................................................................................... 78
10 406 10 Radiator Rem oval-Installation ................................................................................................ 102
10 102 70 Crankshaft front oil seal rem oval installation ........................................................................ 106
10 402 10 Coolant pump rem oval in s ta lla tio n .......................................................................................... 112
10 402 30 Cooling system therm ostat ...................................................................................................... 115
10 206 14 Bosch injection pump rem oval installation ............................................................................ 118
Bosch injection pump tim in g ................................................................................................... 121
Bosch injection pump air b le e d in g ......................................................................................... 123
10 218 30 Injectors rem oval in s ta lla tio n .................................................................................................... 124
10 106 12 Valve clearance adjustment .................................................................................................... 126
10 402 28 Coolant pump overhaul ............................................................................................................ 129
10 001 30 Compression test ...................................................................................................................... 130
6-62720 - 09 - 2006
2 SECTION 10 - ENGINE - CHAPTER 1
G ENERAL SPECIFICATIONS 3 c y lin d e rs 4 c y lin d e rs

E ngin e typ e:
- mod. JX60 normally aspirated - type 8035.05D.939 -
(BOSCH pump) ............................................................................. see data pages
6 -7
- mod. JX 70turbo ch arge d-type 8035.25C.939 -
(BOSCH pump) ............................................................................. see data pages
8 -9
- mod. JX80 normally aspirated - type 8045.05R.939
(BOSCH pump) ............................................................................. “ see data pages
10--11
- mod. JX90 turbocharged - type 8045.25.939
12-13
- mod. JX95 turbocharged - type 8045.25L.939
14-15
Cycle ................................................................................................... Diesel, 4-stroke
Fuel injection ..................................................................................... Direct
Number of cylinders in lin e .............................................................. 3 4
Cylinder liners ................................................................................... dry force-fitted in
cylinder block
Piston diameter
- mod. J X 6 0 ....................................................................................... 104 mm (4.0945 in.) -
- mod. J X 7 0 ....................................................................................... 104 mm (4.0945 in.) -
- mod. J X 8 0 ....................................................................................... - 104 mm (4.0945 in.)
- mod. J X 9 0 ....................................................................................... - 104 mm (4.0945 in.)
- mod. J X 9 5 ....................................................................................... - 104 mm (4.0945 in.)
Piston stroke ..................................................................................... 115 mm (4.5276 in.)
Total displacement:
- mod. J X 6 0 -J X 7 0 .......................................................................... 2931 cm3 -
(178.8496 in.3)
- mod. JX 80-JX 90-JX 95 .............................................................. - 3908 cm3
(238.4662 in.3)
Compression r a t io ............................................................................. 17 to 1 normally aspirated
16.5 to 1 turbocharged
Maximum power 2000/25 EC at 2500 rpm:
- mod. J X 6 0 ....................................................................................... 43.4 kW (59 hp) -
- mod. J X 7 0 ....................................................................................... 50.7 kW (69 hp) -
- mod. J X 8 0 ....................................................................................... - 58.8 kW (80 hp)
- mod. J X 9 0 ....................................................................................... - 65.5 kW (89 hp)
- mod. J X 9 5 ....................................................................................... - 69.1 kW (94 hp)
Maximum power ECE R 24 at 2500 rpm:
- mod. J X 6 0 ....................................................................................... 41.2 kW (56 hp) _
- mod. J X 7 0 ....................................................................................... 47.8 kW (65 hp)
- mod. J X 8 0 ....................................................................................... 55.9 kW (76 hp)
- mod. J X 9 0 ....................................................................................... 63.3 kW (86 hp)
- mod. J X 9 5 ....................................................................................... 66.9 kW (91 hp)
Fast idling speed ............................................................................. 2500 rpm.
Maximum torque (daNm) at 1500 rpm: JX60 m o d e l.................. 20.7 (152.6753 ft lb) -
Maximum torque (daNm) at 1500 rpm: JX70 m o d e l.................. 25.0 (184.3905 ft lb) -
Maximum torque (daNm) at 1500 rpm: JX80 m o d e l.................. - 27.9 (205.9778 ft lb
Maximum torque (daNm) at 1500 rpm: JX90 m o d e l.................. - 32.0 (236.0194 ft lb)
Maximum torque (daNm) at 1500 rpm: JX95 m o d e l................ - 33.7 (248.5584 ft lb)
Number of main b e a rin g s ................................................................ 4 5
S u m p ................................................................................................... Structural cast iron
6-62720 - 09 - 2006
(continued)
L u b ric a tio n ..................................................................................... forced, with gear pump
Pump d r iv e ....................................................................................... camshaft
Engine speed/oil pump speed ratio ............................................ 2:1
Oil c le a n in g ....................................................................................... mesh filter on oil intake and

cartridge filter on delivery line
Normal oil pressure, with engine hot and at fast idling speed . 2.9 to 3.9 bar (42.06 to 56.56 psi)
Pressure relief v a lv e ...................................................................... built into pump housing
Valve opening pressure ................................................................ 3.5 bar (50.76 psi)
For further lubrication d a ta ............................................................ See page 23
C o o lin g syste m ............................................................................ coolant circulation
Radiator on JX60, JX70, JX80 and JX90 models .................... three-row vertical pipes with copper fins
Radiator on JX95 models ............................................................ four-row vertical pipes with

copper fins
Fan, attached to coolant pump pulley ........................................ four-blade steel exhauster fan
6-blade steel exhauster fan (JX95)
Coolant p u m p ................................................................................... centrifugal vane-type
Engine speed/coolant pump speed ratio .................................... 1:1,403
Temperature control ...................................................................... Thermostat
Coolant temperature g a u g e .......................................................... coloured scale divided into three sections
Temperature ranges corresponding to each section:
- initial white section .......................................................... from 30° to 65° C (86° to 149° F)
- middle green s e c tio n ........................................................ from 65° to 105° C (149° to 221° F)
- final red section from 105° to 115° C (221° to 300.2° F)
For further cooling system d a ta .................................................... See page 23
Rev c o u n te r ................................................................................... incorporated in control panel
Rev counter drive .......................................................................... from gear on camshaft
Hour counter calibrated for engine speed o f .............................. 1800 rpm.

(Continued)
6-62720 - 09 - 2006
(continued)

T im in g ............................................................................................. overhead valves operated by a camshaft
located in the engine block through
tappets, pushrods and rockers.
Camshaft is driven by the crankshaft
through helical gears.
Intake:
- start: before T .D .C ...................................................................... 12°
- end: after B .D .C .......................................................................... 31°
Exhaust:
- start: before B.D.C .................................................................... 50°
- end: after T.D.C .......................................................................... 16°
Valve clearance for timing c h e c k .................................................. 0.45 mm (0.0177 in.)
Valve clearance for normal running (engine cold):
- in ta k e ............................................................................................. 0.30 ± 0.05 mm (0.0118 ± 0.0020 in.)
- exhaust ......................................................................................... 0.30 ± 0.05 mm (0.0118 ± 0.0020 in.)
For further timing data .................................................................. See page 20
Fuel System
A ir c le a n in g ....................................................................................... dual cartridge dry air filter, with clogged
filter indicator with centrifugal pre-filter
and automatic dust ejector.
Fuel p u m p ......................................................................................... with double diaphragm
Fuel f ilt e r ........................................................................................... mesh filter in fuel supply pump, and

replaceable cartridge on delivery line to
injection pump.
Minimum fuel flow rate with pump shaft rotating at 1600 rev/min. 100 litres/hour
Operated by eccentric cam .......................................................... on camshaft
BOSCH Injection pump ................................................................ rotary distributor type
A ll-speed governor, incorporated in pump: BOSCH centrifugal counterweights
Autom atic advance regulator, incorporated in pump: BOSCH hydraulic
For further fuel system data: see pages 5 to 15
For fixed advance (pump setting for start of delivery before refer to the data for the relevant engine
TDC) - Pressure setting - Injection order, and other type in the tables from page 6 to page
information regarding the BOSCH pump 14.
6-62720 - 09 - 2006
DATA
Turbocharger (Model JX95):
- ........ GARRETT t y p e .................................................................. T25
Fuel injection p u m p ........................................................................ distributor type with incorporated speed

governor and automatic advance regulator
BOSCH pump:
- ........ JX60 model ........................................................................ VE 3/12 F 1250 L 976 - 504054473
- ........ JX70 model ........................................................................ VE 3/12 F 1250 L 977 - 504054474
- ........ JX80 model ........................................................................ VE 4/12 F 1250 L 985 - 504041416
- ........ JX90 model ........................................................................ VE 4/12 F 1250 L 982 - 504042214
- ........ JX95 model ........................................................................ VE 4/12 F 1250 L 952 - 504042718
Direction of ro ta tio n ........................................................................ anticlockwise
Injection order ................................................................................. 1 -2 -3 (JX60 and JX70)

1 -3 -4 -2 (JX80, JX90 and JX95)
Fuel injectors:
BOSCH ..................................................
- Nozzle holder ty p e ............................
- Nozzle t y p e ........................................
Number of nozzle holes ...................... 5 6
Diameter of nozzle o rific e s ..................
Pressure s e ttin g .................................... 248-272 bar 248-272 bar

(3596.9176-3945.0064 psi) (3596.9176-3945.0064 psi)
JX70 JX95 JX60 JX80 JX90
Fuel delivery lines - BOSCH pump
- Type ....................................................
- D im e n sio n s................................ mm
6-62720 - 09 - 2006
JX60 MODEL - CALIBRATION DATA FOR BOSCH INJECTION PUMP

TYPE VE 3/12 F 1250 L 976 - 504054473
ASSEM BLY DATA Test bench conforming to ISO 4008/1.../2

Pump timing on engine: delivery start 4° ± 0.5° Injectors conforming to ISO 7440-A61 -
before TDC of cylinder 1 compression stroke. (1688901027 with pad 0 0.5 mm)
Plunger pre-lift fortim ing on engine: 1 mm from BDC Injector setting pressure: 250 bar (3625.925 psi).
(with tools 380000228 - 380001601). Fuel supply pressure: 0.35 ± 0.05 bar (kg/cm2).
Cylinder no. 1 delivery line union on pump: marked
(5.0763 ± 0.7252 psi).
with letter A.
Delivery pipes (conforming to ISO 4093.2):
ASSEM BLY DIMENSIONS 6 x 2 x 4 5 0 mm (0 .2 3 6 2 x 0 .7 8 7 x 1 7 .7 1 6 5 in.).
SYMBOL K KF MS1 ya yb Graduate drain time: 30 seconds
mm 3.6 to 3.8 3 0.85 to 36.9 to 41.5 to Test liquid: ISO 4113 at a temperature of 55 ° ± 1° C
1.15 40.9 46.5 (131 ° ± 33.8 ° F).
CALIBRATIO N TEST CONDITIONS
1. START OF DELIVERY
Plunger pre-lift from BDC: Pump rotation (viewed from drive side): Injection o rd e r:1 -2 -3
mm - anticlockwise
2. ADVANCE REGULATOR STROKE

rpm: 1150 Advance stroke: mm 1.6 to 2.0
3. FUEL SUPPLY PUMP PRESSURE

rpm: 1150 Internal pressure: bar 8.4 to 8.8
4. FULL LOAD DELIVERY

rpm :800 Delivery per 1000 shots: cm3 77.3 to 77.7 Spread: cm3 -
5. SPREAD GOVERNOR AT IDLE SPEED

rpm: 325 Delivery per 1000 shots: cm3 9.5 to 10.5 Spread: cm3 < 5.0
6. SPREAD GOVERNOR AT MAXIMUM SPEED

rpm: 1300 Delivery per 1000 shots: cm3 49.5 to 50.5 Spread:-
7. DELIVERY AT STARTING SPEED

rpm: 100 Delivery per 1000 shots: cm3 70 to 110
8. INJECTION ADVANCE PROGRESSION

Rev/min 1250 1150 1050
Advance stroke mm 1.9 to 2.9 1.6 to 2.0 0.8 to 1.6
9. TRANSFER PRESSURE PROGRESSION

Rev/min 500 1150 -
Internal pressure bar 4.8 to 5.8 8.4 to 8.8 -
10. BACKFLOW
Rev/min 500 1250
Backflow cm3/1 0 s 44.5 to 77.7 58.3 to 97.1
(continued)
Note: The values shown above in brackets must be used for checking purposes only.
6-62720 - 09 - 2006
(continued)
11. DELIVERY PROGRESSION
Rev/min Delivery per 1000 shots: cm3

1390 0 to 3
1300 49.5 to 50.5
1250 63.5 to 68.5
800 77.3 to 77.7
450 68,0
12. ZERO DELIVERY (STOP)

Rev/min Voltage (volts) Delivery per 1000 shots: cm3
325 0 0 to 3
13. DELIVERY CHECK AT IDLE SPEED

Rev/min 250 325 390
Delivery per 1000 shots: cm3 35 9.5 to 10.5 0 to 3.0
14. AUTOMATIC START SUPPLEMENT

100 70 to 110
250 67 to 77
BENCH TEST PERFORMANCE DATA

Test C o n d itio n s
TDC fixed advance with cylinder No. 1 in compression stroke: Relative humidity 70% ± 5.
(see previous page).
Engine without fan, air filter and exhaust silencer. Ambient temperature 25 °C.
Atm ospheric pressure: 990 mbar Specific gravity of diesel fuel

830 ± 10 g/litre.
Power output with engine Fuel
Throttle run-in for a total of: consumption
lever Braking load applied Engine rpm
2 hours 50 hours
position
kW (HP) kW kg/h
For maximum
Maximum 2500 - 39,5 - 42,0 9,1 - 9,7
torque
Maximum For maximum torque 1500 - 31,5 - 33,5 6,8 - 7,2
Maximum None (no-load) 2770 ± 25 - - -
Minimum None (no-load) 650 ± 25 - - -
6-62720 - 09 - 2006

TYPE VE 3/12 F 1250 L 977 - 504054474
ASSEM BLY DATA Test bench conforming to ISO 4008/1.../2

Pump timing on engine: delivery start 0° ± 0.5° Injectors conforming to ISO 7440-A61 -
before TDC of cylinder 1 compression stroke. (1688901027 with pad 0 0.5 mm (0.0197 in.))
Plunger pre-lift for pump timing on engine: 1 mm Injector setting pressure: 250 bar (3625.925 psi).
from BDC with tools 380000228 - 380001601). Fuel supply pressure: 0.35 ± 0.05 bar
Delivery line union on pump for cylinder no. 1:
(5.0763 ± 0.7252 psi).
marked with letter A.
ASSEM BLY DIMENSIONS 6 x 2 x 4 5 0 mm (0 .2 3 6 2 x 0 .7 8 7 x 1 7 .7 1 6 5 in.)
SYMBOL K KF MS ya yb Graduate drain time: 30 seconds
mm 3.6 to 3.8 3 0.5 to 0.9 35.5 to 39.8 to Test liquid: ISO 4113 at a temperature of 55 ° ± 1° C
39.5 44.8 (131 ° ± 33.8 ° F).
CALIBRATIO N TEST CONDITIONS
Plunger pre -lift from B.D.C.: mm - Pump rotation (viewed from drive side): Injection o rd e r:1 -2 -3
anticlockwise

1100 rpm LDA pressure: kPa 100 Advance stroke: mm 1.8 to 2.2

rpm: 800 LDA pressure: kPa 100 Internal pressure: bar 7.7 to 8.3
4. FULL-LOAD DELIVERY WITH BOOSTER PRESSURE

rpm: 900 LDA pressure: kPa 100 Delivery per 1000 shots: cm3 76.5 to 76.9 Spread: cm3 < 3.5
5. FULL-LOAD DELIVERY WITHOUT BOOSTER PRESSURE

rpm: 600 LDA pressure: kPa 0 Delivery per 1000 shots: cm3 73.8 to 74.2 Spread: cm3 -

rpm: 325 LDA pressure: kPa 0 Delivery per 1000 shots: cm3 12 to 13 Spread: cm3 < 4.5



LDA pressure kPa 100
Rev/min 1250 1100 900
Advance stroke mm 2.5 to 3.5 1.8 to 2.2 0.3 to 1.3

Rev/min 1250 1100 500
Internal pressure supply: bar 8,7 7.7 to 8.3 4.5 to 5.5
11. BACKFLOW
Rev/min 1250 500
LDA pressure kPa 100 100
Backflow for cm3/1 0 s 66.7 to 105.5 50.0 to 77.6
(continued)
6-62720 - 09 - 2006
(continued)
Rev/min LDA pressure kPa Delivery per 1000 shots: cm3
1390 100 0 to 3.0
1350 100 32 to 33
1250 100 66 to 71
900 100 76.5 to 76.9
600 27,5 76.2 to 77.2
400 100 91
600 0 73.8 to 74.2

rpm: 325 Voltage (volts): 0 Delivery per 1000 shots: cm3: 0to3

Rev/min 325 380 -
Delivery per 1000 shots: cm3 12 to 13 0 to 3.0 -

100 100 to 140
300 77 to 87

(see previous page)
830 ± 10 g/litre.
2 hours 50 hours
position
kW (HP) kW kg/h
For maximum
Maximum 2500 - 47.5 - 50.5 11.1 - 11.8
torque
Maximum For maximum torque 1500 - 37.0 - 39.5 8.2 - 8.7
6-62720 - 09 - 2006

TYPE VE 4/12 F 1250 L 985 - 504041416
ASSEMBLY DATA Test bench conforming to ISO 4008/1 .../2

Pump timing on engine: delivery start 4o ± 0.5o before Injectors conforming to ISO 7440-A61 -
T.D.C. of cylinder 1 on compression stroke. (1.688.901.027 with calibrated pad 0 0.5 mm
Plunger pre-lift fortim ing on engine: 1 mm from BDC (0.0197 in.)).
(with tools 380000228 - 380001601). Injector pressure setting 250 to 253 bar
Delivery union of the pump corresponding to cylinder (3625.925 to 3699.4361 psi)
no. 1: marked with letter A. Fuel supply pressure:
0.35 ± 0.05 bar (5.0763 ± 0.7252 psi).
ASSEMBLY DIMENSIONS Delivery pipes (conforming to ISO 4093.2):
SYMBOL K A MS ya yb 6 x 2 x 4 5 0 mm (0 .2 3 6 2 x 0 .7 8 7 x 1 7 .7 1 6 5 in.).
mm 3.64 to 1.4 to 0.5 to 0.9 38,9 43,0 Graduate drain time : 30”.
3.76 1.5 Test liquid: ISO 4113 at a temperature of 55o ± 1oC
(131 ° ± 33.8 ° F).
CALIBRATION TEST CONDITIONS
Plunger pre -lift from BDC: Pump rotation (viewed from drive side): Injection o rd e r:1 -3 -4 -2
mm - anticlockwise







Rev/min 1000 1250
Advance stroke mm 0.5 to 1.7 2.0 to 3.2

Rev/min 1000 400
Internal pressure bar 6.7 to 8.1 4.1 to 5.5
10. BACKFLOW
Rev/min 400 1250
Backflow l/h 16 to 30 21 to 39
(continued)
6-62720 - 09 - 2006
(continued)

1400 0 to 3
1250 60.0 to 66.0
1000 65.2 to 70.3
450 63.5 to 70.3

325 0 0 to 3

Rev/min 325 380 -
Delivery per 1000 shots: cm3 4.0 to 18.0 0 to 3.0 -

100 75 to 115
250 60.5 to 74.5

(see previous page)
830 ± 10 g/litre.
Power output with engine run-in for a to Fuel
Throttle tal of: consumption
2 hours 50 hours
position
kW (HP) kW (HP) kg/h
For maximum
Maximum 2500 - 54.0 - 57.5 12.3 - 13.1
torque
Maximum For maximum torque 1500 - 39.5 - 42 8.5 - 9.0
6-62720 - 09 - 2006

TYPE VE 4/12 F 1250 L 982 - 504042214

T.D.C. of cylinder 1 on compression stroke. (1.688.901.027 with calibrated pad 0 0.5 mm
Plunger pre-lift fortim ing on engine: 1 mm from BDC (0.0197 in.)).
(with tools 380000228 - 380001601). Injector pressure setting 250 to 253 bar (3625.925 to
Delivery union of the pump corresponding to cylinder 3741.9546 psi).
0.35 ± 0.05 bar (5.0763 ± 0.7252 psi).
ASSEMBLY DIMENSIONS Delivery pipes (conforming to ISO 4093.2):
mm 3.64 to 1.4 to 0.7 to 0.9 37.9 to 39.3 to Graduate drain time : 30”.
3.76 1.5 39.9 44.7 Test liquid: ISO 4113 at a temperature of 55o ± 1oC
(131 ° ± 33.8 ° F).
CALIBRATION TEST CONDITIONS
Plunger pre -lift from BDC: Pump rotation (viewed from drive side): Injection o rd e r:1 -3 -4 -2
mm - anticlockwise







Rev/min 1000 1250

Rev/min 1250 400
Internal pressure bar 8.7 to 10.1 3.6 to 5.0
10. BACKFLOW
Rev/min 400 1250
Backflow l/h 15 to 29 22 to 40
(continued)
6-62720 - 09 - 2006
(continued)

1400 0 to 3
1250 69.5 to 75.5
900 77.5 to 82.5
400 76.5 to 83.5

375 0 0 to 3

Rev/min 375 425 -
Delivery per 1000 shots: cm3 5.5 to 19.5 0 to 3.0 -

100 80 to 120
275 68 to 92

(see previous page)
830 ± 10 g/litre.
Power output with engine run-in for a Fuel
Throttle total of: consumption
2 hours 50 hours
position
kW (HP) kW (HP) kg/h
For maximum
Maximum 2500 - 60.0 - 64.0 13.7 - 14.6
torque
Maximum For maximum torque 1500 - 46.0 - 48.8 9.8 - 10.4
6-62720 - 09 - 2006

TYPE VE 4/12 F 1250 L 952 - 504042718

T.D.C. of cylinder 1 on compression stroke. (1.688.901.027 with calibrated pad 0 0.5 mm)
Plunger pre-lift fortim ing on engine: 1 mm from BDC (0.0197 in.).
(with tools 380000228 - 380001601). Injector pressure setting 250 to 253 bar (3625.925 to
Delivery union of the pump corresponding to cylinder 3741.9546 psi).
0.35 ± 0.05 bar (5.0763 ± 0.7252 psi).
ASSEMBLY DIMENSIONS
mm 3.64 to 0.98 to 0.6 to 36.5 to 41.3 to Graduate drain time : 30”.
3.76 1.02 1.0 38.5 46.7
Test liquid: ISO 4113 at a temperature of 55o ± 1oC
CALIBRATION TEST CONDITIONS (131 ° ± 33.8 ° F).
Plunger pre -lift from B.D.C.: mm - Pump rotation (viewed from drive side): Injection o rd e r:1 -3 -4 -2
anticlockwise

rpm: 1250 LDA pressure: kPa 100 Advance stroke: mm 2.2 to 3.4

1100 rpm LDA pressure: kPa 100 Internal pressure: bar 6.5 to 7.9
4. FULL-LOAD DELIVERY WITH BOOSTER PRESSURE

rpm: 900 LDA pressure: kPa 100 Delivery per 1000 shots: cm3 75.5 to 80.5 Spread: cm3 < 3.5
5. FULL-LOAD DELIVERY WITHOUT BOOSTER PRESSURE


rpm: 350 LDA pressure: kPa 0 Delivery per 1000 shots: cm3 8 to 23 Spread: cm3 < 5.5



Rev/min 1100 1250

Rev/min 500 1100 -
Internal pressure supply: bar 4.1 to 5.5 6.5 to 7.9 -
11. BACKFLOW
Rev/min 500 1250
LDA pressure kPa 100 100
Backflow for 10 sec. l/h 18 to 32 21 to 39
(continued)
6-62720 - 09 - 2006
(continued)
Rev/min LDA pressure kPa Delivery per 1000 shots: cm3
1405 100 0 to 3.0
1250 100 66 to 72
900 100 75.5 to 80.5
600 25 72 to 78
500 0 66 to 72

rpm: 300 Voltage (volts): 0 Delivery per 1000 shots: cm3: 0to3

Rev/min 350 410
Delivery per 1000 shots: cm3 8 to 23 0 to 3.0

100 75 to 115
250 63.5 to 77.5

(see previous page)

830 ± 10 g/litre.
2 hours 50 hours
position
kW kW kg/h
For maximum
Maximum 2500 - 66 - 70 15.5 - 15.9
torque
Maximum For maximum torque 1500 - 51 - 54 11 - 11.7
6-62720 - 09 - 2006
FUEL SUPPLY PUMP DATA mm (in.)
Eccentricity of drive s h a f t .................................................................. 3 (0.1181)
Diameter of drive shaft at bushings ................................................ 31.975 to 32.000 (1.1049 to 1.1050)
Internal diam eter of installed and reamed bushings .................... 32.050 to 32.075 (1.2589 to 1.2628)
Interference between bushings and s e a ts ...................................... 0.063 to 0.140 (0.0025 to 0.0055)
Assembly clearance between shaft and b u s h in g s ........................ 0.050 to 0.100 (0.0020 to 0.0039)
Thickness of internal w a s h e r............................................................ 1.45 to 1.50 (0.0571 to 0.0591)
Thickness of external washer .......................................................... 2.93 to 3.00 (0.1154 to 0.1181)
CRANKCASE/CYLINDER B LO C K DATA m m (in.)
Cylinder block (4-cylinder engines) ................................................ cast-iron monobloc with replaceable

dry-fitted cylinder liners, incorporating
seatings for crankshaft bearings, cam
shaft and pushrod/tappet assemblies
Internal diam eter of cylinder liners (4-cylinder e n g in e s ).............. 104.000 to 104.024 (4.0945 to 4.0954)
(1)
External diam eter of cylinder liners (4-cylinder engines) ............ 107,020 to 107.050 (4.2134 to 4.2146)
Diameter of cylinder bores (4-cylinder engines) .......................... 106.850 to 106.900 (4.2067 to 4.2087)
Interference fit between cylinder liners and bores

(4-cylinder engines) .......................................................................... 0.120 to 0.200 (0.0047 to 0.0079)
Liner internal diam eter oversizes (4-cylinder e n g in e s )................ 0.4 to 0.8 (0.0157 to 0.0315)
Liner external diam eter oversizes (4-cylinder engines) .............. 0.2 (0.0079)
Maximum permissible liner ovality or taper due to wear (2)

(4-cylinder engines) .......................................................................... 0.12 (0.0047)
Diameter of main shell bearing seats ............................................ 84.200 to 84.230 (3.3150 to 3.3161)
Diameter of camshaft bearing seats:
- front ................................................................................................... 54.780 to 54.805 (2.1567 to 2.1577)
- m id d le ................................................................................................. 54.280 to 54.305 (2.1370 to 2.1380)
- r e a r ..................................................................................................... 53.780 to 53.805 (2.1173 to 2.1183)
Diameter of standard tappet bores in crankcase .......................... 15.000 to 15.018 (0.5906 to 0.5913)
Spare tappet o v e rs iz e s ...................................................................... 0 .1 -0 .2 -0 .3 (0.0039-0.0079-0.0118)

(1) Measured after press-fitting and reaming.
(2) Measure in the area swept by piston rings, both parallel and perpendicular to the crankshaft axis.
6-62720 - 09 - 2006
C R AN KSH AFT AND BEARINGS DATA m m (in.)
Crankshaft ........................................................................................... balanced with integral counterweights
Standard journal diam eter ................................................................ 79.791 to 79.810 (3.1414 to 3.1421) (1)
Journal undersizes ............................................................................ 0.254 - 0.508 - 0.762 - 1.016

(0.01 - 0.02 - 0.03 - 0.04)
Standard main bearing shell thickness .......................................... 2.168 to 2.178 (0.0854 to 0.0857)
Main bearing shell undersizes (internal diameter) ........................ 0.254 - 0.508 - 0.762 - 1.016
(0.01 - 0.02 - 0.03 - 0.04)
Bearing shell to journal c le a ra n c e .................................................... 0.034 to 0.103 (0.0013 to 0.0041)
Maximum permitted wear cle a ra n ce ................................................ 0.180 (0.0071)
Standard crankpin d ia m e te r.............................................................. 63.725 to 63.744 (2.5089 to 2.5096) (1)
Crankpin u n d e rs iz e s .......................................................................... 0.254 - 0.508 - 0.762 - 1.016

(0.01 - 0.02 - 0.03 - 0.04)
Standard big-end bearing shell th ic k n e s s ...................................... 1.805 to 1.815 (0.0711 to 0.0715)
Big-end bearing shell undersizes (internal diameter) .................. 0.254 - 0.508 - 0.762 - 1.016
(0.01 - 0.02 - 0.03 - 0.04)
Big-end bearing shell to crankpin c le a ra n ce .................................. 0.033 to 0.087 (0.0013 to 0.0034)
Standard crankshaft thrust washer th ic k n e s s ................................ 3.378 to 3.429 (0.133 to 0.135)
Thrust washer oversizes (thickness) .............................................. 0.127 - 0.254 - 0.381 - 0.508

(0.005 - 0.010 - 0.015 - 0.020)
Width of main bearing including thrust w a s h e rs ............................ 31.766 to 31.918 (1.2506 to 1.2566)
Width of corresponding crankshaft journal .................................... 32.000 to 32.100 (1.2598 to 1.2638)
Crankshaft assembly e n d flo a t.......................................................... 0.082 to 0.334 (0.0032 to 0.0131)
Maximum permitted wear e n d flo a t.................................................. 0.40 (0.0157)
Maximum ovality or taper of journals and crankpin after

regrinding ............................................................................................. 0.01 (0.0004)
Maximum ovality or taper of journals and crankpin ...................... 0.05 (0.002)
Maximum tolerance for alignment of crankshaft journals with

crankshaft supported on the two outer journals ............................ 0.10 (0.0039)
Maximum tolerance for alignment, in both directions, of crankpins

(3-cylinder engines) or each pair of crankpins
(4-cylinder engines) relative to crankshaft jo u rn a ls ...................... 0.25 (0.0098)
Maximum tolerance for run-out between the outer surfaces of

the crankshaft journals and the crankshaft c e n tre lin e .................. ± 0.10 (0.004)
(continued)
(1) Crankshafts with 0.1 mm (0.0039 in.) undersize journals and crankpins and consequently undersize bearing shells may
be fitted in factory production.
6-62720 - 09 - 2006
(continued)
BENCH TEST PERFORMANCE DATA mm (in.)
Maximum permitted tolerance on run-out of flywheel mounting

flange surface relative to the crankshaft centreline, measured
with 1/100 mm (0.0394/3.94 in.) scale dial gauge resting on front
flange surface at a diam eter of 108 mm (4.252 in.)
(total gauge reading)............................................................................ 0.025 (0.001)
Maximum permitted tolerance on co-axial alignment of flywheel

centering seat relative to the crankshaft journals
(total gauge re a d in g ).......................................................................... 0.04 (0.0016)
CONNECTING ROD DATA m m (in.)
Connecting R o d s ................................................................................. cast-iron with oil way
Diameter of small end bushing s e a t ................................................ 41.846 to 41.884 (1.6475 to 1.6490)
Outside diam eter of small end bushing .......................................... 41.979 to 42.017 (1.6527 to 1.6542)
Interference between small end bushing and s e a t........................ 0.095 to 0.171 (0.0037 to 0.0067)
Inside diam eter of small end bushing (measured after fitting) . . . 38.004 to 38.014 (1.4962 to 1.4966)
Diameter of big end shell bearing s e a ts .......................................... 67.407 to 67.422 (2.6538 to 2.6544)
Maximum tolerance for parallelism between the small end and

big end axes measured at 25 mm (0.9843 i n . ) .............................. ± 0.07 (0.0028)
Maximum weight difference between con rods in same engine .. 25 grams (0.0551 lb)
6-62720 - 09 - 2006
mm (in.)
PISTON DATA
JX60, JX80 JX70, JX90, JX95
Pistons ................................................................................................. Light alloy with two compression and

one oil control rings
Standard piston diameter, measured at 57 mm (2.2441 in.) from 103.852 to 103.870 (4.0886 to 4.0893)
base and perpendicularly to the gudgeon pin a x is ........................
Piston clearance in cylinder lin e r...................................................... 0.130 to 0.172 (0.0051 to 0.0067)
Piston oversizes ................................................................................. 0.6 (0.0236)
Piston protrusion at TDC from cylinder block f a c e ........................ 0.355 to 0.761 (0.014 to 0.030)
Gudgeon Pin D ia m e te r...................................................................... 37.983 to 37.990 (1.4954 to 1.4957)
Diameter of gudgeon pin seat in piston .......................................... 37.994 to 38.000 (1.4958 to 1.4960)
Gudgeon pin to seat c le a ra n c e ........................................................ 0.004 to 0.017 (0.0001 to 0.0007)
Gudgeon pin to small end bearing clearance ................................ 0.014 to 0.031 (0.0006 to 0.0012)
Maximum weight difference between pistons in same engine . . . 20 grams (0.00441 lb)
Piston ring groove clearance (measured vertically):
- Top ..................................................................................................... 0.090 to 0.122 0.105 to 0.155

(0.0035 to 0.0048) (0.0041 to 0.0061)
- Second ............................................................................................... 0.060 to 0.092 (0.0024 to 0.0036)
- B o tto m ............................................................................................... 0.040 to 0.075 (0.0016 to 0.0030)
Maximum permissible clearance (wear limit):
- Top ..................................................................................................... 0.50 (0.0197)
- Second and bottom ........................................................................ 0.20 (0.0079)
Piston ring end gap (fitted):
- Top ..................................................................................................... 0.40 to 0.65 0.40 to 0.65

(0.0157 to 0.0256) (0.0157 to 0.0256)
- Second ............................................................................................... 0.30 to 0.55 0.30 to 0.55

(0.0118 to 0.0217) (0.0118 to 0.0217)
- B o tto m ............................................................................................... 0.30 to 0.55 (0.0118 to 0.0217)
Maximum permissible gap (wear lim it) ............................................ 1.20 (0.0472)
6-62720 - 09 - 2006
VALVE TIMING GEAR DATA mm (in.)
Timing gear tooth backlash .............................................................. 0.160 (0.0063)
Inside diam eter of intermediate gear bushings

(fitted and reamed) ............................................................................. 37.050 to 37.075 (1.4578 to 1.4596)
Diameter of intermediate gear journal ............................................ 36.975 to 37.000 (1.4557 to 1.4567)
Journal to bushing c le a ra n c e ............................................................ 0.050 to 0.100 (0.0020 to 0.0039)
Maximum permissible clearance (wear limit) ................................ 0.15 (0.0059)
Bushing interference fit in seat in intermediate g e a r .................... 0.063 to 0.140 (0.0025 to 0.0055)
Outside diam eter of camshaft bearings:
- front ................................................................................................... 54.875 to 54.930 (2.1604 to 2.1626)
- m id d le ................................................................................................. 54.375 to 54.430 (2.1407 to 2.1429)
- r e a r ..................................................................................................... 53.875 to 53.930 (2.1175 to 2.1232)
Interference between bearings and seats in cylinder block 0.070 to 0.150 (0.0028 to 0.0059)
Inside diam eter of camshaft bearings (fitted and reamed):
- front ................................................................................................... 51.080 to 51.130 (2.0110 to 2.0130)
- m id d le ................................................................................................. 50.580 to 50.630 (1.9913 to 1.9933)
- r e a r ..................................................................................................... 50.080 to 50.130 (1.9716 to 1.9736)
Diameter of camshaft journals:
- front ................................................................................................... 50.970 to 51.000 (2.0067 to 2.0079)
- m id d le ................................................................................................. 50.470 to 50.500 (1.9870 to 1.9882)
- r e a r ..................................................................................................... 49.970 to 50.000 (1.9913 to 1.9933)
Clearance between camshaft journals and b e a rin g s .................... 0.080 to 0.160 (0.0031 to 0.0063)
Camshaft endfloat between thrust plate and seat on camshaft .. 0.070 to 0.220 (0.0028 to 0.0087)
For further valve timing gear d a ta .................................................... See page 4
TAPPET DATA m m (in.)
Tappet bore in c ra n k c a s e .................................................................. 15.000 to 15.018 (0.5906 to 0.5913)
Outside diam eter of standard tappet .............................................. 14.950 to 14.970 (0.5886 to 0.5894)
Tappet running clearance ................................................................ 0.030 to 0.068 (0.0012 to 0.0027)
Spare tappet o v e rs iz e s ...................................................................... 0.1 - 0.2 - 0.3 (0.0039-0.0079-0.0118)
6-62720 - 09 - 2006
ROCKER ARM - VALVE DATA mm (in.)
Diameter of shaft bores in rocker arms .......................................... 18.016 to 18.034 (0.7093 to 0.71)
R ocker-arm shaft d ia m e te r.............................................................. 17.982 to 18.000 (0.708 to 0.7087)
Rocker shaft to rocker arm bore c le a ra n c e .................................... 0.016 to 0.052 (0.0006 to 0.0020)
Rocker arm spacing springs:
- free spring length .......................................................................... 59.5 (2.3425)
- length under load of 46 to 52 N (10.4 to 11.7 lb ) ........................ 44 (1.7323)
Valve clearance for timing c h e c k ...................................................... 0.45 (0.0177)
Cam lift:
- inlet v a lv e ........................................................................................... 5.97 (0.2350)
- exhaust valve ................................................................................... 6.25 (0.2460)
(*) in s ta lle d on 4 -c y lin d e r

BALAN C ER DATA (FIG. 108, page 67) (*) e n g in e s o n ly
mm (in.)
Interference fit between bushings (28) and seat in gear (26) . . . . 0.063 to 0.140 (0.0025 to 0.0055)
Clearance between intermediate gear journal (27)
and bushings (28) ............................................................................... 0.050 to 0.100 (0.002 to 0.004)
Interference fit between bushings and carrier (2 0 ) ........................ 0.063 to 0.140 (0.0025 to 0.0055)
Clearance between gear shaft (22) and bushings ........................ 0.050 to 0.100 (0.002 to 0.004)
Tooth backlash between splined sleeve (17) connecting drive
gear (22) and counterweight drive gear ( 1 3 ) .................................. 0.038 to 0.106 (0.0015 to 0.0041)
Interference fit between front bushing (16) and bore in
housing (12) ......................................................................................... 0.063 to 0.140 (0.0025 to 0.0055)
Clearance between counterweight drive shaft (13) and front
bushing (16) ......................................................................................... 0.050 to 0.100 (0.002 to 0.004)
Interference fit between rear bushing of counterweight drive gear
(13) and seat in carrier (6) ................................................................ 0.037 to 0.101 (0.0015 to 0.004)
Clearance between counterweight drive shaft (13) and rear bushing 0.013 to 0.061 (0.0005 to 0.0024)
Interference fit between bushing and seat in counterweight ( 8) . . 0.040 to 0.100 (0.0016 to 0.004)
Clearance between counterweight rotation shaft (4) and bushing .. 0.020 to 0.073 (0.0008 to 0.0055)
Interference fit between intermediate gear bushing (9) and re
lated seat in housing ( 1 2 ) .................................................................. 0.037 to 0.101 (0.0025 to 0.0029)
Clearance between intermediate gear shaft (9) and related bushing 0.013 to 0.061 (0.0005 to 0.0024)
Tooth backlash between meshed g e a rs .......................................... 0.080 (0.0031)
6-62720 - 09 - 2006
CYLINDER HEAD DATA m m (in.)
Cylinder Head ..................................................................................... with valve seats cut directly in the

casting and press-fitted steel valve
guides.
Original height of cylinder h e a d ........................................................ 92 (3.622)
Maximum surface regrinding depth ................................................ 0.5 (0.0197)

Diameter of standard valve guide bores in head .......................... 13.950 to 13.983 (0.5492 to 0.5505)
Outside diam eter of standard valve g u id e s .................................... 13.993 to 14.016 (0.5509 to 0.5518)
Guide interference fit in b o r e s .......................................................... 0.010 to 0.066 (0.0004 to 0.0026)

Inside diam eter of valve guide (fitted in head) .............................. 8.023 to 8.043 (0.3159 to 0.3167)
Valve stem d ia m e te r.......................................................................... 7. 985 to 8.000 (0.3144 to 0.3150)
Assembly clearance between valve stem and g u id e .................... 0.023 to 0.058 (0.0009 to 0.0023)
Maximum run-out of valve guide on its stem measured through

360° with dial gauge contact point resting on valve head contact
band ..................................................................................................... 0.03 (0.0012)
Valve guide o v e rs iz e s ........................................................................ 0.2 (0.0079)
Valve seat angle in head:
- inlet v a lv e ........................................................................................... 60° ± 5'

- exhaust valve ................................................................................... 45° ± 5'
Valve face angle:
- inlet v a lv e ........................................................................................... 60° 30' ± 7'

- exhaust valve ................................................................................... 45° 30' ± 7'
Valve head diameter:
- inlet v a lv e ........................................................................................... 45.300 to 45.500 (1.7835 to 1.7913)
- exhaust valve ................................................................................... 37.500 to 37.750 (1.4764 to 1.4862)
Valve stand-in relative to cylinder head face ................................ 0.7 to 1.0 (0.0276 to 0.0394)
Maximum permissible valve s ta n d -in .............................................. 1.3 (0.0512)
Inlet and exhaust valve springs:
- free spring length .......................................................................... 4.6 (1.7559)

- length with valve closed, under load of 256 to 284 N
(57.54 to 63.71 l b ) ............................................................................... 34 (1.3386)
- length with valve open, under load of 502 to 544 N
(112.87 to 124.78 l b ) .......................................................................... 23.8 (0.9370)
Injector protrusion relative to head face:
• BOSCH injector 0.3 to 1.1 (0.0118 to 0.0433)
6-62720 - 09 - 2006
mm (in.)
LUBRICATION SYSTEM DATA JX60, JX80 JX70, JX90 and
JX95
Assembly clearance between oil pump drive shaft and bushing . 0.016 to 0.055
(0.0006 to 0.0022)
Clearance between shaft and driven g e a r ...................................... 0.033 to 0.066
(0.0013 to 0.0026)
Tooth backlash between drive and driven g e a rs ............................ 0.100 (0.004)
Radial clearance between drive and driven gears and housing .. 0.060 to 0.170
(0.0024 to 0.0067)
Thickness of drive and driven g e a rs ................................................ 40.961 to 41.000
(1.6126 to 1.6142)
Height of gear seat in p u m p .............................................................. 41.025 to 41.087
(1.6152 to 1.6176)
Endfloat between gears and gear housing in p u m p ...................... 0.025 to 0.126
(0.0010 to 0.0050)
Pressure relief valve spring:
- free length ....................................................................................... 45 (1.7717) 35.9 (1.4134)
- length under load of 45 to 49 N (10.14 to 11.02 l b ) .................. 37.5 (1.4764)
- length under load of 88 to 94 N (19.84 to 21.16 l b ) .................. 30.5 (1.2008)
- length under load of 127.8 to 141.2 N (286.60 to 317.46 lb)
(2, fig. 1 8 2 )....................................................................................... 29 (1.1417)
- length under load of 233.4 - 258 N (524.70 to 579.81 lb)
(2, fig. 1 8 2 )....................................................................................... 3.2 (0.9134)
For further lubrication system d a t a .................................................. See pa ge 3
COOLING SYSTEM DATA m m (in.)
Interference fit between pump impeller and shaft ........................ 0.017 to 0.059 (0.0007 to 0.00231)
Interference fit between fan hub and shaft .................................... 0.024 to 0.058 (0.0009 to 0.0023)
Interference fit between front seal bushing and im p e lle r.............. 0.012 to 0.058 (0.0005 to 0.0023
For further cooling system d a ta ........................................................ See page 3
6-62720 - 09 - 2006
AN G LE TIGHTENING TORQUE DATA
Preliminary torque
PART Thread Angle
Nm ft lb
Cylinder head bolts (2) fig. 3 or 5 .............................. M 12x1.25 70 51.6293 90° + 90°
Main bearing cap bolts (4) fig. 3 or 5 ........................ M 14x1.5 80 59.0050 90°
Big-end cap bolts (5) fig. 3 or 5 ................................ M 11 x 1.5 40 29.5025 60°
Flywheel mounting bolts (3) fig. 3 or 5 ...................... M 12x1.25 40 29.5025 60°
TIGHTENING TORQUE DATA
Tightening torque
PART Thread
Nm ft lb
Rocker shaft pedestal bolts (1) fig. 3 or 5 ...................................... M8 25 18.4390
Crankshaft hub retaining nut (7) fig. 3 or 5 .................................... M 30x1.5 294 216.8432
Fan and alternator pulley bolts (6) fig. 3 or 5 ................................ M 10x1.25 55 40.5659
Additional counterweight retaining bolts (1) fig. 6 for JX80, JX90

and JX95 m o d e ls ................................................................................. M 12x1.25 110 81.1318
Inlet manifold retaining bolts (1) fig. 68 .......................................... M8 25 18.4390
Alternator and belt tension adjustment nut (1) fig. 54 .................. M 10x1.25 55 40.5659
Coolant pump retaining bolts (1) fig. 5 9 .......................................... M 10x1.25 55 40.5659
Nuts for injector mounting studs (1) fig. 1 3 8 .................................. M8 25 (*) 18.4390(*)
Rocker cover nuts (1) fig. 8 0 ............................................................ M8 15 11.0634
Rocker shaft pedestal bolts (2) fig. 81 ............................................ M8 25 18.4390
Oil pump and pump cover retaining bolts (1) fig. 89 .................... M8 25 18.4390
Timing gear case and cover bolts (1) fig. 9 3 .................................. M8 25 18.4390
Intermediate flanged journal bolts (1) fig. 9 6 .................................. M 10x1.25 55 40.5659
Camshaft thrust plate retaining bolts (4) fig. 97 ............................ M8 35 25.8146
Rear crankcase cover bolts (2) fig. 1 1 7 .......................................... M8 25 18.4390
Tappet adjuster screw locknuts (1) fig. 1 3 7 .................................... M8 22 16.2263
Exhaust manifold retaining bolts (1) fig. 6 4 .................................... M8 25 18.4390
Injection pump mounting nuts (1) fig. 70 ........................................ M8 25 18.4390
Sump pan retaining bolts (4) fig. 86, to

- inner rear timing cover and gear case ........................................ M 10 X 1.25 39 to 49 28.7692 to
- cylinder block and flywheel case 36.1405
• JX60, JX70, JX80 and JX90 m o d e ls .......................................... M 1 0 X 1.25 49 to 59 36.1405 to
43.5161
• JX95 m o d e ls ................................................................................... M 10 X 1.25 49 to 69 36.1405 to
50.8918
(*) Tighten the nuts in two stages: see the operation in figure 138.
6 -62 7 2 0 - 09 - 2 0 06
TOOLS X 380000219 Punch for valve guide extraction /

installation.
X 380000276 Twist bit for enlarging valve guide

W ARNING: The operations described in this section bore.
can only be carried out with the ESSENTIAL tools
indicated by an (X). X 380000277 Tapered grinder for exhaust valve
guides.
To work safely and efficiently and obtain the best
results, it is also necessary to use the recommended
specific tools listed below and certain other tools X 380000242 Bush for valve guide installation
which are to be made according to the drawings (with 380000219).
included in this manual.
X 380000222 Valve guide reamer.
X 380000302 Valve spring compressor.
L is t o f s p e c ific to o ls re q u ired fo r th e v a rio u s

X 380000246 Set of grinding tools for regrinding
o p e ra tio n s d e scrib e d in th is s e c tio n .
injector seat.
X 380000236 Tractor dismantling stand. X 380000223 Puller for coolant pump impeller.
380000216 Engine lifting hook. X 380000247 Drift for installation of coolant pump
impeller seal.
380000301 Rotating engine service stand.
380000311 Wrench for injection pump delivery
380000313 Engine mounting brackets for line unions.
rotating stand 380000301.
380000254 Injector cleaning kit.
X 380000303 Compression test kit (complete with
dummy injector 380000617. 380000308 Injector splitting support.
291966 Digital rev counter. X 380000309 Wrench set for injector dismantling.
291979 Digital temperature gauge. 380000310 Injection check hand pump.
380000240 Engine oil pressure test kit. 380000215 Hand pump for injector calibration
test.
293240 Check set, turbocharger
(JX95 model). 293830 Adaptor for injector removal
(with 380000549).
293679 Filter cartridge removal tool
380000549 Slide hammer.
X 296118 Drive belt tension test tool.
In je c tio n p um p b e n ch te s t
X 291160 Piston ring pliers.
380000228 Dial gauge (1/100 mm (0.0394/
X 291048 Piston ring clamp. 3.94 in.) scale, 5 mm (0.1968 in.)
stroke, 0 40 mm (1.5748 in.) with
X 292248 Protractor for angular torque 380000229).
measurement.
380000229 Device for BOSCH injection pump
X 291504 Puller for crankshaft pulley hub. timing on engine.
X 380000232 Wrench for valve clearance X 380000322 Extractor for injection pump drive
adjustment. gear.
6-62720 - 09 - 2006
Splining tool to be manufactured for assembling the

crankshaft front seal (print on the tool no. 50138 -
values in mm).
Material UNI C40.
6-62720 - 09 - 2006
Splining tool to be manufactured for assembling the

crankshaft rear seal (print on the tool no. 50139 -
values in mm).
Material UNI C40.
6-62720 - 09 - 2006
3
L o n g itu d in a l s e c tio n o f 3 -c y lin d e r JX60 and JX70 M odels
1. Rocker shaft pedestal bolts 5. Big--end cap bolts

2. Cylinder head bolts 6. Fan and alternator pulley bolts
3. Flywheel bolts 7. Crankshaft hub bolts
4. Main bearing cap bolts
6-62720 - 09 - 2006
4
C ross -s e c tio n o f 3 -c y lin d e r JX60 and JX70 M odels
6-62720 - 09 - 2006
MIG0493A
5
L o n g itu d in a l s e c tio n o f 4 -c y lin d e r m odel JX80, JX90 and JX95 M odels
1. Rocker shaft pedestal bolts 5. Big--end cap bolts

2. Cylinder head bolts 6. Fan and alternator pulley bolts
3. Flywheel bolts 7. Crankshaft hub bolts
4. Main bearing cap bolts
6-62720 - 09 - 2006
6
C ro s s -s e c tio n o f 4 -c y lin d e r m odel JX80, JX90 and JX95
1. Counterweight retaining bolts
6-62720 - 09 - 2006
6-62720 - 09 - 2 0 06
CO
KJ
SECTION
10 - ENGINE
- CHAPTER
1
Lubrication system of normally aspirated 3-cylin d er engines
1. Oil filler cap 2. Filter safety valve (opens when oil pressure at filter inlet exceeds the outlet pressure by 1.5-1.7 bar/cm2 (140.355- 159.068 psi/in2)
3. Filter. 4. Switch for low engine oil pressure warning (on dashboard). 5. Dipstick.
6. Pump. 7. Oil pressure limiting valve. 8. Screen filter on pick-up pipe
SECTION
10 - ENGINE
- CHAPTER
1
6-62720 - 09 - 2 0 06
Lubrication system of normally aspirated 4-cylin d er engines

1. Oil filler cap 2. Filter safety valve (opens when oil pressure at filter inlet exceeds the outlet pressure by 1.5-1.7 bar/cm2 (140.355- 159.068 psi/in2))
3. Filter. 4. Switch for low engine oil pressure warning (on dashboard). 5. Dipstick.
6. Pump. 7. Oil pressure limiting valve. 8. Screen filter on pick-up pipe ^
Co
a. Coolant circulation with therm ostat valve closed 2. Coolant pump

b. Coolant circulation with therm ostat valve open 3. Temperature gauge for engine coolant
c. 3-cylinder models temperature
d. 4-cylinder models 4. Temperature sender
1. Thermostat 5. Fan
6. Radiator
6-62720 - 09 - 2006
ENGINE TROUBLESHOOTING
Faults Possible Cause Correction
E ngin e does n o t sta rt. 1. Batteries partially discharged. Check and recharge battery. Replace
if necessary.
2. Battery terminal connections Clean, inspect and tighten terminal

corroded or loose. nuts. Replace terminals and nuts if
excessively corroded.
3. Incorrect injection pump timing. Adjust injection pump timing.
4. Impurities or water in fuel lines. Disconnect fuel lines from injection

pump and clean thoroughly. If neces
sary clean and dry the fuel tank.
5. No fuel in tank. Fill tank.
6. Fuel supply pump malfunction. Check and replace pump if necessary.
7. A ir in fuel system. Check fuel lines, unions, supply

pump, filters and injection pump for
air, then bleed system.
8. Starter motor faulty. Repair or replace starter motor.
9. Faulty thermostart. Check and replace thermostart, if

necessary.
E ngin e s ta lls . 1. Idle speed too low. Adjust idle speed.
2. Irregular delivery from injection Check injection pump delivery on test

pump. bench.
3. Impurities or w ater in fuel lines. Disconnect fuel lines from injection

4. Fuel filters clogged. Renew filter cartridges.
5. Incorrect valve clearances. Adjust valve clearance.
6. Burnt or cracked valves Replace the valves.
7. A ir in fuel system. Check fuel lines, unions, supply

pump, filters and injection pump for
air, then bleed system.
8. Injection pump drive mechanism Replace damaged parts.

damaged.
(continued)
6-62720 - 09 - 2006
(continued)
E ngin e overheats. 1. Coolant pump malfunction. Overhaul or replace pump.
2. Faulty thermostat. Replace the thermostat.
3. Radiator inefficient. Remove internal deposits by flushing.

Check for leaks and rectify.
4. Deposits in cylinder head and Flush cooling system.

crankcase coolant passages.
5. Coolant pump and fan drive belt Check and adjust belt tension.
slack.
6. Coolant level low. Top up expansion tank with specified

coolant mixture.
7. Incorrect timing. Check and adjust.
8. Injection pump calibration Calibrate pump on test bench to va

incorrect -- delivering too much or lues specified in calibration tables.
too little fuel.
9. A ir cleaner restricted. Clean filter unit and replace filter ele

ment if necessary.
E ngin e lacks p o w e r and 1. Incorrect injection pump timing. Adjust pump timing.
ru n s unevenly.
2. Auto advance regulator in injection Overhaul injection pump and adjust

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

on test bench to the values specified
4. Irregular delivery from injection Overhaul injection pump and adjust

pump. on test bench to the values specified
5. All--speed governor damaged. Overhaul injection pump and adjust

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

damaged. just pressure setting.
7. Impurities or w ater in fuel lines. Disconnect fuel lines from injection

(continued)
6-62720 - 09 - 2006
(continued)
8. Fuel supply pump damaged. Replace fuel supply pump.
9. Incorrect valve clearances. Adjust valve clearance.
10. Cylinder compression low. Test compression and overhaul

engine if necessary.
11. A ir cleaner restricted. Clear air filter unit and replace

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

lerator and injection pump
incorrectly adjusted.
13. Maximum speed screw on Adjust fast idling speed screw.

injection pump incorrectly
adjusted.
E ngin e p ro d u c e s a b no rm a l 1. Injectors partially obstructed or Clean and overhaul injectors and

k n o c k in g noises. damaged. adjust pressure setting.
2. Impurities accumulating in fuel Clean fuel lines and replace severely

lines. dented pipes. Clean injection pump if
necessary.
3. Incorrect injection pump timing. Adjust injection pump timing.
4. Crankshaft knocking due to Re-grind crankshaft journals and

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

balance; if necessary, replace.
6. Flywheel bolts loose. Replace any bolts that have worked

loose and tighten all bolts to the
specified preliminary and angulartor-
que values.
7. Connecting rod axes not parallel. Straighten connecting rods, check

axes parallelism; replace con rods if
necessary.
8. Piston knock due to excessive Rebore cylinder liners and fit oversize
wear. pistons.
9. Noise caused by excessive play Fit oversize gudgeon pin, rebore

of gudgeon pins in sm all-end and piston seats and sm all-end bushings.
piston bushings, or loose fit of Replace bushings.
small--end bushing.
10. Excessive tappet/valve noise. Check for broken springs or

excessive play between valve stems
and guides, cam followers and bores.
Adjust valve clearance.
(continued)
6-62720 - 09 - 2006
(continued)
E ngin e p ro d u c e s excessive 1. Maximum delivery of injection Adjust injection pump on test bench to
b la ck o r dark gre y sm oke. pump too high. the values specified in calibration
chart.
2. Injection pump delivery Adjust injection pump/engine timing

excessively retarded or automatic or check automatic advance
advance regulator damaged. regulator.
3. Injection pump delivery excessively Adjust injection pump/engine timing.

advanced.
4. Injectors partially or totally Clean and overhaul injectors and

obstructed or incorrectly adjust pressure setting; replace if
adjusted. necessary.
5. A ir cleaner restricted. Clean air cleaner and replace filter

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

to: necessary, overhaul the engine.
-- piston rings sticking;
-- cylinder liner wear;
-- worn or incorrectly adjusted
valves.
7. Damaged high--pressure fuel Inspect and replace if necessary.

lines.
Blue, g re y -b lu e o r g re y- 1. Injection pump delivery Adjust injection pump/engine timing

w h ite sm oke. excessively retarded or or check automatic advance
automatic advance regulator regulator.
damaged.
2. Injectors obstructed or damaged. Clean and overhaul injectors and

adjust pressure setting; replace if
necessary.
3. Oil leaking past piston rings due Replace damaged parts or, if
to sticking rings or cylinder liner necessary, overhaul the engine.
wear.
4. Oil leaking through the inlet valve Recondition cylinder head.

guides due to guide or valve stem
wear.
5. Engine does not reach correct Replace the thermostat.

operating temperature (thermostat
faulty).
E ngin e ru n s on a fte r s w it 1. Engine stop solenoid damaged. Replace solenoid.

c h in g off.
2. All--speed governor damaged. Overhaul injection pump and adjust

6-62720 - 09 - 2006
ENGINE
R em oval - In s ta lla tio n (O p eratio n 10 001 10)
------------ A DANGER A -----------

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

Always use suitable tools to align holes in parts.
NEVER USE FINGERS OR HANDS.
1. Disconnect the battery negative cable.

2. Drain oil from the transmission/gearbox.
3. Drain the cooling system.
10
4. Unscrew the nut (1) from the weight retaining pin.
11
6-62720 - 09 - 2006
5. Remove the weights (1) from the front support.
12
6. Remove the exhaust pipe, attach lifting chains to
the bonnet (1) and attach the chain to the hoist.
13
7. Disconnect the electrical leads (1) from
headlamps (2).
14
8. Detach the gas struts (1) from the bonnet.
15
6-62720 - 09 - 2006
9. Remove the four bonnet hinge bolts (1) and lift

the bonnet clear.
10. Remove the wire mesh guard (1) from right-

hand side of the fan.
11. Disconnect the tachom eter cable (1) and

remove the retaining ring and sleeve.
12. Detach the throttle control spring (1) and remove

the throttle lever (2).
6-62720 - 09 - 2006
13. A fter recovering the air-conditioner gas (HRC

134a) with the re cove ry and re c y c lin g s ta tio n
294048, disconnect the pipes of the cab air
conditioner (1) and (2).
20
14. Detach the cab heating pipes (1) and (2).
21
15. Disconnect the power steering hoses (1).
22
6-62720 - 09 - 2006
16. Disconnect the electrical connectors. Detach the

fusebox by unscrewing the nut (1).
23
17. Disconnect the delivery and return lines (1) to the

power steering cylinders.
24
18. Remove the hose (1) from the lift pump suction
pipe.
25
6-62720 - 09 - 2006
19. Detach the lift pump delivery pipe (1).
26
20. Detach the fuel pipes from the injection pump

and fuel pump and the pipe connecting the tank
to the sedimentation filter.
27
21. Remove the fuel filter (1) complete with its

support.
28
6-62720 - 09 - 2006
22. Remove the front, centre and rear retaining bolts

from the front axle drive shaft guard and remove
the guard.
23. Remove the circlip (2) from the front of the prop
shaft and slide the sleeve (1), in the direction
shown by the arrow, until it is free of the splines
on the front axle.
24. Remove the circlip (2) from the rear of the prop
shaft and slide the sleeve (1), in the direction
shown by the arrow, until it is free of the splines
on the crankshaft.
25. Remove the middle support bolts (1) from the

propeller shaft and remove the shaft complete
with support.
32
6-62720 - 09 - 2006
26. W ithdraw the pin securing the differential lock(1)

knob, remove the knob and remove the mat (2)
from the floor.
33
27. Unscrew the nuts (1) and the bolts securing the
engine to the transmission. Access is through
the two slots in the cab floor.
34
28. Unscrew the four lower bolts (1) securing the

engine to the transmission.
35
6-62720 - 09 - 2006
29. Position stand 380000236 underneath the

tractor and insert a wedge (1), either side of the
axle, to prevent the axle from pivoting.
36
30. Insert a wooden block between the stands and
the tractor.
37
31. Place a fixed stand (1) underneath the drawbar
support and apply the handbrake.
25052
38
32. Unscrew the four remaining bolts securing the

33. Separate the engine from the transmission.
34. Remove the spacer collar (1) between the
engine and the transmission on the JX95 model.
39
6-62720 - 09 - 2006
35. Place a fixed stand (1) underneath the front

weight support and chock the wheels with
wooden wedges (2).
40
36. Insert the pin of kit 380000612 (11711” clutch) or

the pin 380000292 (12712” clutch) (1) into the
central hole of the clutch. Unscrew the six bolts
(2) securing the clutch to the flywheel and
remove complete clutch assembly.
41
37. Remove the radiator mounting bolt (1).
42
6-62720 - 09 - 2006
38. Attach the engine to the hoist using an

adjustable chain (1) attached to the lifting
points provided on the engine.
43
39. Remove the lift pump (1) complete with its filter
by unscrewing the four retaining bolts.
44
40. Disconnect all electrical connectors and remove

the complete wiring harness (1).
45
6-62720 - 09 - 2006
41. Slacken of the hose clamp and detach hose (1)

from the inlet manifold.
46
42. Remove the left-hand side fan guard (1)
47
43. Unscrew the bolts (1) securing the silencer to its
bracket.
48
44. Undo the hose clamp and disconnect the top
radiator hose (1).
45. Unscrew the three nuts securing the silencer to
the manifold and lift off the entire silencer assem
bly.
— r—
TRE0613B W \
49
6-62720 - 09 - 2006
46. Using the hoist, raise the engine slightly and

position the moveable stand (1) under the front
axle.
50
47. Undo the hose clamp and disconnect the bottom

radiator hose (1).
48. Unscrew the four bolts (2) securing the engine to
the front axle support, and lower the engine onto
a wooden platform.
51
To re--install the engine, proceed as follows: — Reconnect all electrical leads: thermostart
— Attach the three hooks of an adjustable lifting glow plug, coolant temperature sensor, ‘air
chain to the three eye bolts on the engine. Raise filter blocked’ sensor, horn, front axle support
the engine from the platform and position it in earth, engine stop on injection pump, leads to
front of the front axle support. Join the two units the alternator and relay, oil pressure sensor,
using the four securing bolts. starter motor, fuel dryer filter. Secure all leads
with plastic ties.
— Reposition the moveable stand from under the
front axle differential housing to underthe engine — Fit the clutch back on with the aid of kit
sump, inserting a suitably shaped block of wood 380000612 (11711” clutch) or pin 380000292
between the stand and the sump pan. (12”/12” clutch). Fix clutch to the engine fly
wheel using the six retaining bolts.
— Attach the top radiator hose to the thermostat
housing and secure with an adjustable hose — Reconnect the oil delivery pipe to the 4WD
clamp. control valve. Tighten the pipe union on the
anti-cavitation accumulator; fix the bracket on
— Connect the bottom radiator hose to the coolant the left-hand side near the engine oil filter.
pump and secure at both ends with adjustable
hose clamps. — Clean the distance collar and the mating surfa
ces of the overdrive clutch housing; scrape
— Refit the fuel pump. away all traces of old sealing compound.
— Detach the lifting chain from the engine. — Apply LOCTITE sealing compound to the
— Connect the rigid pipe from the air cleaner to the mating surfaces of engine and distance collar.
inlet manifold and secure with the relative clamp. Fit the distance ring on the engine studs.
6-62720 - 09 - 2006
Apply LOCTITE sealing compound to the mating — Connect the two flexible power steering pipes to
surfaces of the overdrive clutch housing. the union on the left-hand side of the front axle.
Secure the two pipes with the special clamp and
Remove the fixed stand from under the front screw the clamp to the tractor.
weight support. Remove the wooden wedges from
under the front wheels. — Fit the tachom eter cable and secure the sleeve
with the retaining ring.
Attach the adjustable lifting chain to the eyebolts
on the engine. — Fit the silencer onto the exhaust manifold,
remembering to replace the gas seal. Fix the
Place wooden wedges under the rear wheels, front of the silencer to the vertical support
check that the handbrake is fully on and that the bracket. Attach the flexible DONASPIN pipe.
fixed and moveable stands are firmly in place.
— Attach the bonnet stay bracket to the radiator
Detach the lifting chain from the engine. Connect bracket.
the two wires still attached to the cab handrail to
the hook of the hoist. Raise the front part of the — Refit the 4WD propeller shaft and the guard.
cab about 6 cm.
— R e-connect the throttle cable to the accelerator
Replace and tighten all the bolts securing the pedal. It may be necessary to adjust the cable at
engine to the overdrive clutch housing. the injection pump lever end.
Bolt the brake pipe support bracket to the right- — Refit the clutch cable to the clutch pedal. Fix the
hand side of the engine. Lower the hoist and de sleeve to the travel stop.
tach the cables from the cab handrail.
— Replace the plastic plugs in the holes in the cab
floor. Replace the mat.
Lowerthe stands underthe engine sump and the
clutch housing. Remove tool 380000236 and the — Refit the steering column cover panels.
stand from underthe drawbar support.
— Replace the wire mesh fan guards.
Fix the cab in place with the two front securing
bolts. — Attach slings to the bonnet in the manner descri
bed previously in the engine removal instruc
Connect the injector lea k-o ff pipe. Connect the tions. Screw the bonnet hinge to its bracket. A t
pipes to the glowplug and to the fuel dryer filter. tach the gas strut, the electrical leads to the
headlamps and then remove the slings.
Refit the fuel filter mounting to the engine. Connect
the two semi--rigid pipes to the mounting. — Refit the secondary bracket (battery support) to
the overdrive clutch housing. Fit the rotating
Connect the oil suction pipes to the pumps; bracket with the battery to the fixed support.
secure the rubber hoses with hose clamps.
— Refit the front weights and secure with the lock
Connect the rigid lift control valve supply pipe to the pin.
relative pump, remembering to first fit the O--ring.
— Refit the tool box support bracket and then the
Secure the three pipes with the adjustable hose tool box.
clamp.
— Fill the transmission/gearbox and power steer
Connect up all the electrical leads to the ing unit with oil.
connectors on the vertical support bracket.
— Fill the radiator with coolant.
Fit the cab heater pipe union on the engine/
clutch distance collar. Connect the rubber heater — Connect the battery positive and negative leads.
hoses to the union and, if necessary, restore the Replace the plastic battery cover.
gas in the air-conditioning system with tool
294030.
6-62720 - 09 - 2006
ENGINE
A WARNING A -----------
Handle all parts carefully. Do not put your hands or
fingers between parts.
W ear suitable safety clothing, safety goggles, gloves
and footwear.
1. Remove the front and rear retaining screws from

the bonnet stay bracket (1).
2. Remove the bonnet catch support side retaining

bolts (1) and back retaining bolts (2) take off the
bonnet catch and the bonnet stay bracket.
53
3. Loosen the alternator pivot bolt.

4. Loosen the belt tension adjustment bolt (1).
5. Release the belt tension adjustment arm by
unscrewing the retaining nut.
6. Remove the alternator and coolant pump drive
belt.
54
7. Unscrew the bolts securing the fan (1) and pulley
to the coolant pump. Remove the fan and pulley.
55
6-62720 - 09 - 2006
8. Unscrew the union (1) from the w ater supply pipe

to the cab heater.
56
9. Loosen the hose clamp (1) and detach the hose

from the coolant pump. Remove the curved hose
and flexible cab heater hoses.
57
10. Remove the union (1) in order to gain access to

the pump retaining bolt.
58
11. Unscrew the coolant pump retaining bolts (1)
and remove the pump.
59
6-62720 - 09 - 2006
12. Unscrew the pump support bolts (1) and the

silencer support bolt. Remove the two supports.
60
13. Fit mounting bracket (1) of the set 380000313 to

permit attachment of the engine to the rotary
stand 380000201.
61
14. Fit an eyebolt (1) on the front of the engine in

place of the silencer support.
15. Raise the engine from the wooden platform and
move it to the rotary stand 380000301 (2).
Secure it to the stand by means of the bracket (3)
of the set 380000313.
62
16. Undo the alternator support retaining bolts (1)
and remove the complete alternator assembly.
63
6-62720 - 09 - 2006
17. Unscrew the bolts (1) securing the exhaust

manifold to the cylinder head and remove the
manifold.
64
18. Detach the throttle control lever (1) from the

injection pump.
65
19. Remove the therm ostat housing retaining bolts

(1) and remove the therm ostat housing.
66
20. Unscrew the high pressure fuel line unions (1) on
the injection pump and remove the fuel lines.
67
6-62720 - 09 - 2006
21. Unscrew the bolts (1) securing the inlet manifold

to the cylinder head and remove the manifold.
68
22. Unscrew the unions (1) on the fuel supply pump

and detach the fuel lines.
69
23. Unscrew the nuts (1) securing the injection pump

to the timing gear case.
70
24. Undo screws (1) and remove the injection pump
drive gear cover.
71
6-62720 - 09 - 2006
25. Unscrew the nut (1) securing the injection pump

drive gear to the pump shaft.
72
26. Extract the injection pump gearing using tool

380000835 (1) and remove the injection pump.
NOTE: If the injection pum p does not require any

specialist work it m ust be rem oved following the
instructions given on page 118.__________________
73
27. Undo the fuel line unions (1) on the fuel

sedimentation filter.
74
28. Unscrew the bolts securing the sedimentation
filter support to the engine block and recover the
complete filter assembly.
75
6-62720 - 09 - 2006
29. Unscrew the retaining nut (1) and remove the

fuel pump support complete with the pump.
Retain the gasket for re-use, if undamaged.
76
30. Unscrew the power steering pump retaining

bolts (1) and remove the pump complete with
filter and accumulator on the delivery line.
77
31. Remove spacer (3), gasket (2) and the pump

drive connector (1).
78
32. Unscrew the starter motor retaining bolts (1) and
remove starter motor.
79
6-62720 - 09 - 2006
33. Remove the injector mounting nuts and the

spherical washers beneath, then the supports
and the injectors themselves.
34. Remove the rocker cover bolts (1), washers and
seals and then the rocker cover and its gasket.
80
35. Remove the rockershaft retaining bolts (2), then

remove the entire rocker shaft assembly (1).
81
36. Remove the valve collets (1) and withdraw the

pushrods (2). Retain the collets and pushrods for
re-installation later.
82
37. Unscrew the cylinder head bolts (1) and remove

the head using a hoist and lifting hook
380000216.
38. Remove the cylinder head gasket.
83
6-62720 - 09 - 2006
39. Turn the engine upside down on the rotary stand.

Remove the sump pan bolts, the sump pan (1)
and its gasket (2).
40. Unscrew the retaining bolts and remove the oil

pick-up pipe (1) complete with the strainer and
seal.
41. Unscrew the retaining bolts (2) and free the
counterweight housing (3) by moving it outward.
Remove the sleeve coupling (4) and housing.
NOTE: Operations 39, 40 and 41 are to be carried

out on 4-cylinder models only. To disassemble and
reassemble the rotating counterweight dynamic
balance, see pages 67 and 68.
42. Unscrew the sump pan retaining bolts (4) and

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

carrier and the sump pan.
NOTE: When fitting the gaskets (1) and (3) (fig. 86),
apply RHODORSIL CAF1 silicone sealing
compound to the mating surfaces.
6-62720 - 09 - 2006
45. Remove the rotating counterweight oil seal

O -ring (1) installed on the crankcase mating
surface.
88
46. Undo the retaining bolts (1) and remove the

complete oil pump assembly.
NOTE: For JX90 and JX95 models see fig. 106 on

page 66.
89
47. Unscrew the retaining bolts (2) and remove the

crankshaft pulley (1).
90
48. Straighten the lock tab, preventing rotation ofthe
crankshaft and unscrew nut (1).
91
6-62720 - 09 - 2006
49. Pull the pulley hub off the crankshaft using tool
380000226 (1) and retain the woodruff key for
re-use.
92
50. Unscrew the retaining bolt (1) and remove the

timing cover and its gasket.
93
51. Unscrew the retaining bolts and remove the lift
pump drive gear carrier (1).
94
52. Remove the circlip (1) and remove the thrust
washer and the intermediate gear (2).
NOTE: When refitting the intermediate gear see

engine timing instructions on page 73.
95
6-62720 - 09 - 2006

intermediate gear journal.
96
54. Unscrew the retaining bolts (4) and withdraw the

camshaft (2) complete with the camshaft gear
(1) and the end plate (3).
97
55. Remove the circlip (1) and the thrust washer.
W ithdraw the gear with fuel supply pump
camshaft (2) from the opposite side.
NOTE: This gear transmits drive to the injection

pump. On re-assem bly see timing instructions on
page 73.
98
56. Unscrew the bolts (1) and remove the timing
gear case.
99
6-62720 - 09 - 2006
57. Renew the O -ring seal (1) installed in the lift

pump drive shaft lubrication line.
58. Remove the crankcase - timing gear case
gasket.
100
59. Rotate the engine on the stand through 90°.

Unscrew the big-end cap bolts (2) and remove
the big-end caps (1), complete with their half
shell bearings.
101
60. Slide the pistons (1), complete with rings,

gudgeon pins and connecting rods, out of the
cylinder liners.
102
61. Rotate the engine on the stand through 90° back

to the horizontal position. Unscrew the flywheel
bolts and remove the flywheel with the aid of a
hoist and hook 380000216.
62. Unscrew retaining bolts and remove the rear oil
seal carrier (1) complete with gasket.
103
6-62720 - 09 - 2006
63. Unscrew the main bearing cap bolts (1) and

remove the main bearing caps with related
bearing shells. Remove the thrust washers
located on the penultimate main bearing, as
shown in the figure.
64. Lift the crankshaft clear of the crankcase using
a hoist and nylon sling. Remove the bearing
shells, thrust washers and tappets.
104
65. Turn the engine on the stand 380000301 (2)

through 180°. Attach the lifting chain with eye
holes to the crankcase as shown in the figure.
Raise the hook 380000216 with the hoist so that
the lifting chain is under slight tension. Unscrew
the bolts securing the crankcase to the stand (2)
and mounting bracket (3) (from set 380000313).
66. Lift the engine clear of the stand.
67. Unscrew retaining bolts and remove the rear
crankcase housing (1) and its gasket.
105
NOTE: The figure shows the oil pump for the JX90
and JX95 models
68. Remove the retaining screws (4), take off the

washers (3) and the engine lubrication oil pump
(2) complete with pressure relief valve (1).
26106
106
6-62720 - 09 - 2006
NOTE: Operations 1 to 9, relative to the dismantling

of the rotating counterweight dynamic balancer, only
apply to 4-cylinder models.
1. Remove the lubricating oil pipe (3) fig. 108.

2. Remove the circlip (18).
3. Remove the circlip (25) and cover (23) with relati
ve O -ring seal (24).
4. W ithdraw gear (22) from sump.
5. Remove the circlip (2), gear (26) and the two
thrust washers (1).
6. Inspect shaft (27). If it shows signs of scoring or
w ear it must be replaced.
7. Extract the roll pins and remove the
counterweight shafts (8) using a suitable drift.
8. Disassemble the counterweight gear unit (1)
fig. 107 by removing the circlip (5) and the
support retaining bolts (6).
9. Remove the circlip (3) and the intermediate gear
(4) fig. 107.
S e c tio n a l v ie w o f d yn a m ic ba la n ce r 108
1. Thrust washers. 15. Mesh filter retaining bolt.

2. Circlip. 16. Bushing.
3. Lubricating oil pipe for bushing (28). 17. Rigid coupling sleeve.
4. Counterweight rotation shaft. 18. Circlip.
5. Shaft retaining spring pin. 19. Thrust washer.
6. Carrier for counterweight drive gear (13). 20. Carrier for gear (22).
7. Thrust washer. 21. Thrust washer.
8. Rotating counterweights. 22. Counterweight drive gear.
9. Counterweight intermediate gear. 23. Cover.
10. Bolts securing counterweight housing to sump. 24. O--ring seal.
11. Circlip. 25. Circlip.
12. Counterweight housing. 26. Intermediate gear.
13. Counterweight drive gear. 27. Shaft for gear (26).
14. Mesh filter. 28. Bushing.
6-62720 - 09 - 2006
GENERAL NOTES AND INFORMATION

— After dismantling the engine, clean all parts
carefully.
— To reassemble the engine, carry out the dis
mantling operations described on pages 53 to 67
in reverse order.
— The following pages 68 to 77 concern those
assembly operations requiring particular atten
tion.
— Tightening torques are specified on page 24.
IN ADDITION, M AKE SURE TO:

— Replace all seals and gaskets at each complete
or partial engine rebuild.
— Lubricate all rotating parts and oil seals with
engine oil prior to installation.
— Lubricate the oil filter mounting seal prior to fitting
the filter.
---------------------- W ARNING ^ -------

and footwear.
INSTALLING THE BALAN C ER GEARS WITH

COUNTER-ROTATING W EIGHTS (D isa ssem bly
o p e ra tio n s 1 - 9 )
Proceed as follows:
— Assemble the counterweight components in the

housing (2) carrying out dismantling operations
7 to 9 in reverse order. Align the positioning
marks on the gear (4) and counterweights (1)
(indicated by arrows in figure 127).
— The intermediate gear (3) fig. 109 must be

installed with the longer side of its hub towards
the casing side;
— The holes forthe roll pins (1) in the counterweight
shafts (2) must be aligned with corresponding
holes in the casing.
— Install the counterweight assembly on the sump
carrying out operations 1 to 9 (page 67) in
reverse order.
6-62720 - 09 - 2006
INSTALLING THE TAPPETS AND C RANKSHAFT

WITH MAIN BEARING CAPS, BEARINGS AND
THRUST RINGS; CHECKING C RANKSHAFT
END FLO AT (D isa sse m b ly o p e ra tio n s 63 - 64)
Proceed as follows:
— Install the tappets in their crankcase bores.
— Lubricate the main bearing seats (2) with engine
oil and install the half shell bearings (1).
— Stick the sem i-circularthrust washers (3) to both
sides of the penultimate main bearing with
grease.
111
— Lubricate the upper surfaces of the main bearing

shells with engine oil and lowerthe crankshaft (1)
into position taking care not to dislodge the
sem i-circular thrust washers installed
previously.
112
— Lubricate the crankshaft journals with engine oil

and fit the main bearing caps (3) with the
half-shells (4), fitting the top sem i-circularthrust
washers (2) to the penultimate bearing cap.
— Rotate the crankshaft (1) a few times to allow the
parts to settle into position.
— Insert the main bearing cap bolts and screw in
until the head of the bolt is up against the cap.
113
6-62720 - 09 - 2006
— Tighten all cap bolts (1) to a torque of 80 Nm (8.2

kgm).
— Tighten each cap bolt (1) through a further 90°

using tool 380000304 (2).
— Check that crankshaft endfloat does not exceed

the value specified on page 17.
6-62720 - 09 - 2006
INSTALLING THE REAR COVER W ITH SEAL,

AND ENGINE FLYW HEEL
(D isa sse m b ly o p e ra tio n 62)
Proceed as follows:
— Fit the rear oil seal carrier (3) with the outer seal.
Tighten retaining bolts (2) to the torque specified
on page 24. Using a feeler gauge (1), check that
the crankshaft flange is coaxial with the carrier.
117
— Fit the inner rear oil seal using installer and hand
grip 50139 (1).
118
— Fit the flywheel and tighten the retaining bolts (1)
to a torque of 40 Nm (4.1 kgm).
119
— Using tool 380000304 (1), tighten each flywheel

bolt (2) through a further 60°.
120
6-62720 - 09 - 2006
INSTALLING THE PISTONS COM PLETE WITH

RINGS, PINS, CONNECTING RODS, BIG END
CAPS AND BEARINGS - CHECKING
PROTRUSION IN RELATION TO CYLINDER
BLO C K FACE
(D isa sse m b ly o p e ra tio n s 59 a n d 60)
Proceed as follows:
— Lubricate pistons, rings and cylinder liners with
engine oil prior to fitting.
— Fit the piston rings using piston ring pliers
380000221. Make sure that the piston ring gaps
are offset 180° apart.
— Fit piston ring clamp 380000220 (1) to compress
the rings, making sure that the piston ring gaps
remain 180° apart.
— Insert the piston/connecting rod into the cylinder
liner. Ensure that the connecting rod number
corresponds with the cylinder number and that
the number stamped on the connecting rod is
facing away from the camshaft.
— Fit the big-end caps (2) complete with shells to
the crankpins and tighten the cap bolts (1) to a
torque of 40 Nm (29.5025 ft lb).
— Using tool 380000304 (1), tighten each big-end

cap bolt (2) through a further 60°.
— Rotate the engine on the stand through 180° and

clean the upper face of the cylinder block. Bring
the pistons (2) up to TDC and, using a dial gauge
with a magnetic base (1), check that the piston
protrusion from the cylinder block face is within
the tolerance limits specified on page 19.
124
6-62720 - 09 - 2006
SYNCHRONIZING THE TIMING GEARS

(D isa sse m b ly o p e ra tio n s 51 - 55)
Proceed as follows:
— Remove the cover and gasket from the flywheel

housing inspection window.
125
The flywheel is marked in degrees BTDC. Rotate
the crankshaft to bring cylinder no. 1 to TDC of
the compression stroke. Look through the in
spection window and check that the notch aligns
with the appropriate index mark, according to the
type of BOSCH pump installed on the tractor
(see from page 6 to page 14).
126
— Fit the timing gears making sure that the various
reference marks on the mating gears (indicated
by the arrows in the figure) are aligned.
25169
127
6-62720 - 09 - 2006
REFITTING THE COUNTER-ROTATING W EIGHT

BOX TO THE O IL SUMP
When refitting the counter-rotating weight box,

synchronise as follows:
— Bring piston no. 1 to TDC.

— Position the rotating counterweights so that the
timing reference marks are aligned as shown in
the figure.
128
— Turn the rotating counterweight unit over and

insert the locating pin (2) in its hole. The pin
serves to hold the counterweights in the correct
timing position during installation of the unit.
— Using the hoist and a lifting chain, lower the
counterweight unit onto its seating in the sump.
129
— Slide the coupling sleeve (1) over the splines of
the counterweight drive gear as shown in figure
85.
— Slide the other end of the coupling sleeve (1)
over the splined shaft of the counterweight drive
gear, so that the master spline in the sleeve
coincides with the master spline (3) on the shaft
(2).
— Tighten the dynamic balancer housing retaining
bolts (1) fig. 129 to the torque specified on
page 24.
130
6-62720 - 09 - 2006
REFITTING THE BOSCH INJECTION PUMP

(D isa sse m b ly o p e ra tio n s 23 - 26)
— Fit the BOSCH injection pump and proceed with

the injection pump timing in the manner
described on pages 121 to 123.
131
FITTING THE CYLINDER HEAD G ASKET

Proceed as follows:
— Before fitting the cylinder head, carefully clean

and degrease the mating surface of the cylinder
block. Locate a new cylinder head gasket (1)
with the word ALTO uppermost.
132
6-62720 - 09 - 2006
FITTING AND TIGHTENING THE

CYLINDER HEAD
Proceed as follows:
— Lower the cylinder head onto the block and
screw in the cylinder head bolts (1) fig. 135,
finger tight.
— fig. 133 - Tightening sequence for cylinder head
bolts on 3-cylinder engines to be followed for
each of the four tightening stages (A = fan end).
133
— Fig. 134 - Tightening sequence for cylinder head

bolts on 4-cylinder engines to be followed for
each of the four tightening stages (A = fan end).
134
— First phase - Tighten the bolts (1) to a torque of
70 Nm (7.1 kgm) in the sequence shown in the
above figures (fig. 133/134).
— Second phase - Recheck the torque of all the
bolts in the sequence indicated above (fig.
133/134).
135
99. Using the angular tightening tool 380000304
(1), tighten each bolt (2) in sequence through
90° (third phase) and then through a further 90°
(fourth phase) in the sequence indicated above
(figures 133/134).
136
6-62720 - 09 - 2006
ADJUSTING VALVE/ROCKER ARM

CLEARANCE
— Before refitting the rocker cover, adjust the valve

clearances as described on pages 128 - 130.
— Tighten the rocker arm adjuster screw locknuts
(1) to the torque specified on page 24.
137
FITTING THE INJECTORS

Proceed as follows:
— Insert the injectors (2) in their respective bores.

— Position the injector support brackets and fit the
spherical washers.
— Screw the bracket retaining nuts (1) up to the
spherical washers, then tighten to the torque
specified on page 24, in two stages:
first stage - tighten nuts to 10 Nm (7.3756ft lb);
second stage - tighten nuts to 25 Nm 138
(18.4390 ft lb).
— Tighten the lea k-o ff pipe unions.

— Tighten the high-pressure fuel line unions.
ADJUSTING COOLING SYSTEM BELT TENSION

(D isa sse m b ly o p e ra tio n s 3 - 6 )
NOTE: Tension the belt correctly as described on

page 101.
6-62720 - 09 - 2006
CHECKS, MEASUREMENTS AND REPAIRS -

CYLINDER BLO C K a nd CYLINDER LINERS
----------- A WARNING A -----------

and footwear.
Clean all parts carefully before proceeding with the

operations described below.
NOTE: Cylinder liner dimensions must only be mea

sured when the liner is installed in the cylinder bore
as they are subject to deformation when not fitted.
Check liner wear as follows:

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

liners in the engine must be rebored to the same
oversize.
After reboring, the 0.5 mm (0.0197 in.) 30°
chamfer must be restored on the liner (1).
In case of replacement, remove and install the
liners in cylinder block cold using a press as fol
lows:
25307
139
6-62720 - 09 - 2006
— Press the worn liner out of the block, operating

from the bottom of the crankcase, using a
stepped plate of appropriate diameter.
— Check the ovality of the bore in the block and
rebore if necessary to 0.22 mm (0.0087 in.)
oversize.
— P ress-fit the new liner (0.22 mm (0.0087 in.)
oversize if necessary) from the top of the block,
using the stepped plate referred to above.
— Rebore and ream the liner to the specified inside
diam eter (see page 16).
140
25310
141
S ta n d a rd d im e n s io n s (m m ) o f c y lin d e r lin e rs a n d bores in c y lin d e r b lo c k

and p o s itio n s fo r c h e ckin g lin e r wear.
a,b. Position of dial gauge to measure liner inside X. Area for measurement of inside diam eter of
diameter. worn liner (area swept by piston rings) to
c. JX70, JX90 and JX95 Models. determine ovality and taper (measure along
C. Dimension to achieve after press--fitting and axes a and b, respectively parallel and at right
reaming of liner. angles to crankshaft).
Z. Area for measurement of inside diam eter of 1,2,3. Points at which to measure inside diameter
used liner to determine piston running of new or rebored liners along axes a and b.
clearance (measured along axis b at right
angles to crankshaft).
6-62720 - 09 - 2006

CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL
----------- A WARNING: A -----------

fingers between parts. W earsuitable safety clothing,
safety goggles, gloves and footwear.
C ra n ksh a ft
Clean parts carefully before proceeding with
Carefully inspect the crankshaft. Any cracks, even
minor ones, will necessitate replacement of the
crankshaft.
Inspect the crankshaft journals and crankpins;
slight scoring or seizure marks can be removed with
very fine grade emery cloth.
If scoring, ovality or taper exceeds 0.05 mm
(0.002 in.), the crankshaft will have to be reground.
Measure journal diameter, fig. 142 to determine the
nearest undersize (see page 17).
A fter regrinding, restore the journal and crankpin
radii and fillets as shown in the details in fig. 143 and
check that:
— main bearing journal and crankpin ovality does
not exceed 0.008 mm (0.0003 in.);
— main bearing journal and crankpin taper does
not exceed 0.01 mm (0.0004 in.);
142
rZM
rZB
m e
25312 25313
143
S ta nd ard d im e n s io n s (m m ) o f m ain bearing jo u rn a ls and cra n k p in s , m ain b e arings
and s e m i- c irc u la r th ru s t w ashers.
a. JX60 and JX70 models. d. Normal crankshaft journal radii and fillets.
b. JX80, JX90 and JX95 models. e. Radii and fillets of crankshaft journal with
c. Crankpin radii and fillets. thrust washers.
6-62720 - 0 9 - 2006
with the crankshaft resting on parallel gauge — the run--out measured with the dial gauge
blocks, the maximum misalignment of the main contact point resting on surface (A) or (B),
bearing journals does not exceed 0.10 mm fig. 144, does not exceed the measurement
(0.004 in.) (D) fig. 161; given in the chart on page 18;
the centrelines of the crankpins (mod. JX70) or
of each pair of crankpins (JX70, JX80, JX90
— the oil plugs seal against an oil pressure of 14.7
and JX95 models) lie in the same plane as the
bar (213.2 psi);
main journal centrelines, with a maximum
deviation of ± 0 .2 5 mm (0.0098 in.) as
measured perpendicularly to the same plane
(see fig. 143); — if new plugs are fitted, punch--lock in position
the distances between the outersurfaces ofthe and re--check oil tightness with the system
crankpins and the crankshaft centreline are pressurised.
equal with a tolerance of ± 0.10 mm
(0.004 in.);
144
M axim um to le ra n c e s fo r a lig n m e n t o f m ain bearing jo u rn a ls and cra n k p in relative to

cra n k s h a ft c e n tre lin e and a lig n m e n t o f cra n k p in s relative to m ain bearing jo u rn a ls (a)
b. JX60 and JX70 models D. Maximum permissible main bearing journal

c. JX80, JX90 and JX95 models alignment deviation
A. and B. Dial gauge contact point positions for .
checking run-out of flywheel mounting flange.
6-62720 - 09 - 2006
B ea rin g s
Check the clearance between the crankshaft
journals and bearing shells using a calibrated wire
gauge as follows:
— make sure that all parts are perfectly clean and
remove all traces of oil;
— locate the half--shells in their respective seats (5);
— install the crankshaft;
— position lengths of calibrating wire (6) on the
crankshaft journals (4) corresponding with the
crankshaft centreline.
— fit the caps (1) complete with half-shells (2) to
the respective journals; 145
— lubricate the bolts (4, fig. 3 and 5) securing the

main bearing caps with engine oil and tighten
them to the prescribed torque using a torque
wrench (see page 24);
M ain bearin g cap b o lts (4, fig s . 3 and 5)

If the bolts are to be re-used, check that diam eter d
(measured in area “a” shown in fig. 146) is greater
than 13.5 mm (0.5315 in.). If not, replace the bolts.
25318
146
— remove the caps and determine the bearing

clearance by comparing the width of the calibrat
ing wire at the widest point against the scale
printed on the packet (3) fig. 145, containing the
wire;
— after refitting the crankshaft and the bearing
caps and bolts, check crankshaft endfloat about
the penultimate bearing with a dial gauge (1);
— if the endfloat exceeds the specified value (see
page 17), replace the existing thrust washers
with oversized ones.
147
6-62720 - 09 - 2006
F lyw heel
The flywheel is fixed to the crankshaft flange by

means of self-locking bolts. The starter ring gear is
shrunk-fit, after pre-heating, to the register on the
engine side of the flywheel.
If the ring gear is to be replaced, heat in oil to 80° to

90° C (176° to 194° F) before fitting and position with
the bevel on the teeth facing inward towards the
starter motor.
The flywheel mounting holes are offset so that the

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

page 25.
— lubricate the screws securing the engine

flywheel with engine oil, then tighten them to the
prescribed torque (see page 24) using a torque
wrench.
Flyw heel b o lts (3, fig s . 3 and 5)

(measured in area “a” shown in figures 148 and 149)
is greater than 13.5 mm (0.5315 in.). If not, replace
the bolts. 148
149
6-62720 - 09 - 2006

CONNECTING RODS
----------- A CAUTION A -----------

Handle all parts carefully. Do not place hands or
fingers between one part and another. W ear the
recommended safety clothing such as goggles,
gloves and safety boots.
Clean all parts carefully before carrying out the

following operations.
Check that the bushings in the connecting rod small

ends are tight in their bores and are flush with the
sides of the rods.
If necessary, replace the bushings and ream after

fitting to the specified diam eter (A) shown in the
drawing.
D im e n s io n s (m m ) o f s ta n d a rd c o n n e c tin g rods,
bea ring s h e lls , b u s h in g s and g u d g e o n pins.
A = Dimension required by reaming after fitting
bushings - L, M = Oil ports.
150
Check parallelism of small end and big end axes.

Maximum permitted tolerance is ± 0.07 mm
(0.0028 in.) measured at 125 mm (4.9213 in.) from
longitudinal axis of the connecting rod.
Slightly twisted con rods can be straightened using

a press. Severely deformed rods should be
replaced.
New con rods must be marked with the number of the

cylinder in which they are to be fitted. Check that the
difference in weight of connecting rods in the same
151
engine does not exceed 25 grams (0.0551 lb).
Also check that the oil ways (L and M) fig. 150 are
not obstructed by scale or impurities.
6-62720 - 09 - 2006

PISTONS
----------- A WARNING A -----------

H a n d le all p a rts c a re fu lly. D o n o t p u t y o u r h a n d s o r
fin g e rs b e tw e e n p a rts. W e a rs u ita b le s a fe ty c lo th in g ,
s a fe ty g o g g le s , g lo v e s and fo o tw e a r.
C le a n all p a rts c a re fu lly b e fo re c a rry in g o u t th e

fo llo w in g o p e ra tio n s .
D e te rm in e th e d e g re e o f p isto n and lin e r w e a r in th e

m a n n e r d e s c rib e d on p a g e s 16 and 19 and th e fig
ure s below .
If th e p isto n ru n n in g c le a ra n c e e x c e e d s 0 .3 0 m m
(0 .011 8 in.), re b o re and re a m th e lin e rs and fit
o v e rs iz e p is to n s and rin g s (se e p a g e s 16 and 19).
In c a s e o f p isto n re p la c e m e n t, c h e c k th a t th e w e ig h t
d iffe re n c e b e tw e e n p is to n s in th e s a m e e n g in e d o e s
no t e xc e e d 2 0 g ra m s (0.0441 lb).
C h e c k th a t th e p isto n ring g ro o v e c le a ra n c e (b, fig.

