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SECTION 00 -- GENERAL -- CHAPTER 1 1

GENERAL INSTRUCTIONS
IMPORTANT NOTICE
All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND
service technicians, in strict accordance with the instructions given and using any specific tools necessary.
Anyone performing the operations described herein without strictly following the instructions is personally re-
sponsible for any eventual injury or damage to property.

BATTERY
Before carrying out any kind of service operations, disconnect and isolate the battery negative lead, unless other-
wise requested for specific operations (e.g.: operations that require the engine running). Once the specific oper-
ation has been completed, disconnect the lead in order to complete the operation.

SHIMMING
For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add
up the recorder values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated
value indicated for each on shim.

ROTATING SHAFT SEALS
For correct rotating shaft seal installation, proceed as follows:
-- before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes;
-- thoroughly clean the shaft and check that the working surface on the shaft is not damaged;
-- position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direc-
tion and position the grooves so that they will deviate the fluid towards the inner side of the seal;
-- coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing
lip and the dust lip on double lip seals with grease;
-- insert the seal in its seat and press down using a flat punch, do not tap the seal with a hammer or mallet;
-- whilst inserting the seal, check that the it is perpendicular to the seat; once settled, make sure that it makes
contact with the thrust element, if required;
-- to prevent damaging the seal lip on the shaft, position a protective guard during installation operations.

O--RING SEALS
Lubricate the O--RING seals before inserting them in the seats, this will prevent them from overturning and twist-
ing, which would jeopardise sealing efficiency.

SEALING COMPOUNDS
Apply one of the following sealing compounds on the mating surfaces marked with an X: LOCTITE 518, LOC-
TITE 5205, SUPERBOND 559 MASCHERPA or BETABLOCK A272M GURIT ESSEX.
Before applying the sealing compound, prepare the surfaces as follows:
-- remove any incrustations using a metal brush;
-- thoroughly de--grease the surfaces using one of the following cleaning agents: trichlorethylene, petrol or a
water and soda solution.

BEARINGS
When installing bearings it is advised to:
-- heat the bearings to 80 to 90 °C (176 to 194 °F) before fitting on the shafts;
-- allow the bearings to cool before installing them from the outside.

SPRING PINS
When fitting split socket spring pins, ensure that the pin notch is positioned in the direction of the force required
to stress the pin.
Spiral spring pins do not require special positioning.

2 SECTION 00 -- GENERAL -- CHAPTER 1

SPARE PARTS
Only use original NEW HOLLAND spare parts bearing the logo shown below.

1
Only original spare parts guarantee the same quality, duration and safety as they are the same parts that are
assembled during production.
Only original NEW HOLLAND parts can offer this guarantee.
When ordering spare parts, always provide the following information:
-- tractor model (commercial name) and frame number;
-- engine type and number;
-- part number of the ordered part, which can be found in the ”Microfiches” or the ”Spare Parts Catalogue”, used
for order processing.

TOOLS
The tools that NEW HOLLAND propose and illustrate in this manual are:
-- specifically researched and designed for use with NEW HOLLAND tractors;
-- essential for reliable repair operations;
-- accurately built and rigorously tested so as to offer efficient and long--lasting operation.
By using these tools, Repair Personnel will benefit from:
-- operating in optimal technical conditions;
-- obtaining the best results;
-- saving time and effort;
-- working in safe conditions.

NOTE
Wear limit values indicated for certain parts are recommended, but not binding. The terms ”front”, ”rear”, ”right--
hand” and ”left--hand” (when referred to different parts) are intended as seen from the driving position with the
tractor in the normal direction of movement.

MOVING THE TRACTOR WITH THE BATTERY REMOVED
External power supply cables should only be connected to the respective positive and negative cable terminals,
using efficient clamps that guarantee adequate and secure contact.
Disconnect all services (lights, windshield wipers, etc.) before starting the tractor.
If the tractor electrical system requires checking, carry out operations with the power supply connected. Once
checking is completed, disconnect all services and switch off the power supply before disconnecting the cables.

SECTION 00 -- GENERAL -- CHAPTER 1 3

SAFETY REGULATIONS
WARNING AND DANGER SYMBOL
This warning symbol points out important messages
concerning your safety.
Carefully read the following safety regulations and
observe advised precautions in order to avoid poten-
tial hazards and safeguard your health and safety.
In this manual the symbol is accompanied by the fol-
lowing key--words:
WARNING -- Warnings concerning unsuitable repair
operations that may jeopardise the safety of Repair
personnel.
DANGER -- Specific warnings concerning potential
hazards for operator safety or for other persons di-
rectly or indirectly involved. 2
-- Do not carry out repair operations with someone
sitting in the driver’s seat, unless the person is a
ACCIDENT PREVENTION trained technician who is assisting with the oper-
ation in question.
Most accidents or injuries that occur in workshops
are the result of non--observance of simple and fun- -- Do not operate the machine or use any of the im-
damental safety regulations. For this reason, IN plements from different positions, other than the
MOST CASES THESE ACCIDENTS CAN BE driver’s seat.
AVOIDED by foreseeing possible causes and conse- -- Do not carry out operations on the machine with
quently acting with the necessary caution and care. the engine running, unless specifically indicated.
Accidents may occur with all types of machine, re-
-- Stop the engine and check that the hydraulic cir-
gardless of how well the machine in question was de-
cuits are pressure--free before removing caps,
signed and built.
covers, valves, etc.
A careful and judicious service technician is the best
guarantee against accidents. -- All repair and maintenance operations must be
carried out using extreme care and attention.
Precise observance of the most basic safety rule is
normally sufficient to avoid many serious accidents. -- Service steps and platforms used in the work-
shop or elsewhere should be built according to
DANGER. Never carry out any cleaning, lubrication
standard accident prevention regulations.
or maintenance operations when the engine is run-
ning. -- Disconnect the batteries and label all controls to
indicate that the tractor is being serviced. Any
parts that are to be raises must be locked in posi-
tion.
SAFETY REGULATIONS
-- Do not check or fill fuel tanks, accumulator bat-
teries, nor use starting liquid when smoking or
near naked flames, as these fluids are inflam-
GENERAL GUIDELINES mable.
-- Carefully follow specified repair and mainten- -- Brakes are inoperative when manually released
ance procedures. for repair or maintenance purposes. Use blocks
-- Do not wear rings, wristwatches, jewellery, un- or similar devices to control the machine in these
buttoned or loose articles of clothing such as: conditions.
ties, torn clothing, scarves, open jackets or shirts -- The fuel nozzle should always be in contact with
with open zips that may remain entangled in the filling aperture. Maintain this position until fill-
moving parts. It is advised to wear approved ing operations are completed in order to avoid
safety clothing, e.g.: non--slip footwear, gloves, possible sparks caused by the accumulation of
safety goggles, helmets, etc. static electricity.

4 SECTION 00 -- GENERAL -- CHAPTER 1

-- Only use specified towing points for towing the -- If operating outside the workshop, position the
tractor. Connect parts carefully. Make sure that tractor on a flat surface and lock in position. If
all pins and/or locks are secured in position be- working on a slope, lock the tractor in position.
fore applying traction. Never remain near the Move to a flat area as soon as is safely possible.
towing bars, cables or chains that are operating -- Damaged or bent chains or cables are unreliable.
under load. Do not use them for lifting or towing. Always use
-- Transport tractors that cannot be driven using a suitable protective gloves when handling chains
trailer or a low--loading platform trolley, if avail- or cables.
able. -- Chains should always be safely secured. Make
-- When loading or unloading the tractor from the sure that the hitch--up point is capable of sustain-
trailer (or other means of transport), select a flat ing the load in question. Keep the area near the
area capable of sustaining the trailer or truck hitch--up point, chains or cables free of all by-
wheels. Firmly secure the tractor to the truck or standers.
trailer and lock the wheels in the position used by -- Maintenance and repair operations must be car-
the carrier. ried out in a CLEAN and DRY area. Eliminate any
-- Electric heaters, battery--chargers and similar water or oil spillage immediately.
equipment must only be powered by auxiliary -- Do not create piles of oil or grease--soaked rags
power supplies with efficient ground insulation to as they represent a serious fire hazard. Always
avoid electrical shock hazards. store rags in a closed metal container.
-- Always use suitable hoisting or lifting devices Before starting the tractor or implements, make
when raising or moving heavy parts. sure that the driver’s seat is locked in position.
-- Take extra care if bystanders are present. Also check that there are no persons within the
tractor or implement range of action.
-- Never pour gasoline or diesel oil into open, wide
or low containers. -- Empty pockets of all objects that may fall unob-
served into the tractor parts.
-- Never use gasoline, diesel oil or other inflam-
mable liquids as cleaning agents. Use non--in- -- In the presence of protruding metal parts, use
flammable, non toxic commercially available sol- protective goggles or goggles with side guards,
vents. helmets, special footwear and gloves.
-- Wear safety goggles with side guards when -- When welding, use protective safety devices:
cleaning parts with compressed air. tinted safety goggles, helmets, special overalls,
gloves and footwear. All persons present in the
-- Limit the air pressure to a maximum of 2.1 bar (31
area where welding is taking place must wear
PSI), according to local regulations.
tinted goggles. NEVER LOOK DIRECTLY AT
-- Do not run the engine in confined spaces without THE WELDING ARC WITHOUT SUITABLE
suitable ventilation. EYE PROTECTION.
-- Do not smoke, use naked flames, or cause -- Metal cables tend to fray with repeated use. Al-
sparks in the area when fuel filling or handling ways use suitable protective devices (gloves,
highly inflammable liquids. goggles, etc.) when handling cables.
-- Never use naked flames for lighting when work- -- Handle all parts carefully. Do not put your hands
ing on the machine or checking for leaks. or fingers between moving parts. Wear suitable
-- All movements must be carried out carefully safety clothing -- safety goggles, gloves and
when working under, on or near the tractor. Wear shoes.
protective equipment: helmets, goggles and
special footwear.
-- When carrying out checks with the engine run-
ning, request the assistance of an operator in the
driver’s seat. The operator must maintain visual
contact with the service technician at all times.

SECTION 00 -- GENERAL -- CHAPTER 1 5

START UP HYDRAULIC SYSTEMS
-- Never run the engine in confined spaces that are -- A liquid leaking from a tiny hole may be almost
not equipped with adequate ventilation for ex- invisible but, at the same time, be powerful
haust gas extraction. enough to penetrate the skin. Therefore, NEVER
USE HANDS TO CHECK FOR LEAKS but use
-- Never place the head, body, limbs, feet, hands or
a piece of cardboard or wood for this purpose. If
fingers near fans or rotating belts.
any liquid penetrates skin tissue, call for medical
aid immediately. Failure to treat this condition
ENGINE with correct medical procedure may result in seri-
-- Always loosen the radiator cap slowly before re- ous infection or dermatosis.
moving it to allow any remaining pressure in the -- In order to check the pressure in the system use
system to be discharged. Filling up with coolant suitable instruments.
should only be carried out with the engine
stopped or idling (if hot).. WHEELS AND TIRES
-- Never fill up with fuel when the engine is running, -- Make sure that the tires are correctly inflated at
especially if hot, in order to prevent the outbreak the pressure specified by the manufacturer.
of fire as a result of fuel spillage. Periodically check the rims and tires for damage.
-- Never check or adjust fan belt tension when the -- Stand away from (at the side of) the tire when
engine is running. checking inflation pressure.
Never adjust the fuel injection pump when the
-- Only check pressure when the tractor is un-
tractor is moving.
loaded and the tires are cold, to avoid incorrect
-- Never lubricate the tractor when the engine is readings as a result of over--pressure. Do not use
running. parts of recovered wheels as incorrect welding
brazing or heating may weaken and eventually
ELECTRICAL SYSTEMS cause damage to the wheel.
-- If it is necessary to use auxiliary batteries, re- -- Never cut or weld a rim mounted with an inflated
member that both ends of the cables must be tire.
connected as follows: (+) with (+) and (--) with (--). -- To remove the wheels, lock both the front and
Avoid short--circuiting the terminals. GAS RE- rear tractor wheels. After having raised the trac-
LEASED FROM BATTERIES IS HIGHLY IN- tor, position supports underneath, according to
FLAMMABLE. During charging, leave the bat- regulations in force.
tery compartment uncovered to improve -- Deflate the tire before removing any objects that
ventilation. Never check the battery charge using may be jammed in the tire tread.
”jumpers” (metal objects placed on the ter- -- Never inflate tires using inflammable gases, as
minals). Avoid sparks or flames near the battery this may result in explosions and injury to by-
zone. Do not smoke to prevent explosion haz- standers.
ards.
-- Before servicing operations, check for fuel or
REMOVAL AND RE--FITTING
current leaks. Eliminate any eventual leaks be-
fore proceeding with work. -- Lift and handle all heavy parts using suitable ho-
isting equipment. Make sure that parts are sus-
-- Never charge batteries in confined spaces. Make
tained by appropriate hooks and slings. Use the
sure that there is adequate ventilation in order to
hoisting eyebolts for lifting operations. Extra care
prevent accidental explosion hazards as a result
should be taken if persons are present near the
of the accumulation of gases released during
load to be lifted.
charging operations.
-- Handle all parts carefully. Do not put your hands
-- Always disconnect the batteries before perform-
or fingers between parts. Wear suitable safety
ing any kind of servicing on the electrical system.
clothing -- safety goggles, gloves and shoes.
-- Avoid twisting chains or metal cables. Always
wear safety gloves when handling cables or
chains.

6 SECTION 00 -- GENERAL -- CHAPTER 1

CONSUMABLES

NEW HOLLAND
QUANTITY NEW HOLLAND INTERNATIONAL
PARTS TO BE FILLED RECOMMENDED
liter (gal.) SPECIFICATION SPECIFICATION
PRODUCT

Water and liquid Water and liquid SAE1941 ASTM
AMBRA Antifreeze D4985 (EG)
Cooling system: AGRIFLU Fleetguard
without cab . . . . . . . . . . . . . . 10.0 (2.64) 50% + 50% ES Coolant EG
(Ethylene Glycol)
50% + 50%

Decanted and
Fuel tank: . . . . 65 (17.17) -- --
filtered fuel oil

Crankcase sump: AMBRA NH Break-In API
without filter: . . . . . . . . . . . . . 6.7 (1.77) Break-In Engine Oil (10W40) SE/CC
Engine Oil 10W40
(10W40)
with filter: . . . . . . . . . . . . . . . . 7.5 (1.98) NH Super Premium API
(15W40) CH-4/SS
AMBRA Engine Oil CCMC 04
SUPER GOLD UNI 20153
HSP MIL-L2104C
Engine Oil ACEA E3/E5
(15W40)

Brake control circuit . . . . . . 0.7 (0.18) AMBRA NH Brake Oil
BRAKE LHM (86541699DS) ISO 7308
0.5 (0.13) Mineral Brake Oil

Front axle:
axle case . . . . . . . . . . . . . . . . 4.5 (1.19)
TN55 lateral final drives wi-
thout brakes (each) . . . . . . . 0.8 (0.21)
TN55 lateral final drives with
brakes (each) . . . . . . . . . . . . 1.3 (0.34)
TN65, TN70 and TN75 late-
ral final drives without bra-
AMBRA MULTI NH 134D API GL4
kes (each) . . . . . . . . . . . . . . . 1.0 (0.26)
G134 Hydraulic Oil ISO 32/46
TN65, TN70 and TN75 late-
Hydraulic Oil SAE 10W--30
ral final drives with brakes
(each) . . . . . . . . . . . . . . . . . . 1.5 (0.40)

Rear transmission (bevel
gear pair, lateral final drives
and brakes), gearbox, hy-
draulic lift, power take--off
and hydrostatic steering: . . 42 (11.10)

AMBRA GR9 NH Super Premium
Compression cups . . . . . . . -- Multipurpose MP Lithium Grease NLGI 2
Grease (86506331)

SECTION 10 -- ENGINE -- CHAPTER 1 1

SECTION 10 -- ENGINE

Chapter 1 -- Engine

CONTENTS

Section Description Page
10 000 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Lubrication and cooling system diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10 001 10 Engine, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10 001 30 Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10 001 54 Engine, Removal--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10 414 10 Coolant Pump and Alternator Drive Belt -- Tension adjustment . . . . . . . . . . . . . . . . . . . . . . 72
10 101 53 Valve guides, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
10 101 60 Injector holder casing, Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10 102 70 Front engine oil seal, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10 106 12 Valve clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10 126 10 Fuel tank, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10 218 30 Engine injectors, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
10 246 14 Bosch injection pump, Removal--Installation, timing and air bleed check . . . . . . . . . . . . . 86
10 254 44 Exhaust pipe, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10 402 11 Coolant pump, Removal--Installation, with radiator removed . . . . . . . . . . . . . . . . . . . . . . . . 93
10 402 28 Coolant pump, Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
10 402 30 Thermostat, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10 406 10 Radiator, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2 SECTION 10 -- ENGINE -- CHAPTER 1

GENERAL SPECIFICATIONS
Engine type:
-- Hp TN 55 -- type 8035.05B.529 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See data page 6--7
-- Hp TN 65 -- type 8035.05R.539 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See data page 8--9
-- Hp TN 70 -- type 8035.25R.520 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See data page 97
-- Hp TN 75 -- type 8035.25.529 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See data page 10--11
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diesel, 4--stroke
Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . direct
No. of in--line cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dry force--fitted in cylinder
block
Piston diameter:
-- Hp TN 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 mm (4.09 inches)
-- Hp TN 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 mm (4.09 inches)
-- Hp TN 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 mm (4.09 inches)
-- Hp TN 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 mm (4.09 inches)
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 mm (4.53 inches)
Total displacement:
-- Hp TN 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2931 cm3 (0.77 gallons)
-- Hp TN 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2931 cm3 (0.77 gallons)
-- Hp TN 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2931 cm3 (0.77 gallons)
-- Hp TN 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2931 cm3 (0.77 gallons)
Compression ratio, models TN 55 and TN 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17:1 normal intake
Compression ratio, model TN 70 and TN 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5:1 turbocharged
Maximum power:
-- Hp TN 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 kW (50 HP)
-- Hp TN 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 kW (60 HP)
-- Hp TN 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 kW (70 HP)
-- Hp TN 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 kW (72 HP)
Max. power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2300 rpm
Max. torque speed: model TN 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 rpm
Max. torque speed: model TN 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 rpm
Max. torque speed: model TN 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 rpm
Max. torque speed: model TN 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 rpm
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sump pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . structural, cast iron
(continued)

SECTION 10 -- ENGINE -- CHAPTER 1 3
(continued)

GENERAL SPECIFICATIONS
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced, with gear pump
1st 50 hr oil (Break-in Engine Oil) . . . . . . . . . . . . . . . . . . . . . . . . . 10W-40 -- API SE/CC 10W-40
After 50 hr oil (AMBRA SUPER GOLD HSP Engine Oil) . . . . . 15W-40 -- API CH-4/SD
Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . camshaft
Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . 2:1
Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mesh screen on oil pick--up and filter
cartridge in delivery line
Normal oil pressure.
Ideal pressure readings obtained at Oil Pan Temperature of
100 °C ± 5 °C (212 °F ± 9 °F)
TN 55 and TN 65 at min ERPM (650 ± 25) . . . . . . . . . . . . . . . . . * > .69 bar (> 9.94 psi)
TN 55 and TN 65 at max ERPM (2475 ± 25) . . . . . . . . . . . . . . . * > 2.94 to 3.92 bar (> 42.6 to 56.8 psi)
TN 70 and TN 75 at min ERPM (650 ± 25) . . . . . . . . . . . . . . . . . * > 1.08 bar (> 15.62 psi)
TN 70 and TN 75 at max ERPM (2500 ± 25) * > 1.96 bar (> 28.4 psi)
Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . built into pump housing
Valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 bar (50.8 psi)
For further lubrication technical data . . . . . . . . . . . . . . . . . . . . . . See page 19
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . water circulation
Radiator on models TN 55, TN 65 . . . . . . . . . . . . . . . . . . . . . . . . 3--row vertical pipes with copper fins
Radiator on model TN 70 and TN 75 . . . . . . . . . . . . . . . . . . . . . . 4--row vertical pipes with copper fins
Fan, attached to coolant pump pulley . . . . . . . . . . . . . . . . . . . . . 6--blade steel exhauster fan
Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal vane--type
Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . . 1:1.25
Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . thermostat
Coolant thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . coloured scale divided into 3 sections
Temperature ranges corresponding to each section:
-- initial white section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30o to 65o C (86o to 149o F)
-- middle green section (normal working conditions) . . . . . . . . 65o to 105o C (149o to 221o F)
-- final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105o to 115o C (221o to 239o F)
For further cooling system data . . . . . . . . . . . . . . . . . . . . . . . . . . See page 19
Rev counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . incorporated in control panel
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . from gear on camshaft
Hour counter calibrated for engine speed of . . . . . . . . . . . . . . . 1800 rpm
(continued overleaf)
* > means greater than

4 SECTION 10 -- ENGINE -- CHAPTER 1
(continued)

GENERAL SPECIFICATIONS

Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated camshaft
located in engine block through tappets,
pushrods and rockers; camshaft is driven
by the crankshaft through helical gears

Inlet:

-- start: before TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12o

-- end: after BDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31o

Exhaust:

-- start: before BDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50o

-- end: after TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16o

Valve clearance for timing check . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm (0.02 inches)

Valve clearance for normal running (engine cold):

-- inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 ± 0.05 mm (0.01 ± 0.002 inches)

-- exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 ± 0.05 mm (0.01 ± 0.002 inches)

For further timing data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 16
Fuel system
Air cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter, with clogged
filter indicator with centrifugal pre--filter
and automatic dust ejector
Fuel supply pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . double diaphragm
Fuel filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through wire filter in fuel supply pump, and
replaceable cartridge on delivery line to
injection pump
Minimum fuel flow rate with pump shaft rotating at 1600 rpm . 100 litres/hour (26.42 gallons/hour)
Operated by eccentric cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on camshaft
BOSCH injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . distributor type
All--speed governor, incorporated in pump:
BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal counterweights
Automatic advance regulator, incorporated in pump:
BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydraulic
For further fuel system data:
For fixed advance (pump setting for start of delivery before
TDC) -- Pressure setting -- Injection order, and other
information regarding the BOSCH pump . . . . . . . . . . . . . . . . . . . refer to the data for the relevant engine
type in the table on page 2

SECTION 10 -- ENGINE -- CHAPTER 1 5
FUEL SYSTEM DATA

Turbocharger (model TN 70 and TN 75):

-- GARRETT type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 25

Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . distributor type with incorporated speed
governor and automatic advance regulator

BOSCH pump:

-- Hp TN 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 3/11 F 1150 L 767

-- Hp TN 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 3/11 F 1150 L 766

-- Hp TN 70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 3/11 F 1150 L 764--2

-- Hp TN 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 3/11 F 1150 L 764

Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . counter--clockwise

Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2--3

Injectors:

BOSCH type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500307714

-- Nozzle holder type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4791124

-- Nozzle type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DLLA 132S 1320 -- 99469341

Number of nozzle orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Diameter of nozzle orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.23 mm (0.01 inches)

Pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 to 272 bar (3771.2 to 3945.2 psi)

Fuel delivery lines -- BOSCH pump

-- type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99441952

-- dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 x 1.75 x 540 mm (0.24 x 0.07 x 21.26 in.)

6 SECTION 10 -- ENGINE -- CHAPTER 1
MODEL TN 55 -- CALIBRATION DATA FOR BOSCH INJECTION PUMP
TYPE VE 3/11 F 1150 L 767 -- VE 3/11 F 1150 L 767--1

ASSEMBLY DATA CALIBRATION TEST CONDITIONS
Pump timing on engine: delivery start ± 9o
be- 0.5o Test bench conforming to ISO 4008/1 .../2
fore TDC of cylinder 1 compression stroke. Injectors conforming to ISO 7440--A61 --
Plunger pre--lift for timing on engine: mm 1 from P.M.I. (1.688.901.027 and pad with calibrated hole ∅ 0.5
(with tools 291754 -- 291755). mm; 0.02 in.).
Cylinder No.1 delivery line union on pump: marked Injector pressure setting 250 to 253 bar (3626.1 to
with letter A. 5120.1 psi).
Supply pressure:
ASSEMBLY DIMENSIONS . . . . . . . . . 0.35 ± 0.05 bar (5.1 ± 0.7 psi).
Delivery pipes (conforming to ISO 4093.2):
SYMBOL K MS ya yb . . . . . . . . . 6 x 2 x 450 mm (0.24 x 0.08 x 17.72 in.)
Graduate drain time: . . . . . . . . . : 30”.
mm -- -- 38.5 to 40.5 42.8 to 48.0 Test liquid: ISO 4113 at a temperature of 45o ± 1oC
(in.) (1.52 to 1.59) (1.69 to 1.89)
(113o ± 33.8o F).
1. START OF DELIVERY
Plunger pre--lift from TDC: Pump rotation (viewed from drive side): Injection order: 1--2--3
mm -- counter--clockwise

2. ADVANCE REGULATOR STROKE
Rpm: 1200 Advance stroke: mm 0.7 to 1.1 (inches 0.03 to 0.04)

3. FUEL SUPPLY PUMP PRESSURE
Rpm: 1200 Internal pressure: bar 8.1 to 8.7 (psi 117.5 to 126.2)

4. FULL LOAD DELIVERY
Rpm: 700 Delivery per 1000 shots: cm3 59.5 to 60.5 Spread: cm3 -- 3.5
(gal.0.0157 to 0.0159) (gal. --0.000925)

5. SPREAD GOVERNOR AT IDLE SPEED
Rpm: 325 Delivery per 1000 shots: cm3 8.4 to 12.4 Spread: cm3 (gal.)
(gal. 0.0022 to 0.0032)

6. SPREAD GOVERNOR AT MAXIMUM SPEED
Rpm: 1220 Delivery per 1000 shots: cm3 27 to 33 Spread: --
(gal. 0.007 to 0.008)

7. DELIVERY AT STARTING
Rpm: 100 Delivery per 1000 shots: cm3 60 to 100 (gal. 0.016 to 0.026)

8. INJECTION ADVANCE PROGRESSION
Rpm 1200 1250
Advance stroke mm (in.) 0.7 to 1.1 (0.03 to 0.04) 1.4 to 1.8 (0.06 to 0.07)

9. TRANSFER PRESSURE PROGRESSION
Rpm 1200 400 700
Internal pressure supply bar (psi) 8.1to 8.7 (117.5 to 126.2) 3.2 to 3.8 (46.4 to 55.1) 4.7 to 6.1 (68.1 to 88.5)

10. BACKFLOW
Rpm 400 1150
Backflow l/h (gal./h) 13 to 33 (3.43 to 8.72) 25 to 37 (6.60 to 9.77)
(continued overleaf)
Note: the values shown above in brackets must be used for checking purposes only.