152) and th e end g a p (c, fig. 152) a re w ith in th e
to le ra n c e s sp e c ifie d on p a g e 19. If th e end g a p is less
th a n th a t s p e c ifie d , c o rre c t by g rin d in g th e e n d s o f
th e p isto n ring.
C h ecking p is to n s and rin g s
a. C h e c k in g p isto n d ia m e te r a t a d is ta n c e (L) fro m c. C h e c k in g th e end g a p w ith ring in c y lin d e r bore.

th e b a se o f th e s k irt. L. D is ta n c e fro m b a se o f p isto n s k irt: 12 m m
b. C h e c k in g p isto n ring g ro o v e c le a ra n c e . (0 .4 7 2 4 in.).
6-62720 - 09 - 2006
a3o
®T 0,55
2,478
2,490
t a3o
rll< 1 0,55
3,975 I*
m m w
37,983
37,990
a
WWWWWWWN
2,575 m
2,595 0 - Si” ®r 0,85
2,478
2,490
a30
rll< 1 ass
3,975
m m w
37,983
37,990 b
WWWWWWWN
153
D im e n s io n s (m m ) o f s ta n d a rd p is to n s , g u d g e o n p in s and rin g s.
a. JX60 and JX80 models. E Piston diam eter measured at 12 mm

b. JX70, JX90 and JX95 models. (0.4724 in.) from the base of the skirt.
A. Measurement to be obtained with rings inserted
in cylinder liners.
To remove or fit piston rings (1), use pliers

380000221 (2).
Fit rings in grooves in the order indicated in fig. 153.
When fitting pistons on connecting rods, check that

the clearance between the gudgeon pin and its bore
in the piston is within the tolerance specified on page
19.
154
6-62720 - 09 - 2006
Check that the piston/connecting rod assembly is

perfectly square.
If not, replace parts causing the problem.
155
NOTES:
— Oil the pistons, rings and liners before inserting

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

sealing.
156
B ig end cap b o lts (5, fig . 3 and 5)

(measured as shown in the figure alongside, area a,
fig. 157) is greater than 10.5 mm (0.4134 in.). If not,
replace the bolts.
NOTE: It is advisable to replace the big end cap bolts

each time the connecting rods are dismantled.
157
6-62720 - 09 - 2006

CAMSHAFT, TAPPETS AND VALVES
----------- A WARNING A -----------

Clean all parts carefully before carrying out the

following operations.
Valves
Use tool 380000302 for valve removal and installa
tion.
In the case of minor sealing faults, the valves and
their seats in the cylinder head may be re-faced
using a pneumatic grinder or universal grinder. In
case of more serious defects, re--face the seats and
grind the valves as shown in the relative chapter.
After grinding, check that the step below the valve
contact band is no less than 0.5 mm (0.02 in.).
D im e n s io n s (m m ) o f valve s and valve g u id e s

A. Intake.
B. Distance to be obtained by reaming fitted valve
guide.
S. Exhaust.
158
Tappets
Check that the tappets slide freely in their bores
without excessive play.
In the case of excessive tappet--to--bore clearance,
rebore the seats and fit oversize tappets
(see page 20).
Pushrods must be perfectly straight, and the
concave contact surface with the rocker arm ad
juster screw must not show signs of seizure or
excessive wear, otherwise the rod must be replaced.
In case of refacing of the contact surfaces, remove
as little material as possible.
159
6-62720 - 09 - 2006
C am shaft
Place the camshaft on two parallel V blocks, as

shown. Using a dial gauge with 1/100 mm
(0.0394/3.94 in.) scale, check that journal run-out
relative to the axis of rotation does not exceed 0.02
mm (0.0008 in.).
If run-out does not exceed 0.2 mm (0.0008 in.), the

camshaft may be straightened using a press;
otherwise replace the camshaft.
Check cam lift using a dial gauge, which should be

as follows:
160
- in le t va lves = 5.97 m m (0.235 in.);
- e xh a u s t valve s = 6.25 m m (0.2461 in.).
Replace worn bushings using suitable extractors and

drifts. Ream to obtain the inside diam eter indicated
in figure 161.
25331
161
D im e n s io n s (m m ) o f c a m sh a ft jo u rn a ls and relative seats in c y lin d e r blo ck.
a. JX60 and JX70 models. b. JX80, JX90 and JX95 models.
N O TE : The value indicated for the bushing inside diameter is for an installed bush.
6-62720 - 09 - 2006
Valve tim in g check
To check the valve timing after dismantling/assembly

or overhaul of the valve timing gear, proceed as
follows:
Check that the timing reference marks on the timing

gears are aligned as indicated on page 73.
Provisionally set valve clearances to 0.45 mm

(0.0177 in.).
Turn the crankshaft and, using a graduated timing

disc, check that valves open and close at the angles
indicated in the timing diagram. 162
On completion of timing check, set the valve clear

ances for normal running as detailed on pages 127
to 129.
Valve tim in g diagram .

A. Fixed advance (*).
1. TDC.
2. BDC.
3. Inlet.
4. Exhaust.
5. Injection.
(*) According to pump type and engine model (see page 2).
6-62720 - 09 - 2006

CYLINDER HEAD
----------- A WARNING A -----------

Use valve spring compressor 380000302 to remove

and refit valve springs.

Check that the cylinder head mating surface is flat

using a straight edge (2) and feeler gauge (1).
If deviations of more than 0.15 mm (0.059 in.) are

found, the head must be refaced.
NOTE: Remove as little material as possible: the

maximum depth of material that can be ground from
the cylinder head is 0.5 mm (0.02 in.).
Using a dial gauge with magnetic base (1), check the

run-out of the valve head (2) in the guide and the
clearance between the valve stem and guide.
If the clearance exceeds the specified value (see

page 22), replace the valve and, if necessary, the
valve guide.
6-62720 - 09 - 2006
VALVE GUIDES
R eplacem ent (O p e ra tio n 10 101 53)
----------- A WARNING A -----------

equipment.
means of suitable slings and hooks.
Check that no one is in the vicinity of the load to be
lifted.
----------- A WARNING A -------

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

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

using twist drill 380000276.
2. Place the cylinder head on a suitable support and

remove the valve guide to be replaced, using drift
380000219 (1).
165
3. Turn the head upside down, and force fit the new
valve guide with the enlarged bore using drift
380000219 (1) and bush 380000242 (2).
166
4. Ream out the valve guide bore (2) using reamer

(1) 380000222.
167
6-62720 - 09 - 2006
NOTE: When replacing exhaust valve guides you

must also carry out the following further operations.
5. Measure the distance (L) between the cylinder

head face and the base of the valve guide using
a caliper gauge and the special plate of tool
380000277.
The depth of taper milling is given by:
B - L = C
where:
B = depth of taper relative to cylinder head face (see

fig. 175).
L = distance measured between cylinder head face

and valve guide base.
C = depth of taper milling.
E xam ple (4 -c y lin d e r e ngine )
B = 43.1 to 43.6 mm (1.6968 to 1.7165 in.)
L = 34 mm (1.3386 in.) (distance measured).
C = (43.1 to 43.6) - 34 = 9.1 to 9.6 mm.

((1.6968 to 1.7165) - 1.3386 = 0.3582 to 0.3779 in.)
Depth of taper milling.
6. From the upper side of the cylinder head, fit

guide bush (1) of tool 380000277 on the guide
valve to be milled (2).
7. Slide the cutter (1) of tool 380000277, complete

with depth stop (2), into the previously located
guide bush until the cutting head is in contact
with the valve guide.
170
6-62720 - 09 - 2006
8. Position the plate (3) of tool 380000277 flush

against the cylinder head face and slide the
depth stop (2) up to the plate. Measure the
distance (A) between the depth stop and the end
of the cutter shank (1).
171
9. Position the depth stop (1) at a distance
(D) = 35.9 to 336.4 mm (1.4134 to 13.2441 in.)
from the end of the cutter shank and fix in place
with its set screw.
Distance (D) is given by:
D=A - C
where:
D = the distance determining the end of the taper

milling.
A = the distance between the end of the cutter shank

and the depth stop, with the plate flush against the
cylinder head.
C = the depth of taper milling.
Exam ple
A = 45.5 mm (1.7913 in.)
C = 9.1 to 9.6 mm (0.3583 to 0.3780 in.)
D = 45.5 - (9.1 to 9.6) = 35.9 to 36.4 mm

(1.7913 - (0.3583 to 0.3780) = 1.433 to 1.4133 in.).
10. Turn the cutting tool (2) until the plate (3) is
brought up to the cylinder head face by the depth
stop (1).
NOTE: Before fitting the cylinder head, clean it

thoroughly to remove all residue from the milling
operation.
173
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VALVE SEATS IN CYLINDER HEAD.

R eb oring
----------- A CAUTION A -----------

11. If the valve seats need refacing to improve valve

sealing, use the universal valve grinder (1) and
remove as little material as possible.
D im e n s io n s (m m ) o f valve seats and g u id e

valves.
A. Inlet.
B. Depth of taper on 3 and 4-cylinder engines
S. Exhaust.
C. Engines for JX60 and JX80 models.
D. Engines for JX70, JX90 and JX95 models
175
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INJECTOR SLEEVES - Replacement

(O peration 10 101 60).
----------- A WARNING A -----------

1. If the cylinder head face has been reground,

check that injector protrusion is within the
tolerance limits specified on page 22.
C h eckin g in je c to r and valve h e ig h t relative to

th e c y lin d e r head face.
a. Checking injector protrusion (see page 22)
b. Checking valve stand-in: 0.7 to 1.0 mm (0.0276
to 0.0394 in.) (max. permissible stand-in =
1.3 mm (0.0512 in.)).
If injector protrusion exceeds the specified limit,

replace the injector sleeve using tool kit 380000246
and proceed as follows:
2. Set distance (A) on tap (3) 380000829 to 9 mm
(0.0295 in.) by means of the ring nut (5). Fix the
ring nut in position by tightening the set screw
(4).
3. Cut an internal thread (2) in the sleeve to be re

moved using tool 380000829 (M12 x 11.75) ma
king sure that the thread is cut only in the sleeve.
4. Fit tool 380000832 (2) fig. 179 to the injector

mounting studs on the cylinder head by means
of the nuts (3) (M8 x 1,25).
5. Screw part (11) fig. 179) fully into the previously

cut thread and turn nut (1) to withdraw the injec
tor sleeve (12) from the head.
6. Remove any copper residue from inside the

head using tool 380000370.
7. Fit seals (6, fig.179) onto the new injector sleeve

and fit the sleeve into its bore, making sure that
the sleeve butts up against the bottom of the
seating in the cylinder head, and dress with
dressing tool 380000834 (5).
6-62720 - 09 - 2006
8. Fit guide bush 380000830 (10) fig.179 in the new

sleeve (12), securing it in position by turning the
ring nut (9) clockwise. Insert reamer (7)
380000831 in guide bush (10) and ream the low
er part of the sleeve.
9. Remove the reamer (7) fig. 179 and ba ck-off the
ring nut (9) by about 10 mm (0.0328 in.).
10. Press by hand on the ring nut (or tap gently with
a rubber mallet) to release the inside of the guide
bush 380000830 (10) fig. 179.
11. Remove the guide bush, and fit the milling cutter
380000833 (8) fig. 179 in the bush. Install the
bush in the sleeve (12) and fix in position by turn
ing the ring nut (9) clockwise.
12. W ork with the cutter to remove material until the
seating is perfectly smooth and free from all
marks.
13. This done, remove the cutter, fit the injector and
check that stand-out is as specified on page 22.
C y lin d e r head b o lts (2, fig . 3 and 5)

(measured in area a, as shown in fig. 178) is greater
than 11.5 mm (0.0377 in.). If not, replace the bolts.
178
D isassem bly, rem oval o f residue, in s ta lla tio n and ream ing 179
o f in je c to r sleeve in c y lin d e r head u s in g to o l k it 380000246.
1, 2, and 11. Injector sleeve extractor 380000832. 6. O -ring seals.
3. M8 x 1.25 retaining nuts. 7. Reamer 380000831 .
4. Waste removal tool 380000370. 8. C utter 380000833.
5. Injector sleeve dressing tool 380000834. 9. Ring nut.
10. Guide bush 380000830.
12. Injector sleeve.
6-62720 - 09 - 2006

ROTATING COUNTERW EIGHT DYNAMIC
BALAN C ER
----------- A WARNING A -----------

safety goggles, gloves and footwear

Check component w ear and replace any defective
parts.
If the bushings of the counterweights are to be
replaced, pre-heat the counterweights in oil to a
temperature of 140° to 160° C (284° to 320° F) (ordip
the bushings in nitrogen) before shrink--fitting in their
bores.
Ream the new bushings after fitting using a reamer
with expanding cutters to the inside diameter
specified in the table on page 21.
C ro s s -s e c tio n a l v ie w o f ro ta tin g c o u n te rw e ig h t d yn a m ic balancer. 180
1. Thrust washers. 15. Mesh filter retaining bolt.

2. Circlip. 16. Bushing.
3. Bushing lubrication tube. 17. Sleeve coupling.
4. Rotation shaft for counterweight (8). 18. Circlip.
5. Retaining spring pin for shaft (4). 19. Thrust washer.
6. Carrier for counterweight drive gear (13). 20. Carrier for gear (22).
7. Thrust washer. 21. Thrust washer.
8. Counterweights. 22. Drive box gear for dynamic balancer.
9. Counterweight intermediate gear. 23. Cover.
10. Circlip. 24. O--ring seal.
11. Bolts securing balancer housing to sump. 25. Circlip.
12. Dynamic balancer housing. 26. Intermediate gear.
13. Counterweight drive gear. 27. Rotation shaft for intermediate gear (26)
14. Mesh filter. 28. Bushing.
6-62720 - 09 - 2006

LUBRICATION SYSTEM
-------------- A W ARNING A --------------


O IL PUMP - O verhaul
To access the oil pump, remove the sump pan.
When servicing the pump, check component wear

against dimensions specified in the table.
In case of replacement, note that the drive shaft (3)

and drive gear are supplied ready assembled, with
the gear hot shrink-fitted on the shaft.
C ro s s -s e c tio n a l v ie w o f e n g in e lu b ric a tio n o il

pum p m o d e ls JX60 and JX80 M odels
1. External drive gear.
2. Bushing.
3. Drive shaft and gear.
4. Driven shaft and gear.
5. Pressure relief valve.
C ross -s e c tio n a l v ie w o f e n g in e lu b ric a tio n o il

pum p m o d e ls JX90 and JX95 M odels
2. Spring.
3. Pump housing.
4. Internal gears.
182
C ross -s e c tio n a l v ie w o f e n g in e lu b ric a tio n o il

pum p m o d e ls JX70 M odel
1. Pump housing.
2. Internal gears.
183
6-62720 - 09 - 2006
O IL FILTER - R eplacem ent CHECKS, M EASUREMENTS AND REPAIRS -

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

paper cartridge type, and is installed in the pump
delivery line.
Should the filter become clogged, the safety valve (2)
will open to allow the oil to by-pass the filter, thus
The cooling system is filled with a permanent coolant
ensuring that the engine continues to be lubricated,
mixture consisting of w ater and “ A K C E LA
although with unfiltered oil.
PREMIUM AN TIFR EEZE” antifreeze (up to 50% in
volume). This mixture prevents freezing down to the
following temperatures:
Replace the cartridge periodically (every 400
operating hours), remembering to:
-8 -1 5 -2 5 -3 5
Degrees °C (°F)
— oil the outer part of the seal in contact with the (17.6) (5) (-13) (-31)
mounting on the crankcase; % in volume of
“ A K C E LA
— screw on the new cartridge until the seal is up 20 30 40 50
PREMIUM
against the mounting; AN TIFR EEZE”
— tighten the cartridge, by hand only, through a

further 3/4 turn.
This mixture also has anti-oxidant, anti-corrosion,
anti-foam ing and anti-scaling properties to ensure
long-term protection of the cooling system.
The same mixture can be kept in the cooling system

for a maximum of 2 years or 1600 operating hours,
whichever comes sooner; after which it must be
changed.
LOW O IL PRESSURE INDICATOR - F u n ctio n a l
che cks
The indicator consists of a control switch (4) figs. 7

and 8 and a red warning lamp in the instrument panel, RADIATORS - F lu s h in g and checks
which illuminates in the following conditions:
Two valves are built into the radiator cap, one
— low oil pressure (the warning lamp also
compression valve and one depression valve. Check
illuminates in normal conditions, with no faults
periodically that they are working correctly.
present, when the engine is hot and idling at low
speed); When overhauling, remove deposits of lime scale in
the radiator by means of a solution of w ater and
— control switch malfunction. de-scaling agent in the proportions shown on the
container.
If the red lamp fails to illuminate when the engine is
stopped and the ignition switch is turned to the power It is never advisable to limit flushing to the radiator
on position, the possible causes are: only - always extend it to the entire cooling circuit
and top up the engine with the solution referred to
— blown fuse; above.
— blown lamp; Run the engine for about an hour. With the engine off,
drain the solution through the drain plug aperture.
— interruption in wire to the control switch.
In the event of leakage, the radiator is checked by
immersing it in a tank of water at a temperature of
20°-40° C (68°-104° F), introducing air into the
radiator at a pressure of 0.98 bar (14.1 psi) for
approximately two minutes (repeat the test at least
three times).
6-62720 - 09 - 2006
C O O LAN T THERMOMETER - Testing
If m a lfu n c tio n is s u s p e c te d , im m e rs e th e b u lb o f th e
th e rm o m e te r in w a te r and c h e c k th e re a d in g s
a g a in s t a te s t th e rm o m e te r (re p e a t th e te s t a n u m b e r
o f tim e s w ith d iffe re n t w a te r te m p e ra tu re s to be
su re ).
THERMOSTAT - R eplacem ent
T h e th e rm o s ta t (1), fig. 9 is fitte d in th e c y lin d e r head

c o o la n t o u tle t u n io n. T h e th e rm o s ta t c a n n o t be
a d ju s te d and th e re fo re m u s t be re p la c e d if d o e s not
m e e t th e te m p e ra tu re s p e c ific a tio n s in th e ta b le on
pa g e 4.
C O O LAN T PUMP AND ALTERNATOR DRIVE

BELT - T ension a d ju s tm e n t
(O pe ra tion 10 414 10).
T h e fa n /c o o la n t p u m p /a lte rn a to r d riv e b e lt is
te n s io n e d c o rre c tly w h e n it d e fle c ts 10 to 11 m m
(0 .3 9 3 7 to 0.4331 in.) w h e n a fo rc e o f 78 to 98 N
(1 7 .6 4 to 2 2 .0 5 lb) is a p p lie d a t th e m id -p o in t o f th e
run b e tw e e n th e a lte rn a to r and c o o la n t p u m p
pulle ys.
1. C h e c k th e te n s io n u sin g th e b e lt te n s io n te s te r
296118 . A d ju s t te n s io n if n e c e s s a ry as fo llo w s :
2. S la c k e n th e n u t (1) s e c u rin g th e a lte rn a to r to th e

te n s io n e r b ra c k e t;
3. M o ve th e a lte rn a to r to a c h ie v e th e re q u ire d be lt
te n s io n and lo c k th e n u t ( 1 ).
NOTE: W h e n fittin g a n e w belt, c h e c k th e te n s io n

ag a in a fte r o ne h o u r o f ru n n in g .
184
6-62720 - 09 - 2006
RADIATOR
------------ A DANGER ^ -----------

L ift and h a n d le all h e a v y p a rts u sin g s u ita b le lifting
e q u ip m e n t.
M a ke s u re th a t a s s e m b lie s o r p a rts a re s u p p o rte d by
m e a n s o f s u ita b le s lin g s and h o o ks.
C h e c k th a t no on e is in th e v ic in ity o f th e load to be
lifted.
1. R e m o v e th e e x h a u s t p ipe and o p e n th e b o n n e t.
2. D is c o n n e c t th e b a tte ry n e g a tiv e ca b le .
3. R e m o v e th e le ft and rig h t-h a n d s a fe ty g u a rd s
( 1 ) fro m a ro u n d th e fan.
185
4. R e m o v e th e h o se c la m p , d e ta c h th e b o tto m radi
a to r h o se ( 1 ) and d ra in o ff th e co o la n t.
186
5. U n s c re w th e fro n t a xle e a rth c a b le fix in g b o lt (1)
6. D is c o n n e c t e le c tric a l le a d s fro m th e horn.
187
6-62720 - 09 - 2006
7. D is c o n n e c t e le c tric a l le a d s fro m a ir filte r

re s tric tio n s e n s o r ( 1 ).
188
8. R e m o v e th e c la m p (1) on th e in le t m a n ifo ld hose.
189
9. R e m o v e th e c la m p (1) on th e a ir filte r hose.
190
10. R e m o v e th e a ir filte r re s tric tio n s e n s o r (1) and re
c o v e r th e pipe.
191
6-62720 - 09 - 2006
11. U n s c re w th e c la m p and d is c o n n e c t th e p ipe (1)

c o n n e c tin g th e a ir filte r to th e e x h a u s t a s p ira to r.
192
12. U n s c re w th e h o se c la m p (1) and re m o v e th e to p

ra d ia to r hose.
193
13. U n s c re w th e c la m p and re m o v e th e pip e (1) fro m
th e ra d ia to r cap.
194
14. U n s c re w th e tw o b o lts (1) s e c u rin g th e ra d ia to r
to th e fro n t a x le s u p p o rt and re m o v e th e b olts,
ru b b e r m o u n tin g s and s p a c e rs .
195
6-62720 - 09 - 2006
15. R e m o v e th e ra d ia to r (1) and th e u p p e r ru b b e r

m o u n tin g s .
To re fit th e ra d ia to r p ro c e e d as fo llo w s :
— R e p la c e th e ra d ia to r and s e c u re w ith th e tw o
b olts.
— R e fit th e tw o ru b b e r h o s e s to th e c o o la n t p u m p 196
and th e th e rm o s ta t h o u s in g . R e c o n n e c t th e
p ipe to th e ra d ia to r cap.
— R e c o n n e c t th e b o n n e t s ta y b ra c k e t to th e b ra c
k e t m o u n te d on th e ra d ia to r and re p la c e th e re
ta in in g b olts.
— R e fit th e h o se to th e e x h a u s t a s p ira to r.
— R e fit th e h o se c o n n e c tin g th e a ir c le a n e r to th e
in le t m a n ifo ld . R e fit th e a irfilte rc lo g g in g s e n so r.
— R e c o n n e c t th e e le c tric a l le a d s to th e ho rn , a ir
filte r re s tric tio n s e n s o r and th e fro n t a x le e a rth
lead.
— R e fit th e tw o w ire m e sh g u a rd s a ro u n d th e fan.
— Fill th e ra d ia to r w ith co o la n t.
— R e c o n n e c t th e b a tte ry n e g a tiv e lead; c lo se th e
b o n n e t.
6-62720 - 09 - 2006
C R AN KSH AFT FRONT O IL SE A L

R e m o v a l/in s ta lla tio n (O pe ra tion 10 102 70)
------------ A DANGER ^ -----------

e q u ip m e n t. M a k e s u re th a t a s s e m b lie s o r p a rts are
s u p p o rte d by m e a n s o f s u ita b le s lin g s and h o o ks.
C h e c k th a t no on e is in th e v ic in ity o f th e load to be
lifted.
1. R e m o v e th e e x h a u s t p ipe and o p e n th e b o n n e t.
3. R e m o v e th e le ft and rig h t--h a n d w ire m e sh
g u a rd s ( 1 ) fro m a ro u n d th e fan.
197
4. R e m o v e th e h o se c la m p , d e ta c h th e b o tto m
h o se ( 1 ) and d ra in o ff th e co o la n t.
198
5. U n s c re w th e fro n t a xle e a rth c a b le fix in g b o lt (1).
6. D is c o n n e c t e le c tric a l le a d s fro m th e horn.
199
6-62720 - 09 - 2006
7. D is c o n n e c t e le c tric a l le a d s fro m a ir filte r re s tric

tio n s e n s o r ( 1 ).
8. R e m o v e th e c la m p (1) on th e in le t m a n ifo ld hose.
9. R e m o v e th e c la m p (1) on th e a ir filte r hose.
10. R e m o v e th e a ir filte r re s tric tio n s e n s o r (1) and

pipe.
6-62720 - 09 - 2006
11. U n s c re w th e c la m p and d is c o n n e c t th e p ipe (1)

c o n n e c tin g th e a ir filte r to th e e x h a u s t a s p ira to r.
20 4
12. U n s c re w th e h o se c la m p re m o v e th e to p ra d ia to r
h o se ( 1 ).
20 5
13. U n s c re w th e c la m p and re m o v e th e pip e (1) fro m
th e ra d ia to r cap.
20 6
14. U n s c re w th e tw o b o lts (1) s e c u rin g th e ra d ia to r
to th e fro n t a x le s u p p o rt and re m o v e th e b olts,
ru b b e r m o u n tin g s and s p a c e rs .
20 7
6-62720 - 09 - 2006
15. R e m o v e th e ra d ia to r (1) and th e u p p e r ru b b e r

m o u n tin g s .
16. L o o se n th e a lte rn a to r p iv o t bolt.
17. L o o se n th e b e lt te n s io n a d ju s te r b o lt (1) and

re m o v e th e belt.
18. R e m o v e th e ra d ia to r fa n (1).
6-62720 - 09 - 2006
19. U n s c re w th e re ta in in g b o lts (1) and re m o v e th e

c ra n k s h a ft pulley.
212
20. S tra ig h te n th e ta b on th e lo c k w a s h e r, hold th e

c ra n k s h a ft a g a in s t ro ta tio n and u n s c re w n u t ( 1 ).
21 3
21. R e m o v e th e p u lle y h u b fro m th e c ra n k s h a ft

u sin g to o l 380000226 (1) and re trie v e th e w o o d
ru ff key.
21 4
6-62720 - 09 - 2006
22. R e m o v e th e oil s e a l (1) fro m it s e a t.
To in sta ll th e fro n t oil s e a l, p ro c e e d as fo llo w s :

— In sta ll th e oil se a l.
— R e fit th e c ra n k s h a ft h u b and re ta in in g nut; bend
ta b o v e r on lo c k w a s h e r.
— R e fit fan.
— R e fit th e d riv e belt, a d ju s t te n s io n and tig h te n
a lte rn a to r bolts.
— R e p la c e th e ra d ia to r and s e c u re w ith th e tw o
bolts.
— R e fit th e tw o ru b b e r h o s e s to th e c o o la n t p u m p
and th e th e rm o s ta t h o u sin g .
— R e c o n n e c t th e p ipe to th e ra d ia to r cap.
— R e c o n n e c t th e b o n n e t s ta y b ra c k e t to th e
b ra c k e t m o u n te d on th e ra d ia to r and re p la c e th e
re ta in in g b olts.
— R e fit th e h o se to th e e x h a u s t a s p ira to r.
— R e fit th e h o se c o n n e c tin g th e a ir c le a n e r to th e
in le t m a n ifo ld . R e fit th e a ir filte r re s tric tio n
se n so r.
— R e fit th e tw o w ire m e sh g u a rd s a ro u n d th e fan.
— F ill th e ra d ia to r w ith co o la n t.
— R e c o n n e c t th e b a tte ry n e g a tiv e lead; c lo s e th e
b o n n e t.
6-62720 - 09 - 2006
C O O LAN T PUMP
R e m o v a l-In s ta lla tio n (O p eratio n 10 402 10)
----------- A WARNING A -----------

A lw a y s use s u ita b le to o ls to a lig n h o le s in p a rts.
N E V E R U S E Y O U R F IN G E R S O R H A N D S .
1. R e m o v e th e e x h a u s t pip e and o p e n th e b o n n e t.
3. R e m o v e th e w ire m e sh g u a rd s (1) fro m th e left
and rig h t-h a n d s id e s o f th e fan.
21 6
4. R e m o v e th e h o se c la m p , d e ta c h th e b o tto m
ra d ia to r h o se ( 1 ) and d ra in o ff th e co o la n t.
21 7
5. R e m o v e th e fa n s h ro u d (1) re ta in in g b olts.
21 8
6. R e m o v e th e tw o s trip s (1) fro m th e s id e s o f th e

rad iato r.
21 9
6-62720 - 09 - 2006
7. Move the fan shroud towards the engine.

8. Unscrew the three bolts securing the fan to the
coolant pump shaft. Remove the fan and the fan
cowling.
9. Loosen the alternator pivot bolt (2).

10. Loosen the belt tension adjustment bolt (1).
221
11. Remove the coolant pump pulley (1).
12. Loosen the hose clamp (1) and detach the hose
from the coolant pump.
6-62720 - 09 - 2006
13. U n s c re w th e b e lt te n s io n a d ju s tm e n t a rm
re ta in in g n u t ( 1 ) and m o v e th e a lte rn a to r
o u tw a rd .
14. R e m o v e p u m p c o n n e c tio n p ipe (1) to g ain

a c c e s s to th e c o o la n t p u m p re ta in in g b o lt (2 ).
15. U n s c re w th e fo u r b o lts (1) fig. 2 2 6 s e c u rin g th e

c o o la n t p u m p to its m o u n tin g .
16. D is c o n n e c t th e h o se fro m th e c o o la n t p u m p to
th e th e rm o s ta t h o u s in g , th e n re m o v e th e p u m p
(1) fig. 2 27.
To re fit th e c o o la n t p u m p p ro c e e d as fo llo w s :
— R e fit th e c o o la n t p u m p . T a ke c a re n o t to lose th e
se a ls on th e u p rig h t h o se c o n n e c tin g th e p u m p
to th e th e rm o s ta t body.
— R e fit th e c o n n e c tio n p ipe to th e p u m p , and re p la
ce th e tw o re ta in in g b olts.
— R e fit th e c o o la n t p u m p p u lle y and th e fa n . R e fit
th e fa n s h ro u d and th e tw o v e rtic a l s id e s trip s to
th e rad ia to r. F ix th e b e lt te n s io n a d ju s tm e n t arm .
T ig h te n th e a lte rn a to r p iv o t bolt.
— R e fit th e b o tto m ra d ia to r h o se to th e c o n n e c tio n
pipe on th e c o o la n t p u m p and th e ra d ia to r.
— R e fit th e rig h t-h a n d w ire m e sh g u a rd .
— R e fit th e le ft-h a n d w ire m e sh g u a rd .
— Fill th e c o o lin g s y s te m fro m th e ra d ia to r cap.
— R e c o n n e c t th e n e g a tiv e b a tte ry lead and re fit th e
e x h a u s t pipe.
6-62720 - 09 - 2006
COOLING SYSTEM THERMOSTAT

R em oval -In s ta lla tio n
(O pe ra tion 10 402 30)
----------- A WARNING A -------------

A lw a y s use s u ita b le to o ls to a lig n h o le s in pa rts.
2. R e m o v e th e e x h a u s t pipe, a tta c h liftin g c h a in s to
th e b o n n e t ( 1 ) and a tta c h th e c h a in s to th e h oist.
3. D is c o n n e c t th e e le c tric a l le a d s (1) fro m h e a d la m p s

(2 ).
4. D e ta ch th e g a s s tru ts (1) fro m th e b o n n e t.
230
5. R e m o v e th e fo u r b o n n e t h in g e b o lts (1) and lift

th e b o n n e t clear.
231
6-62720 - 09 - 2006
6. D ra in th e co o lin g s y s te m fro m th e d ra in plug on

th e e n g in e block.
7. R e m o v e th e w ire m e sh g u a rd (1) fro m th e rig h t-

hand s id e o f th e ra d ia to r.
8. U n s c re w th e h o se c la m p and d is c o n n e c t th e
h o se ( 1 ) c o n n e c tin g th e ra d ia to r to th e
th e rm o s ta t h o u sin g .
9. R e m o v e th e th e rm o s ta t h o u s in g c o v e r s c re w s
( 1 ).
6-62720 - 09 - 2006
10. L e v e r th e c o v e r (1) o ff th e h o u s in g u sin g a

s c re w d riv e r and re m o v e th e cover.
23 6
11. R e m o v e th e th e rm o s ta t v a lv e (1).
23 7
To re fit th e th e rm o s ta t p ro c e e d as fo llo w s :
— F it th e th e rm o s ta t in its h o u s in g and lo c a te th e
g a s k e t. R e fit th e c o v e r to th e h o u sin g .
— C o n n e c t th e to p ra d ia to r h o se to th e th e rm o s ta t
ho u sin g and s e c u re w ith a h o se c la m p .
— R e fit th e b o n n e t stay.
— R e fit th e rig h t-h a n d w ire g u a rd to th e fan.
— R e fit th e b o n n e t.
— Fill th e c o o lin g s y s te m . Top up as n e ce ssa ry.
— R e c o n n e c t th e b a tte ry n e g a tiv e lead. C lo s e th e
b o n n e t and re fit th e e x h a u s t pipe.
6-62720 - 09 - 2006
Op. 10 246 14
BOSCH INJECTION PUMP Removal-Instal
lation, timing and air bleeding
A CAUTION A ----------
H a n d le all p a rts c a re fu lly. D o n o t p u t y o u r h a n d s o r
fin g e rs b e tw e e n p a rts. W e a r th e p re s c rib e d s a fe ty
clo th in g , in clu d in g g o g g le s , g lo v e s and s a fe ty fo o t
w ea r.
A lw a y s use a p p ro p ria te to o ls to a lig n fix in g holes.
N E V E R U S E F IN G E R S O R H A N D S .
P ro c e e d as fo llo w s :
1. R a ise th e b o n n e t.
2. U n s c re w th e re ta in in g b o lts and ta k e o ff th e in je c
tio n p u m p g e a rb o x c o v e r (2 ); if th e re is an air-
c o n d itio n in g s y s te m c o m p re s s o r, re m o v e th e
b ra c k e t ( 1 ) s u p p o rtin g th e c o m p re s s o r.
3. U n s c re w and re m o v e th e fu e l filter. 23 8
4. R e m o v e th e fly w h e e l in s p e c tio n w in d o w c o v e r
( 1 ) and th e ta p p e t cover.
5. R o ta te th e c ra n k s h a ft to brin g c y lin d e r no. 1 to
T .D .C . and m a k e s u re th e v a lv e s a re c lo se d
(c o m p re s s io n s tro k e ).
6 . D is c o n n e c t th e th ro ttle c o n tro l c a b le (1) fro m th e

le v e r on th e in je c tio n p u m p , th e e n g in e cu t--o u t
e le c tro m a g n e t c o n n e c tio n and th e c o n n e c tio n o f
th e th e rm o m e tric c irc u it b re a k e r cu ttin g o u t s ta r
tin g a d v a n c e a c c o rd in g to te m p e ra tu re (K S B ).
6-62720 - 09 - 2006
7. U n s c re w th e u n io n s o f th e fu e l s u p p ly lin e s (1)
fro m th e in je c tio n p u m p , fro m th e fu e l re tu rn pipe
(2) and fro m th e p u m p fu e l s u p p ly line (3).
8 . D is c o n n e c t th e L .D .A . d e v ic e c o n n e c tin g p ipe to
th e in le t m a n ifo ld (o n ly J X 7 0 and J X 9 5 m o d e ls ).
241
9. U n s c re w th e in je c tio n p u m p lo c k n u t on th e re la ti
ve g e a rin g ( 1 ).
10. U sin g to o l 380000322 (1) re m o v e th e in je ctio n

p u m p fro m th e g e a rin g and re c o v e r th e pu m p .
24 3
11. U n s c re w th e b o lts (1) s e c u rin g th e in je ctio n
pum p .
24 4
6-62720 - 09 - 2006
12. To re fit th e in je c tio n p u m p , p ro c e e d as fo llo w s .
N E V E R U S E F IN G E R S O R H A N D S .
-- R e s p e c t th e tig h te n in g to rq u e s p re s c rib e d on
pa g e 24.
- C h e c k th a t c y lin d e r no. 1 is a t T .D .C . and th e
v a lv e s a re c lo s e d (c o m p re s s io n s tro k e ).
-- P o s itio n th e in je c tio n p u m p in its s e a t and s e c u re
it w ith th e bo lts, c h e c k in g th e y a re in th e m id d le
o f th e slo t.
-- L o c k th e in je c tio n p u m p d riv e g e a r w ith th e nut
tig h te n e d to a to rq u e o f 90 N m , m a k in g s u re th e
c ra n k s h a ft d o e s n o t tu rn .
- L o o se n th e s c re w s to p p in g th e in je c tio n p u m p
fro m tu rn in g . In s e rt th e re le v a n t s p a c e r and
tig h te n th e s c re w b a ck. In th e s e c o n d itio n s , th e
p u m p s p in d le ca n tu rn freely.
-- R e fit th e in je c tio n p u m p d riv e g e a r b o x a c c e s s
cover.
- A s s e m b le th e L D A d e v ic e c o n n e c tio n p ipe to th e
in le t m a n ifo ld (J X 7 0 and J X 9 5 m o d e ls o n ly).
- C o n n e c t th e fu e l s u p p ly and re tu rn lin e s to th e in
je c tio n pum p .
- C o n n e c t th e e n g in e c u t- o u t e le c tro m a g n e t ca b le
and th e c a b le o f th e th e rm o m e tric c irc u it b re a k e r
cu ttin g o u t s ta rtin g a d v a n c e a c c o rd in g to te m
p e ra tu re (K S B ).
- C o n n e c t th e d e liv e ry p ip e s to th e in je c to rs , to th e
in je ctio n pum p .
- C o n n e c t th e th ro ttle lead to th e in je c tio n p u m p .
- F it th e fu e l filter.
-- C lo s e th e b o n n e t.
6-62720 - 09 - 2006
BOSCH INJECTION PUMP

Timing
1. U sin g an e x te rn a l c a b le , s u p p ly 12 V to th e th e r
m o m e tric c irc u it b re a k e r c u ttin g o u t s ta rtin g a d
v a n c e a c c o rd in g to te m p e ra tu re (K S B ) (1)
a tta c h in g th e p o s itiv e te rm in a l to th e c o n n e c tio n
and e a rth to th e p u m p h o u sin g .
24 5
2. M a ke s u re th a t th e K S B fo rk (1) is fre e to m o ve .
24 6
3. U n s c re w th e u n io n s o f th e fu e l s u p p ly lin e s (1),
d e ta c h in g th e m fro m th e in je c tio n pu m p .
If n e ce ssa ry, d is c o n n e c t th e in je c tio n p u m p s u p
ply and re tu rn lin e s (2 and 3) and th e L D A /in ta k e
m a n ifo ld c o n n e c tin g pipe.
24 7
( 1 ) and th e ta p p e t cover.
5. R o ta te th e c ra n k s h a ft to brin g c y lin d e r no. 1 at
T .D .C . and m a k e s u re th e v a lv e s a re c lo se d
(c o m p re s s io n s tro k e ).
24 8
6-62720 - 09 - 2006
6 . C h e c k th ro u g h th e in s p e c tio n w in d o w th a t th e
p o in te r is a lig n e d w ith re fe re n c e m a rk s 4 ° fo r
m od . JX60, 0 ° fo r m o d . JX70 and JX 95 , o r 1 °
fo r m o d. JX80 a nd JX 90 .
7 . W ith th e in je c tio n p u m p in its s e a t, re m o v e th e

plug ( 1 ) on th e p u m p cover.
8 . F it d ia l g a u g e 380000228 (1) fig. 251 and th e a s
s o c ia te d to o l 380000229 (2), p re -lo a d in g th e
s h a ft by a p p ro x im a te ly 2 .5 m m (0 .0 9 8 4 in.).
9. T urn th e fly w h e e l s lo w ly b a c k w a rd s , s o as to
bring th e p lu n g e rto B .D .C . a t th e s ta rt o f th e d e li
v e ry s tro k e (th e p o in t a t w h ic h th e d ia l g a u g e n e
ed le s to p s fa llin g ).
250
10. Z e r o - s e t th e d ia l g a u g e and s lo w ly tu rn th e
fly w h e e l c lo c k w is e (as v ie w e d fro m th e fa n end
o f th e e n g in e ) u ntil th e p o in te r lin e s up w ith
re fe re n c e m a rk s 4 ° fo r JX60 m o d e ls , 0 ° fo r JX70
and JX95 m o d e ls , o r 1 ° fo r JX80 and JX90
m o d e ls.
11. C h e c k on th e d ia l g a u g e th a t th e p lu n g e r has
co m p le te d a s tro k e o f 1 m m (0 .0 3 9 4 in.) up to th is
po int, if not, s la c k e n o ff th e p u m p m o u n tin g b olts.
I f th e p lu n g e r s tro k e is c h e c k e d w ith th e p o in te r
at th e T .D .C . th e re m u s t be a s tro k e of: 1.47 mm
( 0.0578 in . ) fo r m o d . JX60 o r 1.00 m m ( 0.0394
in . ) fo r m od . JX70 and JX 95 , o r 1.12 mm
( 0.0440 in . ) fo r m o d . JX80 and JX 90 .
12. T u rn th e p u m p a n ti-c lo c k w is e if th e p lu n g e r has
c o m p le te d a s h o rte r s tro k e and c lo c k w is e if th e
s tro k e is longer, re p e a tin g th e te s t u n til th e c o r
re c t s tro k e is o b ta in e d .
13. H a vin g o b ta in e d th e c o rre c t p lu n g e r s tro k e , fix
th e p u m p in p o s itio n by tig h te n in g th e m o u n tin g
n u ts to th e to rq u e s p e c ifie d on p a g e 24.
14. R e m o v e th e dia l g a u g e 380000228 (1) and re la ti
ve to o l 380000229 (2) and re p la c e th e plug and
tig h te n to a to rq u e o f 8 - 10 N m (5 .9 0 0 5 - 7 .3 7 5 6
ft lb).
15. D is c o n n e c t th e K S B e x te rn a l p o w e r s u p p ly unit.
16. R e fit o th e r p a rts in th e re v e rs e o f th e d is m a n tlin g
order.
6-62720 - 09 - 2006
BOSCH INJECTION PUMP

A ir ble e d in g
1. Unscrew the plug (1) on the filter.
252
2. Operate the priming lever (1) fig. 253 on the fuel

supply pump until the fuel coming out of the filter
orifice is free of bubbles, then replace and tighten
plug (1) fig. 252.
253
3. Slacken the fuel line unions (1) on the injectors,
start the engine and then re-tightenthe union (1)
when the fuel flows out free of bubbles.
254
6-62720 - 09 - 2006
FUEL INJECTORS
R e m o v a l-In s ta lla tio n (O p eratio n 10 218 30)
----------- A WARNING A -----------

2. A tta c h lifting c h a in s to th e b o n n e t (1) and th e n
a tta c h th e c h a in s to th e h oist.
25 5
3. D is c o n n e c t th e e le c tric a l le a d s (1) fro m h e a d

la m p s (2 ).
25 6

6-62720 - 09 - 2006
6. Unscrew the fuel le ak-off pipe union (1) on the

injector.
259
7. Unscrew the union (1) of the high-pressure fuel
line on the injector.
260
8. Unscrew the two retaining nuts (1) and withdraw
the injector.
To refit the injector, proceed as follows:

— Insert the injector into its seat.
— Replace and tighten the two retaining nuts in two
stages. 1st stage: tighten nuts to 10 Nm (1 kgm)
2nd stage: tighten nuts to 25 Nm (2.6 kgm).
— Reconnect the fuel lea k-o ff pipe union.
— Reconnect the high-pressure fuel line union.
— Replace the bonnet.
— Reconnect the battery negative lead.
6-62720 - 09 - 2006
AD JU STIN G VALVE CLEARANCE

(O pe ra tion 10 106 12)
----------- A WARNING A -----------

2. A tta c h lifting c h a in s to th e b o n n e t (1) and th e n a t
ta c h th e m to th e h oist.
3. D is c o n n e c t th e e le c tric a l le a d s (1) fro m

h e a d la m p s (2 ).

6-62720 - 09 - 2006
6. U n d o th e h o se c la m p and d e ta c h th e h o se fro m
th e s ile n c e r eje cto r.
7. U n s c re w th e tw o s c re w s s e c u rin g th e s ile n c e r
fro n t s u p p o rt.
8. U n s c re w th e re ta in in g n u ts s e c u rin g th e s ile n c e r
to th e e x h a u s t m a n ifo ld and re m o v e th e s ile n ce r.
26 6
9. U n s c re w th e fo u r ro c k e r c o v e r n u ts (1) and
re m o v e cover.

( 1 ).
11. A d ju s t th e c le a ra n c e b e tw e e n th e v a lv e s and th e
ro c k e ra rm s u sin g a fe e le rg a u g e , w re n c h ( 1 ) and
th e s p e c ia l to o l 291883 (2).
NOTE: Before proceeding with adjustment
operations, position the valves as described on the
following page.
26 9
6-62720 - 09 - 2006
To a d ju s t v a lv e c le a ra n c e s on th e 3 --c y lin d e r J X 6 0
and J X 7 0 e n g in e s , p ro c e e d as fo llo w s :
— T urn th e c ra n k s h a ft so th a t th e in le t and e x h a u s t
v a lv e s o f c y lin d e r no. 1 a re b a la n c e d (s ta rt o f
in d u c tio n s tro k e ). In th is p o s itio n th e p o in te r w ill
be a lig n e d w ith th e re fe re n c e m a rk P M S 1
(T D C 1) on th e fly w h e e l.
— R o ta te th e c ra n k s h a ft th ro u g h a fu ll re v o lu tio n ,
re tu rn in g to T D C 1, th e n c h e c k th a t th e v a lv e
c le a ra n c e s c o rre s p o n d w ith th e v a lu e s s p e c ifie d
in th e ta b le on p a g e 4.
— R e p e a t th is o p e ra tio n fo r th e o th e r v a lv e pairs.
N o te th a t th e T D C p o s itio n s o f c y lin d e rs 2 and 3
are n o t m a rk e d on th e fly w h e e l.
To c h e c k v a lv e c le a ra n c e s on 4 - c y lin d e r J X 8 0 , J X 9 0
and J X 9 5 m o d e ls , p ro c e e d as fo llo w s :
— T urn th e c ra n k s h a ft so th a t th e in le t and e x h a u s t
v a lv e s o f c y lin d e r no. 1 a re b a la n c e d (s ta rt o f in
d u c tio n s tro k e ). In th is p o s itio n th e p o in te r w ill be
a lig n e d w ith th e re fe re n c e m a rk P M S 1 (T D C 1)
on th e fly w h e e l.
— C h e c k th a t th e c le a ra n c e b e tw e e n v a lv e s and
ro c k e r a rm s on c y lin d e r no. 4 c o rre s p o n d s w ith
th e v a lu e s s p e c ifie d in th e ta b le on p a g e 4.
R o ta te th e c ra n k s h a ft th ro u g h 3 6 0 ° and c h e c k
v a lv e c le a ra n c e s on th e o p p o s in g c y lin d e r
(N o. 1).
— R e p e a t th is o p e ra tio n fo r th e o th e r v a lv e pairs.
N o te th a t th e o p p o s in g c y lin d e rs a re 1 - 4 and
2 -3 .
To re a s s e m b le p ro c e e d as fo llo w s :
— R e fit th e ro c k e r cover.
— R e fit th e fly w h e e l in s p e c tio n w in d o w cover.
— R e fit th e e x h a u s t s ile n ce r.
— R e fit th e b o n n e t.
— R e c o n n e c t th e b a tte ry n e g a tiv e lead.
6-62720 - 09 - 2006
WATER PUMP - O verhaul

(O pe ra tion 10 402 28)
----------- A WARNING A -----------

U se s u ita b le to o ls fo r a lig n in g h o le s. N E V E R U S E
F IN G E R S O R H A N D S .
NOTE: T h e b e a rin g (9) fo rm s a s in g le p ie ce w ith th e

c o n tro l s h a ft (10). It is a s e a le d u n it and re q u ire s no
lu b ric a tio n d u rin g ru n n in g .
O v e rh a u l th e p u m p as fo llo w s :
27 0
— R e m o v e th e c o v e r (4) fig. 2 7 0 , and th e s h a ft
s c re w (2) re ta in in g th e s h a ft (10) and b e a rin g (9).
— G e n tly ta p th e end o f th e s h a ft (10) fig. 2 7 0 on th e

ro to r sid e (5) to b re a k th e film o f o x id e b e tw e e n
th e s h a ft and th e rotor. In s ta ll th e e x tra c to r
291182 (1) fig. 271 and ta k e o u t th e rotor.
— R e m o v e th e fro n t s e a lin g b u s h in g (7) fig. 2 70.
— U se a pu n ch to e x tra c t fro m th e p u m p h o u sin g

(6) fig. 2 7 0 th e s h a ft (10) c o m p le te w ith b e a rin g
( 9) and th e fa n h u b (1).
NOTE: R e m o v e th e s e a l (8) fig. 2 7 0 o n ly w h e n it

n e e d s to be c h a n g e d .
C h e c k c o m p o n e n ts fo r w e a r, and c h a n g e a n y th a t
a re in p o o r c o n d itio n .
R e fit th e p a rts, p ro c e e d in g as fo llo w s :
— F it th e s h a ft (10) fig. 2 7 0 c o m p le te w ith b e a rin g

(9) and h ub (1) on th e p u m p h o u s in g (6) and s e
c u re it w ith th e re ta in in g s c re w (2), h a vin g firs t
c o a te d it w ith L O C T IT E 2 42.
— If c h a n g in g th e s e a l (8) fig. 2 7 0 , fit th e s e a l into

th e s e a t u sin g to o l 293280 (1) fig. 2 72.
— H e a t th e ro to r (1) fig. 2 7 0 in an a ir o ve n , u ntil it

re a ch a te m p e ra tu re o f 1 3 0 -1 5 0 ° C h ig h e r th a n
th e s h a ft (2).
— P la ce th e ro to r (1) on th e s h a ft (2), e a s in g it o n to
th e end so as n o t to d a m a g e th e b e a rin g , until
yo u o b ta in th e o p e ra tin g c le a ra n c e of
G = 0 .5 - 0 .7 m m (se e fig. 2 7 0 ).
— F it th e s e a l (3) fig. 2 7 0 and th e c o v e r (4),

s e c u rin g it w ith th e re le v a n t s c re w s .
6-62720 - 09 - 2006
ENGINE 5) T u rn th e e n g in e o v e r a fe w tim e s w ith th e s ta rte r

m o to r in o rd e r to e x p e l a n y c a rb o n re sid u e .
C o m p re s s io n te s t (O p eratio n 10 001 30)
6) F it th e d u m m y in je c to r 293862 in p la ce o f th e
In c a s e o f p o o r e n g in e p e rfo rm a n c e , in a d d itio n to in je c to r re m o v e d p re vio u sly, in s e rtin g th e c o p p e r
c h e c k in g th e fu e l in je c tio n s y s te m (in je c to r n o z z le s s e a lin g w a s h e r.
and in je ctio n p u m p ), a lso te s t th e c o m p re s s io n on
e a ch cylin d e r. 7) C o n n e c t th e c o m p re s s io n te s te r 291309/1 and
ta k e re a d in g s w h ile tu rn in g th e e n g in e o v e r w ith th e
s ta rte r m otor.
----------- A DANGER A -----------
D o n o t use m a tc h e s , lig h te rs , b lo w to rc h e s o r a n y O n e n g in e s in p e rfe c t w o rk in g o rder, w ith th e s u m p
n a ke d fla m e as a s o u rc e o f lig h t w h e n in s p e c tin g th e oil a t a p p ro x . 4 0 ° C , a t s e a le ve l (7 6 0 m m m e rc u ry )
e n g in e d u e to th e p re s e n c e o f in fla m m a b le flu id s and and a t an e n g in e s p e e d o f 2 0 0 -- 2 8 0 re v /m in , th e
va p o u r. c o m p re s s io n sh o u ld be 2 5 .5 - 2 7 .5 bar
(26 to 2 8 k g /c m 2).
8) T est th e c o m p re s s io n on th e o th e r c y lin d e rs ,
re p e a tin g s te p s 4, 5, 6 and 7, b e a rin g in m in d th a t:
C o m p re s s io n ratio
T h e m in im u m p e rm is s ib le c o m p re s s io n on a used
T h e c o m p re s s io n ra tio is a m e a s u re o f th e q u a n tity
e n g in e is 2 1 .6 b a r (22 k g /c m 2).
o f a ir d ra w n into th e c y lin d e r and p ro v id e s an
in d ic a tio n o f th e e ffic ie n c y o f th e s e a lin g e le m e n ts in
T h e m a x im u m p e rm is s ib le c o m p re s s io n d iffe re n c e
th e c y lin d e r (p isto n rin g s and v a lv e s ).
b e tw e e n c y lin d e rs is 3 b a r (3 k g /c m 2).
U n ifo rm c o m p re s s io n in all th e c y lin d e rs e n s u re s th a t
E v e ry 100 m e tre s a b o v e s e a le ve l c o rre s p o n d s to a
th e y all p e rfo rm an e q u a l a m o u n t o f w o rk , p ro v id e d
re d u c tio n in c o m p re s s io n by a b o u t 1% .
o f c o u rs e th a t ea ch c y lin d e r is in je c te d w ith th e s a m e
q u a n tity o f fu e l a t th e rig h t tim e .
CONSIDERATIONS:
Low c o m p re s s io n n o t o n ly re d u c e s e n g in e
p e rfo rm a n c e , it a lso c a u s e s in c o m p le te fu e l
c o m b u s tio n d u e to th e la c k o f a v a ila b le c o m b u s tio n
U n ifo rm c o m p re ssio n
air.
A lth o u g h high c o m p re s s io n is im p o rta n t, it is m o re
T h e e n g in e th e re fo re g iv e s p o o r p e rfo rm a n c e w ith
im p o rta n t as re g a rd s s m o o th ru n n in g th a t th e
e x c e s s iv e fu e l c o n s u m p tio n , and c o n s e q u e n tly
c o m p re s s io n is th e s a m e in all cy lin d e rs .
e x h a u s t s m o k e and re s tric tio n o f th e e x h a u s t
p a s sa g e s.
L o w c o m p re s s io n re adings
A s th e c o m p re s s io n ra tio a lso varies w ith the
If v e ry lo w c o m p re s s io n re a d in g s a re o b ta in e d on
te m p e ra tu re o f th e e n g in e (co ld e n g in e s p ro d u c e
o n e c y lin d e r it is a d v is a b le to re p e a t th e te s t.
lo w e r c o m p re s s io n v a lu e s th a n h o t e n g in e s ) th e
c o m p re s s io n sh o u ld o n ly be te s te d w h e n th e e n g in e
B e fo re te s tin g th is tim e , p o u r a b o u t a s p o o n fu l o f
is a t n o rm a l o p e ra tin g te m p e ra tu re .
e n g in e oil in to th e c y lin d e r th ro u g h th e in je c to r bore.
C o m p re s s io n s h o u ld be te s te d u sin g th e
T u rn th e e n g in e o v e r a fe w tim e s to d is trib u te th e oil
c o m p re s s io n te s t kit 291309 as fo llo w s :
e v e n ly o v e r th e c y lin d e r w a lls , and th e n re p e a t th e
te s t.
1) R un th e e n g in e u ntil it re a c h e s n o rm a l o p e ra tin g
te m p e ra tu re . If th e s e c o n d te s t re a d in g s a re s ig n ific a n tly higher,
s u s p e c t w o rn p isto n rin g s, o u t- o f- r o u n d o rd a m a g e d
2) S w itc h o ff th e e n g in e . p is to n s o r liners.
3) D is c o n n e c t th e lead fro m th e e n g in e s to p so le n o id If th e s e c o n d te s t re a d in g s a re n o t higher, th e

on th e in je ctio n p u m p in o rd e r to c lo s e th e s o le n o id p ro b le m w ill be th e v a lv e s .
v a lv e and b lo c k th e flo w o f fu e l to th e in je c to rs .
O n th e o th e r ha n d , if th e s e c o n d te s t re a d in g s h o w s
4) R e m o v e th e in je c to r fro m th e c y lin d e rto b e te s te d . o n ly a s lig h t im p ro v e m e n t, th e p ro b le m w ill be d u e to
b oth th e v a lv e s and th e rings.
6-62720 - 09 - 2006
SECTION 18 - CLUTCH - CHAPTER 1 1
SECTION 18 - CLUTCH
Chapter 1 - Clutch
CONTENTS
18 000 General specifications .................................................................................................................. 1

Tightening torques ....................................................................................................................... 2
Tools ............................................................................................................................................... 3
C ross-sectional views ................................................................................................................. 4
Clutch Troubleshooting ............................................................................................................... 5
18 110 10 Removal - Installation .................................................................................................................. 6
O v e rh a u l....................................................................................................................................... 14
Minimum permissible dimensions after refacing ................................................................... 18
Adjustments ............................................................................................................................... 19
18 100 40 Adjustment of the main and PTO clutch control lin k a g e ....................................................... 21
GENERAL SPECIFICATIONS, CLUTCH 11”/11”
(Models JX60, JX70, JX80 and JX90)
T y p e ........................................................................................................... Dual clutch consisting of two

single dry plate clutches
M e c h a n ic a l............................................................................................... control: pedal operation for
main clutch and hand lever
for power ta k e -o ff clutch
Engagement and release mechanism ................................................ single Belleville spring
Driven plate lining material for main transmission clutch (11”) ....
Models JX60 and JX70 ........................................................................ Organic agglomerate
Models JX80 and JX90 ........................................................................ cerametallic
Driven plate lining material for PTO clutch (11”)
Models JX60, JX70, JX80 and JX90 .................................................. Organic agglomerate
Driven plate thickness:
. main clutch (9, fig. 1)
. VALEO
. Organic agglomerate and c e ra m e ta llic ...................................... mm 10.2 to 10.8
(in.) (0.4016 to 0.4252)
. PTO clutch (11, fig. 1)
. V A L E O ............................................................................................. mm 7.3 to 7.9
(in.) (0.2874 - 0.3110)
. w ear limit ............................................................................................... ” See pages 18
Clearance between main clutch release sleeve and related seat . . mm 0.050 to 0.151
(in.) (0.0020 to 0.0059)
Clearance between PTO clutch release sleeve and related seat . . mm 0.050 to 0.151
(in.) (0.0020 to 0.0059)
Release lever coplanarity adjustment ................................................ See page 19
Clutch control a d ju stm e n t...................................................................... See page 21
6-62720 - 09 - 2006
2 SECTION 18 - CLUTCH - CHAPTER 1
GENERAL SPECIFICATIONS, CLUTCH 11”/11”
(Model JX95)
T y p e ........................................................................................................... Dual clutch consisting of two

single dry plate clutches
Mechanical ............................................................................................... control: pedal operation for
main clutch and hand lever
for power ta k e -o ff clutch
Engagement and release mechanism ................................................ single Belleville spring
Driven plate lining material for main transmission clutch (12”)
Model J X 9 5 ................................................................................... Cerametallic
Driven plate lining material for PTO clutch (12”)
Models J X 9 5 ................................................................................. Organic agglomerate
Driven plate thickness:
. main clutch (9, fig. 1)
. VALEO
. Organic agglomerate and c e ra m e ta llic ...................................... mm 10.2 to 10.8
(in.) (0.4016 to 0.4252)
. PTO clutch (11, fig. 1)
. V A L E O ............................................................................................. mm 7.3 to 7.9
(in.) (0.2874 - 0.3110)
. w ear limit ............................................................................................... ” See pages 18
Clearance between main clutch release sleeve and related seat . . mm 0.050 to 0.151
(in.) (0.0020 to 0.0059)
Clearance between PTO clutch release sleeve and related seat . . mm 0.050 to 0.151
(in.) (0.0020 to 0.0059)
Release lever coplanarity adjustment ................................................ See page 19
Clutch control a d ju stm e n t...................................................................... See page 21
TIGHTENING TORQUES
Tightening torque
PART Thread
Nm ft lb
Clutch/flywheel retaining bolts

- mod. JX60, JX70, JX80 and J X 9 0 ............................................ M 8 x 1.25 25 18.439
- mod. J X 9 5 ..................................................................................... M 10 x 1.25 59 43.5162
Release command fork securing bolt (C3, page 4) ...................... M 16 x 1.5 157 115.7972
Retaining bolts securing clutch casing to engine (C2, page 4) . . . M 12 x 1.25 98 72.2811
Clutch casing/engine retaining nuts (3, fig. 1 page 4) .................. M 12 x 1.25 98 72.2811
Nut for sleeve cover fixing stud (C6 page 4 ) .................................. M 8 x 1.25 17 12.8355
6-62720 - 09 - 2006
380000236 Tractor disassembly stand.
380000612 11”/11” clutch adjustment kit

(pin and gauge).
380000292 Dowel for centring and adjust

ment of 12”/12” clutches.
380000293 12”/12 Clutch adjustment

gauge.
293650 Clutch overhaul outfit.
380000458 Press for clutch lever release

test.
6-62720 - 09 - 2006
LONGITUDINAL SECTION OF CLUTCH VALEO
1
a . Main clutch with driven disc made of organic material. 4. Main clutch release sleeve, complete with thrust
b . Main clutch with driven disc made of cerametallic. bearings.
C2 Bolts securing clutch casing to the engine. 5. PTO clutch release sleeve, complete with thrust
bearings.
C3 Fork lever retaining bolts.
6. Power ta k e -o ff clutch release lever adjustment tie
C 6 Nuts for sleeve studs.
rod.
D . Nominal distance of lever (3) from clutch contact sur
7. Power ta k e -o ff clutch release lever stop nut.
face on flywheel (mod. JX60, JX70, JX80 and JX90,
11”/11” clutch 98 m m (3.8583 in.) - mod. JX95 12”/12”
8. Power ta k e -o ff clutch plate.
clutch 103 m m (4.0551 in.)). 9. Main transmission clutch plate.
D 1 Nominal distance of lever (2) from clutch contact sur 10. Bearing on flywheel.
face on flywheel (mod. JX60, JX70, JX80 and JX90, 11. PTO clutch release sleeve control fork.
11”/11” clutch 123 m m (4.8425 in.) - mod. JX95 12. Main clutch release sleeve control fork.
12”/12” clutch 137 m m (5.3937 in.)). 13. Main clutch release lever adjuster lever.
L 1 Clearance between PTO release lever and related 14. Main clutch release lever adjuster screw.
thrust bearing 2 m m (0.0787 in.). 15. Main clutch release lever adjuster nut.
L 2 Clearance between main clutch release lever and re
lated thrust bearing 2.5 m m (0.0984 in.). WARNING: When refitting the clutch, check that the
clutch plates are positioned as in the drawing.
1. Belleville spring.
2. PTO clutch release lever. NOTE: When refitting, carefully clean and degrease
3. Main clutch release lever. the mating surfaces X and apply sealing compound.
6-62720 - 09 - 2006
CLUTCH TROUBLESHOOTING
Problems Possible causes Correction
Clutch slips 1. Worn clutch plates (8 and 9, Check and compare the data given on
page 4) and/or worn pres the pages indicated; replace any
sure plate and flywheel. parts which are worn up to or over the
limit and adjust levers and clutch
control linkage.
2. Belleville spring (1, page 4) Replace the Belleville spring.
distorted or otherwise
damaged.
3. Friction linings of discs (8 and Replace discs; identify and eliminate
9, page 4) contaminated with the source of lubricant inside the
oil and grease. clutch housing and thoroughly clean
the friction surfaces.
Fierce clutch 1. Partial seizure of the external Check linkage pivots and lubricate.
control linkage.
2. Friction disc (9, page 4) Replace disc and adjust clutch control
distorted. lever.
3. Friction disc (9, page 4) with Replace friction disc.
damaged hub springs or loose
hub rivets.
4. Oil or grease contaminating Replace the discs, identify and
the friction lining of discs eliminate the source of lubricant
(8 and 9, page 4). inside the clutch housing and
thoroughly clean the friction surfaces.
Clutch sticks and drags 1. Disc friction linings (8 and 9, Replace and adjust the discs.
page 4) or discs deformed.
2. Seizure of the external control Check, replace defective parts and
linkage. lubricate.
3. Controls badly adjusted. Adjust controls (see page 21).
Clutch noisy when engaged 1. Thrust bearing worn. Replace bearing.

and/or disengaged
2. Friction disc (9, page 4) with Replace friction disc.
damaged hub springs or loose
hub rivets.
Clutch pedal too stiff 1. Partial seizure of external Check linkage pivots and lubricate.
control linkages.
2. Stiffening of pedal pivot. Check pivot and lubricate.
6-62720 - 09 - 2006
CLUTCH
Rem oval-Refitting (Operation 18 110 10)
To access the clutch it is necessary to separate the

engine complete with the front axle from the
transmission.
------------ A DANGER A -----------

equipment.
means of suitable slings and hooks. Check that no
one is in the vicinity of the load to be lifted.
----------- A ATTENTION A -----------

Always use suitable tools to align holes. NEVER
USE FINGERS OR HANDS.
Proceed as follows:
1. Disconnect the negative battery lead.
2. Drain off the oil from the gearbox/transmission
casing.
3. Drain off the coolant from the engine cooling sys

tem.
4. Disconnect two flexible houses from the power
steering control cylinder and drain off the oil from
the steering system.
5. Remove the front ballast (1).
6-62720 - 09 - 2006
6. To access the engine the hood must be

opened.
5
8. After draining off the oil from the power steering
tank, disconnect the oil pipes (1) from the
hydrostatic steering control valve unit.
6-62720 - 09 - 2006
10. Detach the throttle control spring (1) and remove

the throttle lever (2).
11. After recovering the air-conditioner gas

(H R C _ 1 3 4 a ) with the recovery and
recycling station 294048, disconnect the
pipes of the cab air conditioner (1).
9
12. Slacken the clamps (1) and disconnect the cab
heating pipes (2), being sure to mark them first.
13. Remove the clamp (1) from around the pump

and delivery pipes.
6-62720 - 09 - 2006
14. Disconnect the rubber connecting hose (1) of the

hydraulic pump .
12
15. Disconnect the lift pump delivery line (1).
13
16. Disconnect the fuel line (1) from the glow plug.
14
17. Remove the front, centre and rear screws

securing the front axle prop shaft guard and
remove the guard (1).
15
6-62720 - 09 - 2006
18. Remove circlip (2) and move sleeve (1) in the

direction shown by the arrow to disengage it from
the splined shaft of the front axle.
19. Remove circlip (2) and move sleeve (1) in the

direction shown by the arrow to disengage it from
the splined shaft of the drive.
17
20. Remove the retaining bolts of the central support
(1) of the prop shaft and recover the shaft
complete with support.
21. W ithdraw the pin securing the differential lock (1)

knob, remove the knob and remove the mat (2)
from the cab floor.
6-62720 - 09 - 2006
22. Unscrew the two nuts (1) and bolts securing the
engine to the transmission, working through the
two access slots.
20
23. Unscrew the four lower bolts (1) securing the
21
24. Position two wedges (3) on the front axle to
prevent any movement o f the engine about the
axle pivot. Position the tractor dismantling stand
380000236, so that the fixed support (1) is under
the rear transmission housing in the area of the
engine coupling flange and the mobile support
(2) under the engine in the area of the flange
attached to the transmission housing, as shown
in fig. 23.
22
25. Place another mobile stand 380000236 under
the front ballast carrier to prevent any possibility
of the engine turning and tipping forwards when
the gearbox case is removed.
26. Interpose wooden blocks (1) between the stands

and the tractor, and turn the stand height
adjustment screws to bring the blocks (1) into
contact with the tractor.
23
6-62720 - 09 - 2006
27. Position a fixed stand (1) under the draw bar

support and pull on the hand brake.
24
28. Remove the spacer collar (1) between the

engine and the transmission (Model JX95).
25
29. Using tool 380000612 (mod. JX60, JX70, JX80

and JX90) or with tool 380000292 (mod. JX95)
(2), unscrew the retaining bolts (1) and remove
the clutch.
26
6-62720 - 09 - 2006
To re-install the engine, proceed as follows: Remove the stands of tool 380000236 from under
the engine and the gearbox/transmission and the
Check condition of ball bearings pressed in flywheel; stand under the draw bar.
replace in the event of excessive noise or binding.
To install a new bearing pack, lubricate with grease. Refit the cab heater pipe union on the clutch/engine
spacer collar. Connect the flexible rubber hoses to
the union.
Position the clutch using tool 380000612 (mod.
JX60, JX70, JX80 and JX90) or with tool 380000292
(mod. JX95). Fix the clutch to the flywheel with the Connect the flexible power steering pipes of the
six bolts. front axle and add oil to the system.
Connect the flexible pipe to the injector fuel leak-off

Adjust the coplanarity of the clutch release levers as pipe.
described on page 20.
Refit the multimeter and secure the sleeve with the

Clean the spacer collar and the mating surfaces of relative clamp.
the clutch housing, and also scrape all residue of old
sealing compound from the mating surface of the en
Connect the compressor, condenser and filter/dryer
gine.
inside the cab by connecting the pipes
Spread LOCTITE compound on the mating surfaces Connect all the electrical connections.
of the engine and spacer collar. Install the spacer col
lar on the stud bolts screwed on the engine.
Connect the throttle cable to the injection pump.
Before connecting the transmission casing to the en Refit the 4WD propeller shaft and the relative guard.
gine - front axle assembly, grease the discs hubs.
Refit the front ballast and secure with the vertical
lock pin.
Chock up the rear wheels with wooden wedges,
check that the hand brake is fully on and that the fi
xed and mobile stands are well positioned.
Fill the gearbox/transmission with oil.
Fit and tighten the bolts securing the clutch housing Fill the engine cooling system with coolant.
to the engine.
Connect the battery negative lead.

Make sure that no electrical leads or cables are trap
ped between the two units.
Next rotate the crankshaft by turning the cooling fan,

so as to allow the sleeve to engage the splines on the
power ta k e -o ff shaft.
6-62720 - 09 - 2006
OVERHAUL
The clutch is removed, refitted and adjusted with the
universal outfit 293650.
Parts of the universal outfit 293650 Necessary

to adjust the VALEO clutch.
A. Plate 293332.
B. Central spacer
293728. 0 35mm (1.3779 in.) for 11”/11” clutch
293729. 0 40mm (1.5748 in.) for 12”/12” clutch
C. Gauge 293731.
D. Locknut 293730 for central spacer.
E. Side spacers 293726.
F. Studs 293725.
I. Blocks.
L. Handwheel 293739 securing the gauge.
M. Handwheels 293740 securing the side spacers
N. Spacers for studs.
27
Note - Before fitting the clutch on the outfit 293650

it is advisable to remove the three bolts retaining the
flexible tabs that drive the PTO clutch pressure plate
ring from the supporting housing.
MDH1884A_______________________________________________ l_ _ l___________
28
6-62720 - 09 - 2006
To fit the clutch on the universal outfit 293650

proceed as follows:
- place the central spacer (B) on the plate (A) and
position it with the gauge bearing surface at a
height of:
132 mm (5.1968 in.) (12”/12” clutches)
123 mm (4.8425 in.) (11”/11” clutch)
and lock it at this height with the locknut (D);
- measure the thickness (S) of the PTO driven disc
of the relevant clutch and place the adjustable
side spacers (E) on the circumference of 240 mm
positioning them with the upper face at a height
(h) given by:
h = Rv + S + B
where:
B additional distance to lower the PTO release
levers by 9 mm so as to use the gauge 293731
(with a difference in height between the PTO re
lease levers and the transmission release levers
of 25 mm (0.9842 in.)) to check the coplanarity
2.2 mm (0.0886 in.) for 12”/12” clutches
(mod. JX95)
no increase (already using gauge 293731) for
11”/11” clutches
(mod. JX60, JX70, JX80 and JX90)
RV flywheel external lowering distance
2 mm (0.0784 in.) for 11”/11” clutches
(mod. JX60, JX70, JX80 and JX90)
0.5 mm (0.0197 in.) for 12”/12” clutches
(mod. JX95)
S = measured thickness of the PTO driven disc;
- then lock the adjustable side spacers (E) with the

relevant handwheels (M);
- rest the clutch assembly (of the PTO driven disc)
with the PTO pressure plate on the plate and se
cure it with the three stud bolts (F, page 14),
equipped with blocks (I) and spacers (N) of the
necessary size.
29
6-62720 - 09 - 2006
Remove the nuts (7; page 4) for the PTO clutch re
lease lever adjuster tie rods and gradually unscrew
the studs (F, page 14) thereby making it possible to
extend the Belleville spring and break down the
clutch into its parts.
30
Remove the three bolts retaining the flexible tabs
driving the main clutch pressure plate from the clutch
carrier housing and retrieve the pressure plate.
31
A ATTENTION A ----------
When removing, overhauling and then refitting the
clutch, pay special attention not to move the main
clutch and PTO clutch pressure plate ring driving
tables from their original assembly position on the
pressure plate rings.
Check for wear on the clutch driven discs and replace

them if the retaining rivets are worn down to or
approaching the friction material. Replace the disc
when the oil has soaked into the organic
agglomerate surfaces.
Check the friction surface conditions of the pressure
plates and the clutch casing.
If necessary, it is possible to reface them bearing in
mind that the dimensions (A, B, C and D) of the
refaced parts must not decrease beyond the limits
shown in the figures below, in which case it would be
necessary to replace the parts.
Proceed as follows:
- reface the surfaces of the pressure plates;
- replace damaged or worn discs;
- reface the surface of the clutch housing.
6-62720 - 09 - 2006
Calculate the distance (D), removing material from

the bottom of the clutch housing, using the following
formula.
D = A + B + S 1 + S2 + P + L
where:
A and B = distances measured of the two
pressure plates after refacing;
S 1 and S2 = measurements of the PTO and main
clutch plates:
L = 2 mm (0.0784 in.) for 11”/11” clutches
mod. JX60, JX70, JX80 and JX90
= 0.5 mm (0.0197 in.) for 12”/12” clutch
mod. JX95
Lowering on the flywheel;
P = 4.20 * 4.30 mm (0.1653 * 0.1693 in.)
for 11”/11” clutch
mod. JX60, JX70, JX80 and JX90
= 4.30 * 4.40 mm (0.1693 * 0.1732 in.)
for 12”/12” clutch
mod. JX95 The dimension the spring
must have to restore the original load.
- check that the value obtained (D) is greater than
or equal to the measurement made on the clutch
to overhaul and that, in order to be able to restore
it, the distance (C, fig. 34 and 36) of the housing
must not decrease under the stated value. If this
is not so, replace one or both o f the pressure
plates.
For 11”/11” clutches, check that the distance (E) is

greater than the value given on page 18 fig. 34 and
restore it if necessary.
If required, pass the friction surface over the engine
flywheel, remembering to restore the external
lowering o f the flywheel on completing this process.
Refit the parts of the clutch using the specific tools of
outfit 293650 and taking care to:
- position the Belleville spring (1) correctly on the
main clutch pressure plate (3), making the
centring dowels (2) correspond with the
notches (4);
- adjust the clutch as directed below.
Note - When reassembling, tighten the six bolts

fastening the flexible tabs driving the main and PTO
clutch pressure plates to the supporting housing to
a torque of 1.5 Nm (2.0337 ft lb).
33
6-62720 - 09 - 2006
MINIMUM PERMISSIBLE DIMENSIONS

AFTER REFACING PARTS SUBJECT TO
WEAR FOR VALEO CLUTCHES
11”/11” dual clutches

If it is n e c e s s a ry to re fa c e th e fric tio n s u rfa c e on th e
fly w h e e l, b e a r in m ind th a t th e m a x im u m a m o u n t th a t
can be re m o ve d in re la tio n to th e n o m in a l th ic k n e s s
is 1 m m (0 .0 3 9 4 in.).
O n c e te rm in a te d , m o re o v e r, th e e x te rn a l lo w e rin g
w ill n ee d to be re s to re d to 2 m m (0 .0 7 8 4 in.)
(se e fig. 34).
- 1 1 ”/ 1 1 ” d u a l clu tc h
m od. J X 6 0 , J X 7 0 , J X 8 0 , J X 9 0
A. > 1 2 .5 0 m m (0.4921 in.)
B. > 2 0 .0 0 m m (0 .7 8 7 4 in.)
C. > 1 8 .0 0 m m (0 .7 0 8 7 in.)
D. > 1 2 .5 0 m m (0.4921 in.)
E. > 2 .5 0 m m (0 .0 9 8 4 in.)
1. Engine flywheel.
2. PTO clutch pressure plate.
3. Main transmission clutch pressure plate
4. Supporting housing. 34
12”/12” dual clutches

If it is n e c e s s a ry to re fa c e th e fric tio n s u rfa c e on th e
fly w h e e l, b e a r in m ind th a t th e m a x im u m a m o u n t th a t
can be re m o ve d in re la tio n to th e n o m in a l th ic k n e s s
is 1 m m (0 .0 3 9 4 in.).
O n c e te rm in a te d , th e e x te rn a l re fa c in g w ill nee d to
be r e - s e t to 0 .5 m m (0 .0 1 9 7 in.), as s h o w n in fig
ure 35 and 36.
A. = 352 E 8 mm (1 3 .8 5 8 2 in.)
B. = 313 mm (1 2 .3 2 2 8 in.)
C. = 73.5 mm (2 .8 9 3 7 in.) 35
- 1 2 ”/ 1 2 ” d u a l c lu tc h
m od. JX 9 5
A. > 1 5 .5 0 m m (0 .6 1 0 2 in.)
B. > 2 1 .5 0 m m (0 .8 4 6 4 in.)
C. > 2 0 .5 0 m m (0.4921 in.)
D. > 1 2 .5 0 m m (0.8071 in.)
1. Engine flywheel.
2. PTO clutch pressure plate.
3. Main transmission clutch pressure plate.
4. Supporting housing. 36
6-62720 - 09 - 2006
ADJUSTING THE VALEO CLUTCH

To adjust the clutch correctly it is necessary for the
release levers to be coplanar and set at the distances
(D and D-i, page 4) in relation to the bearing surface
on the engine flywheel.
NOTE: For the 12”/1 2 ” clutches the distance D1 is

reduced by 9 m m (0.3543 in.) (137 - 9 = 128 mm
(5.3937 - 0.3543 =5.0394 in.), see page 15.),
lowering distance o f the point o f contact with the
thrust bearing o f the PTO release levers so as to use
the gauge 293731 where the difference between the
release levers is 25 mm (0.9842 in.).
The adjustment can be made indistinctly with the

clutch on the bench or fitted on the engine flywheel.
1. Adjustm ent with clutch on bench.

Set the clutch on the plate of the universal outfit
293650 and lock it using the parts as described
above for disassembly.
Fit the gauge (C) and lock it with the handwheel (L)
for the universal outfit 293650.
Screw in or unscrew the adjuster screws (2) of the

release levers for the main clutch (1) to obtain the
clearance (V!) between the ends of the gauge pins
(C) and the main clutch release levers. Then lock the
screws with the nuts (3).
C. Gauge.
L. Handwheel 293739.
V 1 = 0.1 m m (0.0039 in.) Clearance to obtain between
the ends of the gauge pins (C) and release levers (1)
for 11711” clutch (mod. JX60, JX70, JX80, JX90) or:
= 0.1 m m (0.0039 in.) for 12712” clutch (mod. JX95).
1. Release levers.
2. Hex wrench.
3. Adjuster screw and locknut. 37
Screw in or unscrew the nuts (2) for the adjuster tie

rods of the release levers for the PTO clutch (1) to
obtain the clearance (V2) between the end of each
release lever and the face of the gauge (C).
C. Gauge.
L. Handwheel 293739.
V 2 = 0.1 m m (0.0039 in.) Clearance to obtain between
the gauge face (C) and release levers (1) for 11711”
clutch ( mod. JX60, JX70, JX80, JX90 ) or:
0.1 m m (0.0039 in.) for 12 ”/ 12 ” clutch ( mod. JX95).
1. Release levers.
2. Adjuster nut. 38
6-62720 - 09 - 2006
After adjusting the clutch lever, remove the hand

wheel (L, page 14) for the universal outfit 293650. Fit
the press 380000458 (P) on the plate of the outfit, ad
just the length of the screws (1) so they are coplanar
and rest on the release levers (3) of the PTO clutch
and use the press lever (P), as shown in the figure,
checking the PTO clutch gets released.
Then rest the screws (2) on the main clutch release
levers (4) and check that this clutch gets released.
39
1. Adjustm ent with clutch fitted on engine fly

wheel
Insert the pin of the adjustment kit (pin T-i with gauge
T2) 380000612 (11”/11”, mod. JX60, JX70, JX80 and
JX90) or 380000292 (Ti, for 12”/12” clutch, mod.
JX95) into the clutch driven disc shaft seats, making
sure the end makes contact with the bearing (10,
page 4) and press the relevant gauge against it
380000612 (T2 for 117 11” clutch, mod. JX60, JX70,
JX80 and JX90) or 380000293 (T2 for 127 12” clutch,
mod. JX95).
40
Then proceed as follows:
- screw in or unscrew the main clutch release lever

adjuster screws so as to create a clearance be
tween the end of the pins of the gauge (1) and the
main clutch release levers of:
0.1 mm (0.0039 in.) for 117 11” clutch
mod. JX60, JX70, JX80, JX90
8.1 mm (0.3189 in.) for 12 7 12” clutch
mod. JX95 41
6-62720 - 09 - 2006
- screw in or unscrew the PTO clutch release lever

adjuster screws so as to create a clearance be
tween the end of the gauge face (1) and the PTO
clutch release levers (2) of:
0.1 mm (0.0039 in.) for 11”/11” clutch
mod. JX60, JX70, JX80, JX90
8.1 mm (0.3189 in.) for 12”/12” clutch
mod. JX95
42
ADJUSTMENT OF THE MAIN CLUTCH
CONTROL LINKAGE (Op. 18.100.40)
Check that pedal free travel before clutch release is
approximately 40 mm . When free travel is down to
25 mm , adjust clutch as follows:
43
- Back off locknut (1) and rotate sleeve (2) counter

clockwise.
- Tighten locknut (1) ;
- Ensure that pedal free travel is 25 mm (0.9842in.).
44
PTO CLUTCH LINKAGE ADJUSTMENT
The only clutch adjustment required is to check and, if

necessary, adjust the clutch pedal free travel. This is the
amount of pedal movement from fully released position
(B) to the point where resistance is first encountered.
The clutch free travel (C, fig. 46) must be 4.5 mm
(0.1772 in.). When this distance is down to 2.5 mm
(0.0984 in.), adjust the clutch as follows:
- Move the PTO clutch lever (A) to position (B) (fully
lowered).
45
6-62720 - 09 - 2006
- Loosen the locknut (1) and remove the split pin (2).
- Turn the sleeve (3) to lengthen or shorten the opera

ting rod, as required.
- Lock the split pin (2) so as to restore the travel with

no load to 4.5 mm (0.1772 in.) then tighten the lock-
nut (1).
46
6-62720 - 09 - 2006
SECTION 21 - TRANSMISSIONS - CHAPTER 1 1
SECTION 21 - TRANSMISSIONS
Chapter 1 - Mechanical Transmission ( 1 2 x4 )
CONTENTS
21 000 M a in d a t a .......................................................................................................................................................... 1
T ig h te n in g to rq u e s ....................................................................................................................................... 2
T ools ................................................................................................................................................................... 3
S e c tio n v i e w s ................................................................................................................................................. 3& 5
D e s c rip tio n and o p e ra tio n ......................................................................................................................... 8
F a u lt d ia g n o s is .............................................................................................................................................. 8
2 1110 R e m o v a l - R e fittin g ................................................................................................................ s e e s e c t 27
21 000 - MAIN DATA - TIGHTENING TORQUES - SECTIONS - TOOL -

DESCRIPTION AND OPERATION - FAULT DIAGNOSIS
G e a r b o x .................................................................................................. 4 -s p e e d , c o n s ta n t-m e s h w ith s y n c h ro

n is e rs on all g e a rs
G e a rin g t y p e ............................................................................................ h e lic a l g e a rs
Range g e a r ............................................................................................ O rd in a ry g e a r tra in w ith 3 fo rw a rd

ra n g e s and 1 re v e rs e ra n g e th o s e g iv
ing a to ta l o f 12 fo rw a rd and 4 re ve rse
speeds
- G e a rin g t y p e ..................................................................................... s p u r g e a rs
- R e d u c tio n ra tio s :
• S lo w ................................................................................................ 23x17
— r-T T - = 1 :(5 .4 9 )
43x50 v ’
• N o rm a l ............................................................................................ 23x27
-rz -rr = 1 :(2 .3 5 )
43x34
• F a s t .................................................................................................. 1
G earbox and range gear c o n t r o ls .............................................. In d e p e n d e n t, han d o p e ra te d le v e rs lo

c a te d on rig h t-h a n d s id e o f o p e ra to r
T h ic k n e s s o f g e a rb o x d riv in g s h a ft a d ju s tm e n t ring mm 3 .0 0 - 3 .2 5 - 3 .5 0 - 3 .7 5 - 4 .0 0
(5, pa g e 5) .............................................................................................. (in.) ( 0 .1 1 8 1 - 0 .1 2 8 - 0 .1 3 7 8 -0 .1 4 7 6 -0 .1 5 7 5 )
In sid e d ia m e te r o f g e a rb o x d riv e n g e a rs .................................. mm 5 0 .0 5 0 - 5 0 .0 7 5
(in.) (1 .9 7 0 5 - 1 .9 7 1 5 )
O u ts id e d ia m e te r o f b u s h in g s (17, p a g e 5 ) ................................ mm 4 9 .9 2 5 - 4 9 .9 5 0
(in.) (1 .9 6 5 5 - 1 .9 6 6 5 )
C le a ra n c e b e tw e e n g e a rs and b u s h in g s ..................................... mm 0 .1 0 0 - 0 .1 5 0
(in.) (0 .0 0 3 9 - 0 .0 0 5 9 )
D ia m e te r o f g e a rb o x d riv e n s h a ft (19, p a g e 5 ) ......................... mm 3 9 .1 7 5 - 39.191
(in.) (1 .5 4 2 3 - 1 .5 4 2 9 )
In sid e d ia m e te r o f b u s h in g s (17, p a g e 5) .................................. mm 3 9 .2 0 0 - 3 9 .2 3 9
(in.) (1 .5 4 3 3 - 1 .5 4 4 8 )
C le a ra n c e b e tw e e n s h a ft and b u s h in g s ..................................... mm 0 .0 0 9 - 0 .0 6 4
(in.) (0 .0 0 0 4 - 0 .0 0 2 5 )
(continued overleaf)
6-62720 - 09 - 2006
2 SECTION 21 - TRANSMISSIONS - CHAPTER 1
TRANSMISSION AND RANGE GEAR MAIN DATA

(continued)
D ia m e te r o f p o w e r ta k e o ff (P T O ) c lu tc h s h a ft (4, p a g e 5 ) ........... mm 2 4 .9 7 9 - 2 5 .0 0 0
(in.) (0 .9 8 3 4 - 0 .9 8 4 3 )
In sid e d ia m e te r o f fitte d b u s h in g (1, p a g e 5 ) ....................................... mm 2 5 .0 4 0 - 2 5 .0 9 2 (1)

(in.) (0 .9 8 5 8 - 0 .9 8 7 9 )
C le a ra n c e b e tw e e n P T O c lu tc h s h a ft and re la tiv e b u sh in g mm 0 .0 4 0 - 0.113

(in.) (0 .0 0 1 6 - 0 .0 0 4 4 )
In te rfe re n c e fit b e tw e e n b u s h in g on d riv in g s h a f t .............................. mm 0 .0 3 7 - 0.091

(in.) (0 .0 0 1 5 - 0 .0 0 3 6 )
S p rin g s (16, pa g e 7) fo r d e te n t b a lls on g e a rb o x and ra n g e g e a r

c o n tro l ro d s :
- S p rin g fre e le n g th ..................................................................................... mm 30

(in.) (1 .1 8 1 1 )
- L e n g th o f sp rin g u n d e rlo a d o f 5 0 - 5 6 N (1 1 .3 1 4 8 -1 2 .5 0 5 9 lb) mm 2 5 .5

(in.) (1 .0 0 3 9 )
G e a rb o x and ra n g e g e a r c o n tro l le v e r re ta in in g s p rin g s :
- S p rin g fre e le n g th ..................................................................................... mm 75

(in.) (2 .9 5 2 8 )
- L e n g th o f sp rin g u n d e rlo a d o f 9 4 -1 0 4 N (2 1 .1 7 4 0 -2 3 .3 7 9 6 lb) mm 42

(in.) (1 .6 5 3 5 )
(1) Measurement to obtain after fitting without reaming.
TORQUE VALUES
Torque s e ttin g s
PARTS Thread
Nm ft lb
R e ta in in g b o lts fo r u p p e r c o v e r o f re a r tra n s m is s io n / g e a rb o x (C-0 M 1 0 x 1 .2 5 59 4 3 .5 1 6 2
B o lts fo r s e c u rin g lift to re a r tra n s m is s io n b o x (C 2) .............................. M 1 2 x 1 .2 5 98 72.2811
B o lts fo r s e c u rin g P T O b o x to tra n s m is s io n / g e a rb o x (C 3) .............. M 1 6 x 1 .5 221 1 6 3 .0 0 1 2
B o lts fo r s e c u rin g fle x io n b a r to tra n s m is s io n / g e a rb o x c a s e (C 4) M 1 6 x 1 .5 221 1 6 3 .0 0 1 2
N u ts fo r s tu d b o lt s e c u rin g fin a l d riv e to tra n s m is s io n / g e a rb o x (C 5) . M 1 2 x 1 .2 5 98 72.2811
N u ts fo r s e c u rin g s te e l p la te d is c to w h e e l d riv e h u b (C 6) ..................... M 1 8 x 1 .5 255 1 8 8 .0 7 8 3
N u ts fo r b o lts s e c u rin g s te e l p la te d is c to d riv e w h e e l rim (C 7) M 1 6 x 1 .5 245 1 8 0 .7 0 2 7
R ing b e ve l g e a r re ta in in g b o lts (C 3) .............................................................. M 1 2 x 1 .2 5 123 90.7201
B e ve l g e a r p a ir s u p p o rt re ta in in g b o lts (C g) .................................................... M 1 0 x 1 .2 5 59 4 3 .5 1 6 2
6-62720 - 09 - 2006
MAIN DATA - GEARBO X AND RANGE GEAR
1
TOOLS L ist o f s p e c ia l to o ls re q u ire d fo r th e v a rio u s
o p e ra tio n s d e s c rib e d in th is S e c tio n :
W arnin g -- T h e o p e ra tio n s d e s c rib e d in th is S e c tio n 380000236 T ra c to r d is m a n tlin g tro lle y.

can o n ly be c a rrie d o u t u sin g th e ESSENTIAL to o ls
m a rke d on th e rig h t s id e w ith an (X ) . 380000227 C lu tc h c a s in g liftin g hook.
H o w e ve r, fo r g re a te r s a fe ty and to o b ta in th e b e st 380000301 R o ta tin g o v e rh a u l s ta n d .
re s u lts w h ile s a v in g tim e and e ffo rt, it is
re c o m m e n d e d th a t th e s e e s s e n tia l to o ls a re used 380000271 F ro n t b ra c k e t (w ith 380000301 ).
to g e th e r w ith th e s p e c ia l to o ls liste d h e re as w e ll as
380000272 R e a r b ra c k e t (w ith 380000301 ).
c e rta in to o ls w h ic h a re to be m a d e fo llo w in g th e
s e c tio n a l d ra w in g s g iv e n in th is m a n u a l. X 380000838 A d a p to r fo r re m o v a l o f re v e rs e g e a r
pin (w ith 380000549 ).
6-62720 - 09 - 2006
D rift to be m a d e fo r re m o v a l o f g e a rb o x d riv in g s h a ft
(to o l to be s ta m p e d no. 50006 -- m e a s u re m e n t in
m m ).
M a ke in m a te ria l U N I C 40.
Tool to be m a d e fo r a d ju s tm e n t o f g e a rb o x d riv in g
s h a ft b e a rin g s (to o l be s ta m p e d no. 50007 -
m e a s u re m e n t in m m ).
M a ke in m a te ria l A q 45.
Tool to be m a d e fo r re m o v a l o f re a r b e a rin g o f ra n g e g e a r d riv in g s h a ft and th e d riv in g g e a r fo r th e slo w

s p e e d s (to o l to be s ta m p e d no. 50028 -- M e a s u re m e n ts in m m ).
M a k e in U N I C 40.
Note -- M a k e tw o p a rts fro m th e to o l s h o w n a t F ig u re 4, u p p e rm o s t o n e .
6-62720 - 09 - 2006
©©© ©
26218
L o n g itu d in a l c u ta w a y s e c tio n th ro u g h g e a rb o x and range gear.

1. P o w e r ta k e --o ff (P T O ) s h a ft s u p p o rt b u sh in g . 11. R e ta in in g h a lf-rin g s .
2. S e al. 12. D riv e n g e a r fo r re v e rs e s p e e d s .
3. G e a rb o x d riv in g s h a ft. 13. D riv e n g e a r fo r lo w s p e e d s .
4. P T O sh a ft. 14. S e le c to r s le e v e fo r high and lo w s p e e d s .
5. D rivin g s h a ft a d ju s tm e n t ring. 15. C irclip .
6. R a n g e g e a r d riv in g s h a ft. 16. S y n c h ro n is e r fo r 1st and 2 nd s p e e d s .
7. C o n tro l g e a r fo r re v e rs e and m id d le s p e e d s . 17. S u p p o rt b u s h in g s fo r g e a rb o x d riv e n g e a rs
8. U p p e r cover. 18. S y n c h ro n is e r fo r 3 rd and 4 th s p e e d s .
9. D rivin g g e a r fo r m id d le s p e e d s . 19. G e a rb o x d riv e n s h a ft.
10. B e ve l p inion s h a ft.
Note - O n a s s e m b ly a p p ly s e a la n t to s u rfa c e s X fo llo w in g th e in d ic a tio n s g iv e n on p a g e 6 in th is S e c tio n .
6-62720 - 09 - 2006
S ealing c o m p o u n d a p p lic a tio n dia g ra m fo r m a tin g su rfa ce s betw een e n g in e , c lu tc h ca sin g and rear
tra n s m is s io n -g e a rb o x.
T h e ty p e s o f s e a lin g c o m p o u n d to use a re in d ic a te d on p a g e 1, S e c t. 00.
6-62 7 2 0 - 09 - 2 0 06
C ro ss -s e c tio n th ro u g h g e a rb o x and range gear
1. R a n g e g e a r c o n tro l re la y rod. 14. C irclip .