SECTION 10 -- ENGINE -- CHAPTER 1 7
(continued)

11. DELIVERY PROGRESSION
Rpm Delivery per 1000 shots: cm3 (gallons)
1280 0 to 3.0 (0 to 0.0008)
1220 27 to 33 (0.007 to 0.008)
1150 50.5 to 53.5 (0.013 to 0.014)
700 59.5 to 60.5 (0.0157 to 0.0159)
400 52.8 to 60.8 (0.0139 to 0.016)

12. ZERO CAPACITY (STOP)
Rpm Voltage (volts) Delivery per 1000 shots: cm3 (gal.)
325 0 0 to 3 (0 to 0.0008)

13. DELIVERY CHECK AT IDLE SPEED
Rpm 325 400 250
Delivery per 1000 shots: cm3 (gal.) 8.4 to 12.4 0 to 3.0 31.2 to 39.2
(0.002 to 0.003) (0 to 0.0008) (0.008 to 0.010)
Note: the values shown above in brackets must be used for checking purposes only.

14. AUTOMATIC START SUPPLEMENT
Rpm Delivery per 1000 shots: cm3 (gallons)
100 60 to 100 (0.0158 to 0.0264)
250 49 to 57 (0.0129 to 0.0151)
150 75 to 105 (0.0198 to 0.0277)

BENCH TEST PERFORMANCE DATA
Test conditions
Fixed advance before TDC cylinder No.1 in compression stroke: Relative humidity 70o/o ± 5.
(see previous page)
Engine without fan, air filter and exhaust silencer. Ambient temperature
25o ± 3o C (77o ± 37.4o F).
Atmospheric pressure 990 ± 10 mbar (14.36 ± 0.15 psi). Specific gravity of diesel fuel
840 g/l. (7 lb./gal.)
Throttle Engine speed Power output with engine run--in for a total of: Fuel consumption
lever Braking load applied 2 hours 50 hours
position rpm kW (hp) kW (hp) kg/h (lb./h)
For maximum 35.7 to 37.9 8.0 to 8.5
Maximum 2300 ≥ 34.9 (47.4)
power output (48.5 to 51.5) (17.64 to 18.74)
For maximum 27.9 to 29.6 6.0 to 6.4
Maximum 1400 ≥ 27.3 (37.1)
torque (37.9 to 40.3) (13.23 to 14.11)
Maximum None (no--load) 2470 to 2500 -- -- --
Minimum None (no--load) 625 to 675 -- -- --

8 SECTION 10 -- ENGINE -- CHAPTER 1
MODEL TN 65 -- CALIBRATION DATA FOR BOSCH INJECTION PUMP
TYPE VE 3/11 F 1150 L 766 -- VE 3/11 F 1150 L 766--1

ASSEMBLY DATA CALIBRATION TEST CONDITIONS
Pump timing on engine: delivery start 9o ± 0.5o be- Test bench conforming to ISO 4008/1 .../2
fore TDC of cylinder 1 compression stroke. Injectors conforming to ISO 7440--A61 --
Plunger pre--lift for timing on engine: mm 1 (0.04 in.) (1.688.901.027 and pad with calibrated hole ∅ 0.5
from P.M.I. (with tools 291754 -- 291755). mm; 0.02 in.).
Cylinder No.1 delivery line union on pump: marked Injector pressure setting 250 to 253 bar (3626.1 to
with letter A. 5120.1 psi).
Supply pressure:
. . . . . . . . . 0.35 ± 0.05 bar (5.1 ± 0.7 psi).
ASSEMBLY DIMENSIONS
Delivery pipes (conforming to ISO 4093.2):
SYMBOL K MS ya yb
. . . . . . . . . 6 x 2 x 450 mm (0.24 x 0.08 x 17.72 in.)
Graduate drain time: . . . . . . . . . : 30”.
mm -- -- 36.5 to 38.5 41.4 to 46.6 Test liquid: ISO 4113 at a temperature of 45o ± 1oC
(in.) (1.44 to 1.52) (1.63 to 1.83)
(113o ± 33.8o F).
1. START OF DELIVERY
Plunger pre--lift from TDC: Pump rotation (viewed from drive side): Injection order:1--2--3
mm -- counter--clockwise

2. ADVANCE REGULATOR STROKE
Rpm: 1240 Advance stroke: mm 0.4 to 1.4 (inches 0.016 to 0.055)

3. FUEL SUPPLY PUMP PRESSURE
Rpm: 1200 Internal pressure: bar 7.7 to 8.9 (psi 111.7 to 129.1)

4. FULL LOAD DELIVERY
Rpm: 700 Delivery per 1000 shots: cm3 64.1 to 69.1 Spread: cm3 ≤ 3.5 (gal. ≤ 0.000925)
(gal. 0.017 to 0.018)

5. SPREAD GOVERNOR AT IDLE SPEED
Rpm: 325 Delivery per 1000 shots: cm3 15.9 to 23.9 Spread: cm3 ≤ 4.0 (gal. ≤ 0.00106)
(gal. 0.004 to 0.006)

6. SPREAD GOVERNOR AT MAXIMUM SPEED
Rpm: 1200 Delivery per 1000 shots: cm3 43.5 to 54.5 Spread:--
(gal. 0.011 to 0.014)

7. DELIVERY AT STARTING
Rpm: 100 Delivery per 1000 shots: cm3 55 to 95 (gal. 0.015 to 0.025)

8. INJECTION ADVANCE PROGRESSION
Rpm 1240 1280
Advance stroke mm (in.) 0.4 to 1.4 (0.016 to 0.055) 1.3 to 1.9 (0.051 to 0.075)

9. TRANSFER PRESSURE PROGRESSION
Rpm 1200 400
Internal pressure supply bar (psi) 7.7 to 8.9 (111.7 to 129.1) 3.5 to 4.7 (50.8 to 68.17)

10. BACKFLOW
Rpm 400 1100
Backflow l/h (gal./h) 14 to 22 (3.70 to 5.81) 22 to 42 (5.81 to 11.10)
(continued overleaf)
Note: the values shown above in brackets must be used for checking purposes only.

SECTION 10 -- ENGINE -- CHAPTER 1 9
(continued)

11. DELIVERY PROGRESSION
Rpm Delivery per 1000 shots: cm3 (gallons)
1270 0 to 3.0 (0 to 0.0008)
1200 43.5 to 54.5 (0.0114 to 0.0144)
700 64.1 to 69.1 (0.0169 to 0.01825)
1100 63.5 to 69.5 (0.0167 to 0.01836)
400 55.8 to 63.8 (0.0147 to 0.01685)
1150 61.5 to 69.5 (0.1625 to 0.01836)

12. ZERO CAPACITY (STOP)
Rpm Voltage (volts) Delivery per 1000 shots: cm3 (gal.)
325 0 0 to 3.0 (0 to 0.0008)

13. DELIVERY CHECK AT IDLE SPEED
Rpm 325 360 275
Delivery per 1000 shots: cm3 (gal.) 15.9 to 23.9 0 to 3.0 37.6 to 51.6
(0.004 to 0.006) (0 to 0.0008) (0.010 to 0.014)
Note: the values shown above in brackets must be used for checking purposes only.

14. AUTOMATIC START SUPPLEMENT
Rpm Delivery per 1000 shots: cm3 (gallons)
100 55 to 95 (0.0145 to 0.0251)
270 52.5 to 62.5 (0.0139 to 0.0165)
180 73 to 103 (0.0193 to 0.0272)

BENCH TEST PERFORMANCE DATA
Test conditions
Fixed advance before TDC cylinder No.1 in compression stroke: Relative humidity 70o/o ± 5.
(see previous page)
Engine without fan, air filter and exhaust silencer. Ambient temperature
25o ± 3o C (77o ± 37.4o F).
Atmospheric pressure 990 ± 10 mbar (14.36 ± 0.15 psi). Specific gravity of diesel fuel
840 g/l. (7 lb./gal.)
Throttle Engine speed Power output with engine run--in for a total of: Fuel consumption
lever Braking load applied 2 hours 50 hours
position rpm kW (hp) kW (hp) kg/h (lb./h)
For maximum 43 to 45.6 9.9 to 10.5
Maximum 2300 ≥ 42 (57.1)
power output (58.5 to 62) (21.83 to 23.15)
For maximum 30.0 to 31.8 6.4 to 6.8
Maximum 1400 ≥ 29.4 (40)
torque (40.8 to 43.2) (14.11 to 14.99)
Maximum None (no--load) 2450 to 2500 -- -- --
Minimum None (no--load) 625 to 675 -- -- --

10 SECTION 10 -- ENGINE -- CHAPTER 1
MODELS TN 70 -- CALIBRATION DATA FOR BOSCH INJECTION PUMP
TYPE -- VE 4/11 F 1150 L 764--2
ASSEMBLY DATA CALIBRATION TEST CONDITIONS
Pump timing on engine: delivery start 6o ± 0.5o before Test bench conforming to ISO 4008/1 .../2
TDC of cylinder 1 compression stroke. Injectors conforming to ISO 7440--A61 --
Plunger pre--lift for timing on engine: mm 1 from P.M.I. (1.688.901.027 and pad with calibrated hole
(with tools 291754 -- 291755). ∅ 0.5 mm; 0.02 in.).
Cylinder No.1 delivery line union on pump: marked Injector pressure setting 250 to 253 bar (3626.1 to
with letter A. 5120.1 psi).
Supply pressure: 0.35 to± 0.05 bar (5.1 ± 0.7 psi).
ASSEMBLY DIMENSIONS Delivery pipes (conforming to ISO 4093.2):
SYMBOL K VHA ya yb mm 6 x 2 x 450 (0.24 x 0.08 x 17.72 in.)
Graduate drain time: . . . . . 30”.
mm -- 30,1 38.6 to 40.6 40.4 to 45.6 Test liquid: ISO 4113 at a temperature of 45o ±to 1oC
(1.45 to 1.60) (1.59 to 1.79) (113o ± 33.8o F).
1. START OF DELIVERY
Plunger pre--lift from TDC: mm -- Pump rotation (viewed from drive side): Injection order:1--2--3--4--2
counter--clockwise
2. ADVANCE REGULATOR STROKE
Rpm: 900 Advance stroke: mm 1.2 to 1.4
(inches 0.047 to 0.055)
3. FUEL SUPPLY PUMP PRESSURE
Rpm: 900 Internal pressure: bar 6.8 to 7.4
(psi 98.6 to 107.3)
4. FULL--LOAD DELIVERY WITH BOOSTER PRESSURE
Rpm: 700 LDA pressure: kPa 100 Delivery per 1000 shots: cm3 80.5 to 81.5 Spread: cm3 ≤ 3.5
(gal. 0.0213 to 0.0215) (gal. ≤ 0.000925)
5. FULL--LOAD DELIVERY WITHOUT BOOSTER PRESSURE
Rpm: 600 Portata per 1000 mandate: cm3 73,5 ÷ 74,5
6. SPREAD GOVERNOR AT IDLE SPEED
Rpm: 325 Delivery per 1000 shots: cm3 10.5 to 12.5 Spread: cm3 ≤ 4.5
(gal. 0.0027 to 0.0033) (gal. ≤ 0.0012)
7. SPREAD GOVERNOR AT MAXIMUM SPEED
Rpm: 1200 LDA pressure: kPa 100 Delivery per 1000 shots: cm3 53 to 54
(gal. 0.0140 to 0.0142)
8. DELIVERY AT STARTING
Rpm: 100 Delivery per 1000 shots: cm3 80 to 110
(gal. 0.0211 to 0.0290)
9. TRANSFER PRESSURE PROGRESSION
LDA pressure kPa 100
Rpm 400 900
Internal supply pressure bar (psi) 3.4 to 4.4 (49.3 to 63.8) 6.8 to 7.4 (98.6 to 107.3)
10. INJECTION ADVANCE PROGRESSION
LDA pressure kPa 100
Rpm 900 1000
Advance stroke mm (in.) 1.2 to 1.4 (0.047 to 0.055) 1.3 to 1.9 (0.051 to 0.074)
11. BACKFLOW
Rpm 600 1150
LDA pressure kPa 0 100
Backflow cm3 (gal.) 19 to 29 (0.005 to 0.007) 24 to 38 (0.006 to 0.010)
(continued overleaf)
Note: The values shown above in brackets must be used for checking purposes only.

2 to 10.4 7. -- Minimum None (no--load) 625 to 675 -.5 (0. air filter and exhaust silencer.9 to 79.0211 to 0.8) For maximum 36. 74 to 86 (0.0188) 700 100 80.0194 to 0.0 (0 to 0.5 (0.5 to 49.) 10.5 to 18. -- .5 to 39.0211) 1270 100 0 to 3.CHAPTER 1 11 (segue) 12.0227) BENCH TEST PERFORMANCE DATA Test conditions Fixed advance before TDC cylinder No.31 ± 0.) 600 35 78.5 to 12.5 10. -. AUTOMATIC START CAPACITY SUPPLEMENT Rpm LDA pressure kPa Delivery per 1000 shots: cm3 (gal.5 to 74. -.1 in compression stroke: Relative humidity 70o/o ± 5.0008) 15. 14.6 to 53. Ambient temperature 25o C (77o F).45 Maximum 1400 ≥ 35.ENGINE -.) 325 0 0 to 3.0008) Note: The values shown above in brackets must be used for checking purposes only. (7 lb. DELIVERY PROGRESSION Rpm LDA pressure kPa Delivery per 1000 shots: cm3 (gal.0142) 1150 100 67.) 100 -.8 (48. DELIVERY CHECK AT IDLE SPEED Rpm 325 410 Delivery per 1000 shots: cm3 (gal.5 to 23.0033) 0 to 3.5 (0.6) Maximum None (no--load) 2475 to 2525 -.0195 to 0.0197) 13.0208 to 0. SECTION 10 -.95 to 8.9 (0.096 psi)./h) For maximum 46.5 (0. Atmospheric pressure 740 ± 5 mbar (14.5 to 71.5 to 81.6) (17.0212 to 0. Throttle Engine speed Power output with engine run--in for a total of: Fuel consumption lever Braking load applied 2 hours 50 hours position rpm kW (hp) kW (hp) kg/h (lbs. (see previous page) Engine without fan. ZERO CAPACITY (STOP) Rpm Voltage (volts) Delivery per 1000 shots: cm3 (gal.7) torque (49.0 (0 to 0.0140 to 0.0290) 250 -.0178 to 0.0 (0 to 0.) at a temperature of 15 oC (59o F).0008) 1200 100 53 to 54 (0. Specific gravity of diesel fuel 840 g/l.0215) 600 0 73.6 (62) power output (63 to 67) (22.0027 to 0.8 Maximum 2300 ≥ 45./gal. 80 to 110 (0.

6 to 40.68) (continued overleaf) Note: the values shown above in brackets must be used for checking purposes only.5 (0. . DELIVERY AT STARTING Rpm: 100 Delivery per 1000 shots: cm3 85 to 125 (gal.08 x 17.2 Spread: cm3 -.12 SECTION 10 -. FULL--LOAD DELIVERY WITH BOOSTER PRESSURE Rpm: 700 LDA pressure: kPa 100 Delivery per 1000 shots: cm3 88 to 93 Spread: cm3 ≤ 3.96 to 8.35 ± 0.0224 to 0.19) 15 to 45 (8.291755). . 0.033) 9. .) 0.021 to 0. . SYMBOL K MS ya yb Delivery pipes (conforming to ISO 4093. .1 psi).5 Spread: cm3 -.5 to 63.051 to 0. 0.)..1 delivery line union on pump: marked Injector pressure setting 250 to 253 bar (3626.I. BACKFLOW Rpm 500 1150 LDA pressure kPa 0 100 Backflow for 10 s l/h (gal. FULL--LOAD DELIVERY WITHOUT BOOSTER PRESSURE Rpm: 500 LDA pressure: kPa 0 Delivery per 1000 shots: cm3 78. --) (gal.9 to 48.M.022) 6.8) 7. 0.) (1. . 0.89) Graduate drain time: . .023 to 0.1 to with letter A. 5120.6 42.(gal. Injectors conforming to ISO 7440--A61 -- Plunger pre--lift for timing on engine: mm 1 (0. .901. . . 0.04 in. .1 . .5 from P.CHAPTER 1 MODEL TN 75 -.9 to 9. -.2): mm -.075) 3.9 (0.) (1. ./2 fore TDC of cylinder 1 compression stroke. ASSEMBLY DIMENSIONS Supply pressure: .VE 3/11 F 1150 L 764--1 ASSEMBLY DATA CALIBRATION TEST CONDITIONS Pump timing on engine: delivery start 6o ± 0.5 (psi 120.1 ± 0. 1.8 to 5.05 bar (5.5 (gal.60) (1. . (with tools 291754 -.3 to 1.0009 to 0. .5 to 1. 0. . ≤ 0. INJECTION ADVANCE PROGRESSION LDA pressure kPa 100 Rpm 1180 1240 Advance stroke mm (in.01677) 8.8o F).07) 10.5 Spread: cm3 ≤ 4.24 x 0.ENGINE -. . . TRANSFER PRESSURE PROGRESSION LDA pressure kPa 100 Rpm 500 1220 1180 Internal supply pressure bar (psi) 3. START OF DELIVERY Plunger pre--lift from TDC: mm -. .025) (gal. mm.2 to 83. . 6 x 2 x 450 mm (0.3 to 9.7 psi). .000925) 5. Cylinder No.5 (120.02 to 0.CALIBRATION DATA FOR BOSCH INJECTION PUMP TYPE VE 3/11 F 1150 L 764 -. --) (gal.(gal. FUEL SUPPLY PUMP PRESSURE Rpm: 1220 LDA pressure: kPa 100 Internal pressure: bar 8. .1 (114.688.3 to 9.0038) (gal. .0 (55.3 to 1. : 30”..69 to 1. Pump rotation (viewed from drive side): counter--clockwise Injection order:1--2--3 2.5o be.19 to 12.4 to 137.06) 1.5 (gal. Test liquid: ISO 4113 at a temperature of 45o ± 1oC (113o ± 33.45 to 1. .001189) 7. 0.05 to 0.4 to 137.0125 to 0.72 in. 38.6 to 132) 11. Test bench conforming to ISO 4008/1 .) (in.027 and pad with calibrated hole ∅ 0./h) 15 to 31 (3.02 in. SPREAD GOVERNOR AT IDLE SPEED Rpm: 325 LDA pressure: kPa 0 Delivery per 1000 shots: cm3 3.5) 8.9 (inches 0. ≤ 0. .8) 4. SPREAD GOVERNOR AT MAXIMUM SPEED Rpm: 1200 LDA pressure: kPa 100 Delivery per 1000 shots: cm3 47. ADVANCE REGULATOR STROKE Rpm: 1240 LDA pressure: kPa 100 Advance stroke: mm 1.5 to 14.1 to 72.

5 (0. -- 2525 Minimum None (no--load) 625 to 675 -.CHAPTER 1 13 (continued) 12.6 For maximum Maximum 2300 ≥ 50.2 (0.55 to 0. .0 (0.36 ± 0.0219 to 0.0008) 14.5 0 to 3.5 (0.) 1300 100 0 to 3. DELIVERY PROGRESSION Rpm LDA pressure kPa Delivery per 1000 shots: cm3 (gal.6 to 60.0008) 1200 100 47.1) 27.8 (0.0207 to 0. Ambient temperature 25o ± 3o C (77o ± 37.0188 to 0.0 (gal.0038) (0 to 0.9 to 12. (7 lb.0264 to 0. (see previous page) Engine without fan.78) 41.0197 to 0./h) 51.0220) 1150 100 74. -. AUTOMATIC START CAPACITY SUPPLEMENT Rpm Delivery per 1000 shots: cm3 (gal. Specific gravity of diesel fuel 840 g/l.9 to 74.2 (2) 9. 0 to 0.0255) 13.) 100 85 to 125 (0.0343) BENCH TEST PERFORMANCE DATA Test conditions Fixed advance before TDC cylinder No.5 (1) 11.0 (0 to 0.01254to 0.0232 to 0. Atmospheric pressure 990 ± 10 mbar (14.0213) 500 100 89. air filter and exhaust silencer.) 3.8 to 16) -.ENGINE -.0330) 250 71 to 91 (0.5) (26.4o F).0008) Note: the values shown above in brackets must be used for checking purposes only.65 (psi 8 to 9.) Engine Fuel Throttle Power output with engine run--in for a total of: speed consumption l lever Braking load applied 2 hours 50 hours position rpm kW (hp) kW (hp) kg/h (lb. SECTION 10 -.6 to 80.0246) 600 42.4 (68.4 to 54.4) (20.5 to 96. ZERO CAPACITY (STOP) Rpm: 325 Voltage (volts): 0 Delivery per 1000 shots: cm3 0 to 3.8 to 90.0240) 160 100 to 130 (0. DELIVERY CHECK AT IDLE SPEED Rpm 325 410 Delivery per 1000 shots: cm3 (gal.24 to power output (69.15 psi).8 (55.4).0009 to 0.2 to 83./gal.95 to 1.1 to 9.0240) 500 0 78. -- Note: Air delivery pressure (1) bar 0.06 to torque (56.16) 2475 to Maximum None (no--load) -.1 (psi 13.5 to 14.(2) bar 0. 15. -.6 For maximum Maximum 1400 ≥ 40.1 in compression stroke: Relative humidity 70o/o ± 5.0168) 700 100 88 to 93 (0.1) 21.0236 to 0.0225 to 0.5 to 63.6 (0.5 82.6 to 44.

. . . . .200 (0. . . . . . . . . . centre . .2067 to 4. .14 SECTION 10 -. . . . . . . . .50 (0. . .780 to 53. .140 (0. . .3161) Diameter of camshaft bearing seats: -. . . . .1154 to 0. . . . .900 (4.975 to 32. . . . . . . . . . .805 (2. . . . . . .0571 to 0.120 to 0. . . . . . . . . . . 106. . . . 53. . . 0. . . . . . . . . . . . . . . . . . . . . . . . .1 -.100 (0. . .2618 to 1.0. .45 to 1. . . . . . . . . 32. . 0. . . . . . . . . . . .0055) Assembly clearance between shaft and bushings . . . . . . . . . . . . . .063 to 0.2628) Interference between bushings and seats . . . . . camshaft and pushrod/tappet assemblies Internal diameter of cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. .0. . . . . . . . . . .0079) Maximum permissible liner ovality or taper due to wear (2) . . . .050 to 32. . .3 (0. . .0039 -. . . . . . . . . . . 54. .0020 to 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rear .1370 to 2. . . . . . .1173 to 2. . .0079 -.CHAPTER 1 FUEL SUPPLY PUMP DATA mm (inches) Eccentricity of drive shaft . . . . . . . .0079) Liner internal diameter oversizes . . . . . . . . . . . . . . . . . .805 (2. . . . . . . .050 (4.024 (4. . .2598) Internal diameter of installed and reamed bushings . . . . .0025 to 0. . . . . . . . . . . . . . . . 15. . (2) Measure in the area swept by piston rings. . . .0945 to 4. . . . . . . .2588 to 1. .2146) Diameter of cylinder bores . . . . cast--iron monobloc with replaceable dry--fitted cylinder liners. . . . . .0118) (1) Measured after press--fitting and reaming. . . . . . . . .200 to 84.8 (0. . . . . . . . . . . . . . . . . . . . . . . . . . .305 (2. . both parallel and perpendicular to the crankshaft axis. . . . . . . . . . .230 (3. . . .4 to 0. .2087) Interference fit between cylinder liners and bores .5913) Tappet oversizes .018 (0. . . 54.ENGINE -. . . . . . . . . . . . . . .780 to 54. . . . . . . . . . . .1380) -.2 (0. . . . .1577) -. . . . .1183) Diameter of standard tappet bores in crankcase . . . . . . . . . . . . . . . . . front . . . . . . . . . .850 to 106. . . . .0. . . . . . . . . 107. . . . . . .1567 to 2. . . . 0. .93 to 3. 104. . . . . . . . .050 to 0. . . . . .0047 to 0.1181) Diameter of drive shaft at bushings .280 to 54. . 0. .0039) Thickness of internal washer . . .0315) Liner external diameter oversizes .1181) CRANKCASE/CYLINDER BLOCK DATA mm (inches) Cylinder block . . . . .000 (1. . . . . . . . . . . . . . . . . .000 to 104. . . . . . .3150 to 3. . 0. . . . . . . . . . . . . . 3 (0. . . . . .2134 to 4. . . .0. . . . .2 -. . . . .0496) Thickness of external washer . . . .12 (0. 84. . . . . . . . 2. . . . . . .00 (0.000 to 15. . . . . . . . .020 to 107. . .0954) (1) External diameter of cylinder liners . . . . . . 0. . . . . . . .5906 to 0. . . . . . . 1. . . . . .0047) Diameter of main shell bearing seats . .075 (1.0157 to 0. . . . . 31. . . . . incorporating seatings for crankshaft bearings. .