2. G e a rb o x c o n tro l re la y rod. 15. U p p e r c o v e r o f tra n s m is s io n / g e a rb o x .
3. L o w and high s p e e d s s e le c to r rod. 16. S p rin g .
4. N o rm a l and re v e rs e s p e e d s s e le c to r rod. 17. D e te n t ball.
5. 3 rd and 4th s p e e d s e le c to r rod. 18. S p e e d c o n tro l s a fe ty paw l.
6. 1st and 2 nd s p e e d s e le c to r rod. 19. P lug.
7. R a n g e g e a r d riv in g s h a ft. 20. S p e e d c o n tro l s a fe ty paw l.
8. In te rm e d ia te g e a r fo r re v e rs e s p e e d s . 21. R a n g e c o n tro l s a fe ty paw l.
9. C o n tro l g e a r fo r n o rm a l and re v e rs e s p e e d s . 22. P lug.
10 . D rivin g g e a r fo r n o rm a l s p e e d s . 23. S e le c to r rod fo r lo w and high s p e e d s .
11. J o u rn a l o f in te rm e d ia te g e a r (8). 24. S e le c to r rod fo r m id d le and re v e rs e s p e e d s .
12. J o u rn a l b o lt (11). 25. 3 rd and 4 th s p e e d s e le c to r rod.
13. B e a rin g s. 26. 1st and 2 nd s p e e d s e le c to r rod.
Note - B e fo r e p lu g s (19 and 2 2 ) a re b o lte d in, th e y m u s t be c o v e re d w ith o n e o f th e s e a la n ts liste d on p a g e 1,

S e ct. 00.
6-62720 - 09 - 2006
DESCRIPTION AND OPERATION
4 -s p e e d g e a rb o x w ith c o n s ta n t-m e s h h e lic a l g e a rs T h e ra n g e g e a r p ro v id e s 3 fo rw a rd ra n g e s and 1 re

c o n tro lle d by tw o s y n c h ro n is e rs . v e rs e ra n g e .
T h e ra n g e g e a r has c a s c a d e -ty p e c o n s ta n t-m e s h T h e g e a rb o x and th e ra n g e g e a rs a re c o n tro lle d by
s p u r g e a rs , e x c lu d in g re v e rs e . tw o in d e p e n d e n t le v e rs lo c a te d on th e rig h t-h a n d
T h e d riv e n g e a rs o f th e ra n g e g e a r a re k e ye d d ire c tly s id e o f th e o p e ra to r.
o n to th e b e ve l p in io n s h a ft.
G EARBO X AND RANGE GEAR TROUBLESHOOTING
P rob lem s P o ssib le causes Rem edies
S p o n ta n e o u s d is e n g a g e m e n t o f 1. L e v e rs and re la y lin k a g e s A d ju s t c o rre ctly.

g e a rb o x and ra n g e gear. in c o rre c tly a d ju s te d .
2. S e le c to r rod re ta in in g s p rin g s R e p la c e th e s p rin g s .

d e fe c tiv e .
3. D e fe c tiv e te e th on s y n c h ro R e m o v e th e tra n s m is s io n /g e a rb o x
n is e r o r e n g a g e m e n t s le e v e . and re p la c e th e s y n c h ro n is e rs o r th e
e n g a g e m e n t s le e v e s .
4. In c o m p le te engagem ent E lim in a te th e c a u s e and re s to re full

tra v e l. e n g a g e m e n t tra v e l.
D iffic u lty in e n g a g in g th e g e a rb o x 1. C o n tro l le v e rs and lin k a g e s A d ju s t c o rre ctly.

and ra n g e gear. in c o rre c tly a d ju s te d .
2. S tiffn e s s and / o r p a rtia l C h e c k p iv o t p o in ts and lu b ric a te .

s e iz u re o f c o n tro l le v e rs and
lin ka g e s.
3. M a in c lu tc h d ra g . S e e p a g e 5, S e c t. 18.
4. S y n c h ro n is e rs or engage R e m o v e th e tra n s m is s io n / g e a rb o x
m e n t s le e v e s d e fe c tiv e . and re p la c e th e s y n c h ro n is e rs o r
e n g a g e m e n t s le e v e s .
5. In te rn a l c o n tro ls d o n o t slid e P e rfo rm th e c h e c k s and o v e rh a u l fo r

fre e ly : ro d s, fo rk s and n e e d e d p a rts.
sle e v e s .
G e a rb o x o r ra n g e g e a r u n d u ly 1. In te rn a l c o m p o n e n t/s w o rn o r R e m o v e th e tra n s m is s io n / g e a rb o x
noisy. d e fe c tiv e . and re p la c e th e w o rn / d e fe c tiv e
pa rts.
6-62720 - 09 - 2006
Chapter 2 - Reverser
CONTENTS
21 000 Main d a t a ......................................................................................................................................... 1

Tools ............................................................................................................................................... 3
Section view s................................................................................................................................. 3
Description and operation ........................................................................................................... 5
Fault diagnosis ............................................................................................................................. 5
21 110 Removal-Refitting........................................................................................................................... 6
21 000 - MAIN DATA - TIGHTENING TORQUES - SECTIONS - TOOLS - DESCRIPTION AND

OPERATION - FAULT DIAGNOSIS
SYNCHRONISER REVERSER MAIN DATA
T y p e ....................................................................................................... Mechanical type spur gear unit,

located between the main clutch
and the gearbox. Comprises 1
driving gear, 1 intermediate gear
and
1 idle gear.
Control................................................................................................... Hand lever located on left-hand
side of the operator
GEARBOX MAIN DATA
G e a r b o x ............................................................................................... 4 speed, constant-mesh, with

synchronisers on all gears
Gearing ty p e ......................................................................................... helical
Reduction u n i t ................................................................................... Ordinary gear train with 3 ranges

providing a total of 12 gears
Gearing ty p e ......................................................................................... spur
Gearbox and reduction unit controls .............................................. Independent, with two hand levers
located on right-hand side of the
operator
For other main data see chapter 1.
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TORQUE VALUES
Torque Settings
PARTS Thread
Nm ft lb
Bolt or nut securing clutch / reverser casing to engine (C-0 M 12 x 1.25 98 72.2811
Sleeve cover retaining nuts (C2) ...................................................... M 8 x 1.25 17 12.5386
Reverser driven shaft cover retaining bolts (C3) ............................ M 8 x 1.25 28 20.6517
Reverser driven shaft plate retaining bolts (C4) ............................ M 10 x 1.25 64 47.2040
Bolts securing clutch / reverser housing to gearbox / rear

transmission (C5) ................................................................................. M 12 x 1.25 98 72.2811
C 98 Nm
C3 28 Nm
C4 6 Nm
C 5 98 Nm
TRE0558A
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TOOLS List of special tools required for the various

operations described in this Section :
Warning - The operations described in this Section
can only be carried out using the ESSENTIAL tools 380000236 Tractor dismantling trolley.
marked with an (X). 380000227 Clutch casing lifting hook.
However, for greater safety and to obtain the best
results while saving time and effort, it is 380000301 Rotating overhaul stand.
recommended that these essential tools are used 380000271 Front support bracket (with
together with the special tools listed here as well as
380000301).
certain tools which are to be made following the
sectional drawings given in this manual. 380000272 Rear support bracket (with
380000301).
Longitudinal cutaway section of synchroniser reverser
1 . Synchroniser reverser control shaft. 6. Reverser control synchroniser.

2 . Seal. 7. Seal.
3. Roller bearing. 8. Synchroniser reverser driven gear.
4. Synchroniser reverser driving gear. 9. Journal for driven gear (8).
5. Roller bearing. 10 . Seal.
Note - On assembly apply jointing compound to surfaces X as indicated on page 6 , chapter 1.
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Synchroniser reverser sectional views

1 . Synchroniser reverser selector fork. 11.
2 . Reverser synchroniser. 12 .
3. External reverser control lever. 13.
4. Seal. 14.
5. Circlip. 15.
6. Thrust washer. 16.
7. Synchroniser reverser idle gear. 17.

18.
8. Roller bearing.
19.
9. Thrust washer.
covered in one of the sealants listed on page 1,
10 . Seal. Sect. 00).
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The synchroniser reverser is a mechanical device fected by means of a synchroniser located in the
which makes it possible to obtain 12 forward and 12 group of gears.
reverse gears. It is controlled by a specific lever
The synchroniser reverser is installed inside the
located on the platform to the left of the operator.
clutch casing between the clutch and the gearbox.
The synchroniser reverser is comprised of a group
of three spur gears : driving reverser gear, interme It is lubricated by the oil in the rear transmission /
diate gear and driven reverser gear. Selection is ef gearbox.
SYNCHRONISER REVERSER TROUBLESHOOTING
Problems Possible causes Remedies
Spontaneous disengagement of 2. Incorrect adjustment of Adjust correctly.

the synchroniser reverser. external levers and linkages.
3. Synchroniser engagement Remove the clutch casing and

teeth damaged. replace the synchroniser.
4. Engagement travel Eliminate the cause and restore full

incomplete. engagement travel.
Difficulty in engaging the reverser. 1. Incorrect adjustment of Adjust correctly.

external levers and linkages.
2. Stiffness and / or partial Check pivot points and lubricate.

seizure of external levers and
linkages.
3. Dragging of main clutch. See page 5, Sect. 18.
4. Synchroniser damaged. Remove the clutch casing and

replace the synchroniser.
5. Internal controls do not slide Perform the checks and overhaul for
freely: rods, forks and needed parts.
sleeves.
Synchroniser reverser unduly 1. Worn or damaged internal Remove the clutch casing and
noisy. part/s. replace damaged part/s.
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CLUTCH/REVERSER CASING
Replacement (Op. 21 110 85)
----------- A WARNING ^ ------------

Handle all parts with great care.
Never insert fingers or hands between one piece and
another. Wear suitable safety clothing, i.e., safety
goggles, gloves and shoes.
1. Fix the clutch / reverser casing (1) to stand

380000301 (2) using the two brackets
380000271 and 380000272.
11
2. Withdraw the spring pin and recover the link

lever ( 1 ) and the internal lever (2).
3. Unscrew the retaining bolt (1) and recover the

detent ball and spring.
13
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4. Remove the circlip (1) and take out : bearing,

thrust washers, synchroniser assembly together
with the selector fork and its rod, the reverser
driven gear (2) complete with roller bearings and
spacer.
14
5. Remove the reverser driving gear (1) complete
with roller bearings.
15
6. Remove the circlip (1) securing the reverser

driving shaft.
16
7. Working from the front of the clutch / reverser

casing with an aluminium drift (2), drive out the
reverser driving shaft ( 1 ) and remove it from the
rear of the casing.
17
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8. Detach the retaining springs and withdraw the

sliding sleeves ( 1 ).
18
9. Unscrew the retaining bolts and remove the

sleeve cover / support ( 1 ).
19
10. Unscrew the two securing bolts (1) of the sliding

sleeve control forks (2).
20
11. Withdraw the external clutch control levers (1)
and remove the forks (2).
21
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12. Relieve the staking and unscrew bolt (1)

securing the stop plate for the journal of the
reverser driven shaft (2) and the intermediate
gear journal, removing the latter from the rear of
the casing.
13. Refitting of the synchroniser reverser according

to the following instructions:
— Refer to the illustrations on pages 3 and 4 to
check the correct orientation of the various parts.
— Refer to the torque settings on page 2.
— Install the intermediate gear journal complete 25004
with the various associated parts, and the journal 22

of the reverser driven gear and secure with the
relative stop plate and bolt.
— Fit the sliding sleeve control forks on the relative
clutch control levers and fix the previous to the
latter.
— Fit the sliding sleeve cover and its support.
— Fit the sliding sleeve assembly to the relative
support and secure with the springs.
— Insert the reverser driving shaft from the rear of
the casing and fix it to the clutch / reverser casing
with the circlip.
— Position the reverser driving gear complete with
bearings on the driven shaft.
— Fit the reverser driving gear complete with the
bearings and spacers.
— Fit the synchroniser assembly complete with
control forks, rod, thrust washers and bearing,
and fix in position with the relative circlip.
— Fit the detent ball, spring, and bolt in the locked
position after covering the bolt using one of the
sealants listed on page 1, Sect. 00.
— Position the internal lever and link lever and fix
with the relative spring pin.
— Remove the clutch / reverser casing from the
stand 380000301.
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Chapter 3 - Reverser and creeper unit
CONTENTS
21 000 M a in d a t a ............................................................................................................................................................ 1
T ools ................................................................................................................................................................... 3
S e c tio n v i e w s ................................................................................................................................................... 4
F a u lt d ia g n o s is .............................................................................................................................................. 6
21 110 R e m o v a l- R e fittin g ........................................................................................................................................... 7
21 000 - MAIN DATA - TIGHTENING TORQUES - SECTION VIEWS - TOOLS - DESCRIPTION AND
OPERATION - FAULT DIAGNOSIS
SYNCHRONISER REVERSER-CREEPER UNIT MAIN DATA 1.
T y p e ..................................................................................................................... M e c h a n ic a l, s p u r g e a rs , lo ca te d
b e tw e e n e n g in e and g e a rb o x .
C o m p ris in g 1 d riv in g g ear, 1
in te rm e d ia te g e a r and 1 idle
gear.
C o n t r o l................................................................................................................ b y han d le v e r lo c a te d on
le ft-h a n d s id e o f o p e ra to r
CREEPER UNIT MAIN DATA
T y p e ..................................................................................................................... O rd in a ry g e a r tra in w ith s p u r

g e a rs , lo c a te d b e tw e e n m ain
c lu tc h and g e a rb o x , in s e rie s
w ith th e re ve rse r.
P ro v id e s 2 0 fo rw a rd s p e e d s and
12 re v e rs e s p e e d s
R e d u c tio n r a t i o ................................................................................................ 1 8 x2 6
----------- = 1 5 524
55x47
C o n t r o l................................................................................................................ b y han d le v e r lo c a te d on
le ft-h a n d s id e o f o p e ra to r
G EARBO X MAIN DATA
G e a r b o x ............................................................................................... 4 -s p e e d c o n s ta n t m e sh ,
s y n c h ro n is e d on all g e a rs
G e a rin g t y p e ..................................................................................................... h e lica l
Range g e a r ......................................................................................... O rd in a ry g e a r tra in w ith th re e

ra n g e s fo r a to ta l o f 12 s p e e d s
G e a rin g t y p e ..................................................................................................... s p u r g e a rs
G earbox and range gear c o n t r o ls ................................................ In d e p e n d e n t, by tw o han d le ve rs
F o r fu rth e r d a ta s e e c h a p te r 1.
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TORQUE VALUES 2.
Torque S e ttin g s
PARTS Thread
Nm ft lb
B o lt o r n u t s e c u rin g c lu tc h c a s in g - re v e rs e r and c re e p e r u n it to th e
e n g in e ( C - i ) ....................................................................................................... M 1 2 x 1 .2 5 98 72.2811
S le e v e c o v e r n u ts (C 2) ................................................................................ M 8 x 1 .2 5 17 1 2 .5 3 8 5
S y n c h ro n is e r re v e rs e r - c re e p e r u n it d riv e n s h a ft c o v e r n u ts (C 3) M 8 x 1 .2 5 17 1 2 .5 3 8 5
G e a rb o x d riv in g and d riv e n s h a ft b e a rin g s c o v e r s c re w s (C 4) .. M 8 x 1 .2 5 28 2 0 .6 5 1 7
B o lt s e c u rin g c lu tc h c a s in g - re v e rs e and c re e p e r u n it to th e re a r
tra n s m is s io n -g e a rb o x ................................................................................ M 1 2 x 1 .2 5 98 7 2 .2 8 1 117
TRE0561A
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TOOLS 3. L ist o f s p e c ia l to o ls re q u ire d fo r th e v a rio u s

o p e ra tio n s in th is S e c tio n :
W arnin g -- T h e o p e ra tio n s d e s c rib e d in th is S e c tio n
ca n o n ly be c a rrie d o u t u sin g th e ESSENTIAL to o ls 380000236 T ra c to r d is m a n tlin g s ta n d .
m a rke d w ith an (X ) .
H o w e ve r, fo r g re a te r s a fe ty and to o b ta in th e b e st 380000227 C lu tc h c a s in g liftin g hook.
re s u lts w h ile s a v in g tim e and e ffo rt, it is
re c o m m e n d e d th a t th e s e e s s e n tia l to o ls a re used 380000301 R o ta tin g o v e rh a u l s ta n d .
to g e th e r w ith th e s p e c ia l to o ls liste d h e re as w e ll as
c e rta in to o ls w h ic h a re to be m a d e fo llo w in g s e c tio n a l 380000271 F ro n t b ra c k e t (w ith 380000301 )
d ra w in g s g ive n in th is m a n u a l.
380000272 R e a r b ra c k e t (w ith 380000301 ).
Tool fo r g e a rb o x d riv in g s h a ft s e a l (m a rk to o l 50137 )

(D im e n s io n s in m m )
m a k e to o l in U N I C 40.
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L o n g itu d in a l s e c tio n th ro u g h re ve rs e r-c re e p e r u n it
1. R e v e rs e r and c re e p e r u n it c o n tro l s h a ft. 6. G e a rb o x d riv in g s h a ft c o n tro l gear.
2. S e al. 7. C re e p e r u n it d riv e n gear.
3. C irclip . 8. T h ru s t w a s h e r.
4. C re e p e r u n it c o n tro l gear. 9. R e v e rs e r d riv e n s h a ft.
5. R e v e rs e r-c re e p e r u n it s y n c h ro n is e r. 10. S eal.
Note - O n a s s e m b ly a p p ly s e a lin g c o m p o u n d to th e s u rfa c e s X fo llo w in g th e in d ic a tio n s g iv e n on p a g e 6 in

C h a p te r 1.
6-62720 - 09 - 2006
---------
X J
l: ^ --------- H
C ross s e c tio n a l v ie w s o f s y n c h ro n is e r reverser - creeper u n it
1. R e v e rs e r c o n tro l fo rk. 12. R o lle r b e a rin g .

2. D e te n t ball. 13. J o u rn a l fo r g e a r (11).
3. R e v e rs e r s y n c h ro n is e r. 14. S eal.
4. S e al. 15. R e a tin g s c re w fo r jo u rn a l (13).
5. E x te rn a l re v e rs e r c o n tro l lever.
16. F a s t s p e e d s lo c k paw l.
6. C re e p e r u n it c o n tro l fo rk.
17. R e v e rs e r and c re e p e r u n it c o n tro l rod.
7. D e te n t ball.
18. R e v e rs e r s y n c h ro n is e r.
8. E x te rn a l c re e p e r c o n tro l lever.
19. C re e p e r u n it c o n tro l gear.
9. S e al.
20. R e ta in in g s c re w fo r rod (17) (a p p ly o n e o f th e
10. C re e p e r u n it c o n tro l gear.
s e a lin g c o m p o u n d s liste d on p a g e 1, S e c t. 00 to
11. In te rm e d ia te g e a r fo r re ve rse r. th e s c re w ).
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DESCRIPTION AND OPERATION 4.
T h e re v e rs e r-c re e p e r u n it is a m e c h a n ic a l d e v ic e a nd is c o n tro lle d by a han d le v e r lo c a te d on th e

p ro v id in g th e p o s s ib ility to o b ta in 2 0 fo rw a rd s p e e d s rig h t-h a n d s id e o f th e o p e ra to r.
and 12 re v e rs e s p e e d s .
The re v e rs e r c o m p ris e s th re e s p u r g e a rs : th e
T h e c re e p e r u n it e n g a g e s o n ly in s lo w and m id d le re v e rs e r d riv in g g ear, an in te rm e d ia te g e a r and th e
ra n g e s, a m e c h a n ic a l in te rlo c k p re v e n ts c re e p e r re v e rs e r d riv e n g e a r; th e re v e rs e r is e n g a g e d by
e n g a g e m e n t in th e fa s t ra n g e s. m eans of a s y n c h ro n is e r lo c a te d in th e gear
a s se m b ly.
T h e c re e p e r u n it c o m p ris e s a g ro u p o f th re e s p u rs
g e a rs : a s lid in g c o n tro l ge a r, a s y n c h ro n is e r c o n tro l T h e re v e rs e r-c re e p e r u n it is in s ta lle d in s id e th e
g e a r and a d riv e n g e a r; th e u n it u tilis e s th e s a m e c lu tc h c a s in g b e tw e e n th e c lu tc h and th e g e a rb o x .
s y n c h ro n is e r as th e re ve rse r.
L u b ric a tio n is p ro v id e d by th e oil c o n ta in e d in th e re a r
T h e c re e p e r is in s ta lle d in s e rie s w ith th e re v e rs e r tra n s m is s io n -g e a rb o x .
SYNCHRONISER REVERSER-CREEPER UNIT TROUBLESHOOTING
P rob lem s P o ssib le causes Rem edies
S p o n ta n e o u s d is e n g a g e m e n t o f 14. E x te rn a l le v e rs and lin k a g e s A d ju s t c o rre ctly.

th e re v e rs e r-c re e p e r unit. in c o rre c tly a d ju s te d .
15. S y n c h ro n is e r te e th d a m a g e d . R e m o v e th e c lu tc h c a s in g and
re p la c e th e s y n c h ro n is e r.
16. E n g a g e m e n t tra v e l E lim in a te th e c a u s e and re s to re full

in c o m p le te . tra v e l.
D iffic u lty in e n g a g in g th e 1. E x te rn a l le v e rs and lin k a g e s A d ju s t c o rre ctly.

re v e rs e r-c re e p e r unit. in c o rre c tly a d ju s te d .
2. S tiffn e s s and / o r p a rtia l C h e c k p iv o t p o in ts and lu b ric a te .

s e iz u re o f e x te rn a l le v e rs and
lin ka g e s.
3. M a in c lu tc h d ra g . S e e p a g e 5, S e c t. 18.
4. S y n c h ro n is e r d e fe c tiv e . R e m o v e th e c lu tc h c a s in g -g e a rb o x
and re p la c e th e s y n c h ro n is e r.
5. In te rn a l c o n tro l e le m e n ts do P e rfo rm th e c h e c k s and o v e rh a u l fo r

n o t s lid e fre e ly : ro d s, fo rk s n e e d e d p a rts.
and s le e v e s .
R e v e rs e r-c re e p e r u n it u n d u ly 1. In te rn a l c o m p o n e n t/s w o rn o r R e m o v e c lu tc h c a s in g and re p la ce

noisy. d e fe c tiv e . d e fe c tiv e p a rts.
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CLUTCH CASING - SYNCHRONISER

REVERSER AND CREEPER UNIT
R eplacem ent (Op. 21 110 87) 5.

- W ARN IN G A ---------------------------------
H a n d le all p a rts w ith g re a t ca re .

N e v e r p la ce y o u r h a n d s b e tw e e n o n e p a rt and
a n o th e r. W e a r s u ita b le s a fe ty c lo th in g , i.e. s a fe ty
g o g g le s , g lo v e s and s h o e s .
To ga in a c c e s s to th e s y n c h ro n is e r re v e rs e r-c re e p e r
unit, firs t re m o v e th e c a b o r p la tfo rm fo llo w in g th e
in s tru c tio n s g ive n in S e c t. 2 7 and re m o v e th e clu tc h
c a sin g as d e s c rib e d in S e c t. 18, and th e n p ro c e e d as
fo llo w s :
1. F ix th e c a sin g to th e ro ta tin g s ta n d 380000301

using th e b ra c k e ts 380000271 a nd 380000272 .
2. R e m o v e c irc lip (1) and s lid e o u t c o n s ta n t m e sh

g e a r (2).
6
3. R e m o v e c irc lip (1) o f re v e rs e r tra n s m is s io n
d riv in g sh a ft.
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4. R e m o v e plug and re m o v e th e c o n tro l le v e r

re ta in in g pin (1).
5. R e m o v e th e re v e rs e r s y n c h ro n is e r a s s e m b ly (1)
to g e th e r w ith c o n tro l fo rk s and g e a rs .
6. W ith d ra w th e d riv e n s h a ft g e a r (1) to g e th e r w ith

th e ro lle r b e a rin g s and re m o v e th e th ru s t
w a sh e r.
10
7. R e m o v e th e c o n tro l fo rk re ta in in g s p rin g s (2) and

w ith d ra w th e c lu tc h p re s s u re p la te b e a rin g
a s s e m b ly (1).
11
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8. U n s c re w th e re ta in in g s c re w s (2) and re m o v e
th e c o n tro l fo rk s (1).
12
9. U n s c re w th e re ta in in g s c re w (15, p a g e 5) and
w ith d ra w th e re v e rs e r in te rm e d ia te gear
a s s e m b ly (1).
13
10. U n s c re w th e re ta in in g b o lts and re m o v e th e

c o v e r (1).
14
11. F ro m th e re a r o f th e c a s in g , w ith d ra w th e s h a ft
(1) c o m p le te w ith th e re la tiv e b e a rin g .
15
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c o v e r-s u p p o rt (1).
16
13. R e m o v e th e c irc lip (2) and w ith d ra w th e

d r iv e -s h a ft (1) c o m p le te w ith b e a rin g .
17
14. R e m o v e th e c irc lip (1).
18
15. R e m o v e th e d riv e s h a ft s e a l (1) u sin g a s u ita b le

im p le m e n t.
19
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16. To re fit all th e re v e rs e r and c re e p e r c o m p o n e n ts

in th e c a sin g fo llo w th e in s tru c tio n s b e lo w :
— R e fe r to th e illu s tra tio n s on p a g e s 4 and 5 fo r
th e o rie n ta tio n o f th e v a rio u s c o m p o n e n ts .
— A d h e re to th e to rq u e s e ttin g v a lu e s p re s c rib e d
on pa g e 2.
— To in sta ll th e s e a l (1, fig .19 ) fo llo w th e
in s tru c tio n s in s te p s 1 7 .- 24.
— In sta ll th e d riv e s h a ft c o m p le te w ith b e a rin g and
circlip s.
— F it th e c o v e r-s u p p o rt.
— In sta ll th e re v e rs e r and c re e p e r d riv e n g e a r
s h a ft.
— F it th e c o v e r fo r th e d riv e n g e a r s h a ft and s e c u re
w ith th e re la tiv e s c re w s .
— In sta ll th e re v e rs e r in te rm e d ia te g e a r a s s e m b ly
and s e c u re w ith th e re la tiv e scre w .
— In sta ll and fix th e c lu tc h c o n tro l fo rk s to th e
re la tiv e levers.
— In sta ll th e p re s s u re p la te b e a rin g s and hold in
p la ce w ith th e re la tiv e s p rin g s .
— In sta ll th e d riv e n g e a r c o m p le te w ith b e a rin g and
th ru s t w a sh e r.
— In sta ll th e c o m p le te s y n c h ro n is e r a s s e m b ly and
s e c u re w ith th e re la tiv e circlip .
— F it th e rod re ta in in g s c re w c o a te d w ith o n e o f th e
s e a lin g c o m p o u n d s liste d on p a g e 1, S e c t. 00.
— In sta ll th e g e a r on th e re v e rs e r d riv e n s h a ft and
s e c u re w ith th e re la tiv e circlip .
— R e m o v e th e c lu tc h c a s in g - re v e rs e r and c re e p e r
u n it fro m th e s ta n d 380000301 .
-WARWn A A --------
A lw a y s use s u ita b le to o ls to a lig n h o le s. N E V E R
U S E Y O U R F IN G E R S O R H A N D S .
17. F it th e c irc lip (1, fig. 18 ) in its se a t.

18. M a ke th e b ra c k e t o f to o l 50043 (4) and th e to o l
50137 (5) (se e p a g e 3).
19. F it th e b ra c k e t (3) on th e c lu tc h c a s in g , in s e rt th e
in s ta lla tio n d rift (4) in th e se a l s e a t in c o n ta c t w ith
th e c irc lip (1, fig. 18).
20. S c re w in n u t (1) to o b ta in a d is ta n c e (H ) b e tw e e n
th e b ra c k e t and n u t o f 3 .3 - 3 .6 m m (0 .1 2 9 9 -
0 .1 4 1 7 in.) and s e c u re th e la tte rw ith th e lo c k n u t
(5).
20
6-62720 - 09 - 2006
Note - L e a ve th e d rift (1) w ith th e n u t in th e p o sitio n

re a ch e d on c o m p le tio n o f th e in s ta lla tio n o p e ra tio n ,
and on fu tu re s e a l in s ta lla tio n o p e ra tio n s s im p ly
c h e c k th a t th e d is ta n c e (H, fig. 2 0 ) is as p re s c rib e d .
21. R e m o v e th e d rift (1), th e b ra c k e t (2) and th e

c irc lip (1, fig. 18).
22. L o c a te th e n e w s e a l in its s e a t (se e p a g e 6 fo r

c o rre c t o rie n ta tio n o f s e a l), re fit th e b ra c k e t (2)
on th e c lu tch c a s in g and in s e rt th e d rift in th e
b ra cke t.
21
23. F o rc e th e s e a l in u n til th e n u t (1, fig. 2 0 ) re a c h e s
up a g a in s t th e b ra c k e t (2).
24. D is m a n tle th e b ra c k e t (2), re m o v e th e d rift (1)

and p ro ce e d w ith th e in s ta lla tio n o f th e o th e r
co m p o n e n ts .
6-62720 - 09 - 2006
SECTION 23 - DRIVE LINES - CHAPTER 1 1
SECTION 23 - DRIVE LINES
Chapter 1 - Drive Lines
CONTENTS
23 000 M a in s p e c if ic a t io n ........................................................................................................................................... 1
T o rq u e s e ttin g s and T ools ......................................................................................................................... 2
C ro s s -S e c tio n a l v i e w s ................................................................................................................................ 3
23 101 26 T ra n s m is s io n s h a fts and g u a rd (D is a s s e m b ly - A s s e m b ly ) ........................................................... 4
23 101 40 D riv e g e a r h o u s in g (R e m o v a l - In s ta lla tio n ) ........................................................................................ 5
23 101 42 D riv e g e a r h o u s in g re m o v e d (D is a s s e m b ly - A s s e m b ly ) ............................................................... 7
MAIN SPECIFICATION
R e d u c tio n ra tio ....................................................................... 3 4 /2 4 x 2 4 /3 4 = 1 to 1
R e la y le v e r pad w id th ............................................................ ..................... mm 7 .9 7 8 - 8 .0 0 0

(in.) (0.3141 - 0 .3 1 5 0 )
P ad s e a t w id th in d riv e n g e a r ........................................... ..................... mm 8 .2 8 0 - 8 .3 7 0

(in.) (0 .3 2 6 0 - 0 .3 2 9 5 )
P ad c le a ra n c e in s e a t ............................................................ ..................... mm 0 .2 8 0 - 0 .4 6 0
(in.) (0 .0 1 1 0 - 0 .3 1 5 )
R e la y le v e r p iv o t d i a m e t e r .................................................. ..................... mm 1 5 .9 7 3 - 1 6 .0 0 0
(in.) (0 .6 2 8 9 - 0 .6 2 9 9 )
P iv o t h o u sin g b o re in c a s in g .............................................. ..................... mm 1 6 .0 1 6 - 1 6 .0 5 9

(in.) (0 .6 3 0 5 - 0 .6 3 2 2 )
P iv o t c le a ra n c e in h o u s in g .................................................. ..................... mm 0 .0 1 6 - 0 .0 8 6
(in.) (0 .0 0 0 6 - 0 .0 1 2 4 )
R e la y le v e r d e te n t s p rin g le n g th
- F re e ......................................................................................... ..................... mm 130

(in.) (5 .1 1 8 1 )
- U n d e r 17 8 .2 to 1 9 7 .8 N (40 to 4 4 l b ) ......................... ..................... mm 142 .5

(in.) (5 .6 1 0 2 )
MAIN SPECIFICATION OF DRIVE SHAFT
F ro n t d riv e s le e v e a d ju s tm e n t see page 4
F ro n t d riv e s le e v e s h im t h ic k n e s s .............................. ......................... mm 2 .2 .-2 .5 -2 .8 - 3 -3 .3 - 3 .7 -4 - 4 .3

(in.) (0 .0 8 6 6 -0 .0 9 8 4 -0 .1 1 0 2 -0 .1 1 8 1 -
0 .1 2 9 9 - 0 .1 4 5 7 -0 .1 5 7 5 -0 .1 6 9 3 )
6-62720 - 09 - 2006
2 SECTION 23 - DRIVE LINES - CHAPTER 1
TORQUE SETTINGS
TRE0400A
T o rq u e s e ttin g
PART TO BE TO R Q U E D T h re a d
Nm ft lb
T ra n s m is s io n s h a ft c e n tra l s u p p o r t re ta in in g b o lt ( C 12) .................... M 1 2 x 1 .5 98 7 2 .2 8 1 1
D riv e g e a r h o u s in g re ta in in g b o lt ( C 13) .................................................... M 1 2 x 1 .2 5 98 7 2 .2 8 1 1
TOOLS
380000821 D riv e s h a ft s e a l k e y
6-62720 - 09 - 2006
Sectional views of transfer box:
C 12 = D rive s h a ft c e n tre b e a rin g c a p s c re w 25. R oll pin

C 13 = A x le d riv e h o u s in g c a p s c re w 26 . In te rm e d ia te s h a ft
X = O n a s s e m b ly ,th o ro u g h ly cle a n and d e g re a s e 27. D u s t e x c u lu d e r
m a tin g s u rfa c e X. 28. S e a l
4. D rive n g e a r 29. R e ta in in g ring
5. In te rm e d ia te g e a r 30. S p lin e d d riv e n s h a ft
6. N e e d le ro lle r b e a rin g
39. D riv e s h a ft g u a rd
10 . D rive n s h a ft
56. C e n tre b e a rin g
11. G u id e s c re w s
22. D e n te n t p lu n g e r
6-62720 - 09 - 2006
Op. 23 101 26
TRANSMISSION SHAFTS AND GUARD
D isa sse m b ly - A s s e m b ly
------------ A WARNING A -------------

H a n d le a ll p a rts w ith g r e a t c a re .
D o n o t p la c e h a n d s o r fin g e r s b e tw e e n o n e p a rt a n d
a n o th e r.
A lw a y s w e a r t h e p re s c r ib e d s a fe ty c lo th in g , in c lu d in g
p r o te c tiv e g la s s e s , g lo v e s a n d s h o e s .
To re m o v e , p ro c e e d a s fo llo w s :
1 .D is c o n n e c t th e n e g a tiv e b a tte ry le a d .
2 .R e m o v e th e fro n t, c e n tre a n d r e a r s c r e w s s e c u r in g
th e fr o n t a x le p ro p s h a ft g u a rd a n d re m o v e th e
g u a rd (1 ).
3 .R e m o v e c irc lip (2 ) fig . 5 a n d m o v e s le e v e (1 ) in th e
d ire c tio n s h o w n b y th e a rr o w to d is e n g a g e it fr o m
th e s p lin e d s h a ft o f t h e fr o n t a x le .
4 .T o r e - f it th e tr a n s m is s io n s h a ft a n d g u a rd , p ro c e e d
a s fo llo w s :
------------ A WARNING A ----------

U s e s u ita b le to o ls to a lig n h o le s . NEVER USE
- F i t a n d s e c u r e th e tr a n s m is s io n s h a ft in p o s itio n
NOTE:
M o v e t h e f r o n t s p lin e d s le e v e (2 7 ) a g a in s t
r e t a in in g rin g ( 2 8 ). U s in g a f e e le r g a u g e ,
m e a s u re g a p b e tw e e n t h e s le e v e a n d t h e
r e t a in in g rin g (2 6 ) a n d in s ta ll s h im (S 5 ) to
o b ta in s le e v e e n d p la y (L ) o f 1 to 1 .5 m m
( 0 . 0 3 9 4 to 0 .0 5 9 1 in .) (s e e S e c t io n 2 5 p a g e 9 ).
- F it a n d s e c u r e th e g u a rd .
6-62720 - 09 - 2006
Op. 23 101 40
DRIVE GEAR HOUSING ASSEM BLY
R em oval - In s ta lla tio n
----------- A WARNING A -----------

D o n o t p la ce h a n d s o r fin g e rs b e tw e e n o n e p a rt and
an o th e r.
A lw a y s w e a rth e p re s c rib e d s a fe ty clo th in g , in clu d in g
p ro te c tiv e g la s s e s , g lo v e s and s h o e s .
To re m o ve , p ro c e e d as fo llo w s :
1 .C a rry o u t o p e ra tio n 23 101 26 T ra n s m is s io n

s h a fts and g u a rd re m o v a l (se e p a g e 4)
2 .R e m o v e th e plug (1) and d ra in th e oil fro m th e
tra n s m is s io n b o x /g e a rb o x .
3 .D e ta c h th e d riv e g e a r e n g a g e m e n t c o n tro l le v e r(1 )
7
4 .R e m o v e th e s c re w s (1) th a t hold th e d riv e g e a r
h o u sin g (tra n s fe r b ox) to th e tra n s m is s io n h o u sin g .
5 .R e m o v e th e d riv e g e a r h o u s in g fro m th e
tra n s m is s io n h o u sin g .
6-62720 - 09 - 2006
6.To re fit th e d riv e g e a r h o u s in g , p ro c e e d as

fo llo w s :
----------- A WARNING A -----------

U se s u ita b le to o ls fo r a lig n in g h o le s. D O N O T U S E
Y O U R H A N D S O R F IN G E R S .
R e fe r to th e tig h te n in g to rq u e s s h o w n on p a g e 2.
C a re fu lly cle a n th e c o n ta c t s u rfa c e s .
A p p ly se a lin g c o m p o u n d (a p p ro x . 2 m m (0 .0 7 8 7 in.)
w id e strip ) to th e c o n ta c t s u rfa c e o f th e d riv e g e a r
h o u sin g .
F it th e d riv e g e a r h o u s in g to th e tra n s m is s io n
h o u sin g .
C o n n e c t th e d riv e g e a r e n g a g e m e n t c o n tro l le v e r
R e p la c e th e tra n s m is s io n oil d ra in plug.
C a rry o u t o p e ra tio n 23101 26 T ra n s m is s io n s h a fts

and g u a rd in s ta lla tio n (se e p a g e 4).
F it th e d riv e s h a ft g u a rd .
M astic a p p lic a tio n d ia g ra m fo r a sse m b ly o f

d riv e gear h o u s in g to tra n s m is s io n h o u s in g .
6-62720 - 09 - 2006
TRANSFER BOX, UNIT REMOVED

D isa sse m b ly - A s s e m b ly (Op. 23 101 42)
----------- A WARNING A -------------

a no th e r.
W ith th e tra n s fe r b o x on th e b e n ch , p ro c e e d as
fo llo w s :
1 .C a rry o u t o p e ra tio n 23 101 26 T ra n s m is s io n s h a fts

and g u a rd re m o v a l (se e p a g e 4).
2 .C a rry o u t o p e ra tio n 23 101 40 D riv e g e a r h o u sin g
re m o v a l (se e p a g e 5).
10
3 .U s e th e s p e c ia l p u n ch to w ith d ra w th e s n a p ring
(1), th e n th e pin (2). R e m o v e th e ro lle r b e a rin g , th e
sp a ce r, th e th ru s t w a s h e rs and th e in te rm e d ia te
g e a r (3).
4 .R e m o v e th e p a rk in g b ra k e c o n tro l lever.
11
5 .U s e a s c re w d riv e r to re m o v e th e d u s t ring (1).
6 .R e m o v e th e s p lin e d d riv e n s h a ft, c o m p le te w ith
p a rts, p a rkin g b ra k e d is c s and th e d riv e n gear.
12
6-62720 - 09 - 2006
7.To re fit th e tra n s fe r box, p ro c e e d as fo llo w s :
----------- 4 k WARNING 4 k -----------

U se s u ita b le to o ls to a lig n h o le s. NEVER USE
13
In s e rt th e s h a ft in th e h o u s in g , th e n a s s e m b le th e
g e a r unit, w a s h e r and circlip .
F it th e in te rn a l le v e r ,the e x te rn a l lever, th e
c o u p lin g pad and s e c u re in p o s itio n by m e a n s o f
th e w a s h e r and re la tiv e circlip .
F it th e b e a rin g and re la tiv e c irc lip s
U sin g to o l 380000821 , fit th e s e a l and d u s t ring

(u se th e s p a c e r to fit th e d u s t ring).
C a rry o u t o p e ra tio n 23101 40 D riv e g e a r h o u sin g

in s ta lla tio n (se e p a g e 5).
C a rry o u t o p e ra tio n 23 101 26 T ra n s m is s io n
s h a fts and g u a rd in s ta lla tio n (se e p a g e 4).
6-62720 - 09 - 2006
SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1 1
SECTION 25 - FRONT AXLE MECHANICAL TRANSMISSION

Chapter 1 - Front axle mechanical transmission
CONTENTS
25 000 M a in d a t a ........................................................................................................................................................... 1
T ools ................................................................................................................................................................... 6
C ro s s -s e c tio n a l v ie w s ................................................................................................................................ 7
25 100 30 C o m p le te fro n t a xle . R e m o v a l - In s ta lla tio n ................................................................................... 10
25 100 38 F ro n t a xle . R e m o v a l - In s ta lla tio n ........................................................................................................ 14
25 108 46 -4 7 S te e rin g k n u c k le b e a rin g pins. R e p la c e m e n t ................................................................................ 24
S tu b a xle a d ju s tm e n t ................................................................................................................................ 25
W h e e l h u b b e a rin g a d ju s tm e n t.............................................................................................................. 27
B e v e l d riv e a d ju s tm e n t.............................................................................................................................. 29
25 102 24 F ro n t a x le d iffe re n tia l. O v e r h a u l............................................................................................................. 36
25 100 27 F ro n t a x le d iffe re n tia l w ith L IM -S L IP . O v e r h a u l............................................................................... 37
F ro n t a x le d iffe re n tia l w ith N O S P IN . O v e rh a u l .............................................................................. 39
44 511 80 L e a d in g d riv e w h e e ls to e - in c h e c k ...................................................................................................... 42
MAIN DATA
T y p e ..................................................................................................................... s te e rin g , load b e a rin g s tru c tu re ,

p iv o tin g a t c e n tre
Bevel gear p a ir - d iffe re n tia l
P in io n -c ro w n g e a r ra tio : 30 km /h :
- J X 6 0 and J X 7 0 M o d e ls 9 /3 8 = 1 :4.2
- J X 8 0 , J X 9 0 and J X 9 5 M o d e ls 9 /3 9 = 1:4.3
P in io n -c ro w n g e a r ra tio : 4 0 km /h :
- J X 6 0 and J X 7 0 M o d e ls 11/38 = 1 :3 .4 5
- J X 8 0 , J X 9 0 and J X 9 5 M o d e ls 11/39 = 1 :3 .5 4
B a c k la s h b e tw e e n b e ve l g e a r pair:
- J X 6 0 and J X 7 0 M o d e ls mm 0 .1 8 - 0 .2 3
(in.) (0.0071 - 0 .0 0 9 1 )
- J X 8 0 , J X 9 0 and J X 9 5 M o d e ls mm 0 .1 5 - 0 .2 0
(in.) (0 .0 0 5 9 - 0 .0 0 7 9 )
R a tio b e tw e e n fro n t w h e e l re vs and re a r w h e e l b e ve l d riv e re vs
- J X 6 0 and J X 7 0 M o d e ls mm 1.3 8 6
(in.) (0 .5 4 5 )
- J X 8 0 , J X 9 0 and J X 9 5 M o d e ls mm 1.3 7 8
(in.) (0 .5 4 2 )
- JX 95 M odel 1.3 9 8
(0 .5 5 0 )
6-62720 - 09 - 2006
2 SECTION 25 - MECHANICAL FRONT AXLE - CHAPTER 1
MAIN DATA
Bevel D rive and D iffe re n tia l
- T h ic k n e s s o f p in io n b e a rin g a d ju s tm e n t s p a c e r
J X 6 0 and J X 7 0 M o d e ls ......................................................... mm 2 .5 - 2 .5 5 - 2 . 6 - 2 . 6 5 - 2 . 7 - 2 . 7 5 - 2 . 8 - 2
.8 5 - 2 .9 - 2 . 9 5 - 3 . 0 0 - 3 .0 5 - 3 . 1 0
3 .1 5 - 3 .2 - 3 . 2 5 - 3 . 3 - 3 .3 5 - 3 . 4 - 3 . 4 5
- 3 . 5 - 3 . 5 5 - 3 . 6 - 3 . 6 5 - 3.7
(in.) ( 0 .0 9 8 4 -0 .1 0 0 4 - 0 .1 0 2 4 -0 .1 0 4 3
0 .1 0 6 3 - 0 .1 0 8 3 -0 .1 1 0 2 -0 .1 1 2 2
0 .1 1 4 2 -0 .1 1 6 1 -0 .1 1 8 1 -0 .1 2 0 1
0 .1 2 2 0 - 0 .1 2 4 0 -0 .1 2 6 0 -0 .1 2 8 0
0 .1 2 9 9 - 0 .1 3 1 9 -0 .1 3 3 9 -0 .1 3 5 8
0 .1 3 7 8 - 0 .1 3 9 8 -0 .1 4 1 7 -0 .1 4 3 7
0 .1 4 5 7 )
J X 8 0 , J X 9 0 and J X 9 5 M o d e ls ........................................... mm 2 .2 - 2 .2 5 - 2 . 3 0 - 2 . 3 5 - 2 .4 0 - 2 . 4 5 - 2 . 5
-2 .5 5 -2 .6 -2 .6 5 -2 .7 -2 .7 5 -2 .8 -2 .8 5
-2 .9 -2 .9 5 -3 .0 0 -3 .0 5 -3 .1 -3 .1 5 -3 .2
- 3 . 2 5 - 3 .3 - 3 .3 5 - 3 . 4
(in.) ( 0 .0 8 6 6 -0 .0 8 8 6 - 0 .0 9 0 6 -0 .0 9 2 5
0 .0 9 4 5 - 0 .0 9 6 5 -0 .0 9 8 4 -0 .1 0 0 4
0 .1 0 2 4 - 0 .1 0 4 3 -0 .1 0 6 3 -0 .1 0 8 3
0 .1 1 0 2 -0 .1 1 2 2 -0 .1 1 4 2 -0 .1 1 6 1
0 .1 1 8 1 - 0 .1 2 0 1 -0 .1 2 2 0 -0 .1 2 4 0
0 .1 2 6 0 - 0 .1 2 8 0 -0 .1 2 9 9 -0 .1 3 1 9
0 .1 3 3 9 )
- T h ic k n e s s o f c ro w n w h e e l p o s itio n a d ju s tm e n t s p a c e r
J X 6 0 and J X 7 0 M o d e ls ......................................................... mm 2 .5 - 2 .6 -2 .7 -2 .8 -2 .9 - 3 .0 0 -3 .1
3 .2 - 3 .3 - 3 . 4 - 3 . 5 - 3 . 6 - 3 . 7
(in.) (0 .0 9 8 4 -0 .1 0 2 4 - 0 .1 0 6 3 -0 .1 1 0 2
0 .1 1 4 2 - 0 .1 1 8 1 1 -0 .1 2 2 0 -0 .1 2 6 0
0 .1 2 9 9 - 0 .1 3 3 9 -0 .1 3 7 8 -0 .1 4 1 7
0 .1 4 5 7 )
J X 8 0 , J X 9 0 and J X 9 5 M o d e ls ........................................... mm 2 .2 - 2 .3 -2 .4 -2 .5 -2 .6 - 2 .7 -2 .8 -2 .9
3 .0 - 3 .1 - 3 . 2 - 3 . 3 - 3 . 4 - 3 . 5
(in.) (0 .0 9 8 4 -0 .1 0 2 4 - 0 .1 0 6 3 -0 .1 1 0 2
0 .1 1 4 2 - 0 .1 1 8 1 1 -0 .1 2 2 0 -0 .1 2 6 0
0 .1 2 9 9 - 0 .1 3 3 9 -0 .1 3 7 8 -0 .1 4 1 7
0 .1 4 5 7 )
- C le a ra n c e b e tw e e n s id e s o f p la n e t and s id e p in io n te e th . m m (in.) 0 .1 5 (0 .0 0 5 9 )
- T h ic k n e s s o f p la n e t p in io n th ru s t w a s h e rs ........................... m m (in.) 1 .4 7 0 - 1 .5 3 0 (0 .0 5 7 9 - 0 .0 6 0 2
- T h ic k n e s s o f s id e g e a r th ru s t w a s h e rs .................................. m m (in.) 1.50 to 1 .60 (0.0591 to 0 .0 6 3 0 )
- D ia m e te r o f c ro s s pin fo r p la n e t p in io n s
J X 6 0 and J X 7 0 M o d e ls ......................................................... m m (in.) 2 1 .9 3 9 - 2 1 .9 6 0 (0 .8 6 3 7 - 0 .8 6 4 6 )
J X 8 0 , J X 9 0 and J X 9 5 M o d e ls ........................................... m m (in.) 2 3 .9 3 9 - 2 3 .9 6 0 (0 .9 4 2 5 - 0 .9 4 3 3 )
- S id e d ia m e te r c ro s s pin b o re d ia m e te r
J X 6 0 and J X 7 0 M o d e ls ......................................................... m m (in.) 2 2 .0 4 0 - 22.961 (0 .8 6 7 7 - 0 .9 0 4 0 )
J X 8 0 , J X 9 0 and J X 9 5 M o d e ls ........................................... m m (in.) 2 3 .9 4 0 - 23.961 (0 .9 4 2 5 - 0 .9 4 3 3 )
- C le a ra n c e b e tw e e n c ro s s pin and b o re s ................................ 0 .0 8 0 - 0 .1 2 2 (0.0031 - 0 .0 0 4 8 )
- D ia m e te r o f o u te r a x le s h a fts and c o rre s p o n d in g b u s h e s
J X 6 0 and J X 7 0 M o d e ls ......................................................... m m (in.) 37.961 - 3 8 .0 0 0 (1 .4 9 4 5 - 1 .4 9 6 1 )
J X 8 0 , J X 9 0 and J X 9 5 M o d e ls ........................................... m m (in.) 43.961 - 4 4 .0 0 0 (1 .7 3 0 7 - 1 .7 3 2 3 )
- In sid e d ia m e te r o f in s ta lle d b u s h e s 0 .7 7 - 0 .8 3 (0 .0 3 0 3 - 0 .0 3 2 7 )
J X 8 0 , J X 9 0 and J X 9 5 M o d e ls ........................................... m m (in.) 4 4 .0 8 0 - 4 4 .1 1 9 (1 .7 3 5 4 -1 .7 3 7 0 )
- C le a ra n c e b e tw e e n a x le s h a fts and b u s h e s ....................... m m (in.) 0 .0 8 0 - 0 .1 5 8 (0.0031 - 0 .0 0 6 2 )
6-62720 - 09 - 2006
MAIN DATA
A xle s h a fts and s te e rin g k n u ckle s

- D ia m e te r o f o u te r a x le s h a fts and c o rre s p o n d in g b u s h e s
J X 8 0 , J X 9 0 and J X 9 5 M o d e ls ........................................... m m (in.) 4 1 .9 7 5 - 4 2 .0 0 0 (1 .6 5 2 6 - 1 .6 5 3 5 )
- In sid e d ia m e te r o f in s ta lle d fro n t bush
J X 6 0 and J X 7 0 M o d e ls ......................................................... m m (in.) 3 0 .0 5 0 - 3 0 .1 0 5 (1.1831 - 1 .1 8 5 2 )
J X 8 0 , J X 9 0 and J X 9 5 M o d e ls ........................................... m m (in.) 4 2 .1 0 0 - 4 2 1 7 5 (1 .6 5 7 5 - 1 .6 6 0 4 )
- C le a ra n c e b e tw e e n pin and bush
J X 6 0 and J X 7 0 M o d e ls ......................................................... m m (in.) 0.1 1 5 - 0.191 (0 .0 0 4 5 - 0 .0 0 7 5 )
J X 8 0 , J X 9 0 and J X 9 5 M o d e ls ........................................... m m (in.) 0 .1 0 0 - 0 .2 0 0 (0 .0 0 3 9 - 0 .0 0 7 9 )
- In te rfe re n c e fit b e tw e e n b u s h e s and re s p e c tiv e b o re s m m (in.) 0 .0 6 4 - 0 .1 2 9 (0 .0 0 2 5 - 0 .0 0 5 1 )
- T h ic k n e s s o f s te e rin g k n u c k le b e a rin g a d ju s te r p la te s . . . . mm 0 .1 0 - 0 .1 5 - 0 .2 0 - 0 .2 5 - 0 .3 0
(in.) ( 0 .0 0 3 9 -0 .0 0 5 9 - 0 .0 0 7 9 -0 .0 0 9 8
0.0 1 1 8 )
P lanetary Final D rives

- R e d u c tio n ratio
J X 6 0 and J X 7 0 M o d e ls ......................................................... m m (in.) 1 5 :(1 5 + 5 4 ) = 1:4.6

0 .5 9 0 6 :(0 .5 9 0 6 + 2 .1 2 6 0 ) = 1:4.6
J X 8 0 and J X 9 0 M o d e ls ......................................................... m m (in.) 1 6 :(1 6 + 6 2 ) = 1 :4 .8 8

0 .6 2 9 9 :(0 .6 2 9 9 + 2 .4 4 0 9 ) = 1 :4 .8 8
- D rive n g e a r th ru s t w a s h e r th ic k n e s s 0 .7 7 - 0 .8 3 (0 .0 3 0 3 - 0 .0 3 2 7 )
A xle p iv o t
P iv o ttin g a n g le (on e ith e r s id e ) ....................................................... 11o
C e n tre p iv o t and s u p p o rt end f l o a t ................................................ m m (in.) 0 .3 - 1.1 (0 .0 1 1 8 - 0 .0 4 3 3 )
M ax. w e a r c le a r a n c e ............................................................................ m m (in.) 2 (0 .0 7 8 7 )
C e n tre p iv o t d i a m e t e r ......................................................................... m m (in.) 5 2 .6 5 2 - 52.671 (2 .0 7 2 9 - 2 .0 7 3 7 )
C e n tre p iv o t fro n t b u s h in g fitte d ..................................................... m m (in.) 5 2 .7 2 0 - 5 2 .7 9 0 (2 .0 7 5 6 - 2 .0 7 8 3 )
C e n tre p iv o t w o rk in g c le a ra n c e in b u s h in g ................................ m m (in.) 0 .0 4 9 - 0 .1 3 8 (0 .0 0 1 9 - 0 .0 0 5 4 )
R e a r b e ve l p inio n c a rrie r s p ig o t ....................................................... m m (in.) 9 9 .0 4 0 - 9 9 .7 2 (3 .8 9 9 2 - 3 .9 0 6 3 )
R e a r b u sh in g fitte d .............................................................................. m m (in.) 9 9 .1 4 6 - 99.221 (3 .9 0 3 4 - 3 .9 0 6 3 )
S p ig o t fitte d c le a ra n c e in b u s h in g .................................................. m m (in.) 0 .0 7 4 - 0.181 (0 .0 0 2 9 - 0 .0 0 7 1 )
A x le fro n t and re a r th ru s t w a s h e r th ic k n e s s .............................. m m (in.) 4 .9 5 - 5 .0 0 (0 .1 9 4 9 - 0 .1 9 6 9 )
T u rn in g ra diu s:
- L ive a xle in B ra k e s on J X 6 0 and J X 7 0 M o d e ls ................ m m (in.) 3 6 0 0 (1 4 1 .7 3 2 )
B ra k e s on J X 8 0 , J X 9 0 and J X 9 5 M o d e ls .... m m (in.) 4 1 0 0 (1 6 1 .4 1 7 )
- L ive a xle in B ra k e s o ff J X 6 0 and J X 7 0 M o d e ls ................ m m (in.) 5 3 0 0 (2 0 8 .6 6 1 )
B ra k e s o ff J X 8 0 , J X 9 0 and J X 9 5 M o d e ls .... m m (in.) 5 6 0 0 (2 2 0 .4 7 2 )
- L ive a xle o u t B ra k e s on J X 6 0 and J X 7 0 M o d e ls ................ m m (in.) 4 2 0 0 (1 4 1 .7 3 2 )
B ra k e s on J X 8 0 , J X 9 0 and J X 9 5 M o d e ls .... m m (in.) 4 5 0 0 (1 6 5 .3 5 4 )
- L ive a xle o u t B ra k e s o ff J X 6 0 and J X 7 0 M o d e ls ................ m m (in.) 4 9 0 0 (1 9 2 .9 1 3 )
B ra k e s o ff J X 8 0 , J X 9 0 and J X 9 5 M o d e ls .... m m (in.) 5 1 0 0 (2 0 0 .7 8 7 )
6-62720 - 09 - 2006
TIGHTENING TORQUES
T ig h te n in g to rq u e
PART T h re a d
Nm ft lb
F ro n t axle
L o c k ring, b e ve l p in io n (C-0
J X 6 0 and J X 7 0 M o d e ls ................................................................................ M 35x1.5 29 4 2 1 6 .8 4 3 2
J X 8 0 J X 9 0 and J X 9 5 M o d e ls .................................................................. M 40x1.5 29 4 2 1 6 .8 4 3 2
C a p s c re w , d iffe re n tia l c a s e to a xle c a s in g (C 2) ................................ M 12x1.25 113 8 3 .3 4 4 5
C a p s c re w , ring g e a r to d iffe re n tia l c a s e (C 3) ..................................... M 12x1.25 113 8 3 .3 4 4 5
S te e rin g kn u c k le c a p s c re w (C 5)
- m o d e ls J X 6 0 and J X 7 0 ......................................................................... M 12x1.25 113 8 3 .3 4 4 5
W h e e l h u b b e a rin g s lo c k n u t (C 6):
- J X 6 0 and J X 7 0 m o d e ls ......................................................................... M 45x1.5 118 8 7 .0 3 2 3
- J X 8 0 , J X 9 0 and J X 9 5 m o d e ls .............................................................. M 75x2 392 2 8 9 .1 1 2 4 3
C a p s c re w , p la n e ta ry fin a l d riv e h o u s in g (C 7) ..................................... M 10x1.25 64 4 7 .2 0 4 0
F ro n t a xle fro n t and re a r p iv o t s u p p o rt b o lt (C g) .................................. M 18x1.5 392 2 8 9 .1 1 2 4 3
D iffe re n tia l c a g e s u p p o rt c a p b o lt (C 10) ................................................ M 12x1.25 113 8 3 .3 4 4 5
F ro n t a xle s u p p o rt to e n g in e re ta in in g b o lt (C 11) ................................ M 18x1.5 314 2 3 1 .5 9 4 5
6-62720 - 09 - 2006
(*) S e e p a g e s 2 5 and 2 6 ( * * ) S e e p a g e 27 1
6-62720 - 09 - 2006
TOOLS
W ARNING: T h e to o ls m a rk e d b e lo w w ith an (X) are

ESSENTIAL fo r th e o p e ra tio n s d e s c rib e d in th is s e c
tio n . To w o rk in s a fe ty and o b ta in th e b e s t re s u lts
w h ils t s a v in g tim e and e n e rg y, th e s e e s s e n tia l to o ls
sh o u ld be s u p p le m e n te d by th e s p e c ific to o ls listed
b e lo w and o th e r to o ls w h ic h a re to be m a d e fro m th e
d ra w in g s p ro vid e d in th is m a n u a l.
List o f s p e c ific to o ls re q u ire d fo r th e v a rio u s o p e ra

tio n s d e s c rib e d in th is s e c tio n .
380000251 F ro n t a x le o v e rh a u l s ta n d . X 380000248 B e v e l p in io n p o s itio n in g a d ju s tm e n t

to o l
380000227 H o o k fo r re m o v a l-in s ta lla tio n o f th e
X 380000532 P in io n ring n u t w re n c h m o d . JX 6 0
fro n t d iffe re n tia l a s se m b ly.
a nd J X 7 0
380000255 O v e rh a u l s u p p o rt fo r fro n t a xle d iffe X 380000268 P in io n ring n u t w re n c h m o d . JX 8 0 ,
re n tia l c a sin g . J X 9 0 and JX 9 5
380000249 U n iv e rs a l g a u g e fo r p o s itio n in g o f X 380000257 P in io n g ro o v e d p ro file fa s te n e r

fro n t b e ve l d riv e p inion. w re n c h .
X 380000252 B e v e l d riv e b e a rin g p re lo a d in g ring
n u t w re n c h m o d . J X 6 0 and J X 7 0
X 380000253 B e v e l d riv e b e a rin g p re lo a d in g ring
n u t w re n c h m o d . J X 8 0 , J X 9 0 and
JX 95
X 380000234 F ro n t a xle p iv o t b e a rin g o u te r ring
re m o v a l to o l.
X 380000235 Tool fo r m e a s u re m e n t o f ro llin g d rag
to rq u e o f fro n t a x le b e a rin g s .
X 380000616 W h e e l h u b ring n u t w re n c h . (JX 60,
J X 7 0 m o d e ls )
X 380000269 W h e e l h u b ring n u t w re n c h . (JX 80,
J X 9 0 and J X 9 5 m o d e ls )
6-62720 - 09 - 2006
2
C ro s s -s e c tio n a l vie w o f fro n t axle d iffe re n tia l
S 1 = B e ve l p inio n b e a rin g s h im 1. B e v e l p inion

S 2 = B e ve l p inio n p o s itio n s h im 2. Seal
3. B e v e l p in io n b e a rin g s p a c e r
C 1 = B e ve l p inio n b e a rin g lo c k rin g . 4. R ing g e a r
C 2 = D iffe re n tia l c a rrie r ca p s c re w . 5. A x le s h a ft w ith u n iv e rs a l jo in t
C 3 = R ing g e a r ca p s c re w . 6. S id e g e a r w a s h e rs
7. D iffe re n tia l p in io n w a s h e rs
Gd , G s = R .H . and L.H . D iffe re n tia l b e a rin g 8. D iffe re n tia l p in io n jo u rn a l c a p s c re w
lo ckrin g . 60. S id e g e a r
61. S id e g e a r
62. D iffe re n tia l pinion
63. D iffe re n tia l p in io n jo u rn a l
NOTE: D u rin g in s ta lla tio n , a p p ly s e a lin g c o m p o u n d to s u rfa c e s X as s h o w n in S e c tio n 00, C h a p te r 1, p a g e 1.
6-62720 - 09 - 2006
3
C ross -s e c tio n a l v ie w o f fro n t axle ste e rin g kn u ckle and h ub
S3 = K ing pin b e a rin g s h im 10. S e a l
C4 = K ing pin b e a rin g ca p s c re w . 11. K ing pin b e a rin g
C5 = S te e rin g k n u c k le ca p s c re w . 12. S e a l
C6 = W h e e l hu b b e a rin g lo ckrin g 13. S e a l
C7 = F in a l d riv e h o u s in g c a p s c re w 14. A x s u le s h a ft b u sh in g
15. S p a c e r
5. W h e e l s h a ft
16. T h ru s t w a s h e rs
9. B e a rin g c a rrie r c a p s c re w
17. P la n e t w h e e l jo u rn a ls
18. P la n e t w h e e l s h im s
19. S u n g e a r
NOTE: D u rin g in s ta lla tio n , a p p ly s e a lin g c o m p o u n d to s u rfa c e s X as s h o w n in S e c tio n 00, C h a p te r 1, p a g e 1.
6-62720 - 09 - 2006
TRE0416A
C ross -s e c tio n a l vie w o f fro n t axle p iv o t
H = 1 m m (0 .0 3 9 4 in.) 22. F ro n t th ru s t w a s h e r
L = 1 to 1.5 m m (0 .0 3 9 4 - 0 .0 5 9 0 in.) 23. R e a r th ru s t w a s h e r
S 5 = S le e v e p o s itio n s h im 24. R e a r b u sh in g
25. R e a r a x le p iv o t s u p p o rt
C 9 = A x le p iv o t s u p p o rt c a p s c re w 26. R e ta in in g rin g s
C 10 = D iffe re n tia l b e a rin g c a p ca p s c re w . 27. F ro n t s p lin e d s le e v e
C 11 = C a p s c re w s s e c u rin g fro n t a x le s u p p o rt 28. R e ta in in g rin g s
to e n g in e . 29. D riv e s h a ft g u a rd
20. F ro n t a xle p iv o t s u p p o rt 30. D riv e s h a ft
2 1 . F ro n t b u sh in g
J X 6 0 , J X 7 0 , J X 8 0 , J X 9 0 and J X 9 5 m o d e ls h a ve a T h e d iffe re n tia l has tw o p la n e t p in io n s ; d riv e is

c e n tra lly p ivo tin g fro n t a x le w ith th e p iv o t and th e tra n s m itte d to la te ra l e p ic y c lic fin a l d riv e u nits
d riv e s h a ft co a x ia l w ith th e lo n g itu d in a l a x is o f th e (in s ta lle d on th e w h e e l h u b s) th ro u g h u n iv e rs a l jo in ts
tra c to r. T h e d riv e s h a ft ha s no u n iv e rs a l jo in ts . w h ic h re q u ire no m a in te n a n c e .
6-62720 - 09 - 2006
COM PLETE FRONT AXLE

R e m o v a l- in s ta lla tio n (Op. 25 100 30)
----------- A DANGER A
e q u ip m e n t w ith a s u ffic ie n t liftin g ca p a city.
C h e c k th a t th e a s s e m b lie s o r p a rts a re held firm ly
and s u p p o rte d by s u ita b le s lin g s and h o o ks. M a ke
s u re n o b o d y is s ta n d in g n e a r to th e load.
NOTE: T h e fro n t a xle a s s e m b ly can be re m o v e d

fro m th e tra c to r e ith e r w ith o r w ith o u t p re v io u s ly
re m o v in g th e d riv e s h a ft. T h e d e s c rip tio n b e lo w
re fe rs to re m o v a l o f th e fro n t a x le w ith th e d riv e s h a ft
in sta lle d on th e tra c to r. F o r re m o v a l o f th e d riv e s h a ft
re fe r to s e c tio n 23.
1. D is c o n n e c t th e n e g a tiv e b a tte ry lead (1).
2. U n s c re w b o lts (1) and re m o v e th e fro n t

m u d g u a rd s u p p o rts (2).
6-62720 - 09 - 2006
3. Attach nylon slings to the front weights (1).

Loosen the locking screw from each weight, lift
the weights clear of the tractor and place them in
a safe position.
4. Unscrew bolts (1) and remove the drive shaft

guard (2 ).
5. Remove the circlip (1) from the front of the drive

shaft. Slide the sleeve rearwards and detach the
drive shaft from the front axle.
6. Pass two nylon slings around the front axle and

attach them to a hoist.
6-62720 - 09 - 2006
7. L ift th e tra c to r w ith th e h o is t and p la ce a sta n d

u n d e r th e s u m p pan.
11
8. U n s c re w u n io n s (1) o f th e rigid p ip e s to th e
p o w e r s te e rin g c y lin d e rs and d e ta c h th e tw o
fle x ib le h o se s
12
9. U n s c re w th e w h e e l b o lts and re m o v e th e fro n t

w h e e ls .
13
10. U n s c re w th e fro n t a x le re a r s u p p o rt re ta in in g
b o lts (1).
14
6-62720 - 09 - 2006
11. U n s c re w th e fro n t a xle fro n t s u p p o rt re ta in in g

b o lts (1.
15
12. U sin g a h o is t and tw o n ylo n c a b le s (o n e fo r ea ch

s id e ) d e ta c h th e fro n t a x le fro m th e tra c to r.
13. R e fit th e fro n t a xle fo llo w in g th e in s tru c tio n s

below .
----------- A WARNING A -----------

— R e fit th e a xle and b o lt th e fro n t and re a rs u p p o rts

in p o sitio n .
— R e c o n n e c t th e th e p o w e r s te e rin g p ipes. 16
— F it th e fro n t w h e e ls .
— R a is e th e fro n t o f th e tra c to r u sin g th e h oist.
— R e m o v e th e fix e d s ta n d .
— D e ta ch th e n ylo n c a b le s.
— R e c o n n e c t th e d riv e s h a ft and re fit th e d riv e
s h a ft g u a rd .
— R e fit th e tw o fro n t m u d g u a rd s .
— A tta c h a nylo n c a b le to th e fro n t w e ig h ts , lift, re fit
to th e tra c to r and s e c u re w ith th e lo c k in g s c re w s .
— R e c o n n e c t th e n e g a tiv e b a tte ry lead.
— A d h e re to th e tig h te n in g to rq u e s in d ic a te d on
pag e 4.
6-62720 - 09 - 2006
FRONT A X LE
R e m o v a l-In s ta lla tio n (Op 25 100 38 )
JX60 and JX70 M odels
----------- A WARNING A -----------

H a n d le all p a rts w ith ca re .
D o n o t in s e rt h a n d s o r fin g e rs b e tw e e n o n e p a rt and
17
1. U n s c re w th e d ra in plug and d ra in th e oil fro m th e

a xle ca sin g .
2. R e m o v e th e p la n e ta ry fin a l d riv e h o u s in g (1)
c o m p le te w ith p la n e t w h e e ls .
3. R e m o v e su n g e a r (2).
4. R e m o v e fin a l d riv e ring g e a r - fix e d g e a r unit,
s la c k e n ring n u t u sin g w re n c h 380000616 and
re m o v e a s s y fro m kn u c k le .
5. R e m o v e w h e e l h u b (6) w ith ta p e r ro lle r b e a rin g
c u p s (7) and a s s o c ia te d s e a l. B e c a re fu l to
p re v e n t se a l d a m a g e .
18
6. R e m o v e s te e rin g k n u c k le (10) w ith w h e e l hub
su p p o rt.
7. R e m o v e a rtic u la te d a x le s h a ft (9) w ith b e a rin g
ho u sin g . B a c k o ff th e c a p s c re w b e fo re w ith d ra w
ing th e a xle s h a ft.
8. R e p la c e w o rn b e a rin g s u sin g s u ita b le p u n c h e s
and u n iv e rs a l p u lle rs. C h e c k s e a l e fficie n cy.
A s s e m b ly a xle p a rts re fe rrin g to

- B e fo re in sta llin g th e fin a l d riv e h o u s in g (1)
th o ro u g h ly cle a n and d e g re a s e m a tin g s u rfa c e s and
a p p ly 2 m m (0 .0 7 8 7 in.) o f s e a in g c o m p o u n d .
19
- In s e rt a rtic u la te d a x le s h a ft (9) in a xle c a s e and

in sta ll s te e rin g k n u c k le c a rrie r (8)
- A d ju s t king pin b e a rin g p re -lo a d as d ire c te d in
th e a p p ro p ria te s e c tio n .
- A d ju s t w h e e l h u b b e a rin g p re -lo a d as d ire c te d
in th e a p p ro p ria te s e c tio n .
- Fill w h e e l h u b s and d iffe re n tia l-b e v e l d riv e
ho u sin g w ith th e s p e c ife d oil.
20
6-62720 - 09 - 2006
JX80, JX90 and JX95 M odels
A WARNING A -----------
H a n d le all p a rts w ith ca re .
D o n o t in s e rt h a n d s o r fin g e rs b e tw e e n o n e p a rt and
NOTE: F o r o v e rh a u l, th e fro n t a xle s h o u ld be m o u n

te d on s ta n d N o. 380000251 .
21
1. U n s c re w th e plug (1) and d ra in th e oil fro m th e

a xle ca sin g .
22
2. U n s c re w plug (1) on th e le ft- h a n d e p ic y c lic fin a l
d riv e c a sin g . R e p e a t th is o p e ra tio n on th e
rig h t-h a n d c a sin g .
23
3. R e m o v e th e fro n t a xle re a r s u p p o rt (1). R e m o v e

th e fro n t s u p p o rt and re trie v e th e w a s h e r.
24
6-62720 - 09 - 2006
4. U n s c re w th e tw o tra c k rod re ta in in g b o lts (1).
25
5. U sin g a s u ita b le puller, w ith d ra w th e p ins fro m

th e ir b o re s in th e s tu b a x le h o u s in g and re m o v e
th e tra c k rod.
26
6. R e m o v e th e c irc lip s (2) fro m th e c y lin d e r rod
p iv o t pins, u n s c re w th e pin re ta in in g b o lts o f th e
c y lin d e r (1), w ith d ra w th e p in s and d e ta c h th e
tw o cylin d e rs .
R e trie v e th e fo u r pins, w a s h e rs , s p a c e rs and
c y lin d e rs , c o m p le te w ith h o se s.
27
7. U n s c re w th e re ta in in g b o lts fro m th e left--hand

fin a l d riv e c a s in g c o v e r (1). S c re w in th e tw o
d o w e ls (2), as s h o w n . U sin g a s lid e h a m m e r
s c re w e d in to th e oil d ra in plug hole, d e ta c h th e
c o v e r (1) fro m th e c a sin g .
28
6-62720 - 09 - 2006
8. R e m o v e th e c irc lip (1) s e c u rin g th e su n g e a r (2)

and re m o v e th e gear.
9. R e m o v e th e in n e r c irc lip (1) fro m th e s tu b a xle

s h a ft.
10. R e m o v e th e sta k in g (1) on th e w h e e l h u b b e a rin g

lo c k ring (2).
31
11. R e m o v e th e w h e e l h u b b e a rin g lo c k ring using

w re n c h 380000269 (1) fo r m o d e ls J X 8 0 , J X 9 0
and JX 9 5 .
32
6-62720 - 09 - 2006
12. R e m o v e th e w h e e l h u b (1) w ith th e ring g e a r (2).

R e trie v e all d is a s s e m b le d pa rts.
33
13. U n s c re w th e th re e re ta in in g b o lts (1) o fth e lo w e r

pin o f th e s tu b a xle h o u s in g . R e c o v e r th e lo w e r
p iv o t pin and th e re la te d a d ju s tm e n t s h im s .
34
14. U n s c re w th e th re e re ta in in g b o lts (1) o f th e

m u d g u a rd b ra c k e t (2).
35
15. W ith d ra w th e u p p e r p iv o t pin (1) and d e ta c h th e

s tu b axle h o u s in g (2). R e trie v e th e d is a s s e m b le d
parts.
36
6-62720 - 09 - 2006
16. U n s c re w th e a x le s h a ft re ta in in g b o lt and re m o v e
th e a xle sh a ft.
37
17. R e m o v e b ra c k e t (1), u n s c re w th e u n ion (3) and

d e ta c h th e fro n t b ra k e p ipe (2).
38
18. U n s c re w tw o o f th e b o lts fix in g th e b e ve l

d riv e --d iffe re n tia l s u p p o rt to th e a xle c a sin g .
S c re w in th e tw o d o w e ls (1). R e m o v e th e
re m a in in g b o lts and s e p a ra te th e b e ve l drive-
d iffe re n tia l s u p p o rt fro m th e a x le c a s in g . A tta c h
a c a b le (2) to th e s u p p o rt and ta k e up th e s tra in
w ith th e h o ist. R e m o v e th e b e ve l d riv e -
d iffe re n tia l s u p p o rt (3) fro m th e a xle c a sin g .
39
19. In sta ll to o l 380000255 (1) in th e v ic e on th e w o rk

b e n ch . B o lt th e b e ve l d riv e --d iffe re n tia l s u p p o rt
on to th e to o l. D e ta c h th e liftin g ca b le .
20. U n s c re w th e b o lt (2) and re m o v e th e ring n u t lo ck

ta b (3).
40
6-62720 - 09 - 2006
21. R e m o v e th e fro n t b ra k e b o lts (1).
41
22. R e m o v e th e fro n t b ra k e h o u s in g (1)
42
23. R e m o v e th e fro n t b ra k e h u b g e a r (1)
43
24. R e m o v e th e fric tio n d is c s (1) and m e ta l d is c s (2)
44
6-62720 - 09 - 2006
25. R e m o v e fro n t b ra k e p isto n (1) and O -rin g s .
45
26. U n s c re w th e tw o b o lts (2) o f th e c ro w n w h e e l-

d iffe re n tia l s u p p o rt c a p s (1).
46
27. R e m o v e th e c ro w n w h e e l--d iffe re n tia l a s s e m b ly
(2) fro m th e h o u s in g (1).
47
28. R e m o v e th e c irc lip (1) fro m th e s p lin e d s h a ft (2).
48
6-62720 - 09 - 2006
29. S tra ig h te n th e lo c k in g ta b on th e s p lin e d s h a ft-

lo c k n u t (1).
49
30. U n s c re w th e n u t u sin g w re n 8 c h 380000268 (1)

w h ile p re v e n tin g ro ta tio n o f th e b e ve l d riv e pinion
s h a ft u sin g w re n c h 380000257 .
50
31. R e c o v e r th e s p lin e d s h a ft d e te n t ball (1)
51
32. W ith d ra w th e b e ve l d riv e p in io n s h a ft (1) fro m th e
re a r o f th e ca s in g and re c o v e rth e sp a c e r, th e a d
ju s tm e n t s h im s and th e b e a rin g .
52
6-62720 - 09 - 2006
33. U sin g a sc re w d riv e r, d e ta c h and re c o v e rth e d u s t

se a l, th e oil s e a l (1) and th e re a r b e a rin g .
R e a s s e m b le th e fro n t a xle a d h e rin g to th e

fo llo w in g in s tru c tio n s :
- R e fe r to th e illu s tra tio n s on p a g e s 7, 8 and - In s ta ll th e b e ve l d riv e -d iffe re n tia l h o u s in g on

9 to c h e c k th e o rie n ta tio n o f th e v a rio u s th e fro n t a xle c a s in g and fit th e e x te rn a l fro n t
co m p o n e n ts . b ra k e pipe.
- R e s p e c t th e tig h te n in g to rq u e s p re s c rib e d on - In s ta ll th e a xle s h a ft and re la tiv e bolt.

pa g e 4.
- F it th e s tu b a xle , th e a d ju s tm e n t s h im s , th e
- C a rry o u t th e a d ju s tm e n ts d e s c rib e d on p a g e s u p p e r and lo w e r p iv o t pins, th e m u d g u a rd
2 9 to 36. b ra c k e t and re la te d b olts.
- In sta ll th e re a r b e a rin g , th e s e a l, th e d u s t se a l, - F it th e w h e e l hub, th e ring g e a r o f th e fin a l d rive

th e a d ju s tm e n t s h im s , th e s p a c e r and th e b e ve l u n it and th e lo c k ring. T ig h te n to th e p re s c rib e d
d riv e p inion s h a ft c o m p le te w ith fro n t b e a rin g . to rq u e v a lu e , w h ile s im u lta n e o u s ly tu rn in g th e
w h e e l hub, to e n s u re th a t th e b e a rin g s are
- P o sitio n th e d e te n t ball, s c re w in th e b e ve l d riv e
c o rre c tly s e a te d .
p inion lo c k n u t and s e c u re in p o s itio n by
s ta k in g . F inally, re p la c e th e circlip . - F it th e s e c u rin g and s to p c irc lip s , th e su n g e a r
and th e c o v e r o f th e fin a l d riv e unit.
- In sta ll th e cro w n w h e e l-d iffe re n tia l a s se m b ly,
th e s u p p o rt c a p s and tig h te n th e re la tiv e b olts. - F it th e pins, w a s h e rs , s p a c e rs and s te e rin g
c y lin d e rs .
- In sta ll th e fro n t b ra k e fric tio n d is c , m e ta l d is c
hu b gear, p isto n and fro n t b ra k e h o u sin g . - In s ta ll th e tra c k rod, th e fro n t and re a rs u p p o rts
T ig h te n th e re s p e c tiv e b olts. and th e oil d ra in p lugs.
6-62720 - 09 - 2006
STEERING KNUCKLE PINS AND BEARINGS

R eplacem ent (Op. 25 108 46 o r 25 108 47)
----------- A WARNING A -----------

D o n o t p u t y o u r fin g e rs o r h a n d s b e tw e e n o n e p ie ce
and a n o th e r. W e a rs u ita b le s a fe ty clo th in g , i.e. s a fe ty
g o g g le s , g lo v e s and fo o tw e a r.
In th e e v e n t th a t th e s te e rin g k n u c k le p in s p ro ve
d iffic u lt to re m o v e , p ro c e e d as fo llo w s .
1. R e m o v e th e g re a s e n ip p le s and th e s te e rin g
k n u c k le pin re ta in in g b olts.
2. F it th e b o lts (1) o f to o l 380000265 .
3. F it th e p la te (2) o f th e to o l and fix it to th e th re e
b o lts w ith n u ts (5).
4. F it th e c e n tra l tie b o lt (4) s c re w in g it fu lly into th e
g re a s e n ip p le b o re on th e pin (6).
5. S c re w in th e n u t (3) to d riv e th e pin o u t o f its bore.
54
6. U sin g e x tra c to r to o l 380000234 (1) re m o v e th e

s te e rin g kn u c k le b e a rin g s .
7. R e --install th e s te e rin g k n u c k le b e a rin g s u sin g a

s u ita b le d rift.
55
6-62720 - 09 - 2006
STUB A X LE AD JU STM EN T
----------- A WARNING A ------------

D o n o t p u t y o u r fin g e rs o r h a n d s b e tw e e n o n e p ie ce
and a n o th e r. W e a rs u ita b le s a fe ty clo th in g , i.e. s a fe ty
g o g g le s , g lo v e s and fo o tw e a r.
In sta ll th e fro n t ax le on s ta n d 293460 a nd p ro c e e d as

fo llo w s .
1. S m e a r g re a s e A K C E L A M ULTI-PURPO SE
GREASE on th e o u te r ra c e s o f th e b e a rin g s and
fit th e u p p e r co ve r, w ith o u t th e a d ju s tm e n t plate,
b u t w ith to o l 380000235 (2). T ig h te n th e re ta in
ing b o lts (C 5, p a g e 5) to th e fo llo w in g to rq u e
va lu e s:
J X 6 0 and J X 7 0 64 Nm
(4 7 .2 0 4 0 ft lb)
J X 8 0 , J X 9 0 and J X 9 5 113 N m
(8 3 .3 4 4 5 ft lb)
56
2. F it th e lo w e r c o v e r w ith o u t th e a d ju s tm e n t pla te
and lu b ric a te th e th re e re ta in in g b o lts w ith
e n g in e oil.
3. G ra d u a lly tig h te n th e lo w e r c o v e r b o lts in
s e q u e n c e , w h ile s im u lta n e o u s ly ro ta tin g th e
c a sin g to a llo w e x c e s s g re a s e to e s c a p e .
57
4. U sin g a to rq u e w re n c h and to o l 380000235 (1),
c h e c k th a t th e to rq u e re q u ire d to ro ta te th e
ca sin g (ig n o rin g th e in itia l to rq u e ) is as fo llo w s :
m o d e ls J X 6 0 and J X 7 0 2 .9 N m
(2 .1 3 8 9 ft lb)
(w ith to rq u e in c re m e n t o f 0 .9 8 N m - 0 .7 2 2 8 ft lb)
J X 8 0 , J X 9 0 and J X 9 5 15 - 2 5 N m
(1 1 ,0 6 3 4 - 1 8 .4 3 9 0 ft lb)
If th e re c o rd e d to rq u e is n o t as s p e c ifie d , a d ju s t
by w a y o f th e lo w e r c o v e r b olts.
5. M e a s u re th e g a p (H ) c re a te d b e tw e e n th e lo w e r
c o v e r and th e c a s in g a d ja c e n t to e a ch o f th e
th re e bolts. 58
6-62720 - 09 - 2006
6. C a lc u la te th e a v e ra g e o f th e th r e e v a lu e s
m e a s u re d . T h e to ta l th ic k n e s s o f th e a d ju s tm e n t
s h im s (p a g e 8 ) to b e fitte d u n d e r th e lo w e r
c o v e r is to b e c a lc u la te d a s fo llo w s :
JX 60 and JX 7 0 S 3= H
JX 80, JX 9 0 and JX 9 5 S 3 = H - 0.20 mm
(0.0079 in .)
If n e c e s s a ry , ro u n d u p th e v a lu e to th e n e x t
0 .0 5 m m (0 .0 0 2 0 in .).
7. P a r tia lly u n s c re w th e b o lts o f th e lo w e r c o v e r,

in s e r t th e s e le c te d s h im s (S3, p a g e 8 ). T ig h te n
th e b o lts (C 4 , p a g e 5 ) to th e fo llo w in g to r q u e
v a lu e s :
JX 60 and JX 7 0 64 Nm
(4 7 .2 0 4 0 ft lb)
JX 80, JX 9 0 and JX 9 5 113 N m
(8 3 .3 4 4 5 ft lb)
8. A f te r h a v in g ro ta te d th e c a s in g a fe w tim e s to
a llo w th e c o m p o n e n ts to b e d d o w n , c h e c k th a t
th e to r q u e n e c e s s a ry to r o ta te th e c a s in g
(ig n o rin g th e in itia l to r q u e ) is fo llo w s : 59
J X 6 0 a n d J X 7 0 2 .9 - 7 .8 N m
(2 .1 3 8 9 - 5 .7 5 3 0 ft lb)
JX 80, JX 9 0 and JX 9 5 118 - 1 4 7 N m

(8 7 .0 3 2 3 - 1 0 8 .4 2 1 6 ft lb)
9. If th e to r q u e v a lu e m e a s u r e d is g r e a te r th a n th e
p re s c rib e d v a lu e , in c re a s e th e th ic k n e s s o f th e
s h im s . If th e m e a s u r e d v a lu e is le s s th a n th e
p re s c rib e d v a lu e , r e d u c e th e th ic k n e s s o f th e
s h im s .
10. F it th e g r e a s e n ip p le s in th e u p p e r a n d lo w e r
c o v e rs a n d g r e a s e th e a s s e m b ly .
6-62720 - 09 - 2006
W H EEL HUB BEARING ADJUSTMENT:
F irs t cla ss axle m od. JX60 and JX70
P ro c e e d a s fo llo w s :
- In s ta ll w h e e l h u b a n d fix e d g e a r u n it o n to th e
s te e rin g k n u c k le ;
- U s in g a to r q u e w r e n c h a n d lo c k rin g w re n c h
380000616 (fo r JX 60 and JX 70 m o d e ls )
p ro g r e s s iv e ly tig h te n th e rin g n u t (C6, p a g e 8)
to 1 4 7 - 1 9 6 N m ( 1 5 - 2 0 k g m ). W h ile tig h te n
in g th e rin g n u t, r o ta te th e h u b to s e ttle t h e b e a
60
rin g s .
- F u lly s la c k e n th e lo c k rin g a n d r e tig h te n to 5 9

Nm (4 3 .5 1 6 2 ft lb ) w h ile ro ta tin g h u b .
- S e c u re th e lo c k rin g b y b e n d in g o v e r a lo c k -
w a s h e r ta b ( if n e c e s s a ry , fu r t h e r tig h te n th e
lo c k rin g to a lig n a s lo t w ith th e ta b )
- T u rn th e h u b b y h a n d to c h e c k f o r e x c e s s iv e
p la y o r b in d in g .
- C a r e fu lly s e c u r e th e rin g n u t.
6-62720 - 09 - 2006
S econd class axle m od. JX80, JX90 and JX95

-- P r o g r e s s iv e ly tig h te n th e rin g n u t, u s in g th e
to r q u e w r e n c h a n d w r e n c h 380000269 (1 ) to o b
ta in a to r q u e v a lu e o f 3 9 2 N m ( 2 8 9 .1 2 4 3 2 ft lb);
a t th e s a m e tim e , r o ta te th e w h e e l h u b to e n s u re
t h a t th e b e a rin g s a re c o r r e c tly s e a te d .
- M e a s u re th e ro llin g re s is ta n c e (R t) o f t h e w h e e l
h u b u s in g th e r e la tiv e to r q u e w r e n c h , o r a to r q u e
m e te r a n d c o rd p o s itio n e d o n th e b a s e o f th e
w h e e l d is k fla n g e .
61
- L o o s e n th e rin g n u t b y h a lf a tu rn a n d m e a s u r e
th e ro llin g re s is ta n c e (R ) as d e s c rib e d
p re v io u s ly . The d iffe re n c e b e tw e e n th e tw o
m e a s u r e m e n ts is th e ro llin g to r q u e v a lu e o f th e
w h e e l h u b b e a rin g s (R c ):
- R c = R t - R = 5 .9 + 1 4 .7 N m ( 4 .3 5 1 6 + 1 0 .8 4 1 6
ft lb ) o r if m e a s u re d w ith a to r q u e m e te r.
R c = R t - R = 7 .5 + 1 8 .7 5 kg (4 1 .3 5 5 4 lb).
- If th e m e a s u re m e n t is le s s th a n 5 .9 Nm
(4 .3 5 1 6 ft lb ) o r w ith th e to r q u e m e te r o n 4 .8 kg
(1 0 .5 8 7 0 lb ) it is n e c e s s a r y to re p la c e th e a f
fe c te d p a rts a n d re p e a t th e c h e c k .
-- P r o g r e s s iv e ly tig h te n th e rin g n u t, u s in g th e
to r q u e w r e n c h an d w re n c h 380000269 (1 ) to
o b ta in a to r q u e v a lu e o f 3 9 2 N m ( 2 8 9 .1 2 4 3 2 ft
lb ); a t th e s a m e tim e , r o ta te th e w h e e l h u b to
e n s u re t h a t th e b e a rin g s a re c o r r e c tly s e a te d .
-- C a r e fu lly s e c u r e th e rin g n u t.
6-62720 - 09 - 2006
BEVEL DRIVE ADJUSTMENTS

A d ju s tm e n t o f th e p re lo a d o f th e p in io n s h a ft
b e aring s
----------- A WARNING A -------------

Handle all parts with care.
Do not insert hands or fingers between one part and
another. W ear suitable safety clothing, i.e. safety
goggles, gloves and footwear.
Proceed as follows. 61
1. Install the bevel pinion bearing cones (7) and

(9) with spacer (8) on tool 293438 (E).
NOTE: For JX60 and JX70 models, place the

spacer M outside the bearings.
2. Fully tighten tool nut (M).
3. Measure the distance (H1) between the end of

the pin on the bottom of the tool and the top
surface of the tool.
62
4. Remove the bearing cones and spacer from the

tool. Lubricate bearings with engine oil and
re-install onto the tool, inserting differential
carrier ( 10 ) with bearing cups.
5. Fully tighten tool nut (M) while rotating the

differential carierthrough ten revolutions to settle
the bearings.
6. Measure dimension (H3) of the tool in this

condition.
63
7. Thickness of shims (S1) will be given by:
S1= H3 - H1 + 0.10 m m (0.00039 in.)
If necessary, round off (S1) to the nearest 0.05 mm

(0.0020 in.)
NOTE On completing the adjustment, do not remove

the adjustment tool from the bevel drive-differential
housing. Leave in place for adjustment of the drive
pinion position. See following subject matter.
64
6-62720 - 09 - 2006
B EVEL DRIVE ADJUSTM ENTS