. . . . . . . . . . . . . . . . . . . . . . . . .10 (0. . . . . . . .02 -. .03 -. . . . . . . .016 (0. . . . . . .0857) Main bearing shell undersizes (internal diameter) . .02 -. .0. . . . . .1414 to 3. .178 (0. . . . of each pair of crankpins relative to crankshaft journals . . . .508 -.05 (0.. . .0. . . . .000 to 32. . 0. . . . .0032 to 0. . . . . . . .. . ..40 (0. . .2566) Width of corresponding crankshaft journal . . .1330 to 0. . .033 to 0. . 1. . . .0. . . .0039) Maximum tolerance for alignment.01 -. . . .0. . . .. . 0. . . . . . .0. . . . . . . . . .015 -. . .100 (1. . . .0041) Maximum permitted wear clearance . .5096) (1) Crankpin undersizes . .1. . . 0. .1.1. .762 -. .02) Width of main bearing including thrust washers . .254 -. . . . . . . . . . . . .0. . . .. . . .0098) Maximum tolerance for run--out between the outer surfaces of the crankshaft journals and the crankshaft centreline . . .0. . . . . 0. . . 0. . .04) Big--end bearing shell to crankpin clearance .. . .0. . .168 to 2. . . . . . .1 mm undersize journals. . . .334 (0. 0. . . . .762 -. . 32. . .0131) Maximum permitted wear endfloat . . 63.0715) Big--end bearing shell undersizes (internal diameter) . . . . . . . . .725 to 63. . 2.0071) Standard crankpin diameter . . . .087 (0. . . . . . . . . . . . 3. 0. .. . . .0. . .0.0.5089 to 2. . . . . . . . . .0854 to 0. . . . . . . . 0. . . . . . .10 (0.508 -. . . .762 -. . balanced with integral counterweights Standard journal diameter .03 -. . . . .791 to 79. .0. . . . 0. . . . .0. . . . . 0. . . . .0071) Standard crankshaft thrust washer thickness . . . . . . . .. . . . . . .ENGINE -. . .034 to 0.810 (3.815 (0.01 -. . . 0.0.CHAPTER 1 15 CRANKSHAFT AND BEARINGS DATA mm (inches) Crankshaft .. .016 (0. . .. .0. . . . .25 (0. . . . .0. . . . . . . . . . .. . .254 -. .01 -. . . . . . . . .. .0. . .254 -. . . . . .. . . .. crankpins and. .0013 to 0. . . . . . .04) Bearing shell to journal clearance . . . . . . . .. . . . . . . 0. . . . .02 -.0020) Maximum tolerance for alignment of crankshaft journals with crankshaft supported on the two outer journals .0157) Maximum ovality or taper of journals and crankpin after regrinding .2638) Crankshaft assembly endfloat . .508 -. . . .0711 to 0. . . . .. . . . . . .1421) (1) Journal undersizes . . .0. . . . 0.180 (0.01 -.2598 to 1. . .02 -. . . . . . .03 -. .127 -. . . .0004) Maximum ovality or taper of journals and crankpin . . . in both directions. . . . .381 -.0. . . . . . . . . . SECTION 10 -. . . . . ± 0. . . . .016 (0.1. . . . . . . . . .508 -. .429 (0.. . .180 (0. . . . . . .0. .254 -. . . . . . . . . . . . .. . . . undersize bearing shells may be fitted in factory production. . . . . . . 79. . .766 to 31.805 to 1. . . . .04) Standard main bearing shell thickness . . .744 (2.0.0. . . . . . consequently. .04) Standard big--end bearing shell thickness . .254 -. . . . . .01 -. . . . .0. . 31. . . . . .508 (0. . . 0. . .2506 to 1. . . . . . . . . . . . . . . . .. . . . . . .378 to 3. . .016 (0. . . . . . . . . . .. . . .918 (1. . . .. . .0. . . .103 (0. . . .0034) Wear limit endfloat .005 -. . .1350) Thrust washer oversizes (thickness) . .0.. . . .03 -. . 0. . .0.082 to 0.762 -. . . . .01 (0. . .0013 to 0. .. . . . . . . .. .0039) (continued overleaf) (1)Crankshafts with 0. . . . . . .

. . . . 41.6544) Max. . page 63 ) relative to the crankshaft journals (total gauge reading) . . . .6527 to 1. . . . . . . . .0037 to 0. . . . . .92 in. . . .0010) Maximum permitted tolerance on co--axial alignment of flywheel centering (B. . . . . . . . . . . . . . . . . . . .04 (0. . .ENGINE -. . . .422 (2. ± 0. . . . . . .6542) Interference between small end bushing and seat . . measured with 1/100 mm scale dial gauge resting on front flange surface (A. . . . . . . . . . . 0.) . . .6490) Outside diameter of small end bushing . .6475 to 1. . . . . .) . . . . . .0002) CONNECTING ROD DATA mm (inches) Connecting rods . . . . . cast--iron with oil way Diameter of small end bushing seat . 41. . .979 to 42. .014 (1. . 0.0067) Inside diameter of small end bushing (measured after fitting) . . .004 to 38. . . . . . . . . . . . . . . . . . .846 to 41. . .CHAPTER 1 (continued) CRANKSHAFT AND BEARINGS DATA mm (inches) Maximum permitted tolerance on run--out of flywheel mounting flange surface relative to the crankshaft centreline. . . . . 25 grams (0. . .017 (1. . .07 (0. . . . . . .) (total gauge reading) . .407 to 67. . .171 (0. . . . . . . . . . . . 67.095 to 0. . . . . 38. . . . . .0028) Maximum weight difference between con rods in same engine . . . . . . . . . . .4962 to 1. . .884 (1. .055 lb. . page 63 ) at a diameter of 108 mm (4. . . .25 in. .4966) Diameter of big end bearing seats . 0. . . . . . . . . . . . . .025 (0.6538 to 2. .16 SECTION 10 -. . . . tolerance for parallelism between the small end and the big end axes measured at 125 mm (4. . . . . . . . . . .

. . . . 0. .65 (0. . . .174 to 0. . . . . . . . . . . . . . . top . . . . . .0001 to 0. . 0. . .044 lb. . . . . . . . light alloy with two compression rings and one oil control ring Standard piston diameter. . . 0. .826 (4. . . . . . . . .212 (0.031 (0. . . . . .092 (0. . . . . . . . . . . .0. . . . . . . .0157 to 0. . . . . . .040 to 0. . . . . . . . . . .0024) Maximum weight difference between pistons in same engine . . . . . . . . . . . . . . . . . 0. . . . . . . .24 in. . . . .990 (1. . 0. . . . . . .) Piston ring groove clearance (measured vertically): -. . . . . . . .4958 to 1.0236) Maximum permissible gap (wear limit) . . . . . . . . . . . . . . . . . .0472) . . . . . . . . . . . . . second . . . . . . . . . . . . . . . .)from skirt base and perpendicularly to the gudgeon pin axis . . .0118 to 0. . .0048) -. . . . . . . . . . . . . . . 37. . . .000 (1. . .ENGINE -.0007) Gudgeon pin to small end bearing clearance . .122 (0. . 0.30 to 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bottom . . second .761 (0. . . . . . .60 (0. . . . . . . . . 0. . . . . 1. . . . . . . .0118) Piston oversizes . . . . . . .4954 to 1. . . . . . . . 103.0016 to 0. . . .0083) Wear limit endfloat . . . . . . .0068 to 0. . . . . . . . . . . . .060 to 0. . . . . . . . . . . . .30 (0. . . . . . . . .075 (0. . .0871 to 4. . . . . . . . . .355 to 0. measured at 57 mm (2. . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 -. . . . . . . . . . . . . . . .0006 to 0. . .CHAPTER 1 17 PISTON DATA mm (inches) Pistons . . . . . . . . . . . . . . . . . . .0012) Wear limit endfloat . . . . . .983 to 37. . . . . . . . . 0. . .20 (0. . . . . . . top . . . . . . . . . 0. . . . 0.0030) Max. . . . . . .0140 to 0. .017 (0. . . . . . . .4961) Gudgeon pin to seat clearance . . . . . . . . . . . . . . . .0217) -. . . permissible clearance (wear limit): -. . . . .55 (0. . . . . . . . .090 to 0. . . 0. . 0. . . . .993 to 38. .0197) -. top . . . . . . . . .0118 to 0.014 to 0. . . .4 -. .0300) Gudgeon pin diameter . . . .0315) Piston protrusion at TDC from cylinder block face . . . . . . . . . . . .0. 0. . . . . . . . . . . . . . . . . 0. .4957) Diameter of gudgeon pin seat in piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 (0. . 20 grams (0. . . . . . . .30 to 0. . . . . . . . . . .0256) -.003 to 0. . . . . . . . . . . . . . . . . . . .20 (0.06 (0. . . . .40 to 0. . . . . .0079) Piston ring end gap (fitted): -. . .0035 to 0. . . . . . . . .0024 to 0. .812 to 103.0876) Piston clearance in cylinder liner . . . . . . . . second and bottom . . . . . . .50 (0. . . . . . . . . . . . . . . . . . . . .0157 -. . . . . . . bottom . . . . . . . . . . . . . . . . . . . . . . . . .0036) -. . . . . . . . . . . . . 0. . . . . . 37. . . . . . . .

. . . . . .9882) -. . . . . . . . rear . . . See page 4 TAPPET DATA mm (inches) Tappet bore in crankcase . . . .ENGINE -. . . . . . . . . . .000 (1. . . .0028 to 0. . . . . . . 0. . . . . . . . 0. . . . . . . .130 (2. . . . . . . . . . 0. . . . .18 SECTION 10 -. . . .1626) -. . .1429) -. .5913) Outside diameter of standard tappet . . .20 (0.0063) Wear limit endfloat . . . . . .4567) Journal to bushing clearance . . . . 0. .375 to 54. . . . . . . . . . . . . . .0063) Inside diameter of intermediate gear bushings (fitted and reamed) . . . . 0. . . . . .0055) Outside diameter of camshaft bearings: -. . . . . . . . . . .030 to 0. . . . . . . . . . . .930 (2. . . . . . . . . . . . . . . . . .0059) Inside diameter of camshaft bearings (fitted and reamed): -.1626) Diameter of camshaft journals: -.100 (0. . . . . . . . . . .070 to 0. . .063 to 0. . . . . . . . . . . . . . . . . . . . 37.875 to 53. . . . . . . . . . . . . . . .9913 to 2. . . . . .1604 to 2. . . . . . . .15 (0. . . . . . . . . . . . . . . .580 to 50. . . .1407 to 2. . . . . . . . . . . .1211 to 2. . . . . . . . . . . . . . . . . . .5886 to 0. . . . . . 50.0.9870 to 1.0079) -. . . . . .0059) Bushing interference fit in seat in intermediate gear . . 15. . 14. . . . . . . . . . .1604 to 2. . . . .000 (1. .3 (0. . . . . . . .930 (2. . . . . . . . front .1604 to 2. . . .4587 to 1. . 0. . . . . .220 (0. . . . . . rear . 0. . . . . . . . . . .0025 to 0. . . . . . . . . . . 50.018 (0. . . . . . . . . . . . . . . . . . . . . .075 (1. . . . . . . . . . . . . . . . . . . 51. 53. . . . . .1 -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36. . . . . . . . . .970 (0.500 (1. .000 to 15. . . . . 0. . . . . . . . . . . .0087) For further timing data . . . centre . . . . . .0. . . . 50. . . . . . . . .9673 to 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 (0.0028 to 0. . . . . . . . . . . . . . . . . . . . . . . . . . .080 to 50. . . . . .950 to 14. . . . .0027) Wear limit endfloat . . . 50. . . . . . 0.050 to 0.080 to 51. . . . . . . . .140 (0. . . . .160 (0. . . . . . . . . . . . . . . . . .150 (0. . . .0118) . .15 (0. . .000 (1. . . . . . . . . . . . . . . . . . . . . . . .0079) Camshaft endfloat between thrust plate and seat on camshaft . 54. . . . . . . . . . . .875 to 54. . . . . . . . .630 (2. . . rear . .5906 to 0. .0020 to 0. . . . . . . . . . . .0039 -. . . .970 to 50. . . . . . . . . . .9685) Clearance between camshaft journals and bearings .1626) -. . . . . . . . . . . . . . . . . .070 to 0. centre . . . 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . front . . . . . . . . . . .0130) -. . . . . . . . . . . . . . . . . .068 (0.5894) Tappet running clearance . . . . . . . . . . . . . . .2 -. . . . . . . . . . . . .0039) Wear limit endfloat . . . . . . . . . . . .430 (2. . . front . . . . . .4557 to 1. . . . .975 to 37. . . .1232) Interference between bearings and seats in cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . .CHAPTER 1 VALVE TIMING GEAR DATA mm (inches) Timing gear tooth backlash . . . . . . . . . . . centre . . . . .0. . . . . . . . 49. . . . . . . .0. . .130 (2. . . . . . . . .470 to 50. . . .4596) Diameter of intermediate gear journal . . . . .050 to 37. . . . . . . . . . . . . . . 54. . . . . .080 to 0. .0110 to 2. . . . .0031 to 0. .0012 to 0. . . 0. . . . .970 to 51. . .0078 -.0059) Tappet oversizes . . .

5. free length .67 (0. . . . . . . . . . . . . . .016 to 18. . . . . . . . . . . . .2343) . . . . . 0. . .VALVE DATA mm (inches) Diameter of shaft bores in rocker arms . . . . . . 44 (1. . . . 0. . .0177) Valve clearance for normal running (engine cold): -. . . . . . . . .7087) Rocker shaft to rocker arm bore clearance . . . . . . . . . . . . .0059) Rocker arm spacing springs: -. .95 (0. . . . . . . . . . . . . . . . . . . . .016 to 0. . . . . . . .45 (0. 59. . . . inlet valve . . . . . . . .2232) -. .0118 ± 0. . . . . . . . 0. . . .3425) -. . . .7 to 5. . .7080 to 0. . . . . . . . . . . . . . . . . .7323) Valve clearance for timing check . . . . . . . . . . . . 0. . . . . . . . . . . . . . . . . . . . .0006 to 0. . . . . . . . . . . . . .30 ± 0. .05 (0.000 (0. . . . . . 5. . . . . . . . . .30 ± 0. . . . . . 17. . . . . .15 (0. . . . . . . . . . .0020) Cam lift: -. . . . . . . . .ENGINE -. . . .0020) Wear limit endfloat . . . . . . .982 to 18. . . . . . . . . . . . . SECTION 10 -. . . . .0020) -. . . . . . . . . . . . . . . . exhaust valve . . . .05 (0. . . . . . . . .052 (0. . . . . . . . .5 (2. . . . . . . .7100) Diameter of rocker arm shaft . . . . length under load of 46 to 52 N (4. . . . . . . . . . . . . . . .7093 to 0. . exhaust valve . . . . . . . . . . . . . . . . . . . . . . . .3 kg) . . . . .CHAPTER 1 19 ROCKER ARM -. . . . 0. . . . . . 18. . . .034 (0.0118 ± 0. inlet valve . . . . . . .

. . . . . . . .016 (0. . . . . .5 to 63. . . . . . . . . . . . . . . .0276 to 0. . . . . . . . . .. . . . .0118 to 0. . . 7. .0012) Valve guide oversizes . . . ... . . . . . . . . . . . . . . . . . . . . .3159 to 0. . . . 0. . . . . . . . . .0512) Inlet and exhaust valve springs: -.0023) Wear limit endfloat . . . .. . .0197) Diameter of standard valve guide bores in head . . . . . . . inlet valve . . . . . . .9 kg -. . . . . . . 0. . . . . . 0. under load of 256 to 284 N (26. . . . free length . .. . . . . . .. . . . . 0. . . .023 to 8. . . . . . . .. . . . . 0. . . 92 (3. . . . . . . . . .750 (1. exhaust valve .13 (0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0433) . . . . .066 (0. . . . . . . . . . . . . . . 0. . . . . . exhaust valve . . .5 (0. . . . ..03 (0.500 (1. . .. .1 to 28. . . . .57. . . . . .. . . . with valve seats cut directly in the casting and press--fitted steel valve guides. . . . . . . . . . . .. . . . . . . . . . under load of 502 to 554 N (51. . . . . . . . .2 to 56. .. . . . . . . . . .7559) -. . . . . . . . . . . . . . length with valve closed. 45. . . . . . .2 (0.9370) Injector protrusion relative to head face: • BOSCH injector . . . . . . . . . . .. . . . ..7835 to 1. ..985 to 8. . . .. . .9 to 124. . .983 (0. . . 23. . . . . . . . . . . . . . 13. . . . . .7913) -. . . . length with valve open. . . .112. . . . . . . . . . . . . . . . . . . 37. . .. . . .. .300 to 45.7 lb.. . .. 45o ± 5’ Valve face angle: -.6 lb. . .CHAPTER 1 CYLINDER HEAD DATA mm (inches) Cylinder head . . . . . . . . . .5492 to 0. . . . . . . . .4862) Valve stand--in relative to cylinder head face . .1 (0. . . . . . . . . . . . . . . . . . . . .3144 to 0.5 kg -. .. . . . . . . . . . . . . . . .000 (0. . . .7 to 1.. . . . . . . . . . . . . . . . .010 to 0. . . . . . . . . . . . . . . .. .. . . .3150) Assembly clearance between valve stem and guide . . . . . . . . ..0026) Inside diameter of valve guide (fitted in head) . . . . .0394) Maximum permissible valve stand--in . . . .950 to 13. . . . . . . .. 13. . . . .6 (1. . . . . . . . Original height of cylinder head .3386) -. .ENGINE -. . . . . . . inlet valve . . .0009 to 0. . . .. . . 45o 30’ ± 7’ Valve head diameter: -. .. . . . . . . .058 (0. . . . .0051) Maximum run--out of valve guided on its stem measured through 360o with dial gauge contact point resting on valve head contact band . . . . . . .8 (0. . . . . ... . . . . . . . . .0004 to 0. . . .5505) Outside diameter of standard valve guides . . . . . . . . . . . . . . . . . . . . . . .043 (0. . .5518) Guide interference fit in bores . . . . .3 (0.6220) Maximum face re--grinding depth .. . . . . .. .. . . . . . . . . . . .3 to 1. .023 to 0. . . .) . . . . .3167) Valve stem diameter . . . . . . . . . . . .) . . . . . . . . .0079) Valve seat angle in head: -. . . . . . . . . . . . . . . . . .500 to 37. . .993 to 14. . . 0. .. . 60o ± 5’ -. . . . . . . 0. . . . . . 44. . . . . . . . . . . . 60o 30’ ± 7’ -. 34 (1. . . . 1. . . . . . . . .5509 to 0. . . . . .. . . . . . exhaust valve . . .4764 to 1.. . . . . . . . . . ..20 SECTION 10 -. . . . . . . . . . . . . . inlet valve . . .0 (0. . 8. . . . . . . .

.0010 to 0. See page 3 -- COOLING SYSTEM DATA mm (inches) Interference fit between pump impeller and shaft .4764) -- -. . . . .1417) -. .00228) Interference fit between front seal bushing and impeller . .0005 to 0. . . . . . . .100 (0. .5 (1. . . .5 (1. . . . . . .012 to 0. spring free length . . . . . . .00228) For further cooling system data . 23. .0067) Thickness of drive and driven gears .0050) Pressure relief valve spring -- -. . 37. . . .6 to 5 kg) . . . .055 -- (0. . fig. . . . 0. . . . . . . spring length under load of 45 to 49 N (4. . . . 0. . . . . .6176) Endfloat between gears and gear housing in pump . . . . . . . . .0013 to 0. . . . . . spring length under load of 88 to 94 N (9 to 9. . . . 149) under load of 233. . . . . . . . . spring length (2. . . . .066 -- (0. .060 to 0.058 (0. . . . . . . . . . 149) under load of 127. . . . 0.4134) -. . . . . . .7717) 35. . . . . 0. . . . .0024 to 0. . . . .6126 to 1. . . .025 to 41. . . . .017 to 0. . -. . . . . . .170 -- (0. . spring length (2.126 -- (0. . . 40. . . . . . .0007 to 0.025 to 0. 29 (1. . . . . . .016 to 0. . . .961 to 41. . . . . . . . . . . . . . . . . . . . . .8 to 141.6 kg) . .9134) For further lubrication technical data .2 (0. 0. . . . . . . . .6142) Height of gear seat in pump . . .0026) Tooth backlash between drive and driven gears . . . . . 0. . . . . 41. . . . . . . . . . . . . . . . . .9 (1. . . . . . 30.0039) -- Radial clearance between drive and driven gears and housing . . . . . . . . . .ENGINE -. . . . . . . . . . SECTION 10 -. . . .024 to 0. 45 (1. . . . . . . . . . . . . . . . . . -.0022) Clearance between shaft and driven gear . .033 to 0. . . . .058 (0. . . . See page 3 . . . . . . . . . . . . .CHAPTER 1 21 mm (inches) LUBRICATION SYSTEM DATA TN 55 and TN 65 TN 70 and TN 75 Assembly clearance between oil pump drive shaft and bushing . . . . .059 (0. . . . . . . . fig. .6152 to 1. . .087 -- (1. . . . . . . . . . . . . .0006 to 0. .000 -- (1. . . . . . . .2008) -- -. . . . . . 0.0009 to 0. . .0023) Interference fit between fan hub and shaft .4 to 258 N (238 to 263 kg) . . .2 N (130 to 144 kg). . . . . 0.

. fig. 65) . timing gear seal. . . M8 25 18 Sump pan retaining bolts . . . M8 25 18 Alternator and belt tension adjustment nut . . . . . . . . . . . . . .25 55 41 Additional counterweight retaining bolts (1. . . . . . .25 40 30 60o TIGHTENING TORQUE DATA Tightening torque PART Thread Nm ft-lbs Rocker shaft pedestal bolts (1. M 12 x 1. . page 23) . . . . . . M8 22 16 Nuts for injector mounting studs (1. . . . . . . . . . . . . fig. . M 10 x 1. . . . .25 55 41 Tappet cover nuts (1. . . . . . . . fig. . . . . 48) . . . .25 49 to 69 36 to 51 (*) Tighten nuts in two stages: see operations described in fig. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49) . . . . . . .25 69 51 -.5 40 30 60o Flywheel mounting bolts (3) . . . . . . . . . . fig. . . . . . M 14 x 1. .25 55 41 Camshaft thrust plate retaining bolts (2. . . . . . . . . . . . . . . cover and casing . . . . . 61) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 SECTION 10 -. . .5 80 59 90o Big--end cap bolts (5) . . . . . . . M8 25 18 Crankshaft hub retaining nut (7) . . . . . . . . fig. . . . M 10 x 1. . . . . M 10 x 1. . . . . . . . . . . . . . . . . . M 11 x 1. . . . . . . . . . . . . . . . . M8 15 11 Rocker shaft pedestal bolts (2. . . . . . . . . . . . M8 25 (*) 18 (*) Exhaust manifold retaining bolts . . . fig. . . . . . . . . . . . . .25 49 to 59 36 to 44 models TN 70 and TN 75 . . . M8 25 18 Oil pump and pump cover retaining bolts (1. . . M 10 x 1. . . . . . . flywheel housing crankcase and casing: models TN 55 and TN 65 . . . . . M 10 x 1. . . . 57) . . . . . . . . M 10 x 1. . . . . . . . . . . . . . . . . . . . . . . . . . .5 294 217 Fan and alternator pulley bolts (6) . . . . . . . . . . . . . . 104) . . . . . . . . . . . . . .25 110 81 Inlet manifold retaining bolts . . . . . . . . .ENGINE -. . . . . . . . . . . 85) . . . . . fig. . . . . . . . . . . . . . . . M8 25 18 Intermediate flanged journal bolts (1. . . . . . 105. . . . . . . . . . . . . . . . . . . . . . . . M8 25 18 Timing gear case and cover bolts (1. . . . . . . . . . . . . . . . . . . . . . . page 24) . . .CHAPTER 1 TORQUE SETTINGS WITH ANGLE Torque setting PART Thread Angle Nm ft-lbs Cylinder head bolts (2. . 105) . . . . . . . . . . . . . . . . . . . . M10x1. . . . . . M 12 x 1. . . . . . . . . . . . . . . . . .25 55 41 Coolant pump retaining bolts . . . . . . . . . . . . . . . . page 23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 30 x 1. .25 39 to 49 29 to 36 -. . M8 25 18 Injection pump mounting bolts . . . . . . M8 35 26 Rear crankcase cover bolts (2. . . . . . . . . . . . . . . . . fig. . . . . . . . . M 12 x 1. . . . fig. M8 25 18 Tappet adjuster locknuts (1. . . . . . . . . . . . . . . . M 10 x 1.25 70 52 90o + 90o Main bearing cap bolts (4) . . . . 64) . . . . . . . . . . . .

X 291177 Valve guide reamer. 291755 Device for BOSCH injection pump tim- X 291504 Puller for crankshaft pulley hub. Injection pump bench test X 291048 Piston ring clamp. X 291309 Compression test kit. 290740 Engine lifting hook. ment. turbo charger (for 90 hp TN 70 and TN 75). Use the hollowed injector X 294028 8o tapered grinder for swaging exhaust to screw into engine and the other end valve guides.CHAPTER 1 23 TOOLS X 293231 Bush for intake/exhaust valve guide installation (with 291046).ENGINE -. 291754 Dial gauge (1/100 mm. Remove the internal guts.The operations described in this section can only be carried out with ESSENTIAL tools indi. X Test Cylinder Compression X 291046 Drift for valve guide extraction / instal- (dummy injector) lation. 5 mm stroke. X 293280 Drift for installation of coolant pump im- List of specific tools required for the various peller seal. 292870 Engine oil pressure test kit. X 295042 Extractor for injection pump drive gear. 40 mm with 291755). X 291050 Valve spring compressor. 293860 Set of engine mounting brackets for re- volving stand 290090. which are to be made according to the drawings in- cluded in this manual. for the gage. To work safely and efficiently and obtain the best re- sults. SECTION 10 -. Warning -. (500307714) from parts. 293240 Check set. cated by an (X). X 293761 Wrench set for injector dismantling (with 295008). . ∅ X 292248 Protractor for angular torque measure. operations described in this section. 290284 Hand pump for injector calibration test. X 291182 Extractor for coolant pump impeller. ment. 293671 Injector cleaning kit. 293786 Wrench for injection pump delivery line unions. 293814 Charger impeller reaction block (for 90 hp TN 70 and TN 75). X 291883 Wrench for valve clearance adjust. 290090 Revolving engine service stand. X 291160 Piston ring pliers. Order a complete injector assembly X 294027 Twist bit for enlarging valve guide bore. it is also necessary to use the recommended X 293270 Set of grinding tools for regrinding in- specific tools listed below and certain other tools jector seat. ing on engine (with 291754).

Values in mm -.06 x 0.33 --5.8 (2.24. 10.5 the crankshaft rear seal (print on the tool no.inches).5 (1.CHAPTER 1 Splining tool to be manufactured for assembling the crankshaft front seal (print on the tool no.5 -.24 SECTION 10 -. Ø 129 (5.22) 50139 -. 34.inches).0.ENGINE -.71) 26103 2 .2 Construct in UNI C40 material.08) Ø 115 (4.2.35) Ø 83 (3.27) Ø 46 (1.60) Ø 59.18) (0.81) 24.33 -.0.95 -.36) 50138 -.5 -.5 x 15 (0. (0.1 -.96) 26102 1 Splining tool to be manufactured for assembling 4.5.136 (5. Construct in UNI C40 material.2 -.35 ) Ø 145 (5.Values in mm -.53) Ø 135.40) 1. 30 (1.59.18 -.5 (0.

CHAPTER 1 25 1 2 7 6 5 4 3 25355 3 Longitudinal section of engine (modelsTN 55 and TN 65). SECTION 10 -. .ENGINE -.

ENGINE -.CHAPTER 1 25356 4 Cross--section of engine (modelsTN 55 and TN 65). .26 SECTION 10 -.