D e te rm in in g th e th ic k n e s s o f th e d rive p in io n
p o s itio n a d ju s tm e n t sh im
P ro c e e d a s fo llo w s .
1. F it to o l 380000249 (1 ) in th e b e v e l d r iv e - d iff e r e n
tia l h o u s in g (2 ), c o m p le te w ith o u te r b e a rin g
rin g s , c ro w n w h e e l b e a rin g s a d ju s tm e n t rin g ,
c ro w n w h e e l b e a rin g s a d ju s tm e n t s h im , c irc lip
and d iffe re n tia l h o u s in g c a p s , ta k in g c a re to
tig h te n th e b o lts ( C 1o) to a to r q u e o f 113 N m
(8 4 .3 4 4 5 ft lb).
2. S c r e w th e c o n e s (3 ) o f to o l 380000249 (1 ) in o r
o u t in o r d e r to p o s itio n th e m ic r o m e te r s h a ft (4)
in th e d ire c tio n o f th e in n e r b e a rin g rin g (5 ) a n d
e lim in a te e n d flo a t b e tw e e n th e c o n e s a n d th e
o u te r rin g s o f t h e b e v e l c ro w n w h e e l b e a rin g s .
3. A d ju s t th e m ic r o m e te r s o t h a t th e s h a ft (4 ) is in
66
c o n ta c t w ith th e in n e r b e a rin g rin g (5 ) and
m e a s u re th e d is ta n c e (H 3).
4. D e te rm in e th e c o r r e c t d is ta n c e ( H5) b e tw e e n th e
c ro w n w h e e l a x is a n d th e la rg e d ia m e te r b a s e o f
th e p in io n :
H 5 = H4 ± C
w h e re :
H4 = N o m in a l d is ta n c e b e tw e e n c ro w n w h e e l
c e n tre lin e a n d p in io n b ig e n d
- 1 0 0 m m f o r J X 6 0 , J X 7 0 m o d e ls .
- 15 m m f o r J X 8 0 , J X 9 0 , J X 9 5 m o d e ls .
C = a c o r re c tio n v a lu e s ta m p e d o n th e p in io n
p re c e d e d b y a + o r - s ig n ( if o th e r th a n 0 ). T h is
v a lu e to b e a d d e d to o r s u b tra c te d fr o m th e
67
n o m in a l d is ta n c e ( H4) a c c o rd in g to th e s ig n .
5. T h e th ic k n e s s o f th e a d ju s tm e n t s h im ( S 2) w ill be
g iv e n by:
S 2 = H3 - H5
w h e re :
H3 = th e d is ta n c e m e a s u re d u s in g th e m ic r o
m e te r;
H5 = c o rr e c te d n o m in a l d is ta n c e b e tw e e n th e
c ro w n w h e e l a x is a n d th e la rg e d ia m e te r b a s e o f
th e p in io n .
6-62720 - 09 - 2006
E xam ples (m od e ls JX60 and JX70)
E xam ple 1:
- D is ta n c e m e a s u r e d u s in g m ic r o m e te r H 5 = 1 0 3 .3
m m ( 4 .0 6 6 9 in .).
- N o m in a l d is ta n c e b e tw e e n c ro w n w h e e l a x is a n d
la rg e d ia m e te r b a s e o f p in io n H4 = 100 m m
(3 .9 3 7 0 in .).
-- C o rr e c tio n v a lu e C = + 0 ,2 m m (0 .0 0 7 9 in .).
- C o r re c te d n o m in a l d is ta n c e H 5 = 1 0 0 + 0 .2 =
1 0 0 .2 m m (3 .9 3 7 0 + 0 .0 0 7 9 = 3 .9 4 4 9 in .).
-- T h ic k n e s s o f a d ju s tm e n t s h im
S 2 = 1 0 3 .3 - 1 0 0 .2 = 3.1 m m (4 .0 6 6 9 - 3 .9 4 4 9
= 0 .1 2 2 0 in .).
E xam ple 2:
m m ( 4 .0 6 6 9 in .).
(3 .9 3 7 0 in .).
- C o rr e c tio n v a lu e C = - 0 .2 m m ( 0 .0 0 7 9 in .).
- C o r re c te d n o m in a l d is ta n c e H 7 = 1 0 0 - 0 .2 =
9 9 .8 m m (3 .9 3 7 0 - 0 .0 0 7 9 = 3 .9 2 9 1 in .).
S 2 = 1 0 3 .3 - 9 9 .8 = 3 .5 m m (4 .0 6 6 9 - 3 .9 2 9 1 =
0 .1 3 7 8 in .).
E xam ple 3:
m m ( 4 .0 6 6 9 in .).
(3 .9 3 7 0 in .).
- C o rr e c tio n v a lu e C = 0 m m (0 in .).
- C o r re c te d n o m in a l d is ta n c e H 5 = H 6 = 1 0 0 m m
(3 .9 3 7 0 in .).
S 2 = 1 0 3 .3 - 1 0 0 = 3 .3 m m ( 4 .0 6 6 9 - 3 .9 3 7 0 =
0 .1 2 9 9 in .).
6-62720 - 09 - 2006
BEVEL DRIVE ADJUSTM ENTS
A d ju s tm e n t o f th e c ro w n w heel b e a rin g s and

c h e c k in g th e backla sh betw een th e p in io n and
c ro w n w h ee l.
1. In s ta ll th e b e v e l p in io n w ith a ll p a rts (le s s th e

s e a l b u t in c lu d in g s h im s ( S 1 a n d S 2 , p a g e 7)
in th e d iffe re n tia l c a rrie r. S h im s iz e s to b e a s
d e te r m in e d in th e p r o c e d u r e d e s c rib e d on
p a g e s 29 and 30.
2. F it p in io n re ta in in g to o l 380000257 .
3. In s e rt w r e n c h 380000532 o n th e a d ju s te r rin g
nut m od. JX 60 and JX 7 0 380000268 m o d .
JX 80, JX 9 0 and JX 95.
4. U s in g th e to r q u e w r e n c h o n th e p in io n re ta i
n in g w re n c h , h o ld th e b e v e l p in io n in p o s itio n
a n d , u s in g a to r q u e w r e n c h p o s itio n e d e x a c tly
a s in fig . 6 8 o n th e rin g n u t w r e n c h , tig h te n th e
rin g n u t (C 1 ) to a to r q u e v a lu e o f 2 9 4 N m 68
( 2 1 6 .8 4 3 5 2 ft lb ) w h ile s im u lta n e o u s ly ro ta tin g
th e p in io n s h a ft to e n s u r e t h a t th e b e a rin g s a re
s e a te d c o rre c tly .
5. W ith to r q u e w r e n c h 380001633 (1 ) fitte d on

p in io n re ta in in g w r e n c h 380000257 (2 ), c h e c k
th a t th e p in io n ro llin g to rq u e , w ith o u t o il s e a l
a n d re la tiv e d u s t s e a l, is 0 .5 + 1 N m (0 .3 6 8 8
+ 0 .7 3 7 6 ft lb).
If th e ro llin g to r q u e is le s s th a n th e p re s c rib e d
v a lu e , fit a t h in n e r a d ju s tm e n t s h im ( S 1 , p a g e
7 ); o n th e c o n tra ry , if th e to r q u e is g r e a te r
th a n th e p re s c rib e d v a lu e , fit a th ic k e r a d ju s t
m e n t s h im .
6. U n s c re w th e rin g n u t a n d fit th e s e a l a n d th e
re la tiv e d u s t s e a l rin g . T ig h te n th e n u t to a
to r q u e v a lu e o f 2 9 4 N m ( 2 1 6 .8 4 3 5 2 ft lb ) w h ile 69
s im u lta n e o u s ly ro ta tin g th e p in io n s h a ft to
e n s u re t h a t th e b e a rin g s a re s e a te d c o rre c tly .
7. W ith to r q u e w r e n c h 380001633 (1 ) fitte d on

p in io n re ta in in g w r e n c h 380000257 (2 ) c h e c k
th a t th e p in io n ro llin g to rq u e , w ith th e o il s e a l
a n d re la tiv e d u s t s e a l, is - 0 .5 0 N m ( 0 .3 6 8 8 ft
lb ) f o r m o d . J X 6 0 a n d J X 7 0 o r - 0 .7 5 N m
( 0 .5 5 3 2 ft lb ) f o r m o d . J X 8 0 , J X 9 0 a n d J X 9 5 .
F in a lly , s e c u r e th e rin g n u t a n d fit th e c ir c lip on
th e b e v e l p in io n s h a ft.
6-62720 - 09 - 2006
8. In s ta ll th e d iffe re n tia l u n it in th e c a r r ie r e n s u
rin g t h a t rin g g e a r is n o t fo rc e d o n to th e p in io n .
T ig h te n s c r e w s ( C 10) to 5 9 N m (4 3 .5 1 6 2 ft lb)
th e n s la c k e n a n d r e tig h te n to 2 0 N m ( 1 4 .7 5 1 2
ft lb).
9. L u b ric a te th e rin g gear b e a rin g s , fit th e

a d ju s te r s h im o n th e le ft--h a n d s id e ( fro n t
b ra k e s id e f o r fo u r- - c y lin d e r m o d e ls if th is
v a r ia n t is in c lu d e d in th e t r a c t o r v e rs io n ),
ro ta te th e b e v e l d riv e a n d tig h te n th e d iffe re n
tia l b e a rin g lo c k rin g ( G S, p a g e 7).
70
10. U s in g w r e n c h (1 ) 380000252 , f o r J X 6 0 o r
J X 7 0 m o d e ls , o r w r e n c h 380000253 , f o r J X 8 0 ,
J X 9 0 o r J X 9 5 m o d e ls , c h e c k t h a t t h e to r q u e is
3 9 to 5 9 N m (2 8 .7 6 4 9 to 4 3 .5 1 6 2 ft lb ) to
e s ta b lis h th e s p e c ifie d a x ia l p r e - lo a d .
11. M e a s u re b e v e l d r iv e b a c k la s h (1, fig . 7 2 ) u s in g
a d ia l g a u g e p o s itio n e d a t rig h t a n g le s to a
b e v e l g e a r to o th .
12. R e p e a t th e m e a s u r e m e n t a t tw o o th e r e q u id i
s ta n t p o in ts , 1 2 0 ° a p a rt. C o m p a re t h e a v e ra g e
of th e th r e e r e a d in g s w ith th e s p e c ifie d
b a c k la s h o f 0 .1 5 - 0 .2 0 m m (0 .0 0 5 9 - 0 .0 0 7 9
in .) (a v e ra g e 0 .1 8 m m (0 .0 0 7 1 in .)).
71
13. If th e m e a s u re d b a c k la s h e x c e e d s t h e p r e s c r i
b e d v a lu e , fit a t h in n e r a d ju s tm e n t s h im .
Note: O n t h r e e - c y lin d e r m o d e ls o r f o u r - c y lin d e r

m o d e ls w ith o u t th e fr o n t b ra k e , if th e c le a r a n c e v a
lu e is n o t w ith in th e p re s c rib e d fie ld o f to le ra n c e ,
u n s c re w o n e o f th e rin g n u ts , w h ils t tig h te n in g th e
o th e r to a n e q u a l a m o u n t, s o a s to r e s e t th e p re
s c rib e d c le a ra n c e .
72
T h e d e fin itiv e v a lu e to fit o n th e b e v e l d r iv e - d if f e r

e n tia l s u p p o r t w ill b e g iv e n by:
S = Sp + {(0.18 - G m ) x 1.35}
w h e re :
Sp = th ic k n e s s o f te s t s h im in s ta lle d in th e b e v e l
d r iv e --d iffe re n tia l h o u s in g .
Gm = a v e ra g e b a c k la s h m e a s u r e d b e tw e e n th e
s id e s o f th e te e th o f t h e b e v e l d riv e .
14. If th e b a c k la s h m e a s u re d is le s s th a n th e
p re s c rib e d v a lu e , it w ill b e n e c e s s a r y to fit a
th ic k e r a d ju s tm e n t s h im , th e v a lu e b e in g g iv e n
by:
6-62720 - 09 - 2006
S = Sp + {(0.18 - G m ) x 1.35}
w h e re :
Sp = th ic k n e s s o f te s t s h im in s ta lle d in th e b e v e l
d r iv e - d iff e r e n t ia l h o u s in g .
Gm = a v e ra g e b a c k la s h m e a s u r e d b e tw e e n th e
s id e s o f th e te e th o f t h e b e v e l d riv e .
15. F it a s h im o f th e c a lc u la te d th ic k n e s s a n d w ith a
1 /1 0 0 s c a le d ia l g a u g e p o s itio n e d p e r p e n d ic u la r
to th e o u ts id e e d g e o f o n e o f th e c ro w n w h e e l
te e th , c h e c k t h a t th e b a c k la s h b e tw e e n th e
p in io n a n d th e c ro w n w h e e l is w ith in th e p re
s c rib e d to le r a n c e lim its 0 .1 5 * 0 .2 0 m m (0 .0 0 5 9
to 0 .0 0 7 9 in .).
16. U s in g w r e n c h 380000252 , f o r J X 6 0 o r J X 7 0
m o d e ls , o r w r e n c h 380000253 , f o r J X 8 0 , J X 9 0 o r
J X 9 5 m o d e ls , tu r n th e a d ju s te r rin g n u t a n d ,
u s in g w r e n c h 380001633
to r q u e fitte d on
w re n c h 380000257 (1, fig . 7 3 ), c h e c k t h a t th e
ro llin g re s is ta n c e to r q u e o f th e c ro w n w h e e l a n d
p in io n b e a rin g s , as m e a s u re d in th e sam e
c o n d itio n s u s e d to c h e c k o n ly th e p in io n , is:
A 2 = A 1 + 1 * 1.5 Nm (0.7376.5 to 1.1063 ft lb)

w h e re :
A 2 = p in io n - c r o w n w h e e l ro llin g re s is ta n c e to r q u e ;
A 1 = ro llin g to r q u e o f p in io n o n ly , 0 .5 N m (0 .3 6 8 8
lb ) f o r J X 6 0 o r J X 7 0 m o d e ls a n d 0 .7 5 N m (0 .5 5 3 2
ft lb ) w ith th e p in io n fitte d w ith th e s e a l, m e a s u re d
p re v io u s ly ;
1 * 1.5 Nm (0.7376.5 to 1.1063 ft lb) = ro llin g re s i
s ta n c e to r q u e o f c ro w n w h e e l o n ly m e a s u re d a t
th e e n d o f th e p in io n , u s in g w r e n c h 380000257
a n d to r q u e w r e n c h 380001633 .
73
17. T ig h te n th e c a p b o lts (C 1 , p a g e 4 ) to a to r q u e
o f 113 N m (8 3 .3 4 4 5 ft lb).
18. F it th e s a fe ty p la te s , s c re w in g th e a d ju s tm e n t
rin g n u t in o r o u t, to re a c h th e n e a re s t n o tc h .
19. A tta c h th e d iffe re n tia l b e v e l d riv e c a r r ie r to th e

a x le c a s in g a f te r h a v in g c a r e fu lly c le a n e d a n d
d e g re a s e d th e m a tin g s u r fa c e s and a p p ly
s e a lin g c o m p o u n d (a p p ro x . 2 m m ( 0 .0 7 8 7 )
a lo n g th e m a rk e d lin e s h o w n in th e d ra w in g
b e lo w .
74
6-62720 - 09 - 2006
20. A tta c h th e d iffe re n tia l b e v e l d riv e c a r r ie r to th e

a x le c a s in g a f te r h a v in g c a r e fu lly c le a n e d a n d
d e g re a s e d th e m a tin g s u r fa c e s and a p p ly
s e a lin g c o m p o u n d (a p p ro x . 2 m m ) a lo n g th e
m a rk e d lin e s h o w n in th e d ra w in g b e lo w .
S ea lin g c o m p o u n d a p p lic a tio n diagram fo r

a s s e m b ly o f bevel d rive u n it and e p ic y c lic
fin a l d riv e u n it.
T h e ty p e s o f m a s tic to u s e a re lis te d o n p a g e 1 o f
s e c tio n 0 0 .
75
6-62720 - 09 - 2006
FRONT A X LE DIFFERENTIAL
O verhaul (Op. 25 102 2 4 )
When overhauling the differential assembly it is nec

essary to adjust the backlash between the teeth of
the planet pinions and the side gears.
Proceed as follows:
1. Thoroughly clean the components of the differ

ential to remove any traces of oil which would
otherwise prevent accurate backlash measure
ment.
2. Install the two side gears without thrust washers.
3. Fit the planet pinions complete with thrust wash

ers and pins and screw the pin retaining bolts in
by a few turns sufficient to hold the pins in place.
4. Position a dial gauge on the differential housing,

as shown.
5. Move the left-hand side gear to bring it into full

contact with the planet pinion and then push it up
against the differential housing, reading the end-
float (G s) on the dial gauge.
76
6. Repeat the above operations to measure the
endfloat on the right-hand side gear (Gd).
The endfloat should be 0.25 m m (0.0098 in.).
Therefore the shims to be inserted in the differ
ential housing are given by:
Ss = Gs - 0.25 m m (0.0098 in.) fo rth e left-hand
side gear;
Sd = Gd - 0.25 m m (0.0098 in.) for the right-
hand side gear.
7. Install shims as near as possible to the calcu

lated value and, using a dial gauge and following
the procedure described above, check that the
endfloat of the left and right-hand side gears is
77
approximately 0.25 mm (0.0098 in.).
6-62720 - 09 - 2006
LIM ITED -SLIP, S E LF -LO C K IN G DIFFEREN

T IA L LO CK
O pe ra tion
T h e d iffe re n tia l w ith lim ite d s lip lo c k in g ( L lM -
S L IP ) is o f th e tw o p la n e t g e a r - t y p e . It is p ro v id e d
w ith tw o m u lt i- d is c c lu tc h a s s e m b lie s fitte d b e
tw e e n th e s id e g e a r s a n d th e d iffe re n tia l c a s in g .
T h is d iffe re n tia l Io c k d e v ic e is to ta lly a u to m a tic . It
r e q u ire s n o m a n u a l o p e ra tio n a n d s ig n ific a n tly
re d u c e s (b u t d o e s n o t c o m p le te ly e lim in a te ) w h e e l
s lip .
T h e d iffe re n c e in s p e e d b e tw e e n th e s id e g e a rs
a n d th e d iffe re n tia l c a s in g w h e n a w h e e l lo s e s g rip
a n d b e g in s to s lip , is p re v e n te d b y th e c lu tc h
a s s e m b lie s t h a t a re c o m p re s s e d b y a x ia l th r u s t
fr o m th e b e v e l d riv e to r q u e t r a n s m itte d to th e s id e
g e a rs b y m e a n s o f th e te e th o n th e tw o p la n e t
g e a rs .
T h e s e to r q u e v a lu e s m a y b e d iffe re n t, a c c o rd in g
to th e n a tu re o f th e g ro u n d a n d th e ro u te fo llo w e d
b y th e tr a c to r . T o rq u e m a y v a r y in in te n s ity ,
t h e re b y p ro p o r tio n a lly v a ry in g th e a x ia l th r u s t on
t h e c lu tc h e s . T h is c a u s e s th e s id e g e a rs to m e s h
78
w ith th e d iffe re n tia l c a s in g w h ic h , in tu r n , p e rm its
t h e a x le to o v e r c o m e th e u n e v e n n e s s o f th e LIM ITE D -S LIP s e lf-lo c k in g d iffe re n tia l lo ck
g ro u n d .
FRONT A X LE D IFFERENTIAL W ITH L lM IT E D -

S LlP UNIT
O verhaul (Op. 25 102 27 )
----------- A WARNING A -----------

H a n d le a ll p a rts w ith c a re fu lly .D o n o t p u t y o u r h a n d s
o r fin g e r s b e tw e e n p a rts . W e a r s u ita b le s a fe ty
c lo th in g , s a fe ty g o g g le s , g lo v e s a n d fo o tw e a r.
1 . R e m o v e th e b e v e l d riv e -- d iffe re n tia l c a s in g

a s s e m b ly fr o m th e fr o n t a x le a n d a tta c h to th e
s u p p o r t 380000255 (4 ). L o c k th e s u p p o r t in a v ic e
a n d p ro c e e d w ith d is a s s e m b ly , a s fo llo w s .
2. R e m o v e th e b o lts (2 ) a n d th e le f t - and
r ig h t - h a n d rin g n u t Io c k p la te s (3 ).
3. C h e c k t h a t th e rig h t a n d I e f t- h a n d c a p s (1 ) a re
c le a rly m a rk e d , s o a s n o t to m ix th e p a rts d u rin g
re a s s e m b ly .
4. R e m o v e th e le f t - a n d r ig h t - h a n d b e a rin g
a d ju s tm e n t rin g n u ts (G d ) fr o m th e c ro w n w h e e l.
5. R e m o v e th e b o lts (C g ), s e c u rin g th e c a p s (1)
a n d s e p a r a te th e c ro w n w h e e l fr o m th e b e v e l
79
p in io n s u p p o r t.
6. If n e c e s s a ry , u n s c re w th e re ta in in g b o lts (C 3 ,
p a g e 4 ) a n d re m o v e th e c ro w n w h e e l.
6-62720 - 09 - 2006
Disassemble the LiM -SLiP self-locking differen

tial lock as follows:
7. Remove the retaining bolts (1) from the
differential half-casing.
8. Open the differential casing (6).
9. Remove the half-casing (7) the differential pin
(4), complete with the planet gears (3), the thrust
washers (2) and the pins (9).
10. Remove the side gear (5) the friction disc (11),
the metal discs (1 0) and the friction discs ( 12 ) from
the half-casing (8).
11. Check the w ear on the metal discs (10) and the
friction discs ( 1 1 ) and ( 12 ) - see table below.
Replace any parts that show signs of wear.
12. Proceed with the self-locking differential
assembly operations, carrying out the previously
described operations in reverse order. Apply
LOCTITE 270 to the threads on the screws (1) and
tighten to a torque value of 50 Nm (36.8781 ft lb).
80
LIM -S L IP s e lf-lo c k in g d iffe re n tia l lo ck
13. Re-install the crown wheel (if previously

disassembled) to the half-casing (8). Tighten the
screws (C3, page 4) to a torque of 113 Nm
(11.5 kgm).
14. Check the rolling torque of the bevel pinion as
indicated on page 32 and following.
15. Assemble the crown wheel, complete with
LIM -S LIP self-locking differential lock, onto the
bevel drive support. Do not forget to fit the
previously marked crown wheel bearing support
caps in the correct order. Assemble and then
adjust the crown wheel bearings as indicated on
page 32 and following.
F ric tio n p a rts d e tail 81
L IM -S L IP SELF - lo c k in g d iffe re n tia l lo c k fric tio n d is c s
Part no. Description Quantity Thickness Maximum wear per disc

mm (in.) mm (in.)
10 Metal discs 10 1.5 (0.0591) -
11 Friction discs 2 2.8 (0 . 1102 ) 0.10 (0.0039)
12 Friction discs 8 1.6 (0.0630) 0.15 (0.0059)
6-62720 - 09 - 2006
NO SPIN DIFFERENTIAL (o p tio n a l)
82
S e ctio n th ro u g h d iffe re n tia l w ith NO -SPIN u n it
C 1 = C a s e c a p s c re w , tig h te n in g to r q u e 5 6 to 6 2 N m (4 1 .3 0 3 4 to 4 5 .7 2 8 8 ft lb)
1 - Case, flange half 8 - Retaining ring

2 - Case, cap half 9 - Cam holdout rings
3 - Side gear 10 - Driven clutch
4 - Side gear 11 - Centre cam
5 - Springs 12 - Stop
6 - Spring retainer 13 - Ring gear
7 - Central driven assembly 14 - Axle shafts
15 - Front axle housing
6-62720 - 09 - 2006
NOTE:
C heck NO S P IN d iffe re n tia l u n it o p e ra tio n as W h e n th e t r a c t o r is in a s tr a ig h t fo rw a rd o r r e v e rs e

fo llo w s : m o d e o f o p e ra tio n , th e NO SPIN a llo w s e q u a l
s p e e d to b e d is tr ib u te d to b o th w h e e ls .
- W ith t h e e n g in e o ff, e n g a g e a g e a r a n d th e fr o n t
w h e e l d riv e , a p p ly p a rk in g b ra k e a n d ra is e fr o n t W h e n th e t r a c t o r m a k e s a tu r n o r a fr o n t w h e e l
o f tra c to r. p a s s e s o v e r a n o b s tru c tio n , th e o u te r w h e e l o r t h e
w h e e l o n th e o b s tru c tio n m u s t tr a v e l fa s t e r a n d
- R o ta te t h e fr o n t w h e e ls in a fo rw a r d d ire c tio n to
fa r t h e r th a n th e o th e r. To d o th is it a u to m a tic a lly
e lim in a te p la y. H o ld th e L .H . w h e e l a n d ro ta te
d is e n g a g e s , p a s s e s o v e r th e o b s tru c tio n o r n e g o
th e R .H . w heel re a r w a r d s . The NO S P IN
tia te s th e c u rv e a n d r e - e n g a g e s a g a in a u to m a ti
d iffe re n tia l w ill d is e n g a g e a n d th e w h e e l w ill
ca lly .
ro ta te w ith an in d e x in g o r m e ta llic c lic k in g
sound. If o n e w h e e l s h o u ld Io s e tr a c tio n m o m e n ta rily , th e
o p p o s ite w h e e l, w h ic h s till h a s tr a c tio n , c o n tin u e s
- S to p th e R .H .w h e e l, th e n tu rn fo r w a r d s s lig h tly .
to p u ll th e v e h ic le u n til tr a c tio n is re g a in e d b y b o th
T h e N O S P IN d iffe re n tia l w ill e n g a g e a n d s to p
w h e e ls .
th e w h e e l. R o ta te b o th w h e e ls b a c k w a rd s to
e lim in a te p la y, h o ld th e L .H .w h e e l a n d ro ta te T u rn in g : In a le ft tu rn , f o r in s ta n c e ,th e r ig h t - h a n d
th e R .H . w heel fo r w a rd s . The NO S P IN w h e e l in c r e a s e s s p e e d . T h e a x le s h a ft (1 4 ) (p a g e
d iffe re n tia l w ill d is e n g a g e a n d th e w h e e l w ill 3 9 ), tr a n s m its th is s p e e d in c re a s e to th e le ft s id e
ro ta te w ith an in d e x in g o r m e ta llic c lic k in g g e a r (3 ) to th e le ft d r iv e n c lu tc h (1 0 ) a n d to th e
sound. a s s o c ia te d c a m h o ld o u t rin g (9 ). W h e n th e s p e e d
d iffe re n c e b e tw e e n th e tw o w h e e ls re a c h e s a
- S to p R .H . w h e e l, th e n tu m b a c k w a r d s s lig h tly .
g iv e n v a lu e , rin g (9 ) a n d c lu tc h (1 0 ) o v e rc o m e
T h e N O S P IN d iffe re n tia l w ill e n g a g e a n d s to p
s p rin g Io a d a n d d is e n g a g e fr o m th e c e n tre c a m
th e w h e e l.
(1 1 ), re m a in in g in th is p o s itio n u n til1 h e e n d o f th e
- R e p e a t th e a b o v e o p e r a tio n s w h ile h o ld in g th e c u rv e .
R .H . w h e e l.
o p e r a t io n
NOTE: F o r c o r r e c t NO SPIN d iffe re n tia l o p e ra tio n ,
The NO SPIN d iffe re n tia l p e rfo rm s th e fo llo w in g k e y ty r e s m u s t b e e q u a l (w ith in a fe w m illim e tre s ) in
fu n c tio n s : ro llin g c ir c u m fe r e n c e . S m a ll d iffe re n c e s m ay be
c o r re c te d b y a d ju s tin g ty r e in fla tio n p re s s u re . To
- P e rm its fu ll u s e o f t r a c t o r p u ll. c h e c k th e ro llin g c ir c u m fe r e n c e o f a ty re , p ro c e e d a s
fo llo w s :
- P re v e n ts w h e e l- s p in w hen one wheel Io s e s
tra c tio n . W ith th e t r a c t o r o n a h a rd , le v e l s u rfa c e , m a r k th e
e d g e o f th e ty re , w ith c h a lk , a t th e lo w e s t p o in t
- C o m p e n s a te s f o r d iffe re n c e s in w h e e l tr a v e l
(w h e r e it c o n ta c ts th e g ro u n d ) . M a r k th e g ro u n d a t
w h ic h occur w hen tu r n in g o r tr a v e lin g over
th e s a m e s p o t.
u n e v e n g ro u n d .
M o v e th e t r a c t o r fo rw a rd s o t h a t th e ty r e ro ta te s
e x a c tly o n e re v o lu tio n , i.e ., w h e n th e c h a lk m a r k on
th e ty r e c o n ta c ts th e g ro u n d a g a in . M e a s u r e th e
d is ta n c e tra v e lle d . T h is is th e ro llin g c ir c u m fe r e n c e
o f th e ty re .
R e p e a t o n th e o p p o s ite w h e e l to c h e c k t h a t b o th
ty r e s h a v e th e s a m e ro llin g c ir c u m fe r e n c e .
6-62720 - 09 - 2006
FRONT AX LE D IFFERENTIAL W ITH NO SPIN

OP. 25 102 26
O verhaul
WARNING
H a n d le a ll p a rts w ith c a re fu lly . D o n o t p u t y o u r h a n d s
o r fin g e r s b e tw e e n p a r ts .W e a r s u ita b le s a fe ty c lo
th in g , s a fe ty g o g g le s , g lo v e s a n d fo o tw e a r.
1 . R e m o v e th e b e v e l d r iv e - d iff e r e n t ia l c a s in g
a s s e m b ly fr o m th e fr o n t a x le a n d a tta c h to th e
s u p p o r t 380000255 (4 ). L o c k th e s u p p o r t in a v ic e
a n d p ro c e e d w ith d is a s s e m b ly , a s fo llo w s .
2. R e m o v e th e b o lts (2 ) and th e left-- and
r ig h t - h a n d rin g n u t Io c k p la te s (3 ).
3. C h e c k t h a t th e rig h t a n d I e f t- h a n d c a p s (1 ) a re
c le a rly m a rk e d , s o a s n o t to m ix th e p a rts d u rin g
re a s s e m b ly .
4. R e m o v e th e le f t - a n d r ig h t - h a n d b e a rin g
a d ju s tm e n t rin g n u ts (G d ) fr o m th e c ro w n w h e e l.
5. R e m o v e th e b o lts ( C -io ), s e c u rin g th e c a p s (1 )

a n d s e p a r a te th e c ro w n w h e e l fr o m th e b e v e l
p in io n s u p p o r t. 83
6. If n e c e s s a ry , u n s c re w th e re ta in in g b o lts (C 3
p a g e 4 ) a n d re m o v e th e c ro w n w h e e l.
D is a s s e m b le th e N O S P IN s e lf- lo c k in g d iffe re n tia l

Io c k a s fo llo w s .
7. R e m o v e th e re ta in in g b o lts (1 ) fr o m th e d iffe r e n
tia l h a lf - c a s in g .
8. O p e n th e d iffe re n tia l c a s in g
9. R e m o v e th e c e n tra l d riv e n (7 ), re ta in in g th e
d iffe re n tia l h a lf -- c a s in g .
10. P r o c e e d w ith s e lf- lo c k in g th e d iffe ra n tia l
a s s e m b ly o p a r a tio n s , c a rry in g o u t th e p re v io u s ly
d e s c ir ib e d o p e r a tio n s in re v e r s e o r d e r T ig h te n th e
b o lts ( C i, fig . 8 4 ) to r g u e v a lu e o f 5 6 - 6 2 N m
( 4 1 .3 0 3 4 - 4 5 . 7 2 8 8 ft lb)
11. R e fit th e c ro w n w h e e l b o lts (C 3 , p a g e 4 ) a n d

to r q u e to a v a lu e o f 113 N m (8 3 .3 4 4 5 ft lb)
12 . A s s e m b le th e c ro w n w h e e l, c o m p le te w ith N O
S P IN s e lf- lo c k in g d iffe re n tia l lo c k , o n to th e b e v e l
d riv e s u p p o rt. R e m e m b e r to fit th e p r e v io u s ly
m a rk e d c ro w n w h e e l b e a rin g s u p p o r t c a p s in th e
c o r r e c t o r d e r a n d a s s e m b le a n d th e n a d ju s t th e
c ro w n w h e e l b e a r in g s a s in d ic a te d o n p a g e 3 2 a n d
fo llo w in g .
84
6-62720 - 09 - 2006
CHECKING THE ALIG N M EN T OF STEERING

DRIVE W HEELS (Op 44 511 80 )
W h e n tr a v e llin g fo rw a rd in a s tr a ig h t p a th , th e w h e e ls
o f f o u r - w h e e l d riv e tr a c to r s m u s t b e p a ra lle l to th e
lo n g itu d in a l a x is o f th e tra c to r, a lte r n a tiv e ly a s lig h t
t o e - in o f th e fr o n t w h e e ls is p e r m is s ib le u p to a m a x i
m u m o f 6 m m ( 0 .2 3 6 2 in .) a s m e a s u re d a t t h e e d g e s
o f t h e w h e e l rim s .
To c h e c k th e e x a c t v a lu e o f th e t o e - in s e ttin g o f f o u r -
w h e e l d riv e tr a c to r s , p ro c e e d a s fo llo w s .
1. In fla te th e fr o n t t y r e s to th e p re s c rib e d p re s s u re .
2. P o s itio n th e s te e rin g a t th e s tr a ig h t ahead

p o s itio n (a lo n g th e lo n g itu d in a l a x is o f th e
tra c to r ).
3. C heck th a t th e w h e e ls a re p a ra lle l to th e
lo n g itu d in a l a x is o f th e tra c to r.
4. M a k e a c h a lk m a r k o n th e fro n t in s id e e d g e s o f
b o th w h e e l rim s , a t th e h e ig h t o f t h e w h e e l h u b
c e n tre s . M e a s u re th e d is ta n c e (1 ) b e tw e e n th e
c h a lk m a rk s .
5. M ove th e t r a c t o r fo r w a rd to tu rn b o th fr o n t
w h e e ls th r o u g h 1 8 0 o . T h e c h a lk m a r k s w ill n o w
b e m e a s u re b e tw e e n t h e rear in s id e e d g e s o f th e
wheel rim s a t th e h e ig h t o f th e w heel hub
c e n tre s . M o w m e a s u re t h e d is ta n c e (2 ) c h e c k in g
t h a t t h is n e w m e a s u r e m e n t is e q u a l to o r g r e a te r
th a n th e d is ta n c e (1 ) b y a m a x im u m o r 6 m m .
T h e ro ta tio n o f th e w h e e ls t h r o u g h 1 8 0 o is n e c e s s a r y
to e lim in a te th e e ffe c t o f w e a r, m is a lig n m e n t o r
d is to rtio n o f th e w h e e l rim s o n th e m e a s u r e m e n ts
o b ta in e d .
6. If it is n e c e s s a r y to c o r r e c t th e w h e e l a lig n m e n t,
re m o v e n u t (2 ) a n d p u ll th e tr a c k ro d e n d (1 ) o u t
o f its h o u s in g . S la c k e n o f f lo c k n u t (3 ) a n d s c r e w
th e t r a c k ro d e n d (1 ) in o r o u t to in c r e a s e o r
d e c r e a s e th e d is ta n c e (2 ) fig . 8 4 .
R e p o s itio n th e t r a c k ro d e n d (1 ) in its h o u s in g
a n d r e - c h e c k a lig n m e n t a s d e s c rib e d in p o in ts 4
and 5 above.
A f te r h a v in g a d ju s te d th e a lig n m e n t to w ith in th e
p re s c rib e d lim its , tig h te n lo c k n u t (3 ) to a to r q u e
o f 1 8 0 N m ( 1 3 4 . 9 7 3 8 f t lb ) a n d n u t (2 ) to 1 0 0
N m ( 7 3 .7 5 6 2 f t lb ).
NOTE: T h e s e lf- lo c k in g n u t (2 ) m u s t b e r e n e w e d
e a c h tim e it is r e m o v e d o r p a r tia lly u n s c re w e d . 85
6-62720 - 09 - 2006
SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1 1
SECTION 27 - REAR AXLE AND TRANSMISSION
Chapter 1 - Rear axle and transmission
CONTENTS
27 000 Main d a t a ........................................................................................................................................ 1

Special tools ................................................................................................................................. 5
Cross-sectional views ................................................................................................................. 7
Description and operation and troubleshooting ....................................................................... 9
21.118.10 - 12 Transmission-gearbox casing Removal-Installation............................................................ 10
21.118.85 Transmission-gearbox casing Disassembly-Overhaul......................................................... 27
Gearbox driven shaft end float adjustment............................................................................. 35
Differential lock engagement sleeve adjustm ent................................................................... 36
Determining the bevel pinion positioning adjustment ring .................................................. 37
Adjusting the taper roller bearings for the bevel pinion s h a ft.............................................. 39
Adjusting the bearings and checking the backlash .............................................................. 40
Differential pinion and side gear backlash adjustment ........................................................ 44
27 000 - MAIN SPECIFICATION - TORQUE SETTINGS - SPECIAL TOOLS - SECTIONAL VIEWS -

DESCRIPTION AND OPERATION - FAULT FINDING
MAIN SPECIFICATION OF BEVEL GEAR PAIR AND DIFFERENTIAL
JX60 - JX70 JX80 - JX90 - JX95

Bevel gear pair gear ra tio .................................................... 9/43 = 1:4.8 (30 kph (18.6 mph))
11/43 = 1:3.9 (40 kph (24.9 mph))
Bevel gear pair tooth clearance.......................................... mm 0.18 - 0.23
(in.) (0.0071 - 0.0091)
Type of differential................................................................ with two planet gears
Mechanical differential lock control.................................... by means of pedal
Release for mechanically controlled differential lock . . . . controlled by foot brake pedals
25.040-25.061
24.040 - 24.061 (0.9858 - 0.9867)
(0.9465 - 0.9473) (for JX80-JX90)
Differential pinion internal seat d ia m e te r.......................... mm
(in.) 28.040-28.061
(1.1039 - 1.1048)
(for JX95)
Differential pinion pin diameter ............................................ mm 23.939 - 23.960 24.939-24.960
(in.) (0.9425 - 0.9433) (0.9818 - 0.9823)
(for JX80-JX90)
27.939-27.960
(1.1000 - 1.1007)
(for JX95)
Clearance between differential pinions and their pins . . . mm 0.080 - 0.122 0.080 - 0.122
(in.) (0.0031 - 0.0048) (0.0031 - 0.0048)
Diameter of side gear hub seats on differential box . . . . mm 44.080 - 44.119 51.100 - 51.146
(in.) (1.7354 - 1.7370) (2.0118 - 2.0136)
Diameter of side gear hubs ................................................ mm 43.961 - 44.000 50.954 - 51.000
(in.) (1.7307 - 1.7323) (2.0061 - 2.0079)
Clearance between side gears and their s e a ts ................ mm 0.080 - 0.158 0.100 - 0.192
(in.) (0.0031 - 0.0062) (0.0039 - 0.0076)
(see over)
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2 SECTION 27 - REAR AXLE AND TRANSMISSION - CHAPTER 1
MAIN SPECIFICATION OF BEVEL GEAR PAIR AND DIFFERENTIAL

(cont.)
JX60 - JX70 JX80 - JX90 -

JX95
Bevel pinion positioning adjustm ent.......................................... see pages 39
Adjuster shims for bevel pinion positioning ................................ mm 1.85 - 1.90 - 1.95 - 2.00 - 2.05 -
2.10 - 2.15 - 2.20 - 2.40 - 2.45 -
2.50 - 2.55 - 2.60 - 2.65 - 2.70
(in.) (0.0728 - 0.0748 - 0.0. 768 - 0.0787
- 0.0807 - 0.0827 - 0.0846 -0.0866 -
0.0945 - 0.0965 - 0.0984 - 0.1004 -
0.1024 - 0.1043 - 0.1063)
Adjusting ring bevel gear bearings and bevel gear pair coupling
clearance ....................................................................................... see page 181
Differential pinion and side gear backlash................................ mm 0.15 0.18

(in.) (0.0059) (0.0071)
Thickness of differential side gear clearance adjustment shims mm 1.5--1.6

(in.) (0.0591--0.0630)
Thickness of differential pinion thrust bearings........................ mm 1.47--1.53

(in.) (0.0579-0.0602)
Adjusting clearance between pinion and side gear teeth . . . . see page 185
Adjusting differential lo c k ............................................................ see page 177
Differential lock control fork adjuster s h im ................................ mm 0.5

(in.) (0.0197)
Spring for differential lock control fork:

- free spring len g th .................................................................... mm 220
(in.) (8.6614)
- length of spring under load of 177-195 N (3.9922-4.3892 lb) mm 157.5
(in.) (6.2008)
MAIN SPECIFICATIONS OF FINAL DRIVES
JX60 - JX70 JX80 - JX90 -

JX95
T y p e ................................................................................................. pinion type and spur gears
11:67=1:6.1
Reduction ratio ............................................................................... 11:62= 1:5.6 (for JX80-JX90)
11:68=1:6.2
(for JX95)
6-62720 - 09 - 2006
TORQUE SETTINGS - Refer to fig. 1 on page 4
Torque settings
PART TO BE TIGHTENED Thread
Nm ft lb
Retaining bolts for rear transmission/gearbox upper cover (C-i) . . . M 10 x 1.25 59 43.5161
Bolts for securing lift to rear transmission box (C2) ...................... M 12 x 1.25 98 72.2811
Bolts for securing PTO box to transmission / gearbox case (C3) M 16 x 1.5 221 163.0012
Bolts for securing torsion bar to transmission / gearbox case (C4) M 16 x 1.5 221 163.0012
Nuts for stud bolt securing final drive box to transmission /

gearbox case (C5) ............................................................................... M 12 x 1.25 98 72.2811
Drive wheel hub to disc retaining nuts (C6) .................................... M 18 x 1.5 255 188.0783
Drive wheel rim to disc retaining nuts (C7) .................................... M 16 x 1.5 245 188.7027
Ring bevel gear retaining bolts (C3) ................................................ M 12 x 1.25 123 90.7201
Bevel drive - differential support retaining self-locking bolts (Cg) M 10 x 1.25 59 43.5161
Final drive casing cover retaining bolts (C 10) ................................ M 10 x 1.25 59 43.5161
Drive wheel axle retaining nut (C 1 1 )................................................ M 55 x 1.5 882 650.5297

M 60 x 2 882 650.5297
Differential lock pedal support retaining b o lt s ................................ M 10 x 1.25 49 36.1405
Nuts for drive wheel ballast ring retaining bolts ............................ M 14 x 1.5 98 72.2811
6-62720 - 09 - 2006
SECTIONAL VIEWS
6-62720 - 09 - 2006
SPECIAL TOOLS 380000277 Hook for lifting clutch box.
380000301 Rotating stand for overhaul.
380000271 Rear mounting (with 380000301).

IMPORTANT: The operations described in this
380000272 Front mounting (with 380000301).
Section must be performed only with the
ESSENTIAL tools marked with (X). X 380000838 Adapter for extracting bevel pinion
To work in complete safety and to ensure optimal (with 380000549).
technical results with a minimum of time and effort,
they must be supplemented by the special tools 380000549 Slide hammer.
recommended below and with those to be specially 380000249 Bevel pinion positioning gauge.
constructed by you and for which the construction
diagrams are given in this manual. 50006 Punch for removing gearbox drive
shaft (see page 4, Sect.21,
Chapter 1).
List of special tools required for the various
operations described in this Section : 50007 Tool for adjusting gearbox drive
shaft (see page 4, Section 21,
380000236 Trolley for tractor disassembly. Chapter 1).
Tool to make for bevel pinion extraction

(Mark part with No. 50144 - Measurements in mm)
Make in UNI C40 material. Spring pin 3 x 20 mm.
6-62720 - 09 - 2006
Tool to make for adjusting the bevel drive

(engrave number 50027 on the tool - measurements in mm)
Make in Fe 42 C material.
26259
Tool to make for adjusting the assembly position of the bevel pinion shaft
(Mark tool with no. 50004 - Measurements in mm)
Make using Aq 45 material.
6-62720 - 09 - 2006
Sectional drawings of transm ission-gearbox case
1. Mid-range and reverse gear control rod 13. Range engagement safety pawl.
2. Slow and fast gear control rod. 14. Plug.
3. 1st and 2nd gear control rod. 15. Reverse gear support pin.
4. Detent balls. 16. Retaining bolt.
5. Spring for ball (4). 17. Reverse idler gear.

18. Thrust bearing.
6. Gear engagement safety pawl.
19. Snap ring.
7. Spring for ball (8).
20. PTO shaft.
8. Detent ball.
21. Reverser drive shaft.
9. 3rd and 4th gear control rod.
22. Engagement gear for mid-range and reverse
10. PTO external control lever. gears.
11. Gear engagement safety pawl. 23. Driving gear for mid-range gears.
12. Plug. 24. Snap ring.
NOTE: Screw in plugs 12 and 14 using one of the sealing compounds listed on page 1, Section 00.
6-62720 - 09 - 2006
Cross-sectional view of final drive
a. JX70 models 6. Roller bearing

b. JX80, JX90, JX95 models 7. Ball bearing
C l. Final drive housing cover capscrews 8. Final drive driven gear

C 2. Capscrews securing final drive housing to 9. Axle shaft
transmission housing 10. Final drive casing
C 3. Nuts securing disc to wheel rim 1 1 , 12 .Seals
C4. Capscrews securing disc to wheel hub 13. Seal guard
C 5. Nut 14,15,16.Retaining rings
T Drain plug 17. Seal thrust ring
1. Wheel disc 18. Grease nipple
2. Wheel shaft 19. Lockwasher
3. Final drive housing cover 20. Seal
4,5. Ball bearings
NOTE: During installation, apply sealing compound to surfaces X as shown in Section 00, Chapter 1, page 1.
6-62720 - 09 - 2006
The rear transmission transmits power from the Final drives are of the pinion type and are controlled
gearbox to the lateral final drives by means of the by the bevel gear pair output half-shafts, the same
bevel gear pair. The bevel gear pair is of the helical shafts that control the footbrakes.
tooth type and is supported by taper-roller bearings.
The differential has two pinions and is equipped with When the differential lock is not in use, it is kept dis
a mechanically controlled differential lock. engaged by a spring that exerts a force on the fork.
FAULT FINDING FOR BEVEL GEAR PAIR AND DIFFERENTIAL
Transmission noisy while the trac 1. Incorrect adjustment of bevel Remove the rear transmission box
tor is moving, even when the gear pinion and / or ring bevel gear and adjust the pinion and ring bevel
box is in neutral (not arising from bearings. gear bearings correctly (page 36).
final drives).
Transmission noisy when tractor 2. Excessive clearance between Remove the rear transmission box
ia operated with or without load. pinion and ring gear teeth. and correctly adjust the pinion and
ring gear bearings (page 36).
Differential repeats noise within 3. An internal component is bro Remove the rear transmission box,
short intervals. ken or defective. replace the worn parts and correctly
adjust the differential gear clearance
(page 39).
Transmission noisy and assembly 4. Pinion and / or ring gear Remove the rear transmission box
overheats. bearing clearances insuffi and correctly adjust the pinion and
cient. ring bevel gear bearings (page 36).
5. Insufficient coupling clear Remove the rear transmission box

ance between the teeth of the and correctly adjust the ring bevel
pinion and the ring gear. gear bearings (page 39).
FAULT FINDING FOR FINAL DRIVES
Final drive noisy when tractor is

6. An internal component is bro Remove the final drive box and re
moving, even with the gearbox in
ken or defective. place the damaged parts.
neutral.
6-62720 - 09 - 2006
REAR TRANSMISSION - GEARBOX CASE

Rem oval-Refitting (Op. 21 118 10 - 21 118 12)
Related service instructions up to item 44 - see
pages from 10 to 20. Also describes removal
operations of suspended cab/platform (Op. 90 110
36) with the exception of heating pipes and air
conditioning components removal.
----------- A WARNING A -----------
Lift and handle all heavy parts using proper
equipment of adequate lifting capacity.
Make sure that the assemblies and parts are
supported by appropriate tools and hooks. Keep
personnel away from the vicinity of the load to be
lifted.
To remove the gearbox-rear transmission, proceed

as follows:
1. Disconnect the negative terminal from the
battery. Remove the rear transmission drain plug
(1) and the gearbox drain plug (2). Drain the oil
into suitable containers.
2. Remove the drain plug from the 4WD transfer

box (1) and drain the oil into a suitable container.
3. Place the tractor dismantling stand 380000236,

so that the fixed support (1) is beneath the rear
transmission case in supporting the engine
coupling flange and the moveable support (2)
under the engine in supporting the flange
attached to the gearbox case.
6-62720 - 09 - 2006
4. Place another moveable stand 380000236

under the front weight carrier to prevent any
possibility of the engine tipping forwards when
the gearbox is removed. Put wooden blocks (1)
between the stands and the tractor body. Turn
the stand height adjustment lever to bring the
blocks (1) into contact with the tractor.
10
5. Remove electrical connections (1) going to the

instrument panel.
11
6. Remove the socket (1) with its cable that passes
from the instrument panel and over the gearbox
to the rear fender.
12
7. Remove the support bolt (1) from the injection
pump and disconnect the hand and foot throttle
cables.
13
6-62720 - 09 - 2006
8. After retrieving the oil from the power steering

tank, disconnect the hoses (1) from the power
steering pump. (Mark the hoses, before removal,
to facilitate refitting in the correct position).
9. Disconnect the proofmeter drive cable from its

adapter (1) and remove the retaining bolt (2).
10. Remove the filter line (1) and pressure pipe (2)
from hydraulic pump.
11. After draining off the coolant into suitable

containers, unscrew the clamp (1) and remove
the cab heating system intake pipe.
17
6-62720 - 09 - 2006
12. Loosen the clamps (1) and remove the cab

heater outlet pipes (2). (Mark the hoses, before
removal, to facilitate refitting in the correct
position).
13. Remove the wing nut (1) securing the condenser

(2).
19
14. Remove the compressor retaining bolts (1) and
take out the earth connection.
20
15. Move the disconnected compressor (1), con
denser (2) Fig. 19 and filter/dryer, together with
flexible hoses and valves, onto the platform.
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16. Remove the rubber floor mat from the c a b -

platform, then remove the surrounding bolts (1)
securing engine-clutch assembly to the gear
box-rear transmission case.
22
17. Place a hydraulic jack (1) underneath the centre

of the fuel tank (2) and lift it, as necessary.
23
18. Using an Allen key, unscrew the plug (1) and
drain the fuel tank using a suitable container
(Choose a container taking into consideration
the tank capacity of 90 litres (19.7879 gall. Imp.).
25
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20. Remove the bolts (1) and (2) from steel support
bracket beneath the fuel tank.
26
21. Remove the securing screws and remove the

sheet metal protector (1) from beneath the fuel
tank.
27
22. Rest the front edge of the fuel tank on the
ground.
28
23. Loosen the clamps and remove the inlet (1) and
return (2) pipes from the fuel tank. Remove the
fuel tank completely.
29
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24. Remove the pin (1) and remove the clutch pedal
cable from the upper surface of the cab/platform.
30
25. Remove the nut (1) from the parking brake

control cable. Remove the slave cylinder pipes
(2) on both sides.
31
26. Remove the reatining pin (1) and disengage the

PTO clutch cable.
32
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27. Remove the retaining pin (1) from the 4WD

engagement lever and remove the lever.
33
28. Remove the pin from the mechanical differential

lock pedal and take off the pedal head (1).
34
29. Pull up the plastic boot, remove the retaining bolt
(1) and take out the reverser control lever.
35
main and range gear selector levers.
36
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31. Remove the indicator and light connectors (1)

from both sides of tractor.
38
33. Remove the retaining pins (1) and take out the
auxiliary hydraulic valve control rods.
39
34. Disconnect the auxiliary valve nuts (1) from their
pipes.
40
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35. Remove the split pins (1) and respective draft

and position control levers.
41
36. Remove the Lift-o-maticTM control cable (1)
from the lever and from its mounting (2).
42
37. Remove the retaining pin (2) from the bottom and
the support bracket bolts (1) from the top of the
hydraulic lift control rod. Remove the left- and
right-hand lift rods.
43
38. Remove the bolt (1) that secures the gearbox
breather pipe clamp.
44
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39. Remove the bolt (1) that secures each side of the
front supports to the cab/platform.
45
40. Remove four bolts (1) that secure the rear of the
cab/platform to each end of the axle casing.
46
41. Attach the lifting bar to the lifting rings on the left
and right side of the cab roof. Take all necessary
precautions to prevent to prevent damaging the
structure by using supports, where required.
Raise the cab a little and check that there are no
forgotten parts that will prevent the cab from
being lifted further. If satisfactory, complete the
lifting operation.
47
42. Attach two hooks to the signal support bar at the
front and clamp the lifting tool to the roll-bar at
the rear.
48
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43. Remove the front retaining bolts (1), the centre

bolts (2) and the rear retaining bolts from the
4WD drive shaft guard.
44. Remove the snap ring (2) and withdraw the

sleeve (1) from 4WD transfer box, moving it in
the direction of the arrow.
45. Remove the snap ring (2) and withdraw the

sleeve (1) from the 4WD transfer box, moving it
in the direction of the arrow.
51
46. Unscrew the drive shaft centre support bolts (1)
and remove the shaft complete with support.
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47. Disconnect the trailer brake pump inlet pipes (1)

and (2) from the transmission-gearbox case.
Remove the coupling from the trailer brake
control valve supply pipe (3).
53
48. After removing the trailer brake control pipe,

remove the retaining bolts (1) together with the
complete trailer brake valve assembly.
54
49. Disconnect the trailer brake control pipe (1) and
the auxiliary valve pipes from the support plate
(2).
55
50. Connect a chain to one of the final drive
assemblies and remove it from the
transmission-gearbox case. Repeat on the
other side.
56
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51. Remove the retaining bolts and lift the hydraulic

housing using the hoist.
52. Use a chain to attach the tow hook and PTO to

the hoist. Remove the three retaining bolts (1)
from both sides and remove the unit from the
rear transmission-gearbox case.
53. Unscrew the nut (1) and remove the bolt.

Remove the right-hand lower link (3) and its
spacer (2). Repeat on the left-hand lower link.
54. Attach a belt to both the ends of the torsion bar

(1). Ensure that belt is strong enough to lift the
assembly. Remove the retaining bolts (2) and
take off the assembly.
60
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55. Remove the bolts securing the gearbox cover

(1). Remove the cover.
56. Unscrew the bolt (1) and remove the internal oil
tank (2) from the rear transmission case.
57. Connect the rear transmission-gearbox case to

the hoist by chain. Remove the rear
transmission-gearbox case using trolley stand
380000236.
63
6-62720 - 09 - 2006
SECTION
27 - REAR AXLE AND TRANSMISSION
- CHAPTER
6-62720 - 09 - 2006
1
Diagram for application of sealing compound to the rear transmission-gearbox casing 64
The types of sealing compound to be applied are listed on page 1 o f Section 00. kj
Ol
58. Refit the rear transmission-gearbox case as Fit the rear wheels and remove stand
follows: 380000326.
Fit the 4WD drive shaft and secure it by means

of the central support and, the front and rear
----------- A WARNING A ----------- sliding sleeves.
Use appropriate tools to align the holes. NEVER
USE YOUR FINGERS OR HANDS. Fix the guard onto the transfer box shaft.
Screw in the rear transmission-gearbox case oil

drain plugs and the fuel tank drain plug.
— For the correct orientation of the various parts, Lower the cab onto the transmission casing and
refer to the illustrations on pages 10 to 26. secure using the retaining bolts.
Connect the Lift-o-maticTM control cable.

— Before refitting boxes, supports and covers,
thoroughly clean and degrease the mating Connect the differential lock control rod.
surfaces and apply a strip of sealing compound
of about 2 mm (0.0787 in.) diameter as shown in Connect the parking brake control cable.
the diagram on page 25.
Fit the gearbox and final drive control levers and
— Apply the torque settings given on page 3. connect the H I-LO control connection, if
present.
— Using the stand 380000326, refit the rear
transmission-gearbox case onto the clutch box. Fit the reverser control lever.
— Fit the torion bar support complete with internal Connect the PTO speed selection cable.
connecting rod.
Connect the synchronised PTO control lever.
— Position the left and right brake friction discs. Fit
Connect the auxiliary hydraulic valve control
the brake assembly, and the lateral final drive
levers.
assembly.
Fix the fuel tank together with fixing brackets,
— Refit the PTO cover to the transmission-gearbox
mountings and rear transmission-gearbox
case.
breather pipes.
— Fit the internal tank complete with oil discharge Connect the pipes and connections to the fuel
pipe. tank.
— Fit the lower links and spacers. Refit and secure the compressor, the condenser
and the filter/dryer.
— Fit the tow hook assembly.
Connect and secure the heater control pipes.
— Re-install the hydraulic lift complete.
Connect the gearbox clutch control rod.
— Insert the springs and poppet balls and fit the
gearbox and final drive control rod support cover Connect the front service brake feed and control
to the rear transmission-gearbox case. pipes.
— Fit and connect the lift control and oil filler pipes. Connect the throttle control cable.
— Fit the three-point linkage support together with Make good all electrical socket connections
the quick-release fitting support plate and elec between the cab and the tractor body.
trical power sockets with related connectors.
Connect up the front headlights.
— Fit the trailer brake valve complete with hydraulic Screw in the engine cooling system drain plug.
valves. Fit and connect the auxiliary hydraulic
valve and trailer brake valve pipes. Fill up the fuel tank, the rear transmission-
gearbox case and the cooling system.
— Fit and connect all the hydraulic pump inlet and Recommended products and quantities are
outlet pipes and the connection pipes to the given on page 6 of Section 00.
auxiliary hydraulic valves, hydraulic lift, 4WD
transfer box, etc. Connect the negative terminal to the battery.
6-62720 - 09 - 2006
TRANSM ISSIO N-GEARBOX CASE

Rem oval-Refitting (Op. 21 118 85)
------------ A WARNING A ------------

Never place your hands or fingers between one part
and another. Wear the prescribed safety clothing,
including glasses, gloves and protective footwear.
1. Secure the transmission box-gearbox to the

rotating stand 380000301 using the front
380000272 and rear 380000271 mountings.
2. Turn the box by 180°, undo the bolts (1) and

remove the transfer box (2).
2
3. Turn the box back 180°, then use a punch to
remove the roll pins (1) and take out the rods, the
prongs, the gearbox and final drive control forks.
3
4. Use a punch to remove the roll pin (2) retaining
the differential lock engagement fork (1).
Withdraw the rod (4) and remove the helical
spring (3) and the fork.
6-62720 - 09 - 2006
5. Unscrew the lock rings of the differential support

bearing pre-load ring nuts (2) and slightly
slacken the ring nuts.
6. Unscrew the differential support retaining bolts
(1), retrieve the supports and then remove the
entire differential bevel crown wheel assembly
from the rear of the casing.
7. Remove the roll pin (2) and withdraw the external

lever (1) that controls the PTO synchronised with
the gearbox.
6
8. Extract the internal lever (2) complete with spring
(1) and sliding block (3).
7
9. Straighten out the notches and undo the driven
shaft locking nut (1).
6-62720 - 09 - 2006
10. Remove from the rear the snap ring (1) that
retains the final drive driving shaft bearing.
9
11. Using a hammer and a brass punch (1) withdraw
the gear (2) for the mid-range speeds together
with the related bearings and engagement
sleeve (3).
10
12. Withdraw the final drive driving shaft (1).
11
13. Remove the snap ring (1) that holds the bearing
(2) onto the gearbox drive shaft.
12
6-62720 - 09 - 2006
14. Fit the tool 50006 (2) (see page 4, Section 21,
Chapter 1) onto the driving shaft and use the
extractor (1) to withdraw the driving shaft.
Remove the bearings, gears and respective
bushings.
25797 .4fK^ ^
14
16. Screw the adapter 380000838 (2) onto the slide
hammer 380000549 (1) to move the bevel pinion
by a few millimetres in the direction shown by the
arrow.
15
17. Move the engagement sleeve (1) until it is
possible to gain access with pliers (2) to remove
the retaining snap ring.
16
6-62720 - 09 - 2006
18. Move the gear (1) in the direction shown by the

arrow and remove the two retaining half-rings
(2). Undo the nut (3) completely and withdraw
the bevel pinion, removing all parts.
17
19. Undo the bolts (3), take out the support plate (1)
and remove the bearing (2).
18
20. Use a brass punch (2) and a hammer to move the

driven shaft (1), withdraw the shaft and remove
all the parts.
21. Mount the rear transmission-gearbox case by

following sectional views and instructions given.
22. Apply the torque settings listed on page 3.
19
6-62720 - 09 - 2006
----------- A WARNING A -------------

USE YOUR FINGERS OR HANDS.
23. Position the box vertically, insert the gearbox

driven shaft gear set (2) and insert the shaft (1).
20
24. Turn the box by 90°, fit the front bearing (1) and
the nut (2) and tighten to the prescribed torque.
21
25. Fit the bearing (2) in its housing on the box (front
end) and lock it using the plate (1).
22
6-62720 - 09 - 2006
26. Insert the gear shift forks (1) and (3) on the
sliding rings (2) and (4) of the synchronisers.
27. Fit the bevel pinion complete with all the parts
and carry out the adjustments given on pages 37
to 39.
23
28. Fit the gearbox drive shaft complete with all parts
and the adjuster shim, then position the bearing
(2) and secure it using the snap ring (1).
24
29. Insert the final drive driving shaft from the rear
end, fit the bearing (2) into its seat and secure
with the snap ring (1).
25
6-62720 - 09 - 2006
30. Fit the lever (1) that controls the PTO

synchronised with the gearbox, complete with
spring, pawl and external lever.
31. Fit the ring bevel gear complete with support and
adjuster shims (see adjustments on pages 37 to
39.
32. Fit the differential lock engagement control fork

complete with spring-rod unit, external plate and
the corresponding adjuster shims (see page 36).
33. Fit the piston and the corresponding differential

lock control union. 26
34. Fit all the rods, forks and gearbox and final drive
control prongs.
35. Fit the transfer box assembly.
6-62720 - 09 - 2006
TRANSM ISSIO N-GEARBOX CASE

Adjusting gearbox driving shaft axial clearance
----------- A WARNING A -----------

Proceed as follows :
NOTE: Once fitted, the driving shaft gears must have

an axial clearance of 0-0.25 mm (0-0.0098 in.). The
bearings must therefore be adjusted to prevent them
from being mounted with an axial preload.
To perform this adjustment, it is recommended ma
king a tool in the workshop according to the specifica
tions given in the drawing on page 4, Section 21,
Chapter 1.
1. On the bench mount all the various components

on the driving shaft together with the snap ring
(2), replacing the two rear bearings and the
adjuster ring with the tool 50007 (1) (see page 4,
Section 21, Chapter 1).
2. Insert a screwdriver between the gear and its

bushing and use a feeler gauge to measure the
clearance (H).
3. Measure the height (C) of the tool 50007 and the

thickness of the inner rings of the two rear
bearings (1 and 2).
4. The adjuster shims to be fitted is given by :
S = H+C- A - B
where:
H = measured clearance
A and B = measured thickness of the bearings
C = height of the tool.
Example :
- measured clearance H = 1.3 mm (0.0512 in.)
- height of tool = 43.5 mm (1.7126 in.)
- thickness of ball bearing (1) = 22.9 mm
(0.9016 in.)
- thickness of roller bearing (2) = 18 mm
(0.7087 in.)
Thickness of adjuster ring :
S = 1.3 + 43.5 - 22.9 - 18 = 3.9 mm
(0.0512 + 1.7126 - 0.9016 - 0.7087 = 0.1535 in.)
NOTE: The gears should be mounted with an axial

clearance of 0-0.25 mm. In this instance, it will be
necessary to fit a shim (S) of 3.75 mm to provide an
axial clearance of : 3.9-3.75 = 0.15 mm.
6-62720 - 09 - 2006
TRANSM ISSION-GEARBOX
Adjusting the position of the differential lock en
gagement sleeve
----------- A WARNING A -----------

Proceed as follows:
1. Mount the differential release device without the

adjuster shim (S).
2. Fit the differential bevel crown wheel assembly
on its supports.
G. Clearance between differential lock sleeve and

the right-hand bevel crown wheel bearing sup
port.
0.5 + 1.25 mm (0.0197 + 0.0492 in.) All models

C3.Lock pedal support retaining bolt.
S. Differential lock sleeve travel adjuster shim.
1. Differential lock pedal.
2. Pedal support.
3. Fork control rod.
4. Fork.
5. Return spring.
6. Spring pin
7. Sliding Sleeve.
8. Differential support right-hand bearing. 29
3. Check there is a clearance (G) between the

sliding sleeve (7) of the differential lock and the
right-hand support bearing of the differential (8)
of:
0.5 + 1.25 mm (0.0197 + 0.0492 in.)

mod. JX60 and JX70,
JX80, JX90 and JX95
that can be measured with the feeler gauge (T).

4. Adjust this clearance by varying the shims (S)
fitted between the support (2) and the trans
mission casing.
30
6-62720 - 09 - 2006
ADJUSTING THE BEVEL GEAR PAIR

Determining the bevel pinion positioning
adjustment ring
Proceed as follows:
1. On the transm ission-gearbox case mount the
outer ring of the bearing (1) fig. 31 with the test
shim (2) and the outer bearing ring (3) fig. 32.
31
2. Position the bearing (2) on tool 50004 (1), insert
the bearing (3) and lock the tool (1).
32
3. Position the tool 380000249 (2) with two conical
parts in the ring gear supports and insert the
micrometer ( 1 ) with depth rod into its seat and
lock using the bolt.
4. Screw down or unscrew the cones (1) and (2) so

as to align the micrometer rod with the bearing.
Adjust the cones (1) and (2) to lock the tool on the
supports and eliminate any axial clearance.
5. Move the depth rod of the micrometer into
contact with the bearing and measure the value
(H 1).
6-62720 - 09 - 2006
6. Calculate the corrected nominal distance (H3)

between the ring gear axis and the major base of
the bevel pinion :
h3 = h2 + C
where :
H2 = 145.5 mm (5.7283 in.). Nominal distance
between the ring gear axis and major base of the
bevel pinion.
C = Correction value stamped on the pinion, ex
pressed in mm and preceded by a + or - sign (if
other than 0) to be added to or subtracted from
the nominal distance (H2) respectively.
7. Thickness of the adjuster ring (S) is given by :

S = H 1 + Sp - H3
where :
Hi = Distance measured with the micrometer

gauge.
H3 = Corrected nominal distance between
the ring gear axis and the major base of
the bevel pinion.
Sp = Test ring.
Examples:
Distance measured with the micrometer gauge
H-i = 145.9 mm (5.7441 in.).
Thickness of test ring Sp = 1.90 mm (0.0748 in.).
Nominal distance between the ring gear axis and
major base of the bevel pinion H2 = 145.5 mm
(5.7283 in.).
a) Correction value C = + 0.2 mm (0.0079 in.).
Corrected nominal distance H3 = 145.5 + 0.2 =
145.7 mm (5.7283 + 0.0079 = 5.7362 in.).
S = 145.9 + 1.90 - 145.7 = 2.10 mm (5.7441 +
0.0748 = 5.7362 in.). 35
b) Correction value C = - 0.2 mm (0.0079 in.).

Corrected nominal distance H3 = 145.5 - 0.2 =
145.3 mm (5.7283 - 0.0079 = 5.7204 in.).
S = 145.9 + 1.90 - 145.3 = 2.50 mm (5.7441 +
0.0748 - 5.7204 = 0.0985 in.).
c) Correction value C = 0 mm.

Corrected nominal distance H3 = H2 = 145.5 mm
(5.7283 in.).
Thickness of adjuster ring:
S = 145.9 + 1.90 - 145.5 = 2.30 mm (5.7441 +
0.0748 - 5.7283 = 0.0906 in.).
8. Remove the tools 380000249 and 50004; take

out the bearing external rings, the test shim and
two differential supports.
6-62720 - 09 - 2006

Adjusting the tap er-ro ller bearings for pinion
shaft
1. Mount the external track of the bearing together

with the previously calculated adjuster shim (S)
and the bevel pinion complete with its parts.
2. Tighten the bearing adjustment nut (1) while
turning the pinion shaft to allow the bearings to
bed in until rolling torque of 0.73-1.47 Nm
(1.1063-1.4751 ft lb) is obtained.
3. Mesh the range selecting sleeve with the slow

range gear. Then measure the rolling torque with
a torque meter and a cord wound around the
slow range gear of the pinion; the prescribed
torque corresponds to a force measured with the
torque meter (1) of 8.63 - 17.2 N (1.9409 -
3.8598 lb)
4. After obtaining the recommended torque, bend

the securing thrust washer (1) onto the adjuster
nut to prevent it unscrewing and decreasing the
bearing pre-load.
38
6-62720 - 09 - 2006
BEVEL DRIVE ADJUSTMENTS
Adjusting the ring bevel gear bearings and

checking the clearance between the teeth of the
bevel gear pair.
______ ^ WARNING ^ _______
Never place your hands or fingers between one part
and another. Wear the prescribed safety clothing, in
cluding glasses, gloves and protective footwear.
----------- A WARNING A -----------

Always use appropriate tools to align the holes.
NEVER USE YOUR FINGERS OR HANDS.
Proceed as follows :
1. With the bevel pinion fitted, insert the differen

tial assembly complete with the bevel crown
wheel. Secure the right- and left-hand sup
ports on the gearbox transmission casing and
bring the relevant ring nuts into contact with
the races of the bearings.
2. Using wrench 50027 (see page 6) slightly
screw the right-hand ring nut (2) onto the
support (1), and then do the same for the
left-hand ring nut. So as to obtain a slight
pre-load on the bearings.
39
3. Using a 1/100 dial gauge (1) measure the

radial clearance on the sides of the bevel drive
teeth (three measurements at 120o and
arithmetic mean of the three readings, the
difference between the three measurements
must not exceed 0.05 mm) and compare the
result with the nominal clearance: 0.18 +
0.23 mm (0.0071 0.0090 in.).
We will initially be looking for a clearance of
0.18 mm (0.0071 in.).
40
4. Setting high - low backlash depends on the ratio
between the decrease - increase in clearance
and the movement of the differential casing.
As a result, the end displacement (Z) of the
differential unit is:
Z = (G -0.18) x 1.4
where:
1.4 = Ratio between decrease-increase in back
lash and movement of the differential casing.
G = bevel drive backlash, as previously measu
red.
After calculating Z, proceed as follows:
if Z < 0 move the crown wheel away from the
pinion.
if Z > 0 move the crown wheel nearer to the bevel
pinion.
6-62720 - 09 - 2006
5. One complete turn of the ring nut corresponds to

a 2 mm axial movement of the crown wheel. A
60° turn of the ring nut, equivalent to one side of
the ring nut hexagon, corresponds to an axial
movement of the ring nut of:
Z = (60 : 360) x 2 = 0.33 mm (0.0130 in.)
TRE0519A
41
6. Making the differential turn, unscrew the right-
hand ring nut with tool 50027 (2) and tighten the
left-hand ring nut (1) by the same amount if Z >
0, otherwise unscrew the left-hand ring nut (1)
and tighten the right-hand ring nut by the same
amount if Z < 0 in order to obtain a backlash
initially of 0.18 mm.
Z = (60 : 360) x 2 = 0.33 mm (0.0130 in.)
7. On obtaining a clearance of 0.18 mm, tighten the

right-hand ring nut to obtain a rolling torque of:
42
Pinion rolling torque on Total rolling torque of pinion

Pinion rolling torque crown wheel (with bearings not measured on crown wheel (with
pre-loaded) bearings not pre-loaded)
ft lb Nm ft lb Nm ft lb Nm
torque
torque measured
measured on
on pinion
0.5421 to 2.8934 to + pinion
0.735 to 1.471 3.923 to 6.865 +
1.0849 5.0634
(0.7235 to
(0.981 to
1.4463)
1.961)
8. Making sure you do not drive the shafts of the

gearbox, it is possible to check the rolling torque
with a torque meter (1) and a cord wound around
the outer diameter of the differential casing,
keeping to the values stated in the table:
43
6-62720 - 09 - 2006
Differential casing 0 187 mm (7.3622 in.)
Force of the pinion at the tor

Force of the pinion at the torque meter
que meter measured on the
Pinion rolling torque measured on the crown wheel (with bea
crown wheel (with bearings
rings pre-loaded)
not pre-loaded)
ft lb Nm lb N lb N
Force on pinion Force on pinion

0.5421 to 0.735 to 9.4401 to 41.97 to + +
1.0849 1.471 16.5201 73.45
(2.36 to 4.72) (10.49 to 20.99)
Differential casing 0 206 mm (8.1102 in.)
Force of the pinion at the tor

Force of the pinion at the torque meter
que meter measured on the
Pinion rolling torque measured on the crown wheel (with bea
crown wheel (with bearings
rings pre-loaded)
not pre-loaded)
ft lb Nm lb N lb N
Force on pinion Force on pinion

0.5421 to 0.735 to 8.5578 to 38.05 to + +
1.0849 1.471 14.9982 66.68
(2.1394 to 4.2789) (9.51 to 19.02)
9. Using a 1/100 dial gauge (1), check the

clearance between the teeth of the bevel
drive; if this backlash remains between 0.18 +
0,23 mm (0.0071 0.0090 in.) (0.21 mm
(0.0083 in.) on average) fine, otherwise:
— if the backlash is any greater, use the wrench

50027 (1) to unscrew the right-hand ring nut and
tighten the left-hand one by an equal amount.
— if the backlash is any lower, unscrew the
left-hand ring nut and tighten the right-hand one
by an equal amount.
NOTE: It is important to unscrew one ring nut and

alternately tighten the opposite one by an equal
amount so as not to change the bearing pre-load
that has already been calculated.
45
6-62720 - 09 - 2006
10. Lock the right and left-hand ring nuts in

position with the lock ring (1).
46
6-62720 - 09 - 2006
Differential pinion and side gear backlash

adjustment
W ith th e d is tm a n tle d d iffe re n tia l on th e b e n ch ,

p ro c e e d a s fo llo w s :
IMPORTANT
A ll parts o f the d iffe re n tia l m u st be cle a n e d so th a t oil
re s id u e d o e s n o t e ffe c t th e a c c u ra c y o f th e
a d ju s tm e n t.
1. M o u n t th e side g e a rs (2) and (5) w ith o u t rings (1)

an d (6) on th e d iffe re n tia l box. In s e rt th e
d iffe re n tia l p in io n s (3) a n d (8) c o m p le te , w ith
th e ir re lated c le a ra n c e rings and w ith th e pin (7).
T ig h te n th e re ta in in g b o lt (4) by a fe w tu rn s in
o rd e r to p re v e n t th e pin fro m m o v in g .
47
2. M a n ip u la te th e RH side g e a r so th a t it co m e s into
c o n ta c t w ith th e s id e p in io n and, usin g a d e p th
m ic ro m e te r, m e a s u re th e d is ta n c e (H-0, m a kin g
tw o d ia m e tric a lly o p p o s e d m e a s u re m e n ts and
ta k in g th e a rith m e tic m e a n o f th e tw o v a lu e s
m e a s u re d .
48
3. P u s h th e s id e g e a r so th a t it to u c h e s th e
d iffe re n tia l ca s in g and m e a s u re th e
d is ta n c e (H 2).
4. R e p e a t th e s a m e o p e ra tio n s fo r th e le ft-h a n d
s id e g ear.
49
6-62720 - 09 - 2006
5. A x ia l m o v e m e n t o f e a c h s id e g e a r (2) and (5)

w ith o u t s h im s is g iv e n as :
Gs o r Gd = H 1 - H2
w h e re :
Gs = a xia l m o v e m e n t o f LH s id e g e a r;
Gd = a xia l m o v e m e n t o f RH s id e g e a r;
H1 and H2 = d is ta n c e s m e a s u re d on LH o r RH sid e
g e a r (s te p s 2 and 3).
T h e n o rm a l c le a ra n c e e n v is a g e d b e tw e e n th e s id e s
o f th e p in io n a n d s id e g e a r te e th is 0 .1 5 m m
(0 .0 0 5 9 in.) fo r J X 6 0 and JX 7 0 m odels. It is 0.18 m m
(0.0071 in.) fo r J X 8 0 , J X 9 0 and J X 9 5 m o d e ls . 50
B e a r in m ind th a t th e a v e ra g e ra tio b e tw e e n th e
n o rm a l cle a ra n ce o f d iffe re n tia l p in io n -s id e g e a r and
th e e q u iv a le n t a xia l m o v e m e n t o f th e s id e g e a rs
is 1 -1 .7 .
T h e axial m o ve m e n t o f th e sid e g e a rs co rre sp o n d in g

to th e n o rm a l p re s c rib e d c le a ra n c e b e tw e e n th e
te e th is :
0 .1 5 x 1.7 = 0.25 mm (0 .0 0 5 9 x 1.7 = 0.0098 in.) fo r
J X 6 0 a nd J X 7 0 m o d e ls ;
0 .1 8 x 1.7 = 0.30 mm (0.0071 x 1.7 = 0.0118 in.) fo r
J X 8 0 , J X 9 0 and J X 9 5 m o d e ls .
T h ic k n e s s o f th e s p a c e r rin g s (1) and (6) to be

in se rte d on th e d iffe re n tia l b o x a re :
Ss = Gs - 0.25 mm (0.0098 in.)

(fo r LH s id e g e a r o f JX 6 0 a n d J X 7 0
m o d e ls)
Sd = Gd - 0.25 mm (0.0098 in.)

(fo r RH s id e g e a r o f JX 6 0 a n d J X 7 0
m o d e ls)
Ss = Gs - 0.30 mm (0.0118 in.)

(fo r LH s id e g e a r o f J X 8 0 , J X 9 0 and
Sd = Gd - 0.30 mm (0.0118 in.)

(fo r RH s id e g e a r o f J X 8 0 , J X 9 0 and
A v a ila b le s h im s a re 1.5 a n d 1.6 m m to use fo r th e

sid e g e a r as s h o w n on p a g e 2. F it s h im s o f th e
c lo s e s t th ic k n e s s fo r th e LH a n d R H s id e g e a rs
a c c o rd in g to c a lc u la tio n s ).
6-62720 - 09 - 2006
51
Longitudinal and Cross Sectional Views of Bevel Gear Pair and Differential Unit
a. JX60 and JX70 models 12. Side gear shim
b. JX80, JX90 and JX95 models 13. Side gear shim
c. Longitudinal section for all models 14. Differential box
C1. Ring gear retaining screw 15. Bevel pinion shaft
C2. Differential support retaining screw 16. PTO shaft
S. Bevel pinion positioning shim 17. PTO control sleeve
1. Differential support 18. Fork
2. Differential support 19. Differential lock shaft
3. Taper roller bearing 20. Range gear retaining ring
4. Taper roller bearing 21. Bevel pinion securing plate
5. Differential lock sleeve 22. Differential bearing ring nut
6. Ring gear 33. Reverse driven gear
7. Side gear 34. Driven gear for slow speed gears
8. Side gear 35. Engagement sleeve for slow and fast speed
9. Differential pinion gears
10. Differential pinion shaft 36. Transmission driven shaft ring
11. Differential pinion shaft retaining screw 37. Retaining half-ring
6-62720 - 09 - 2006
FINAL DRIVE REMOVAL
----------- A WARNING A ------------

N e v e r pla ce y o u r h a n d s o r fin g e rs b e tw e e n one p a rt
and ano ther. W e a r th e p re s c rib e d s a fe ty clo th in g, in
c lu d in g g la s s e s , g lo v e s and p ro te c tiv e fo o tw e a r.
----------- A WARNING A -------------

A lw a y s use a p p ro p ria te to o ls to a lig n th e holes.
----------- A CAUTION A -----------

R a ise a n d h a n d le all h e a v y c o m p o n e n ts u sin g a
s u ita b le lift.
E n su re th a t u n its o r p a rts are s u p p o rte d by s u ita b le
s lin g s o r h o o ks. E n s u re th a t th e re is no o n e in th e
v ic in ity o f th e load to be lifted
R e m o v e th e fin a l d riv e as fo llo w s :
6. D rain oil fro m re a r tra n s m is s io n a n d fin a l d riv e

h o u s in g s .
7. P o sitio n a s u p p o rt s ta n d u n d e r tra n s m is s io n
h o u s in g a nd re m o v e R O P S fra m e , w h e e ls ,
fe n d e rs a n d p la tfo rm .
8. T ake o u t c a p s c re w s (C 5) F ig .1 , P a g e 4 and
re m o v e fin a l d riv e a s s e m b ly as s h o w n at Fig.52.
52
Disassembly (Cover)
R e m o v e th e fin a l d riv e as fo llo w s :

9. T ake o ff c a p s c re w s (C-0 Fig. 6, P a g e 8 and
re m o v e fin a l d riv e c o v e r (3) Fig. 6 w ith d riv e n
g e a r (8) Fig. 6.
6-62720 - 09 - 2006
Driven gear retaining nut removal
R e m o v e th e g e a r re ta in in g :
10. T ig h te n tw o M 1 6 x 1,5 s c re w s (C 5) Fig. 53, into
tw o o f th e w h e e l d is c h o le s on h u b a n d c la m p
w h e e l s h a ft in v ic e Fig. 53;
11. U n s c re w n u t (C 5, Fig. 6, p a g e 8) a s s h o w n in
Fig. 53 w ith a s u ita b le s p a n n e r (B).
53
12. W ith d ra w d riv e n g e a r (8). Fig. 6, p a g e 8 fro m

w h e e l s h a ft (2) u sin g p u lle r as s h o w n in Fig. 54
54
Wheel shaft removal (installation) (Fig. 55)
(A rro w in d ic a te s s h a ft re m o v a l d ire c tio n )
13. K n o c k o u t w h e e l s h a ft (2) by b e a tin g w ith lead

h a m m e r in th e d ire c tio n s h o w n by a rro w in Fig.
55.
14. U se p u lle r to w ith d ra w o u te r ring (7) fro m c o v e r
(3);
15. F inally, w ith d ra w th e b e a rin g (4) fro m cover,
h a vin g firs t re m o v e d re ta in in g c irc lip (21).
55
DISASSEMBLY (housing) (Fig. - 56)
16. R e m o v e th e b e a rin g (5) fro m th e h o u s in g (10)
Fig. 56, w ith a s u ita b le p u lle r;
17. R e m o v e re taining ring (17) Fig. 56, and w ith d ra w
a xle s h a ft (9) Fig. 56, to g e th e r w ith b e a rin g (6)
Fig. 56, in th e d ire c tio n s h o w n by arrow .
56
6-62720 - 09 - 2006
18. R e m o v e th e ro lle r b e a rin g in te rn a l ring (7)

F ig .5 6 , page 48, fro m th e axle sh a ft, using p u lle r
s e p e ra to r as s h o w n in F ig .57, and th e ball
b e a rin g (7) Fig. 6, page 8, fro m the axle s h a ft (9)
Fig. 56, h a vin g firs t re m o v e d th e lo ckrin g ;
19. C h e c k and re p la c e d a m a g e d and w o rn parts;
20. C h e c k lip s e a ls (1 1 -1 2 ) Fig. 6, p a g e 8, and
re p la c e if n ece ssa ry; p o sition as s h o w n in Fig. 6.
ASSEMBLY
C a rry o u t th e a b o ve o p e ra tio n s in th e re ve rse order,
b e a rin g in m ind th e fo llo w in g :
21. P la ce th e ro lle r b e a rin g (7) Fig. 55, o u te r ring in

its s e a t in th e fin a l d riv e c o v e r w ith m a rk on th e
o u tsid e ;
22. In sta ll th e o th e r b e a rin g s , u sin g a p p ro p ria te

in sta lle rs;
23. F it th e h a lf s h a ft and w h e e l sh a ft, ta kin g care not

to d a m a g e th e s e a ls (1 1 -1 2 ) Fig. 6;
24. F it the ro lle r bearing internal ring (7) Fig.56, page

48, on th e h a lf s h a ft (9) Fig. 56 h a v in g h e a te d it
in th e oil to 8 0 - 9 0 0 C (1 7 6 -1 9 4 0 F );
25. T ig h te n th e g e a r lo ckn u t (C 5) Fig. 6 page 8, using

w re n c h (B ) Fig. 53 p a g e 48, p re v io u s ly use d fo r
d is a s s e m b ly .
26. T ig h te n all th e n u ts a n d s c re w s to th e to rq u e
v a lu e s g ive n on p a g e 3.
27. C le a n and g re a s e th e s u rfa c e s in c o n ta c t

b e tw e e n th e h o u s in g (10) Fig. 6 p a g e 8 and th e
c o v e r (3) Fig. 6 page 8, in serting a ne w seal (20)
Fig. 6 p age 8;
28. T h ro u g h ly cle a n a n d g re a s e th e s u rfa c e s (X)

F ig .6 4 p a g e 25, a p p ly in g jo in tin g c o m p o u n d .
6-62720 - 09 - 2006
6-62720 - 09 - 2006
SECTION 31 - POWER TAKE-OFF - CHAPTER 1 1
SECTION 31 - POWER TAKE-OFF
Chapter 1 - Mechanical Power take-off
CONTENTS
31 000 M a in s p e c if ic a t io n .......................................................................................................................................... 1
T ools ................................................................................................................................................................... 3
T o rq u e s e ttin g s .............................................................................................................................................. 4
S e c tio n a l d ra w in g s ....................................................................................................................................... 5
T ro u b le s h o o tin g ............................................................................................................................................ 10
R e m o v a l - R e fittin g ....................................................................................................................................... 11
31 101 B e n c h o v e r h a u l ............................................................................................................................................. 14
31 000 - MAIN SPECIFICATION - TORQUE SETTINGS - TOOLS - SECTIO NAL DRAWINGS -

DESCRIPTION AND OPERATION - TROUBLESHOOTING
M ECHANICAL POWER TA K E -O FF
JX60 and JX70 JX80, JX90 and

JX95
540 rev/m in PTO
£ 1) In d e p e n d e n t o f tra c to r tra v e l
sp e e d
T yp e (In d e p e n d e n t and g ro u n d s p e e d P T O ) ........................... < or:
2) S y n c h ro n iz e d w ith g e a rb o x
E n g a g e m e n t and c o n tro l ................................................................ m e c h a n ic a l by m e a n s o f hand

le v e rs lo c a te d on R H and LH s id e o f
d riv e r’s s e a t (se e p a g e 9 and 10)
D ire c tio n o f ro ta tio n (v ie w e d fro m re a r o f t r a c t o r ) .................. c lo c k w is e
E n g in e sp e e d w ith P T O s h a ft ro ta tin g a t 5 4 0 re v /m in re v /m in 2200
P T O sp e e d w ith e n g in e a t m a x im u m p o w e r (2 5 0 0 re v /m in ) re v /m in 614
G ro u n d sp e e d P T O . R e a r w h e e l s p e e d w ith P T O s h a ft wheel
ro ta tin g a t 5 40 re v /m in speed
(30 km /h v e r s io n ) ................................................................................ re v /m in 8.2 8.9
(4 W D 4 0 k m /h v e r s i o n ) .................................................................. re v /m in 6 .7 3 7 .2 5
D ia m e te r o f P T O s h a ft a t p o s itio n o f b e a rin g s ....................... mm 4 9 .9 3 8 - 5 0 .0 0 0

(in.) (1.9661 - 1 .9 6 8 5 )
D ia m e te r o f P T O s h a ft a t s p lin e d end ....................................... 13/ 8 in. (6 -s p lin e )
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2 SECTION 31 - POWER TAKE-OFF - CHAPTER 1
(continued)

JX95
2 -s p e e d 540/750 rev/m in PTO (o p tio n - all m odels)
T y p e ....................................................................................................... as fo r s in g le -s p e e d P T O
E n g a g e m e n t and c o n tro l .............................................................. as fo r s in g le -s p e e d P T O
D ire c tio n o f ro ta tio n (v ie w e d fro m re a r o f t r a c t o r ) ................ as fo r s in g le -s p e e d P T O
S p e e d s e le c t io n ................................................................................ by m e a n s o f han d le v e r lo c a te d to
re a r R H s id e o f d riv e r’s s e a t
P T O sp e e d w ith e n g in e a t m a x im u m p o w e r sp e e d
(2 5 0 0 re v/m in ):
- fo r 5 4 0 re v /m in P T O ................................................................ re v /m in 614
- fo r 7 5 0 re v /m in P T O ................................................................ re v /m in 787
ro ta tin g a t 5 40 re v /m in speed s e e 5 4 0 re v /m in P T O
(30 and 4 0 km /h v e rs io n s ) ............................................................ re v /m in
(30 km /h v e r s io n ) .............................................................................. re v /m in 10.51 11.4
(40 km /h 4 W D v e r s io n ) .................................................................. re v /m in 8 .5 9 9 .3 6
D ia m e te r o f d riv e n s h a ft a t g ro o v e d te rm in a l ......................... 13/ 8 in. (6 -s p lin e )
2 -s p e e d 540/1000 rev/m in PTO (o p tio n - all m odels)
T y p e ....................................................................................................... as fo r s in g le -s p e e d P T O
E n g a g e m e n t and c o n tro l .............................................................. as fo r s in g le -s p e e d P T O
D ire c tio n o f ro ta tio n (v ie w e d fro m re a r o f t r a c t o r ) ................ as fo r s in g le -s p e e d P T O
S p e e d s e le c t io n ................................................................................ by m e a n s o f han d le v e r lo c a te d on
re a r R H s id e o f d riv e r’s s e a t
E n g in e sp e e d w ith P T O s h a ft ro ta tin g a t 1 000 re v /m in . . . re v /m in 2380
P T O sp e e d w ith e n g in e a t m a x im u m p o w e r
(2 5 0 0 re v/m in ):
- fo r 5 4 0 re v /m in P T O ................................................................ re v /m in 61 4
- fo r 1000 re v /m in P T O .............................................................. re v /m in 1050
6-62720 - 09 - 2006
(continued)
JX95
Ground speed PTO. Rear wheel speed with PTO shaft wheel
rotating at 540/750 rev/min speed as for single-speed PTO
(30 and 40 km/h versions) ...................................................... rev/min
rotating at 1000 rev/min speed
(30 km/h v e rs io n )...................................................................... rev/min 14.1 15.2
rotating at 1000 rev/min speed
(40 km/h 4WD v e rs io n )............................................................ rev/min 11.5 12.4
Diameter of PTO shaft at splined end:

- 540 rev/min ........................................................................ 1 3/s in. (6-spline)
- 750 rev/min ........................................................................ 1 3/s in. (6-spline)
- 1000 rev/min ...................................................................... 1 3/8 in. (2 1 -spline)
External diam eter of driven gear support bushings ............ mm 49.925 - 49.950
(in.) (1.9655 - 1.9665)
Internal diam eter of driven gears .......................................... mm 50.050 - 50.089

(in.) (1.9705 - 1.9720)
Clearance between driven gears .......................................... mm 0.100 - 0.164

(in.) (0.0039 - 0.0065)
Diameter of driven shaft at front and centre bushings mm 39.166 - 39.191

(in.) (1.5420 - 1.5429)
Diameter of driven shaft at rear bushing .............................. mm 34.984 - 35.000

(in.) (1.3773 - 1.3780)
Internal diam eter of front and centre b u s h in g ...................... mm 39.200 - 39.239

(in.) (1.5433 - 1.5448)
Internal diam eter of rear bushing .......................................... mm 35.009 - 35.048

(in.) (1.3783 - 1.3798)
Clearance between shaft and front and centre bushings .. mm 0.009 - 0.073
(in.) (0.0004 - 0.0029)
Clearance between shaft and rear b u s h in g .......................... mm 0.009 - 0.064

(in.) (0.0004 - 0.0025)
TO O LS 380000227 Hook for lifting PTO
Important - The operations described in this section

380001597 Guide pins for PTO unit
must be performed solely with the ESSENTIAL tools
marked below with (X).
To work in complete safety and to ensure optimal 380000233 Installer for PTO driving shaft
technical results with a minimum of time and effort, bearings
they must however be supplemented with the
specific tools recommended below and with those to
be specially constructed by you and for which the
construction diagrams are given in this manual.
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TORQUE SETTINGS
C 3 - 162 Nm
S in g le -s p e e d 540 rev/m in PTO 2 -sp e e d 540/750 rev/m in PTO
26276
TORQUE SETTINGS
PART TO BE T O R Q U E D T h re a d
Nm ft lb
P T O b o x fixin g s c re w s (C 1 , fig. 1) ......................................................... M 1 6 x 1 .5 221 1 6 3 .0 0 1 2
P T O g u a rd fixin g s c re w s (C 2, fig. 1) ..................................................... M 8 x 1 .2 5 25 1 8 .4 3 9
G ro o v e d e n d p ie c e s e lf-lo c k in g n u ts (2 -s p e e d P T O ) (C 3, fig. 1 ) . M 1 2 x 1 .2 5 162 1 19.485
D rive n g e a r s h a ft lo c k n u t:
(C 4, fig. 1) fo r s in g le - o r 2 -s p e e d P T O ................................................ M 3 2 x 1 .5 294 2 1 6 .8 4 3 2
B earing su p p o rt fixing scre w s (2 - and 3 -s p e e d P TO ) (C5, fig. 35) M 1 2 x 1 .2 5 98 72.281
6-62720 - 09 - 2006
a - single-speed 540 rev/min PTO b - 2-speed 540/750 rev/min PTO

26278
S e ctio n a l d ia g ra m s o f s in g le - and 2 -sp e e d PTO

a. S e c tio n a l d ia g ra m o f s in g le -s p e e d P TO . 13. R e a r tra n s m is s io n s u p p o rt.
b. S e c tio n a l d ia g ra m o f 2 -s p e e d P TO . 14. D riv e n gear.
1. 54 0 re v /m in P T O cover. 15, 27, 28, 16 a nd 5. S n a p rings.
2. 5 4 0 /7 5 0 re v/m in P T O cover. 17. P T O g u a rd re ta in in g s c re w s .
3. P T O u n it fixin g scre w . 18. 54 0 re v /m in P T O d riv e n s h a ft
4. D rive s h a ft b e a rin g s . 19. D riv e n g e a r s u p p o rt b u s h in g s .
6. S e lf-lo c k in g n u t to s e c u re s p lin e d s h a ft. 20. D riv e n s h a ft lo c k nut.
7. 54 0 re v /m in s p lin e d s h a ft. 21. F ixe d gear.
8. 75 0 re v /m in s p lin e d s h a ft. 22. C o u p lin g s le e v e .
9. S ea l. 23. D riv e n g e a r fo r 7 5 0 re v /m in sp e e d .
10 . D rive n s h a ft b e a rin g s . 24. D riv e n g e a r fo r 5 4 0 re v /m in sp e e d .
1 1 . C o v e r lo ca tin g pin. 25. D o u b le d riv e gear.
12. R e a r tra n s m is s io n c a sin g . 26. D riv e gear.
NOTE : W h en installing use sealing com p o u n d o f th e typ e show n on page 1 section 00 on su rfa ce X as show n above.
6-62720 - 09 - 2006
S e c tio n a l diag ram o f s in g le - and 2 -s p e e d PTO

2. 5 4 0 /1 0 0 0 re v /m in P T O cover. 12. R e a r tra n s m is s io n c a sin g .
3. P T O u n it re ta in in g scre w . 13. R e a r tra n s m is s io n s u p p o rt.
4. D rive s h a ft b e a rin g s . 19. D riv e n g e a r s u p p o rt b u s h in g s .
5. S n a p ring. 20. D riv e n s h a ft lo c k nut.
6. S e lf-lo c k in g n u t to s e c u re s p lin e d s h a ft. 21. F ixe d gear.
7. 54 0 re v /m in s p lin e d s h a ft. 22. C o u p lin g s le e v e .
8. 1000 re v /m in s p lin e d s h a ft. 23. D riv e n g e a r fo r 1 000 re v /m in sp e e d .
9. S ea l. 24. D riv e n g e a r fo r 5 4 0 re v /m in sp e e d .
10 . D rive n s h a ft b e a rin g s . 25. D o u b le d riv e gear.
1 1 . C o v e r lo ca tin g pin. 27. S n a p ring.
NOTE : W h en installing use sealing com p o u n d o f th e typ e show n on page 1 section 00 on su rfa ce X as show n above.
6-62720 - 09 - 2006
S e c tio n a l diag ram o f s in g le - and 2 -s p e e d PTO

17. PTO speed selector lever. 20. Rear cover.
18. Roll pin. 21. Fork.
19. Shaft. 22. O -ring.
6-62720 - 09 - 2006
S e ctio n vie w s - 540 - 1000 rev/m in PTO N orth A m e rica n ve rs io n (available on request), n o t
s y n c h ro n is e d w ith gearbox, w ith speed s e le c tio n by replacem en t o f s p lin e d o u tp u t shaft.
1. S p lin e d 1 3/g” o u tp u t s h a ft (6 s p lin e s ) fo r 5 4 0 rpm
P T O , o r 1 3/s ” o u tp u t s h a ft (21 s p lin e s ) fo r 1000 6. R e tu rn sp rin g .
rp m P T O .
7. R e tu rn rod.
2. D rive n s h a ft.
8. S p e e d s e le c to r le v e r s u p p o rt
3. S n a p ring s e c u rin g p a rt . 9. S p e e d s e le c to r lever.
4. S p e e d s e le c to r rod. 10 . S p e e d s e le c to r s le e v e .
5. S p e e d s e le c to r s le e v e c o n tro l fo rk. 11. T h ru s t w a s h e r.
6-62720 - 09 - 2006
DESCRIPTION AND OPERATION OF

M ECHANICAL PTO
T h e P T O , lo ca te d a t th e re a r o f th e tra c to r, tra n s fe rs
p o w e r to th e im p le m e n t be in g tra n s p o rte d o r to w e d .
It can be c o n tro lle d e ith e r d ire c tly fro m th e e n g in e
c lu tch o r fro m th e g e a rb o x c lu tc h . T h e P T O is s h o w n
w ith th e s a fe ty ca p (1) and th e g u a rd (2) in p o sitio n .
T h e s a fe ty ca p m u s t be re m o v e d to c o u p le up an
im p le m e n t to th e P T O s h a ft.
The PTO w ith m e c h a n ic a l engagem ent /

d is e n g a g e m e n t is a v a ila b le in th re e v e rs io n s :
— s in g le -s p e e d P T O , 5 4 0 re v /m in (s ta n d a rd )
— tw o -s p e e d P T O , 5 4 0 /7 5 0 re v /m in (o p tio n )
— tw o -s p e e d P T O , 5 4 0 /1 0 0 0 re v /m in (o p tio n ).
In d e p e n d e n t PTO
— w ith th e P T O c lu tc h d is e n g a g e d , i.e. w ith th e

c o n tro l le v e r (1) fig. 7, re a rw a rd a t p o s itio n A ;
— m o ve th e P T O s e le c to r le v e r (1) fig. 8, to p o sitio n

B so as to e n g a g e th e P T O s le e v e (3) fig. 9, w ith
th e to o th e d c o u p lin g o f th e s h a ft (2) w h ic h is
d riv e n by th e e n g in e ;
— e n g a g e th e P T O by s lo w ly m o v in g th e le v e r (1)
fig. 7, fo rw a rd to p o s itio n D.
W h e n e n g a g e d , th e P T O s h a ft ro ta te s and th e P T O
w a rn in g la m p on th e in s tru m e n t p a n e l lig h ts up.
In th e se conditions th e operation o f th e P T O is
co m ple tely ind ependent o f th e tra ve l o f th e tractor, so:
— th e tra c to r can be s to p p e d w ith o u t s to p p in g th e

PTO ;
— th e P T O ca n be s to p p e d w ith o u t s to p p in g th e
tra c to r (b y d is e n g a g in g th e P T O c lu tc h ).
To d is e n g a g e th e P T O m o v e th e P T O c lu tc h c o n tro l
le v e r (1) fig. 7, re a rw a rd to p o s itio n A th e n m o v e th e
sp e e d s e le c to r (1) fig. 8, to th e c e n tra l p o s itio n E.
6-62720 - 09 - 2006
G ro u n d speed PTO
— w ith th e P T O c lu tc h c o n tro l le v e r (1 ) fig . 7, a t

p o s itio n D;
— fu lly d e p re s s th e g e a rb o x /e n g in e c lu tc h p edal;
— w a it briefly, th e n m o v e th e P T O s p e e d s e le c to r
(1) fig. 8, fo rw a rd to p o s itio n C and re le a s e th e
g e a rb o x /e n g in e c lu tc h p edal;
In th e se conditions th e P T O coupling sleeve (3) fig. 9,

is turned d irectly by th e too th e d coupling o f g e a r (1) in
th e gearbox.
W h e n th e tra c to r is s ta tio n a ry th e P T O s h a ft d o e s not

tu rn . W h e n c h a n g in g fro m fo rw a rd to re v e rs e gear,
th e d ire c tio n o f ro ta tio n o f th e P T O s h a ft re v e rs e s .
NO TE : W h e n th e P T O is n o t be in g u se d , m o v e th e
le v e r (1) fig. 8, to p o s itio n E (th e n e u tra l p o s itio n o f
th e P T O e n g a g e m e n t s le e v e (3) fig. 9).
PTO speed s e le c to r leve r (2) fig . 10
To c h a n g e P T O s p e e d , p ro c e e d as fo llo w s :
— lift th e s p rin g -lo a d e d c o lla r (1) u p w a rd s ;
— m ove th e leve r (2) forw ard to position (3) to select

750 o r 1000 rev/m in P T O speed.
T h is a c tiv a te s th e e x te rn a l c o n tro l le v e r (1 7 ) fig . 4

b y m e a n s o f a tie - r o d . T h e e x te rn a l c o n tro l le v e r in
tu rn ro ta te s th e in te rn a l fo r k d e v ic e (2 1 ) a n d
s e le c ts th e P T O s p e e d b y m e a n s o f th e c o u p lin g
s le e v e s
TROUBLESHOOTING FOR M ECHANICAL PTO
F a u lts P o s s ib le c a u s e s R e m e d ie s
S lip p in g w ith loss o f s p e e d o f P T O W e a r o f c lu tc h d is c o r o f e n g in e C h e c k th e d a ta g iv e n in th e

o u tp u t sh a ft. fly w h e e l p re s s u re plate. a p p ro p ria te p a g e s o f s e c tio n 18,
P o o r a d ju s tm e n t o f P T O clu tch re p la c e th e w o rn p a rts and a d ju s t th e
c o n tro l lever. c lu tc h c o n tro l lever.
D iffic u lty in s e le c tin g P T O sp e e d E x te rn a l c o n tro l stiff. C h e c k th e c o n tro l lever.

by m e a n s o f le v e r (2) fig. 10.
6-62720 - 09 - 2006
540/750 M ECHANICAL PTO

R em oval - R e fittin g (Op. 31 112 20)
------------ A WARNING A -----------

L ift and h a n d le all h e a v y p a rts u sin g liftin g ta c k le o f
s u ffic ie n t ca p a city.
M a ke s u re th a t th e u n its o r p a rts a re s u p p o rte d by
s u ita b le h a rn e s s e s and h o o ks. C h e c k th a t no o n e is
in th e v ic in ity o f th e load to be lifted.
1. D is c o n n e c t th e n e g a tiv e c a b le fro m th e battery.
2. R e m o v e th e to p lin k (1) o f th e th r e e -p o in t
linkage.
12
4. R e m o v e th e to w b a r (1), if fitte d
13
6-62720 - 09 - 2006
5. Rem ove the six tow hook support fixing

screw s (1) (Three on left and three on right
side).
6. Drain out the transmission/gearbox oil from the

drain plug ( 1 ) and collect it in a suitable
container.
7. Remove the PTO speed selector control lever

( 1 ).
16
8. Remove the screws (2) that fasten the retaining
bracket (1) for the PTO speed selector control.
6-62720 - 09 - 2006
9. R e m o v e th e tw o u p p e r s c re w s (1) w h ic h fa s te n
th e P T O u n it to th e tra n s m is s io n .
18
10. In s e rt th e tw o g u id e p in s 380001597 (1) and
re m o v e th e tw o lo w e r s c re w s (2) (F ig. 3
P a g e .6 ) w h ic h fa s te n th e P T O u n it to th e
tra n s m is s io n .
19
11. E ngage th e le ve r (1) fig. 8, in position (C), ground
speed P TO , so th a t th e sleeve (3) fig. 9, rests on
th e sh a ft (2) during th e rem oval operation.
W ith d ra w th e P T O unit by a fe w ce n tim e tre s and
detach using th e ho o k w ith lifting chain 380000227
(1).
To re in s ta ll p ro ce e d as fo llo w s :
— C le a n th e m a tin g s u rfa c e s b e tw e e n th e
tra n s m is s io n and P T O c o v e r and a p p ly s e a lin g
c o m p o u n d as s h o w n in fig u re 21.
— R a is e th e P T O u n it and p o s itio n it d ire c tly b e h ind
th e tra n s m is s io n c a s in g . S lid e th e P T O c o v e r
o n to th e g u id e p in s 380001597 , fo r e a s e o f
a sse m b ly.
— R e m o v e th e h o o k w ith ch a in (1) fig. 20, and
fa s te n th e P T O u n it u sin g th e tw o lo w e r s c re w s .
— R e m o v e th e tw o g u id e p ins 380001597 and
in sta ll th e tw o u p p e r s c re w s .
— R e in s ta ll th e b ra c k e t (1) fig. 17, th a t re ta in s th e
P T O sp e e d s e le c to r c o n tro l lever.
— R e fit th e to w b a r s u p p o rt.
— R e fit th e to w bar, th e to w h o o k and th e th r e e -
p o in t lin ka g e to p link.
— S c re w in and tig h te n th e oil d ra in plug and fill th e
tra n s m is s io n /g e a rb o x w ith oil.
— R e c o n n e c t th e n e g a tiv e b a tte ry ca b le .
21
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M ECHANICAL PTO (540/750 rpm PTO)

B ench o ve rh a u l (Op. 31 112 45 - 31 112 48)
------------ A WARNING A ------------

an o th e r.
1. P la c e th e P T O u n it in th e v ic e on th e w o rk
b e n c h (1 ).
22
2. U se a p u n ch to s tra ig h te n th e c o rru g a tio n s (1) on
th e ring n u t th a t re ta in s th e d riv e n s h a ft
c o m p o n e n ts .
23
3. R e m o v e th e ring n u t (1) fro m th e d riv e n s h a ft
24
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4. R e m o v e th e fo u r P T O u n it in te rn a l s u p p o rt fixin g
s c re w s (1).
25
5. R e m o v e th e pin (1) s e c u rin g th e fo rk rod
26
6. W ith d ra w th e rod (1) fro m th e re a r cover.
27
7. P a rtia lly w ith d ra w th e P T O o u tp u t s h a ft (1) and

re m o v e th e in te rn a l s u p p o rt (3) to g e th e r w ith th e
d riv e s h a ft (2), th e d riv e n g e a rs (4), th e s le e v e
and th e e n g a g e m e n t/d is e n g a g e m e n t/n e u tra l
c o n tro l fo rk o f th e 5 4 0 /7 5 0 P T O . A ls o , re ta in th e
th ru s t w a s h e r fro m th e g e a r (11) fig 5, fo r re u se
d u rin g re a sse m b ly .
28
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8. R e m o v e th e re a r b e a rin g th ru s t w a s h e r (1) and

re m o v e th e s e c o n d a ry s h a ft (2) c o m p le te w ith
P T O o u tp u t s h a ft.
29
9. R e m o v e th e re ta in in g s n a p ring, th e b e a rin g (1)

and th e s e a l (if it n e e d s re p la c in g ) fro m th e re a r
cover.
30
To re in sta ll, R e fe r to fig. 2 b and p ro c e e d as fo llo w s :
— M o u n t th e se a l (9) (if re m o v e d in s te p 2 0 ), th e
re a r b e a rin g and th e re ta in in g s n a p ring (5) on
th e re a r cover.
— R e fit th e th ru s t w a s h e r on th e d riv e n s h a ft.
— R e fit th e d riv e n s h a ft g e a r (23), th e fix e d g e a r

(21), th e s le e v e (22), th e fo rk and th e fo rk
s u p p o rt rod.
— In s e rt th e g e a r (24) o n to th e d riv e n s h a ft, m o u n t

th e in te rn a l s u p p o rt (13) c o m p le te w ith d riv e
s h a ft (25). F a s te n th e s u p p o rt (13) u sin g th e fo u r
sc re w s , tig h te n in g th e m to th e to rq u e s e ttin g
sp e c ifie d on p a g e 4.
— M o u n t th e th ru s t w a s h e r on g e a r (11) fig 5, and

in sta ll th e b e a rin g on th e in te rn a l s u p p o rt (13) o f
th e d riv e n s h a ft.
— F a s te n th e rod th a t s u p p o rts th e P T O sp e e d
s e le c to r c o n tro l fo rk pin as re m o v e d in s te p 5.
— T ig h te n th e d riv e n s h a ft lo c k n u t to th e to rq u e
sp e c ifie d on p a g e 4, th e n , u sin g a s u ita b le
pu n ch , n o tch th e s a fe ty th ru s t w a s h e r in o rd e r to
p re v e n t it fro m lo o s e n in g .
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M ECHANICAL PTO (540/1000 rpm PTO)

(In te rcha ng e able PTO S haft) (NASO V e rsion)
B ench o ve rh a u l (Op. 31-114)
----------- A WARNING A ------------

an o th e r.
1. P la c e th e P T O u n it in th e v ic e on th e w o rk
b e n c h (1 ).
31
2. R e m o v e th e b o lts (1) and ta k e o ff th e c o v e r (2)
32
3. R e m o v e th e s p a c e r (1).
33
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4. R e m o v e th e tw o s o c k e t hea d s c re w s (1) and

ta k e o ff th e P T O e n g a g e m e n t m e c h a n is m (2)
co m p le te ly.
34
5. W ith d ra w tw o ro d s (1) fro m th e cover.