7 bar/cm2) -- 3.CHAPTER 1 Engine lubrication system 5 1.ENGINE -. Oil pressure limiting valve -. Screen filter on pick--up pipe 27 .8. Dipstick -.4. Pump -. Oil filler cap -. SECTION 10 -.6. Switch for low engine oil pressure warning (on dashboard) -- 5.5--1. Filter -.2. Filter safety valve (opens when oil pressure at filter inlet exceeds the pressure at the outlet by 1.7.

Coolant circulation with thermostat valve open 4. Radiator . Coolant circulation with thermostat valve closed 3. Fan 2. Thermostat 5.ENGINE -. A. Electric thermometer for engine coolant temperature B.28 SECTION 10 -. Pump 6. Temperature value transmitter 1.CHAPTER 1 a b 1 2 3 4 25363 6 5 6 Engine cooling system.

damaged. Check and replace pump if neces- sary. bench. Check fuel lines. supply pump.ENGINE -. Irregular delivery from injection Check injection pump delivery on test pump. No fuel in tank. Fuel filters clogged. If neces- sary clean and dry the fuel tank. then bleed system. Thermostarter faulty. Idle speed too low. Disconnect fuel lines from injection pump and clean thoroughly. Replace terminals and nuts if excessively corroded. Incorrect valve clearances. unions. 6. Check and recharge battery. Air in fuel system. inspect and tighten terminal roded or loose. Injection pump timing incorrect. Battery partially discharged. 7. Check and replace thermostarter if necessary. Replace if necessary. Disconnect fuel lines from injection pump and clean thoroughly. Impurities or water in fuel lines. 6.CHAPTER 1 29 ENGINE TROUBLESHOOTING Problems Possible causes Remedies Engine does not start. Check fuel lines. Impurities or water in fuel lines. Burnt or cracked valves. Fuel supply pump malfunction. supply pump. 3. 5. Air in fuel system. 7. Fill tank. Renew filter cartridges. Replace valves. filters and injection pump for air. filters and injection pump for air. Engine stalls. If neces- sary clean and dry the fuel tank. 2.Clean. 4. Adjust injection pump timing. unions. 8. 8. nuts. 3. Repair or replace starter motor. 1. (continued overleaf) . 9. Battery terminal connections cor. Starter motor faulty. Adjust idle speed. SECTION 10 -. 1. 2. 5. 4. then bleed system. Adjust valve clearances. Injection pump drive mechanism Replace damaged parts.

Top up expansion tank with specified coolant mixture. on test bench to values specified in calibration table. 6. 3. Radiator inefficient.CHAPTER 1 ENGINE TROUBLESHOOTING (continued) Problems Possible causes Remedies Engine overheats. Impurities or water in fuel lines. Thermostat faulty. If neces- sary clean and dry the fuel tank. Deposits in cylinder head and Flush out coolant system. Engine lacks power and 1. Air filter clogged.delivering too much or too ues specified in calibration tables. Injection pump timing incorrect. tors. crankcase coolant passages. Coolant level low. runs unevenly. (continued overleaf) . 3. 6. Overhaul pump or replace. little fuel. Distributor journal worn. Replace thermostat. Coolant pump malfunction. Auto advance regulator in injec. Disconnect fuel lines from injection pump and clean thoroughly. Overhaul injection pump and adjust on test bench to values specified in calibration table.30 SECTION 10 -. 8. All--speed governor damaged. 9. Adjust injection pump timing. on test bench to values specified in calibration table. 7. 5. Overhaul injection pump and adjust on test bench to values specified in calibration table. 5. Coolant pump and fan drive belt Check and adjust belt tension. 7. Injection pump calibration incor. Clean filter unit and replace filter ele- ment if necessary. 2. 1. Check and adjust.Calibrate pump on test bench to val- rect -.Overhaul injection pump and adjust tion pump damaged. 4. 2. overhaul and calibrate injec- damaged. Injectors partially obstructed or Clean. slack. Check for leaks and repair.ENGINE -. Remove internal deposits by flushing. Incorrect timing. 4. Irregular delivery from injection Overhaul injection pump and adjust pump.

Ad- just valve clearances. Maximum speed screw on injec. 9. Tie--rod in linkage between acce. Clean injection pump if necessary. piston bushings. 9. Test compression and overhaul en- gine if necessary. lerator and injection pump incor- rectly adjusted. 4. Fit oversize shell bearings or big--end bearings or excessive and thrust washers.Re--grind crankshaft journals and cessive play in one or more main crankpins. Connecting rod axes not parallel. damaged. Adjust injection pump timing. dented pipes. Replace fuel supply pump. Replace any bolts that have worked loose and tighten all bolts to the speci- fied preliminary and angular torque values. Crankshaft unbalanced. 10. 7. (continued overleaf) . cam followers and bores. replace con rods if necessary. check axes parallelism. Air filter clogged. Excessive tappet / valve noise. Clean filter unit and replace filter ele- ment if necessary. or loose fit of Replace bushings.CHAPTER 1 31 ENGINE TROUBLESHOOTING (continued) Problems Possible causes Remedies 8. Engine produces abnormal 1. Injectors partially obstructed or Clean. Flywheel bolts loose. Noise caused by excessive play Fit oversize gudgeon pin. Straighten connecting rods. re--bore pis- of gudgeon pins in small--end and ton seats and small--end bushings. 12. Impurities accumulating in fuel li. 6. Fuel supply pump damaged.Adjust max. speed screw. 2. 10. Check for broken springs or exces- sive play between valve stems and guides. Check crankshaft alignment and bal- ance. 11. 8. 3. SECTION 10 -. Cylinder compression low.Adjust to correct length. Adjust valve clearances. Incorrect valve clearances. Injection pump timing incorrect. Piston knock due to excessive Re--bore cylinder liners and fit over- wear. Crankshaft knocking due to ex. tion pump incorrectly adjusted. size pistons. small--end bushing. overhaul and calibrate injec- knocking noises.ENGINE -. 13. replace if necessary. 5. endfloat.Clean fuel lines and replace severely nes. tors.

CHAPTER 1 ENGINE TROUBLESHOOTING (continued) Problems Possible causes Remedies Engine produces excessive 1. Loss of engine compression due Replace damaged parts or. recondition engine. vely advanced. 6. if neces- to sticking rings or cylinder liner sary. tor.ENGINE -. Replace solenoid. operating temperature (thermo- stat faulty).Adjust injection pump / engine timing white smoke. 4.1.worn or incorrectly adjusted val- ves. 3. -. Engine does not reach correct Replace thermostat. Maximum delivery of injection Calibrate pump on test bench to val- black or dark grey smoke.Clean and overhaul injectors and ad- structed or incorrectly adjusted.Inspect and replace if necessary.Adjust injection pump timing. Damaged high--pressure fuel li. Oil leaking past piston rings due Replace damaged parts or.or check automatic advance regula- ce regulator damaged. replace if nec- essary. Clean filter unit and replace filter ele- ment if necessary. nes. 2. 2. ching off. Injectors partially or totally ob. pump too high. vely retarded or automatic advan. 2. Clean and overhaul injectors and ad- just pressure setting. grey--blue or grey-. replace if nec- essary.cylinder liner wear. Engine runs on after swit. Air filter clogged.Adjust injection pump / engine timing vely retarded or automatic advan. guides due to guide or valve stem wear 5.piston rings sticking. if neces- to: sary. 4. wear. ues specified in calibration tables. Injection pump delivery excessi. All--speed governor damaged.32 SECTION 10 -. -. Engine stop solenoid damaged. 5. tor.1. . 7. 3. Injection pump delivery excessi. just pressure setting. Overhaul injection pump and adjust on test bench to values specified in calibration table. -. Injection pump delivery excessi.or check automatic advance regula- ce regulator damaged. Blue. Oil leaking through the inlet valve Recondition cylinder head. Injectors obstructed or damaged. recondition engine.

27765 8 4. 7 3. Loosen the clamps (1. 1. Disconnect the horn connection (1).ENGINE -. WARNING Always use appropriate tools to align fixing holes. 27180 9 . 27764 2. 2 and 3) and remove the inlet manifold.CHAPTER 1 33 Op. 10 001 10 ENGINE Removal--Installation DANGER Lift and handle all heavy parts using suitable lifting equipment. SECTION 10 -. Remove the clogged air filter sensor connection (1). only remov- al (see sect. NEVER USE YOUR FINGERS OR HANDS. Carry out Clutch operation 18 110 10. Make sure that no--one is standing in the vicinity of the load to be lifted. Make sure that assemblies or parts are supported by means of suitable slings and hooks. 18). Proceed as follows.

NEVER USE YOUR FINGERS OR HANDS. Carry out Clutch operation 18 110 10. -.CHAPTER 1 5. Fit and secure the inlet manifold. Attach the chains so that the engine is balanced during hoisting and position two wood blocks between the support and the front axle. 7. Apply the torque settings listed on page 20. 27808 11 -. Re--install the front axle--support unit on the en- gine. -. 9. proceed as follows.ENGINE -. . detach the radiator bracket (1).34 SECTION 10 -. WARNING Always use appropriate tools to align fixing holes. 8. Connect and secure the upper and lower radiator hoses and the connecting bracket. only remov- al (see sect. Loosen the front axle support retaining bolts (1). to prevent oscillation. 18). To re--install the engine. -. Unscrew the band clamps and detach the upper (2) and lower radiator hoses. 27807 10 6. Position two fixed stands under the front axle sup- port and under the engine. -. -. Remove the engine from the axle--support unit. Connect the horn and clogged air filter connec- tions.

temperature. On the other hand. SECTION 10 -. it also causes incomplete fuel combustion due to the lack of available combustion air. is uniform in all cylinders. of the efficiency of the sealing elements in the cylinder Every 100 meters (109. portant for smooth engine running that compression haust smoke and restriction of the exhaust passages.CHAPTER 1 35 Op. the compression should be 25. lighters. Uniform compression in all the cylinders ensures that 1%. as follows: Turn over the engine a few times to distribute the oil evenly over the cylinder walls. it is more im- excessive fuel consumption and. 2) Switch off the engine. out--of--round 3) Disconnect the lead from the engine stop electro. to rpm. and provides an indication between cylinders is 3 bar (43. or damaged pistons or liners. 8) Test the compression on the other cylinders.ENGINE -. the problem may be worn piston rings. .36 yards) above sea level cor- (piston rings and valves). in addition to posing the copper sealing washer. in place of the injector removed previously. provided that each cylinder is injected with the same quantity of fuel at the right time.9 to 398. lem will be the valves.6 bar (313.9 psi). On engines in perfect working order.3 psi). CONSIDERATIONS: mance. and then repeat the 1) Run the engine until it reaches normal operating test. the prob- valve and block the flow of fuel to the injectors.5 psi). fluids and vapour. 4) Remove the injector from the cylinder to be tested. both the valves and the rings.92 in. also test the compression on and take readings while turning the engine over with each cylinder. Uniform compression The engine therefore gives poor performance with Although high compression is important. -. the problem will be due to motor in order to expel any carbon residue. Before testing this time. pour approx. If the second test readings are significantly higher. responds to a reduction in compression by approx. if the second test reading shows 5) Turn the engine over a few times with the starter only a slight improvement. with the sump oil DANGER at approx. 40 oC (104 oF) at sea level (760 mm -- 29. magnet on the injection pump in order to close the If the second test readings are not higher. consequently. 10 001 30 COMPRESSION TEST 6) Fit the dummy injector made from “Tools” on page 21.of mercury) and at an engine speed of 200 Do not use matches. bearing in mind that: The minimum permissible compression on a used en- Compression ratio gine is 21. ex.5 bar ing the engine due to the presence of inflammable (369.5 to 27. Low compression not only reduces engine perfor. they all perform an equal amount of work. inter- In case of poor engine performance. The compression ratio is a measure of the quantity of The maximum permissible compression difference air drawn into the cylinder. blow torches or any form of naked flame as a source of light when inspect. checking the fuel injection system (injection nozzles 7) Connect the compression test instrument 291309 and injection pump). the starter motor. one spoonful of engine oil into the cylinder through the injector bore. As the compression ratio also varies with the tem. re- peating steps 4--5--6--7. sion should only be tested when the engine is at nor- mal operating temperature. Compression should be tested using the compres- sion test kit 291309. the compres- one cylinder it is advisable to repeat the test. Low compression readings perature of the engine (cold engines produce lower If extremely low pressure readings are obtained on compression values than hot engines).

the inlet line retaining unions (1) from the pump and the in- jectors. 27772 14 4. Unscrew: the hydraulic pumps piping retaining bolts (2). Proceed as follows. 27770 12 2. 27773 15 .safety goggles. and detach the piping (1).CHAPTER 1 Op. Unscrew the retaining bolts and remove the hy- draulic pumps from the lift (2) and services (1). Wear suitable safety clothing -.ENGINE -. 27771 13 3. from the engine and remove.36 SECTION 10 -. 1. complete with the support. which completes the piping (3). Do not put your hands or fingers between parts. the oil filter (1) retaining bolts. 10 001 54 ENGINE Removal--Assembly WARNING Handle all parts carefully. remove the pump and the fuel filter. gloves and shoes. Unscrew: the thermostarter union (2). Unscrew: the connecting lines (2) to the injection pump and the support retaining bolts (1).