C 4: S h a ft s e c u rin g n u t tig h te n in g to rq u e : 2 5 5 N m
(1 8 8 .0 7 8 3 ft lb)
C 6: C o v e r re ta in in g b o lts tig h te n in g to rq u e : 98 N m
(72.2811 ft lb)
35
6. R e m o v e th e n u t (1) s e c u rin g th e s h a ft and ta k e

o ff th e 4 b o lts (2).
36
7. R e m o v e th e s o c k e t h ead s c re w b o lt (1) on th e
sid e o f th e cover.
37
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8. R e m o v e th e c o v e r (1).
38
9. R e m o v e th e w a s h e r (1) and ta k e o ffth e g e a r (2).
39
10. R e m o v e th e rod (1), s p rin g (2), fo rk (3) and th e

s y n c h ro n is e r (4).
40
11. R e m o v e th e d riv e n g e a r (1).
41
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12. R e m o v e th e c irc lip (1).
13. R e m o v e th e d riv e s h a ft(1 ).
14. R e m o v e b oth b e a rin g s (1) and (2) .
15. R e m o v e th e s h a ft (1) and th e p la te (2).
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To re in sta ll, re v e rs e th e re m o v a l p ro c e d u re and re fe r

to fig. 5 and p ro c e e d as fo llo w s :
— M o u n t th e s h a ft (1) and th e p la te (2) on th e re a r

c o v e r (fig. 45).
— R e fit th e tw o b e a rin g s (1 and 2) (fig. 44).
— R e fit th e d riv e s h a ft (1) (fig. 43)
— In sta ll th e c irc lip (1) s e c u rin g th e b e a rin g (fig. 42)
— In s e rt th e g e a r (1) (fig. 41).
— In sta ll th e rod (1), s p rin g (2), fo rk (3) and th e

s y n c h ro n is e r (4) (fig. 40).
— In sta ll th e w a s h e r (1) and th e g e a r (2) (fig. 39)
— In sta ll th e c o v e r (1) fig. 38.
— In sta ll th e s o c k e t hea d s c re w (1) on th e s id e o f

th e c o v e r (fig. 37)
— In sta ll th e n u t (1) s e c u rin g th e s h a ft and re fit th e

4 b o lts (2, fig. 36). T ig h te n th e n u t (1) to 2 5 5 N m
(1 8 8 .0 7 8 3 ft lb) and b o lts (2) to 98 N m
(72.2811 ft lb).
— In sta ll th e tw o ro d s (1) fig. 35.
— R e fit th e P T O e n g a g e m e n t m e c h a n is m (1) and

in sta ll th e s o c k e t h ead s c re w s s e c u rin g th e
m e c h a n is m fig. 34.
— In sta ll 1000 rp m P T O s h a ft w ith re la te d circlip .
NOTE: T h e a d ju s tm e n t p ro c e d u re s h o u ld be d o n e
O N L Y w ith th e 100 0 rp m P T O s h a ft is in s ta lle d .
— U sin g a s c re w d riv e r (1) and a s p a n n e r (2) a d ju s t

th e d is ta n c e X to “ 0 m m (0 in .)” fig. 46.
— In sta ll th e s p a c e r (1) fig. 33.
— In sta ll th e c o v e r (2) fig. 32 and tig h te n th e b o lts

46
(1).
— U se s u ita b le h o o k s to a s s e m b le th e u n it to th e
tra c to r fig. 31.
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SECTION 33 - BRAKING SYSTEM - CHAPTER 1 1
SECTION 33 - BRAKING SYSTEM

Chapter 1 - Braking system
CONTENTS
33 000 Main d a t a ........................................................................................................................................ 1

Cross-sectional views ................................................................................................................. 2
Description & Operation............................................................................................................... 9
Tools - Troubleshooting............................................................................................................. 10
33.206 Front brake assembly mod. JX60 and JX70 removal and refitting -
overhauling on the bench .............................................................................................................11
33.202.60 Service brake removal and refitting .......................................................................................... 14
33.202.50 Removal-Refitting of front brake pum ps.................................................................................. 19
33.202.40 Bleeding air from the front braking sys te m .............................................................................. 23
33.120.08 Adjusting service brake pedals travel ...................................................................................... 24
33.110.08 Parking brake travel adjustment................................................................................................ 24
33 000 - MAIN SPECIFICATION - TORQUE SETTINGS - TOOLS - SECTIONAL DRAWINGS -
MAIN SPECIFICATION
Type:
- service brake ................................................................................. with oil bath discs acting on

differential half-shafts
- parking brake ................................................................................. with oil bath discs acting on

differential half-shafts
with oil bath discs acting on the
bevel pinion shaft by means of a
gear (Optional)
Control:
- service brake ................................................................................. mechanical, with independent

pedals
(connected by means of a pin)
- parking brake ................................................................................. mechanical, by means of a hand

lever
Disc material for service brake ........................................................ organic agglomerate
Disc material for parking brake ........................................................ steel
Mobile sector material for parking brake ........................................ sintered

or
organic agglomerate
Disc thickness:
- service brakes ............................................................................... mm 4

(in.) (0.1575)
Discs for service brake:
- JX60 and J X 7 0 ............................................................................... no 3
- JX80, JX90 and JX95 .................................................................. no 4
(see over)
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2 SECTION 33 - BRAKING SYSTEM - CHAPTER 1
MAIN SPECIFICATION
(cont.)
T h ic k n e s s o f m o b ile s e c to rs fo r in d e p e n d e n t p a rk in g b ra ke :
- la te ra l s e c t o r s ............................................................................................ mm 3.1 - 3.4

(in.) (0 .1 2 2 - 0 .1 3 3 9 )
- in te rm e d ia te s e c to rs .............................................................................. mm 4 .2 - 4 .5
(in.) (0 .1 6 5 3 - 0 .1 7 7 2 )
F ro n t b ra k e s (w ith 4 W D m o d e ls - on re q u e s t)
H y d ro s ta tic co n tro l
H y d ra u lic p u m p .............................................................................................. w ith 2 c o n tro l p u m p s o p e ra te d in

d e p e n d e n tly by m e a n s o f
th e b ra k e p e d a ls
A d ju s tin g th e c o n tro l p e d a ls ....................................................................... s e e p a g e 24
B le e d in g a ir fro m th e fro n t b ra k e c irc u its ( O p tio n a l) ......................... s e e p a g e 23
TORQUE SETTINGS
T ig h te n in g to rq u e
P A R T S T O B E T IG H T E N E D T h re a d
Nm ft lb
N u ts s e c u rin g fin a l d riv e b o x to tra n s m is s io n b o x (C-i) .................. M 12 x 1.25 98 72.281
B ra ke b o x re ta in in g b o lt (C 5, p a g e 8 ) ..................................................... M 10 x 1.25 70 5 1 .6 2 9 3
6-62720 - 09 - 2006
Sectional drawing of service and parking brakes

a. m o d e ls J X 6 0 and J X 7 0 . 6. B a c k -u p d is c s
b. m o d e ls J X 8 0 , J X 9 0 and JX 9 5 . 7. A c tu a to r re tu rn sp rin g .
1. B ra ke link. 8. D iffe re n tia l s u p p o rt.
2. Pin. 9. A x le s h a ft.
3. B all. 10. B o o t c o v e r plate.
4. B ra ke a ctu a to r. 11. B oot.
5. B ra ke discs. 20. D iffe re n tia l s u p p o rt re ta in in g
Note. - W h e n m o u n tin g a p p ly s e a lin g c o m p o u n d to s u rfa c e s X as s h o w n on p a g e 18.
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4 SECTION 33- BRAKING SYSTEM - CHAPTER 1
BRAKES
View of service and park brake controls
a. R.H. brake pedal in rest position and L.H. brake applied. SL. Slave cylinder 4. Brake actuator. 9. Axle shaft.
b. Brakes applied. MS. Master cylinder 5. Brakes discs. 12. Final drive housing.
c. Brakes in rest position. T. Parking brake link. 6. B ack-up discs. 13. Park brake control lever.
Lm. Parking brake hand lever. 1. Brake links. 7. Actuator return spring. 14. Park brake control cable
M. Brake pedal return springs. 3. Actuator ball. 8. Differential support. 15. Brake pivoting shaft.
Pd. R.H. brake pedal.
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6-62720 - 09 - 2006
FRONT LIVE AXLE DRIVE SHAFT BRAKE (JX60 & JX70 MODELS)
Section through the brake fitted on drive shaft to front live axle
1. S elf-centering brake disc 6. Front washer.

2. Disc retaining screw
7. Rear washer.
3. Shaft/sleeve assembly
8. Outer retaining ring
4. Carrier.
5. Bearing. 9. Inner retaining ring
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FRONT BRAKE (MODELS JX80, JX90 and JX95)
4
View of brake mounted in front axle.
a. Cross-sectional view of axle with differential. 4. Seal.
b. Cross-sectional view of axle with NO -SPIN 5. Piston contact spring.
assembly. 6. Centring ring.
c. View of oil delivery union and brake bleed. 7. Gear.
C5 Brake box retaining bolt. 8. Circlip.
1. Brake box. 9. Drive oil inlet pipe union.
2. Brake drive piston. 10. Plug pipe with breather.
3. Seal. 11. Splined shaft.
Note. - When mounting apply sealing compound to surfaces X.
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SERVICE BRAKES c a u s in g a c tu a to r d is c s to tu rn , ball (3) in th e ta p e re d

s e a ts to fo rc e th e d is c s a p a rt as s h o w n in d e ta il (c).
T h e s e rv ic e b ra k e s a re h y d ra u lic w ith oil b ath d iscs.
A s a re su lt, tw o s im u lta n e o u s a c tio n s c o m p re s s th e
T h e tw o co n tro l p u m p s (o n e fo r e a ch p e d a l) are b ra k e d is c s a g a in s t th e d iffe re n tia l s u p p o rt (8) and
h o u se d in th e fro n t s e c tio n o f th e c a b a n d are th e b a c k up d is c s , im m e d ia te ly u p o n re le a s in g th e
c o n n e c te d to th e ir respective p edals by m e a n s o f tw o p e d a l s p rin g (7), p ull th e a c tu a to r (4) b a c k into th e
ro d s . re s t position (figure b and d e ta il d) and as a re su lt th e
d is c s a re re le a s e d . T h e a c tio n is s im ila r w h e n th e
T h e s e p u m p s can be a c tu a te d e ith e r in d e p e n d e n tly
rig h t-h a n d b ra k e p e d a l is p re s s e d (R d).
o r to g e th e r. If a c tu a te d to g e th e r, th e p e d a ls are
c o n n e c te d by a pin. T h e b ra k e d is c s (o n e fo r e a ch re a r w h e e l) are
p o s itio n e d b e tw e e n th e re a r tra n s m is s io n b o x and
A c o n n e c tin g p ip e b e tw e e n th e tw o p u m p s e n s u re s
th e la te ra l fin a l d riv e b o x and a re s p lin e d o n to th e
b a la n c e d bra kin g eve n w h e n th e bra ke d is c s are not
d iffe re n tia l o u tp u t h a lf-s h a fts .
e q u a lly w o rn .
T h e tw o c o n tro l p u m p s a re fe d fro m a s in g le ta n k
lo ca te d a b o v e th e p u m p s. PARKING BRAKE
R e fe r to th e illu s tra tio n s on p a g e 5. T h e s e rv ic e
b ra k e s are s la v e c y lin d e r o p e ra te d . W h e n th e R e fe r to th e illu s tra tio n s on p a g e 5. W h e n th e han d
le ft-h a n d b ra ke p e d a l (fig. a ) is d e p re s s e d , th e b ra k e le v e r (L m) is pulled, th e co n tro l ca b le (14) pulls
m a s te r c y lin d e r (M S ) s e n d s th e oil to th e s la v e th e co n tro l le v e r (13), a t th e d ire c tio n o f a rrow . T he n
c y lin d e r (S L). T h e b ra k e lin ks (1) m o v e a s in d ic a te d th e b ra k e lin k s (1) a c ts on th e b ra ke
by th e a rro w s, by th e h e lp o f s la v e c y lin d e r (S L ) th is d is c s .
6-62720 - 09 - 2006
TOOLS
WARNING - T h e o p e ra tio n s d e scrib e d in th is s e c L is t o f s p e c ia l to o ls n e c e s s a ry fo r th e v a rio u s o p

tio n m u st be p e rfo rm e d o n ly w ith th e ESSENTIAL e ra tio n s d e s c rib e d in th is s e c tio n .
e q u ip m e n t m a rk e d w ith (X). X 380000822 D riv e r fo r b o o t in s ta lla tio n .
To o p e ra te s a fe ly and a c h ie v e b e st re su lts h o w e v
er, w h ile s a v in g tim e a n d effort, e s s e n tia l e q u ip 380000227 L iftin g h o o k .
m e n t m u st be used in co n ju n c tio n w ith th e s p e cia l
to o ls re c o m m e n d e d be lo w , and to o ls w h ic h yo u
m u s t m a ke y o u rs e lf and fo r w h ic h you w ill find the
d e s ig n in th is m a n u a l.
BRAKE TROUBLESHOOTING
P ro b le m s P o s s ib le c a u s e s R e m e d ie s
B ra kin g in e ffe ctu a l. 1. F ric tio n m a te ria l on b ra ke R e p la c e th e b ra k e d is c s .

d is c s w o rn .
U n b a la n c e d b ra kin g . 1. In c o rre c t ty re p re s s u re . In fla te th e ty re s to th e c o rre c t

p re s s u re .
2. F ric tio n m a te ria l on one o f th e R e p la c e th e d is c s .

b ra k e d is c s w o rn .
B ra kin g noisy. 1. F ric tio n m a te ria l on b ra ke R e p la c e th e d is c s .

d is c s w o rn .
1. B ra k e d is c s w o rn . R e p la c e th e b ra k e d is c s .
P a rkin g b ra ke d o e s n o t lock.
1. B ra k e d is c s s e iz e d on b ra ke R e le a s e and re p la c e d a m a g e d p a rts.
B ra k e s lo cke d on w h e n th e p a rk d is c s .
ing b ra ke is d is e n g a g e d .
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FRONT BRAKE ASSEMBLY

MOD: JX60 AND JX70
Rem oval-Installation (Operation 33-206)
----------- A DANGER A -----------

L ift and h a n d le all h e a v y c o m p o n e n ts u sin g lifting
e q u ip m e n t o f a d e q u a te ca p a city.
M a ke s u re th a t th e u n its o r p a rts a re s u p p o rte d by
a p p ro p ria te h arn e sse s and hooks. C h e c k th a t no one
is in th e v ic in ity o f th e load to be lifted.
P ro c e e d as fo llo w s to re m o v e th e unit:
1. A p p ly th e h a n d b ra k e .
g u a rd s fro m th e p ro p e lle r sh a ft.
Note. - S h o u ld th e c a lip e r (11) n o t nee d a n y

s e rv ic in g , b a c k o ff its re ta in in g s c re w s (1 3 ) and
d is c o n n e c t takin g care not to un co u p le th e hose (12):
re s t on s u ita b le s ta n d o r s u s p e n d by w ire .
5
3. D is c o n n e c t w ire (10) fig. 5 o f th e brake pad w e a r
w a rn in g in d ic a to r and re m o v e th e p a d s (14 and
15) fig. 6.
4. R e m o v e th e fro n t s le e v e re a r re ta in in g ring and

b a c k o ff th e tw o s c re w s (16) re ta in in g th e b ra ke
s le e v e a s s e m b ly ca rrie r.
5. S lid e th e fro n t s le e v e a lo n g th e d riv e s h a ft and
re m o v e th e c o m p le te a s s e m b ly (s h a ft and
b ra k e /b e a rin g ca rrie r).
6-62720 - 09 - 2006
6. T ake th e tw o d riv e s h a fts o u t o f th e c a rrie r and

c la m p th e la tte r in a vice .
7. U n s c re w th e re ta in in g b o lts (17, fig. 8) o f th e

c a llip e r b ra c k e t and re m o v e th e b ra cke t.
8. U n s c re w th e re ta in in g b o lts (2) o f th e b ra ke d is c
and re m o v e th e d is c (4).
9
9. T ake o u t re ta in in g rin g s (8 a n d 9) fro m th e
s u p p o rt (4)
10
10. U sin g a s u ita b le p uller, re m o v e th e s h a ft/s le e v e
a s s e m b ly (3) fro m th e s u p p o rt (4).
11. R e m o v e th e b e a rin g (5) u sin g a s u ita b le p u lle r
and ta k e o u t th e w a s h e r (6) Fig. 3.
11
6-62720 - 09 - 2006
Bench overhaul (Operation 33-206)
----------- A DANGER A -----------

A lw a y s use s u ita b le to o ls to a lig n h o le s. N E V E R
U S E F IN G E R S O R H A N D S .______________________
R e v e rs e th e re m o v a l o p e ra tio n s e q u e n c e m in d in g
th e fo llo w in g p o in ts :
1. P o sitio n th e s h a ft/s le e v e a s s y (3) Fig. 3, upright,
in tro d u c e th e s u p p o rt (4) fig. 12, fo llo w e d by th e
w a s h e r (6) Fig. 3 in th e b e a rin g s e a t w ith th e
c h a m fe re d s id e fa c in g o u tw a rd s .
12
2. In s e rt b e a rin g (5) fig. 3 on a s s e m b ly (3) fig. 13

and brin g into c o n ta c t w ith s e a t u sin g a s u ita b le
d rift o r p re ss to o l; lo c k w ith th e re ta in in g ring (9)
fig. 3.
3. C la m p th e c a rrie r in a v ic e th e n , using a s u ita b le
d rift o r press to o l, locate p ro p e rly a g a in s t w a s h e r
(6) Fig. 3. P o s itio n w a s h e r (7) Fig. 3 w ith th e
c h a m fe re d s id e fa c in g th e b e a rin g (5) a n d lo ck
th e a s s e m b ly w ith th e re ta in in g ring (8) fig. 3.
13
6-62720 - 09 - 2006
SERVICE BRAKE
Removal - Installation (Operation 33 202 60)
----------- A DANGER A -----------

L ift and h a n d le all h e a v y c o m p o n e n ts u sin g lifting
e q u ip m e n t o f a d e q u a te ca p a city.
M a k e s u re th a t th e a s s e m b lie s a n d p a rts are
s u p p o rte d by a p p ro p ria te to o ls and h o o k s . C h e c k
th a t no on e is in th e v ic in ity o f th e load to be lifted.
P ro c e e d as fo llo w s to re m o v e th e fin a l d riv e box.
1. D is c o n n e c t th e n e g a tiv e b a tte ry c a b le (1).

2. C h o c k th e fro n t w h e e ls u sin g s u ita b le w h e e l
s to p s .
14
3. R e m o v e th e v e rtica l rod (1) and th e LH s ta b ilis e r
s tru t (2).
15
4. R a ise th e re a r s e c tio n o f th e tra c to r and p la ce a
s ta n d (1) b e n e a th th e to w b a r s u p p o rt.
16
6-62720 - 09 - 2006
5. U n d o th e reta in in g b o lts and re m o v e th e re a r LH

w h e e l.
17
6. U n d o th e b o lts (1) s e c u rin g th e c a b to its

m o u n tin g
7. R a ise th e ca b s lig h tly and p la ce a s u ita b le piece

o f w o o d b e tw e e n th e h y d ra u lic lift a n d th e cab,
ta k in g ca re to a vo id c o n ta c t w ith p ipes.
18
8. R e m o v e th e plug (1) a n d d ra in th e oil fro m th e
re a r tr a n s m is s io n -g e a rb o x c a sin g .
19
9. U n d o th e b o lts s e c u rin g th e c a b to its m o u n tin g
(1).
20
6-62720 - 09 - 2006
10. P o sitio n a sta n d (1) u n d e rn e a th th e re a r s e c tio n

o f th e fu e l ta n k.
21
11. F it liftin g h o o k s (1) 380000227 o n to th e fin a l

d riv e box. C o n n e c t a h y d ra u lic lift to th e h o o ks,
und o th e reta in in g bolts and re m o v e th e LH final
d riv e b o x fro m th e tra n s m is s io n box.
22
12. R e m o v e th e pin (1).
23
6-62720 - 09 - 2006
13. B a c k o ff th e lin k (1) a n d re m o v e th e c o m p le te

b ra ke unit.
14. C h e c k a c tu a to r and b ra k e d is c s fo r w e a r.
----------- A ATTENTION A -----------

A lw a y s use a p p ro p ria te to o ls to a lig n fix in g h oles.
N E V E R U S E F IN G E R S O R H A N D S . 24
15. R e fit th e fin a l d riv e b o x to th e re a r tra n s m is s io n

b o x as fo llo w s :
— R e fe r to th e illu stra tio n s on pag e 3 fo r th e co rre ct
o rie n ta tio n o f th e v a rio u s c o m p o n e n ts .
— B e fo re re fittin g th e fin a l d riv e b o x to th e re a r
tra n s m is s io n box, th o ro u g h ly c le a n and
d e g re a s e th e m a tin g s u rfa c e s a n d a p p ly a s trip
o f se a lin g c o m p o u n d o f d ia m e te r a b o u t 2 m m as
sh o w n in th e illu s tra tio n on p a g e 17.
— A p p ly th e to rq u e s e ttin g s g iv e n on p a g e 2.
— U sin g to o l 380800022 (A ) as s h o w n , p o s itio n
b o o t (11) c o rre c tly on b ra ke lin k (1). (see fig. 25)
— F it th e b ra ke d is c and s p a c e rs .
TRE0303A
— U sin g to o l 380000227 an d a h y d ra u lic lift, refit
th e fin a l d riv e c o m p le te w ith a x le s h a ft. 25
— F it th e re a r c a b m o u n tin g re ta in in g b olts.
— R e m o v e th e piece o f w o o d b e tw e e n th e ca b and
th e lift body.
— T ig h te n th e b o lt s e c u rin g th e c a b to th e re a r LH
su p p o rt.
— F it th e LH w h e e l.
— F it th e s ta b ilis e r s tru t a n d th e v e rtic a l rod.
— R e m o v e th e s ta n d s .
— S c re w in th e oil d ra in plug and refill.
— C o n n e c t th e b a tte ry n e g a tiv e lead.
6-62720 - 09 - 2006
26
Diagram for application of sealing compound when fitting braking assembly between the final drive
housing and the rear transmission box.
T h e ty p e s o f se a lin g c o m p o u n d to be a p p lie d a re liste d on p a g e 1 o f S e c tio n 00.
6-62720 - 09 - 2006
HYDRAULIC FRONT BRAKE PUMP

(OPTIONAL)
Removal - Installation (Operation. 33 202 50)
A a t t e n t io n A ----------
H a n d le all p a rts ca re fu lly.
D o n o t in se rt fin g e rs o r h a n d s b e tw e e n o n e p a rt and
a n o th e r. A lw a y s w e a r th e p re s c rib e d s a fe ty c lo th in g,
in c lu d in g p ro te c tiv e g la s s e s , g lo v e s and s h o e s .
P ro c e e d as fo llo w s to re m o v e th e h y d ra u lic pu m p .
1. D is c o n n e c t th e n e g a tiv e b a tte ry c a b le (1).

2. C h o c k th e fro n t w h e e ls u sin g s u ita b le w h e e l
s to p s .
27
3. D is c o n n e c t th e e le c tric a l c o n n e c tio n s fro m th e
plug (2) o f th e ta n k (1) and a fte r re trieving th e oil,
re m o v e th e s e rv ic e b ra k e c o n tro l p ip e s (3).
28
4. R e m o v e th e ste e rin g w h e e l (1) re ta in in g n u t and

re m o v e th e s te e rin g w h e e l and h and th ro tltle
lever.
29
6-62720 - 09 - 2006
5. Remove the four securing screws (1) from the

instrument panel (2).
30
6. Disconnect the electrical leads (1) from the rear

of the instrument panel. Unscrew the the
tachometer cable (2). Remove the instrument
panel and store in a safe place.
31
7. .Unscrew the rear hood screws (1)
8. Take off the complete rear hood (2)
TRE0436A
32
9. Remove the electrical connections:from the
pressure sensor (1) and remove the service
brake control pipes (2).
33
6-62720 - 09 - 2006
10. R e m o v e th e re ta in in g p in s and w ith d ra w th e

b ra ke p u m p c o n tro l fo rk a rtic u la tio n d o w e ls (1).
11. U n d o th e b o lts (2) th a t s e c u re th e b ra k e c o n tro l

p u m p s to th e c a b and w ith d ra w th e p u m p s fro m
th e e n g in e sid e .
----------- A WARNING A -------------

U se a p p ro p ria te to o ls to a lig n th e h o le s. N E V E R
34
35
Sectional drawing of service brake control pump (Master cylinder)
1. S p rin g . 4. R e a r se a l.
2. P u m p body. 5. C e n tra l se a l.
3. C o n tro l p isto n . 6. F ro n t se a l.
12. R e fit th e h y d ra u lic b ra k e c o n tro l p u m p u n it as

fo llo w s .
— F it th e p u m p s , s e c u re th e m , th e n c o n n e c t th e m
to th e c o n tro l p e d a ls.
— C o n n e c t th e c o n tro l p ip e s and th e ta n k and
p re s s u re s e n s o r c o n n e c tio n s .
— C o n n e c t th e n e g a tiv e b a tte ry ca b le .
— C a rry o u t th e fo llo w in g a d ju s tm e n t and bleed the
a ir fro m th e circ u it, o b s e rv in g th e p o in ts
d e s c rib e d on p a g e 22.
6-62720 - 09 - 2006
HYDRAULIC BRAKE SLAVE CYLINDER

P ro ce e d as fo llo w s to re m o v e th e h y d ra u lic b ra k e
s la v e c y lin d e r:.
13. R e m o v e th e pin (1).
14. R e m o v e th e b o lts s e c u rin g th e p u m p (2).
15. Take o ff th e p ip e c o n n e c tio n s (3) a n d (4).
36
16. W ith d ra w th e s la v e c y lin d e r (1) fro m link.
37
17. R e m o v e th e fro n t h y d ra u lic p u m p in te rn a l parts.
C h e c k th e s e a ls and p isto n .
----------- A WARNING A -------------

U s e a p p ro p ria te to o ls to a lig n th e h o le s. N E V E R
TRE0306A
38
18. R e fit th e h y d ra u lic b ra k e s la v e c y lin d e rs as
fo llo w s .
— In s e rt th e m a s te r c y lin d e r (1) fro m link.
— F it th e pin (1).
— A s s e m b ly th e b o lts s e c u rin g th e p u m p (2).
— A s s e m b ly th e p ip e c o n n e c tio n s (3) a n d (4).
6-62720 - 09 - 2006
HYDRAULIC FRONT BRAKE SYSTEM

(Optional)
A ir bleeding (Op. 33 202 04 )
A ir m u st be bled w h e n e v e r w o rk is ca rrie d o u t on the

fro n t b ra ke h y d ra u lic s y s te m .
P ro c e e d as fo llo w s .
1. T h o ro u g h ly cle a n th e e x te rn a l p a rts o f th e un it
a ro u n d th e b le e d s c re w s (1) fig. 4 0 , (1) fig. 42
and th e h y d ra u lic oil ta n k lid (1) fig. 39.
2. M a ke s u re th a t th e h y d ra u lic oil ta n k (1) is fille d 39

up b e fo re a n d d u rin g th e b le e d in g o p e ra tio n s .
N.B. - F ilte r all d ra in e d oil b e fo re re u sin g .
3. D e p re s s th e LH b ra ke p edal, slowly and to the

end of its travel , s o th a t th e oil is p la ce d u n d e r
p re ssu re .
4. K e e p in g th e p e d a l d e p re s s e d , u n d o th e ble e d
s c re w (1) by h a lf a tu rn and a llo w th e oil m ixe d
w ith a ir b u b b le s to flo w out.
5. R e tig h te n th e s c re w (1) a n d re p e a t th e a b o v e
o p e ra tio n s u ntil th e oil th a t c o m e s o u t is fre e o f
a ir b u b b le s.
6. D e p re s s th e LH b ra k e p e d a l a g a in to p la ce th e
c irc u it u n d e r p re s s u re : th is o c c u rs w h e n th e
tra v e l o f th e p e d a l re tu rn s to n o rm a l.
7. R e p e a t th e a b o v e o p e ra tio n s fo r th e R H b ra ke
p e d a l fro m th e ble e d s c re w (2).
40
8. D e p re s s th e LH and RH b ra ke p edal, s lo w ly and

to th e end o f its tra v e l, so th a t th e oil is p la ce d
u n d e r p re ssu re .
9. K e e p in g th e p e d a ls d e p re s s e d , u n d o th e ble e d
s c re w (1) on th e RH b ra ke s la v e c y lin d e r by h a lf
a tu rn and a llo w th e oil m ixe d w ith a ir b u b b le s to
flo w out.

a ir b u b b le s.
11. W h e n th e o p e ra tio n has b e e n c o m p le te d ,

re p le n is h th e oil in th e ta n k (1) fig. 39.
41
6-62720 - 09 - 2006
12. D e p re s s th e LH and RH b ra ke p edal, s lo w ly and

to th e end o f its tra v e l, so th a t th e oil is p la ce d
u n d e r p re ssu re .
13. K e e p in g th e p e d a ls d e p re s s e d , u n d o th e ble e d
s c re w (1) by h a lf a tu rn and a llo w th e oil m ixe d
w ith a ir b u b b le s to flo w out.

a ir b u b b le s.
15. W h e n th e o p e ra tio n has b e e n c o m p le te d ,

re p le n is h th e oil in th e ta n k (1) fig. 39.
42
16. F o r J X 6 0 & J X 7 0 m o d e ls fro n t b ra k e b le e d in g

s c re w (1) is lo c a te d on fro n t w h e e l d riv e s h a ft
th a t is sh o w n on fig. 43.
SERVICE BRAKE PEDALS

Adjusting height of service brake pedals
(Op. 33 120 08 )
1. W ith th e b ra k e p e d a ls c o n n e c te d to th e ir
re s p e c tiv e fo rk s a n d th e p e d a l c o n n e c tin g pin
re m o v e d , c h e c k th a t th e h e ig h t (A ) fro m th e
c e n tre o f th e p e d a ls to th e to p o f th e c a rp e t is:
162 m m fo r tra c to rs fitted w ith ca b o r 20 5 m m fo r
tra c to rs w ith o u t cab.
2. If a d ju s tm e n t is re q u ire d , s la c k e n th e lo c k nu ts
(2) an d tig h te n o r s la c k e n b o lt (1) u ntil th e
re q u ire d h e ig h t (A) is o b ta in e d . La stly tig h te n the
lo c k nuts.
6-62720 - 09 - 2006
3. T h e le n g th o f th e b ra k e lin k s m u s t be 1 9 0 m m
0 1 m m . If a d ju s tm e n t is re q u ire d , fu lly re le a s e
th e h a n d b ra k e (le v e r d o w n ). R e m o v e th e
co n n e c tin g pin (3). S la cke n th e lo ck nuts (1) and
tu rn th e h e x a g o n s le e v e s (2) u n til th e le n g th o f
b ra ke links is 190 m m . F inally, tig h te n th e lo ck
n u ts (1).
46
SECTIONAL VIEW OF SLAVE CYLINDER
6-62720 - 09 - 2006
HAND BRAKE CONTROL

Adjusting travel (Op. 33 110 08)
The travel of the parking brake control lever must be

adjusted whenever work is carried out on the unit and
when the lever is not on the third notch of the gear
sector when the brake is engaged.
Proceed as follows.
1. Slacken the lock nut (1).
2. Tighten or slacken the adjusting screw (2) until

the control lever is locked on the third notch.
3. Tighten the lock nut (1).
47
6-62720 - 09 - 2006
6-62720 - 09 - 2006
SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1 1
SECTION 35 - HYDRAULIC SYSTEM

Chapter 1 - Rear mechanical hydraulic lift
CONTENTS
35 000 M a in s p e c ific a tio n ........................................................................................................................................... 1

T ig h te n in g to rq u e s .......................................................................................................................................... 5
T o o ls ................................................................................................................................................................... 6
C ro s s -s e c tio n a l v ie w s ................................................................................................................................... 7
D e s c rip tio n & O p e r a tio n .................................................................................................................................9
H y d ra u lic c i r c u it .................................................................................................................................................9
D e s c rip tio n and o p e ra tio n o f lift p h a s e s .............................................................................................. 10
F a u lt d ia g n o s is ............................................................................................................................................ 13
35 110.30 H y d ra u lic lift - d is a s s e m b ly r e a s s e m b ly ................................................................................................ 15
35.110.40-42-46 H y d ra u lic lift - b e n ch o v e rh a u l ................................................................................................................ 21
A d ju s tin g th e l i f t .............................................................................................................................................. 26
35.110.08 L in k a g e a d ju s tm e n t .......................................................................................................................................32
35.110.30 P re s s u re re lie f va lv e - d is a s s e m b ly r e a s s e m b ly ................................................................................34
35.110.32 P re s s u re re lie f va lv e - s e t t in g .................................................................................................................... 34
35.110.14 L ift c o n tro l v a lv e - d is a s s e m b ly a s s e m b ly and o v e rh a u l on b e n ch ........................................... 36
35.0101.10 L ift p u m p ........................................................................................................................................................... 41
35 000 - MAIN SPECIFICATION - TORQUE SETTINGS - TOOLS - SECTIONAL DRAWINGS -

MAIN SPECIFICATION OF REAR MECHANICAL HYDRAULIC LIFT
T y p e ..................................................................................... p o s itio n o r d ra ft c o n tro l w ith a

c o m b in a tio n o f th e tw o
O p e ra tin g s y s te m ......................................................... tw o in d e p e n d e n t le ve rs
L IF T -O -M A T IC .............................................................. p ro v id e s fa s t liftin g /lo w e rin g

o p e ra tio n s u sin g p u s h b u tto n s ,
w ith o u t u sin g th e p o s itio n o r
d ra ft c o n tro l le ve rs
S in g le -a c tin g c y lin d e r:
- rate d d ia m e te r a n d stro k e :
A ll m o d e ls mm 100x128
(in.) (3 .9 3 7 0 x 5 .0 3 9 4 )
- ca p a c ity :
A ll m o d e ls cm 3 1005
(in .3) (6 1 .3 3 )
P re s s u re re lie f v a lv e s e t t in g ....................................... .............................. bar 186 - 191

psi (1 2 6 9 7 .6 9 - 2 7 7 0 .2 1 )
C y lin d e r s a fe ty v a lv e s e ttin g ..................................... .............................. bar 210 - 215

psi (3 0 4 5 .7 8 - 3 1 1 8 .3 0 )
MAIN SPECIFICATION OF REAR MECHANICAL HYDRAULIC LIFT
(continued)
L ift p isto n d ia m e te r:
- A ll m o d e ls ................................................................... ......................... mm 9 9 .9 8 0 - 1 0 0 .0 0 0
(in.) (3 .9 3 6 2 - 3 .9 3 7 0 )
In te rn a l d ia m e te r o f c y lin d e r liner:
??.??.???.?? - ?? - ????
2 SECTION 35 - HYDRAULIC SYSTEM - CHAPTER 1
- A ll m o d e ls ................................................................................................ mm 1 0 0 .0 3 6 - 100.071
(in.) (3 .9 3 8 4 - 3 .9 3 9 8 )
C le a ra n c e b e tw e e n p isto n a n d l i n e r ....................................................... mm 0 .0 3 6 - 0.091
(in.) (0 .0 0 1 4 - 0 .0 0 3 6 )
D ia m e te r o f lift a rm s h a ft (11, fig. 3) a t p o s itio n o f b u s h in g s :
- rig h t-h a n d s id e ....................................................................................... mm 5 4 .9 7 0 - 5 5 .0 0 0
(in.) (2 .1 6 4 2 - 2 .1 6 5 4 )
- le ft-h a n d s id e ......................................................................................... mm 6 2 .6 7 0 - 6 2 .7 0 0
(in.) (2 .4 6 7 3 - 2 .4 6 8 5 )
In te rn a l d ia m e te r o f b u s h in g s fitte d on lift body:
- rig h t-h a n d s id e (8, fig. 3 ) ..................................................................... mm 5 5 .1 0 0 - 5 5 .1 8 4 (1)
(in.) (2 .1 6 9 3 - 2 .1 7 2 6 )
- le ft-h a n d s id e (12) ................................................................................ mm 6 2 .8 0 0 - 6 2 .8 8 4 (1)
(in.) (2 .4 7 2 4 - 2 .4 7 5 7 )
C le a ra n c e b e tw e e n lift a rm s h a ft and b u s h in g s ................................ mm 0 .1 0 0 - 0 .2 1 4
(in.) (0 .0 0 3 9 - 0 .0 0 8 4 )
In te rfe re n c e b e tw e e n b u s h in g s and th e ir s e a ts ................................ mm 0 .0 6 5 - 0 .1 8 5
(in.) (0 .0 0 2 6 - 0 .0 0 7 3 )
A x ia l c le a ra n c e o f s h a ft c o m p le te w ith lift a rm s ................................ mm 0 .2 - 1.4
(in.) (0 .0 0 7 9 - 0 .0 5 5 1 )
E x te rn a l d ia m e te r o f d ra ft c o n tro l id le r s h a f t ....................................... mm 2 1 .9 6 7 - 2 2 .0 0 0
(in.) (0 .8 6 4 8 - 0 .8 6 6 1 )
In te rn a l d ia m e te r o f s e a ts in s u p p o rt ..................................................... mm 2 2 .0 2 0 - 2 2 .0 7 2
(in.) (0 .8 6 6 9 - 0 .8 6 9 0 )
C le a ra n c e b e tw e e n d ra ft c o n tro l id le r s h a ft a n d p o s itio n c o n tro l mm 0 .0 2 0 - 0 .1 0 5
id le r s h a ft ......................................................................................................... (in.) (0 .0 0 0 8 - 0 .0 0 4 1 )
D ia m e te r o f p o s itio n c o n tro l id le r s h a f t .................................................. mm 1 3 .9 7 3 - 1 4 .0 0 0
(in.) (0.5501 - 0 .5 5 1 2 )
In te rn a l d ia m e te r o f p o s itio n c o n tro l id le r s h a f t .................................. mm 1 4 .0 1 6 - 1 4 .0 5 9
(in.) (0 .5 5 1 8 - 0 .5 5 3 5 )
C le a ra n c e b e tw e e n d ra ft c o n tro l id le r s h a ft a n d p o s itio n c o n tro l
id le r s h a ft ......................................................................................................... mm 0 .0 1 6 - 0 .0 8 6
(in.) (0 .0 0 0 6 - 0 .0 0 3 4 )
C le a ra n c e b e tw e e n c o n tro l v a lv e b lo c k pin (8, fig. 4) a n d its s e a t
on th e c o n tro l v a lv e b lo c k b o d y ................................................................ mm 0 .0 0 8 - 0 .0 1 2 (2)
(in.) (0 .0 0 0 3 - 0 .0 0 0 5 )
C le a ra n c e b e tw e e n lift c o n tro l v a lv e (10) a n d its s e a t on th e c o n
tro l v a lv e b lo c k b o d y ..................................................................................... mm 0 .0 0 8 - 0 .0 1 2 (2)
(in.) (0 .0 0 0 3 - 0 .0 0 0 5 )
C o n tro l v a lv e b lo c k pin re tu rn s p rin g (5, fig. 4):
- fre e s p rin g le n g th .................................................................................. mm 5 0 .5
(in.) (1 .9 8 8 2 )
- sp rin g le n g th u n d e r load o f 3 1 .7 - 35 N (7 .1 2 4 2 - 7.8741 lb) mm 34
(in.) (1 .3 3 8 6 )
C o n tro l v a lv e re tu rn s p rin g (9, fig. 4)
- fre e s p rin g le n g th .................................................................................. mm 44
(in.) (1 .7 3 2 3 )
- sp rin g le n g th u n d e r load o f 103 - 114.7 N mm 29
(in.) (1 .1 4 1 7 )
??.??.???.?? - ?? - ????
MAIN SPECIFICATION OF IMPLEMENT HITCHING DEVICE
T y p e ....................................................................................................... three-point linkage

Category:
- All Models ..................................................................................... 2
Draft control ......................................................................................... by means of lower arms
with flex bar
Maximum liftable load with centre of gravity 610 mm from the
lower arm link ends: with arms horizontal
(with top link connected to hole on upper support):
- JX60, JX70 Models .................................................................... kg 2260
(lb) (4982.45)
- JX80, JX90 and JX95 M o d e ls.................................................... kg 2700
(lb) (5952.48)
Maximum liftable load: with arms horizontal
(with top link connected to upper support pin):
- JX60, JX70 Models .................................................................... kg 3000
(lb) (6613.87)
- JX80, JX90 and JX95 M o d e ls.................................................... kg 3565
(lb) (7859.48)
Flex bar diameter:
- JX60, JX70, JX80, JX90, JX95 Models .................................. mm 24.867 - 24.900
(in.) (0.9790 - 0.9803)
Axial clearance of flex bar ................................................................ mm 1.2 - 4.1
(in.) (0.0472 - 0.1614)
MAIN SPECIFICATION OF HYDRAULIC PUMP (All models)
Filter
T y p e ...................................................................... paper cartridge
L o ca tio n ................................................................ fixed to the pump housing on

suction side
Pump
T y p e ...................................................................... gear type with oil suction from

transmission casing
L o ca tio n ................................................................ Flanged on the rear left-hand

side of the engine
C o n s tru c tio n ........................................................ BOSCH
M o d e l.................................................................... A31
Operation ............................................................ by means of the engine gears
Direction o f rotation (as seen from drive side) left (counter clockwise)
Engine speed to pump speed r a tio .................. 1 : 0.931
Maximum speed of pump rotation (with engine at maximum

power equivalent to 2500 rpm) .......................................................... rpm 2328
Bench output at 1450 rpm and pressure of 172 bar ( 175 kg/cm2):
- for new or reconditioned p u m p .................................. dm3/min (in.3/min) 19 (1159.5)
- for worn pump ............................................................ dm3/min (in.3/min) 13.3 (811.6)
- test oil te m p e ra tu re ...................................................................... C°(F°) 55 - 65 (131 - 149)
- test oil v is c o s ity ............................................................................ SAE 20
??.??.???.?? - ?? - ????
MAIN SPECIFICATION OF HYDRAULIC PUMP (All models)

(continued)
Driven and driving gear shaft diam eter .......................................... mm 17.400 - 17.418
(in.) (0.6850 - 0.6857)
Internal diam eter of seats in supports ............................................ mm 17.450 - 17.470
(in.) (0.6870 - 0.6878)
Clearance between gear shafts and their s e a ts ............................ mm 0.032 - 0.070
(in.) (0.0013 - 0.0025)
- maximum clearance due to w e a r .............................................. mm in.) 0.1 (0.0039)
Radial clearance of gears in pump b o d y ........................................ mm 0.020 - 0.064
(in.) (0.0008 - 0.0025)
Maximum w ear on pump body, suction side, at position of gears mm(in.) 0.1 (0.0039)
Width of gears (5, fig. 104) .............................................................. mm 24.000 - 24.015
(in.) (0.9449 - 0.9455)
Width of supports (4 and 6) .............................................................. mm 24.490 - 24.510
(in.) (0.9642 - 0.9650)
Width of pump body (3) for gear seats and supports .................. mm 73.135 - 73.160
(in.) (2.8793 - 2.8803)
Axial clearance of gears complete with supports in pump body
(recondition if n e c e s s a ry ).................................................................. mm 0.100 - 0.180
(in.) (2.8793 - 2.8803)
LIFT HYDRAULIC PUMP (OPTIONAL) DATA
Filter
T y p e ...................................................................... paper cartridge
Location .............................................................. fixed to the pump housing on

suction side
Pump
T y p e ...................................................................... gear type with oil suction from

transmission casing
Location .............................................................. Flanged on the rear left-hand
side of the engine
C o n s tru c tio n ........................................................ Bosch
M o d e l.................................................................... Rexroth
Operation ............................................................ by means of the engine gears
Direction o f rotation (as seen from drive side) left (counter clockwise)
Engine speed to pump speed r a tio .................. 1 : 1.080

Maximum speed of pump rotation (with engine at maximum
power equivalent to 2500 rpm) .......................................................... rpm 2700
Nominal flow rate .............................................. dm3/turn (in.3/turn) 0.01950 (1.1930)
Corresponding rated output for new pump dm3/min (in.3/min) 48 (2929.14)
Corresponding rated output for pump with 300 hours

of w o r k .......................................................................... dm3/min (in.3/min) 43 (2624.02)
Bench output at 1500 rpm and a pressure of 2175 psi (150 bar):
- for new pump .............................................. dm3/min (in.3/min) 24.8 (1513.39)
- for pump with 300 hours o f w o r k .............. dm3/min (in.3/min) 22.3 (1360.83)
??.??.???.?? - ?? - ????
- test oil temperature .................................. ................................ °F 131 to 149

(°C) (55 to 65)
- test oil v is c o s ity.......................................... 16 CST
TORQUE SETTINGS
Torque setting
Thread
Nm ft lb
Lift
Capscrew, lift to rear transmission case (C-i Fig.1) ........................ M 12 x 1.25 98 72.28
Capscrew, control valve body to lift (C 3 F ig .2 8 )................................ M 8 x 1.25 26 19.18
Capscrew, lift arm plates (C2, F ig .1 ).................................................... M 14 x 1.5 147 108.42
Plug, max. arm raising adjustment (3, Fig.28) .................................. M 12 x 1.25 103 75.97
Nut, position control shaft .................................................................... M 10 x 1.25 59 43.52
Nuts for lever quadrant bracket securing stud bolts (2, Fig.32) . . . . M8x1.25 25 18.44
Lift cylinder securing bolts: M14x1,5 211 155.63
M16x1.5 260 191.77
Securing bolts for top link attachment bracket .................................. M14x1.5 147 108.42
Inner lift arm securing bolts .................................................................. M 10 x 1.25 61 44.99
Capscrew, suction c o n n e c tio n .............................................................. M 12 x 1.25 98 72.28
Capscrew, delivery connection on lift control valve .......................... M 10 x 1.25 59 43.52
Capscrew, lift pump (Fig.86) ................................................................ M6x 1 8 5.90
Nut, pump cover ..................................................................................... M 10 x 1.25 41 30.24
Capscrew, flexion bar s u p p o rt.............................................................. M 16 x 1.5 221 163.00
Capscrew, chain support ...................................................................... M 16 x 1.5 221 163.00
Capscrew, check link support .............................................................. M 16 x 1.5 221 163.00
Nut, tow bar ............................................................................................. M 18 x 1.5 343 252.98
Control valves
Nut, control valve links .......................................................................... - 20 14.75
Connection, outlet to f i t .......................................................................... - 20 14.75
Plug, relief bar spring ............................................................................ - 20 14.75
??.??.???.?? - ?? - ????
TOOLS
HYDRAULIC LIFT EQUIPMENT X 380000225 Ring for fitting piston with lift seals.
X 380000274 Union for checking control valve

seal.
Warning - The operations described in this section
cannot be carried out without the ESSENTIAL tools X 380000262 Punch for fitting lift arm shaft seals.
marked below with (X ).
X 380000261 Punch for fitting needle bearings on
control valve block control lever
However, to ensure greater safety and obtain the
bushing.
best results while saving time and effort, we recom
mend that these essential tools are used in conjunc X 380000260 Punch for fitting needle bearings to
tion with the specific tools listed below as well as cer upper/lower draft control levers and
tain tools which are to be made following the to draft control link rod.
construction drawings given in this manual.
X 380000230 Wrench for cylinder safety valve
setting ring nut.
X 380000217 Union for lift pressure relief valve

calibration.
X 380000218 Union for cylinder safety valve

calibration.
380000215 Hand pump for valve calibration.
X 380000267 Wrench for maximum lift screw lock-
nut.
380000224 Lifting hook.
X 380000263 Draft control setting tool.
380000238 Hook adapter 380000224. X 380000264 Position control setting tool.
??.??.???.?? - ?? - ????
TRE0700A
48
Sectional drawing of lift
C 1 . .Lift capscrews. 8 . L.H.Bushing.
C 2 .Thrust plate capscrews. 10 . Thrust washers.

G =: 0.2 to 1.4 mm (0.0079 to 0.551 in.) 1 1 . Top link support.
Shaft end float.
12 . Piston rod pin.
1 . Inner arm.
13. Travel limit adjusting screw.
2 . Cross shaft.
3. Link arm. 14. Travel limit adjusting screw locknut.
4. Arm thrust plates. 15. Travel limit control rod.
5. R.H.Seal. 16. Control valve link pin.
6 . L.H.Seal. 18. Draft control inner lever pivot.
7. R.H.Bushing. 19. Set screw.
??.??.???.??- ??- ????

TRE0701A
49
Sectional drawing of hydraulic lift control valve block

a. Detail of O -ring and arm lowering adjuster valve 14. Ring.
anti-extrusion ring.
15. Cylinder safety valve.
1. Spool valve.
16. Response control valve.
2. Spool valve seat.
17. Arm lowering speed control valve.
3. Plug.
18. Ball.
4. Spool return spring.
19. Response control valve adjusting pin
5. Valve plunger.
20 . Delivery connection.
6. Plunger spring.
7.
2 1 . Check valve spring.
Plug.
8. Piston seat. 22 . Check valve.
9. Piston. 23. Check valve seat.
10 . Spring cup. 30. .Retaining ring.

1 1 . Draft sensitivity adjustment valve spring. 31. .Roll pin.
12 . Draft sensitivity adjustment valve. 32. .Back-up ring.
13. Plug. 33. .O-ring.
Note - Install the O -ring 33 and anti-extrusion ring 32 as illustrated in the drawing (a) using the protection device
380000266 and heating the ring 32 in oil at 50 °C.
Take care to install ring 32 with the flat surface facing upwards and concave surface facing O -ring 20. Take
necessary precautions not to damage them.
??.??.???.?? - ?? - ????

The mechanical lift can operate with controlled Draft control is actuated by the flex bar positioned in
position or draft control and with a combination of the the special box mounted under the rear
two. The lift is controlled by two levers located on the transmission.
operator’s right. It also features the Lift-O -M a tic The lower lift arms and corresponding control rods
device which raises and lowers the implement are connected to the flex bar.
without the need to use the position and draft control
levers.
□ S ta tic o il
□ O i l i n s u c tio n
| | T r a c to r b ra k e c irc u it o il (b ra k e s o f f )
□ P r e s s u r is e d o il
□ E x h a u s t o il flo w
50
HYDRAULIC LIFT CIRCUIT

1. Delivery line to control valve (3). 6 . Lift control valve.
2. Trailer brake control valve. 7. Suction line.
3. Auxiliary control valves. 8 . Oil filter.
4. Auxiliary control valve lines. 9. Hydraulic pump.
5. Trailer brake control valve line.
??.??.???.?? - ?? - ????
□ Pressurised oil
□ Oil in suction, delivery or return
□ Static oil
TRE0702A
51
ARM LIFT PHASE
F. Filter. 5. Plunger.
P. Hydraulic pump. 6 . Plunger spring
T. Lift arm piston. 8 . Piston seat.
V. Reliefvalve. 9. Piston.
1. Valve spool. 22 . Check valve.
When the position control lever (located on the Oil flow to piston (9) is cut off and plunger (5) is forced
operator’s right-hand side) is used to raise the arms, to the left by spring (6), thus closing the exhaust port.
the movement shown by the arrows is transmitted by Pressure oil opens check valve (22) and operates
the internal lever mechanisms to the control valve piston (T) to raise the arms.
block pin ( 1 ).
??.??.???.?? - ?? - ????
52
NEUTRAL PHASE
F. Filter. 9. Piston.
P. Hydraulic pump. 12 . Draft sensitivity valve.
V. Relief valve. 15. Cylinder safety valve.
1. Valve spool. 17. Arm lowering speed control valve
5. Plunger. 18. Ball.
6. Plunger spring. 22 . Check valve.
With spool (1) in the neutral position, oil is delivered and directs oil flow to the tank in the rear transmission
through the response adjusting valve ( 12 ) to piston housing rather than to the cylinder.
(9), which overcomes spring reaction (6) and moves
plunger (5) to the right. This opens the exhaust port
??.??.???.?? - ?? - ????
ARM LOWERING PHASE

F. Filter. 5. Plunger.
P. Hydraulic pump. 9. Plunger spring.
T. Lift arm piston. 12 . Draft sensitivity valve.
V. Relief valve. 17. Arm lowering speed control valve
1. Valve spool. F1. .Spool port
When the operator lowers the position control lever Unscrewing the screw (16) decreases the load on
on his right, the return spring (4) pulls spool (1) to the the spring (15), therefore the valve (14) can vibrate
right. Cylinder oil is exhausted under piston pressure faster, slowing down the descent speed. Tightening
(T) through lowering speed adjustment valve (17) the screw (16) slows down the vibration of the valve
and the port uncovered by spool. (14) that increases the descent speed of the arms
since the valve (14) can remain in position in corre-
Through spool port (F1) and draft sensitivity valve spondence with the larger orifice where the oil flows
(12) oil flows to piston (9), which holds plunger (5) in out from the cylinder.After adjusting the arm descent
the position shown, thus allowing pump delivery to be speed it will not depend on the weight bearing on the
exhausted past plunger (5). arms but will be virtually constant.
??.??.???.?? - ?? - ????
HYDRAULIC LIFT DIAGNOSTICS
The lift does not raise. 1. Oil filter clogged. Replace filter.
2. Control valve jammed in dis Release control valve.

charge position.
3. Hydraulic pump defective. Overhaul or replace pump.
The lift operates jerkily. 1. Oil filter clogged. Replace filter.
2. Air has got into the pump suc Check that the couplings are airtight
tion line. and the seals are effective.
The lift raises too slowly. 1. Oil filter clogged. Replace filter.
2. Oil leaking past piston seals or Replace all defective seals.

seals on discharge fitting to
cylinder, with consequent loss
of pressure.
3. Hydraulic pump defective. Overhaul or replace pump.
The lift operates too quickly. 1. Foreign matter between the Take off the valve, remove the foreign
ball and its seat on the dis matter and inspect the oil filter.
charge control valve.
2. Discharge control valve ball Replace discharge control valve.

seal defective.
3. Discharge control valve piston Take off the valve and free the piston.
jammed.
The lift operates too slowly. 1. Discharge ports on the dis Take off the valve, unblock the holes
charge control valve blocked. and inspect the oil filter.
2. Discharge control valve piston Take off the valve and free the piston.
jammed.
??.??.???.?? - ?? - ????
HYDRAULIC LIFT DIAGNOSTICS

(continued)
The lift is unable to keep the load 1. Defective seal on check valve. Take off, check, clean and if neces
raised (with the engine running, sary replace the parts concerned.
the load moves up and down
rhythmically; with the engine 2. Oil leaking past the seals on Replace seals.
turned off, the load lowers). the control valve block pin
seat.
3. Control valve block pin seal Take off and clean the seal and
defective. replace the control valve block pin
and its seat if defective.
4. Oil leaking past the lift piston Replace the seals.

seal or the seals on the
cylinder oil discharge fitting.
5. Defective seal or cylinder safety Replace the valve.

valve set to very low value.
The pressure relief valve cuts in 1. Lift arm travel set incorrectly. Set correctly.
when the lift arms reach their com
pletely raised position.
Lift has poor lifting capacity. 1. Pressure relief valve set Replace the valve.
incorrectly.
2. Cylinder safety valve set Replace the valve.

incorrectly.
3. Poor pump efficiency (gener Overhaul or replace the pump.

ally accompanied by a consid
erable increase in lift time).
??.??.???.?? - ?? - ????
REMOVAL - REFITTING - OVERHAUL OF REAR MECHANICAL HYDRAULIC LIFT ASSEMBLY

REAR HYDRAULIC LIFT ASSEMBLY
----------- A DANGER A -----------

equipment with sufficient hoisting capacity.
Check that the assemblies or parts are held firmly
and supported by suitable slings and hooks. Make
sure nobody is standing near to the load.
To remove the hydraulic lift assembly from the rear

transmission casing, proceed as follows.
1. Disconnect the negative cable (1) from the

battery.
54
2. Remove the top link (1).
56
??.??.???.?? - ?? - ????
4. Remove the split pins and withdraw the shafts

(1). Remove the lift rods (2) and the lateral
stabiliser struts (3).
57
5. Unscrew: the trailer brake control pipe (1) and
the auxiliary control valve pipes from the support
plate (2 ).
58
6. Remove auxiliary control valve pipes (2) from
their support ( 1 ).
59
7. Undo the two bolts (1) that secure the seven-
pole socket (2 ) and remove the socket.
60
??.??.???.?? - ?? - ????
8. Undo the bolts (1) and remove the support (2).
9. Undo the bolt (1) and disconnect the breather

pipe connection.
62
10. Remove the electric socket (1).
11. Remove the retaining springs (1) and detach the

two control rods (2 ) from the lift levers.
??.??.???.?? - ?? - ????
12. Remove the LIFT-O -M A TIC control rod (1).
65
13. Connect a suitable hoist (2) to the cab lifting

hooks ( 1 ) and tension the hoist.
66
14. Unscrew the two cab front securing bolts (1).
67
15. Unscrew the two cab rear securing bolts (1).
Raise the cab approximately 5 -6 cm
(0.1969-0.2362 in.) and place wooden blocks
( 1 ) between the cab upright and the housing.
Lower the hoist so that the cab rests securely on
the wooden block.
68
??.??.???.?? - ?? - ????
16. Remove the pipes on the lift (1) and the control
valve body (2 ).
69
17. Unscrew the bolts (1) that secure the hydraulic
lift assembly to the transmission casing.
70
18. Fit tool 380000237 (1) on the lift and tighten the
four bolts (2 ).
71
19. Fit tool 380000224 (1) onto tool 380000238 (2).
Attach the hoist to tool 380000224, raise the
hydraulic lift by a few centimetres and pull it
backwards, tilting it so that it clears the breather
pipe (3) without damaging it.
??.??.???.?? - ?? - ????
20. Refit the hydraulic lift assembly to the transmis

sion casing as follows.
----------- A WARNING A -----------

Always use appropriate tools to align fixing holes.
Before refitting the hydraulic lift assembly to the

rear transmission casing, clean and degrease
the mating surfaces thoroughly and apply a strip
of sealing compound of about 2 mm (0.0787 in.)
diam eter as shown in fig. 73.
Apply the torque settings listed on page 5.
Use tools 380000224 and 380000238 to fit the

hydraulic lift assembly to the transmission casing
and tighten the bolts securely.
Insert the electric leads into their clips on the lift

body.
Diagram showing application of sealing
compound when fitting the hydraulic lift
Fit the lift control pipe. assembly to transmission casing.
The types of sealing compounds to be applied are
Raise the cab by a few millimetres, remove the specified on page 1 , section 00.
wooden blocks and tighten the bolts to secure
the cab.
Fit the trailer brake control pipe (if fitted) and the
oil filler pipe.
Connect the L ift-o -M a tic control rod.
Connect the lift control levers to their linkages.
Fit the windscreen washer tank and transmission

breather pipes onto the cab upright.
Fit the top link attachment bracket and the quick-

fitting support plate for auxiliary control valves.
Fit the seven-pole socket, the earth leads, the

quick-fittings and the trailer brake control pipe to
their corresponding support brackets.
Fit the additional control valve rods and the PTO

operating mode rod.
Fit the ground lift control lever.
Fit the lift rods and the lateral stabiliser struts.
Fit the pick-up hitch hook and the top link.
Connect the negative cable to the battery.

? ? .? ? .? ? ? .? ? - ?? - ????
REAR HYDRAULIC LIFT ASSEMBLY

Disassem bly-Assem bly
(Op. 35 110 40 - 35 110 42 - 35 110 46)
----------- A DANGER A -------------

Handle all parts with the utmost care.
Do not place your hands or fingers between one part
and another. W ear the prescribed safety clothing,
including glasses, gloves and protective footwear.
To disassemble the hydraulic lift, proceed as follows.
74
1. Position the hydraulic lift on a stand (1) fig. 74,
that will allow the assembly to be rotated.
2. Unscrew the securing bolts (1) and remove the
control valve block (2) fig. 75.
75
3. Unscrew the two cylinder securing bolts posi
tioned outside the cylinder body. Turn the lift
assembly and unscrew the lateral bolt (3).
4. Undo the bolts (1) that secures the internal
linkage (2 ) to the lift cylinder.
76
5. Remove the cylinder (1) complete with piston
77
??.??.???.?? - ?? - ????
6. Remove the retaining pin from the internal draft

lever, unscrew the nut ( 1 ), then remove the unit
complete with internal linkages and the LIF T -
O -M ATIC control lever.
78
7. Take off the snap ring and remove the internal
position control lever ( 1 ).
Unscrew the nuts (2) and remove the spring and
fixing bracket (4).
8. Take off the snap ring and remove lever (3), the
friction discs, lever (5) and the stud bolts.
79
9. Slacken the eccentric pin (2) retaining bolt (1),
withdraw the eccentric pin and remove the
internal linkage.
10. Unscrew the bolt (3), remove the washer (4),

withdraw the lift arm (5) and remove the thrust
washer. Repeat on the other lift arm.
80
11. Remove the crimping on the internal arm locking
bolt (1) and unscrew the bolt. Withdraw the shaft
(2) and remove the seals (3).
81
??.??.???.?? - ?? - ????
12. Use compressed air to remove the piston (2)

from its cylinder ( 1 ).
82
13. Use striker tool 380000260 (1) to replace the

bearings in the internal draft control lever (2 ).
14. Use striker tool 380000261 to replace the control

valve block control lever bearings.
15. Fit the hydraulic lift as follows.
----------- A WARNING A -----------

83
16. Insert the piston (1) into its cylinder (3), using tool
380000225 (2).
84
17. Fit the lift arm shaft (2) and the internal arm (1)
inside the lift box, matching up the reference
marks, as shown. Tighten the securing bolt.
85
??.??.???.?? - ?? - ????
18. To avoid damaging the internal seal lips, use a

flexible brass sheet (1) of size 200 x 90 mm
(7.8740 x 3.5433 in.) and thickness
0.05 - 0.1 mm (0.0020 - 0.0039 in.). Roll the
sheet up and insert the seal inside. Position the
unit on the spline and push the seal manually into
its seat. Then remove the sheet.
86
19. Use striker tool 380000262 (1) to complete the

fitting of the seals into the their seats on the lift
arm shaft.
87
20. Fit the lift arms (1) on the shaft, matching up the
reference marks, as shown. Secure them by
tightening the bolts.
88
??.??.???.?? - ?? - ????
21. Fit the internal linkages and the corresponding

eccentric pin. Fasten the eccentric pin by
tightening the securing bolts.
22. Fit the control levers complete with friction discs,
snap rings and stud bolts.
23. Fit the spring and use the bracket to secure the
lever unit.
24. Fit the internal position control lever.
25. Fit the internal linkages and the L ift-o -M a tic
control lever.
26. Fit the cylinder complete with piston and secure
it.
27. Fit the internal linkages and fasten them to the
cylinder.
28. Clean the mating surfaces thoroughly and apply
a 2 mm (0.0787 in.) diam eter strip of sealing
compound to the lift box, as shown in fig. 89.
The types of sealing compound to be used are
shown on page 1 , section 00.
Fit the hydraulic control valve block on the lift box TRE0705A
and secure it using the screws.
Make the following adjustments. 89
NOTE - The adjustments must be made in the order

specified.
??.??.???.?? - ?? - ????
ADJUSTING THE LIFT

The following adjustments refer to a lift assembly
without hydraulic control valve block and mounted on
a rotary stand.
These adjustments must be made in the order
specified.
The LIFT-O -M ATIC device must be kept turned off
(external control lever ( 1 ) locked in the vertical
position) until otherwise specified.
Adjusting position control

Proceed as follows:
1. Move the external position control lever (1) fully
forward, against the spacer for the stud bolt
securing the spring retaining bracket. Move the
external draft control lever (2 ) fully rearward
against the spacer.
2. Turn the lift arm control shaft until the internal

arm is in contact with the lift body.
3. Use tool 380000267 (1) figure 92, to slacken the

lock nut (4) figure 93. Loosen the end stop
adjusting screw (5) until it is no longer in contact
with the control valve block control lever (3).
??.??.???.?? - ?? - ????
4. Fit tool 380000264 (4) fig 94, to the lift body. The
tool has a plunger operating in a tube, the outer
end of which has two reference surfaces ( 1 ) and
(5).
5. Using two spanners (2) and (3), unscrew the lock
nut (1) fig. 93 and tighten or loosen the
adjustable push rod (2) fig. 93, so that the end of
the plunger (5) fig 94, is flush with the outer
register surface (6) of the tool.
NOTE - This corresponds to a distance (L-i fig. 93)

o f 82.0 - 82.1 mm (3.2283 -3 .2 32 3 in.) between the
end o f the lever (3) fig. 93 and the front surface of
the lift body when a force (F! fig. 93) of
4 - 4.5 da N (25.40 - 39.82 in.lb) is applied to the
end o f the lever.
6. Tighten the lock nut (1) fig. 93.

rearwards against the stud bolt spacer. Turn the
lift arm control shaft so that the piston is fully
forward and check that the plunger (5) fig. 94 is
flush with or slightly inside the inner reference
surface (1) of the tool (4).
NOTE - This corresponds to a distance (L-^ fig. 93,

of greater than 86.5 mm (3.4055 in.) between the
end o f the lever (3) and the front surface o f the lift
body when a force (F-^ of
4 - 4.5 da N (25.40 - 39.82 in.lb) is applied to the
end o f the lever.
Adjusting the maximum height of the lift arms

Proceed as follows.
8. With tool 380000264 (4) fig. 94 fitted on the lift
body, move the external draft control lever (2 )
fully rearward, against the spacer. Move the
external position control lever ( 1 ) fully forward
against the spacer.
9. Turn the lift arm control shaft until the internal
arm touches the lift body.
??.??.???.?? - ?? - ????
10. Connect the fitting (5) of tool (2) to the workshop

compressed air system. Feed air into the
cylinder barrel to make the piston perform its
complete lifting stroke and use the air pressure
to keep it in this position.
11. Using tool 380000267 (1), tighten the screw (5)
fig. 93, until the end of the plunger (4) is flush with
the inner reference surface (3) of the tool (2) or
up to 0.5 mm (0.0197 in.) further in.
97
NOTE - This corresponds to a distance (L1) of

86.3-86.7 mm (3.3976-3.4134 in.) between the end
of the lever (3) and the front surface of the lift body.
12. Tighten the lock nut (4) to a torque of 15 Nm

(11.0624 ft lb).
98
Adjusting draft control
Proceed as follows:
13. Remove the end section of the draft control rod

(3) and mount it on the rod (5) of tool 380000263
(1). Fasten it using lock nut (4).
14. Place the tool 380000263 (1) complete with its

rod (5) and the end section of the draft control rod
(3) on a surface plate. Using a micrometer depth
gauge (2), measure the distance (L3) between
the upper surface of the rod and the micrometer
gauge bearing surface on the tool (be sure to
tighten rod (3) onto rod (5) so that the surface of
rod (5) is a few mm lower than the micrometer
99
bearing surface on the tool).
15. With tool 380000264 (2) fig. 97 mounted on the

lift body and disconnected from the compressed
air system, move the position control lever ( 1 )
fig. 100 and the draft control lever (2 ) fully back
against the spacer.
16. Move the eccentric pin (1) fig. 105, connected to

the internal draft control lever, to the horizontal
position with the eccentric cam pointed towards
the rear of the lift assembly.
100
??.??.???.??- ??- ????

17. Fit tool 380000263 (1) to the lift body and fasten
it to the two holes in the box as shown in figure
10 1 .
18. Turn the screw (2) fig. 101 on the internal draft
control lever (3) fig. 101 until the end of the
plunger ( 1 ) fig. 102 is flush with the inner
reference surface (3) of tool 380000264 (2).
19. Turn the eccentric pin (1) slightly to withdraw the

end of the plunger of tool 380000264 as far as
possible.
20. Again turn the screw (2) fig. 101 to adjust the
internal draft control lever (3) until the end of the
plunger fig. 103 is flush with the inner reference
surface (3) of the tool 380000264.
21. Finally turn the eccentric pin (1) fig. 103 until the
end of the plunger is flush with the outer register
surface (2) of the tool 380000264.
22. Insert rod of tool 380000263 (1) into the internal

draft control lever seat (2 ).
23. With the end of the plunger of tool 380000264

flush with the outer reference surface (2) fig. 103,
set the adjustable linkage (3) fig. 104 and use a
micrometer depth gauge to measure the dis
tance (L2) between the upper surface of the rod
and the micrometer gauge bearing surface on
the tool 380000264 (1).
??.??.???.?? - ?? - ????
24. The distance (L2, page 29) must be:

L2 = L3 + L4
where:
L3 = distance measured with tool 380000263
mounted on a surface plate:
L4 = 22.9 - 23.1 mm (0.9016 - 0.9094 in.). Oper
ating distance between the lift box bearing sur
face on the transmission casing and the rod rest
ing surface on the lever (3, fig. 104).
NOTE - This corresponds to a distance (L1, fig. 93)

of 82.0 - 82.1 mm (3.2283 - 3.2323 in.) between the
end of the lever and the front surface of the lift body,
measured with a force (F1) of 4 - 4.5 da N
(25.40 - 39.82 in. lb) applied to the end of the lever.
WARNING - Always make sure that when the plung

er of tool 380000264 is flush with the outer reference
surface (2) the the distance (L2, fig.104 ) is:
L2 = L3 + L4
where:
L3 = distance measured with the tool 380000263
mounted on the reference surface;
L4 = 22.9 - 23.1 mm (0.9016 - 0.9094 in.). Operating
distance between the lift box bearing surface on the
transmission casing and the rod bearing surface on
the lever (3) fig. 104.
If these conditions are not met, adjust the eccentric
pin (1) and the knurled screw (2) fig. 104 of tool
380000263 until they are.
25. Fit the threaded dowel (3) and tighten the screw
( 1 ) without bending over the safety w asher (2).
26. Remove the tools 380000264 and 380000263
and fit the hydraulic control valve block on the lift
body.
Proceed to mount the lift assembly onto the tractor

as follows.
WARNING - First position tool 380000263 (1) on a

surface plate and use a micrometer depth gauge (2)
to measure the distance (L5) between the surface
plate and the point where the micrometer gauge
rests on the tool.
Make a note of the measured distance (L5).
107
??.??.???.?? - ?? - ????
27. Fit the draft measuring device complete with

transmission lever (3) and draft control lever (2),
but without the flex bar, onto the rear transmis
sion casing.
28. Rest the transmission lever (3) on the draft
measuring device box and fit tool 380000263.
Fasten it to two holes on the box so that the draft
control rod (2 ) fits exactly inside the tool hole as
shown in figure 109
29. Using a micrometer depth gauge (2) fig.109,
measure the distance (L8) fig.109, between the
top end of the rod (3) fig.109 and the micrometer
gauge resting surface on the tool.
NOTE - The distance (L6) the top end of rod (2) pro
trudes with respect to the transmission casing (with
flex bar removed) is given by:
L6 = L5 - L8
where:
L 5 and L8 = distance measured with tool 380000263
108
fitted on the surface plate (L5) fig. 107 or on the trans
mission casing (L8) fig. 109.
30. Fit the flex bar and measure the new distance
(L9) between the top end of the rod (3) and the
micrometer gauge resting surface on the tool.
NOTE - The distance (L7) fig. 108, that the top end
of the rod (2 ) fig. 108, protrudes with respect to the
transmission casing (with flex bar fitted) is given by:
L7 = L5 - L9
where:
L 5 and L9 = distance measured with tool 380000263
mounted on surface plate (L5) fig. 107 or on the
transmission casing (L9).
31. Check that the distance (L7) is at least 5 mm

(0.1969 in.) greater than the distance (L6).
32. Slacken the lock nut (1) fig. 108 and adjust the
length of the draft control rod until it protrudes by
a new distance (L7 = 18.3 - 18.5 mm (0.7205 -
0.7283 in.)).
33. This distance (L7) can be calculated by subtrac
tion using tool 380000263:
L10 = L5 - L7
where:
L7 = 18.3 - 18.5 mm (0.7205 - 0.7283 in.).
Distance the end of the rod (2) fig. 108, protrudes
with respect to the transmission casing during
operation.
L5 = distance measured with tool 380000263
mounted on the surface plate.
L 10 = distance to be measured with the
micrometer gauge on tool 380000263.
34. Tighten the lock nut (1) fig. 108, and mount the
lift on the tractor.
??.??.???.?? - ?? - ????
ADJUSTING LINKAGES (Op. 35 110 08)
Adjusting position control linkage.

Proceed as follows.
1. Move the position control lever (1) fully forward
on the quadrant and check that the distance (L)
is between 15 and 20 mm
(0.5906 and 0.7874 in.).
110
rearward, against the spacer.
3. Connect the control linkage and adjust its length,

if necessary.
4. Fasten the linkage using the lock nuts.
111
Adjusting draft control linkage
Test conditions:
engine running at medium speed;
allow the oil in the system to reach a temperature
of 30 - 40 °C (86 - 104 °F).
Then proceed as follows:
5. Move the position control lever (1) fully forward
on the quadrant and the draft control lever (2 ) to
a distance (L1) of 15 - 20 mm
(0.5906 - 0.7874 in.) from the beginning of the
slot.
6. Move the draft control lever (2) fully back against

the spacer. 112
7. Connect the control linkage and adjust its length

if necessary.
113
??.??.???.??- ??- ????

8. Move the draft control lever (2) to a distance (L2)

of 95 - 105 mm (3.7402 - 4.1338 in.) from the
beginning o f the slot and check that at this
position the arms start to rise.
9. If they do not, adjust the eccentric pin (1) fig. 105,

to restore this distance.
10. Fasten the eccentric pin using the securing bolt

(1) fig. 106 .
114
Adjusting LIFT-O -M A TIC device
Proceed as follows:
11. Move the position control lever (1) and the draft
control lever (2) fully forward in the sector.
115
12. Raise the lift arms by means of the lever (1).
116
13. Tighten the nut (1) fig. 117, until the arms lower.
14. With the lever (1) fig. 116, still in the same
position, unscrew the nut (1) fig. 117, until the
arms begin to rise.
15. Unscrew the nut (1) by another 1.5 turns.
16. Using the levers (1) and (2) fig. 116, lower and
raise the arms a few times to ensure that the
system is operating correctly.
117
? ? ? ? ? ? ? ? ? - ?? - ????
LIFT PRESSURE RELIEF VALVE
Rem oving-Refitting (Op. 35 110 30)

Auxiliary control valve blocks. The lift pressure relief
valve (1) is located as shown in fig.118)
If defective, remove and change the valve.
118
LIFT PRESSURE RELIEF VALVE
Calibration (Op. 35 110 32)

Proceed as follows.
1. Run the engine until the oil reaches a tempera
ture of about 50°C (122 °F).
2. Insert the fitting 380000554 (1) in a quick-fit

female half-coupling and connect it to the 0 -
3555.84 psi scale pressure gauge supplied with
kit 380000240.
3. Activate the half-coupling control valve block

lever until the pressure relief valve cuts in.
4. With the engine running at medium speed the 119

pressure gauge must show a pressure of about
186 - 191 bar (2697.69 - 2828.22 psi). If the val
ve setting does not correspond to the prescribed
value, it is best to change it immediately. If ne
cessary it can be adjusted by turning the cap, af
ter removing the plastic sealing and unscrewing
the locknut, with a 4mm hex wrench. Tighten it to
increase the valve setting, unscrew it to decrea
se the setting.
Pressure relief valve section.
1. One-way valve.
2. Additional control valve body.
3. Pressure relief valve body.
4. Valve spring.
5. Locknut.
6. Adjustable needle (4 mm wrench).
7. Plastic sealing.
120
??.??.???.?? - ?? - ????
NOTE - The pressure relief valve setting can be

bench tested as follows:
8. Fit the pressure relief valve (1) on the valve union

380000217 (2) and connect the union to the hand
pump 380000215 (3).
9. Operate the hand pump (3) and check that the

pressure relief valve opens at a pressure of about
186 - 191 bar (2697.69 - 2828.22 psi).
Warning - During assembly, the pressure relief valve

is calibrated using oil flow and the check using hand
pump 380000215 is to be considered only approxi
mate. It is therefore advisable to check the pressure
relief valve setting with the valve fitted on the tractor
as described above.
25720
121
??.??.???.??- ??- ????

LIFT CONTROL VALVE BLOCK, DETACHED
Disassem bly-Assem bly (Op. 35 110 14)

Proceed as follows.
A WARNING A
Handle all parts with the utmost care.
Do not place your hands or fingers between one part
and another. W ear the prescribed safety clothing, in
cluding glasses, gloves and protective footwear.
1. Before removing the control valve, first remove

the transmission cover (1).
2. Before disassembly, thoroughly clean the sur

faces of the control valve block. Lock the control
valve block in a vice.
3. Unscrew the cap (1) and remove the spring (2)

and the control valve (3).
??.??.???.?? - ?? - ????
4. Take off the cylinder safety valve (4) and remove

the arm lowering speed adjustment valve (3), the
spring (2) and the pin (1).
124
5. Remove the check valve union (1), spring (2) and
ball (3).
6. Take off the control valve block pin (1) and

remove the seat (3) and the spring (2).
??.??.???.?? - ?? - ????
7. Check the wear of the seals on the control valve

block pin seat. If damaged, replace them using
protection device 380000275 (1), following the
instructions given on page 9.
8. Check the efficiency of the control valve block pin

as follows.
127
9. Fit the control valve block pin (2) complete with
seat (3) on the tool 380000274 (1).
128
10. Fit the control valve block pin spring (1) and the
cap (2) of tool 380000274. Tighten the cap as far
as it will go and check that the control valve block
pin slides in its seat.
129
11. Fit tool 380000274 (2) on the hand pump
380000215 (3), supplied with HYDROSYSTEM
68 oil. Connect a dial gauge (1) and secure it with
its screw.
130
??.??.???.?? - ?? - ????
12. Operate the hand pump and at the same time

tighten screw (1) on the tool until oil stops flowing
out through the control valve block pin seat
outlet.
13. Now zero the dial gauge.
14. Tighten the screw (1) on the tool further to move

the control valve block pin by 1.8 - 2 mm
(0.0709 - 0.0787 in.), using the dial gauge to
read this distance.
131
15. Operate the hand pump until the oil in the system
is at an initial pressure of 245 bar - 3553.41 psi.
Using the pressure gauge, check that it takes
more than six seconds for the pressure to fall
from 196 bar - 2842.73 psi to
98 bar - 1421.36 psi. If it takes less than this,
replace the control valve block pin. Bear in mind
that this part is supplied together with its seat.
132
??.??.???.?? - ?? - ????
16. Fit the cylinder safety valve (1) on the valve union
380000218(2) and connect it to the hand pump
380000215 (3).
17. Operate the hand pump (3) and check that the
cylinder safety valve opens at a pressure of
210 - 215 bar (3045.78 - 3118.30 psi). If the
valve setting does not correspond to the speci
fied value, it is best to replace the valve straight
away. If necessary, however, it can be adjusted
by turning the threaded cap using spanner
380000230. Tighten to increase the valve setting
value, or slacken to decrease the value.
18. Fit the hydraulic control valve block as follows:
----------- A WARNING A -----------

Refer to the illustrations on page 8 for the

orientation of the various components:
Apply the torque settings listed on page 5.
Fit the complete control valve block pin.
Fit the check valve.
Fit the cylinder safety valve.
Fit the control valve.
Fit the complete pressure control valve.
Fit the cover on the control valve block.
25720
133
??.??.???.??- ??- ????

Hydraulic lift control pump components
1. Front cover. 11. Driving shaft seal

2. Cover seals. 12. Snap ring.
3. Pump body. 13. Safety washer.
4. Gear support. 14. Nut.
5. Driven and driving gear shafts. 15. Bolt.
6. Gear support. 16. Washer.
7. Bushing. 17. Key.
8. Control side cover. 18. Bushing.
9. Driving shaft seal. 19. Safety washer.
10. Spacer. 20. Nut.
HYDRAULIC LIFT CONTROL OIL PUMP
Removal - refitting with pump removed 6. Remove the seals (2) and the anti-extrusion
(Op. 35 0101 10) rings.
Proceed as follows:
1. Remove the cover fastening nuts (20), then the
bolts (15) and the safety washers.
2. Remove the nut (14) that fastens the sleeve to the
pump driving shaft and the safety washer.
3. Remove the front cover (8), the snap ring (12)
and the seals (9 and 11).
4. Mark parts 3, 4, 5 and 6 to enable them to be
remounted in the same position if they are in
good condition.
5. Remove the supports (4 and 6) and the gears (5)
from the rear cover (8) and the pump body (3).
??.??.???.?? - ?? - ????
Once the parts are removed, proceed as follows:
7. Check that the gear contact surfaces are flat and

perpendicular to their supports. Insert a thin layer
of carbon black. Small rough spots can be
removed using extremely fine and well lubricated
abrasive paper.
8. Check that the axial play of the gear-support unit

in the pump body is 0.090 - 0.160 mm
(0.0035 - 0.0063 in.). The distance (2) must be
0.090 - 0.160 mm (0.0035 - 0.0063 in.) smaller
than the distance (1).
If necessary, true the flat surfaces involved using
lubricated abrasive paper to remove extremely small
quantities of material. Ensure that axial play is still
within the limits of 0.090 - 0.160 mm
(0.0035 - 0.0063 in.).
9. Clean all constituent parts thoroughly.
10. Replace the seals (2, 9 and 11).
11. Lubricate the parts with the same oil as the

system. Refit the pump, referring to fig. 134 and
proceed as follows:
12. refit, performing operations 6 to 1 in reverse

order;
always ensure maximum cleanliness to prevent

foreign matter from entering, as this could dam
age the pump;
fit together previously marked parts (3), (4), (5)

and (6) fig.134; see procedure on page 41 to refit
them in their original position;
mount the gear supports (4) and (6) fig. 134, in

the pump body. Mount them with the fittings on
the external circumference matched up with the
discharge pipes and the front faces with lubrica
tion millings in contact with the gears;
fit the plastic anti-extrusion rings on the seals (2)

fig. 134:
mount the seals (9) and (11) fig. 134, on the con
trol side cover (8), complete with spacer (10).
Mount them so that the cavity is between the seal
lips on the opposite side from this spacer. Finally
fill the cavity with AKCELA MULTI-PURPOSE
GREASE 251H EP grease.
??.??.???.?? - ?? - ????

Chapter 2 - Open centre system auxiliary control valves
CONTENTS
35 000 Main data - Tools .......................................................................................................................... 1

Auxiliary control valves - sectional v ie w s ................................................................................. 2
Fault diagnosis ......................................................................................................... see chapter 1
35 204 46 Auxiliary control valves - Assem bly-Disassem bly ................................................................. 7
Spool binding test ....................................................................................................................... 15
Spool leakage test ..................................................................................................................... 16
Adjustment of the automatic detent release p re ssu re .......................................................... 17
35 000 - MAIN DATA - TORQUE DATA - TOOLS - SECTIONAL VIEWS

- DESCRIPTION AND OPERATION
MAIN DATA
F i l t e r ...................................................................... full-flow filter, with paper

cartridge, (common to the
hydraulic lift circuit)
Pump .................................................................... gear pump (common to the

hydraulic lift circuit, see chapter 1)
Auxiliary control valves
Location .................................................................. valve stack (up to a maximum of

3 valves) attached to the rear of
the centre housing
Operation .............................................................. manually with hand lever
Pressure relief valve s e ttin g ................................ ............................ bar 186-191

(psi) (2697.70 - 2770.22)
Type ........................................................................ convertible for operation of sin g le -
or double-acting cylinders,
convertible for operation of sin g le -
and double-acting cylinders and
with automatic detent release, for
operation of double-acting
cylinders with float control and
automatic detent release
TOOLS List of specific tools required for the various

operations described in this section.
WARNING: The operations described in this section
must only be carried out using the ESSENTIAL tools 380000240 Universal pressure testing kit.
marked below with an (X ).
For greater safety and to obtain the best results while
saving both time and effort, we recommend that
these essential tools are used in conjunction with the
specific tools listed below, and with certain tools
which are to be made following the constructional
drawings in this manual.
???.??.??.?? - ?? - ????
TRE0711A
Auxiliary control valves - Section views

a. Auxiliary control valve for convertible single/ 11. Spool return spring.
double-acting cylinder. 12. Spring cup.
b. Auxiliary control valve for convertible single/ 13. Seal.
double-acting cylinder with automatic 14. Seal.
hydraulic release. 15. Control lever
16. Control lever support.
17. Tapered needle.
NOTE: Section view of auxiliary control valve 18. Seal.
configured for operation of double-acting cylinder 19. Spring.
with float and automatic detent release was shown 20. Detent balls.
at page 3 . 21. Detent ball support.
22. Seal.
23. Internal plunger.
1. Cover. 24. Spring.
2. Spacer. 25. Cover.
3. Spool. 26. Detent release pressure adjuster screw.
4. Check valve. 27. Spool return spring.
5. Single/double-acting conversion valve body. 28. Spring cup.
6. Seal. 29. Seal.
7. Seal 30. Seal.
8. Single/double-acting switchover screw. 31. Detent notch body.
9. Single/double-acting operation adjusting spool 32. Detent screw locknut.
10 . Valve body. 33. Circlip.
???.??.??.??- ??- ????

The auxiliary control valves serve to control hydraulic 3. Neutral - When the lever is released from the
loads external to the tractor. lifting and lowering positions it will automatically
Up to a maximum of three auxiliary control valves may return to neutral position.
be mounted at the rear of the centre housing.
4. Float - Push the lever forward beyond the
The auxiliary control valves are operated by hand
levers located to the right of the driving position. “lowering” position to select “float position”. In this
position the only force exerted on the implement
Each control lever will have three or four positions will be that created by its own weight, thus allowing
depending on the type of control valve it operates. the implement to follow the profile of the terrain.
1. Lifting - Pull lever back to lift the implement.
2. Lowering - Push the lever forward to lower the The operation of the hydraulic control valves is
implement. described in the following pages.
OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR OPERATION OF A DOUBLE-ACTING

CYLINDER WITH AUTOMATIC DETENT RELEASE AND FLOAT POSITION
Section view
2. Spool.
23. Internal plunger. NOTE: Some parts releated with automatic detent
24. Spring. release are not shown in this view. Automatic detent
25. Cover. release working principle of valve shown in Fig. 2 is
26. Detent balls. same as the valve shown at Fig. 9 & Fig. 10.
28. Spring cup.
32. Float mode selection groove.
FLOAT CONTROL OPERATION

To select float control operation, push the control le exhaust lines T. No pressure applied to both ports. In
ver (located in the cab) fully forward. The control this condition, the only force acting on the attached
valve spool (2) will move and detent balls (26) will en implement is that created by its own weight and the
gage in the grooves (32) where they will be held in hydraulic lift may be operated. Automatic detent re
position by the support and the spring (24). In this lease does not occur during float control as there is
position the spool directs the oil at A and B ports to no pressure inside the auxiliary control valve.
???.??.??.?? - ?? - ????
OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR OPERATION A D O U B LE- ACTING

CYLINDER AUTOMATIC DETENT RELEASE AND FLOAT POSITION
□ Pressurised oil
□ Suction, delivery or exhaust oil
□ Static oil
\ \ \ \ \V
TRE0750B
LIFTING
When the spool (2) moves to left, the detent balls (26) exhaust line (T) by way of line (A), intercepting the
engage the groove (33), where they are held in place supply of oil to the hydraulic lift control valve. Automatic
by the support (28) and spring (24). The movement of detent release working principle is explained at
the spool (2) connects: the pressure line (P) with the page 6.
line (B), and also the upper cylinder chamber with the
□ Pressurised oil
□ Static oil
TRE0750C
LOWERING
When the spool (2) moves to right, the detent balls line (B), while the upper chamber is connected with
engage in the groove (34) where they are held in the pressure line (P) by way of line (A). On
position by the support (28) and the spring (24). In completion of the lowering operation, the detent will
this condition the oil contained in the lower chamber be automatically released as explained at Page 6.
of the cylinder can flow to the exhaust (T) by way of
?? ? ?? ?? ?? - ? ? - ????
OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR OPERATION OF A DOUBLE-ACTING

CYLINDER (FIGS. 5 & 6) AND SINGLE -A C TIN G CYLINDER (FIGS. 7 & 8)
1. LIFTING - On pulling back the control lever, (located

in the cab) the control valve spool (2) moves to
connect: pressure line (P) with the lower chamber of
the cylinder by way of line (A), and also exhaust line (T)
by way of line (B), intercepting the supply of oil to the
lift control valve. Keep the lever pulled back, to extend
the cylinder to its full stroke. On releasing the lever it
will automatically return to neutral position, under the
action of the return spring, and the entire flow from the
pump will be conveyed to the lift control valve by way
of line (P).
5
2. LOWERING - To lower the implement, push the
control lever (located in the cab) forward. The control
valve spool (2) will move to the position indicated in
fig. 6, thus allowing the oil in the lower cylinder
chamber to flow to the exhaust (T) through line (A),
while the upper chamber is connected to the
pressure line (P) through line (B) .
3. LIFTING - On pulling the control lever back, the

control valve spool (2) fig. 7 moves to connect the
cylinder with the pressure line (P) by way of line (A).
Line (C), for the control of single-acting cylinders, is
used in this stage as it is permanently connected to the 6
exhaust (T) by the open position of the switching valve
(1).
4. LOWERING - On pushing the control lever forward,

the spool (2) will move to the position indicated in fig.
8. The oil contained in the cylinder, pressurised by the
weight of the lifted implement, will flow to the exhaust
(T) by way of line (A), while the entire flow from the
pump is also conveyed to the exhaust (T) through the
line (B).
□ Pressurised oil
□ Static oil
NOTE: To operate a double-acting cylinder, tighten

screw (1) fully home. To operate a single-acting
cylinder, fully undo screw (1).
8
???.??.??.?? - ?? - ????
OPERATING STAGES OF AUXILIARY CONTROL VALVE OPERATING A DOUBLE-ACTING CYLINDER

WITH AUTOMATIC DETENT RELEASE
□ Pressurised oil
□ Static oil
TRE0716A
©
9
LIFTING
On pulling back the control lever, the spool (2) moves through port (V), it overcomes the resistance of the
and the detent balls (26) engage the groove, where spring of the needle valve (23). Inside chamber (D), the
they are held in place by the support (28) and spring oil pressure increases and, acting on the detent ball
(24). The movement of the spool (2) connects: the support (28), it overcomes the resistance of the spring,
pressure line (P) with the line (B), and also the upper thus moving the support (28). In this condition the two
cylinder chamber with the exhaust line (T) by way of detent balls (26) drop onto the support, releasing the
line (A), intercepting the supply of oil to the hydraulic lift spool (2) which, under the action of spring (6) returns
control valve. to neutral position. Consequently the entire flow from
On completion of the lifting movement, the oil pressure the pump is conveyed to the lift control valve through
increases to 170-175 bar (173-178 kg/cm2). Acting lines (P).
10
LOWERING
To lower the implement, push the control lever by way o f line (B), while the upper chamber is
forward. The control valve spool (2) moves and the connected with the pressure line (P) by way of line
detent balls engage in the central groove where they (A). On completion of the lowering operation, the
are held in position by the support (28) and the spring detent will be automatically released in the manner
(24). In this condition the oil contained in the lower described previously.
chamber of the cylinder can flow to the exhaust (T)
???.??.??.?? - ?? - ????
AUXILIARY CONTROL VALVES (REMOVED FROM TRACTOR)
Disassembly - A ssem bly (Op. 35 204 46)

of valves removed from tractor
11
Convertible single/double-acting auxiliary control ----------- A WARNING A -------------

valve.
Do not insert fingers or hands between one part and
Disassemble the auxiliary control valve into its another.
component parts referring to the sectional views (fig. W ear suitable safety clothing, i.e., safety goggles,
1) and the following instructions: gloves and shoes.
1. Remove cover (3) and O -rings (7). ----------- A WARNING A -----------

2. Remove the control lever support (4) and take out Always use suitable tools to align holes. NEVER USE
YOUR FINGERS OR HANDS.
the seal (7).
3. W ithdraw the spool (8).
4. Remove plug (6) and extract the single/double
acting switching valve (5).
5. Remove relief valve block (1) and check valve (2)
6. Remove the valve housing (9)
7. Check the condition o f the seals before re
assembly.
???.??.??.?? - ?? - ????
Convertible single/double-acting auxiliary control valve with float control and detent release.
----------- A WARNING A -------------

Do not insert fingers or hands between one part and
another.
W ear suitable safety clothing, i.e., safety goggles,
gloves and shoes.
----------- A WARNING A -----------

Always use suitable tools to align holes. NEVER USE
YOUR FINGERS OR HANDS.

2. Check valve
3. K ick-out (detent) and float control assembly
4. Control lever support
5. Single double acting converting valve
6. Oil return valve
7. Spool O -ring kit
8. K ick-out control assembly.
Disassemble the auxiliary control valve into its

component parts referring to the sectional views (fig.
1) and the following instructions:
???.??.??.?? - ?? - ????
A WARNING A
During the overhaul and disassem bly-assem bly of
the units, put special protective devices between the
bits of the vice, for preventing any damage to the
valve components.
1. Remove Allen screws (1) Fig.14.
2. Remove both covers (1) Fig.15
3. Remove both spacers (1) Fig.16
4. Remove the circlip (1) and take the cover (2)

Fig.17 of the valve (Float & detent release)
???.??.??.?? - ?? - ????
5. Withdraw the spool assembly (1) Fig.18.
18
6. Complete spool assembly (Float & detent
release) is shown at Fig.19.
19
7. Remove circlip (1) and take off the washer (2)
Fig. 20. Disassamble the unit to all its
components.
20
8. Disassambled unit (Float & detent release) is
shown at Fig.21.
I
B z t n n o - *» i — udoO d- o o
21
???.??.??.?? - ?? - ????
9. Remove circlip (1) Fig.22.
22
10. Take off the cover (1) Fig. 23.
23
11. Remove the spool assembly (Detent release) (1)
Fig.24.
24
12. Remove the nut (1) Fig.25 fixing the assembly.
25
???.??.??.?? - ?? - ????
13. Remove the spring and the detent body (1)

Fig.26.
14. Remove the nut fixing the detent body (1) Fig.27
15. Complete spool assembly (Detent Release) is

shown at Fig.28.
16. Remove oil return valve (1) Fig.29.
???.??.??.?? - ?? - ????
17. Take off oil return valve (1) Fig.30
30
18. Remove relief valve (1) Fig.31.
31
19. W ithdraw relief valve (1) Fig.32.
The relief valve can be checked when the engine is

running. When the relief valve is tested as explained
Section 35 Chapter 1 Page 35 the pressure gauge
must show a pressure of 186-191 bar
(2697.69 - 2828.22 psi).
If the valve does not correspond to the prescribed
value, it is best to change it immediately.
32
20. Slacken, single-double acting converting valve
(1) Fig.33.
33
???.??.??.?? - ?? - ????
21. Remove, single-double acting converting valve

(1) Fig.34.
34
22. Take off the ball of, single-double acting convert
ing valve (1) Fig.35.
35
23. Slacken the allen screws (1) fixing the cover the
cover (2) Fig.36.
36
24. W ithdraw the cover (1) and the spacer (2) Fig.37.
25. Check the condition o f all seals before reas
sembly.
37
???.??.??.?? - ?? - ????
Double-acting auxiliary control valve with float

control and automatic detent release.
Disassemble the auxiliary control valve into its
component parts referring to the sectional views (fig. 1)
3. Withdraw the spool (10).
and the following instructions:
4. Remove the valve housing and extract the check
1. Unscrew the retaining screws and remove the
valve and spring.
cover (11) and the distance piece.
2. Unscrew the retaining screws and remove the 5. Check the condition o f the seals before re
control lever support (12) and related seal. assembly.
SPOOL BINDING TEST
Control valve spool binding test (fig. 38). tion) the flow goes through the valve from inlet to
Install the auxiliary control valve assembly and the test outlet (tank line) (P) to (T). Now regulate the
apparatus as indicated in the diagrams (fig. 38 ) and re maximum pressure of the VS (main relief valve)
valve inside bank A (in the schematic). This
ferring to the following instructions:
pressure is the maximum pressure that can be
— The test is carried out with mineral oil in obtained with the type of valve and spring used.
accordance with DIN 32 norm. Flow rate is the Now move each single spool in each section.
nominal for the valve (for VDM07 it is 50 l/min). With the ports closed, the pressure will rise until
Connect line P (pump line) to the inlet port of the the relief valve opens. In this situation check if
valve and close the working ports A and B of spools move to the neutral (central) position
each section (see schematic) with plugs. without sticking, under the action of springs and
Start the test, increasing the flow coming from flow forces only. The relief valve D, in line before
the pump until nominal flow plus 25% is reached the directional valve, has to substitute the VS in
(in the case of VDM07 it is 75 l/min). With the A in case of problems or in case of directional
control lever in the neutral position (m id-posi- valve without VS.
???.??.??.?? - ?? - ????
SPOOL LEAKAGE TEST
39
Valve leakage test seconds). From this stroke, calculate the volume of
oil per minute through that section of the cylinder.
After the binding test (with hot oil and valve), This check has to be carried out for each section
measure the leakage rate for each section. It is (each spool).
important to do this with the system hot. Connect After this check, with the pump disconnected, move
working ports A and B of each section to the cylinders the spool to its working position: now test the check
(one for each section). Alongside each cylinder lay a valve (VU:Check Valve) of the distributor. This valve
ruler to measure the stroke. closes the connection from P to T (N), also the
Supply oil to the cylinder, moving the spool to the connection P with A or P when B is open (spool in
working position (oil flowing from A or B) until it working position). If the check valve is working
reaches the end of its stroke and the main relief valve correctly, the normal flow rate will be seen (the same
opens. Now that the oil column is pressurised from value observed with spool in the neutral position). If
the working section to the cylinder allow the lever to it is see that one or more sections operates more
return to the neutral position (called 0). The spool than in a previous check, it means that check valve
closes A and B ports. Now check the position of the is not working properly (does not close completely).
cylinder observing the ruler beside it. As the cylinder
moves, check the stroke in a fixed time (say 60
???.??.??.?? - ?? - ????
ADJUSTMENT OF THE AUTOMATIC DETENT RELEASE PRESSURE
After servicing the detent regulating valve or if the will fluctuate and the handle return to the neutral
control levers and spool are returning to neutral pre position. Note the gauge reading immediately
prior to the needle fluctuation. The reading
maturely, the detent regulating valve should be
should be within the specified value
tested as follows: (1741-1886 lbf/in2) 120 bar+10 bar-0 bar.
NOTE: Detent release pressure is ONLY adjustable

on one spool in the valve that is NOT fitted with float.
The spools fitted with kick out and float have no
- If the reading is not to specification adjust the
visible means of adjustment.
detent pressure as follows:
- Install inlet hose of flowmeter (1) into lift coupler Remove the circlip (33) and the cover (25),
of valve to be tested. (Fig.1. Page.2) of the valve .
Loosen locknut (32) on detent regulating ad

- Install return hose from flowmeter into lift coupler juster screw (26).
of the same valve on tractor.
Turn detent regulating valve adjusting screw
(26) to change pressure setting.
- Ensure load valve on flow meter is fully open;
- Start tractor and set engine speed to 1700

rev/min;
- Pull lever of remote control valve to be tested,

fully rearwards, to extend position.
- Adjust load valve (2) on flowmeter until pressure

is 80 bar (1161lbf/in2) and run until hydraulic oil
is at an operating temperature of 65°C □ 5°C.
- With lever of remote control valve to be tested in

the cylinder extend position slowly close the
flowm eter load valve while observing the
flowm eter pressure gauge.
- The pressure should steadily rise until the detent

regulating valve opens, at which point the needle
???.??.??.?? - ?? - ????
NOTES
???.??.??.?? - ?? - ????
Chapter 3 - Trailer brake auxiliary control valve
CONTENTS
35 000 S e c tio n v i e w s .................................................................................................................................................... 1
D e s c rip tio n a n d o p e ra tio n ......................................................................................................................... 1
H y d ra u lic d ia g r a m .......................................................................................................................................... 2
D e s c rip tio n and o p e ra tio n o f va lv e p h a s e s ......................................................................................... 3
T ra ile r b ra k e a u x ilia ry c o n tro l v a lv e lin k a g e a d ju s tm e n t .................................................................. 6
Section view of auxiliary control valve for trailer

braking
1. F lo w c o n tro l va lv e .
2. P isto n .
3. C h e c k va lve .
4. R e lie f va lve .
T he tra ile r brake valve is m ounted on the rear T h e tra ile r brake valve has priority o v e r th e auxiliary
transm ission casing forw ard o f th e hydraulic lift. It is control valves and th e hydraulic lift.
supplied by the sa m e pu m p as the lift circuit. T h e hydraulic operation o f these valves is described on
pages 3 and 4.
???.??.???.?? - ?? - ????
HYDRAULIC DIAGRAM OF TRAILER BRAKE AUXILIARY CONTROL VALVE
□ S ta tic o il
□ O i l i n s u c tio n
| | T r a c to r b r a k e c ir c u it o il (b ra k e s o f f )
□ P r e e u r is e d o i l
□ E x h a u s t o il flo w
26428
Diagram of the hydraulic trailer brake circuit
1. D e liv e ry line to c o n tro l v a lv e (3). 6. L ift c o n tro l v a lv e

2. T ra ile r b ra ke c o n tro l v a lv e . 7. S u c tio n line.
3. A u x ilia ry c o n tro l v a lv e s . 8. O il filter.
4. A u x ilia ry c o n tro l v a lv e lines. 9. H y d ra u lic pu m p .
5. T ra ile r b ra ke c o n tro l v a lv e line.
? ? ? ? ? ? ? ? ? - ?? - ????
TRAILER BRAKES OFF - When tractor brakes are

inactive, pressure limiter (4) and slide piston (2) take
up the positions shown in fig 3.
Oil from hydraulic pump (8, fig 2) is directed to fitting

(P-i) through diaphragm (11) and restriction (9) which
causes a pressure drop to move flow control valve
(1) to the right.
Most of the oil flows through connection (N) to the

auxiliary control valves. The remaining output is
drained into the hydraulic lift through port (10), piston
(2) and union (R).
Trailer brakes off

Pressurised oil
N. To auxiliary control valves.
P i. From hydraulic pump to lift circuit.
R. To lift return line. □ Static oil
START OF BRAKING - On operating the tractor

brake pedal (Pf), the fork (F) shifts the pressure relief
valve (4) and the slide piston (2) to the left, which in
its turn closes the passage between the oil return
port (R), trailer brake port (B) and the line (10).
The oil inside the flow control valve (1) is maintained

at a uniform pressure and so the valve element,
under the action of the spring, shifts to the left to
assume the position indicated in fig.4.
Part of the oil from the hydraulic pump in union (P1)

flows to the auxiliary control valves through union
(N). while the remaining part arrives at the trailer
braking element via the diaphragm (11), line (12),
check valve (3) and port (B).
As the pressure of the oil in the trailer brake union (B) Start of braking
increases, it acts on the active surface (13) of the
spool (2), opposing the effect of control fork (F) on B. To trailer brake.
relief valve (4) N. To auxiliary control valves.
P 1 . Oil from the hydraulic pump to lift circuit.
R. Discharge line.
???.??.???.?? - ?? - ????
BRAKING - Continued brake pedal application

causes an increase in oil pressure at trailer brake
connection (B) which, acting on active surface (13)
of slide piston (2), moves the latter to the right threby
overcoming the opposition of relief valve springs (8).
When the trailer brake circuit oil pressure is equal to

spring (8) pressure, slide piston (2) stabilises as shown
in fig 5 and establishes communication between oil
from pump and lift drain through connection (P-0,
diaphragm (11), restriction (9), port (10) and
connection (R).
□ Static oil
Braking
B. To trailer brake.
N. To auxiliary control valves.
Diaphragm (11) and restriction (9) cause a pressure P 1 . Oil from the hydraulic pump to lift circuit.
drop in flow control valve (1) which moves to the right R. Discharge line.
to close line (12) and consequently, check valve (3).
Further pressure on the tractor brake pedals (Pf)

causes a leftward movement of relief valve (4) and
piston (2), with a consequent increase in trailer brake
circuit oil pressure as the sequence described in
paragraph b START OF BRAKING on page 3.
Upon releasing brake pedals, system returns to the

conditions shown in fig 3 at page 3.
???.??.??.?? - ?? - ????
Trailer brake remote control valve linkage adjustment
C. W re n c h fla ts on lin k (6) 3 - D e liv e ry line to tra ile r b ra ke
G = 0 ,3 -0 ,5 m m . C le a ra n c e b e tw e e n fo rk (7) and pis 4 - C up

to n (10)
5 - Locknut
M P re s s u re g a u g e w ith 0 to 2 5 0 k g /c m 2 s c a le o f kit
380000240 6 - L in k
V T ra ile r b ra ke c o n tro l v a lv e 7 - F o rk
1 - C o n n e ctio n 380000841 s u p p lie d in kit 3 8 0 0 0 0 2 4 0 8 - B ra k e p e d a ls
2 - C o n n e ctio n 3 8 0 0 0 0 8 4 0 s u p p lie d in kit 3 8 0 0 0 0 2 4 0 1 0 - T ra ile r b ra k e c o n tro l v a lv e p isto n
???.??.???.?? - ?? - ????
TRAILER BRAKE REMOTE CONTROL VALVE LINKAGE ADJUSTMENT

P ro c e e d as fo llo w s : 8. R un e n g in e a t a ro u n d 2 0 0 0 rpm .
1. A d ju s t th e brake pedal (8) free tra ve l as indicated 9. C h e c k th a t p re s s u re g a u g e (M ) re a d in g is z e ro
b e fo re in S e c tio n 33. w h e n b ra k e p e d a ls (8) a re n o t a p p lie d .
2. Adjust parking brake lever as indicated before in
10. D e p re s s b ra k e p e d a ls u ntil p e d a l fre e tra v e l is
Section 33.
ta k e n up and c h e c k on p re s s u re g a u g e (M ) th a t
3. F u lly tig h te n c u p (4), s la c k e n lo c k n u t (5) and p re s s u re is 100 b a r (1 4 5 0 .3 7 psi)
a d ju s t le n g h t o f lin k (6), using w re n c h fla ts (C) to
o b ta in a c le a ra n c e (g ) o f 0,3 to 0,5 m m (0.0 1 1 8 11. R e p e a t th is o p e ra tio n a t le a s t th re e tim e s ,
to 0 .0 1 9 7 in.) b e tw e e n fo rk (7) and p isto n (10). c h e c k in g th a t s y s te m p re s s u re re a d in g d ro p s to
z e ro w h e n p e d a ls (8) a re re le a s e d .
4. T ig h te n lo c n u t (5).
5. D is c o n n e c t tra ile r b ra k e oil d e liv e ry lin e (3) fro m
12. A p p ly p a rk in g b ra k e (9) a fe w tim e s w ith o u t
d e p re s s in g b ra k e p e d a ls and check th a t
b ra ke c o n tro l v a lv e b o d y (V).
p re s s u re re a d in g on p re s s u re gauge (M )
6. C o n n e c t p re s s u re g a u g e (M ) w ith 0 to 2 5 0 kg /
re m a in s a t z e ro .
c m 2 scale o f kit 380000240 to co n tro l va lve body,
using c o n n e c tio n s 380000841 (1) and
380000840 (2) (B o th c o n n e c tio n s b e lo n g to kit
380000240 )
7. S ta rt th e e n g in e a n d ta k e th e oil up to a
te m p e ra tu re to 50 - 6 0 0C (1 2 2 - 140 oF).
999 99 99 99 - ?? - ????
SECTION 41 - STEERING - CHAPTER 1 1
SECTION 41 - STEERING
Chapter 1
CONTENTS
41 000 P r in c ip a l d a t a .............................................................................................................................................................. 1
T ig h te n in g to r q u e s ................................................................................................................................................. 3
S e c tio n v i e w s .............................................................................................................................................................. 4
H y d r a u lic d i a g r a m .................................................................................................................................................... 6
O p e ra tio n ..................................................................................................................................................................... 7
F a u lt d ia g n o s is ......................................................................................................................................................... 9
T o o ls ............................................................................................................................................................................ 10
41 204 30 H y d r o s ta tic s te e rin g c o n tro l v a lv e - R e m o v a l- I n s t a ll a t io n ....................................................................11
41 204 34 H y d r o s ta tic s te e rin g c o n tro l v a lv e - D is a s s e m b ly - A s s e m b ly ........................................................ 14
41 204 38 H y d r o s ta tic s te e rin g c o n tro l v a lv e - B e n c h te s tin g .............................................................................. 2 8
H y d r o s ta tic s te e rin g o il p u m p - D is a s s e m b ly - A s s e m b ly ................................................................ 3 0
41 216 20 S te e r in g c y lin d e r ( t w o - w h e e l d riv e a x le ) - R e m o v a l- R e fitt in g ..................................................... 3 2
S te e r in g c y lin d e r ( fo u r w h e e l d r iv e a x le ) - R e m o v a l- R e fitt in g .................................................... 3 3
PRINCIPAL DATA
HYDROSTATIC STEERING
T y p e ............................................................................................................................. in d e p e n d e n t h y d r o s ta tic c o n tro l,

H y d r a u lic c i r c u i t ..................................................................................................... fe e d b y h y d r a u lic p u m p
O il filt e r ...................................................................................................................... m e ta l c a rtr id g e , b u ilt

in to o il r e s e r v o ir
C o n tro l valve
M ake ........................................................................................................................... DAN FO SS OR ORSTA
T y p e ............................................................................................................................. ro ta ry v a lv e c o n tro lle d d ir e c tly
fr o m th e s te e rin g c o lu m n ; th e
s te e rin g c o n tin u e s to fu n c tio n
e v e n if t h e p u m p is
n o n - f u n c tio n a l
O u tfit c o d e :
- D A N F O S S ............................................................................................................ O S P C 100
- O R S T A .................................................................................................................... L A G -B 1 0 0 -L V P 1 6 -2
P r e s s u re r e lie f v a lv e s e ttin g (2 2 ) fig . 2

- 2 W D m o d e ls ..................................................................................................... 1 0 0 b a r (1 4 5 0 .3 7 p si)
- 4 W D m o d e ls ..................................................................................................... 1 2 5 b a r (1 8 1 2 .9 6 p si)
2 SECTION 41 - STEERING - CHAPTER 1
MAIN SPECIFICATIONS OF HYDRAULIC PUMP C25
Pum p
Type .................................................................................... g e a r ty p e w ith oil s u c tio n fro m

L o c a t io n ............................................................................... tra n s m is s io n c a s in g
b e h in d tim in g g e a r c o v e r
M odel ................................................................................. C25

C o n s t r u c t io n ..................................................................... BOSCH
O p e ra tin g s y s te m ......................................................... g o v e rn e d b y tim in g g e a r s
D ire c tio n o f ro ta tio n (a s s e e n fr o m d riv e s id e ) c lo c k w is e
E n g in e s p e e d to p u m p s p e e d ra tio .................... 1 :0 .9 3 1
M a x im u m s p e e d o f ro ta tio n (w ith e n g in e a t m a x im u m p o w e r) re v /m in 2328
C o rre s p o n d in g ra te d o u t p u t ..................................... ................. l/m in (in.3/m in) 2 6 .4 (1 6 1 1 .0 3 )
B e n c h o u tp u t a t 1 4 5 0 re v /m in a n d p re s s u re o f
1 5 3 b a r (1 5 6 k g /c m 2):
- f o r n e w o r re c o n d itio n e d p u m p ......................... ................. l/m in (in.3/m in) 1 5 .3 (9 3 3 .6 6 )
-fo rw o rn pum p ........................................................... ................. l/m in (in.3/m in) 1 0 .7 (6 5 2 .9 5 )
- t e s t o il t e m p e r a t u r e ................................................. ............................. °C (°F ) 5 5 - 6 5 (131 - 1 4 9 )
- te s t o il v is c o s ity ......................................................... S A E 20
D ia m e te r o f d r iv e n a n d d riv in g g e a r s h a fts ... ........................... m m (in .) 1 7 ,4 0 0 - 1 7 ,4 1 8 ( 0 .6 8 5 0 - 0 .6 8 5 7 )

In te rn a l d ia m e te r o f s e a ts in s u p p o r ts ............... ........................... m m (in .) 1 7 ,4 5 0 - 1 7 ,4 7 5 ( 0 .6 8 7 0 - 0 .6 8 8 0 )
C le a r a n c e b e tw e e n g e a r s h a fts a n d t h e ir s e a ts ........................... m m (in .) 0 ,0 3 2 - 0 ,0 7 5 ( 0 .0 0 1 3 - 0 .0 0 3 0 )
- m a x im u m p e rm itte d w e a r c le a r a n c e ............... ........................... m m (in .) 0,1 (0 .0 0 3 9 )
R a d ia l c le a ra n c e o f g e a rs in p u m p b o d y .......... ........................... m m (in .) 0 ,0 2 0 - 0 ,0 6 4 ( 0 .0 0 0 8 - 0 .0 0 2 5 )

M a x im u m w e a r o n p u m p b o d y , s u c tio n s id e ,
a t p o s itio n o f g e a rs ...................................................... ........................... m m (in .) 0,1 (0 .0 0 3 9 )
C y lin d e r
T y p e ...................................................................................... D o u b le a c tin g , lo c a te d b e h in d
fr o n t a x le
C o n s t r u c t io n ..................................................................... W E B E R o r S IM A o r E R B E R
C y lin d e r b o re d i a m e t e r ............................................... 4 8 m m (1 .8 9 in)

P is to n ro d d i a m e t e r ...................................................... 2 2 m m (0 .8 6 6 in)
M a x im u m p is to n s tr o k e
W EBER or ERBER .................................................... 2 1 5 m m ( 8 . 4 6 4 in)
S IM A .................................................................................... 2 1 4 m m (8 .4 2 5 in)
M a x im u m p is to n s tr o k e
W E B E R o r E R B E R ...................................................... 2 0 0 m m (7 .8 7 4 in)
S IM A .................................................................................... 1 9 4 m m ( 7 .6 3 8 i n )
TORQUE SETTINGS
PART T h re a d
Nm ft lb
B o lt fix in g h y d r o s ta tic s te e rin g to t r a c t o r ......................................................... 3 /8 ” - 1 6 U N C 44 3 2 .4 5 2 7
B o lt fix in g c o v e r to h y d r o s ta tic s te e rin g h o u s in g (1 3 , fig . 2 ) ................. M 8x1 34 2 5 .0 7 7 1
M 8x1* 29 2 1 .3 8 9 3
H y d r o s ta tic s te e rin g c o n tro l p u m p fix in g b o lt ............................................... M 6 x 1 8 5 .9 0 0 5
N u t f o r b o lt fix in g c o v e r to p u m p h o u s in g (2 0 , fig . 1 ) ................................ M 1 0 x 1 ,2 5 39 2 8 .7 6 4 9
N u t f o r s e c u r in g th r u s t s le e v e to p u m p d riv e s h a ft (1 4 , fig . 1)) 7 /1 6 in

-2 0 U N F -2 B 28 2 0 .6 5 1 7
N u t, p o w e r c y lin d e r p iv o t p in ................................................................................. M 1 8 x 1 .5 294 2 1 6 .8 4 3 3
N u t, p o w e r c y lin d e r p is to n ro d to s te e rin g a r m ............................................ M 1 4 x 1 .5 147 1 0 8 .4 2 1 6
N u t, p is to n to ro d
- W E B E R c y lin d e r ....................................................................................................... M 1 6 x 1 .5 83 6 1 .2 1 7 7
- S I M A c y li n d e r ............................................................................................................... M 1 6 x 1 .5 98 7 2 .2 8 1 1
- E R B E R c y l i n d e r .......................................................................................................... M 1 6 x 1 .5 98 7 2 .2 8 1 1
C a p s c re w , c o n to l v a lv e s u p p o r t .......................................................................... M 1 6 x 1 .5 147 1 0 8 .4 2 1 6
C a p s c re w , L V P s a fe ty v a lv e b lo c k to b o d y .................................................... - 64 4 7 .2 0 4 0
* ORSTA
H y d ro s ta tic s te e rin g - O il p um p c o m p o n e n ts
1. F ro n t c o v e r 11. D riv in g s h a ft s e a l
2. C o v e r s e a ls 12. S n a p rin g
3. P um p body 13. Lock w asher
4. G e a r s u p p o rt 14. Nut
5. D riv e n a n d d riv in g g e a r s h a fts 15. B o lt
6. G e a r s u p p o rt 16. W asher
7. B u s h in g 17. Key
8. C o n tr o l s id e c o v e r 18. B u s h in g .
9. D riv in g s h a ft s e a l 19. S a fe ty w a s h e r
10. S pacer 20. N u t.
24725
H y d ro s ta tic ste e rin g - C o n tro l valve c o m p o n e n ts
1. D ust seal
2. R e flu x v a lv e b a lls 12. R o to r c o n tro l s h a ft -- s le e v e tr im pin
3. R e flu x v a lv e p in s 13. C o v e r fix in g s c re w s
4. C o n tro l v a lv e b o d y , ro ta ry v a lv e a n d ro ta r y 14. C h e c k v a lv e s e a t s c r e w
v a lv e s e a t s le e v e 15. W a s h e rs
5. C h e c k v a lv e b a ll 16. C over
6. T h re a d e d p lu g o f c h e c k v a lv e 17. O --rin g s
7. O - r in g s e a l 18. R o to r a n d fix e d rin g f o r ro to r
8. S u p p o r t rin g f o r O - r in g (7) 19. T h ru s t w a s h e r
9. T h r u s t b e a rin g c o m p o n e n ts 20. O --rin g
10. R e ta in in g rin g f o r s p r in g s (11) 21. R o to r c o n tro l s h a ft
11. S p rin g s f o r r e tu r n in g s le e v e to ne utra l p o s itio n 22. P r e s s u r e r e lie f v a lv e c o m p le te w ith s p rin g
TRE0431A
3
G eneral h y d ra u lic diagram
H P o w e r s te e rin g c y lin d e r 2 6 O il in in ta k e lin e
D 1 - - - H y d r o s ta tic s te e rin g c o n t r o l v a lv e 2 7 O il in d e liv e r y lin e fr o m p u m p

E F ilte r
T O il t a n k M - O il d e liv e r y to c o n tro l v a lv e
P Pum p S - O il a t lu b r ic a tio n p re s s u re
OPERATION d ir e c t m e c h a n ic a l c o n n e c tio n b e tw e e n th e c o lu m n
a n d th e s te e re d w h e e ls .
T h e o il ta k e n in b y th e re a r a x le is p u s h e d in to th e
N eutral p o s itio n
p u m p th r o u g h a filte r, p re s s u r iz e d b y th e ro ta tin g W hen th e s te e rin g w heel is s ta tio n a ry , th e le a f
g e a r s a n d e x p e lle d fr o m th e d e liv e r y s id e o f th e s p rin g s in th e s te e rin g m o to r p u s h th e s p o o l a n d th e
p u m p to th e s te e rin g m o to r. O n c e in th e s te e rin g s le e v e in, a n d k e e p t h e m in th e n e u tr a l p o s itio n . T h is
m o to r, th e p r e s s u riz e d o il is d ire c te d to th e s te e rin g e n s u re s t h a t n o fu r t h e r o il is s u p p lie d to th e s te e rin g
c y lin d e r w h e n th e s te e rin g w h e e l is tu rn e d . c y lin d e r. T h e s le e v e a ls o b lo c k s th e o il in s id e th e
c y lin d e r, k e e p in g th e w h e e ls in a s e t p o s itio n , fig . 4.
In s id e th e s te e rin g m o to r, th e r e is a m e a s u rin g
d e v ic e w h ic h c o n tro ls th e v o lu m e o f o il s u p p lie d to □ O il in in ta k e lin e
th e c y lin d e r s o t h a t it is p r o p o rtio n a l to th e a n g u la r
m o v e m e n t o f th e s te e rin g w h e e l. T h e m e te rin g v a lv e □ O il
to g e t h e r w it h th e in ta k e v a lv e s a ls o a llo w s M ANUAL □ O il
□
o p e ra tio n o f th e s te e rin g , w ith o u t p re s s u r iz e d oil
b e in g e m itte d b y th e p u m p . O il
T h e s y s te m is t o ta lly h y d r o s ta tic a n d a s s u c h , h a s no
D iagram o f h y d ro s ta tic ste e rin g o p e ra tio n
a 2 W D m o d e ls 7. P u m p
1. E q u a liz a tio n v a lv e 8. F ilte r
2. S te e rin g c y lin d e r 9. R e tu rn lin e to r e s e r v o ir
3. M e te rin g v a lv e 10. P re s s u r e r e lie f v a lv e
4. C h e c k v a lv e 11. C o n tro l v a lv e e x te rn a l ro to r
5. N o n - r e t u r n v a lv e 12. C o n tr o l v a lv e in te rn a l ro to r
6. R esonance dam per 13. A n t i- c a v it a t io n v a lv e s
S te ering to th e rig h t (fig. 5) S teering to th e rig h t m a n u a lly

W h e n y o u tu rn th e s te e rin g w h e e l c lo c k w is e , th e
s p rin g s (11 ) fig . 2 d e fo r m , a llo w in g th e v a lv e (1 2 ) fig . If th e re is a fa u lt o r lo s s o f o il p re s s u r e a t th e
4 to ro ta te in re la tio n to th e s le e v e (11 ). h y d r o s ta tic s te e rin g p u m p , s te e rin g can a ls o be
p e rfo rm e d m a n u a lly .
In th is s ta te , th e fo llo w in g t a k e s p la c e :
- d e - s y n c h r o n is a t io n o f th e in te rn a l d u c ts w ith W h e n y o u tu rn th e s te e rin g w h e e l c lo c k w is e , th e
p a rts (1 1 ) a n d (1 2 ) fig . 4 , w h ic h w e r e a lig n e d in th e r o to r in s id e th e h y d r o s ta tic s te e rin g c o n tro l v a lv e (3)
n e u tra l p h a s e , re s u ltin g in in te r ru p tio n o f th e flo w fig . 4 p e rfo r m s th e fu n c tio n o f a h a n d p u m p , s e n d in g
o f o il to th e o u tle t. o il to th e c o n tro l c y lin d e r ro d s id e (2 ), th u s a llo w in g
- a lig n m e n t w ith th e s a m e n u m b e r o f in te rn a l d u c ts th e w h e e ls to b e s te e re d to th e rig h t m a n u a lly .
c o n n e c te d m o m e n t b y m o m e n t w ith th e ro to r
S teering to th e le ft m a n u a lly
c o m p a r tm e n ts a t in ta k e fr o m th e p u m p (7 ) fig . 4
a n d in th e d e liv e r y lin e to th e s te e rin g c y lin d e rs W h e n y o u tu r n th e s te e rin g w h e e l a n tic lo c k w is e , y o u
(2 ), th u s a llo w in g th e w h e e ls to b e s te e re d to th e a c t u p o n th e r o to r in s id e th e h y d r o s ta tic s te e rin g
rig h t. c o n tro l v a lv e w h ic h , b y o p e r a tin g a s a h a n d p u m p a s
S te ering to th e le ft p re v io u s ly d e s c r ib e d , s e n d s o il to th e c o n tro l c y lin d e r
p is to n s id e , th u s a llo w in g th e w h e e ls to b e s te e re d to
W h e n y o u tu rn th e s te e rin g w h e e l a n tic lo c k w is e , th e
t h e le ft m a n u a lly .
g r o o v e s in s id e p a rts (11 ) a n d (1 2 ) fig . 4 a n d th e
d e liv e r y lin e s to th e s te e rin g c y lin d e rs a re re v e rs e d ,
th u s a llo w in g th e w h e e ls to b e s te e re d to th e le ft.
D iagram s h o w in g o p e ra tio n o f th e h y d ro s ta tic ste e rin g

a 2 W D m o d e ls □ O il in in ta k e lin e
A S te e r in g to th e rig h t I I O il in d e liv e r y lin e fr o m p u m p
B S te e rin g to th e le ft I I O il in d e liv e r y lin e to h y d r a u lic c y lin d e r
□ O il re tu rn in g to r e s e r v o ir
HYDROSTATIC STEERING FAULT DIAGNOSIS
R e fe r to fig . 2 f o r c o m p o n e n t id e n tific a tio n
P ro b le m P o s s ib le c a u s e s C o r r e c tiv e a c tio n
O il le a k in g fr o m h y d r o s ta tic 13. O - r in g s e a l d e fe c tiv e (7 ). R e n e w th e s e a l a n d th e s to p rin g

s te e rin g u n it: u s in g s p e c ia l to o l 380000836.
a . C o n tro l s id e .
b . C o v e r s id e .
14. S c r e w s (1 3 ) n o t s u ffic ie n tly T ig h te n th e s c r e w s to th e p re s c rib e d
tig h t. to r q u e
( 2 4 - 3 6 N m , 1 7 .7 0 1 5 - 2 6 . 5 5 2 2 ft lb).
15. S e a lin g w a s h e rs (1 5 ) or R e n e w th e w a s h e r s a n d s e a ls .
O - r in g s (1 7 ) d e fe c tiv e .
S te e rin g w h e e l e x c e s s iv e ly s t if f 1. H y d r a u lic p u m p in e ffic ie n t. R e p a ir th e p u m p .
2. C h e c k v a lv e (5 ) h e ld o p e n b y E lim in a te fo re ig n b o d ie s a n d c le a n
fo re ig n b o d ie s o r o p e n d u e to th e filte r; p u t a n e w b a ll in to th e s e a t
a b s e n c e o f b a ll. ( if m is s in g ).
3. P re s s u r e r e lie f v a lv e (2 2 ) R e s e t th e v a lv e .
in c o r r e c tly s e t.
4. P re s s u r e r e lie f v a lv e (2 2 ) E lim in a te fo re ig n b o d ie s a n d c le a n
ja m m e d o r h e ld o p e n b y f o r th e filte r.
e ig n b o d ie s .
5. S te e r in g c o lu m n h a s b e c o m e E lim in a te th e c a u s e s .
s t if f on its b u s h in g due to
ru s tin g , s e iz in g , e tc .
E x c e s s iv e p la y o f s te e rin g w h e e l 1. E xce ssive play be tw ee n th e R e n e w th e w o r n p a rts .

stee ring co lu m n and th e
coupling w ith th e rotary valve
(4).
2. E x c e s s iv e p la y in th e c o u p lin g R e n e w th e w o r n p a rts .
b e tw e e n s h a ft (2 1 ) a n d trim
pin (1 2 ).
3. E x c e s s iv e p la y in th e s p lin e d R e n e w th e w o r n p a rts .
c o u p lin g b e tw e e n th e s h a ft
(2 1 ) a n d th e r o to r (1 8 ).
4. C o m b in a tio n of e x c e s s iv e R e n e w th e m o s t w o rn p a rts .
p la y a s d e s c r ib e d a b o v e .
5. L e a f s p rin g s (1 1 ) b ro k e n or R e n e w th e s p rin g s .
fa tig u e d .
T h e s te e rin g w h e e l tu r n s n o rm a lly , 1. In a d e q u a te seal of c o n tro l R e n e w th e s e a l.

b u t s te e rin g is: c y lin d e r.
a . S lo w . 2. C y lin d e r ro d b ro k e n . R e n e w th e d a m a g e d p a rt.
b . N o s te e rin g . 3. R o to r c o n tro l s h a ft (2 1 ) o r pin R e n e w th e d a m a g e d p a rt.

(1 2 ) b ro k e n .
W ith th e e n g in e s to p p e d , th e 1. E x c e s s iv e w e a r b e tw e e n r o to r R e n e w th e w o rn p a rts .
s te e rin g w h e e l c a n b e tu rn e d a n d fix e d rin g (1 8 ).
w ith o u t tu r n in g th e w h e e ls .
2. C h e c k v a lv e d a m a g e d . R e n e w th e c o n tro l v a lv e .
(continued)
HYDROSTATIC STEERING FAULT DIAGNOSIS
R e fe r to fig . 2 f o r c o m p o n e n t id e n tific a tio n
(continuation)
P ro b le m P o s s ib le c a u s e s C o r r e c tiv e a c tio n
S te e rin g wheel jo lts , s te e rin g 1. In c o rre c t s y n c h r o n iz a tio n of S y n c h r o n iz e c o rre c tly .

u n c o n tro lla b le , w h e e ls s te e rin g in h y d r o s ta tic s te e rin g . C o r r e c t th e c o n n e c tio n s .
th e o p p o s ite d ire c tio n to th e 2. H o s e s to c y lin d e r re v e rs e d .
d e s ire d d ire c tio n .
T h e w h e e ls d o n o t m a in ta in th e 1. H y d r a u lic c y lin d e r p is to n s e a l R e n e w th e s e a l.
d e s ire d a lig n m e n t a n d c o n tin u a l w o rn .
c o r re c tio n w ith th e s te e rin g w h e e l 2. R e flu x v a lv e (2) d a m a g e d o r E lim in a te th e fo re ig n b o d ie s and
is n e c e s s a ry . he ld o p e n b y fo re ig n b o d ie s. c le a n th e filt e r o r r e n e w th e c o n tro l
v a lv e .
3. M e c h a n ic a l w e a r o f c o n tro l
v a lv e . R e n e w th e c o n tro l v a lv e .
N e u tra l phase of h y d r o s ta tic 1. L e a f s p rin g s (1 1 ) f o r re tu rn in g R e n e w th e p a c k o f le a f s p rin g s .

s te e rin g u n o b ta in a b le . D u rin g s le e v e (4 ) to n e u tra l p o s itio n
m anual c o n tro l, o p e r a tio n is b ro k e n o r fa tig u e d .
n o rm a l. W hen s to p p in g m anual 2. S le e v e and ro ta ry v a lv e (4) E lim in a te th e fo re ig n b o d ie s and
c o n tro l, th e s te e rin g w h e e l m o v e s b lo c k e d in d e liv e r y p o s itio n b y c le a n th e filte r.
o n its o w n o r re m a in s s ta tio n a ry , fo r e ig n b o d ie s .
b u t s te e rin g c o n tin u e s s lo w ly in
3. C ru s h in g of s le e v e (4 ) on C h e c k th e s e ttin g o f th e p r e s s u re
th e d ire c tio n fir s t tu r n e d
ro ta r y v a lv e d u e to e x c e s s iv e r e lie f v a lv e (2 2 ).
(m o to rin g ), s o th e s te e rin g w h e e l
p re s s u re .
m u s t b e c o n tin u a lly c o r re c te d .
F ro n t w h e e l v ib ra tio n (s h im m y ). 1. A ir p o c k e ts in th e h y d r a u lic B le e d t h e a ir a n d e lim in a te th e c a u s e s

c y lin d e r. o f p o s s ib le in filtra tio n .
2. W e a r o f m e c h a n ic a l jo in ts o f R e n e w th e w o r n p a rts .
s te e rin g tie ro d s .
3. R e flu x v a lv e (2 ) d a m a g e d o r R e m o v e th e fo re ig n b o d ie s a n d c le a n
h e ld o p e n b y fo re ig n b o d ie s . th e filt e r o r re n e w th e c o n tro l v a lv e .
D iffic u lty in s te e rin g in g e n e ra l, o r 1. In s u ffic ie n t p re s s u re . C h e c k th e h y d r a u lic p u m p a n d th e

in o n e d ire c tio n . s e ttin g o f th e p re s s u re r e lie f v a lv e
(2 2 ).
2. E x c e s s iv e le a k a g e in s id e th e R e n e w th e c o n tro l v a lv e .
c o n tro l v a lv e .
L is t o f s p e c ia l to o ls n e c e s s a r y f o r th e v a rio u s
TOOLS o p e r a tio n s d e s c r ib e d in th is s e c tio n .
W ARNING: T h e o p e r a tio n s d e s c rib e d in th is s e c tio n

m u s t b e p e rfo r m e d o n ly w ith th e ESSENTIAL
X 380000307 H y d . s te e rin g r o to r re ta in in g le v e r.
e q u ip m e n t m a rk e d w ith (X ) . X 380000223 S te e rin g w h e e l e x tra c to r.
To o p e ra te s a fe ly a n d a c h ie v e b e s t re s u lts , w h ile
s a v in g tim e a n d e ffo rt, e s s e n tia l e q u ip m e n t m u s t be
X 380000240 U n iv e r s a l p r e s s u re c h e c k in g kit.
used in c o n ju n c tio n w ith th e s p e c ia l to o ls X 380000305 T o o l f o r fittin g h y d r o s ta tic s te e rin g
re c o m m e n d e d b e lo w , a n d to o ls w h ic h you m ust to r o id a l s e a l.
m a k e y o u r s e lf a n d f o r w h ic h y o u w ill fin d th e d e s ig n 380000306 P lu g f o r fittin g h y d r o s ta tic s te e rin g
in th is m a n u a l. ro ta ry v a lv e re tu rn s p rin g s .
HYDROSTATIC STEERING CONTROL VALVE

R em oval -R e fittin g (Op. 41 204 30)
------------ A WARNING A -----------
H a n d le a ll p a rts w ith g r e a t c a re . D o n o t p u t y o u r
h a n d s o r fin g e r s b e tw e e n o n e p a rt a n d a n o th e r.
W e a r th e re c o m m e n d e d s a fe ty c lo th in g s u c h a s
g o g g le s , g lo v e s a n d s a fe ty b o o ts .
To re m o v e th e h y d r o s ta tic s te e rin g c o n tro l v a lv e ,

1. D is c o n n e c t th e n e g a tiv e c a b le (1 ) fr o m th e
b a tte ry .
2. D ra in th e o il fr o m th e s te e rin g s y s te m .
6
3. To a c c e s s th e e n g in e th e hood m u s t be
opened.
4. D is c o n n e c t th e o il p ip e s fr o m th e h y d r o s ta tic
s te e rin g c o n tro l v a lv e u n it (1 ).
5. R e m o v e th e s te e rin g w h e e l (1 ) re ta in in g n u t a n d
re m o v e th e s te e rin g w h e e l a n d h a n d th r o ttle
le v e r.
9
6. R e m o v e th e f o u r s e c u rin g s c r e w s (1 ) fr o m th e
in s tr u m e n t p a n e l (2 ).
10
7. D is c o n n e c t th e e le c tric a l le a d s (1 ) fr o m th e re a r
of th e in s tr u m e n t p a n e l. U n s c re w th e th e
t a c h o m e t e r c a b le (2 ). R e m o v e th e in s tr u m e n t
p a n e l a n d s to r e in a s a fe p la c e .
11
8. .U n s c re w th e r e a r h o o d s c r e w s (1)
12
9. T a k e o f f t h e c o m p le te re a r h o o d
13
10. R e m o v e th e h y d r o s ta tic s te e rin g u n it s u p p o r t

b o lts a n d ta k e o f t h e h y d r o s ta tic s te e rin g u n it.
14
-- To re fit th e c o n tro l v a lv e , p ro c e e d a s fo llo w s :
-- R e fit th e h y d r o s ta tic s te e rin g u n it
-- R e fit th e c o m p le te re a r h o o d .
-- S e c u r e th e r e a r h o o d w ith th e s c r e w s p re v io u s ly
re m o v e d .
-- R e c o n n e c t th e e le c tric a l le a d s a n d re c o n n e c t
th e th e t a c h o m e t e r c a b le .
-- R e --in s ta ll th e fo u r s c re w s s e c u r in g th e
in s tr u m e n t p a n e l.
-- R e --in s ta ll th e h a n d th r o ttle a n d s te e rin g w h e e l.

S e c u r e th e w h e e l w ith th e c e n tra l re ta in in g n u t.
-- R econnect th e o il p ip e s to th e h y d r o s ta tic
s te e rin g c o n tro l v a lv e u n it.
-- F ill th e th e s te e rin g s y s te m w ith oil.
-- R e c o n n e c t th e n e g a tiv e c a b le to th e b a tte ry a n d
c lo s e th e h o o d .

D is a s s e m b ly -A s s e m b ly on th e bench
(Op. 41 204 34 )
To d is a s s e m b le th e h y d r o s ta tic s te e rin g c o n tro l
v a lv e , p ro c e e d a s fo llo w s :
1. R e m o v e th e c o n tro l v a lv e c o v e r re ta in in g b o lts .
15
2. R e m o v e th e c o v e r b y s lid in g to o n e s id e .
16
3. R e m o v e th e r o to r fix e d rin g , th e r o to r a n d th e
in n e r s p a c e r.
4. R e m o v e th e tw o O --rin g s e a ls o n th e r o to r fix e d
rin g .
18
6. E x tr a c t th e th r u s t w a s h e r.
19
7. R e m o v e th e th r e a d e d p lu g o n th e n o n --re tu rn
v a lv e s e a t.
20
8. E x tr a c t th e O --rin g s e a l fr o m th e c o n tro l v a lv e
b o d y.
21
9. P o s itio n th e c o n tro l v a lv e b o d y a n d th e ro to r
d riv e s h a ft s o t h a t th e s le e v e --c o n tro l s h a ft trim
p in is in a h o r iz o n ta l p o s itio n .
10. P u s h th e r o ta ry v a lv e in w a rd s , s o t h a t th e v a lv e ,
th e v a lv e s e a t s le e v e a n d th e th r u s t b e a rin g c a n
b e e x tr a c te d fr o m th e c o n tro l v a lv e b o d y.
22
11. Extract the thrust bearing from the rotary valve,

complete with the two external rings. Remove
the spring retaining ring from the valve seat
sleeve.
24
W AR N IN G : On assembly, two reference marks

(arrowed) were made on the rotary valve and the
sleeve, corresponding to the neutral position
maintained by the springs. Before removing the
springs, check that the marks are clearly visible. If
not clear, make new reference marks.
25
13. Extract the rotary valve from the valve seat sleeve
26
14. R e m o v e th e n eu tral p o s itio n s p rin g s , e x tra c tin g

th e m fr o m t h e ir s e a ts .
27
15. R e m o v e th e d u s t s e a l a n d th e O - r in g s e a l fro m
t h e ir s e a ts in th e c o n tro l v a lv e b o d y.
28
16. U s in g a 6 mm A lle n w re n c h , re m o v e th e
th r e a d e d p lu g s fr o m th e tw o c y lin d e r s a fe ty
v a lv e s a n d e x tr a c t th e s e a ls .
29
17. U s in g a 6 m m A lle n w r e n c h , re m o v e th e s e ttin g

a d ju s te r s c r e w s fr o m th e c y lin d e r s a fe ty v a lv e s .
S e e a ls o fig . 3 1 .
18. T u rn th e c o n tro l v a lv e b o d y o v e r a n d e x tr a c t th e
b a lls , th e s p r in g s a n d th e s p r in g g u id e s fr o m th e
tw o c y lin d e r s a fe ty v a lv e s .
30
C y lin d e r s a fe ty v a lv e s c o m p o n e n ts (o rd e r of
d is a s s e m b ly - a s s e m b ly ) .
1. C y lin d e r s a fe ty v a lv e b a ll.
2. P re s s u r e s p rin g .
3. S e ttin g a d ju s te r s c re w .
4. S e a l.
5. P lu g .
31
19. U s in g a 6 mm A lle n w re n c h , re m o v e th e
th r e a d e d p lu g o n th e p r e s s u re r e lie f v a lv e a n d
e x tr a c t th e s e a l.
32
20. R e m o v e th e p re s s u re r e lie f v a lv e a d ju s te r s c re w .
21. T u rn th e c o n tro l v a lv e b o d y o v e r a n d c o m p le te
d is a s s e m b ly b y e x tra c tin g th e s p r in g a n d th e
p r e s s u re r e lie f v a lv e p is to n .
33
P re s s u re r e lie f v a lv e c o m p o n e n ts (o rd e r of
a s s e m b ly ).
1. P re s s u r e r e lie f v a lv e .
2. P re s s u re s p rin g .
4. S e a l.
5. P lu g .
34
22. Thoroughly clean all control valve component

parts.
23. Replace the washers and seals.
24. Carefully check all mechanical parts, replacing

components that show signs of wear.
25. Before refitting, lubricate the components with

hydraulic oil.
26. R e -fit the rotary valve on the sleeve, checking

that the reference marks indicated in the drawing
coincide.
35
27. Use tool 380000306 to insert the flat and curved

springs (12) fig. 2.
(Diagram for fitting springs (12) fig. 2 ne utra l position
for OSPC 80 O N -150N 1058 hydrostatic steering).
36
28. A fter inserting the springs in the seat, align and
centre (as shown in the drawing).
37
29. F it th e ne utra l p o s itio n s p rin g re ta in in g rin g on

th e v a lv e s e a t s le e v e , r e m e m b e rin g th a t th e rin g
m u s t ro ta te fr e e ly w ith o u t b e in g im p e d e d b y th e
s p rin g s .
40
1. B e a rin g e x te rn a l rin g .
2. T h r u s t b e a rin g .
©—
3. B e a rin g in te rn a l rin g w ith b e v e l fa c in g c o n ta c t
s u r fa c e o f p a rt (5 ).
4. R o ta ry v a lv e .
5. R o ta r y v a lv e s e a t s le e v e .
41
32. P o s itio n th e c o n tro l v a lv e b o d y s o th a t th e

h o u s in g seat on th e r o ta r y v a lv e s le e v e is
p o s itio n e d h o riz o n ta lly , th e n in s e rt th e g u id e
b u s h in g (1 ) o f to o l 380000305.
42
33. L u b r ic a te t h e s u p p o r t rin g (1 ) a n d O - r in g s e a l (2)

w ith h y d r a u lic o il a n d fit th e m o n th e h e a d (3 ) o f
th e to o l 380000305 , a s s h o w n in th e d ra w in g .
S u p p o rt head fo r s u p p o rt and seal rin g s

(p a rt o f to o l 380000305)
34. In s e rt th e c o m p le te d r ift in th e g u id e b u s h in g
p r e v io u s ly in s ta lle d .
44
35. Holding the external bushing in position

manually, press fully down, whilst simultaneously
rotating the drift, in order to facilitate the entry of
the O -ring seal in the control valve body seat.
45
36. Extract the components of tool 380000305

(external bushing and drift).
NOTE: The support head of the support and seal

rings remains on the control valve body (see fig. 43).
37. Insert the parts that were previously fitted in

operations 26 - 31 on the control valve body.
Hold the sle e ve -to -ro to r drive shaft trim pin in a
horizontal position, to prevent it from slipping out
and jamming in the slots inside the control valve
body.
38. Press the rotary valve so as to bring the thrust

bearing into contact with the control valve body.
This operation simultaneously expels the head
(1) of tool 380000305, inserting the rings (1) and
(2) fig 43 into the seat of the control valve body
(see operation 33).
48
39. R o ta te th e c o n tro l v a lv e b o d y a n d in s e r t th e
n o n --re tu rn v a lv e b a ll in to th e s e a t in d ic a te d b y
th e a rro w .
40. S c r e w th e th re a d e d p lu g in to th e n o n --re tu rn
v a lv e s e a t u n til th e u p p e r s u r fa c e is b e lo w th e
c o u p lin g s u r fa c e o f th e c o n tro l v a lv e b o d y.
50
41. L u b r ic a te th e O - r in g s e a l a n d in s e rt in to th e s e a t
o n th e c o n tro l v a lv e b o d y.
42. F it th e th r u s t w a s h e r, s o th a t th e h o le s c o in c id e
w ith th e h o le s in th e c o n tro l v a lv e b o d y.
52
43. Make a reference mark on the upper part of the

teeth (1), in line with the seat (2), to indicate the
exact position of the valve-to-sleeve trim pin.
53
44. Fit the rotor drive shaft into the control valve
body. Insert tool 380000307 for retaining and
centring the rotor drive shaft, between the rotor
drive shaft and the thrust washer. Rotate the
shaft so as to facilitate coupling between the seat
(2) fig. 53 and the trim pin installed in the sleeve.
54
45. To refit the rotor, proceed as follows:
a) each time the hydrostatic steering is

disassembled, turn the rotor over so as to limit
w ear to the splined coupling;
b ) in the drawing below, the rotor shaft has been

removed in orderto show the phasing between the
rotor, rotor drive shaft and the trim pin;
c) fit the rotor on the drive shaft, remembering that

phasing is obtained by aligning the teeth (1), on the
trim pin axis plane (shown in fig. 53) with the centre
line of one of the recesses between the lobes of the
rotor.
55
46. L u b r ic a te th e tw o O - r in g s e a ls (1 ) w ith h y d r a u lic

o il a n d in s e r t th e m in th e r o to r fix e d rin g s e a t. F ix
in p o s itio n b y a lig n in g th e re ta in in g h o le s (2 ) w ith
th o s e o n th e th r u s t w a s h e r.
56
47. F it th e c o v e r, a lig n in g th e re ta in in g h o le s w ith

th o s e o n th e r o to r fix e d rin g .
57
48. R e m o v e re ta in in g to o l 380000307 a n d fit th e

s p e c ia l s c r e w a n d w a s h e r in th e n o n --re tu rn
v a lv e s e a t, s h o w n in th e d ra w in g .
49. F it th e o th e r s ix c o v e r re ta in in g b o lts w ith th e

w a s h e rs a n d tig h te n in d ia g o n a l s e q u e n c e to th e
to rq u e s e ttin g v a lu e s h o w n in th e ta b le on p a g e 3.
59
50. T u rn o v e r th e c o n tro l v a lv e b o d y a n d in s e rt th e
p r e s s u re r e lie f v a lv e p is to n in th e s e a t, as
in d ic a te d in th e d ra w in g . See fig . 34 fo r
c o m p o n e n t a s s e m b ly o rd e r.
61
52. U s in g a n 8 m m A lle n w re n c h , in s e r t t h e p r e s s u re
r e lie f v a lv e s e ttin g s c re w .
NO TE : S e ttin g s h o u ld be c a rrie d out on th e

w o r k b e n c h o r o n th e t r a c t o r to th e v a lu e s s h o w n in
th e ta b le o n p a g e 1.
62
53. T ig h te n th e p lu g (2 ), w ith th e a s s o c ia te d s e a l,
u s in g a n 8 m m A lle n w re n c h . T ig h te n to th e
p re s c rib e d to r q u e v a lu e 40 -- 60 Nm
(2 9 .5 0 2 5 - 4 4 .2 5 3 7 ft lb ), a f te r h a v in g c a rrie d o u t
th e s e ttin g o n th e w o r k b e n c h o r o n th e tra c to r.
54. In s e rt th e b a lls (1 ) in to th e tw o c y lin d e r s a fe ty
v a lv e s e a ts , in d ic a te d b y th e a rro w s . S e e fig . 6 4
c o m p o n e n t a s s e m b ly o rd e r.
63
C y lin d e r s a fe ty v a lv e s c o m p o n e n ts (o rd e r of
a s s e m b ly )
1. C y lin d e r s a fe ty v a lv e b a ll.
2 . P r e s s u r e s p rin g .
4 . S e a l.
5. P lu g .
64
55. In s e rt th e s p r in g s (2, fig . 6 9 ) in th e c y lin d e r

s a fe ty v a lv e s e a ts .
56. U s in g a 6 m m A lle n w re n c h , tig h te n th e tw o
c y lin d e r s a fe ty v a lv e s e ttin g a d ju s te r b o lts
(3, fig . 6 9 ).
N O TE : S e ttin g s h o u ld be c a rrie d out on th e

w o r k b e n c h o r o n th e t r a c t o r to th e v a lu e s s h o w n in
th e ta b le o n p a g e 1.
20475
65
57. T ig h te n th e tw o p lu g s (5, fig . 6 9 ) a n d th e

re la tiv e s e a ls (4 ) u s in g a 6 m m A lle n w re n c h .
O nce s e ttin g is c o m p le te d , tig h te n to th e
p re s c r ib e d to r q u e v a lu e of 30 Nm
(2 2 .1 2 6 9 ft lb).
66
58. W h e n th e u n it h a s b e e n a s s e m b le d , in s e rt th e
d u s t s e a l in th e s e a t in th e c o n tro l v a lv e b o d y.
24764
67

B ench te s tin g (Op. 41 204 38 )
Test c o n d itio n s .
O il ty p e ID R A U L IC A R A P 5 1
O il v is c o s ity ...................................................... S A E 2 0 W
O il t e m p e r a tu r e ....................................... 6 0 ° C (1 4 0 °F )
H y d r a u lic p u m p c a p a c ity ...........................litre s /m in 12
.................................................................. (g a ll. im p /m in 2 .6 4 )
S p e e d o f e le c tr ic m o t o r ..................................... rp m 1 4 5 0
seals and fo r s e ttin g th e pressure re lie f valve.

1. S p lin e d c o n tro l s h a ft 4 . R e s tr ic tio n
2. To rq u e w r e n c h 5. P re s s u re a d ju s tm e n t h a n d w h e e l
3. D e liv e r y lin e
A - CHECKING ROTARY VALVE W EAR
1. M a k e th e c o n n e c tio n s s h o w n in fig . 6 8 a n d
c o m p le te th e c ir c u it a s in fig . 6 9 . U s in g th e
s p lin e d c o n tro l s h a ft (1 ), h o ld th e s te e rin g c o n tro l
v a lv e in s te e rin g p o s itio n (rig h t o r le ft).
2. U s in g th e h a n d w h e e l (5 ), in c re a s e th e c irc u it
p r e s s u re to a s n e a r a s p o s s ib le th e p re s s u re
r e lie f v a lv e c ra c k in g p r e s s u re (p a g e 1) w ith o u t
th e v a lv e a c tu a lly o p e n in g .
3. U s in g a to r q u e w r e n c h (2 ), a p p ly a to r q u e o f
a p p ro x . 3 4 N m (2 5 .8 1 4 7 ft lb ) to th e c o n tro l s h a ft
(1 ), a n d c h e c k t h a t th e ro ta ry v a lv e ta k e s m o re
th a n 10 s e c o n d s to c o m p le te o n e fu ll ro ta tio n . If
it t a k e s le s s th a n 10 s e c o n d s , c h a n g e th e ro ta ry
v a lv e (4, fig . 2 ) a n d th e s le e v e .
B - CHECKING RETURN TO NEUTRAL POSITION

In t h e s a m e te s t c o n d itio n s a s A , c h e c k t h a t th e v a lv e
a u to m a tic a lly re tu r n s to n e u tra l p o s itio n w h e n th e
c o n tro l s h a ft (1 ) is re le a s e d a f te r e a c h s im u la te d
s te e rin g m o v e m e n t.
C - CHECKING S E A L EFFICIENCY
In th e s a m e t e s t c o n d itio n s a s A , h o ld th e v a lv e in
s te e rin g p o s itio n w ith th e c o n tro l s h a ft (1 ) f o r a b o u t
th r e e m in u te s a n d c h e c k th e s e a ls f o r le a k s .
D - SETTING THE PRESSURE RELIEF VALVE
1. M a k e th e c o n n e c tio n s a s s h o w n in fig u r e (6 8 )
a n d c o m p le te th e c irc u it a s in fig u re (6 9 ).
2. U s in g th e c o n tro l s h a ft (1 ), s im u la te a s te e rin g
c y c le (to rig h t o r le ft) s o a s to in te rr u p t th e o il flo w
to th e o u tle t.
3. G r a d u a lly in c re a s e th e p re s s u re in th e c irc u it b y
tu r n in g th e h a n d w h e e l (5 ) fig . 6 8 , a n d c h e c k on
th e p re s s u re g a u g e t h a t th e p re s s u r e r e lie f v a lv e
(2 2 , fig . 2 ) c u ts in a t th e p re s s u r e s h o w n on
p a g e 1. If n o t, in c r e a s e o r re d u c e th e p re s s u re
r e lie f v a lv e s e ttin g b y tig h te n in g o r s la c k e n in g
th e a d ju s te r s c re w .
24911
©
1. S p lin e d c o n tro l s h a ft 69
2. P lu g G 1 /2 ”
3. To th r o ttle
4. O u tle t
5. T h r e e - w a y c o u p lin g G 1 /2 ”
6. F ro m d e liv e r y lin e
CHECKING THE HYDROSTATIC STEERING 7. O u tle t c o u p lin g G 1 /2 ”
PRESSURE RELIEF VALVE W ITH STEERING
CONTROL VALVE INSTALLED ON TRACTOR.
1. S ta r t t h e e n g in e a n d ru n u n til th e o il t e m p e r a tu r e
re a c h e s a p p ro x . 5 0 ° C ( 1 2 2 ° F ).
2. S w itc h o f f t h e e n g in e a n d u n s c r e w th e o il d e liv e ry
p ip e u n io n (4 ) o n th e h y d r a u lic c y lin d e r (5 ).
3. F it u n io n (2 ) in p la c e o f u n io n (4 ), a n d c o n n e c t th e
p r e s s u re g a u g e (1 ) w ith a 0 - 2 1 .3 3 5 0 p s i s c a le
b y w a y o f u n io n (3 ).
4. S ta r t th e e n g in e a g a in , b rin g th e s p e e d u p to
m e d iu m rp m , a n d a p p ly f u ll- s te e r in g lo c k to
b rin g th e h y d r a u lic c y lin d e r to th e s t r o k e - e n d
p o s itio n .
In th is c o n d itio n , th e p r e s s u re r e lie f v a lv e (2 2 , fig . 2 ) 380000240 )
1. P re s s u re g a u g e (s u p p lie d in k it
s h o u ld o p e n a n d th e p re s s u re g a u g e s h o u ld in d ic a te 2 . U n io n 380000618 (s u p p lie d in k it 380000240 ) to
th e v a lu e g iv e n o n p a g e 1. b e fitte d in p la c e o f o r ig in a l u n io n
5. If th e p re s s u r e g a u g e re a d in g d e v ia te s s ig n ifi 3. U n io n 380000613 (s u p p lie d in k it 380000240 )
c a n tly fr o m th e p re s c rib e d v a lu e , a d ju s t th e v a lv e 4 . H y d r a u lic c y lin d e r o il fe e d p ip e
o p e n in g p re s s u r e b y w a y o f t h e a d ju s te r s c re w . 5. H y d r a u lic c y lin d e r.
H y d ro s ta tic ste e rin g o il p um p c o m p o n e n ts 71
H y d ro s ta tic s te e rin g o il p um p c o m p o n e n ts
11 .D riv in g s h a ft s e a l.
1. F r o n t c o v e r
12. S n a p rin g
2. C o v e r s e a ls
13. S a fe ty w a s h e r
3. P u m p b o d y
14. N u t
4. G e a r s u p p o r t
15. B o lt
5. D riv e n a n d d r iv in g g e a r s h a fts
16. W a s h e r
6. G e a r s u p p o r t
17. K e y
7. B u s h in g
18. B u s h in g
8. C o n tro l s id e c o v e r
19. S a fe ty w a s h e r
9. D riv in g s h a ft s e a l
20. N ut
10. S p a c e r
P r o c e e d a s fo llo w s :
1. R e m o v e th e c o v e r fa s te n in g n u ts (2 0 ), th e n th e
b o lts (1 5 ) a n d th e s a fe ty w a s h e r s .
2. R e m o v e th e nut (14) th a t fa ste n s th e sle e ve to th e
p u m p driving sh a ft and th e sa fe ty w asher.
3. R e m o v e th e fr o n t c o v e r (8 ), th e s n a p rin g (1 2 )
a n d th e s e a ls ( 9 a n d 11 ).
4 . M a r k p a rts 3, 4, 5 a n d 6 to e n a b le th e m to be
re m o u n te d in th e s a m e p o s itio n if th e y a re in g o o d
c o n d itio n .
5. R e m o v e th e s u p p o r ts (4 a n d 6 ) a n d th e g e a rs
(5 ) fr o m th e re a r c o v e r (8 ) a n d th e p u m p b o d y (3 ).
6 . R e m o v e th e s e a ls (2 ) a n d th e a n ti--e x tru s io n
r in g s .O n c e th e p a rts a re re m o v e d , p ro c e e d a s
fo llo w s :
7. C h e c k t h a t th e g e a r c o n ta c t s u r fa c e s a re fla t
a n d p e rp e n d ic u la r to t h e ir s u p p o rts . In te rp o s e a
th in la y e r o f c a rb o n b la c k . S m a ll ro u g h s p o ts c a n
b e r e m o v e d u s in g e x tr e m e ly fin e a n d a d e q u a te ly
lu b ric a te d a b ra s iv e p a p e r.
8. C h e c k t h a t th e a x ia l p la y o f th e g e a r- -s u p p o rt
u n it in th e p u m p b o d y is 0 .1 0 0 - 0 .1 8 0 m m
(0 .0 0 3 9 - 0 .0 1 8 9 in .). T h e d is ta n c e (F ig 7 2 , 2 )
m u s t b e 0 .1 0 0 - 0 .1 8 0 m m ( 0 .0 0 3 9 - 0 .0 1 8 9 in .)
s m a lle r t h a n th e d is ta n c e (F ig 7 2 , 1 ) .If n e c e s s a ry ,
tr u e th e fla t s u r fa c e s in v o lv e d u s in g lu b ric a te d
a b r a s iv e p a p e r to re m o v e e x tr e m e ly s m a ll
q u a n titie s o f m a te ria l
9. C le a n a ll c o n s titu e n t p a rts th o ro u g h ly .
1 0. R e p la c e th e s e a ls (2, 9 a n d 11).
11. L u b r ic a te th e p a rts w ith th e s a m e o il a s th e
s y s te m R e fit th e p u m p , re fe rr in g to fig . 71 a n d
p r o c e e d in g a s fo llo w s :
1 2. re fit, p e rfo r m in g o p e r a tio n s 6 to 1 in re v e rs e
o rd e r;-- a lw a y s e n s u r e th e m a x im u m c le a n lin e s s
72
to p re v e n t fo re ig n m a tte r fr o m e n te rin g , a s th is
c o u ld d a m a g e th e p u m p ;-- fit t o g e t h e r p re v io u s ly
m a rk e d p a rts (3, 4, 5 a n d 6 , fig . 7 1 ); s e e o p . p a g e
4 5 to re fit th e m in t h e ir o r ig in a l p o s it io n ; - m o u n t
th e g e a r s u p p o r ts (4 a n d 6 fig . 7 1 ) in th e
p u m p b o d y ; o rie n t th e m w ith th e fittin g s o n th e
e x te rn a l c ir c u m fe r e n c e m a tc h e d u p w ith th e
d is c h a r g e p ip e s a n d th e fr o n t fa c e s w ith
lu b ric a tio n m illin g s in c o n ta c t w ith th e g e a r s ; - fit
th e p la s tic a n t i- e x t r u s io n rin g s o n th e s e a ls
(2, fig . 7 1 ) ; - m o u n t th e s e a ls (9 a n d 11, fig . 7 1 ) on
th e c o n tro l s id e c o v e r (8 ) c o m p le te w ith s p a c e r
(1 0 ); o r ie n t t h e m s o t h a t th e c a v ity is b e tw e e n th e
s e a l lip s o n th e o p p o s ite s id e fr o m th is s p a c e r;
la s tly fill th is c a v ity w ith A K C E L A MULTI -
PURPOSE GREASE g r e a s e .In s ta ll th e p u m p on
th e tr a c to r . F ill th e s u c tio n p ip e a n d th e p u m p
h o u s in g w ith A K C E LA NEXPLORE o il in o r d e r t o
f a c ilita te p rim in g a n d p re v e n t th e ris k o f s e iz u r e
d u rin g in itia l o p e ra tio n .
FRONT A X LE STEERING CYLINDER

(Two w heel d riv e axle) (Op. 41 216 20)
R e m o v a l-R e fittin g
------------ A WARNING A -----------

To re m o v e th e fr o n t a x le s te e rin g c y lin d e r, p ro c e e d
a s fo llo w s :
1. R e m o v e th e e x h a u s t p ip e , lift th e hood and
d is c o n n e c t th e n e g a tiv e c a b le fr o m th e b a tte ry . 73
2. U n s c re w t h e u n io n s s e c u rin g th e o il d e liv e r y a n d
re tu rn h o s e s (1 ) to th e c y lin d e r (2 ).
3. R e m o v e th e n u t s e c u rin g th e c y lin d e r ro d b a ll
e n d to th e s te e rin g a rm (1 ).
74
4. U s in g a s u ita b le p u lle r (1 ), s e p a r a te th e c y lin d e r

ro d b a ll e n d fr o m th e s te e rin g a rm .
75
5. R e m o v e th e p in s e c u rin g th e s te e rin g c y lin d e r
(1 ) to th e a x le a n d re m o v e th e c y lin d e r.
6. To re fit t h e s te e rin g c y lin d e r, fo llo w t h e re m o v a l
p ro c e d u re in re v e r s e o rd e r.
76
FRONT A X LE STEERING CYLINDER

(F o u r w heel d rive axle)
R em oval -R e fittin g
------------ A WARNING A -------------

To re m o v e th e fr o n t a x le s te e rin g c y lin d e r, p ro c e e d
a s fo llo w s :
1. D is c o n n e c t th e n e g a tiv e c a b le fr o m th e b a tte ry .
2. U n s c re w th e u n io n s s e c u r in g th e d e liv e r y a n d
re tu rn h o s e s to th e s te e rin g c y lin d e r.
3. R e m o v e th e s n a p rin g (1 ) a n d re m o v e th e
c y lin d e r ro d a r tic u la tio n p in (2 ) c o n n e c te d to
th e s tu b a x le h o u s in g .
78
4. R e m o v e th e re ta in in g s c r e w a n d e x tr a c t th e pin
(1 ) s e c u rin g th e s te e rin g c y lin d e r to th e a x le .
R e m o v e th e s te e rin g c y lin d e r.
NOTE: S h o u ld y o u w a n t to re m o v e b o th s te e rin g
c y lin d e rs c o m p le te w ith s u p p ly p ip e s , o m it s te p 3
d e s c rib e d a b o v e a n d c a r r y o u t s te p s 2 a n d 4 f o r th e
o th e r c y lin d e r to o .
79
5. R e m o v e th e tw o a c tu a to r c y lin d e rs c o m p le te
w ith s u p p ly p ip e s .
80
SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1 1
SECTION 44 - FRONT AXLE AND WHEELS
Chapter 1 - Front axle and wheels
CONTENTS
44 000 P r in c ip a l d a t a .............................................................................................................................................................. 1
S e c tio n a l v ie w s ......................................................................................................................................................... 3
T o rq u e s e ttin g s ......................................................................................................................................................... 4
E q u ip m e n t - F a u lt d i a g n o s i s ............................................................................................................................. 5
44 101 30 R e m o v a l- R e fitt in g - O v e r h a u l ............................................................................................................................ 6
44 101 22 W h e e l h u b d is a s s e m b ly - a s s e m b ly ................................................................................................................ 9
44 101 46 S tu b a x le o v e rh a u l ................................................................................................................................................ 16
44 101 80 C h e c k in g w h e e l a l ig n m e n t ................................................................................................................................. 20
PRINCIPAL DATA
T y p e ............................................................................................................................. in v e rte d U - s e c tio n , t e le s c o p

ic
a n d o s c illa tin g a t c e n tre
W h e e l a n g l e ............................................................................................................ 2 °, c o r re s p o n d in g to 15 m m
(0 .5 9 0 6 in .) f o r 16 in. w h e e ls
T o e - in ........................................................................................................................ m m (in .) 0 - 5 (0 - 0 .1 9 6 9 )
S tu b axle a rtic u la tio n
D ia m e te r o f s tu b a x le p in (7, p a g e 3 ) a t b u s h in g ................................ mm 3 7 .9 6 1 - 3 8 .0 0 0
(in .) (1 .4 9 4 5 - 1 .4 9 6 1 )
B o re o f in s ta lle d b u s h in g s (6 ) ....................................................................... mm 3 8 .0 5 0 - 3 8 .1 4 0 (*)

(in .) ( 1 .4 9 8 0 - 1 .5 0 1 6 )
C le a r a n c e b e tw e e n s tu b a x le p in a n d r e la tiv e b u s h i n g s ................. mm 0 .0 5 0 - 0 .1 7 9
(in .) ( 0 .0 0 2 0 - 0 .0 0 7 0 )
A xle a rtic u la tio n
D ia m e te r o f a x le a rtic u la tio n p in (1, p a g e 3 ) .......................................... mm 3 7 .9 6 1 - 3 8 .0 0 0

(in .) (1 .4 9 4 5 - 1 .4 9 6 1
B o re o f in s ta lle d b u s h in g s (6 ) ....................................................................... mm 3 8 .0 5 0 - 3 8 .1 4 0 (*)

(in .) ( 1 .4 9 8 0 - 1 .5 0 1 6 )
C le a r a n c e b e tw e e n s tu b a x le p in a n d b u s h i n g ..................................... mm 0 .0 5 0 - 0 .1 7 9
(in .) ( 0 .0 0 2 0 - 0 .0 0 7 0 )
(*) Value to be obtained without refacing.

2 SECTION 44 - FRONT AXLE AND WHEELS - CHAPTER 1
MAIN DATA
(cont.)
S ta n d a rd A lte r n a tiv e tr a c k s e ttin g s m m (in .)

MODEL T y re s w h e e l tr a c k s
m m (in .) A B C D E F
JX 60 1500 1400 1500 1600 1700 1800 1900

7 . 5 0 - 1 6 in.
JX 70 (5 9 .0 5 5 0 ) (5 5 .1 1 8 0 ) (5 9 .0 5 5 0 ) (6 2 .9 9 2 0 ) (6 6 .9 2 9 0 ) (7 0 .8 6 6 0 ) (7 4 .8 0 3 0 )
JX 80
1510 1410 1510 1610 1710 1810 1910
JX 90 7 . 5 0 - 1 8 in.
(5 9 .4 4 8 7 ) (5 5 .5 1 1 7 ) (5 9 .4 4 8 7 ) (6 3 .3 8 5 7 ) (6 7 .3 2 2 7 ) (7 1 .2 5 9 7 ) (7 5 .1 9 6 7 )
JX 95
DIAGRAM OF 2WD FRONT W H EEL TRACKS
1
S e c tio n s o f s tu b axle, a rtic u la tio n pin and fro n t axle

1. A x le a r tic u la tio n p in 10. B r o n z e th r u s t rin g
2. A x le a r tic u la tio n b u s h in g 11. Seal
3. S te e rin g tr a n s v e r s e tie ro d 12. W h e e l hub
4. S tu b a x le c o n tro l le v e r 13. S te e l th r u s t w a s h e r
5. A x le s u p p o r t 14. G r u b s c r e w f o r c a p (1 1 ) a n d th r u s t w a s h e r (1 2 )
6. B u s h in g 15. T a p e r r o lle r b e a rin g f o r w h e e l
7. S tu b a x le p in 16. B e a rin g c o v e r f o r g re a s in g a n d a d ju s tm e n t
8. S u p p o r t rin g g r u b s c r e w (1 3 ) 17. C y lin d e r fu lc r u m p in (1 8 )
9. Cap 18. P o w e r s te e rin g c y lin d e r in s ta lla tio n p o s itio n
F ro n t axle to rq u e s e ttin g s
C 1 A x le a r tic u la tio n p in fix in g s c r e w C 5 N u t f o r s tu b a x le p in c o n tro l le v e r fix in g s c r e w

C 2 N u t s e c u r in g d is c to w h e e l h u b C 6 N u t s e c u r in g c y lin d e r to fu lc r u m pin
C 3 B e a rin g a d ju s te r n u t
C 4 A x le e n d fix in g n u t
* S e e o p e r a tio n s 12 a n d 13, p a g e 15.

TORQUE SETTINGS
PART T h re a d
Nm ft lb
F ro n t axle
B o lt s e c u rin g a x le to e n g in e ( 5 ) .......................................................................... M 1 8 x 1 ,5 353 4 7 8 .6 0 4 5
B o lt s e c u rin g a x le a rtic u la tio n p in (9 ) ............................................................. M 1 0 x 1 ,2 5 49 6 6 .4 3 5 2
N u t f o r a x le e n d fix in g s c r e w ............................................................................... M 1 6 x 1 ,5 211 1 5 5 .6 2 5 6
N u t s e c u rin g L H a n d R H le v e rs o n th e s tu b a x le s (4 ) ........................... M 1 6 x 1 ,5 294 2 1 6 .8 4 3 3
N u t s e c u rin g b a ll e n d f o r tr a n s v e r s e s te e rin g tie r o d ............................. M 1 4 x 1 ,5 118 8 7 .0 3 2 3
N u t s e c u rin g tr a n s v e r s e s te e rin g tie ro d ...................................................... M 20 x 1 176 1 2 9 .8 1 0 9
S c r e w s e c u rin g fr o n t w h e e l to h u b (3 ) ........................................................... M 18x1,5 314 2 3 1 .5 9 4 5
EQUIPMENT
L is t o f s p e c ia l to o ls n e c e s s a ry f o r th e v a rio u s
W ARNING: T h e o p e r a tio n s d e s c rib e d in th is s e c tio n o p e r a tio n s d e s c r ib e d in th is s e c tio n .
m u s t b e p e r fo rm e d o n ly w ith th e ESSENTIAL
e q u ip m e n t m a rk e d w ith (X ) .
To o p e ra te s a fe ly a n d a c h ie v e b e s t re s u lts , w h ile
X 380000541 A d a p t o r ( M 1 2 x 1 .2 5 ) fo r a x le
s a v in g tim e a n d e ffo rt, e s s e n tia l e q u ip m e n t m u s t be
a r tic u la tio n p in (u s e w ith s lid e
used in c o n ju n c tio n w ith th e s p e c ia l to o ls
ham m er 380000549 )
re c o m m e n d e d b e lo w a n d to o ls w h ic h y o u m u s t m a k e
y o u r s e lf a n d f o r w h ic h y o u w ill fin d th e d e s ig n in th is
m a n u a l.
380000237 W h e e l liftin g h o o k .
FAULT DIAGNOSIS
P r o b le m P o s s ib le c a u s e C o r r e c tiv e a c tio n
A b n o r m a l w e a r o f ty re s . 1. In c o rre c t ty r e p re s s u re . In fla te th e ty r e s to th e c o r re c t
p re s s u re , re fe rrin g to th e p re s s u re s
re c o m m e n d e d in th e U se an d
M a in te n a n c e handbook, and m o re
e sp e cia lly, to th e p re s s u re s
re c o m m e n d e d b y th e m a n u f a c t u r e r o f
2. In c o r r e c t to e --in o f fr o n t th e ty r e s fitte d .
w h e e ls . C o r r e c t th e to e --in .
P o o r s ta b ility o f tra c to r. 1. In c o rre c t ty r e p re s s u re . In fla te th e ty r e s c o r r e c tly a s d e ta ile d

above.
FRONT A X LE
R e m o v a l-R e fittin g (Op. 44 101 30)
A DANGER A ---------
L ift a n d h a n d le a ll h e a v y p a rts w ith liftin g e q u ip m e n t
o f s u ita b le c a p a c ity . M a k e c e rta in t h a t th e u n its o r
p a rts a re s u p p o rte d b y a p p r o p r ia te s lin g s a n d
h o o k s . E n s u re t h a t th e re a re n o p e rs o n s in th e
v ic in ity o f t h e lo a d to b e lifte d .
To re m o v e th e c o m p le te a x le fr o m th e tra c to r,
1. D is c o n n e c t th e n e g a tiv e c a b le fr o m th e b a tte ry
a n d is o la te it; c h o c k th e r e a r w h e e ls .
2. L ift th e fr o n t o f t h e tra c to r.
3. P la c e a s ta n d (1 ) b e n e a th th e e n g in e s u m p ,
in s e rtin g a b lo c k o f w o o d b e tw e e n th e e n g in e
s u m p a n d s ta n d .
4. R e m o v e th e fr o n t w h e e l fix in g b o lts (1)
6
5. D is c o n n e c t th e h o s e s (1 ) o f th e p o w e r s te e rin g
c y lin d e r (2 ).
6. R e m o v e th e a x le a rtic u la tio n p in s e c u rin g b o lt (1)
7. S e c u re th e a x le b y m e a n s o f a s lin g (1 ).
8. T a k e o u t th e a x le a rtic u la tio n p in (1 ) u s in g s lid e

h a m m e r 380000549 , e q u ip p e d w ith a d a p to r
380000541 a n d e x te n s io n .
10
9. R e m o v e th e c o m p le te a x le (1 ).
11
10. To re fit th e c o m p le te a x le , fo llo w th e d is a s s e m b ly

p ro c e d u re in re v e r s e o rd e r. In s ta ll th e a x le
a r tic u la tio n p in (1 ) u s in g a b ro n z e p u n c h .
11. F it th e s c r e w fix in g th e a x le a r tic u la tio n p in .
12
12. R e c o n n e c t th e h o s e s (1 ) o f th e p o w e r s te e rin g
c y lin d e r (2 ).
13
AX LE W H EEL HUB
R em oval:
------------ A WARNING A -----------
T he w heel hubs can be r e m o v e d w ith th e a x le

in s ta lle d o n th e tra c to r. P ro c e e d a s fo llo w s f o r e a c h
w h e e l.
1. D is c o n n e c t th e n e g a tiv e c a b le o f th e b a tte ry a n d
is o la te it; c h o c k th e r e a r w h e e ls .
14
3. P la c e a l s ta n d (1 ) b e n e a th th e e n g in e s u m p ,
15
4. R e m o v e th e fr o n t w h e e l fix in g b o lts
16
5. R e m o v e th e w h e e l h u b b e a rin g c o v e r (1 ).
17
6. R e m o v e th e g r e a s e n ip p le a s s h o w n in fig u re .
18
7. R e m o v e th e s p lit p in (1 ) s e c u rin g th e w h e e l h u b
b e a rin g a d ju s te r n u t.
19
8. U s in g a s o c k e t w r e n c h , u n s c r e w th e w h e e l h u b
b e a rin g a d ju s te r n u t.
20
9. R e m o v e th e w h e e l h u b b e a rin g a d ju s te r n u t (1 ).
21
10. R e m o v e th e w h e e l h u b b e a rin g w a s h e r (1 ).
22
11. R e m o v e th e w h e e l h u b (2 ) a n d ta k e o u t th e
b e a rin g s (1 a n d 3).
23
12. R e m o v e th e b e a rin g (1 ).
24
13. R e m o v e b la c k (T w in lip ) w h e e l b e a rin g s e a l (1 ).
25
14. R e m o v e w h ite b a c k u p rin g (1 ).
26
15. R e n e w w o rn b e a r in g s a n d s e a ls , u s in g s u ita b le
e x tr a c to r s a n d p u n c h e s .
27
AX LE W H EEL HUB
R e fittin g :
16. P la c e a h y d r a u lic ja c k b e n e a th th e s tu b a x le a n d
u n s c re w th e b o lt (1 ) fix in g th e c o n tro l le v e r (2 ) to
th e s tu b a x le p in .
28
17. W ith d r a w th e c o n tro l le v e r (1 ) fr o m th e s tu b a x le

p in ( 2 ).
29
18. L o w e r th e h y d r a u lic ja c k a n d re m o v e th e s tu b
a x le (1 ).
30
19. P u t th e s tu b a x le o n a s u ita b le v ic e a n d in s ta ll
w h ite b a c k u p rin g (1 ).
31
20. In s ta ll b la c k (T w in lip ) w h e e l b e a rin g s e a l (1 ).
32
21. In s ta ll b o th b la c k (T w in lip ) w h e e l b e a rin g s e a l

a n d w h ite b a c k u p rin g t o g e t h e r w ith a s u ita b le
in s ta lle r a n d a h a m m e r.
33
22. In s ta ll b e a rin g w ith a s u ita b le in s ta lle r a n d a

h a m m e r.
34
23. T h e w e a r s le e v e (1 ) f o r t h e s e a l m u s t b e in s ta lle d
in th e hub w ith a h ig h s tr e n g th b e a rin g fit
a d h e s iv e com pound (lo c tite ) to e n s u re th e
s e c u r e r e te n tio n in th e h u b .
T h e h u b a n d th e w e a r s le e v e m u s t b e th r o u g h ly
c le a n and d ry . A p p ly h ig h s tr e n g th b e a rin g fit
com pound. P re s s in th e w e a r s le e v e , u s in g a
s u ita b le p re s s .
A f t e r in s ta llin g th e w e a r s le e v e , th e c o m p o u n d m u s t
b e a llo w e d to c u re f o r a m in im u m o f th r e e h o u rs p rio r
to a s s e m b lin g th e b e a rin g s a n d s e a ls in th e h u b .
35
24. P a c k th e w h e e l h u b w ith A K C E LA NEXPLORE

g re a s e .
25. R e fit th e w h e e l h u b (2 ) c o m p le te w ith b e a rin g s

(1 a n d 3).
36
26. In s ta ll a n e w n u t a n d , u s in g a to r q u e w re n c h ,
tig h te n th e nut to a to r q u e of 196 Nm
(2 6 5 .7 4 0 7 ft lb ), tu r n in g th e wheel hub (1)
s im u lta n e o u s ly in o r d e r to s e ttle th e b e a rin g s .
27. L o o s e n th e n u t s lig h tly a n d tig h te n it a g a in to a
to r q u e o f 2 4 - 2 9 N m (3 2 .5 3 9 7 - 3 9 .3 1 8 8 ft lb)
w h ile c o n tin u in g to tu r n th e w h e e l h u b .
Note - th e n u t m u s t b e c h a n g e d e a c h tim e th e w h e e l
h u b is fitte d .
28. C h e c k t h e ro llin g to r q u e R , b e a rin g in m in d th a t:

R < 5 .7 8 6 4 ft lb
37
29. In s ta ll th e s p lit p in (1 ) s e c u rin g th e w h e e l h u b

b e a rin g a d ju s te r n u t a n d b e n d it o v e r th e n u t to
p re v e n t tu r n in g th e n u t.
38
30. In s ta ll th e g r e a s e n ip p le a s s h o w n in fig u r e
39
31. In s ta ll th e w h e e l h u b b e a rin g c o v e r (1 ).
40
STUB AX LE
O verhaul (Op. 44 101 46)
------------ A WARNING A ------------

The s tu b a x le s can be re m o v e d w ith th e a x le

in s ta lle d o n th e tra c to r. P ro c e e d a s fo llo w s f o r e a c h
w h e e l.
1. D is c o n n e c t th e n e g a tiv e c a b le o f th e b a tte ry a n d
is o la te it; c h o c k th e r e a r w h e e ls .
41
3. P la c e a l s ta n d (1 ) b e n e a th th e e n g in e s u m p ,
42
4. R e m o v e th e fr o n t w h e e l fix in g b o lts (1 ).
43
5. P la c e a h y d r a u lic ja c k b e n e a th th e s tu b a x le a n d
u n s c re w th e b o lt (1 ) fix in g th e c o n tro l le v e r (2 ) to
th e s tu b a x le p in .
44
6. W ith d r a w th e c o n tro l le v e r (1 ) fr o m th e s tu b a x le
p in ( 2 ).
45
7. L o w e r th e h y d r a u lic ja c k a n d re m o v e th e s tu b
a x le (1 ).
46
8. U n s c re w th e a x le e n d s e c u rin g b o lts (1 ).
47
9. R e m o v e th e a x le e n d (1 ).
48
10. C la m p th e e n d o f th e a x le in a v ic e a n d u s in g a
s lid e h a m m e r, ta k e out th e s tu b a x le pin
a rtic u la tio n b u s h in g (1 ).
49
11. To re fit th e s tu b a x le , fo llo w th e d is a s s e m b ly

p ro c e d u re in re v e r s e o rd e r, u s in g a s u ita b le
h a m m e r t o fit th e n e w b u s h in g s o n th e a x le e n d s .
50
12. F it th e a x le e n d (1 ).
51
13. A t th e b a s e o f th e s tu b a x le re fit th e c a p (9, fig . 2 ),

th e n th e le v e llin g rin g s (1 ), in s e rtin g th e m o n th e
s to p g r u b s c r e w s (8 a n d 14, a s s h o w n in fig u re 2 ).
52
14. F it th e s tu b a x le o n th e a x le e n d .
15. P o s itio n th e c o n tro l le v e r (1 ) o n th e s tu b a x le pin
(2 ) a n d tig h te n th e s e c u rin g s c re w .
53
CHECKING THE ALIG N M E N T OF THE FRONT

W HEELS (Op. 44 511 80)
C h e c k th e a lig n m e n t o f th e fro n t w h e e ls , b e a rin g in

m in d th a t fo r d riv in g in a s tra ig h t line, th e w h e e ls m u s t
be a t an a n g le o f 2 ° to th e v e rtic a l. T h is c o rre s p o n d s
to a d iffe re n c e o f a p p ro x im a te ly 15 m m (0 .5 9 0 6 in.) fo r
16 in. w h e e ls , b e tw e e n th e to p e d g e o f th e rim (A ) a n d
b o tto m e d g e (A + X ).
W h e n d riv in g in a s tr a ig h t lin e , th e w h e e ls m u s t be
p a ra lle l to th e lo n g itu d in a l a x is o f th e t r a c t o r o r h a v e
a m a x im u m o f 5 m m ( 0 .1 9 6 8 in .) t o e - in a t th e fro n t,
m e a s u r e d b e tw e e n th e w h e e l- r im s .
To c h e c k th e t o e - in , p ro c e e d a s fo llo w s :
1. In fla te th e fr o n t ty r e s to a p re s s u re o f 2 .5 b a r
(3 6 .2 5 p s i).
2. P o s itio n th e s te e rin g w h e e l in th e m id d le o f its 54

tra v e l, w ith o n e s p o k e a lo n g th e lo n g itu d in a l a x is
o f t h e tra c to r.
3. C h e c k t h a t th e w h e e ls a re p a ra lle l w ith th e
lo n g itu d in a l a x is o f th e tra c to r.
4. W ith th e t r a c t o r p a rk e d o n a fla t, le v e l s u r fa c e ,
m e a s u re th e d is ta n c e (B -i) b e tw e e n th e fro n t o f
th e w h e e l rim s , a t h u b h e ig h t. M a k e a c h a lk m a rk
o n th e rim s w h e r e th e m e a s u r e m e n t h a s ta k e n
p la c e . M o v e th e t r a c t o r fo rw a r d to r o ta te b o th
w h e e ls e x a c tly 180o and check th e
m e a s u r e m e n ts a g a in a t th e c h a lk m a rk s B 2 (n o w
p o s itio n e d a t th e r e a r o f th e w h e e ls ) . T h is w ill
e lim in a te w h e e l rim r u n - o u t e rro rs .
5. C o r r e c t th e t o e - in , if n e c e s s a ry , b y a d ju s tm e n t
o f t h e e n d o f th e tr a n s v e r s e s te e rin g t ie - r o d .
SECTION 50 - AUXILIARY UNITS - CHAPTER 1 1
SECTION 50 -AUXILIARY UNITS
Chapter 1 - Auxiliary units
CONTENTS
50 000 Safety instructions ....................................................................................................................... 2
General characteristics ............................................................................................................... 3
Equipment ..................................................................................................................................... 4
Operating principles ..................................................................................................................... 5
Fault diagnosis ............................................................................................................................. 7
Cab c o n tro ls .....................................................................................................................................11
Use ............................................................................................................................................... 14
Main components of the cab air conditioning system ........................................................ 15
Refrigerant recovery-recycling and evacuation-charging stations .................................. 20
50 200 04 Drying recharging and checking cooling .................................................................................. 22
50 200 03 Functional testing of air conditioning system .......................................................................... 27
Summary of the cab air-conditioning system charging operations .................................. 28
Checking for refrigerant leaks using an electronic leak d e te c to r........................................ 30
Summary of fault diagnosis and maintenance ..................................................................... 31
A ir conditioning and heating pipes - R e p la c e m e n t.............................................................. 33
50 200 0 4 -7 4 R eceiver-drier - Replacement ............................................................................................... 36
50 200 04-72 Condenser - Replacement ....................................................................................................... 38
50 200 04-26 Compressor - Rem oval-Refitting ........................................................................................... 39
50 200 10 Compressor drive belt tension adjustment ............................................................................ 41

2 SECTION 50 - AUXILIARY UNITS - CHAPTER 1
CAB AIR CONDITIONING SYSTEM
SAFETY — freezing of the skin caused by contact with liquid

refrigerant can be treated by gradually warming
the injured area with cold w ater followed by
application of a greasy cream. Seek medical
Refrigerant must be handled with extreme care to
assistance.
avoid injury; always wear safety gloves and goggles.
— the air conditioning system contains a mixture of

Liquid refrigerant can cause freezing of the skin and refrigerant and oil under high pressure; under no
serious damage to the eyes, even blindness in some circumstances loosen pipe fittings/couplings or
cases. work on pipes without having first evacuated the
system.
Keep refrigerant containers away from heat sources, — for the same reason, never unscrew the
as the increase of internal pressure due to heating compressor oil level plug when the system is
could cause the container to explode. charged.
— do not heat the refrigerant container. Above 50°C

In contact with a naked flame or hot metal surfaces
(122°F) the pressure increases very rapidly.
the refrigerant may give off a toxic gas. If inhaled this
gas can cause serious harm.
— keep the air conditioning system away from heat
sources to prevent possible explosion due to the
increase of pressure in the system.
To avoid the possibility of accidents take the simple
precautions described below.
When transferring refrigerant from one container to

The operation of emptying the system must be
another, only use homologated liquid refrigerant
carried out in a w ell-ventilated area, well away from
containers equipped with safety valves.
any naked flames.
During the charging and emptying operations, take

Never fill liquid refrigerant containers over 80% of
the necessary precautions to protect the face and
their maximum capacity.
above all the eyes from accidental contact with
refrigerant.
Do not modify the settings of safety valves and the

In case of accident, proceed as follows:
control devices.
— if has entered the eyes, wash immediately with

a few drops of mineral oil, then wash them
thoroughly with a solution of boric acid and water Never connect the recovery/recycling and
(one spoonful of acid in 1/4 cup of water) and evacuation/charging stations to electrical power
seek medical assistance immediately. outlets with voltages other tan those specified; do not
leave the stations powered on unless they are to be
used immediately.
CAB AIR CONDITIONING SYSTEM CHARACTERISTICS
SANDEN SD 7H15 Compressor
Number of c y lin d e rs .................. 7
Total displacement .................. ............................................................ cm3(in.3) 155 (9.46)
Maximum speed ...................... ...................................................................... rpm 6000
Weight ........................................ .................................................................. kg (lb) 6,5 (14.33)
Quantity of lubricating oil ........ ............................................................ cm3(in.3) 185 (11.29)
Type of lubricating oil (code) PAG SP 20
A ir conditioning system Gas HFC134a
Quantity o f H FC -134a re frig e ra n t............................................ gr (lb) 1600 (3.5274)
System delivery side p re s s u re .............................................. bar (psi) 16-24 (232.06 - 348.09)
System suction side pressure .............................................. bar (psi) 0 ,5-3 (7.25-43.51)
Pressure switch setting (high pressure) .............................. bar (psi) 25 (362.59)
Pressure switch setting (high pressure) .............................. bar (psi) 2 (29.01)
Temperature of refrigerant fluid at outlet o f compressor . . . . oC(oF) 6 0-120 (140-248)
Temperature of refrigerant fluid at outlet of condenser oC(oF) 4 0 -6 0 (104-140)
Temperature of refrigerant fluid at outlet of evaporator oC(oF) 0 -1 5 (32-59)
Maximum capacity of electric centrifugal fan I, II, III speed . m3/min 3,5-8,5
.....................................................................................................(in.3/min) (21.36-51.87)
Remember that altitude affects pressure, as shown Altitude Absolute atmospheric Correction
in the table on the right. (m) pressure (psi) (psi)
To obtain the effective pressure in the system,
s.l.m.
subtract the corresponding correction value from the
pressure gauge reading. 0 14.63 0
300 14.13 - 0.50
600 13.64 - 1.00
900 13.14 - 1.49
1200 12.64 - 2.00
1500 12.14 - 2.50
1800 11.64 - 3.00
2100 11.25 - 3.39
2400 10.85 - 3.82

TOOLS REQUIRED FOR SERVICING THE AIR CONDITIONING SYSTEM
Warning - The operations described in this section cannot be carried out without the ESSENTIAL tools marked
(X) in the following list.
To work in safety and to obtain the best possible results whilst saving both time and energy, we recommend that
the other specific tools in the list are also used.
List of specific tools for the various operations in this section
X 294030 Evacuation and charging station
X 294048 Recovery and recycling station
294044 Set of flexible hoses for 294030 and 294048
294043 Tool kit for 294030
294042 Receiver-drier for 294048
294036 Gas leak detector with audible leak indication
293826 Athermal tape for expansion valve
X 293831 Combs for cleaning and straightening the fins on the condenser
and evaporator
293825 Oil for pumps of stations 294030 and 294048

OPERATING PRINCIPLES As regards the purity of the air, there are no precise
limits, but it is important to remember that the human
The function of the air conditioning system is to
metabolism alters the composition of the
create and maintain optimum working conditions
surrounding air, increasing the humidity and the
inside the tractor cab.
quantity of carbon dioxide, while decreasing the
percentage of oxygen, etc..
These conditions regard four main factors:
— temperature; By drawing in small quantities of fresh air from
— humidity; outside the cab, it is possible to eliminate impurities
— speed; in the air, particularly important in the case of
— purity of the air in the cab. agricultural tractors, where dust from earth, hay etc.
can cause extreme discomfort, by installing dry
filters on the external air inlets.
Obviously ”ideal” conditions will vary from person to
person, and so it is not possible to specify optimum
values for the above factors; however, we can Air conditioning systems in tractors and agricultural
specify a range of values within which the majority of vehicles in general thus serves to neutralise the heat
people will feel most comfortable. and humidity generated in the cab by controlling the
temperature and humidity of the air in - o r drawn into-
the cab to create comfortable working conditions for
As regards temperature and humidity, it is possible
the operator.
to define a zone, known as the ’’comfort zone”, within
which the tem perature-hum idity combination
corresponds to pleasant environmental conditions. The operating principle of an air conditioner is similar
to that of a domestic refrigerator: to cool an
environment, heat must be removed by means of a
From the diagram it can be seen that humidity should
physical process (evaporation of a liquid) which
be within the range of 30% to 70% (below 30% there
absorbs heat from the surrounding air.
is excessive dehydration of the mucous tissues of
the nose and throat, while above 70% the subject has
an uncomfortable sensation of dampness in many The liquid used in this process, known as the refriger
areas of the body) whereas temperature can vary ant, is product with a high refrigeration coefficient,
between 18 and 28°C ( 64.4 and 82.4°F). low toxicity, which mixes well with lubricating oil.
The air flow speed must not be so high as to cause The various components of the system are
discomfort; speeds of 0.07 - 0.25 m/s connected by suitable pipes which ensure that the
(0.2296 - 0.8200 ft/s) are normally acceptable pressure of the system is maintained.
Simplified psychrometric diagram

1. Sensation of unbearable cold.
2. Sensation of cold.
3. Comfort zone.
4. Sensation of heat.
5. Sensation of unbearable heat.
1
There are five main components of the air (depending on the ambient temperature) which thus
conditioning system: changes its state from a vapour to a liquid.
1. compressor;
2. condenser; The refrigerant, in liquid state at high pressure, is
purified by passing through the receiver-drier (3)
3. receiver-drier;
from where it flows to the expansion valve (4), which
4. expansion valve; restricts the flow of refrigerant and thus reduces its
5. evaporator. pressure.
To understand the operating cycle of the system, As it passes through the expansion valve (4), part of
follow the flow of the refrigerant starting from the the refrigerant is transformed into vapour and the low
compressor (1). temperature mixture of vapour and liquid thus
formed enters the evaporator (5).
The compressor draws in refrigerant in vapour form

at a pressure of 0.5 +- 3 bar (7.25 + 43.51 psi) and it Here the electric fan causes a continuous circulation
compresses it to a pressure of 16 +- 24 bar of the cab air over the fins of the evaporator (5),
(232.06 + 348.09 psi). helping the refrigerant to absorb heat from the air and
thus change completely from a liquid to vapour.
The refrigerant, heated by compression to hot

The evaporation process removes heat from the air
vapour with a temperature of 60^120 °C
passing over the evaporator (5) and thus reduces
(140^248 °F), enters the condenser coil (2) located
the temperature inside the cab.
forward of the engine radiator.
The flow of air over the cold surface of the evaporator

The air flow passing over the condenser fins and (5) also condenses some of the moisture in the air
tubes produced by the forward movement of the and therefore reduces the humidity in the cab.
tractor cools the refrigerant.
On leaving the evaporator (5) at 0^15 °C (32^59 °F),

This action cools the refrigerant to the point of the low pressure mixture is aspirated by the com
condensation between 40^60 °C (104^140 °F) pressor (1) to repeat the cycle.
2
Simplified system diagram
1. Compressor. 4. Expansion valve with thermostatic sensor.
2. Condenser. 5. Evaporator.
3. Receiver-drier.
AIR CONDITIONING SYSTEM FAULT DIAGNOSIS
THE SYSTEM DOES NOT W ORK
1. Check fuses.
2. Check compressor drive belt
tension.
3. Check if the clutch coil is
receiving power.
4. Check that the earth contact is
efficient.
5. Check the system control

devices - the relays, wiring,
thermostat, etc.
6. Visually check the condition of
all fittings, unions and pipes.
7. Check the clearance between
the front disc and pulley of the
electrom agnetic clutch..
Schematic of air conditioning system.
1. Compressor. 6. Receiver-drier.
2. Compressor inletpipe (low pressure). 7. Sight glass.
3. Compressor outlet pipe (high pressure). 8. Expansion valve with thermostatic sensor.
4. Hot air. 9. Evaporator.
5. Condenser. 10. Cool, dehumidified air.
A IR CONDITIONING SYSTEM FAULT DIAGNOSIS (cont.)



CAB HEATING AND VENTILATION CONTROLS

VENTILATION
Turn on cab ventilation by operating switch (2) fig. 4
and direct the air flow as required by positioning the
front vents (3, fig. 5).
The operator may select outside air or inside air by

adjusting the rear air recirculation vents (1, fig. 6)
which can assume two positions.
— vents closed: air is drawn from outside the cab
through the lateral filters.
— vents open: the greater part of the air is drawn TRE0024A
from inside the air through the vents.

4
Fresh air drawn into the cab from outside is always
filtered.
With the fan in operation, and the doors, windows

and recirculation vents closed, the pressure inside
the cab is greater than the external pressure and thus
air can only enter the cab through the lateral filters
after it has been suitably filtered.
Note - To increase the pressure inside the cab,

select outside air only
(air recirculation vents 1, fig. 6 closed).
Fan
The fan control switch (1, fig. 7) is powered when
the ignition switch (fig. 8) is in position B .
A. Low speed.
B. Medium speed.
C. High speed.
TRE0025A
A ir filter
6
----------- A DANGER A -----------

Remember that the filters of the cab provide no
protection against antiparasitic chemicals in general.
Therefore complete protection against these
products can only be achieved by the adoption of
additional specific safety measures for the individual
product. This applies to all types of filter, for which the
prescriptions for use and maintenance must be
followed scrupulously.Even the use of active carbon
filters does not exempt the operator from adopting
the personal safety precautions recommended for TRE0024A
the product in question.
7
HEATING
The heating control knob (1, fig. 4) allows the

operator to regulate the temperature of the air by
increasing or decreasing the circulation of coolant
from the engine.
The fan control switch (1, fig 7) allows the operator

to adjust the quantity of air blown into the cab through
the vents (3, fig 5)
Temperature control knob (1)
— Turned fully counter-clockwise = minimum

temperature (circulation of hot water shut off).
— Turned fully clockwise = maximum temperature

(circulation o f hot w ater fully open).
Note - The total capacity of the cooling system

(‘ including the cab heating system) is 14 litres in the
JX60 model or 16 litres in JX70, JX80, JX90 and
JX95 models.
IGNITION SWITCH
The ignition switch (1) can assume four different

positions:
A. No circuits powered (key can be removed).

Engine stop:automatic operation of fuel injection
sh u t-o ff device.
B. Predisposition for engine starting. Turn signals

and instruments operational. Various devices
powered.
C. Start engine: key returns automatically to

position (B) when released.
P. Parking lights on, control panel illuminated,

auxiliary lights switch powered (key can be
removed).
TRE0012A
CAB AIR CONDITIONING CONTROLS
SWITCHING ON THE AIR CONDITIONING

AND TEMPERATURE CONTROL
A ir conditioning and temperature control

button.
Operational when ignition switch is in the starting

position.
With fan control knob (1, fig 9) in positions A -B or C,
turn knob (2, fig 9) to switch on the air conditioning.
Heating control knob (fig 4)
Turn the knob (1) fully clockwise for maximum

heating.
Turn knob (1) fully counter-clockwise to shut off the
flow of water to the heater and thus switch the
heating off.
3-speed fan control knob
Operational when ignition switch is in starting

position.
A. Low speed .
B. Medium speed.
C. High speed.
Note - To pressurise the cab see the chapter

Ventilation on page 11 o f this section.
USE OF THE AIR CONDITIONING SYSTEM
The air conditioning system provides cool, To lower the temperature and, at the same time, the
dehumidified air or warm dehumidified air. humidity of the air inside the cab, turn knob (2, fig. 9)
counter-clockwise until the desired temperature is
To operate the system proceed as follows.
obtained.
Warning - Before starting the engine, check that the

Warning - The air conditioning system is not
air conditioning knob (2 fig. 9) is in the ”off” position.
operational when the engine is not running as the
compressor is driven by the engine.
Note -W hen working in very dusty conditions, to

increase the pressure inside the cab to prevent dust
SWITCHING ON THE AIR CONDITIONING entering, it is advisable to close the recirculation
With the engine running, turn knob (2, fig. 9) to start vents.
the air conditioning.
If you wish to use the dehumidifying function without

Warning - Before switching on the conditioner, lowering the air temperature, turn knob (2, fig. 9)
always switch on the fan. clockwise to obtain the desired temperature.
When the fan control knob is in the ”off” position, the
air conditioning cannot function.
After prolonged operation in hot sunshine, to bring
the air inside the cab back to the optimum
After a few minutes of operation, liquid visible in the temperature, without the tractor moving switch on
sight glass (7, fig. 3) on top of the filter should be clear the air conditioner and open the rear window or hatch
and free of bubbles. If not, consult the specialised to discharge the hot air.
personnel at your dealer.
ADJUSTMENT SWITCHING OFF THE AIR CONDITIONING

SYSTEM
To obtain correct cab air conditioning, when the
system is in operation keep the recirculation vents Before stopping the engine, always switch off the air
open and keep the doors, hatch and rear window conditioner by turning knob (2, fig. 9), then turn the
closed. fan control knob (1, fig. 9) to the ”off ” position.
MAIN COMPONENTS OF THE AIR

CONDITIONING SYSTEM
Axial flow reciprocating piston com pressor

SANDEN SD 7H15
1. Combined inlet and discharge valve.
2. Piston with seal ring.
3. Drive gear.
4. Swash-plate.
5. Cam rotor.
10
Compressor
The compressor serves to pressurise the refrigerant

and force it through the system.
SANDEN SD 7H15
Axial reciprocating piston type, driven from the

engine crankshaft via a v-belt.
The operating principle of the compressor is as

follows:
The swashplate (4), on which pivot the ball ends of

the connecting rods of the pistons (2), rests on the
cam rotor (5).
As the cam rotor rotates it exerts a continuous thrust

on the swashplate which cannot rotate as it is held by
the fixed gear (3).
The angle of the swashplate relative to the axis of

rotation causes the pistons to reciprocate in their
bores.
A reed valve (1) in the cylinder head with seven lobes

(one for each piston) controls the inlet and discharge
stages of the cylinders.
The automatic opening and closing of these valves is

obtained by preloading of the reeds.
The rotating parts of the compressor are lubricated

by special oil, inserted during assembly, some of
which circulates through the system mixed with the
refrigerant.
Condenser
In the condenser the refrigerant is transformed from

a vapour to a liquid state.
As this occurs by transfer of the heat from the

refrigerant to the ambient air, the condenser
functions in a similar way to the engine radiator.
The condenser consists of a series of tubes through

which the refrigerant circulates and a finned block
which is pressed onto the tubes to covers them
completely in thin aluminium fins to help dissipate
heat to the ambient air.
The condenser is installed in front of the engine

cooling radiator so as to benefit from the air flow
caused by forward motion of the tractor.
R eceiver-drier
The receiver-drier, installed between the condenser

and the expansion valve, performs two basic
functions, acting as a filter to remove dirt and
moisture from the refrigerant and as a temporary
storage container during variable charge stages.
W ater in the system can cause corrosion and

damage to system components.
For this reason the filter contains substances to

absorb humidity.
Solid contaminants, such as sand, metal particles

resulting from wear of compressor components,
oxides, particles from the pipes, etc., can cause
damage to the system and therefore must be
removed by suitable filters.
R eceiver-drier
1. Sight glass.
2. Upper screen.
3. Disc.
4. Drying agent.
5. Lower screen.
11
Thermostatic expansion valve
Serves to reduce the pressure of the refrigerant as it

enters the evaporator so that it can change state and
thus remove heat from the surrounding air.
The expansion valve performs two basic functions:
— metering: the calibrated orifice (6, fig. 12) in the

valve body creates a difference in the pressure of
the refrigerant at the inlet (4) (liquid state) and the
outlet (7) (mixed liquid/vapour); the calibrated
orifice (6) also serves to atomise the refrigerant
to facilitate subsequent evaporation;
— modulation: inside the valve body a thermostatic
sensor controls the valve aperture so that the
right quantity of refrigerant enters the evaporator
to ensure complete evaporation.
If the thermostatic sensor (2, fig. 12) detects an

increase in the cab temperature, the flow of
refrigerant is increased.
A drop in the temperature or an increase in the

compressor capacity (due to an increase in the
engine speed) w ill cause a reduction in the flow of
refrigerant into the evaporator.
The expansion valve is installed on the evaporator

inlet fitting (7), and as the internal refrigerant flow
control system is completely automatic, it requires no
special maintenance.
To perform functional testing, with the system is fully

charged, check that the system operating pressures
are those indicated on page 3.
Note - In case of malfunction, replace the valve.
Expansion valve block.

1. From evaporator outlet.
2. Thermostatic sensor.
3. To compressor suction inlet.
4. From receiver-drier.
5. Spring.
6. Calibrated orifice and ball.
7. To evaporator inlet.
12
Thermostatic switch (ANTIFROST)
The thermostatic switch is a safety device equipped

with a sensor (1) which is inserted between the fins of
the evaporator (2) where it constantly monitors the
temperature.
13
The bulb of the sensor (1) is filled with a special gas

which expands or contracts according to the
temperature and thus acts on a membrane
connected to a complex mechanism which opens or
closes a switch in the electrical circuit of the magnetic
clutch to switch the compressor on or off as required.
The thermostatic sensor (1) thus prevents ice

from forming on the evaporator and obstructing
the flow of air into the cab.
For this reason it is very important to insert the

sensor (1) between the fins of the evaporator (2) as
shown in figure 13.
Note - In case of malfunction, replace the entire

therm ostatic switch.
Evaporator WARNINGS REGARDING SERVICING AND

REPAIR OF THE AIR CONDITIONING SYSTEM
The cycle is completed inside the evaporator.
Switching on the air conditioning system when the

ambient temperature is low can damage the
The refrigerant leaving the expansion valve is a low compressor. Only operate the air conditioner when
temperature, low pressure mixture of vapour and the engine is hot and the temperature inside the cab
liquid. is at least 20 °C (68 °F).
As it passes through the evaporator it absorbs heat When disassembling pipes, plug the ends with
from the ambient air, vaporises and, having plastic caps to prevent moisture and dust getting
performed its cooling function, is aspirated by the inside.
compressor as a vapour.
Handle the tube of the thermostatic sensor with great

The operation of the evaporator is controlled by the care to avoid damage which could prevent the entire
expansion valve which delivers the exact quantity of system from operating correctly.
refrigerant needed to produce the required air
conditioning effect.
When unscrewing pipe fittings and unions, always

use two spanners to avoid undue torsion.
The evaporator performs the opposite function to the
condenser, but its basic construction is the same, the
only differences being its overall dimensions and the
layout of the internal pipes.
Do not use engine oil of any type to lubricate the
system or the compressor.
The evaporator also performs another function:

dehumidification of the cab.
Do not leave the compressor oil container open.
Make sure that the cap is replaced and fully
tightened. The oil will absorb moisture, which is
The air passing over the evaporator contains a harmful to the system.
certain quantity of moisture, and this must be kept
within certain limits for operator comfort.
Do not transfer compressor oil from its original

container to another.
Part of the moisture condenses on the fins
evaporator and is thus removed from the air.
Do not add any substances to the refrigerant or

The centrifugal fan draws the ambient air through the compressor oil. Any additives might contain
fins of the evaporator (where it is cooled and elements incompatible with the refrigerant and thus
dehumidified) and into the cab. alter its characteristics.
The housing around the evaporator is equipped with

a condensate trap from which the condensate is Check that the thermostatic sensor is correctly
carried outside the vehicle through discharge tubes. inserted between the fins of the evaporator.
REFRIGERANT RECOVERY-RECYCLING AND 2 -w a y pressure gauge unit, with refrigerant flow

EVACUATION-CHARGING STATIONS indicator and pressure gauges (1 and 2) controlling
the pressure in the cylinder and at the inlet.
----------- A WARNING A -----------
Never under any circumstances use 294053, Humidity indicator (15) for checking the
recovery/recycling or evacuation/charging stations
decontaminated refrigerant.
designed for a different refrigerant than that used
in the system, as the different chemical
compositions of different types of refrigerant render
Low pressure switch for automatic cycling of the
them incompatible with each other.______________
compressor.
When connecting the stations to the system service Graduated container for the discharge of recovered
valves, always connect the low pressure blue pipes contaminated oil.
(11, fig. 15, or 17, fig. 16) to the service valve on the
suction side of the compressor (S-Suction), and the Switch (5) 1 -0 -2 for recovery and cylinder heating.
high pressure red pipes (12, fig. 15, or 15, fig. 16) to
the service valve on the discharge side of the Indicator lights.
compressor (D-Discharge).
294044 flexible service pipes (11, 12 and 16) with
Important: check the seals in the pipe
safety cocks.
connectors (11, 12, 16, fig. 15), or (15, 17, 24, fig.
16) and replace if faulty. (kit 294052) Recovery capacity: 200 grams/minute
Remember that the pipe fittings fitted with seals (0.4411 lb/minute).
are to be hand-tightened only without forcing,
Power supply: 220 V (50 Hz).
otherwise the seal will be damaged.
RECOVERY AND RECYCLING STATION (294048)

Maintenance
Description (Refer to figure 15)
The station is designed for the recovery and
Replacement of refrigerant decontamination
recycling of refrigerants used in the cab air filter (3)
conditioning systems.
The recovered refrigerant is first separated from the Refer to figure 15 and proceed as follows:
system oil by means of a process of vaporisation
which takes place in a suitable container.
Warning - Every 12 months or earlier if the humidity
In the filter section, the acidity is neutralised,
indicator (15) turns yellow and stays yellow
moisture is absorbed and solid particles are
throughout the recovery/recirculation stage, renew
screened out.
the filter (3).
The decontaminated refrigerant is then stored in the
metering cylinder.
6. Close all the valves including the yellow service

TECHNICAL CHARACTERISTICS valve (9) installed below the distillation cylinder
(4).
Recovery compressor equipped with oil level 7. If refrigerant is present in the circuit set
indicator, discharge valve and service connection. pushbutton (5) to position ”1” and carry out the
refrigerant recovery operation. The compressor
will stop automatically when the pressure gauge
294042 anti-acid decontaminating filter (3), with a (2) drops to -0 .3 bar (-4.35 psi).
high moisture absorption capacity.
8. Remove and replace the contaminated filter (3).
9. Carry out a normal evacuation operation for
Refrigerant/oil distillation cylinder (4) with heating
about 30 minutes using the evacuation/charging
element, automatic device for return of oil to the
system (294030) proceeding as follows:
recovery station compressor and automatic flow
connect the pipe (17, fig. 16) to the service valve
control valve for refrigerant entering the station.
(14, fig. 15), open the cock installed on the pipe
itself and cocks (4, 10 and 9, fig. 16).
Graduated cylinder (19) for recovered refrigerant, On completion of the evacuation operation, close
2.2 kg (4.8524 lb) capacity, with heater and a safety cocks (4, 10 and 9), the cock on the pipe (17) and
valve. disconnect pipe (17).
Check filter connections for leaks (3) 8. Record the operation on the appropriate service
report card.
Refer to figure 15 and proceed as follows:
10. To check for leaks at the connections of the

previously replaced filter (3) open the yellow
service cock (9) on the distillation cylinder (4).
EVACUATION/CHARGING STATION (294030)
11. Perform a brief recycling operation on the
refrigerant contained in the cylinder (19),
proceeding as described in the operations Description (Refer to figure 16)
18^21, on page 23 and check with a leak detector
for leaks at the connections of the new filter.
The station is designed for the evacuation and
12. Record the operation on the appropriate service subsequent charging of refrigerant in the cab air
report card. conditioning systems.
The system must first be evacuated to remove any

moisture and impurities.
Changing the com pressor oil in the
recovery/recycling station The new refrigerant from the external cylinder is
transferred to the graduated cylinder before being
Refer to figure 15 and proceed as follows: pumped into the air conditioning system.
Warning -T h e oil in the compressor of the Technical characteristics

recovery/recycling station should be replaced with
new oil (code 293825) every 12 months to maintain Double-acting, ballasted, rotary vacuum pump (21)
the station’s refrigerant treatm ent capacity and to in oil bath.
protect the compressor.
Charging cylinder (31) with maximum level indicator
and graduated scale for measurement of quantity of
refrigerant.
1. Open cock (13), and drain the oil into a container
to be disposed of in accordance with local 5 -w a y pressure gauge manifold with 2 pressure
regulations for waste oil disposal. gauges (5 and 6) and 1 vacuum meter.
2. Close cock (13).

294044 flexible service pipes (17, 15 and 24) with
3. Remove the caps from the service valves (14) on safety cocks:
the side of the compressor and (13) on the sight
glass.
Power supply: 220V (50 Hz).
4. Connect the service pipe of the evacuation
station (294030) to valve (14) and connect a
pick-up pipe from kit 294043to valve (13) on the
Maintenance
sight glass.
Check level and change oil in pump of
5. Perform the evacuation operation with the pump evacuation/charging station (periodic check)
in operation. The new oil can be aspirated from
an external container by means o f the pick-up Refer to figure 16 and proceed as follows:
pipe.
Periodically check the level and condition of the oil.
6. Once the compressor has been filled with correct
Drain off the old oil, if necessary, through plug (18).
quantity of oil (half-way up the sight glass) close
Old oil must be disposed of in accordance with local
valve (13), disconnect the pick-up pipe, and
regulations.).
replace the cap on service valve (13). Continue
the evacuation for approx. 30 minutes.
Remove cap (13) and fill the vacuum pump (21) with
7. On conclusion, close the cocks, switch off the new oil o f the type indicated by the pump
pump, disconnect the service pipe and replace manufacturer up to the half-w ay line on the sight
the cap on service valve (14). glass (14).
AIR CONDITIONING SYSTEM 7. Connect the blue service pipe (11) to the valve on
Dehydration, recharging and refrigeration check the suction (low pressure) side of the
(Op. 50 200 04) compressor (marked ”S”).
8. Connect the red service pipe (12) to the valve on

Recovery of refrigerant from the cab air the discharge (high pressure) side o f the
conditioning system using the compressor (marked ”D”).
recovery/recycling station 294048
9. Switch on the cab ventilation fan at maximum
Note - the recovery operation can be performed speed to assist the transfer of heat between the
more quickly and completely if the system is ambient air and the evaporator coil.
previously heated, as heat will cause the refrigerant
10. Open cock (10) on pipe (12).
to evaporate and thus be more easily evacuated
from the system. 11. Slowly open cock (6-LO W ) on the pressure
gauge manifold. Pressure gauge (2) will indicate
Refer to figure 15 and proceed as follows: the presence and pressure o f any refrigerant in
the system; if the needle is near the ”0”, the
1. If possible, operate the air conditioning system system is empty.
for a few minutes with the tractor engine running
and the hood down, so that the heat produced is 12. Set switch (5) to position ”1” (RECOVERY) -
gradually transferred to the various components green indicator light will illuminate. The recovery
in the system, thus allowing any pockets of very compressor will now start.
cold fluid in the system to evaporate.
During the recovery operation, the refrigerant will
2. Stop the engine. pass through the distillation cylinder (where it will
separated from the oil) and into the decontamination
----------- A DANGER ----------- filter (where it will partially cleaned of impurities) to
arrive finally in the graduated cylinder.
The recovery operation must only be performed
with the tractor engine stopped. The compressor will stop automatically when the
pressure gauge (2) indicates a pressure of -0 .3 bar
(-4.35 psi).
3. If the charging cylinder (19) already contains
refrigerant, check that there is still sufficient free 13. Wait a few minutes to allow any pockets of liquid
volume to contain all the refrigerant in the system refrigerant left in the system to evaporate and be
(maximum cylinder capacity is 2 kg (4.4112 lb)); evacuated.
if not, transfer the excess refrigerant to an exter
nal cylinder in the manner described on page 24. 14. Check the pressure gauge (2): if the pressure
has risen above the previous value of -0 .3 bar
4. Connect the station’s supply lead to a power
(-4.35 psi), the station will automatically start a
outlet.
second recovery operation; if on the contrary
5. Make sure that all cocks are closed except the the pressure has remained near the value
service cock (9). obtained during the first recovery operation, this
indicates that all the refrigerant has been re
moved from the system and therefore the opera
tion is complete.
Note - If after 10 minutes of operation the station has

not recovered more than 1 kg (2.2056 lb) of refriger
ant, check pressure gauge (1). If the pressure read
ing is over 10 bar (145 psi) open cock (21) and dis
charge air, then check that pressure gauge (1) does
not exceed a maximum of 10 bar (145 psi) through
out the entire recovery operation.
15. Close all the cocks except cock (9), disconnect

the service pipes (11 and 12) from the air
conditioning system compressor and switch off
6. Remove the caps from the service valves the station.
installed on the suction and discharge lines of the
compressor. 16. Switch off the cab ventilation fan.
Recycling recovered refrigerant 19. Connect the 2 ends of the yellow (16) and blue
(11) pipes with connector supplied.
On completion of the recovery operation, the 20. Slowly open the cock (18-R EF) and the blue
refrigerant, which has already been through an oil cock (6-LO W ) on the pressure gauge manifold,
separation process, must now be completely and the cocks on the two previously connected
decontaminated. service pipes (16 and 11).
----------- A WARNING A ----------- 21. Set switch (5)to position ” 1” (RECOVERY) -
At this stage the recovered refrigerant has not yet green indicator light on.
been completely decontaminated and therefore The recovery compressor will start to operate
must not be used in the air conditioning system in this and the refrigerant will pass from the graduated
condition.
cylinder to the recovery circuit (distillation
Proceed as follows: cylinder, filter and compressor) and then return
to the graduated cylinder.
17. All cocks must be closed, with the exception of
22. Continue the operation until the circular sector of
cock (9, fig. 15) and the station must be switched
the humidity indicator (15) turns green.
off - switch (5) in position ”0” and green indicator
If after 15 minutes the circular sector of indicator
light off.
(15) still has not turned green, replace the filter
18. Connect the end of the yellow service pipe (16) (3) as described on page 20.
without the cock to the free connector (17)
located on the left-hand side of the pressure
gauge manifold.
Refrigerant recovery and recycling station
1. Cylinder pressure gauge. 12. Red service pipe for connection to discharge
2. Recovery control pressure gauge. side of compressor.
3. A nti-acid and decontamination filter. 13. Recovered compressor oil discharge cock.
4. Recovered refrigerant/oil distillation cylinder. 14. Recovery compressor service valve (suction).
5. Switch. 15. Humidity indicator.
6. Refrigerant inlet control cock (LOW). 16. Yellow service pipe for refrigerant transfer.
7. Recovered oil discharge cock (yellow). 17. Fitting for refrigerant transfer.
8. Recoveered oil discharge pipe. 18. Cock (REF) for refrigerant transfer and
9. Oil return to compressor control cock (yellow). recycling.
10. Q uick-fit connectors. 19. Refrigerant cylinder.
11. Blue service pipe for connection to suction side 20. Safety valve.
of compressor. 21. Cylinder (gaseous stage) discharge cock
(yellow).
and connect the other end (with the cock) to the

Note - The circular sector of the humidity indicator red connector of the external cylinder.
(15, fig. 15) must remain green throughout the 29. Set switch (5) to position ”2” HEATING
recycling operation. CYLINDER to switch on the refrigerant heater
If the colour of the sector tends to vary between fitted to the cylinder (19) so as to facilitate the
yellow and green, or turns completely yellow, this transfer of the refrigerant from the cylinder to the
means that the filter is saturated with moisture and external cylinder.
therefore must be replaced.
30. Open the yellow cock (18-REF), the yellow cock
on the service pipe and red cock on the external
cylinder.
23. On completion of the decontamination operation,
close the yellow cock (18-R EF) and continue to 31. On completion of the transfer, close all cocks and
recover the refrigerant.The compressor will stop switch off the station by turning switch (5) to
automatically when .the pressure gauge (2) position 0.
shows a reading of -0 .3 bar (-4.35 psi).
Evacuation and charging the cab air
24. Close the cock (6-LO W ), the two cocks on the conditioning system using the evacuation/
ends of the yellow (16) and blue (11) service charging station 294030.
pipes, disconnect pipes (16 and 11) and switch
off the station, turning switch (5) to position ”0”.
Note - Operations 32 +- 34, must only be carried out

Discharge of recovered oil if the graduated cylinder (31) is empty of refrigerant.
The presence of contaminated recovered oil can be

seen in the distillation cylinder (4). The recovered oil
must always bee discharged and disposed of Evacuation of the graduated cylinder (31) of the
evacuation/charging station
according to local regulations.
Refer to figure 16 and proceed as follows:
Proceed as follows: 32. Close cocks (4, 22 and 27).
25. Slowly open the yellow cock (7) and discharge 33. Open cocks (3, 9 and 10).
the recovered oil in the graduated container. 34. Start the pump by turning switch (19) to position
“1” to evacuate the cylinder (31). After 5 minutes
26. If no refrigerant leaks, w hether major or minor,
close cocks (3, 9 and 10) and switch off the
have ever been detected in the system, on
pump.
recharging, replace the contaminated oil with
same quantity o f new oil (see page 26).
Charging the graduated cylinder (31) of the
Transfer of decontaminated refrigerant from evacuation/charging station
cylinder (10) to an external cylinder
If the decontaminated refrigerant in the
If for any reason the decontaminated refrigerant is recovery/recycling station is to put back into the
not to be put back into the air conditioning system tractor air conditioning system immediately, it must
immediately, for reasons o f safety it must be be transferred from cylinder (19, fig. 15) to cylinder
transferred from cylinder (19) to a homologated (31, fig. 16) of the evacuation/charging station,
refillable gas container. proceeding as follows:
35. With reference to figure 16, connect the end

Proceed as follows: (without cock) of the yellow service pipe (24) to
the free connector (28) on the left-hand side of
the pressure gauge manifold of the evacuation/
27. Check that all the cocks are closed with the
charging station..
exception of cock (9) and that the station is
switched off. Check that the container (cylinder) 36. Connect the other end (with cock) of the service
is large enough to contain all the refrigerant to be pipe to the free connector (17, fig. 15) on the
transferred without exceeding the permitted left-hand side of the pressure gauge manifold of
safety level. the recovery/recycling station.
37. With reference to figure 15, check that all the
28. Connect the end o f the yellow service pipe (16) cocks of the recover/recycling station are closed
without the cock to the free connector on the with the exception of cocks (9 and 18) and that
left-hand side o f the pressure gauge manifold, on the pipe (16).
38. Check that all the cocks of the 42. Check the quantity of refrigerant in the graduated
evacuation/charging station are closed, with the cylinder (31).
exception of cock (27). 43. From the total quantity of refrigerant required in
39. Check that the stations are switched off with the air conditioning system indicated in the note
switches (5 and 19) in position ”0” . on page 26, calculate the quantity of refrigerant
that must be added to the cylinder (31) to make
40. With reference to figure 15, turn switch (5) to up the total amount required.
position ”2” HEATING CYLINDER to switch on
44. Transfer refrigerant from the external cylinder to
the refrigerant heater installed on cylinder (19),
the graduated cylinder (31) proceeding as
to facilitate the transfer of refrigerant to cylinder
follows.
(31) of the evacuation/charging station.
45. Connect the yellow pipe (24) to connector (28)
41. On completion of the refrigerant transfer and to the external cylinder containing the
operation, close all the cocks with the exception refrigerant (upside down if not equipped outlet
of cock (9, fig. 15) and switch off the valve).
recovery/recycling station by turning the switch 46. Open the cock on the external cylinder, the cock
(5)to position ”0” . on the charging pipe (24) and cock (27).
16
Evacuation/charging station.
1. Safety valve. 17. Blue service pipe for connection to suction side
2. Cylinder pressure gauge. of compressor.
3. Refrigerant charging cock. 18. Oil drain plug.
4. Low pressure side cock (LOW). 19. On/Off switch (I), heater (II).
5. Low pressure gauge. 20. Oil meter connector.
6. High pressure gauge (red). 21. Vacuum pump.
7. % -w ay pressure gauge manifold. 22. High pressure side cock (HIGH).
8. Vacuum meter. 23. Sight glass.
9. Vacuum test cock (VAC). 24. Yellow service pipe.
10. Vacuum meter test cock. 25. Cylinder heater.
11. Vacuum meter safety valve. 26. External ring.
12. Oil charging cock. 27. Refrigerant transfer cock (REF).
13. Oil filler cap. 28. Refrigerant transfer connector.
14. Sight glass. 29. Glass rod.
15. Red service pipe for connection to discharge 30. Outer casing (Plexiglas).
side of compressor. 31. Refrigerant charging cylinder.
16. Q uick-fit cocks.
47. Rotate the outer casing (30) so that pressure Refer to figure 16 and proceed as follows:
value indicated on the graduated scale
corresponds with the value shown on pressure 56. Pour the oil into the graduated oil meter of kit
gauge (2). 294043.
48. When the refrigerant in the cylinder has reached 57. Connect the oil meter to the oil meter (20).
the required level, as indicated on the glass rod
(29), close the cock of the external cylinder, the 58. Close cocks (4 and 10).
cock on the charging pipe (24) and cock (27).
59. Set switch (19) to position ”2” to switch on the
refrigerant heater on cylinder (31).
Note - If excessive time is required to transfer 60. Open cock (12) and the cock on the graduated
refrigerant from the external cylinder to cylinder (31), oil meter.
slightly open valve (1) and discharge air from the
61. Check the quantity of oil flowing from the oil
cylinder (31); the pressure reading on gauge (2) meter, and once the required quantity has been
should not exceed 5 bar. reached, close cocks (12) and the cock on the oil
meter, and remove the graduated meter.
Evacuation of the cab air conditioning system

(previously discharged using the recovery/recycling Charging the cab air conditioning system with
station) refrigerant (after evacuation)
49. Remove the caps from the service valves on the

suction and discharge lines of the compressor.
Note - The quantity of refrigerant to be put into the
Refer to figure 16 and proceed as follows: system is 1600 grams (3.5274 lb)
(refrigerant R134a).
50. Connect the blue service pipe (17) to the valve on
the low pressure side of the compressor marked
“ S ”. Refer to figure 16 and proceed as follows:
51. Connect the red service pipe (15) to the valve on 62. Keep switch (19) in position 2, with the refrigerant
the high pressure side of the compressor marked heater in cylinder (31) on, and heat the
“ D ”. refrigerant for approx. 10 ^ 15 minutes to
facilitate transfer from the cylinder to the air
52. Open the quick-fit cocks (16). conditioning system on the tractor.
53. Open cocks (4 - 9 - 10 - 22). 63. According to the refrigerant type, rotate the outer
casing (30) so that the graduated scale and the
54. Start the pump by turning switch (19) to position pressure values correspond with the pressure
“I” and evacuate the system for at least thirty reading on gauge (2).
minutes; pressure gauges (5 - 6 - 8) should
show a negative reading. If the evacuation 64. Move the external ring (26) along the cylinder
procedure dose not function correctly, check all glass to mark the quantity of refrigerant to be
connections. charged.
55. Close cock (9), switch off the pump by turning 65. Open cock (22) and charge from the high
switch (19) to position ”0” and check the vacuum pressure side.
seal for at least five minutes using vacuum meter
(8). This done, close all cocks. 66. Open cock (3), charge approx. 300 grams
(0.6617 lb) of refrigerant, close cock (3) and
check for leaks.
Charging the cab air conditioning system (after
evacuation) with new oil 67. If there are no leaks, continue charging up to the
prescribed quantity.
If no refrigerant leaks, whether major or minor, have
68. On completion of charging, turn switch (19) back
ever been found in the system, on recharging,
to position ”0”, close cocks (3 and 22),
replace the contaminated oil previously recovered in
disconnect pipes (17 and 15), and replace the
operations (25 and 26, page 24) with the same
caps on the service valves.
quantity of new oil. If, on the contrary, significant
leaks have occurred in the past, proceed with the Carry out functional tests with the system set to
compressor oil level check procedure. maximum performance levels, as described below.
FUNCTION TESTING OF CAB AIR

CONDITIONING SYSTEM
(Op. 50 200 03)
With the pressure gauges connected to the system in

the manner described previously and the cocks
closed, proceed as follows:
1. Start the engine and bring it up to a speed of 1500

rpm.
2. Set the cab ventilation fan (1, fig. 9) to the
maximum speed.
17
3. Turn knob (2, fig. 9) to switch on the air
conditioning.
After about 15 minutes of operation, take the

following readings:
4. Pressure on suction side of compressor as

indicated by low pressure gauge. 10. Check that the compressor does not make
undue noise; there should be an audible click
when the drive is engaged..
5. Pressure on discharge side of compressor, as
indicated on high pressure gauge.
The sight glass on the receiver-drier can provide
6. Ambient air temperature. useful information about system operation.
The four main possible conditions of the sight glass

7. Ambient relative humidity.
are shown in figure 17.
8. Temperature of air leaving vents inside the cab.

A. Glass clear: indicates that the system is correctly
charged, or that there is no refrigerant in the system
The pressure values will depend on the external ( in the latter case the cooling action of the evaporator
ambient conditions and the altitude. would be absent). In some cases, the glass may be
clear when the system has been charged with an
excessive quantity of refrigerant; in this case it would
The system is to be considered as functioning be necessary to check the pressure readings.
correctly if the pressure readings are within the value
ranges indicated on page 3, and the temperature
readings are within the value ranges indicated on B. Bubbles: the formation of vapour or foam
page 29. bubbles indicates that the system contains an
insufficient quantity of refrigerant or the presence of
air in the system; bubbles may also be seen on
9. Check also the temperature of the low and high switching on the system and on disengagement of
pressure sides of the system: the electromagnetic clutch.
— the high pressure side, from the compressor
discharge to the expansion valve on the
C. Threads of oil: indicates a lack of refrigerant and
evaporator, should be uniformly hot to the touch;
that the compressor oil is circulating the system.
— the low pressure side, from the evaporator outlet
to the suction side of the compressor, should be
uniformly cold to the touch. There should not be D. Fluid appearance not uniform, streaky:
excessive condensation on the suction pipe and indicates that the drying agent in the filter has
the low pressure pipe connector on the escaped, as a result of the containment discs
compressor. breaking,, and is circulating in the system.
SUMMARY OF THE AIR CONDITIONING

SYSTEM CHARGING OPERATIONS
Note - The pressure readings reported below are

valid for an ambient temperature of 25 °C (77 °F).
— Pressure gauge readings on completion of

refrigerant recovery and recycling operation.
— pressure gauge readings with cocks (4 - 10 - 22

and 9, fig. 16 page 25) open, cylinder (31) with
2000 gr (4.4112 lb) of refrigerant, red and blue
service pipes connected to tractor system, cocks
(16) closed and compressor off.
19
— Pressure gauge readings with cocks (4 - 10 - 22
and 9, fig. 16) open, cylinder (31) with 2000 gr of
refrigerant, red and blue service pipes connected
to tractor system, cocks (16) open and
compressor on (initial evacuation stage).
— Pressure gauge readings with cocks (4 - 10 - 22

and 9, fig. 16) open, cylinder (31) with 2000 gr
(4.4112 lb) of refrigerant, red and blue service
pipes connected to tractor system, cocks (16)
open and compressor on (final stage of evacua
tion after 30 minutes).
21
— Pressure gauge readings with cocks (4 - 10 - 22,

fig. 16) open, cylinder (31) with 2000 gr
(4.4112 lb) of refrigerant, red and blue service
pipes connected to tractor system, cocks (16)
open, compressor off and cock (9) closed (check
on vacuum meter that no pressure drops occur
over a period of 5 minutes).
22
— Pressure gauge readings (start of charging - end

of charging). All previously opened cocks are to
be closed, with the exception of (4 and 3, fig. 16),
compressor off. The level of refrigerant in the
charging cylinder can be seen to drop; proceed
until only 600 gr o f refrigerant remain in the
charging cylinder (1400 transferred). The
reading of vacuum meter (8) remains the same
from the beginning to the end of the charging
operation.
23
Checking the temperature of the air coming out external ambient air temperatures specified, the
of the vents inside the cab. system is functioning efficiently.
If the temperature of the air at the vents exceeds the

If the temperature of the air measured at the vents is maximum value indicated in the table, refer to the
within the value range indicated in the table for the fault diagnosis guide in the following pages.
AIR CONDITIONING SYSTEM OPERATING TEMPERATURE VARIATIONS
External ambient temperature 20 °C 27 °C 28 °C 35 °C 36 °C 43 °C

(68 (80.6 (82.4 (95 (96.8 (109.
°F) °F) °F) °F) °F) 4 °F)
Temperature of air at vent outlets 4 - 8 °C 6 - 12 °C 12 - 20 °C

(inside cab) (39.2-46.4 °F) (42.8-53.6 °F) (53.6-68 °F)
CHECKING FOR REFRIGERANT LEAKS

USING AN ELECTRONIC LEAK DETECTOR
Leak detector (294036)

The leak detector 294036 is supplied in its own
carrying case which also contains the two power
supply batteries, the sensitivity test phial and an ear
plug connection for audible leak indication.
The instrument consists of a hand-held unit with a
flexible probe which houses the sensing tip.
To orient the flexible probe, first slacken off the lock
ring on the lower left-hand corner of the case.
The front of case mounts the sliding on/off switch, the
red indicator led, and the audible leak indicator.
The rear of the case mounts the ear plug connection
socket.The battery compartment also houses a Maintenance
sensing tip and a number of spare felt pads.
Use Always make sure that the instrument is switched off

before replacing the sensing tip. To remove the tip,
Switch the unit ON: start looking for leaks; the
unscrew it in a counter-clockwise direction. Fit a new
frequency and the amplitude of the audible signal will
tip and a new felt pad, screwing them in a clockwise
increase if gas is detected.
direction onto the flexible probe.
In areas affected by gas leaks, switch the instrument
on and off; the detector will automatically select a
Do not switch on the instrument unless the sensing
new acoustic level.. Perform this test each time the
tip is firmly screwed on to the end of the flexible
instrument is to be used.
probe.
Hold the sensing tip near the open phial to test
sensitivity; when the instruments starts to emit a
On fitting the tip, check that there is no grease or dirt
signal, switch it on and then off.
in the connecting hole between the probe and the tip.
Refrigerant leak test
In this stage the instrument automatically regulates
its sensitivity in accordance with the presence of gas
in the environment around the sensing tip, and the
test is performed solely by means o f the on/off
switch.
In ventilated areas, it can be extremely difficult to

trace a large leak due to the rapid dispersion of gas
from the source; in this case, place screens around
the suspected source to enable more precise
localisation of the leak.
In cases where large leaks obscure the presence of

smaller leaks, locate and repair the large leaks first,
and then locate the small leaks.
25
Leak detector probe

1. Flexible probe.
2. Sensing tip.
3. Felt pad.
4. Cover.
AIR CONDITIONING SYSTEM AIR CONDITIONING SYSTEM FAULT

DIAGNOSIS SUMMARY
Testing for leaks with leak detector 294036 and

elimination of leaks (Op. 50 200 06) There are three main ways in which the system can
malfunction:
With the system charged and the pressure gauges

connected, proceed as follows: — the system does not work at all;
— the system does not provide sufficient cooling;

1. Start the engine. — the compressor operates irregularly.
Bearing in mind that insufficient cooling may also

2. Set the ventilation fan to maximum speed.
result from causes external to the air conditioning
system, generally a mechanical check and visual
3. Turn knob (2, fig. 9) to switch on the air inspection will provide useful information about the
conditioner. efficiency of the system.
4. Bring the engine up to a speed of approximately

1500 rpm. This information can then be completed by electrical
testing.
5. Switch on the electronic leak detector.
If at this stage the problem has still not been

identified, it will be necessary to carry out a more
6. Move the probe around all pipe connections and detailed search by analysing the pressure readings
all possible points of leakage: in the various parts of the system.
— The presence of refrigerant, and thus al leak, is

signalled by an increase in the frequency of the Visual inspection of components
audible signal.
These checks are to be carried out with the engine

stopped and with the heating and air conditioning
system switched off.
Not - Refrigerant is heavier than air, and so it is

— Check the compressor mountings and the
easier to detect below the leak rather than above it.
relative support, pulley alignment, belt tension..
— Look for visible signs of refrigerant leakage

(presence of oil on fittings).
— Look for visible leaks of liquid refrigerant.
7. If leaks are found in the pipe connections, tighten — Inspect the condition of the pipes, particularly
the fittings to eliminate them. those in contact with the engine, as well as pipe
fittings/connectors and hose clamps.
— Check that the evaporator, the heater matrix,
and the condenser are clean and remove any
foreign bodies.
Warning - If any of the system components requires — Check the condition and position of the
thermostatic sensor (fig. 13) in the evaporator.
replacement, it is always necessary to perform the
recovery, recycling and charging operations — Check that external air intakes are not blocked.
described on pages. 22 to 27.
— Check the condition of the condensate discharge
pipes.
MAINTENANCE OF THE AIR CONDITIONING

SYSTEM
Note -C a rry out the same checks on the
At the start of the season in which the system will be EVAPORATOR (9) and CONDENSER (5).
used, check that the system is functioning correctly
and efficiently efficiency.
If the system has been out of use and charged for a 3) RECEIVER-DRIER: the sight glass on the
prolonged period, oil may have flowed out of the receiver-drier can provide useful information
compressor to other parts of the system and regarding system operation; see page 27. Replace
consequently this oil must be returned to the the receiver-drier after the system has been
compressor. repaired on two occasions.
To do this, start the engine and run it at approximately
1500 rpm for about 10 minutes. 4) EXPANSION VALVE: does not require
Switch on the ventilation fan at maximum speed. maintenance; in the case of malfunction, check the
Turn control knob (2, fig. 9) to switch on the air valve and thermostatic sensor as described on
conditioning. pages 17 and 18 or refer to specialised personnel of
service network.
Check that the relative temperatures of the external
ambient air and the air flowing out of the vents inside If the temperature of the air at the vent outlets does
the cab correspond to the values indicated in the not conform to the indications given in the table on
table on page 29. page 29, proceed with the system fault diagnosis
If so, the system is operating efficiently, and a visual procedure outlined on page 31.
inspection of the main components will be sufficient:
1) COMPRESSOR: check the mountings, drive belt
tension and oil level.
Warning - Should one or more system components
2) CONDENSER: check mounting, and that the fins
require replacement, in all cases it will be necessary
are free from excessive deposits. Straighten any
to carry out the recovery, recycling and charging
bent fins using the special comb 293831.
operations described on pages 22 to 27.
26
Schematic of the air conditioning system.
1. Compressor. 6. Receiver-drier.
2. Suction line (low pressure). 7. Sight glass.
3. Discharge line (high pressure). 8. Expansion valve with thermostatic sensor.
4. Hot air. 9. Evaporator.
5. Condenser. 10. Cool, dehumidified air.
AIR CONDITIONING AND HEATING

PIPES
Replacement (Op. 50 200 04 - 50 206 56 -
50 206 5 1 - 50 206 66 - 50 200 40 - 50 200 60)
----------- A DANGER A -----------

When recovering refrigerant from the system adhere
to the safety rules on page 2.

2. Recover the refrigerant from the system using
the recovery/recycling station 294048 as
described on page 22.
3. Drain off approx. 3 litres (0.6599 gall. Imp.) of

coolant from the drain plug (1) on the engine
block.
27
4. Remove the 4 cab roof retaining bolts (1)
28
5. Remove the cab roof as shown in the figure 29
29
6. Remove plate fastening screws and take of the

plate (1)
30
7. Remove A/C assembly fastening screws (1).
8. Remove A/C inlet and outlet pipes (1).Remove

front retaining screws (2).
9. Remove heater pipe connections (1) and take off

the pipes.
33
10. Remove the bracket (1) that secures the pipe.
34
11. Remove all electric connectors and take off the
A/C assembly (1) completely.
36
13. To reassemble, clean all parts and proceed as follows:
— Refit A/C assembly completely and refit all electric connectors.
— Assembly the bracket that secures the heater pipe.
— Assembly the heater pipe connections refit the pipes.
— Refit A/C assembly inlet & outlet pipes.
— Refit A/C assembly fastening screws.
— Refit top cover plate.
— Assembly the cab roof.
— Refit the 4 cab roof retaining bolts.
— Pour the previously drained coolant back into the radiator.
— Reconnect the negative battery lead.
— Charge the air conditioning system with HFC 134 a refrigerant, using the evacuation/ charging station
294030 as described on page 24.
R ECEIVER-DRIER
Replacement (Op. 50 200 04 - 50 200 74)
------------ A DANGER A -------------

When recovering the refrigerant from the system
adhere to the safety instructions on page 2.

station 294048 as described on page 22.
2. Detach the exhaust pipe and raise the hood.
4. Disconnect the electrical connector (1) from the

receiver-drier.
37
5. Detach the flexible pipe (1) connecting the
condenser to the receiver-drier.
38
6. Detach the flexible pipe (1) connecting the
receiver-drier to the evaporator.
39
7. Remove the screw (1) securing the

receiver-drier band clamp.
41
To refit proceed as follows:

— Replace the receiver-drier in the support clamp.
— Reconnect the two flexible return and delivery
pipes. Connect the electrical connections on the
filter.
— Connect the negative battery lead.
— Evacuate the system then charge with HFC
134a refrigerant, using the evacuation/charging
station 294030,as described on page 24.
— Close the hood.
CONDENSER
Replacement (Op. 50 200 04 - 50 200 72)
----------- A DANGER A -----------

Recover the refrigerant from the system adhering to
the safety instructions on page 2.

the station 294048 as described on page 22.
3. Detach the flexible refrigerant delivery (1) and re
turn pipes (2) from the condenser.
4. Unscrew the wingnut (1) securing the

condenser.
24893
5. For tractors equipped with front mudguards,

remove the two screws (1) securing the top
bracket of the condenser (for tractors without
front mudguards turn the steering wheel to full
right-hand lock and withdraw the condenser
from the right-hand side of the tractor).
6. For tractors with front mudguards, remove the

condenser group (1) with the top bracket.
— Refit the condenser and the relative bracket, and
secure the condenser with the wingnut and the
bracket with the two retaining screws.
— Reconnect the two flexible pipes to the condenser.
— Evacuate the air conditioning system and charge
with HFC 134 a refrigerant, using the evacuation/
charging station 294030 as described on page 24.
— Close the hood.
45
COMPRESSOR
Rem oval-Refitting (Op. 50 200 04 - 50 200 26)
----------- A DANGER A -----------

Recover the refrigerant from the system adhering to
the safety instructions reported on page 2.

station 294048 as described on page 22.
2. Raise the hood.
4. Disconnect the flexible pipes (1) from the
compressor.
46
5. Remove the right-hand guard retaining screws (1)
47
6. Remove the two securing nuts (1) of the

compressor belt tensioner arm.
48
7. Disconnect the earth lead (1) from the
compressor.
49
8. Loosen the bolt (1) securing the compressor to

the engine and remove the drive belt from the
pulleys.
50
9. Remove the compressor bolt (1) and recover the
compressor.
— Refit the compressor, the support/belt tensioner
arm. Reconnect the earth lead..
— Refit the right-hand guard.
— Reconnect the two flexible pipes to the
compressor.
— Evacuate the air conditioning system and charge
with HFC 134a refrigerant, using the
evacuation/charging station 294030 as
described on page 24. 51
— Close the hood.
COMPRESSOR OIL - TYPE AND QUANTITY

The tractor is equipped with a SANDEN SD 7H15
compressor for refrigerant R134a.
The compressor is filled during assembly with
185cm3 (11.29in.3) of PAG SP 20 lubricating oil.
In case of top up or oil change only use this type of
oil.
It is not necessary to check the compressor oil level
unless the system develops significant gas leaks.
Warning - If the system develops significant leaks

of R134a refrigerant, there will also be a significant
loss of compressor oil PAG SP20. It will therefore be
necessary to check the compressor oil level, bearing
in mind that, on average, only 130 +- 135 cm3
(7.93 +- 8.24 in.3), of the total quantity of lubricating
oil (185 cm3 (11.29 in.3)) will be present in the com
pressor, as the remaining 50-55 cm3 (3.05-3.36 in3)
will be in circulation through the various system com
ponents. For problems of this type, we recommend
that you seek assistance from an authorised service
centre.
COMPRESSOR DRIVE BELT
Tension adjustment (Op. 50 200 10)
The tension and condition of the belt transmitting

drive from the engine to the compressor is
particularly important as regards the correct
operation of the air conditioning system.
This drive belt therefore requires careful attention as

follows:
1) Fit the belt correctly. 52
2) Check the tension.
3) Check the condition of the belt.

Periodic checking of drive belt
When checking the tension, also check the amount

of drive belt wear.
Fitting the com pressor drive belt The main problems are as follows:
a) Belt shiny : smooth sides may slip on pulleys.

When first fitted, the belt must not be forced, pulled
with a screwdriver, or rolled over the edge of the
b) Belt cracked : may break suddenly due to splits
pulley, as this would stretch the less deformable
on the inner surface caused by excessive
fabric in the belt thus causing subsequent breakage
flexure.
of the other fabrics.
When first fitted, the belt must more installed at a c) Worn sides : with the sides worn or the inner
greater tension than normal to compensate for initial surface cracked, the belt can break at any
stretching during the running-in period. The belt moment.
must therefore be checked again after 50 hours of
operation and adjusted to the normal tension.
d) Belt impregnated with grease : the belt will
This check is absolutely essential as if the belt is too wear more rapidly as the grease will cause
taut, in addition to damaging the pulley bearings, it softening of the internal part.
will cause premature fatigue of the reinforcement
fabrics and thus early deterioration of the belt.
Take the following action:
If on the contrary the belt is too slack, it will start to a) If the belt is too slack, tension it correctly; if the
slip and overheat, and it will therefore w ear out very belt is very hot, renew it.
quickly.
b) If cracking is deep, extending to half the
thickness of the belt, renew the belt.
c) Renew the belt.

Checking com pressor drive belt tension
d) If the belt is very hot.
Check the tension only when the belt is cool (at a

temperature below a 40 0C (104 0F)). If the belt squeaks when running, check the tension
and adjust if necessary. If the noise continues, renew
Check the tension by applying a load of 78-98 N the belt.
(17.6450-22.0562 lb) to the centre of the belt run in
dicated in the figure: the belt should deflect = 12-13 If the belt has been over-stretched and it is not
mm (0.0394-0.0426 ft). possible to tension it sufficiently, renew it.
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1 1
SECTION 55 - ELECTRICAL SYSTEM
Chapter 1 - INSTRUMENTS
CONTENTS
Description . Page
Analogue instruments Introduction . 1

Transmitter and switch 4
ANALOGUE INSTRUMENTS
INTRODUCTION
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The analogue instrument panel consists of four display sections:
1) Warning and indicator lights;
2) Fuel level gauge;
3) Proofmeter;
4) Engine coolant temperature gauge.
603.54.331.00 - 12 - 1996
2 SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 1
Condition Indicator
1- Left direction indicator Flashing (green)

2- Side ligts Fixed (green)
3- Main beam headlights Fixed (blue)
4- Water in fuel Fixed (red)
5- Air filter blocked Fixed (amber)
6- First trailer direction indicator Flashing (green)
7- Second trailer direction indicator Flashing (green)
8 -.Engine oil pressure low Fixed (amber)

9 - Battery charge low Fixed (red)
1 0 - Brake fluid level low Fixed (red)
11 - Hand brake on Fixed (red)
1 2 - Right direction indicator Flashing (green)
1 3 - Power take-off on Fixed (amber)
Fuel level gauge (Fig. 3).
This instrument shows the level of fuel in the tank.
When the tank is full, the hand moves completely to

the right.
When the tank is less than 1/4 full, the hand moves
into the red area.
603.54.331.00 - 12 - 1996
Proofmeter (Fig. 4).
Engine speed indicator and chronograph with a six

figure hourmeter. The figures on black background
count hours of work done and the figure on red
background (far right) shows tenths of an hour.
The green, blue and yellow sectors show the

engine speed at which optimum power ta ke -o ff
performance is achieved (respectively 540, 540E
and 1000 rev/min).
- Green symbol = power ta ke -o ff at 540 rev/min
- Blue symbol = power ta ke -o ff at 540E rev/min.
- Yellow symbol = power ta k e -o ff at 1000

rev/min.
Engine coolant temperature gauge (Fig. 5).
- Green area = normal temperature.
- White area = temperature too low.
- Red area = engine overheating.
TRE0075A
603.54.331.00 - 12 - 1996
TRANSMITTERS, SENSORS AND SWITCHES
A. MAIN FUSE BOX

The tractors fuses relays are housed under a plastic cover.
B. BATTERY
The tractors are fitted with maintenance-free batteries. Keep the top part clean and dry. Check that the level
of electrolyte reaches the top mark and never falls below the lower mark.
C. ALTERNATOR
This provides a square wave signal and recharges the battery. It also provides power required by electric
devices.
D. TRANSMISSION CLUTCH PEDAL SWITCH

This switch is activated when the clutch pedal is pressed and it prevents starting if the clutch pedal is not
lowered.
E. AIR CLEANER CLOGGED SENSOR

This is activated when the vacuum in the air operating system exceeds a pre-set value. It lights up the
warning light.
F. FUEL SEDIMENTER
Activated when w ater gets into the fuel filter and the relevant warning light comes on.
G. ENGINE OIL PRESSURE SWITCH

This is activated as soon as oil pressure in the engine drops less than 0.68 bar (9.86psi). It lights up the
warning light. This switch is usually closed.
H. FUEL TANK LEVEL TRANSMITTER

A signal from the transm itter potentiometer defines the level of fuel in the tank. The level is shown by the
gauge.
I. ENGINE COOLANT TEMPERATURE

The temperature transm itter resistance varies in proportion to the coolant temperature, generating a
modulated voltage signal picked up by the gauge.
J. BRAKE LIGHT SWITCHES

These are activated when the brakes are on.
K. BRAKE OIL LEVEL SWITCH

This switch is activated when the fluid level drops below the minimum value and lights up the warning light.
L. PARKING BRAKE SWITCH

Activated when the parking brakes are applied, switching on the indicator light on the dashboard.
M. OPERATOR SEAT TRANSMITTER (NAR MARKET ONLY)

A transm itter in the seat detects when an operator is seated.
603.54.331.00 - 12 - 1996
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TRANSMITTERS AND SWITCHES
603.54.331.00 - 12 - 1996
TRANSMITTERS AND SWITCHES
603.54.331.00 - 12 - 1996
603.54.331.00 - 12 - 1996
Chapter 2 - COMPONENTS
CONTENTS
Section Description ......................................................................................................................... Page
55 500 Introduction ................................................................................................................................... 1

Component description ............................................................................................................... 1
55 500 INTRODUCTION
The components described in this section are located on the instrument console (rear hood), in the cab roof and
on the right-hand fender, inside the cab.
COMPONENT DESCRIPTION
INSTRUMENT CONSOLE CONTROLS
1. Lights control lever.
The lever operates external lights, horn and the

direction indicators.
REAR HOOD CONTROLS
Starter switch
To operate the four switch functions, turn the key

(1) through the following positions:
A. No power to circuits (key can be removed).

Engine stopped: automatic activation of fuel
injection cut-off.
B. Control instrument and indicator power supply.

Power supplied to various circuits.
C. Starting the engine: when released, the key

returns automatically to position (B).
P. Parking lights on, instrument panel lighted (key

removable).
603.54.331.00 - 12 - 1996
1. Starter switch.
2. Thermostarter.
3. Hazard warning lights switch.
4. Cigar lighter
1. Beacon on/off switch (tractors without cab)
TRE0020A
IN -C A B CONTROLS
1. Fender-mounted controls
1. Windscreen washer,
2. Windscreen wiper,
3. Rear working lights,
4. Front working lights and
5. Beacon controls (with cab)
603.54.331.00 - 12 - 1996
2 . Heating and air-conditioning controls
1. Electric fan speed control

2. Heating control
3. Air-conditioning control
603.54.331.00 - 12 - 1996
603.54.331.00 - 12 - 1996
Chapter 3 - STARTING SYSTEM
CONTENTS
55 000 Technical information .................................................................................................................... 1

Starting circuit ............................................................................................................................... 3
System tests ................................................................................................................................. 5
55 201 Removal and re-installation of starter m o t o r ............................................................................ 8
S e rv ic in g ......................................................................................................................................... 9
Bench tests ................................................................................................................................. 10
55 000 TECHNICAL INFORMATION
CHARACTERISTICS JX60 JX70 JX80 JX90 JX95

Starter motor BOSCH
Power (kW) 2.5 3.5
Maximum current drain with 60 A 160
out load (Amp) at 11,6 V at 11.5 V
and 8600 rev/min and 8000 rev/min
Minimum brush length (mm)
(in.) — 7.0 (0.2756)
Minimum switch diameter
(mm) (in.) 42 (1.6535) 42.5 (1.6732)
Maximum armature shaft end
play (mm) (in.) 0.5 - 0.8 (0.0197 - 0.0315) 0.4
TIGHTENING TORQUES
Nm
Starter motor and engine block fastening bolts 34 (25.0771)

Box on starter motor/earth (ground) cable side 16 (11.8010)
Solenoid valve wire nuts 7 (5.1629)
Box nuts on starter motor side 10 (7.3756)
Solenoid valve fastening bolts 5 (3.6878)
603.54.331.00 - 12 - 1996
DESCRIPTION AND OPERATION means of an flexible joint mechanism, makes the

driving pinion engage the flywheel ring gear. The
moment the pinion touches the ring gear, the plunger
closes a series of contacts and powers all four field
windings directly from the battery, thus giving full
power to the starter motor.
The starting system installed depends on the type of
gearbox fitted on the tractor. All systems consist of
an ignition key switch, heavy-duty wiring, a starter
motor with solenoid, a sta rt-u p relay and a clutch
pedal switch. These are the basic circuit components
used on versions with mechanical gearbox. More
sophisticated systems include other components,
which ensure the engine can be started only under
the proper conditions.
At this stage, one end of the pull-in coil is connected
to the positive battery pole through the starter switch,
while the other end in connected to the positive pole
through the solenoid valve contacts. The pull-in coil
is thus bypassed, without absorbing power, and the
hold-in coil alone keeps the plunger in position.
There are four types of gearbox: with range reduction

gear (synchro command), with range reduction gear
and inverter (shuttle command). The starting circuit
is illustrated in figure 1.
The starter motor includes a series of contacts and a

tw o-part solenoid plunger which completely closes
the contacts even if the pinion teeth are not perfectly
in line with the ring gear. When this happens, a clutch
spring compresses the pinion, forcing it to connect
completely as soon as the starter motor starts
turning.
There are two available types of starter motors: 2.5
kW or 3.5 kW rating. They both have four poles, four
brushes with integrated solenoid and positive mesh
engagement control.
When the key ignition switch is released, power is

taken from both the solenoid and the motor. The
solenoid return spring, acting on the flexible joint
mechanism, frees the driving pinion from the gear
and opens the solenoid valve contacts again.
The solenoid consists of two coils connected in
parallel. The low resistance pull-in coil is earthed
(grounded) via the engine, while the high resistance
hold-in coil is earthed (grounded) via the solenoid
body.
A roller type clutch is incorporated to the driving
pinion group. This prevents the pinion from
overspeeding if it stays engaged with the flywheel
ring gear after the engine has been started.
When the ignition switch is closed, with the clutch

pedal depressed and gear in neutral (except in the
case of mechanical gearboxes), the coils are
energised and the plunger is magnetically drawn
inside the solenoid. This movement, transmitted by
603.54.331.00 - 12 - 1996
STARTING CIRCUIT
STARTING CIRCUIT
1 - In s tru m e n t p a n e l
2 - S ta rte r s w itc h
11 - B a tte ry
12 - S ta rte r
13 - A lte rn a to r
14 - O v e r v o lta g e c irc u it b re a k e r (D IO D E )
31 - S ta rte r in h ib ito r un it
35 - M ain F u se
603.54.331.00 - 12 - 1996
603.54.331.00 - 12 - 1996
F u se p a n e l 2 S ta rte r m o to r 3
SYSTEM TESTS
STARTING SYSTEM ON TRACTOR TEST
To e a s ily and q u ic k ly tr o u b le - s h o o t th e s ta rtin g
s y s te m p ro b le m s and reach c o n c lu s iv e results, it is
re c o m m e n d e d th a t you use a b a tte ry/sta rtin g te s te r
(h ig h d is c h a rg e m u ltim e te r) w ith in c o rp o ra te d
0 - 2 0 V v o ltm e te r a n d 0 - 5 0 0 A a m m e te r.
W h e n using te s tin g d e v ic e s , fo llo w te s t p ro c e d u re s

re c o m m e n d e d by th e m a n u fa c tu re r. If yo u d o not
h a ve a c c e s s to te s tin g d e v ic e s , c a rry o u t th e
fo llo w in g te s t using a norm al 0 - 2 0 V vo ltm e te r and a
0 - 5 0 0 A m p a m m e te r in o rd e r to c h e c k c o rre c t
s ta rte r m o to r fu n c tio n in g w ith o u t re m o v in g it fro m
th e e n g ine .
B e fo re c a rry in g o u t th e te st:
• c h e c k th e b a tte ry is fu lly c h a rg e d ;
• c h e c k th a t no w ire s in th e s ta rtin g s y s te m are

b ro ke n o r fra y e d a n d th a t th e re a re no lo o se
c o n n e c tio n s ;
• c h e c k th e e n g in e is n o t s e iz e d .
603.54.331.00 - 12 - 1996
POWER ABSORPTION IN STARTER MOTOR

CIRCUIT (Fig. 4)
1. D is c o n n e c t e a rth (g ro u n d ) (n e g a tiv e ) b a tte ry
c a b le (3).
2. D is c o n n e c t p o s itiv e b a tte ry c a b le fro m s ta rte r

s o le n o id . C o n n e c t th e p o s itiv e a m m e te r p o in t
(1) to th e p o s itiv e b a tte ry te rm in a l c la m p and
th e n e g a tiv e p o in t to th e s o le n o id in p u t
te rm in a l.
3. R e c o n n e c t e a rth (g ro u n d ) (n e g a tiv e ) c a b le to
n e g a tiv e b a tte ry te rm in a l c la m p (3).
4. C o n n e c t th e p o s itiv e v o ltm e te r p o in t (2) to th e

p o s itiv e b a tte ry te rm in a l c la m p a n d th e
n e g a tiv e to th e n e g a tiv e b a tte ry te rm in a l
cla m p .
4
5. D is c o n n e c t th e w ire fro m th e in je c tio n p u m p
s h u t- o ff so le n o id .
6. R un th e e n g in e a n d n o te v o ltm e te r and
a m m e te r re a d in g s. V o lta g e m u st be c o n s ta n tly
a b o u t 1 2 V a n d a b s o rp tio n in th e ra n g e o f
2 5 0 -3 0 0 A.
• If a b s o rp tio n c o rre s p o n d s to th e re a d in g s
a b o ve , th e n th e s ta rte r m o to r (4) fig. 4, is
w o rk in g co rre c tly . If v o lta g e d ro p s d u rin g th e
te s t, fo llo w “ R e s is ta n c e in s ta rtin g s y s te m
c irc u it” p ro c e d u re (se e re la tiv e p a ra g ra p h ).
• If ab so rp tio n is h ig h e r th a n th e re a d in g s above,
c h e c k th e c irc u it as fo llo w s . If th e s ta rtin g
s y s te m c irc u its a re in g o o d c o n d itio n , th e n th e
s ta rte r m o to r is m a lfu n c tio n in g and m u s t be
re m o v e d fo r fu rth e r e x a m in a tio n .
• If a b s o rp tio n is lo w e r th a n th e re a d in g s a b o ve ,
th e s ta rte r m o to r is m a lfu n c tio n in g and m u st be
re m o v e d fo r fu rth e r e x a m in a tio n .
603.54.331.00 - 12 - 1996
RESISTANCE IN IGNITION SYSTEM CIRCUIT

(VOLTAGE DROP) (Fig. 5)
If there is a higher than necessary power absorp

tion, check the circuit to find the cause of the volt
age drop occurring within circuit components.
IMPORTANT: Disconnect the injection pump sole

noid fuel closing wire.
POSITIVE BATTERY CABLE
1. Connect the positive voltm eter point (1) to the

positive battery terminal clamp (2).
2. Connect the negative voltmeter point to starter

motor solenoid terminal (3).
3. Run the engine and check the readings on the

voltmeter. If voltage is higher than 0.2 V., check
and tighten wire connections. Check voltage
again and if it is still high install a new battery
cable.
STARTER MOTOR EARTH (GROUND) (Fig. 6)

starter motor casing (2).
2. Connect the negative voltmeter point to the

engine block (3).

earth (ground) connections between the starter
motor flange and the rear engine cover.
BATTERY EARTH (GROUND) CABLE (Fig. 7)

engine block (2).
2. Connect the negative voltmeter point to the

negative battery terminal clamp (3).

and tighten the earth (ground) cable
connections. Check the voltage again and if it is
still higher, then install a new earth (ground)
cable.
603.54.331.00 - 12 - 1996
STARTER MOTOR REMOVAL AND

RE-INSTALLATION (Fig. 8) (Op. 55 201 50)
1. D is c o n n e c t n e g a tiv e b a tte ry ca b le .
2. U n s c re w th e n u t and b o lt (1) and re m o v e th e

p ro te c tio n c o v e r (2) fro m s ta rte r m o to r (3).
3. U n s c re w th e n u t a n d re m o v e p o w e r c la m p (5)
and e m e rg e n c y s w itc h c la m p (4).
4. R e m o v e th e s ta rte r m o to r s e c u rin g b o lts (6)

and re m o v e th e s ta rte r m otor.
5. To re - in s ta ll th e s ta rte r m o to r, re v e rs e th e
o rd e r o f re m o v a l. 8
Starter motor components 9

1. S o le n o id 7. F ie ld w in d in g s and c a sin g
2. S o le n o id bo lts 8. B ru s h h o ld e r
3. B o lt and stu d g ro u p 9. B ru s h pla te
4. C o n tro l sid e s u p p o rt 10. A rm a tu re
5. Lever 11. C lu tc h
6. R educer
603.54.331.00 - 12 - 1996
SERVICING 7. R e m o v e th e m o to r casing fro m th e a rm a tu re and

th e c o n tro l s id e b ra cke t.
DISASSEMBLY (Op.55 201 54)
8. R e m o v e th e c o n tro l le v e r k n u c k le pin fro m th e
c o n tro l s id e o f th e ca sin g .
R e fe r to fig u re 9.
9. R e m o v e th e re ta in in g ring w h ic h h o ld s th e
1. P la ce th e s ta rte r m o to r in a v ic e w ith p ro te c te d
c o n tro l g ro u p and th e in n e r p la te fro m th e
ja w s .
a rm a tu re s h a ft, by firs t re m o v in g th e p re s s u re
2. D is c o n n e c t th e b ig g e s t b ra id e d w ire w h ic h runs c o lla r p e rp e n d ic u la rly fro m th e re ta in in g ring
fro m th e fie ld w in d in g c a s in g to th e s o le n o id . s u p p o rt by m e a n s o f an a p p ro p ria te ly sized tube.
T h e n le v e r th e re ta in in g ring fro m th e g ro o v e .
3. R e m o v e th e th re e s c re w s fro m th e fro n t ca sin g
and re m o v e th e s o le n o id . N o te th a t th e p lu n g e r 10. R e m o v e a rm a tu re and c o n tro l g ro u p .
w ill re m a in c o n n e c te d to th e c o n tro l lever.
4. R e m o v e s o le n o id p lu n g e r fro m th e c o n tro l le v e r REASSEMBLE

by h o ld in g a n d liftin g it a t th e fro n t in o rd e r to
u n c lip it fro m th e lever. 1. To re a s s e m b le th e s ta rte r m o to r, re v e rs e th e
re m o v a l p ro c e d u re .
5. R e m o v e th e tw o n u ts fro m th e re a r c a s in g and
th e tw o s c re w s w h ic h fa s te n th e re a r c o v e r and B e fo re re c o n n e c tin g , te s t th e a rm a tu re s h a ft end
b ru sh p la te to th e c a sin g . R e m o v e c la m p C and p la y a n d te s t th e s ta rte r m o to r w ith o u t load.
a rm a tu re s h a ft end p la y s p a c e rs , le a v in g th e
b rush g e a r on th e co m m u ta to r. R e m o v e th e thin
m e ta l w a s h e r on th e c o m m u ta to r s id e o f th e
ARMATURE SHAFT END PLAY
a rm a tu re .
1. P la c e th e s ta rte r m o to r in a v ic e w ith p ro te c te d
6. A t this sta g e o f th e procedure, c h e c k th e b rushes
ja w s and c o n n e c t a d ia l g a u g e to th e fla n g e on
and c o m m u ta to r. C h e c k th a t th e b ru sh e s are not
th e c o n tro l s id e o f th e c a s in g . P o s itio n th e d ia l
stickin g and, if n e ce ssa ry, clean th e b ru sh e s and
g a u g e p o in te r on th e e n d o f th e a rm a tu re sh a ft.
th e ir re sp e ctiv e c h a n n e ls w ith a rag and so lve n t.
C h e c k th e b ru sh e s are not w o rn . If th e y are w o rn
2. P u sh th e a rm a tu re fo rw a rd and re s e t th e g a u g e
and m in im u m le n g th is le ss th a n th a t s h o w n in
to z e ro . P u sh th e a rm a tu re b a c k as fa r as it w ill
th e te c h n ic a l in fo rm a tio n ta b le , it w ill be
g o and n o te th e g a u g e re a d in g .
n e c e s s a ry to c h a n g e th e s ta rte r m otor.
3. R e a d in g s m u s t fa ll w ith in th e lim its s p e c ifie d in
NO TE : The brushes are not serviced separately. th e te c h n ic a l in fo rm a tio n ta b le . If th e v a lu e is
They are welded to their support and will not be higher, c h e c k th a t a rm a tu re and bru sh p la te are
changed for the whole operating life o f the starter n o t w o rn . C h a n g e th e w o rn c o m p o n e n ts , as
motor. n e c e s s a ry , and c h e c k e n d p la y a g a in.
603.54.331.00 - 12 - 1996
STARTER MOTOR TEST W ITHOUT LOAD (Fig.

10)
NO TE : A fully charged battery and a battery/start

ing tester (high discharge multitester) with carbon
battery (variable load resistance) are needed to
carry out this test.
1. P la ce th e s ta rte r m o to r in a vice w ith protected

ja w s .
2. C o n n e c t n e g a tiv e b a tte ry c a b le (4) to th e

s ta rte r m o to r fla n g e .
3. B rid g e th e s o le n o id c o n ta c ts (6) w ith a s h o rt

w ire (7).
4. C o n n e c t th e p o s itiv e v o ltm e te r p o in t (3) to th e

p o s itiv e b a tte ry te rm in a l c la m p a n d th e
n e g a tiv e v o ltm e te r p o in t to th e n e g a tive b a tte ry
te rm in a l cla m p . C o n n e c t th e a m m e te r p o sitive
p o in t (1) to th e p o s itiv e b a tte ry c la m p (4) and
th e n eg ative po in t to th e b a tte ry o r to th e sta rte r
m o to r te rm in a l c la m p .
5. P la ce a m a n u a l ta c h o m e te r (5) on th e end o f
th e a rm a tu re s h a ft. C h e c k m a x im u m p o w e r
a b s o rp tio n . T h is v a lu e is s p e c ific fo r ea ch
s ta rte r m o to r and m u st be included in th e range
o f v a lu e s in th e T E C H N IC A L IN F O R M A T IO N
ta b le . R e g u la te c a rb o n b a tte ry v o lta g e (2) and
a rm a tu re sp e e d a cc o rd in g to th e in fo rm a tio n in
th e te c h n ic a l in fo rm a tio n ta b le .
6. If th e s ta rte r m o to r d o e s n o t w o rk a c c o rd in g to
th e te c h n ic a l in fo rm a tio n s p e c ific a tio n , c h e c k if
th e re are e a rth e d (g ro u n d e d ) fie ld w in d in g s , if
th e a rm ature is scuffed o r scraped o r if th e sh a ft
is m is s h a p e n o r o th e rw is e d a m a g e d .
BENCH TESTS
ARM ATURE (Fig. 11)
1. T h e c o m m u ta to r s u rfa c e m u s t be cle a n and

n o t burnt. If burning n e e d s to be re m o ve d , use
fine s a n d p a p e r and not a b ra sive fa b ric (e m e ry
c lo th ). F inally, cle a n th e c o m m u ta to r w ith a
rag and so lv e n t.
2. If th e c o m m u ta to r n e e d s re fa c in g , c h e c k it is
n o t s m a lle r th a n th e m in im u m v a lu e s p e c ifie d
in th e T E C H N IC A L IN F O R M A T IO N ta b le .
A fte r re fa c in g , th e c o m m u ta to r m u s t be
p o lis h e d w ith s a n d p a p e r and c le a n e d w ith a
rag and so lv e n t.
N O TE : Do not cut the armature m etal when mak

ing insulation slots.
603.54.331.00 - 12 - 1996
3. A rm a tu re in s u la tio n can be c h e c k e d by
c o n n e c tin g an o h m m e te r (1) b e tw e e n
c o m m u ta to r s e g m e n ts and a rm a tu re s h a ft.
T h is re a d in g s h o u ld s h o w in fin ity , in o th e r
w o rd s th e re s h o u ld be no c o n tin u ity.
4. To te s t th e re a re no s h o rt c irc u its , use an

a p p ro p ria te te s tin g d e vice . T h e o n ly a lte rn a tive
is to try c h a n g in g th e a rm a tu re .
5. If th e a rm a tu re c irc u m fe re n c e has o b v io u s ly
b een in c o n ta c t w ith p ole p ie ce s, th e p ole
b e a rin g s a re p ro b a b ly w o rn . F irs t c h e c k th e
p o le p ie ce s a re fix e d and th a t th e a rm a tu re
s p in s w e ll in a la th e . If n e c e s s a ry , c h a n g e th e
a rm a tu re b e a rin g . 11
FIELD W INDINGS (Fig. 12)

1. To te s t fie ld w in d in g in s u la tio n , c o n n e c t an
o h m m e te r to e a c h o f th e co il b ru s h e s in tu rn
and to a cle a n and u n p a in te d a re a o f th e
ca sin g . T h e re s h o u ld be no re a d in g s , th a t is,
th e re sh o u ld be no c o n tin u ity.
2. To te s t coil co n tin u ity, c o n n e c t an o h m m e te r to

each o f th e coil b ru sh e s in tu rn and to th e m ain
p o w e r c la m p (b ig g e s t b ra id e d w ire ). T h e
re a d in g sh o u ld be 1 f i.
3. If th e re is a fa ilu re in th e fie ld w in d in g s , th e n it
w ill be n e c e s s a ry to ch a n g e th e w h o le b o x and
fie ld w in d in g s y s te m .
12
BEARING BUSHINGS
1. C h e c k if th e b u s h in g on th e bru sh p la te and in
th e b o x on th e p in io n s id e are w o rn . A s s e m b le
th e a rm a tu re s h a ft a n d n o te play. C h a n g e th e
b u s h in g if th e re is to o m u ch play. C h e c k th e
fie ld p o le s to s e e if th e re a re a n y s ig n s o f
s c ra p in g a g a in s t th e c a s in g . T h is can a lso be
ca u s e d by a w o rn b u s h in g .
DRIVING PINION
1. C h e c k th e ro lle r clu tc h o p e ra tio n . T h e p in io n
m u s t spin clo c k w is e only. If th e pinion is e ith e r
se iz e d o r s p in s in b oth d ire c tio n s , o r if th e
p in io n te e th a re d a m a g e d , a s s e m b le a ne w
c o n tro l g ro u p .
If th e re is c le a r e v id e n c e o f d a m a g e to th e pinion
te e th , c h e ck th e flyw h e e l ring gear, as de scrib e d in
s e c tio n 10, E n g in e s .
603.54.331.00 - 12 - 1996
603.54.331.00 - 12 - 1996
Chapter 4 - CHARGING SYSTEM
CONTENTS
Section Description ......................................................................................................................... Page
55 000 T e ch n ic a l in fo rm a tio n .................................................................................................................................... 1

S y s te m te s tin g and tr o u b le - s h o o t in g ..................................................................................................... 4
55 301 R e m o v a l, re -in s ta lla tio n and s e rv ic in g ............................................................................................... 10
TYPE OF ALTERNATOR
CHARACTERISTICS BOSCH
14V-45, 65 and 85A
P o la rity N e g a tiv e e a rth
N o m in a l v o lta g e (V) 14
M a x ro ta tio n sp e e d (rpm ) 1 5 .0 0 0
M a x im u m o u tp u t (A) 45 65 85
R e g u la to r c o n tro lle d v o lta g e (V) 1 3.6 - 14 1 3.6 - 14.4
R o to r fie ld w in d in g re s is ta n c e ( f i) 3 . 4 - 3.8 2 .9
S ta to r fie ld w in d in g re s is ta n c e ( f i) - 0 .2
N e w bru sh le n g th (m m ) (in.) - 2 0 (0 .7 8 7 4 )
M in im u m bru sh le n g th (m m ) (in.) - 5 (0 .1 9 6 9 )
B ru sh sp rin g fo rc e (N ) (lb) - 1 .3 -2 .7
( 0 .2 9 - 0 .6 0 )
TIGHTENING TORQUE
Nm (ft lb)
A lte rn a to r fa s te n in g b o lts 5 .5 (4 .0 5 6 6 )
P u lle y fa s te n in g nut 70 (5 1 .6 2 9 3 )
R e c tifie r fa s te n in g s c re w s 4 .0 (2 .9 5 0 2 )
B ru sh b o x and re g u la to r s c re w s 2 .7 (1 .9 9 1 4 )
T e rm in a l nuts 2 .7 (1 .9 9 1 4 )
603.54.331.00 - 12 - 1996
ALTERNATOR DESCRIPTION
E ith e r a M a g n e ti M a re lli o r a B o s c h , 4 5 o r 6 5 A,
a lte rn a to r, w ith e x te rn a l c o o lin g fa n , is fitte d on all
m o d e ls. S ta to r w in d in g is v e n tila te d w ith an a ir
c o n d u c tin g d ia p h ra g m in th e s u p p o rt on th e re ctifie r
b rid g e s id e and p e rip h e ra l o p e n in g s in th e s u p p o rt
on th e co n tro l sid e . T h e a lte rn a to r, in s ta lle d on th e
le ft sid e o f th e en g ine , is o p e ra te d by a pulley and a
V - ty p e d riv in g belt. A lte rn a to rs a re fitte d w ith a
b u ilt-in re g u la to r.
45 or 65 A alternator
1. Battery connection (B+ terminal)
2. Terminal protection sheath
3. Alternator charge indicator connection
(D+ terminal)
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Alternator charging circuit 2
1. Ignition switch B+ Battery connection

2. Alternator charge warning light D+ Alternator charge indicator
3. Battery
4. Alternator
5. Alternator electronic voltage regulation circuit
ALTERNATOR FUNCTIONING T h e d ire c t c u rre n t is th e n re in tro d u ce d into th e circu it

to in c re a s e c u rre n t flo w th ro u g h th e ro to r field
w in d in g .
S e e fig u re 2.
T h is a c tio n c a u s e s a c o n s ta n t in c re a s e in th e ro to r
m a g n e tic fie ld and a fa s t in c re a s e o f c u rre n t and
W h e n th e ig n itio n ke y is tu rn e d , a s m a ll c u rre n t
v o lta g e o u tp u t.
p a s s e s fro m th e b a tte ry th ro u g h th e ro to r field
w in d in g w irin g . T h e c irc u it c lo s e s p o w e rin g th e
c h a rg e w a rn in g light, th e a lte rn a to r D + te rm in a l, th e
ro to r field w in d in g , th e a lte rn a to r re g u la to r and earth A s th e g e n e ra te d v o lta g e o u tp u t (re fle c te d by D +
(g ro u n d). te rm in a l) in c re a s e s , th e w a rn in g lig h t in te n s ity d e
c re a s e s and w h e n th e v o lta g e a t th e D + te rm in a l
e q u a ls th a t on th e b a tte ry s id e o f th e w a rn in g light,
th e lig h t g o e s out.
A t th is s ta g e , th e w a rn in g lig h t c o m e s on and th e
ro to r is p a rtia lly m a g n e tis e d .
V o lta g e in c re a s e s u ntil it re a c h e s th e p re - s e t
re g u la te d v o lta g e level.
W h e n th e e n g in e s ta rts and th e rotor, p a rtia lly
m a g n e tis e d , tu rn s in s id e th e s ta to r w in d in g s and
g e n e ra te s th r e e -p h a s e a lte rn a tin g c u rre n t. A
c o n s ta n t q u a n tity o f th is c u rre n t is tra n s fo rm e d into If th e d riv in g b e lt b re a k s , th e re w ill be no v o lta g e
d ire c t c u rre n t by th re e fie ld d io d e s b u ilt in to th e a c c u m u la tio n in th e a lte rn a to r. T h e c h a rg e w a rn in g
rectifier. lig h t w ill s ta y on, th u s in d ic a tin g a fa u lt.
603.54.331.00 - 12 - 1996
3 4
Fan belt tensioner
Fig. 3. Belt for versions without air conditioning Fig. 4. Belt for versions with air conditioning
1. Alternator 3. Belt tensioner securing nut

2. Belt tensioner 4. Belt
SYSTEM TESTING AND TROUBLE-SHOOTING
PRECAUTIONS 1. CHECKING THE BATTERY
To a vo id d a m a g in g a lte rn a to r c h a rg in g s y s te m C h e c k all b a tte ry e le m e n ts w ith a d e n s im e te r. T h e

c o m p o n e n ts , ta k e th e fo llo w in g p re c a u tio n s : b a tte ry m u s t be a t le a s t 7 0 % c h a rg e d and e fficie n t.
• DO NOT MAKE OR INTERRUPT a n y c h a rg in g 2. CHECKING THE DRIVING BELT

c irc u it c o n n e c tio n , in c lu d in g th e battery, w h ile
th e e n g in e is ru n n in g .
In s p e c t th e a lte rn a to r d riv in g b e lt and pulley, c h e c k
ing th a t th e y a re b oth c le a n , w ith no tra c e s o f oil o r
• NEVER SH O R T-C IR C U IT th e a lte rn a to r
lu b ric a n t and in g o o d c o n d itio n .
p o s itiv e te rm in a l to c h e c k if it is w o rk in g .
• ALWAYS DISCONNECT b a tte ry c a b le s w h e n C h e c k th e a lte rn a to r d riv in g b e lt te n s io n re g u larly. If

re c h a rg in g th e b a tte ry in th e tra c to r w ith a yo u s u s p e c t th e b e lt is n o t tig h t, c h e c k th e te n s io n e r
b a tte ry ch a rg e r. as fo llo w s :
• ALWAYS CHECK b a tte ry p o la rity w h e n

B e lt fo r v e rs io n s w ith o u t a ir c o n d itio n in g (Fig. 3)
in s ta llin g a b a tte ry o r u sin g a s u p p le m e n ta ry
b a tte ry to s ta rt th e e n g in e . - s la c k e n th e n u t (3) w h ic h s e c u re s th e
a lte rn a to r to th e te n s io n e r b ra c k e t (2).
• DO NOT SH O R T-C IR C U IT re g u la to r in p u t/ - w ith a lever, m o ve th e a lte rn a to r (1) on th e
o u tp u t te rm in a ls w h e n th e a lte rn a to r is w o rk in g . te n s io n e r b ra c k e t (2) to re a ch c o rre c t belt
te n s io n and tig h te n th e s e c u rin g n u t (3) to 55
• CONNECT POSITIVE TO POSITIVE AND N m (4 0 .5 6 5 9 ft lb).
NEGATIVE TO NEGATIVE.
B e lt fo r v e rs io n s w ith a ir c o n d itio n in g (Fig. 4)
PRELIMINARY CHECKS
- s la c k e n th e b e lt te n s io n e r s e c u rin g n u ts (3)
- h old th e be lt te n s io n e r a rm (2) and m o ve it on
B e fo re c a rry in g o u t th e s e e le c tric a l te s ts , c a re fu lly th e b ra c k e t to re a ch th e c o rre c t b e lt te n s io n ,
in s p e c t th e c h a rg in g s y s te m and th e e le c tric a l th e n tig h te n th e s e c u rin g n u ts (3) to 55 N m
s y s te m in g e n e ra l. (4 0 .5 6 5 9 ft lb).
C h e c k c o n tin u ity in all c o n d u c to rs and c o n n e c tio n s . C o rre c t d e fle c tio n v a lu e s, m e a s u re d by a p p lyin g th e

C h e c k th e y are all cle a n and w e ll fa s te n e d . fo llo w in g lo a d s to th e m id d le o f th e belt:
603.54.331.00 - 12 - 1996
If th e w a rn in g lig h t s ta y s on, c h e c k th e re is no s h o rt
c irc u it b e tw e e n D + w ire e n d in g a n d w a rn in g light.
Version w ith
out cab or Version with
with cab w ith cab and air PRELIMINARY TESTS
out air condi conditioning
tioning T h e s e p re lim in a ry te s ts ca n be c a rrie d o u t w ith o u t
Load (N ) (lb) 78 - 98 60 - 75 re m o v in g a n y c o m p o n e n ts fro m th e tra c to r ch a rg in g
(1 7 .2 0 -2 1 .6 1 ) (1 3 .2 8 -1 6 .5 3 ) c irc u it. T h e s e te s ts ch e ck:
D e fle c tio n 1 0 -11 10

• th e a lte rn a to r w ire c o n n e c tio n s
(m m ) (in.) 0 .3 9 3 7 -0 .4 3 3 1 ) (0 .3 9 3 7 )
• a lte rn a to r c h a rg in g c u rre n t and c o n tro lle d

v o lta g e
3. CHECKING THE WARNING LIGHT
• v o lta g e d ro p in th e a lte rn a to r c h a rg in g c irc u it
T urn th e ignition key and c h e c k th e light is co m p le te ly
lit. • m a x im u m a lte rn a to r o u tp u t
If th e w a rn in g lig h t d o e s n o t lig h t c o m p le te ly , c h e c k T h e fo llo w in g te s tin g d e v ic e s a re re q u ire d :

th e light bulb. If th e light b ulb has not blow n, ca rry out
th e a lte rn a to r w irin g c o n n e c tio n te s ts as d e s c rib e d in • 0 - 3 0 V m o v in g c o il v o ltm e te r
th e p a ra g ra p h “ P R E L IM IN A R Y T E S T S ” in th is
se c tio n . • 0 - 1 V m illiv o ltm e te r
If th e lig h t is on, s ta rt th e e n g in e and run it a b o v e • 0 -1 1 0 A m o v in g co il a m m e te r

m in im u m sp e e d . T h e w a rn in g lig h t s h o u ld g o out.
• 1.5 o h m , 110 A v a ry in g load re s is ta n c e
If th e w a rn in g lig h t d o e s n o t g o out, s to p th e e n g in e
and d is c o n n e c t th e D + te rm in a l w ire . If th e w a rn in g NOTE: M ost testing devices on the market today
lig h t g o e s o u t now, one o f th e a lte rn a to r c o m p o n e n ts combine several electrical test functions
is m a lfu n c tio n in g . C a rry o u t “A L T E R N A T O R C O M (multimeters). When using these devices, follow the
P O N E N T T E S T S ” d e s c rib e d in th is s e c tio n . m anufacturer’s instructions.
603.54.331.00 - 12 - 1996
1. ALTERNATOR W IRE CONNECTIONS TEST
S e e fig u re 5.
1. D is c o n n e c t th e battery.
2. D is c o n n e c t B+ (2) and D+ (3) a lte rn a to r

te rm in a ls .
3. R e c o n n e c t th e b a tte ry and tu rn th e ignition key

into position O N but w ith o u t sta rtin g th e engine.
C o n n e c t a v o ltm e te r (4) b e tw e e n e ach te rm in a l
a nd e a rth (g ro u n d ) (1). T h e re m u s t be v o lta g e
a t th e battery.
5
If th e re is no v o lta g e a t th e ba tte ry, c h e c k fo r a
c o n tin u ity fa u lt in th e e x te rn a l w irin g . S e e c irc u it
d ia g ra m in fig u re 2.
4. C o n n e c t D + te rm in a l, w a rn in g lig h t w ire (red)

a nd e a rth (g ro u n d ). T h e w a rn in g lig h t s h o u ld
illu m in a te .
5. D is c o n n e c t th e b a tte ry and re c o n n e c t th e
c a b le s to th e a lte rn a to r a t (2) and (3) fig. 5.
NOTE: If the warning light does not light up when

the wire is connected to the alternator, this means
that there is a fault either in the alternator regulator
circuit or in the rotor circuit. Check D + terminal is
clean and then test the alternator components as
described in this section.
2. CHARGING CURRENT AND REGULATED VO LT

AG E TESTS
S e e fig u re 6.
1. C h e c k th a t all tra c to r e le c tric a l d e v ic e s are

s w itc h e d o ff a n d th e ig n itio n ke y is in th e O F F
p o sitio n.
2. D is c o n n e c t th e n e g a tive b a tte ry te rm in a l cla m p

a n d th e B + n e g a tiv e a lte rn a to r te rm in a l.
3. C o n n e c t an a m m e te r (1) b e tw e e n th e
d is c o n n e c te d w ire (re d ) (4) and th e B+
a lte rn a to r te rm in a l (3).
6
4. C o n n e c t a v o ltm e te r (2) b e tw e e n th e B+
a lte rn a to r te rm in a l (3) a n d e a rth (g ro u n d ).
5. R e c o n n e c t th e battery. S ta rt th e engine and run

it a t 2 0 0 0 re v /m in . N o te th e re a d in g s on th e
v o ltm e te r and th e a m m e te r.
T h e v o ltm e te r re a d in g s h o u ld be h ig h e r th a n th e
b a tte ry v o lta g e and w h e n th e a m m e te r reading falls
b e lo w 10 A , th e v o ltm e te r re a d in g s h o u ld s ta b ilis e
a t 13.6 - 14 V (M a g n e ti M arelli a lte rn a to r) o r 13.6 -
14.4 V (B o sch a lte rn a to r).
603.54.331.00 - 12 - 1996
If th e v o ltm e te r re a d in g is h ig h e r th a n 14 V o r 14.4
V, fo r M a g n e ti M a re lli o r B o s c h a lte rn a to rs re s p e c
tive ly, th e a lte rn a to r re g u la to r m u st be ch a n g e d , as
d e s c rib e d in th is s e c tio n . (A fte r in s ta llin g a n ew
re g u la to r, c a rry o u t te s ts 4 and 5).
If th e v o ltm e te r re a d in g is less th a n 13.6 V, th e re is

e ith e r a fa u lty c o m p o n e n t in th e a lte rn a to r o r a
fa ilu re d u e to e x c e s s iv e re s is ta n c e in th e e x te rn a l
c h a rg in g s y s te m c o n n e c tio n s .
If th e a m m e te r re a d s z e ro a m p s, th e n o n e o f th e
a lte rn a to r c o m p o n e n ts is m a lfu n c tio n in g . T urn th e
e n g in e o ff and c a rry o u t th e a lte rn a to r c o m p o n e n t
te s t, as d e s c rib e d in th is ch a p te r.
3. CHARGING CIRCUIT VOLTAGE DROP TESTS
(a) Insulated side voltage drop test
S e e fig u re 7.
C h e c k th e ig n itio n ke y is in O F F p o sitio n .
1. D is c o n n e c t th e n e g a tiv e b a tte ry c a b le and th e

B + a lte rn a to r w ire (1).
2. C o n n e c t a m illiv o ltm e te r (5) b e tw e e n th e

p o s itiv e b a tte ry te rm in a l c la m p and D + w ire (3)
(p o s itiv e s id e o f th e w ire )
3. C o n n e c t an a m m e te r (2) b e tw e e n th e B +
a lte rn a to r te rm in a l and th e D + w ire (n e g a tiv e 7
s id e o f th e w ire ).
4. R e c o n n e c t th e n e g a tiv e b a tte ry c a b le and
c o n n e c t a v a ry in g load re s is ta n c e (4) w ith
c u rs o r in m in im u m c u rre n t a b s o rp tio n p o sitio n
(m a x im u m re s is ta n c e ) th ro u g h th e b a tte ry
te rm in a l cla m p s .
5. S ta rt th e e n g in e a n d in c re a s e s p e e d to 2 0 0 0
re v/m in .
6. D e c re a s e re s is ta n c e c h a rg in g load (d e c re a s
ing re s is ta n c e ) s lo w ly u n til th e a m m e te r re a d s
45 o r 6 5 A . a c c o rd in g to th e ty p e o f a lte rn a to r.
7. N o te th e re a d in g on th e m illiv o ltm e te r. T h is
m u s t n o t be h ig h e r th a n 4 0 0 m illiv o lts .
A re a d in g h ig h e r th a n 4 0 0 m illiv o lts in d ic a te s m a l
fu n c tio n in g d u e to e x c e s s iv e re s is ta n c e in th e
e x te rn a l circu its .
If th e a lte rn a to r d o e s not o u tp u t required p o w e r and

th e m illiv o ltm e te r re a d in g is less th a n 4 0 0 m illivolts,
th e re is a m a lfu n c tio n in g c o m p o n e n t in th e a lte rn a
tor. C a rry o u t th e a lte rn a to r c o m p o n e n t te s ts , as
d e s c rib e d in th is s e c tio n .
8. S to p th e e n g in e .
603.54.331.00 - 12 - 1996
(b) G ro u n d sid e vo lta g e d ro p te s t
S e e fig u re 8.
1. C h e c k th e ig n itio n ke y is in O F F p o sitio n.
2. T h e c irc u it is th e s a m e as th a t d e s c rib e d in th e
p re v io u s te st, e x c e p t th a t th e m illiv o ltm e te r (4)
is now co n n e c te d b e tw e e n th e n e g a tive b a tte ry
te rm in a l c la m p a n d th e a lte rn a to r c a sin g
(n e g a tiv e s id e o f ca s in g ).
NOTE: Check the varying load resistance (3) is in

minimum current absorption position (maximum
resistance). 8
3. S ta rt th e e n g in e a n d in c re a s e s p e e d to 2 0 0 0
re v/m in .
4. In c re a s e re s is ta n c e c u rre n t load (d e c re a s in g
re s is ta n c e itse lf) s lo w ly u ntil th e a m m e te r (2)
re a d s 45 o r 6 5 A . a c c o rd in g to th e ty p e o f
a lte rn a to r.
5. N o te th e re a d in g on th e v o ltm e te r. T h is m u st
no t be h ig h e r th a n 2 0 0 m illiv o lts .
A re a d in g h ig h e r th a n 2 0 0 m illiv o lts in d ic a te s
m a lfu n c tio n in g d u e to e x c e s s iv e re s is ta n c e in th e
e x te rn a l circu its .
If th e a lte rn a to r d o e s not o u tp u t required p o w e r and

th e m illiv o ltm e te r re a d in g is less th a n 2 0 0 m illivolts,
th e re is a m a lfu n c tio n in g c o m p o n e n t in th e a lte r
nator. C a rry o u t th e a lte rn a to r c o m p o n e n t te s ts as
d e s c rib e d in th is s e c tio n .
6. S to p th e e n g in e .
4. MAXIMUM ALTERNATOR OUTPUT TEST
S e e fig u re 9.
1. C h e c k th e ig n itio n ke y is in th e O F F p o sitio n .
2. D is c o n n e c t th e n e g a tiv e b a tte ry c a b le a n d th e
B + a lte rn a to r w ire (4).
3. C o n n e c t an a m m e te r (5) b e tw e e n B+
a lte rn a to r te rm in a l (4) a n d D + w ire (1)
(n e g a tiv e s id e o f th e w ire ).
4. C o n n e c t a v o ltm e te r (4) b e tw e e n th e B+
a lte rn a to r te rm in a l (5) and e a rth (g ro u n d ).
9
5. R e c o n n e c t th e n e gative b a tte ry cable. S ta rt th e
e n g in e and in c re a s e s p e e d to 2 0 0 0 re v/m in .
603.54.331.00 - 12 - 1996
6. Increase resistance current load (2)

(decreasing resistance) slowly until the
ammeter reads 45 or 65 A., according to the
type of alternator.
7. Note the reading on the voltmeter. This must

not be less than 13.6 V.
A reading lower than 13.6 V. shows there is a

malfunctioning component in the alternator. Carry
out the alternator component tests, as described in
this section.
ALTERNATOR COMPONENT TESTS
These alternator tests must be carried out only if

the PRELIMINARY TESTS have shown a malfunc
tioning alternator component. These tests check:
• the regulator,
• rotor field winding continuity,
• rotor brushes, springs and contact rings.
NOTE: The previously described component tests
can be carried out with the alternator installed in the
tractor. In order to carry out the other alternator
tests, it will be necessary to remove the alternator
from the tractor. R efer to the section “FUNC
TIONAL TESTS" in this chapter.
603.54.331.00 - 12 - 1996
REMOVAL, REASSEMBLY AND

SERVICING (Op. 55 301 10)
IMPORTANT NOTE: Before disconnecting the
alternator wires, check that the ignition key is in the
OFF position.
REMOVING THE ALTERNATOR

S e e fig u re s 10 a n d 11.
1. D is c o n n e c t th e n e g a tiv e b a tte ry ca b le .
2. D is c o n n e c t B + (1) a n d D + (2) w ire s fro m th e

a lte rn a to r.
10
1. S la c k e n a n d re m o v e th e n u t a n d b o lt (3)
s e c u rin g the a lte rn a to r to th e belt te n s io n e r (4).
2. M o ve th e a lte rn a to r to re d u c e b e lt te n s io n (5)
a nd re m o v e it fro m th e a lte rn a to r p u lle y (6).
3. U n s c re w and re m o v e th e n u t a n d b o lt (7).
R e m o v e th e a lte rn a to r.
11
603.54.331.00 - 12 - 1996
Alternator components 12
1. Pulley retaining nut 6. Stator 10. Electronic voltage regulator with

2. Pulley 7. R ear support plate built-in brushes
3. Cooling fan 8. Rectifier bridge
4. Front support plate 9. Protection guard
5. Rotor
F irm ly fix th e a lte rn a to r h o riz o n ta lly to an a p p ro p ri

a te h o ld e r w ith in te rn a l s u rfa c e s p ro te cte d w ith s o ft
m a te ria l.
R e m o v e th e g u a rd (1) a fte r u n s c re w in g th e nuts

w h ic h fa s te n it to th e a lte rn a to r (F ig. 13)
B e fo re d is m a n tlin g th e a lte rn a to r co m p le te ly , ca rry

o u t th e o p e ra tio n s and te s ts d e s c rib e d on th e
fo llo w in g pa g e s.
13
603.54.331.00 - 12 - 1996
ROTOR A ND REGULATOR FIELD CIRCUIT

TEST
The following testing devices are required:
• 12 volt battery
• multitester
• 2 watt test lamp.
See figure 14.

1. Disconnect all alternator wires.
2. Connect a 12 V. battery and a 2.2 watt test lamp

(2) in series to D+ (1) and alternator casing
(negative side of the casing). 14
3. The test lamp should light up.
If the test lamp does not light up, then the rotor
circuit is faulty. Check brushes, contact rings and
rotor field winding continuity.
If the test shows these components are satisfacto

ry, then the regulator may be faulty.
CHECKING THE CONTINUITY OF THREE

STATOR WINDINGS
Position the points of an ohmmeter (regulated on fi

x1 scale) so that they touch the stator phase ends
(a - b - c) in the three possible ways shown in
figures 15, 16 and 17. Each reading should show a
certain resistance value which should be the same
for all three readings.
If resistance shows infinity or zero, the measured

phase is either interrupted or short-circuited and
the stator needs to be changed.
15
16
603.54.331.00 - 12 - 1996
CHECKING THE DIODES
D is c o n n e c t th e te rm in a l w ire c o n n e c to r (1) o f th e
e x c ita tio n d io d e s fro m th e p o s itiv e b ru sh pin (F ig.
18)
U n w e ld s ta to r w in d in g te rm in a ls (2) fro m th e re c ti

fie r b rid g e (F ig. 19).
EXCITATION DIODES TEST
In s e rt an o h m m e te r p o in t in th e c o n n e c to r m e n
tio n e d a b o v e (1) (F ig. 18). T h e s e c o n d p o in t m u s t
be put in co n ta c t su cc e s s iv e ly w ith e ach o f the three
te rm in a ls ( A - B - C ) : R e p e a t th e th re e m e a s u re
m e n ts a fte r re v e rs in g th e in s tru m e n t p o in ts (F ig.
20).
603.54.331.00 - 12 - 1996
POSITIVE POWER DIODES TEST
P u t an o h m m e te r p o in t in c o n ta c t w ith th e p o s itiv e
(X ) a lte rn a to r te rm in a l a n d th e o th e r s u c c e s s iv e ly
w ith each o f the th re e te rm in a ls ( A - B - C ) (Fig. 21).
R e p e a t th e th re e m e a s u re m e n ts a fte r re ve rsin g the

in s tru m e n t p o in t c o n n e c tio n s .
21
NEGATIVE POWER DIODES TEST
P ut an o h m m e te r p o in t in c o n ta c t w ith th e n e g a tive
(Y ) d io d e s p la te a n d th e o th e r s u c c e s s iv e ly w ith
ea ch o f th e th re e te rm in a ls ( A - B - C ) (Fig. 22).
R e p e a t the thre e m e a s u re m e n ts a fte r re ve rsin g the

in s tru m e n t p o in t c o n n e c tio n s .
22
In the th re e te s ts d e s c rib e d a b o v e , th e in s tru m e n t

s h o u ld s h o w re s is ta n c e a t e a ch te rm in a l ( A - B - C ) .
R e v e rs in g th e in s tru m e n t p o in t c o n n e c tio n , th e re
s h o u ld be no re s is ta n c e (Fig. 2 2 ). If th e re is re s is
ta n c e in b oth ca s e s , th is m e a n s s h o rt-c irc u ite d
d io d e s . O th e rw is e , w ith a R =0 v a lu e (in te rru p te d
d io d e), c h a n g e th e w h o le re c tifie r b rid g e .
ROTOR
CHECK ON ROTOR W INDING RESISTANCE

MEASURED BETWEEN PINS CONNECTED TO
BRUSHES
D is c o n n e c t th e e x c ita tio n d io d e te rm in a l w ire

c o n n e c to r (1) fro m the pin co n n e cte d to the positive
b ru sh . P ut b oth p o in ts o f an o h m m e te r (re g u la te d
on Q x 1 s c a le ) in c o n ta c t w ith th e tw o v o lta g e
re g u la to r-b ru s h h o ld e r pins. If re sista n ce reading is
d iffe re n t fro m th e in d ic a te d v a lu e o r if it s h o w s
in fin ity (in te rru p te d circuit), c h e c k and, if necessary,
ch a n g e th e ro to r (F ig. 23).
23
603.54.331.00 - 12 - 1996
DISASSEMBLY (Op. 55 301 12)
P la ce a su ita b le A lle n w re n c h in th e h e xa g o n a l hole

in th e a lte rn a to r sh a ft to p re v e n t th e a lte rn a to r s h a ft
fro m tu rn in g . W ith a n o th e r w re n c h , u n s c re w th e fan
and ro to r p u lle y fa s te n in g nut. D ra w o u t th e a b o v e
m e n tio n e d p arts, s p a c in g c o lla rs a n d a lte rn a to r
w a s h e rs (F ig. 24).
24
D is c o n n e c t th e e x c ita tio n d io d e te rm in a l w ire

c o n n e c to r (2) fro m th e pin co n n e cte d to th e positive
b ru sh . U n s c re w and re m o v e th e s c re w s (3) s e c u r
ing th e e le c tro n ic v o lta g e re g u la to r (4), c o m p le te
w ith b ru s h e s , to th e re a r a lte rn a to r s u p p o rt.
U n s c re w nuts (5) and re m o ve th e s c re w s fa ste n in g
th e a lte rn a to r m ain e x te rn a l p a rts (F ig. 2 5 ).
25
ELECTRONIC VOLTAGE REGULATOR (Fig. 26)
a. B ru s h e s
b. P ins
26
S e p a ra te th e p a rts (as illu s tra te d ) b e a rin g in m ind

th a t it is n e c e s s a ry to a p p ly a c o n s id e ra b le d e g re e
o f p re s s u re on th e ro to r s h a ft to fre e th e fro n t
s u p p o rt p la te (6) a n d th e ro to r (7) (F ig. 2 7 ).
If you do not have a press, use a brass drift, to avoid

damaging the thread.
26665
27
603.54.331.00 - 12 - 1996
U n s c re w th e s c re w s (9) w h ic h fa s te n th e re c tifie r
b rid g e (10 ) to th e re a r s u p p o rt p la te (8) (F ig. 28).
The rectifier bridge m ust not be dismantled: the

spare p art is supplied as a complete unit.
S e p a ra te th e re c tifie r b rid g e (1 0 ) fro m th e re a r

s u p p o rt p la te . U n w e ld th e s ta to r w in d in g te rm in a ls
(11) (F ig. 29).
29
S e p a ra te th e s ta to r (12) and th e te rm in a ls (11) fro m

th e re a r s u p p o rt p la te (8) (F ig. 30).
30
INDUCTOR COIL INSULATION TEST
P u t both o h m m e te r p o in ts (fixe d a t Q x 1 sc a le ) in
c o n ta c t re s p e c tiv e ly w ith a s lip ring and th e ro to r
ca sin g (see a rro w s ). T h e in s tru m e n t s h o u ld s h o w
in fin ity resista nce . If th is is not th e case, c h a n g e th e
ro to r (F ig. 31).
31
603.54.331.00 - 12 - 1996
C heck ro to r in d u c to r re sista n ce on s lip rings
P u t both o h m m e te r p o in ts (fixe d a t Q x 1 s c a le ) in
c o n ta c t re s p e c tiv e ly w ith th e s lip rin g s (se e a r
ro w s ). T h e in s tru m e n t s h o u ld s h o w a c e rta in
d e g re e o f re s is ta n c e (Fig. 32).
If th e in s tru m e n t re a d in g is d iffe re n t fro m th e

p re s c rib e d v a lu e o r s h o w s in fin ity (in te rru p te d
c irc u it), c h a n g e th e rotor.
32
C h e c k th e ball b e a rin g m o ve s fre e ly, w ith o u t s tickin g

o r noise . C h e c k th e c o lle c to rs h a ve n o t been
d a m a g e d by th e b ru s h e s . If th is is th e ca se , c h a n g e
th e w h o le rotor.
REASSEMBLY
To re a s s e m b le , re v e rs e th e o rd e r o f th e o p e ra tio n s
d e s c rib e d .
SERVICING
1. C h e c k the rotor and s ta to r poles a re not w orn. If

th is is th e ca se , it m e a n s th e ball b e a rin g s a re
w o rn , th e c a s in g s a re n o t in line o r th e ro to r
s h a ft is m is s h a p e n .
NOTE: alternator ball bearings cannot be serviced

separately. When necessary, therefore, both must
be changed.
2. U n s c re w th e s c re w s (1) s e c u rin g p la te (2) th a t

lo cks b e a rin g (3). R e m o v e it fro m th e fro n t
s u p p o rt plate (4) (Fig. 33). C h e c k if it is w o rn o r
d a m a g e d ; if so, c h a n g e it. B e fo re in sta llin g th e 33
ball b e a rin g , c h e c k th e fro n t s u p p o rt p la te
h o ld e r a nd c le a n it ca re fu lly.
3 . In s ta lla tio n o f b e a rin g (5) on s u p p o rt p la te side

is d iffe re n t fro m th e o n e d e s c rib e d a b o v e . A
n e w ro to r c o m p le te w ith b e a rin g m u s t be
in s ta lle d (Fig. 34).
34
603.54.331.00 - 12 - 1996
RE-INSTALLATION • C h e c k th e n e g a tiv e (g ro u n d ) b a tte ry c a b le is

d is c o n n e c te d fro m th e b a tte ry w h ile re -in s ta llin g
1. R e -in s ta ll th e a lte rn a to r by re v e rs in g th e th e a lte rn a to r.
re m o v a l p ro c e d u re .
• A d ju s t th e a lte rn a to r d riv e be lt, as d e s c rib e d
D u rin g re -in s ta lla tio n , re m e m b e r to: p re v io u s ly in th is ch a p te r.
603.54.331.00 - 12 - 1996
Chapter 5 - BATTERY
CONTENTS
55 000 T e c h n ic a l in fo rm a tio n .................................................................................................................................... 1

55.301.040 R e m o v a l a n d re -in s ta lla tio n ...................................................................................................................... 2
B a tte ry c h e c k in g a n d m a in te n a n c e ....................................................................................................... 3
C h a rg in g th e b a tte ry ..................................................................................................................................... 4
B a tte ry p ro b le m s - F re q u e n t c a u s e s ..................................................................................................... 7

TYPE OF BATTERY
JX95 model
CHARACTERISTICS JX60/JX70/JX80/JX90
(optional for
models
other models)
V o lta g e (V) 12
C old s ta rt a m p e ra g e (C .C .A ) 1 x7 6 0 1 x8 0 0
C a p a c ity (A h) 105 120
N u m b e r o f e le m e n ts 6
N u m b e r o f p la te s p e r e le m e n t 16 21
E n e rg y re s e rv e (S A E ) (m in.) 160 210
W e ig h t (kg) (lb) 2 5 (5 5 .1 2 ) 35 (7 7 .1 6 )
E a rth (g ro u n d ) te rm in a l N e g a tiv e

B oth ty p e s o f b a tte ry a re of th e “s e a le d , • to s u p p ly e le c tric ity w h e n th e p o w e r re q u ire d is
m a in te n a n c e -fre e ” typ e . h ig h e r th a n th a t p ro d u c e d b y th e a lte rn a to r.
• to s u p p o rt in a c tiv e lo a d s fro m ra d io and
105 A h b a tte rie s are fitte d on JX 6 0 , J X 7 0 , J X 8 0 and m ic ro p ro c e s s o r m em ory.
J X 9 0 m od els. T h e b a tte ry is p o sitio ne d in fro n t o f the
rad ia to r, in th e fro n t a xle s u p p o rt c o m p a rtm e n t E ach e le m e n t o f th e b a tte ry c o n s is ts o f p o s itive and
(F ig. 1). n e g a tiv e p la te s, p o s itio n e d a lte rn a tiv e ly , o n e n e x t to
th e o ther. E a ch p o s itiv e p la te is s e p a ra te d fro m th e
a d ja c e n t n e g a tiv e p la te by m e a n s o f a p o ro u s
120 A h b a tte rie s a re fitte d on J X 9 5 m o d e ls w ith cab
in s u la tin g sp a c e r. If o n e o f th e p o s itiv e p la te s
a ir c o n d itio n in g and a re o p tio n a l fo r J X 6 0 , JX 7 0 ,
to u c h e s a n e g a tive plate in th e e le m e n t, th e e le m e n t
J X 8 0 and J X 9 0 m o d e ls . T h e b a tte ry is in s ta lle d
w ill s h o rt-c irc u it a n d be irre v e rs ib ly d a m a g e d . T h e
a b o v e th e fro n t a x le s u p p o rt (F ig. 2).
p o s itiv e p la te s a re w e ld e d to a c o lle c tin g b a r and
fo rm a p o s itiv e te rm in a l. T h e n e g a tiv e p la te s are
N O T E : “M aintenance-free” means that the battery w e ld e d to a s im ila r collecting b a r and fo rm a negative
electrolyte, in norm al conditions o f use, does not te rm in a l.
leak. It could leak if the battery is loaded over 14.4 V.
This, in fact, causes the water to boil due to gas
formed as the battery charges up completely. It can E a ch p o s itiv e p la te c o n s is ts o f a lead g rid w ith lead
be caused by a faulty charging system, by quick p e ro x id e p a s te d to th e g rid h o le s. T h e n e g a tiv e
charging or topping up. p la te s c o n s is t o f a lead grid w ith lead s p o n g e pasted
to th e g rid h oles.
T h e fo u r m ain fu n c tio n s o f a b a tte ry are:

T h e p la te s a re c o v e re d by an e le c tro ly te w h ic h
• to s u p p ly a s o u rc e o f e le c tric ity fo r s ta rtin g , c o n s is ts o f d ilu te d s u lp h u ric a cid so lu tio n .
ig n itio n and in s tru m e n t lig h tin g and fu n c tio n in g .
• to c o n tro l v o lta g e in th e e le c tric a l s y s te m . T h e b a tte ry c a s in g is m a d e o f p o ly p ro p y le n e .
603.54.331.00 - 12 - 1996
REMOVAL AND RE-INSTALLATION

(Op. 55 301 40)
REMOVAL
105 Ah and 120 Ah batteries fitted in front of the

radiator (Figures 1 and 2)
1. L ift th e e n g in e hood.
2. D is c o n n e c t e a rth c a b le (g ro u n d ) fro m tra c to r 1

s tru c tu re and p o s itio n it sa fe ly, a w a y fro m th e
s tru c tu re itself.
3. S la c k e n th e b o lts on b oth te rm in a l c la m p s and

d is c o n n e c t th e p o s itiv e a n d n e g a tiv e b a tte ry
c a b le s. M a ke s u re th e y d o not to u c h th e b a tte ry
itself.
4. L ift th e b a tte ry fro m th e tra c to r by th e tw o

h a n d le s a t e a ch e n d o f th e battery.
RE-INSTALLATION
Applicable to all types of battery.
1. To re - in s ta ll th e battery, re v e rs e th e re m o v a l
p ro c e d u re , w ith th e fo llo w in g p re c a u tio n s :
• C h e c k th a t th e b a tte ry is c le a n , th e re a re no
s ig n s o f e le c tro ly te le a k and th e b re a th e r c o ve rs
are c o m p le te ly in s ta lle d . C o a t th e te rm in a ls and
c la m p s w ith a p e tro le u m je lly (such as V a s e lin e ).
D o not use tra d itio n a l lu b rica n ts as th e y can lead
to e le c tro ly tic c o rro s io n .
• C h e c k th e b a tte ry c o m p a rtm e n t o r s u p p o rt. T h e

c la m p s s h o u ld be cle a n a n d th e re s h o u ld be no
s to n e s o r o th e r sm a ll o bjects, w h ic h could pierce
th e b a tte ry c a sin g .
• C h e c k th a t te rm in a l p o la rity is c o rre c t. C h e c k
te rm in a l c la m p c o n n e c tio n s a re n o t to o tig h t.
• If a radio is installed, it w ill lose all saved d ata and

w ill need to be re p ro g ra m m e d . E le c tro n ic p a n e ls
and m ic ro p ro c e s s o rs , fo r th o s e m o d e ls to w h ich
th e y are fitte d , w ill n o t lo se th e ir m e m o ry
fu n c tio n .
603.54.331.00 - 12 - 1996
BATTERY CHECKING AND MAINTE T able 1

NANCE
T em perature F u lly ch a rg e d b a tte ry
p e rfo rm a n ce
RELATIVE DENSITY
2 5 .0 °C (7 7 .0 °F) 100%
-4 .5 °C (2 3 .9 °F) 8 2%
T h e re la tiv e d e n s ity o f th e b a tte ry e le c tro ly te s h o w s -2 4 .0 °C (-1 1 .2 °F) 64%
th e c h a rg e leve l o f th e battery. W h e n th e b a tte ry is -2 7 .5 °C (- 1 7 .5 °F) 58%
fu lly charged , th e relative d e n s ity o f th e e le ctro lyte , at -3 1 .0 °C (- 2 3 .8 °F) 50%
2 5 °C (7 7 °F ), is a t le a s t 1.280. -3 4 .5 °C (-3 0 .1 °F) 40%
-3 7 .5 °C (- 3 5 .5 °F) 33%
A lte rn a tiv e ly , a p p ro x im a te c h a rg e ca n be m e a s u re d
u sin g a d ig ita l v o ltm e te r (± 0.01 V ) as fo llo w s :
le ss th a n 1 0.5 V u n u s a b le b a tte ry * M a x im u m b a tte ry life can be o b ta in e d by p a yin g th e

le ss th a n 11.8 V fla t b a tte ry rig h t a tte n tio n a n d by c a rry in g o u t re g u la r ch e cks.
le ss th a n 1 2.3 V h a lf-c h a rg e d b a tte ry T h e e n e rg y ca p a city o u tp u t m u st not be e xce e de d by
m o re th a n 1 2.6 V fu lly -c h a rg e d b a tte ry c o n s ta n t o v e rlo a d and c h a rg in g re q u ire m e n ts m u st
be re s p e c te d .
* S ee no tes to p a ra g rap h “T E S T S ” fo r in stru ctio n s on
h o w to re c u p e ra te a s lig h tly s u lp h u riz e d battery.
BATTERY MAINTENANCE
B a tte ry v o lta g e m u s t be re g is te re d on a fla t b a tte ry
c o n s id e rin g th e fo llo w in g :
A ) th e b a tte ry m u s t be fla t fo r a t le a s t 4 h o u rs
b ) if th e v e h ic le h a s bee n use d re ce n tly, o r if th e
b a tte ry has bee n c h a rg e d re ce n tly, s w itc h th e W ARNING: Batteries contain sulphuric acid and
h e a d lig h ts on fo r 2 m in u te s. generate a highly explosive hydrogen and oxygen
m ix during charging.
W h e n a b a tte ry is fla t, th e s u lp h u ric a cid in th e • Do not use devices producing flames or sparks
e le c tro ly te c o m b in e s c h e m ic a lly w ith th e p la te s and to inspect the electrolyte level.
th is d e c re a s e s th e re la tiv e d e n s ity o f th e s o lu tio n .
• Do not remove battery caps without protecting
your hands and your eyes.
A b a tte ry d e n s im e te r w ill d e te rm in e th e re la tiv e

d e n s ity o f th e e le ctro lyte in an elem ent. A reduction in
th e a m o u n t o f s u lp h u ric acid in th e s o lu tio n w ill s h o w D u rin g b a tte ry m a in te n a n c e , fo llo w th e s te p s below :
th e d e g re e o f c h a rg e o f th a t e le m e n t.
1. K e e p th e e le c tro ly te le ve l 17 m m (0 .6 9 9 3 in.)
(o v e r th e plates. If th is is not re s p e c te d , th e acid
c o n c e n tra tio n w ill vary, w h ic h c o u ld d a m a g e
T h e lo w e r th e te m p e ra tu re a t w h ic h th e b a tte ry
s p a c e rs and c a u s e a d e te rio ra tio n in plate
o p e ra te s , th e m ore n e ce ssa ry it is to ke e p th e battery
p e rfo rm a n c e .
fu lly c h a rg e d . F o r e x a m p le , a b a tte ry w ith a re la tiv e
d e n s ity o f 1.2 25 a t 2 7 °C (8 0 °F ) can s ta rt th e e n g in e
a t m ild o u ts id e te m p e ra tu re s b u t m ig h t n o t d o so at
2. U se d istilled o r d e -m in e ra liz e d w a te r only. N e ve r
lo w e r te m p e ra tu re s b e c a u s e o f lo w e r b a tte ry
use ta p w a te r o r rain w a te r o r w a te r fro m a n y
p e rfo rm a n c e . o th e r s o u rc e .
3. K e e p th e b a tte ry c h a rg e d a t le a s t 7 5 % to a vo id
T able 1 s h o w s th e e ffe c t o f te m p e ra tu re on b a tte ry p la te s u lp h u riz a tio n , p e rfo rm a n c e lo ss and
p e rfo rm a n c e . p o s s ib le fre e z in g a t lo w te m p e ra tu re s .
603.54.331.00 - 12 - 1996
4. A v o id o v e rc h a rg in g th e battery. E x c e s s iv e NORMAL CHARGING (TOP UP)

c h a rg e w ill g e n e ra te high in te rn a l h e a t w h ic h w ill
c a u s e grid d e te rio ra tio n and w a te r loss. 1. C h a rg e th e b a tte ry c o m p le te ly w ith a slo w
b a tte ry c h a rg e r at 3 to 6 a m p e re s fo r th e required
5. D u rin g q u ic k re c h a rg e , c h e c k th e b a tte ry tim e . T h is can la s t 3 6 h o u rs, o r m o re , if th e
te m p e ra tu re d o e s n o t e x c e e d 5 0 °C (1 2 2 °F ). b a tte ry is v e ry fla t. A s e v e re ly s u lp h a te d b a tte ry
m a y n o t ch a rg e . W h e n th e b a tte ry is c o m p le te ly
6. D o n o t a d d s u lp h u ric a cid to an e le m e n t u n le ss c h a rg e d , th e e le m e n ts w ill p ro d u c e g a s fre e ly
s o m e e le c tro ly te h a s bee n sp ilt. B e fo re fillin g , a nd th e re la tiv e d e n s ity w ill re m a in c o n sta n t.
c h e c k th e s o lu tio n h a s th e c o rre c t re la tiv e D is c o n n e c t th e b a tte ry c h a rg e r a fte r th re e
d e n sity. S lo w re c h a rg e is th e o n ly w a y to c o n s e c u tiv e d e n s im e te r re a d in g s , re co rd e d
re c h a rg e th e b a tte ry c o m p le te ly . You can use a e v e ry hour, s h o w in g th a t re la tiv e d e n s ity has
h igh a m p e ra g e b a tte ry c h a rg e r to c h a rg e th e s ta b ilis e d .
b a tte ry w ith high c u rre n t in te n s ity fo r s h o rt
p e rio d s o f tim e . U se a s lo w c h a rg e to b rin g th e 2. W h e n using a fa s t o r high a m p e re ch a rg e , fo llo w
b a tte ry to its fu ll ca p a city. th e m a n u fa c tu re r’s in s tru c tio n s c a re fu lly. H igh
c h a rg in g a m p e ra g e in c re a s e s e le c tro ly te
te m p e ra tu re a n d , if th e b a tte ry c h a rg e r is not
e q u ip p e d w ith an a u to m a tic tim e o r te m p e ra tu re
DRY CHARGED BATTERIES s w itc h , it ca n c a u s e th e e le c tro ly te te m p e ra tu re
to rise a b o v e 5 0 °C (1 2 2 °F ). T h is can c a u se
v io le n t boiling in th e b a tte ry and d a m a g e internal
D ry c h a rg e d ba tte rie s m u st be p re p a red as fo llo w e d : c o m p o n e n ts .
3. C h e c k e le c tro ly te le v e l in e a ch e le m e n t a g a in
1. R e m o v e th e b re a th e r c a p s fro m e a ch b a tte ry an d , if n e c e s s a ry , to p up w ith d is tille d w a te r.
e le m e n t.
W ARNING : Explosive gas is formed when a battery
2. Fill each e le m e n t to th e re c o m m e n d e d level w ith is charged. Do not smoke or use naked flames when
e le c tro ly te a t a re la tiv e d e n s ity o f 1.260. checking electrolyte level. Check that the battery
charger is switched off, before connection and dis
connection, to avoid sparks which could ignite the
NOTE: The electrolyte consists o f diluted sulphuric gas.
acid, preferably at a temperature o f 21° - 32°C (69.8
- 89.6°F).
3. A fte r fillin g , le a v e th e b a tte ry to re st fo r 15 CHARGING VERY FLAT BATTERIES
m in u te s . C h e c k th e e lectrolyte level and to p up, if
n e ce ssa ry.
To re c h a rg e a P b -C a m a in te n a n c e -fre e b a tte ry w e
4. C h a rg e th e b a tte ry fo r 4 h o u rs a t 5 - 8 A ., re c o m m e n d u sin g a c o n s ta n t v o lta g e b a tte ry
c h e c k in g th a t all th e e le m e n ts are p ro d u cin g gas c h a rg e r. F o r v e ry fla t b a tte rie s , c h a rg e fo r 48 hours,
freely. a t 16 V., w ith c u rre n t lim ita tio n (50 A . fo r 105 A h and
6 6 A fo r 120 A h ).
5. R e p la c e th e b re a th e r ca p s.
T h is m e th o d is s e lf-re g u la tin g . H ig h c u rre n t is

p ro v id e d a t th e b e g in n in g (w h e n th e b a tte ry v o lta g e
CHARGING THE BATTERY is v e ry low ). C u rre n t d e c re a s e s p ro g re s s iv e ly w h e n
th e b a tte ry is fu lly c h a rg e d (and its v o lta g e is high).
B e fo re c h a rg in g a b a tte ry:
If o n ly c o n s ta n t v o lta g e b a tte ry c h a rg e rs are
a v a ila b le , w e re c o m m e n d u sin g v o lta g e le v e ls and
1. C le a n th e b a tte ry c a s in g and e le m e n t c o v e rs tim e s sh o w n in ta b le 2. T h e s e fig u re s re fe r to v e ry flat
c a re fu lly w ith a m m o n ia d ilu te d in w a rm w a te r b a tte rie s . If th e b a tte ry is o n ly 5 0 % d is c h a rg e d , use
and cle a n th e te rm in a ls ; h a lf th e tim e s h o w n (slo w ch a rg in g p ro g ra m m e ). F o r
o th e r c o n d itio n s , re d u c e c h a rg in g tim e
2. C h e c k th e e le c tro ly te le ve l a nd, if it is b e lo w th e p ro p o rtio n a lly . W h e n fe a s ib le , use th e s lo w e s t
p la te level, to p up w ith d istille d w a te r to c o v e r the c h a rg in g p ro g ra m m e fo r in c re a s e d b a tte ry life.
p late s.
If v io le n t b o ilin g o c c u rs d u rin g c h a rg in g , d u e to g a s
fo rm a tio n o r e le c tro ly te le a ka ge , o r if th e b a tte ry b o x
603.54.331.00 - 12 - 1996
is hot (50°C (122°F) or higher), temporarily reduce or Example 1:

stop battery charging to avoid damaging the battery. Temperature below 30 °C (86°F)
Battery electrolyte temperature 19 °C (66.2 °F)
Densimeter reading 1.270
Subtract 11.0 x 0.004
“5T5"
Correct relative density = 1.262
Table 2
Type of battery
105Ah 120Ah
(760 cca) (800 cca)
25 hrs at 5A 30 hrs at 5A Example 2:

Slow charging
12,5 hrs at 15 hrs at 10A Temperature above 30 °C (86 °F)
programmes
10A Battery electrolyte temperature 40 °C (104 °F)
Densimeter reading 1.220
Add 10.0 x 0.004 0.007
Fast charging pro 7 hrs at 10A 10 hrs at 18A 5T5-
grammes (emer
Correct relative density = 1.227
gency use only)
2. Use the following table to determine the charge

TESTS
level.
Before carrying out battery tests, check the breath

ers are not blocked, there is no rust, the breather Correct Correct
caps are not open and the casing is not cracked. Charge relative relative Average
condition density at density at battery
15°C (86°F )25°C (86°F) voltage
100% 1.295 1.287 12.66

Required testing equipment: 75% 1.253 1.246 12.45
50% 1.217 1.210 12.30
25% 1.177 1.170 12.00
Flat 1.137 1.130 11.84
• Densimeter
• Battery starter tester (high amperage tester)
• Thermometer
NOTE: Relative density should not vary more than
• Battery charger 0.025 points between cells.
Relative density: This test shows the charge level of 4. If relative density is 1.280 or higher, the battery is
a battery. fully charged and in good working condition.
5. If the correct relative density is less than 1.280,

1. With the float in a vertical position, note the charge the battery and check the charging
reading. system, to find the cause of low battery load.
2. Regulate the densimeter reading for battery NOTE: If distilled water has recently been added, the
electrolyte temperature variations subtracting 4 battery m ust be charged for a short period o f time to
points (relative density 0.004) for every 5.5 °C obtain precise densimeter readings.
(41.9 °F) below the temperature the densimeter
is calibrated at and adding 4 points (relative
density 0.004) for every 5.5 °C (41.9 °F) above If the battery has been loaded and kept still, the
this temperature. battery electrolyte will be thicker at the base of the
elements. The battery must be shaken periodically to
mix the electrolyte. This will improve charging
The following examples have been calculated with a amperage and allow more precise densimeter
densimeter calibrated at 30 °C (86 °F). readings during tests.
603.54.331.00 - 12 - 1996
Performance tests 3. T u rn th e b a tte ry c h a rg e r tim e r to m o re th a n a 3

m in u te c h a rg e and th e n b a c k to a 3 m in u te
P e rfo rm a n c e te sts help to unde rsta n d if a b a tte ry can c h a rg e .
a d e q u a te ly run th e e n g in e . V o lta g e re a d in g s s h o w
b a tte ry co n d itio n . B e fo re ca rry in g o u t th e te st, c h e c k
th e b a tte ry e le c tro ly te le v e l is c o rre c t a n d th e o p e n
c irc u it v o lta g e is 1 2 .5 V o r m o re . T h e b a tte ry ca n be
te s te d in th e tra c to r o r re m o v e d .
4. S e t th e ch a rg in g a m p e ra g e as clo se as p ossib le
to 4 0 A.
1. S w itc h th e b a tte ry s ta rt te s te r c u rre n t c o n tro l to

“o ff” (high a m p e ra g e d is c h a rg e te s te r). C a lib ra te
th e v o lta g e s e le c tio n s w itc h to th e n o m in a l 5. A fte r a 3 m in u te fa s t ch a rg e , read th e vo ltm e te r.
b a tte ry v o lta g e o r s lig h tly hig h er. C o n n e c t th e
p o sitive te s te r c o n d u c to rs to th e p o sitive b a tte ry
te rm in a l and th e n e g a tiv e c o n d u c to rs to th e
• If th e to ta l v o lta g e is h ig h e r th a n 1 5.5 V., th e
n e g a tiv e b a tte ry te rm in a l.
b a tte ry is n o t s a tis fa c to ry . It is p ro b a b ly
s u lp h a te d o r w o rn and m u s t be c h a n g e d .
2. T urn th e c u rre n t c o n tro l k n o b u ntil th e a m m e te r

re a d in g re a c h e s h a lf th e co ld s ta rt b a tte ry
NOTE: A slightly sulphated battery can be renewed
a m p e ra g e and n o te th e v o lta g e re a d in g .
using a multiple type battery charger, with upper
open circuit voltage lim it o f 50V. A sulphated battery
has high resistance and for this reason it will be
• If th e re a d in g s h o w s 9 .6 V. o r h ig h e r a fte r 15 necessary to set a high voltage at the beginning to
s e c o n d s , th e b a tte ry has a d e q u a te p o w e r o u tp u t overcome resistance. A t the beginning there m ay be
and can e a s ily be c h a rg e d fo llo w in g th e n o rm a l no visible sign o f charging. A fter some minutes o f
p ro c e d u re . inactivity, a low charge will show. This is followed by a
fast rise in amperage. Amperage m ust not exceed
• If th e re a d in g is lo w e r th a n 9 .6 V., b a tte ry is not 14.0 A. and the battery electrolyte temperature m ust
s a tis fa c to ry fo r use a n d th e c h a rg e m u s t be not exceed 5 0 °C (122 °F). When amperage
te s te d as fo llo w s . stabilizes, set the voltage until amperage
corresponds to 5 A. Continue this amperage until the
relative density o f the battery electrolyte stabilises
(1.275 - 1.280 at 20°C (68°F)). This could take
W ARNING : Do not leave a high discharge tester on approximately 48 hours. Let the battery rest for 24
the battery for more than 15 seconds. hours and then carry out the previously described
performance test.
• If th e to ta l v o lta g e is less th a n 15.5 V., c h e c k th e

re la tiv e d e n s ity o f e a ch e le m e n t and re c h a rg e
th e b a tte ry a c c o rd in g to th e fo llo w in g sc a le :
Test charging : T h is te s t is o n ly fo r th o s e b a tte rie s

w h ic h have n o t p a sse d th e p e rfo rm a n c e te s t a b o ve .
Relative density Fast charge up to:
1 .1 5 0 o r less 6 0 m in u te s
1. C o n n e c t th e p o s itiv e b a tte ry c h a rg e r te s te r fro m 1.151 to 1.1 7 5 4 5 m in u te s

c o n d u c to rs (h ig h a m p e ra g e d is c h a rg e te s te r) to
th e p o s itiv e b a tte ry te rm in a l a n d th e n e g a tiv e fro m 1 .1 7 6 to 1.2 0 0 30 m in u te s
c o n d u c to rs to th e n e g a tiv e b a tte ry te rm in a l.
fro m 1 ,2 0 0 to 1.2 2 5 15 m in u te s
(s lo w c h a rg e o n ly)
2. C o n n e c t th e p o s itiv e b a tte ry c h a rg e r c o n d u c to r
to th e p o sitiv e b a tte ry te rm in a l and th e n e g a tiv e
c o n d u c to r to th e n e g a tiv e b a tte ry te rm in a l.
NOTE: When there are problems with a battery,
check fan belt tension and the complete charging
system.
603.54.331.00 - 12 - 1996
BATTERY PROBLEMS - FREQUENT 5. Crystals are formed when batteries are left flat.
CAUSES High temperature and long periods with the
battery flat increase this condition. If a battery is
1. Internal open circuit. left at room temperature for a week it can rarely
be charged in the vehicle. Battery recharge
requires higher constant voltage. After three
2. Internal short-circuit. weeks the battery will be permanently
jeopardized and it will be necessary to follow the
3. Battery electrolyte leakage. procedure described for “very flat batteries”.
4. Grid active material separation.
Fully charged batteries have longer a life. A

5. Accumulation of sulphate crystals too big to be lead-calcium battery discharges 3% a month. This
dispersed. means that in 16 months it will reach 50% charge. In
the tractor, inactive load is approximately 50 mA. To
forecast discharge on a vehicle not in use add
approximately 8 Ah a week to this value.
These problems are commonly caused by the
following:
1. Component failure inside the elements.

2. Excessive crystal growth which can pierce the
spacers and cause short circuits. It is worth noting that if a battery is weak during
engine start-up, it is best to let the battery rest for two
3. Excessive overload (bad charging system, high
minutes. This rest time increases as the temperature
voltage fast charging, high operating
decreases.
temperatures).
4. Battery electrolyte freezing.
A fully charged battery freezes at -6 5 °C
(-85 °F). A 50% charged battery freezes
between -1 7 °C and -2 7 °C (16.6 °F). A
completely flat battery freezes between - 3 °C When two batteries are installed, do not use an old
(26.6 °F) and -11 °C (12.2 °F). Excessively fast battery with a new one. One battery will always stop
charging and boiling caused by gas formation before the other one. If the battery has lasted as
cause the separation of active material from the forecasted, charge both batteries. If one has stopped
grids. Separation destroys the battery chemical before the forecasted time due to a defect, then
function. change only the defective battery.
603.54.331.00 - 12 - 1996
603.54.331.00 - 12 - 1996
Chapter 6 - ELECTRICAL CIRCUITS
CONTENTS
55 100 C o n te n ts ................ 1
F u s e s (all v e rs io n s ) ....................................................................................................................................... 2
S y m b o ls use d in e le c tric a l c irc u its ............................................................................................................ 4
E le c tric a l w ire c o lo u r c o d in g ....................................................................................................................... 5
G ro u n d lo c a tio n s .............................................................................................................................................. 5
E le c tric a l d ia g ra m s ..............................................................................................................................................
- G e n e ra l d ia g ra m s (W /C a b ) ........................................................................................................9
- G e n e ra l d ia g ra m s (W /O u t C a b ) ............................................................................................ 15
- A n a lo g u e in s tru m e n t c irc u it a n d c o n n e c to r o v e rv ie w ................................................ 19
- S ta rt-u p c irc u it a n d c o n n e c to r o v e rv ie w ......................................................................... 21
- D ire c tio n in d ic a to r & h a z a rd w a rn in g lig h t c irc u it and c o n n e c to r o v e rv ie w . . . . 25
- W in d s c re e n and re a r w in d o w w ip e r/w a s h e r c irc u it and c o n n e c to r o v e rv ie w . . . 31
- B ra k e lig h t c irc u it a n d c o n n e c to r o v e rv ie w ..................................................................... 35
- H e a tin g and a ir-c o n d itio n in g s y s te m c irc u it and c o n n e c to r o v e rv ie w .................. 41
- W o rk la m p (w ith o u t c a b c irc u it and c o n n e c to r o v e rv ie w ) ........................................ 45
- W o rk la m p (w ith o u t c a b c irc u it and c o n n e c to r o v e rv ie w ) ........................................ 49
- S id e lig h ts ,m a in a n d d ip p e d h e a d lig h ts , p a rk in g lig h t c irc u it a n d c o n n e c to r
o v e rv ie w 53
603.54.331.00 - 12 - 1996
FUSES AND RELAYS MAIN BOX
H 15A Ur 15A
Cl 1QA * - 15A
s 10 A i 30A
KORNAR&ESi
s 7,5A ■W1 5 A H0RNRB.AY
□ 7,5A
+ 40A
□ 10A 30A UZUN FAR ROLES)

HIGH BEAH RELAY
□ 10A 20A
H 20A
w 15 A
KORNAR^LESj
LOW BEAH RBAY
I5 A
□1
47
Fuses PROTECTED CIRCUITS Am ps

1 Main beam headlights 15
2 Dipped beam headlights 10
3 Front right and rear left side lights 10
4 Front left and rear right side lights 7,5
5 Engine shut-dow n solenoid 7.5
6 Instruments, turn signal switch, horn 10
7 Hazard warning switch, fuel sedimentor 10
8 Relays 20
9 Hazard warning switch 15
10 Beacon lamp, (radio, interior lam ps- with cab models) 15
11 Cigarette lighter 15
12 Power for cab (with cab models) 30
13 Thermostart 15
14 Power socket (with cab models) 40
15 Power for cab (with cab models) 30
16 Turn signal switch 20
17 Brake lights 15
I Dipped beam relay -
II Main beam relay -
III Horn relay -
IV Brake relay -
603.54.331.00 - 12 - 1996
FUSES AND RELAY BOX (INSIDE CAB) F u s e s and p ro te c te d c irc u its a re lis te d be lo w :
FIG - 48 - 49
Fuses PROTECTED CIRCUITS Am ps
& * ■
0 <C
o 1.
2.
F ro n t w ip e r
W asher
10
7.5
<C
& * ■ B e a c o n la m p , in te rio r la m p s,
3. 15
radio
© -►
9k <c
<c
o
4.
5.
H e a te r/A ir C o n d itio n in g
R e a r w ip e r
20
7.5
® " * ' <N
6. W o rk in g la m p s s w itc h e s 10
<c 7. F ro n t w o rk in g la m p s 15
© -► □
8. R e a r w o rk in g la m p s 25
RELAY
<c
ROLE
© -► o
m
o <c
om
mi
o <c
© - *■ om <N
TRE0849A
48
R e la y s and re la te d c irc u its a re liste d b elow :
Relays CIRCUITS
1. F ro n t w o rk lig h ts
2. R e a r w o rk lig h ts
3. P o w e r s u p p ly
4. P o w e r s u p p ly
603.54.331.00 - 12 - 1996
SYM BOLS
THERMOSTARTER SWITCH
HEADLAMPS WATER TEMP. GAUGE SENDING UNIT
BRAKE SWITCH
HANDBRAKE SWITCH
ENGINE OIL PRESSURE SWITCH
STARTER SWITCH
FRONT SIGNAL AND PARKING LIGHT
SOLENOID
FUEL SEDIMENTER
REAR INDICATOR LIGHT
SPEAKER
INTERIOR LIGHTS (LAMPS) [C O
BEACON LAMP
LIGHTER
COMPRESSOR COMPRESSOR
NUMBER PLATE LAMP
SWITCHES
GROUND
WORKLAMPS
REAR WIPER
I FUSE I
-457 15y » STARTER SWITCH
I I MAIN FUSE
HORN
THERMOSTARTER
FUEL LEVEL SENSOR
£
ALTERNATOR
FRONT BRAKE OIL UNIT
DIODE
■i —
AIR FILTER RESTRICTION SWITCH
-mi— □
603.54.331.00 - 12 - 1996
ELECTRICAL WIRE COLOUR CODING
B B la c k
G G re e n
K P in k
LG L ig h t g re e n
LN Tan
N B ro w n
O O ra n g e
P P u rp le
R R ed
S G re y
TQ T u rq u o is e
U B lue
W W h ite
Y Y e llo w
GROUND LOCATIONS (Pages 6 - 8)

1. In s tru m e n t c lu s te r g ro u n d p o in t
2. F u se b o x g ro u n d p o in t
3. C a b flo o r g ro u n d p o in t
4. S te e rin g p u m p p re s s u re s e n s o r g ro u n d p o in t
5. B a tte ry g ro u n d p o in t
6. W in d s c re e n w a s h e r p u m p g ro u n d point.
7. 7 pin tra ile r c o n n e c to r g ro u n d p o in t
8. E v a p o ra to r to p g ro u n d p o in t
9. U p p e r ca b g ro u n d p o in t
10. P ro te c tiv e d io d e g ro u n d p o in t
603.54.331.00 - 12 - 1996
GROUND LOCATIONS
603.54.331.00 - 12 - 1996
603.54.331.00 - 12 - 1996
603.54.331.00 - 12 - 1996
GENERAL DIAGRAM -C EN TR E(W ITH CAB)
1,5 U/W 1,5 U/W

1,5 U/R 1,5 U/R
1,5 R 1,5 R/W
1,0 R A1,0 R/B
1,5 Y/W ,1,5 P/Y
1.5 Y/W '1.5 G
1,5 Y/W 1,0 G
3,0 Y/W 3,0 P/W \ 1,0 R
1,5 N 1,5 P v
2,0 N
1,5 N 1,5 P
5,0 N 5,0 Y/W
2,5 N/R 2,5 N/R
6,0 N 6,0 N
5,0 N 5,0 Y/W
1,5 Y/W 1,5 S
1,5 G/O 1,5 G/O
UPG JX KABINLI 1
603.54.331.00 - 12 - 1996
603.54.331.00 - 12 - 1996
n u
@
603.54.331.00 - 12 - 1996
603.54.331.00 - 12 - 1996

1 - Instrument panel
1 - High beam
2 - Park
3 - Left signal
4 - 2 nd trailer
5 - 1 st trailer
6- Earth
7 - Fuel gauge
1 0 - Engine w ater temperature gauge
1 2 - Right signal
1 3 - A ir filter
1 5 - Oil pressure
1 8 - Battery charge indicator
1 9 - Parking brake
2 - Starter switch
3 - Turn signal switch
4 - Hazard warning lights indicator sending unit
5 - Fuse Box
6- Low beam relay
7 - High beam relay
8- Horn relay
9 - Compressor
1 0 - Flasher
11- Battery
1 2 - Starter
1 3 - Alternator
1 4 - Over voltage circuit breaker (DIODE)
1 5 - Engine oil pressure switch
1 6 - A ir cleaner restriction indicator sending unit
1 7 - Water temperature gauge sending unit
1 8 - Therm ostarter button
1 9 - Horn
2 0 - Right front parking and turn signal lights
2 1 - Rear left parking,turn signal and stop lights
2 2 - Working lamp
2 3 - Fuel level sensor
2 4 - Beacon lamp
2 5 - Trailer plug
2 6 - Number plate lamp
2 7 - Engine shut off solenoid
6 0 3 .5 4 .3 3 1 .0 0 -1 2 - 1996
28- Thermostarter
29- Hand brake switch
30- Brake stop light switch
31- Starter inhibitor unit
32- Headlamps
33- Worklights switch
34- Rear right parking,turn signal and stop lights
35- Main fuse20
36- Front brake oil unit
37- Rear wiper
38- Cabin fuse box
39- Canin plug
40- Switches
41- Rear work lamps
42- Front work lamps
43- Speaker
44- Interior lamps
45- W iper
46- Radio
47- Heater
48- Washer
49- Beacon lamp
50- Fuel sedimenter
51- Brake disc
52- Front working lamp relay
53- Rear working lamp relay
54- Front and rear working lamp relay
55- Power relay
56- Front left signal and parking light
A -M ain and chassis harness connector

B-M ain and cab harness connector
C -M ain and headlamp connector
D-M ain and right front signal connector
E-M ain and left front signal connector
F-C hassis and rear right indicator connector
G -C hassis and rear left indicator connector
603.54.331.00 - 12 - 1996
GENERAL DIAGRAM -C EN TR E(W ITH O U T CAB)
2,0 B
1,5 B / / 1 1,0 E
1,5 P
2,0 U/R
UPG JX ROPS 1
603.54.331.00 - 12 - 1996
603.54.331.00 - 12 - 1996
SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6
GENERAL DIAGRAM -C E N TR E(W ITH O U T CAB)

1 - High beam
2 - Park
3 - Left signal
4 - 2 nd trailer
5 - 1 st trailer
6- Earth
7 - Fuel gauge
1 0 - Engine w ater temperature gauge
1 2 - Right signal
1 3 - A ir filter
1 5 - Oil pressure
1 8 - Battery charge indicator
1 9 - Parking brake
2 - Starter switch
5 - Fuse Box
6- Low beam relay
7 - High beam relay
8- Horn relay
9 - Fuel sedimenter
1 0 - Flasher
11- Battery
1 2 - Starter
1 3 - Alternator
1 4 - Over voltage circuit breaker (DIODE)
1 5 - Engine oil pressure switch
1 6 - A ir cleaner restriction indicator sending unit
1 7 - Water temperature gauge sending unit
1 8 - Therm ostarter button
603.54.331.0 0 - 1 2 - 1996
19- Horn
20- Right front parking and turn signal lights
21- Rear left parking,turn signal and stop lights
22- Working lamp
23- Fuel level sensor
24- Beacon lamp
25- Trailer plug
26- Number plate lamp
27- Engine shut off solenoid
28- Thermostarter
29- Hand brake switch
30- Brake stop light switch
31- Starter inhibitor unit
32- Headlamps
33- Worklights switch
35- Main fuse
36- Front brake oil unit
37- Brake disc
A - Main and chassis harness connector

C - Main and headlamp connector
D - Main and right front signal connector
E - Main and left front signal connector
F - Chassis and rear right indicator connector
603.54.331.00 - 12 - 1996
ANALOGUE INSTRUMENT CIRCUIT
1- L e ft tu rn in d ic a to r 9 - B ra k e oil le v e l low
2- S id e la m p s 10 - P a rk in g b ra ke
3- H e a d la m p m a in b e a m 11- R iH ht tu rn in d ic a to r
4 - W a te r in fu e l 12- 1st. tra ile r tu rn sig n a l

5 - A ir filte r b lo c k e d 13 - 2 n d .tra ile r tu rn s ig n a l
6- U nused 14 - U nused
7- E n g in e oil p re s s u re 15 - U nused
8- B a tte ry c h a rg e r
603.54.331.00 - 12 - 1996
0 ,5 G / B
0 ,5 G / U
0 ,5 B
0 ,5 L G / Y
0 ,5 L G / R
0 ,5 G / R
0 ,5 R / W
0 ,5 U / W
0 ,5 U
0 ,5 G / W
0 ,5 B / S
0 ,5 W / N
0 ,5 N / Y
0 ,5 W / B
0 ,5 G
0 ,5 R / K
603.54.331.00 - 12 - 1996
STARTING CIRCUIT
STARTING CIRCUIT
2 - Starter switch
11 - Battery
12 - Starter
13 - Alternator
14 - Over voltage circuit breaker (DIODE)
31 - Starter inhibitor unit
35 - Main Fuse
603.54.331.00 - 12 - 1996
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
- DIRECTION INDICATOR AND HAZARD WARNING LIGHT CIRCUIT
603.54.331.00 - 12 - 1996
26
- DIRECTION INDICATOR AND HAZARD WARNING LIGHT CIRCUIT
2 - Starter switch
5 - Fuse Box
1 0 - Flasher
11- Battery
1 2 - Starter
1 3 - Alternator
2 5 - Trailer plug
3 4 - Rear right parking,turn signal and stop lights
3 5 - Main fuse2 0 - Right front parking and turn signal lights
5 6 - Front left signal and parking light

E - Main and left connector
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
- WINDSCREEN AND REAR WINDOW WIPER/WASHER CIRCUIT
603.54.331.00 - 12 - 1996
32
- WINDSCREEN AND REAR WINDOW WIPER/WASHER CIRCUIT
2 - Starter switch
5 - Fuse Box
11- Battery
1 2 - Starter
1 3 - Alternator
3 5 - Main Fuse
3 7 - Rear wiper
3 8 - Cabin fuse box
4 0 - Switches
4 5 - W iper
4 8 - Washer
5 5 - Power relay
B - Main and cabin harness connector
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
6 N
6 Y /W '
2 ,5 N / U ■
1 ,5 R -
2 ,5 W / Y
1 ,5 U -
1 R /W
1 R /W
1 R
1 R
1 ,5 P / G
1 ,5 P / R
1 G
1 G
1 LG /B
1 L G
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
__________________ SECTION 55 - ELECTRICAL SYSTEM - CHAPTER 6 35
- BRAKE LIGHT CIRCUIT
603.54.331.00 - 12 - 1996
- BRAKE LIGHT CIRCUIT
2 - Starter switch
11- Battery
1 2 - Starter
1 3 - Alternator
2 5 - Trailer plug
3 0 - Stop light switch
3 4 - Rear right parking turn signal and stop light
3 5 - Main Fuse
G - Chassis and rear left indicator connector
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603 . 54 . 331.00 - 12 - 1996

CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
603.54.331.00 - 12 - 1996
- HEATING AND AIR-CONDITIONING SYSTEM CIRCUIT
603.54.331.00 - 12 - 1996
- HEATING AND AIR-CONDITIONING SYSTEM CIRCUIT
2 - Starter switch
5 - Fuse Box
9 - Compressor
11- Battery
1 2 - Starter
1 3 - Alternator
3 5 - Main Fuse
3 8 - Cab fuse box
4 7 - Heater
5 4 - Compressor
5 5 - Power relay
B - Main and cab harness connector
I - Electrical fans
II- A ir conditioning-therm ostat
III-.Air-conditioning pressure switch
IV - Electric fan control switch
V - Air-conditioning control switch
V I- Heating control
V II- Air-conditioning control switch connection
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
603.54.331.00 - 12 - 1996
- WORK LAMP (WITHOUT CAB) CIRCUIT
603.54.331.00 - 12 - 1996
- WORK LAMP (WITHOUT CAB) CIRCUIT

2- Starter switch
3- Turn signal switch
5- Fuse Box
11- Battery
12- Starter
13- Alternator
22- Work lamp
33- W orklight switch
35- Main Fuse
57- Work lamp
C -M ain and headlamp connector
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
- WORK LAMP (WITH CAB) CIRCUIT
603.54.331.00 - 12 - 1996
50
- WORK LAMP (WITH CAB) CIRCUIT

2- Starter switch
5- Fuse Box
11- Battery
12- Starter
13- Alternator
35- Main Fuse
38- Cab fuse box
40- Switches
41- Rear work lamps
42- Front work lamps
5 2 - Front work lamps relay
53-R e ar w ork lamps relay
54-F ronrt and rear work lamps relay
55-P ow er relay
B-M ain and cab harness connector
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
603.54.331.00 - 12 - 1996
- SIDE LIGHTS, MAIN AND DIPPED HEADLIGHTS, PARKING LIGHT CIRCUIT
603.54.331.00 - 12 - 1996
54
- SIDE LIGHTS, MAIN AND DIPPED HEADLIGHTS, PARKING LIGHT CIRCUIT

2 - Starter switch
5 - Fuse Box
6- Low Beam Relay
7 - High beam relay
11- Battery
1 2 - Starter
1 3 - Alternator
2 5 - Trailer plug
2 6 - Number plate lamp
3 3 - Worklight switch
3 4 - Rear right parking,turn signal and stop lights
3 5 - Main Fuse
5 6 - Front left signal and park lights
C - Main and headlamp connector
E - Main and left connector
G - Chassis and rear left indicator connector
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
CONNECTOR OVERVIEW
603.54.331.00 - 12 - 1996
SECTION 90 - CAB - CHAPTER 1 1
SECTION 90 - CAB
Chapter
1 - Removing parts
CONTENTS
90 160 42 - 4 3
90 120 10 C o n tro l le v e rs , s e a t a n d e le c tr ic a l c o n tro ls - d is a s s e m b ly a n d r e a s s e m b ly ............................. 2
90 156 52 R e a r w in d o w , h a n d le a n d lo c k - d is a s s e m b ly a n d r e a s s e m b ly ................................................... 10
90 154 30 L e f t- h a n d d o o r e x te r io r h a n d le a n d lo c k - d is a s s e m b ly a n d r e a s s e m b l y .................................... 11
90 154 10 L e f t- h a n d d o o r - d is a s s e m b ly a n d r e a s s e m b ly ...................................................................................... 12
90 160 60
55 518 52 W in d s c r e e n w ip e r m o to r - d is a s s e m b ly a n d r e a s s e m b ly .................................................................. 13
90154 24
90 156 10 - 14
90 156 28 C a b w in d o w s - r e p la c e m e n t ............................................................................................................................. 15
????
2 SECTION 90 - CAB - CHAPTER 1
CONTROL LEVERS, SEAT,

ELEC TR IC AL CONTROLS
D is a s s e m b ly -A s s e m b ly
(Op. 90 160 43 -9 0 160 42-90 120 10)
2. T a k e o u t th e f o u r s e c u r in g s c r e w s (1 ) a n d re
m o v e th e c o v e rin g o f th e c o n tro l p a n e l (2 ).
3. D is c o n n e c t th e e le c tric a l c o n n e c to r fr o m th e c a b
in te r io r lig h t s w itc h e s (3 ) a n d re m o v e th e c o v e r.
4. R e m o v e th e L H p a n e l re ta in in g s c r e w s (1)
5. R e m o v e t h e th r e e L H p a n e l re ta in in g s c r e w s (1)
???
6. R e m o v e th e s c r e w s (1 ) o n r e a r p a n e l
7. R e m o v e th e L H p a n e l (1 ).
8. R e m o v e t h e s c r e w s (1 ) o f th e R H p a n e l re ta in in g
e le m e n ts .
9. R e m o v e th e s c r e w s (1 ) fr o m th e R H fe n d e r s .
????
10. R e m o v e th e s c r e w s (1 ) fr o m th e r e a r p a n e l
11. R e m o v e th e L H p a n e l (1 ).
10
12. R e m o v e th e th e h a n d th r o ttle le v e r (1 ).
11
13. R e m o v e th e re ta in in g n u t (1 ) a n d ta k e o u t th e
s te e rin g w h e e l.
12
???
14. R e m o v e th e re ta in in g b o lts o n th e c o n tro l p a n e l

a n d d e ta c h th e e le c tric a l c o n n e c to r. R e m o v e th e
t a c h o m e t e r a n d th e c o n tro l p a n e l (1)
13
15. U n s c re w th e re ta in in g s c r e w (2 ) o n th e s id e o f
th e in s tr u m e n t c o n s o le ( r e a r h o o d ) (1 ).
14
16. R e m o v e t h e re ta in in g s c r e w s (1 ) o n t o p o f in s tr u
m e n t c o n s o le ( r e a r h o o d ) (2 ).
15
17. R e m o v e th e in s tr u m e n t c o n s o le ( r e a r h o o d ) (1 ).
16
????
18. R e m o v e th e s c r e w s (1 ) s e c u r in g th e k n o b s to th e
c o n tro l le v e rs a n d re m o v e th e k n o b s .
17
19. U n s c re w th e fo u r s c r e w s (1 ) s e c u r in g th e le v e r
p a n e l.
18
20. U n s c re w th e l i f t - o - m a t i c s w itc h re ta in in g s c re w s
(1 ).
???
21. R e m o v e re m o v e th e p r o te c tiv e c o v e r a n d th e
s c r e w s (1 ) s e c u rin g th e h y d r a u lic c o n tro l le v e r
s u p p o r t (2 ) to th e p la tfo rm .
20
22. R e m o v e th e s c r e w s (1 ) h o ld in g th e a u x ilia ry
c o n tro l v a lv e le v e rs in p la c e .
21
23. R e m o v e th e s c r e w s s e c u r in g th e p a rk in g b ra k e
s u p p o r t (1 ) to th e p la tfo rm . D is c o n n e c t th e
p a rk in g b ra k e re la y a n d th e c o n tro l le v e r fr o m
v e r tic a l ro d .
22
24. U n s c re w th e s c r e w s (1 ) s e c u rin g th e s h u ttle

le v e r (2 ).
23
????
25. U n s c re w th e c o n tro l le v e r re ta in in g s c r e w s (1)

a n d re m o v e th e c o n tro l le v e rs .
24
26. R e m o v e th e P T O c lu tc h le v e r s u p p o r t s e c u rin g
s c r e w s (1 ). D is c o n n e c t th e P T O c o n tro l le v e r
fr o m th e p a tfo rm .
27. U n s c re w th e re ta in in g s c r e w s (1 ) fr o m th e P T O
s y n c h r o n is e d c o n tro l le v e r s u p p o r t (2 ).
26
???
28. R e m o v e th e f o u r s e a t s e c u r in g s c r e w s (1 ).
R e m o v e th e s e a t a n d th e c o v e rin g b e n e a th it.
To re fit, p ro c e e d a s fo llo w s :
— R e fit th e PTO c lu tc h le v e r and PTO

s y n c h r o n is e d c o n tro l le v e r s u p p o r t.
— R e fit th e tr a n s m is s io n c o n tro l le v e rs .
— R e fit th e L I F T - O - M A T I C c o v e r, s e c u rin g it t o t h e
R H p a n e l w ith th e th r e e s c r e w s .
— R e fit th e R H s id e p a n e l, s e c u rin g it to th e c a b
b o d y w ith th e fiv e s c re w s .
— R e fit th e r e c ta n g u la r P T O c o v e r, th e y e llo w
p u s h b u tto n a n d p la s tic p lu g . S e c u r e th e c o v e r
w ith th e tw o s c re w s .
— R e fit th e th e L I F T - O - M A T I C s w itc h , th e p ro
te c tiv e c o v e r a n d th e c o n tro l le v e rs .
— R e fit th e in s tr u m e n t panel and p lu g in th e

e le c tric a l c o n n e c to r.
— S e c u r e th e LH s id e p a n e l w ith th e s c re w s
p re v io u s ly re m o v e d .
— F ix th e R H s id e p a n e l a n d c a b lig h t c o n tro l u n it
a n d w ith th e s e c u rin g s c r e w s . R e c o n n e c t th e
e le c tric a l c o n n e c to r to th e p lu g o n th e c o n tro l
p a n e l.
— R e in s ta ll th e d r iv e r ’s s e a t.
— R e c o n n e c t th e n e g a tiv e c a b le to th e b a tte ry .
????
REAR W INDOW, HANDLE AND LO CK

D is a s s e m b ly -A s s e m b ly (Op. 90 156 52)
2. R em ove th e h a n d le (2 ), th e s e a ls and th e
th r e a d e d p in (1 ).
28
3. D is c o n n e c t th e tw o g a s s tr u ts a t th e b a ll a n d
s o c k e t jo in ts (1 ).
29
4. R e m o v e th e s e c u r in g s c r e w s (1 ) fig . 3 0 fro m
th e h in g e s and ta k e out th e cab re a r
w in d s c r e e n c o m p le te w ith fr a m e (2 ) fig . 2 9 .
5. W ith t h e c a b r e a r w in d s c r e e n re m o v e d , re m o v e
th e s e c u rin g s c r e w s a n d th e fr a m e (2 ) fig . 2 9 .
6. To re fit, p ro c e e d a s fo llo w s :
— R e fit th e c o m p le te h a n d le u n it.
— R e fit th e lo c a tin g p in .
— R e n e w th e re a r w in d o w r u b b e r s e a l.
30
???
LO C K AND EXTERIOR HANDLE

LH DOOR
2. U n s c re w th e th r e e s c r e w s (1 ) s e c u rin g th e in te rio r
lo c k c o v e r (2 ).
31
3. R e m o v e th e e x te rio r h a n d le b y u n s c re w in g th e
tw o re ta in in g s c r e w s (1 ) fr o m th e in s id e .
— R e fit th e e x te rio r h a n d le .
— F it th e lo c k .
32
4. R e m o v e t w o s c r e w s (1 ) s e c u r in g t h e in te r io r lo c k
(2 ).
33
????
LH DOOR
34
2. R e m o v e th e d o o r c lo s u re (g a s s tru t).
35
3. F ro m in s id e t h e c a b , u n s c re w th e tw o t o p s c r e w s
(1 ) s e c u r in g th e d o o r h in g e .
36
4. R e m o v e th e d o o r.
— R e fit th e le ft h a n d d o o r.
— R e fit th e le ft h a n d p illa r s e a l.
37
???
W INDSCREEN W IPER MOTOR

D is a s s e m b ly -A s s e m b ly
(Op. 90 160 60 - 5 5 518 52)
38
2. R e m o v e th e r o o f s e c u rin g s c re w s
39
3. R e m o v e th e c a p to p c o v e r (1 ) a n d d is c o n n e c t
th e e le c tric a l c o n n e c tio n fr o m th e fr o n t w ip e r
m o to r.
40
4. U n s c re w th e w ip e r b la d e re ta in in g s c r e w (1)
41
????
5. U n s c re w th e s m a ll n u t (1 ) s e c u r in g t h e w ip e r m o
t o r u n it.
42
6. U n s c re w th e la rg e n u t a n d re m o v e th e w ip e r
m o to r u n it (1 ) fr o m t o p th e c a b .
To r e in s ta ll, p ro c e e d a s fo llo w s :
M R« s ' ^ . Q ....
— R e fit th e m o to r u n it a n d s e c u r e it w ith th e tw o : E = — - - -a • ••
. Ii '-----—
. : . / L/— \\ *■J o 1t
1
n u ts
— R e fit th e w ip e r b la d e
— R e c o n n e c t th e e le c tric a l c o n n e c to r to th e m o to r
— R e fit th e cab ro o f lin in g and a ll th e p a rts o
mT nr~x ^Dl 1
p r e v io u s ly re m o v e d .
43
???
C A B W INDOW S
R eplacin g b on d e d cab w in d o w s
(Op.90 154 24 - 90 156 10 - 90 156 14 - 90 156 28)
R em oving w in d o w
P r o c e e d a s fo llo w s .
----------- A WARNING A -----------

H a n d le a ll p a rts w ith g r e a t c a u tio n .
D o n o t in s e r t y o u r h a n d s o r fin g e r s b e tw e e n o n e p a rt
a n d a n o th e r.
W e a r th e p re s c rib e d s a fe ty c lo th in g , in c lu d in g
g la s s e s , g lo v e s a n d s a fe ty fo o tw e a r.
1. If p o s s ib le , re m o v e a n y w in d o w s u p p o r t b lo c k s
p re s e n t a s th e y c a n r e s tr ic t th e a c tio n o f th e
c u ttin g w ire .
2. F ro m in s id e th e c a b u s e a p a ir o f p lie rs to p u s h
th e c u ttin g w ire (1 ) fig . 4 4 th r o u g h th e a d h e s iv e
(2 ) b e tw e e n th e g la s s a n d th e fra m e .
3. T h re a d th e c u ttin g w ir e (1 ) fig . 4 5 in to th e h a n d le
a n d lo c k it w ith th e s c r e w (2 ).
4. A n c h o r th e p o in te d e n d o f th e th e to o l in to th e
a d h e s iv e (s e e fig u re A ). K e e p th e w ire c lo s e to
th e g la s s a n d p u ll o n th e h a n d g rip (2 ) fig . 4 6 .
5. P u ll th e p o in te d to o l fr o m th e a d h e s iv e a n d
re p o s itio n it fu r t h e r a lo n g , a s s h o w n a t (2 ). A g a in ,
p u ll o n th e w ire , m a k in g lo n g c u ts o n s tr a ig h t
s e c tio n s a n d s h o r t c u ts a ro u n d c o rn e r s to a v o id
b re a k in g th e g la s s . R e p e a t th is o p e ra tio n u n til
th e w in d o w is c o m p le te ly d e ta c h e d .
6. U s e a to o l w ith s u c tio n c u p s to re m o v e th e
w in d o w a n d p la c e it o n a s u ita b le s u r fa c e to a v o id
d a m a g in g it.
7. C o m p le te ly re m o v e th e a d h e s iv e fr o m th e
w in d o w s u rr o u n d , ta k in g c a re n o t to d a m a g e th e
s u rro u n d .
8. R e m o v e th e a d h e s iv e fr o m th e g la s s u s in g a
s u ita b le s o lv e n t.
NOTE: W h e n r e p la c in g a b ro k e n w in d o w , re m o v e
th e g la s s fr a g m e n ts s till a tta c h e d to th e c a b a n d u s e
a k n ife b la d e to c u t th e a d h e s iv e (1 ) fig . 4 7 , a w a y
fr o m th e fra m e . T a k e c a re n o t to d a m a g e th e fra m e .
9. C le a n th e fra m e , a s d e s c r ib e d in o p e ra tio n 7.
????
R e fittin g th e w in d o w
1. M a k e s u re t h a t th e c o n ta c t a re a b e tw e e n th e
g la s s a n d th e m e ta l fr a m e in th e c a b is p e r fe c tly
c le a n .
2. U s in g a c le a n tis s u e , a p p ly th e a c tiv a to r (V P
0 4 6 0 4 G U R IT E S S E X ) a ro u n d th e e d g e o f th e
g la s s , w h e r e c o n ta c t w ill b e m a d e w ith th e m e ta l
fra m e . A llo w to d ry.
3. S h a k e th e b o ttle o f g la s s p r im e r ( B e ta p r im e 5 1 0 0
G U R IT ESSEX) fo r 6 0 seconds. U s in g th e
a p p lic a to r p ro v id e d (1 ) fig . 4 8 , a p p ly th e p r im e r
(2 ) a ro u n d th e e d g e o f th e g la s s , o v e r t h e to p o f
th e d rie d a c tiv a to r. A llo w to d r y th o ro u g h ly .
4. S hake th e b o ttle of m e ta l p la te p r im e r
( B e ta p rim e 5402 G U R IT ESSEX) fo r 60
s e c o n d s . U s in g th e a p p lic a to r p ro v id e d a p p ly
a ro u n d th e m e ta l fr a m e , w h e r e c o n ta c t w ill be 48
m a d e w ith th e g la s s . A llo w to d r y th o ro u g h ly .
5. C u t th e s p o u t o f th e a d h e s iv e d is p e n s e r a s
s h o w n in fig . 4 9 to o b ta in a b e a d o f t r ia n g u la r
c r o s s - s e c tio n .
6. A p p ly a s m o o th , c o n tin u o u s bead of
p o ly u re th a n e a d h e s iv e ( B e ta s e a l 1 7 0 3 G U R IT
E S S E X ) a ro u n d th e e d g e o f th e g la s s o v e r th e
p re v io u s ly p rim e d a re a (th e c r o s s - s e c tio n o f th is
b e a d m u s t b e tria n g u la r , w ith a b a s e w id th o f 10
m m a n d a h e ig h t o f 10 m m ).
NOTE: M ake s u re th a t th e a d h e s iv e bead is

c o n tin u o u s , i.e ., th e re a re n o a re a s w h e r e a d h e s iv e 49
is m is s in g , o th e r w is e w a te r m a y p e n e tra te .
7. In s e rt th e w in d o w s u p p o r t b lo c k s , if p re s e n t.
8. U s in g a to o l w ith s u c tio n cups, p o s itio n th e

w in d o w in its s u r ro u n d a n d u s e s u ita b le c la m p s
to a p p ly a u n ifo r m p re s s u re to o b ta in a 4 m m
th ic k n e s s of a d h e s iv e and e n s u re p e r fe c t
a d h e s io n .
NOTE: L e a v e th e c la m p s in p la c e f o r 4 h o u rs u n til th e
a d h e s iv e h a s c o m p le te ly p o ly m e ris e d . To p ro m o te a
g o o d b o n d , d o n o t m o v e th e c a b o r t h e t r a c t o r d u r in g
t h is tim e .
???

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CASE III

JX60 - JX70 - JX80 - JX90 - JX95

TEXT AND ILLUSTRATIONS ARE THE PROPERTY

CNH ITALIA S.p.A. - Viale delle Nazioni, 55 - 41100 MODENA - Italy

General Instructions and Health and Safety Chapter 1

Section Description Page

00 000 General in s tru c tio n s .........................................................................................................................1

Engine System Chapter 1

10 000 General specification ....................................................................................................................... 2

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

Mechanical Transmission (12x4) Chapter 1

21 000 Main d a t a ...........................................................................................................................................1

Reverser (12x12) Chapter 2

21 000 Main d a t a ............................................................................................................................................ 1

Reverser and Creeper (20x12) Chapter 3

21 000 Main d a t a ............................................................................................................................................ 1

DRIVE LINES SECTION 23

Drive Lines Chapter 1

23 000 Main s p e c ific a tio n ....................................................................... .............. 1

FRONT AXLE MECHANICAL TRANSMISSION SECTION 25

Front Axle Mechanical Transmission Chapter 1

25 000 Main d a t a ............................................................................................................................................ 1

REAR AXLE AND TRANSMISSION SECTION 27

Rear Axle And Transmission Chapter 1

27 000 Maind a t a ............................................................................................................................................ 1

POWER TAKE-OFF SECTION 31

Mechanical Power Take - Off Chapter 1

31 000 Main s p e c ific a tio n ..............................................................................................................................1

BRAKING SYSTEM SECTION 33

Braking System Chapter 1

33 000 Main d a t a ...........................................................................................................................................1

HYDRAULIC SYSTEM SECTION 35

Rear Mechanical Hydraulic Lift Chapter 1

35 000 Main s p e c ific a tio n ............................................................................................................................1

Open Centre System Auxiliary Control Valves Chapter 2

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

Trailer Brake Auxiliary Control Valve Chapter 3

35 000 Section v ie w s ....................................................................................................................................1

Description and operation .............................................................................................................. 1

Description and operation of valve p h a s e s .................................................................................. 3

Trailer brake auxiliary control valve linkage a d ju s tm e n t............................................................6

41 000 Principal d a ta .................................................................................................................................... 1

FRONT AXLE AND WHEELS SECTION 44

44 000 Principal d a ta ......................................................................................................................................1

AUXILIARY UNITS SECTION 50

Auxiliary Units Chapter 1

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

General characteristics .................................................................................................................. 3

Operating p rin c ip le s ........................................................................................................................ 5

Fault diagnosis ................................................................................................................................ 7

Cab c o n tro ls .....................................................................................................................................11

Main components of the cab air conditioning system ........................................................ 15

Refrigerant recovery-recycling and evacuation-charging stations .................................. 20

50 200 04 Drying recharging and checking c o o lin g .................................................................................. 22

50 200 03 Functional testing of air conditioning system .......................................................................... 27

Summary of the cab air-conditioning system charging operations .................................. 28

Checking for refrigerant leaks using an electronic leak d e te c to r........................................ 30

Summary of fault diagnosis and maintenance ..................................................................... 31

A ir conditioning and heating pipes - Replacement ............................................................. 33

50 200 0 4 -7 4 R eceiver-drier - Replacement ............................................................................................... 36

50 200 04 -7 2 Condenser - Replacement ..................................................................................................... 38

50 200 04 -2 6 Com pressor --Removal--Refitting ........................................................................................... 39

50 200 10 Com pressor drive belt tension adjustment ............................................................................ 41