On models with horizontal exhaust pipes. Unscrew the retaining bolts and remove the ex- haust silencer (1) complete with the vertical pipe. 27774 16 6. Unscrew the retaining bolts and remove the cover (3). 27776 18 8. SECTION 10 -. Unscrew the retaining nuts and remove the fuel pump (1).ENGINE -. remove when disassembling the engine. Unscrew the retaining bolts and remove the start- er motor (1). 27777 19 . 27775 17 7. loosen the retaining nut (2) on the injection pump (1) and remove from the opposite side.CHAPTER 1 37 5.

Unscrew the retaining bolts and detach the cool- ant pump hose(1). remove the alterna- tor (1) and recover the drive belt. Unscrew the retaining bolts. 27780 22 13. 27781 23 . 27778 20 11.38 SECTION 10 -. 10. 27779 21 12.CHAPTER 1 9. Unscrew the retaining bolts and remove the ex- haust manifold (1).ENGINE -. Remove the engine oil filter (2). Unscrew the retaining bolts and detach the cool- ant pump (1) complete with fan (2).

27782 24 15.CHAPTER 1 39 14. 18. 27783 25 16. washers and seals. Remove the rocker cover bolts (1). the underly- ing spherical washers. Unscrew the retaining bolts and remove the inlet manifold (1). Remove the injector mounting nuts.ENGINE -. 2 25098 27 . Unscrew the retaining bolts and detach the cool- ant pump support (1). Unscrew the retaining bolts and disconnect the thermostatic valve unit (2) complete with bracket (1). and then the rocker cover (2) and its gas- ket. then the supports and the 1 injectors themselves. 27784 26 17. SECTION 10 -.

Unscrew the sump pan retaining bolts (4) and re- move the sump pan using a hoist. lifting hook 1 2 290740 and lifting chain with eyeholes. 25101 1 30 23.40 SECTION 10 -. Unscrew the cylinder head bolts (1) and remove the head using a hoist and lifting hook 290740. then remove the entire rocker shaft assembly (1). Remove the valve collets (1) and extract the pushrods (2).CHAPTER 1 19. Remove the cylinder head gasket.ENGINE -. Remove the rocker shaft retaining bolts (2). Remove the half--gaskets (1) and (3) between the crankcase and sump pan and the gasket (2) be- tween the timing gear carrier and sump pan. 24. 1 2 25099 28 20. 22. 4 3 25104 31 . 1 2 25100 29 21.

1 25107 34 28.CHAPTER 1 41 25. 31). 1 25106 33 27. Unscrew retaining bolts (1) and remove the com- plete oil pump. Remove the gasket (1) between the flywheel car- rier and the sump pan. NOTE: When relocating gaskets (1) and (2. 1 2 25108 35 . 1 25105 32 26. apply RHODORSIL CAF1 silicone sealing compound to the mating surfaces. fig.ENGINE -. Remove the rotating counterweight oil seal O-- ring (1) installed on the crankcase mating sur- face. Unscrew the retaining bolts (2) and remove the crankshaft pulley (1). SECTION 10 -.

42 SECTION 10 -. Pull the pulley hub off the crankshaft using tool 291504 (1) and recover the woodruff key. Straighten the lock tab. 1 25112 39 . 1 25111 38 32. 1 25109 36 30.ENGINE -. 1 25110 37 31. securing the crankshaft against rotation and unscrew nut. Unscrew the retaining bolts and remove the lift pump drive gear carrier (1). Unscrew the retaining bolt (1) and remove the timing cover and gasket.CHAPTER 1 29.

CHAPTER 1 43 33. 1 25114 41 35. On re--assembly see timing instructions 1 on page 49. Remove the circlip (1) and the thrust washer.ENGINE -. Remove the circlip (1) and recover the thrust washer and the intermediate gear (2): 1 2 NOTE: When refitting the intermediate gear see en- gine timing instructions on page 49. and withdraw the gear with fuel supply pump cam- shaft (2) from the opposite side. 1 2 3 4 25115 42 36. 25113 40 34. NOTE: This gear transmits drive to the injection pump gear. 2 25108 43 . SECTION 10 -. Unscrew the retaining bolts (1) and remove the intermediate gear journal. Unscrew the retaining bolts (2) and withdraw the camshaft (3) complete with the camshaft gear (1) and the end plate (4).

Rotate the engine through 90_. out of the cylinder linings. on the stand. 1 25108 47 . 39. Remove the crankcase -.44 SECTION 10 -.ENGINE -. 1 25118 45 40. Renew the O--ring seal (1) installed in the lift pump drive shaft lubrication line.timing gear case gas- ket. Unscrew the retaining bolts (1) and remove the timing gear case. Slide the pistons (1). complete with rings. 1 2 25119 46 41. 1 25109 44 38. Un- screw the big--end cap bolts (2) and recover the big--end caps (1) with their half shell bearings.CHAPTER 1 37. gud- geon pins and connecting rods.

Recover the bearing shells. Rotate the engine on the stand through 90_ back to the horizontal position. thrust washers and tappets. 25109 48 44. Lift the crankshaft clear of the crankcase using a hoist and nylon sling. Turn the engine through 180_ on the stand 290090 (2). Unscrew the retaining bolts and remove the rear oil seal carrier (1) complete with gasket. unscrew the bolts securing the crankcase to the stand (2) and mounting bracket (3) from set 293860. 25123 50 . Unscrew the retaining bolts and remove the rear 3 2 crankcase housing (1) and its gasket. Lift the engine clear of the stand.ENGINE -. 48. Unscrew the main bearing cap bolts (1). Attach the lifting chain with eye holes to the crankcase. as shown in the fig- ure. Raise 1 the hook 290740. 45. 47. and re- move the main bearing caps with relative bearing shells. SECTION 10 -. as shown in the figure. 1 25122 49 46. Unscrew the flywheel bolts and remove the flywheel with the aid of a 1 hoist and hook 290740.CHAPTER 1 45 42. and recover the thrust washers located on the penultimate main bearing. 43.

To re--assemble the engine. BEAR- INGS AND THRUST RINGS: CHECKING AXIAL PLAY ON CRANK SHAFT (Disassembly operations 44 to 45) Proceed as follows: -.safety goggles. IN ADDITION. -. REMEMBER TO: -. 51 . Stick the semi--circular thrust washers (1) to both 3 2 25109 sides of the penultimate main bearing with grease.ENGINE -. Lubricate the main bearing seats with engine oil and install the half--shell bearings (3).CHAPTER 1 GENERAL NOTES AND INFORMATION -. Always use suitable tools to align holes in parts. Install the tappets in their crankcase bores. -. -. After dismantling the engine. Lubricate all rotating parts and oil seals with en- gine oil prior to installation. Do not put your hands or fingers between parts. clean all parts care- fully. The following pages 44 to 50 concern assembly operations that require special attention. carry out the disman- tling operations described on pages 34 to 43. WARNING Handle all parts carefully. -. Lubricate the oil filter mounting seal prior to fitting the filter. Wear suitable safety clothing -. -. Tightening torques are specified on page 20.46 SECTION 10 -. gloves and shoes. 1 -. -. MOUNTING THE TAPPETS AND DRIVE SHAFT WITH MAIN BEARING CAPS. Replace all seals and gaskets at each complete or partial engine rebuild.

-.ENGINE -. SECTION 10 -. 4 25108 53 -. fitting the top semi--circular thrust 1 2 3 washers (2) to the penultimate bearing cap. Insert the main bearing cap bolts and screw in un- til the head of the bolt is up against the cap.lb). -. 24718 52 -. Rotate the crankshaft (1) a few times to allow the parts to settle into position. Tighten all cap bolts (1) to a torque of 80 Nm (59 lfb. 1 2 24744 55 . 1 24720 54 -.CHAPTER 1 47 -. taking care not to dislodge the 1 semi--circular thrust washers installed previously. Using tool 292248 (2) tighten each cap bolt (1) through a further 90o. Lubricate the crankshaft journals with engine oil and fit the main bearing caps (3) with the half-- shells (4). Lubricate the upper surfaces of the main bearing shells with engine oil and lower the crankshaft (1) into position.

48 SECTION 10 -. 24760 56 MOUNTING THE REAR COVER WITH CRANKSHAFT SEAL AND ENGINE FLY. Using a feeler gauge (1). The seal that was originally installed had a 6mm (0. The correct handling and installation procedures are as follows: 1.236″) gap. 1. and 2 the molded plastic insert. Tighten the retaining bolts (2) to the torque speci- fied on page 20. check that the crankshaft flange is coaxial with the carri. Check that the crankshaft endfloat does not ex- ceed the value specified on page 13. between the seal housing.CHAPTER 1 -. Fit the rear oil seal carrier (3) with the outer seal. 3 20026008 58 .ENGINE -. 2. 57 Oil leakage from the crankshaft rear oil seal (part number 98461686) will result if the seal is not handled or installed correctly. 3. 1 WHEEL (Disassembly operation 43) 3 Proceed as follows: 2 -. 24752 er.

157″) between the seal housing.8 to 4 mm (0. The insert should only be removed after the new seal has been completely installed as detailed in these instructions. Installer Bushing OD: 129 mm (5. must only be installed using the special made tools described below.150 to 0. The insert is to protect the seal from any damage during parts stock and during installation.150 to 0. Installer Bushing: 115 mm (4. 3. NOTE: The spacer is used for the correct clearance gap of 3. (See dimensions for the spacer and installer bushing as shown) 1. 2.150 to 0. The seal.5 to 136 mm (5. and the molded 2 plastic insert. It is recommended to manufacture the special tools prior to requirement. The first replacement seal should be installed with a gap. Carefully handle the seal by the molded plastic insert only.8 to 4 mm (0.079″) .157”). The installer bushing is used to install the seal into the housing. Spacer Width: 3.ENGINE -.335 to 5. complete with the insert. Spacer OD: 145 mm (5. The machined sealing surface area of the crankshaft MUST NOT be cleaned using any type of abrasive paper. 2. 1. Installer Bushing Width: 30 mm (1. 3 20026009 59 5. of 3.354″) 20026010 2.8 to 4 mm (0.181″) 6.157″) 3. SECTION 10 -.709″) 60 4.CHAPTER 1 49 IMPORTANT: The seal is preassembled with a protective molded plastic insert. 4. This is to prevent the new seal lip from riding in the wear groove made by the previous seal lip. The new seal lip should never be positioned in the exact same location on the crankshaft as the previous seal that was removed.527″) 5. Spacer ID: 135. The protective molded plastic insert MUST NOT be removed or rotated in the seal prior to installation. 3.

CHAPTER 1 Seal Installation 6.ENGINE -. Lightly oil the crankshaft seal area with new engine oil. IMPORTANT: The engine MUST NOT be started within 24 HOURS of the seal installation and plastic insert removal. NOTE: The molded plastic insert should not be removed until the seal is correctly positioned. Fit the flywheel and tighten the retaining bolts (1) to a torque of 40 Nm (30 lfb. Use the installed bushing to push the seal into position in the seal housing. 8. -. Using tool 292248 (1). tighten each flywheel bolt (2) through a further 60o.50 SECTION 10 -. Install the spacer onto the molded plastic insert. 7. 1 2 24763 62 .lb). This is required to allow the seal to expand and settle onto the crankshaft after the molded plastic insert is removed. Ensure that the seal is installed evenly around the full circumference (the spacer should be against the molded plastic insert and the housing all the way around). 1 24762 61 -.

Lubricate pistons.ENGINE -. 63 -. 25166 66 . to the crankpins and tighten the cap bolts (2) to a torque of 40 Nm (30 lfb. Make sure that the piston ring gaps are offset at 180o. Insert the piston / connecting rod into the cylinder liner. check that the piston protrusion from the cylinder block face is within the tolerance limits specified on page 13. checking that the connecting rod number 1 2 corresponds with the cylinder number and that the number stamped on the connecting rod is fac- ing away from the camshaft. Bring the pistons (2). Fit the big--end caps (1). Rotate the engine on the stand through 180o and clean the upper face of the cylinder block.CHAPTER 1 51 MOUNTING THE PISTONS COMPLETE WITH RINGS. Fit piston ring clamp 291048 (1) to compress the rings (2). 1 2 25165 65 -. -. 25164 64 -. making sure that the piston ring gaps re- main in the positions specified in the previous point. PINS. CONNECTING RODS.lb). up to TDC and. BIG END CAPS AND BEARINGS -. SECTION 10 -. Using tool 292248 (1). rings and cylinder liners with en- gine oil prior to fitting. Using the piston ring pliers 291160 fit the piston 25163 rings. using a dial 1 2 gauge with a magnetic base (1). tighten each big--end cap bolt (2) through a further 60o. complete with shells. -.CHECKING PRO- TRUSION IN RELATION TO CYLINDER BLOCK FACE (Disassembly operations 40 and 41) Proceed as follows: -. -.

as described on page 86. 25169 69 REFITTING THE BOSCH INJECTION PUMP (Disassembly operations 6) -.Fit the BOSCH injection pump and proceed with the injection pump timing. 1 25181 70 .ENGINE -. Fit the timing gears.52 SECTION 10 -.Remove the cover of the flywheel housing in- spection window and its gasket. Turn the drive shaft so as to bring cylinder No. according to the type of BOSCH pump installed on the tractor (see pages 6--8--10). 26107 68 -. Look through the inspection window to check that the notch in degrees aligns with the index mark. 1 to TDC (compression stroke). making sure that the various reference marks indicated by the arrows in the figures are aligned. 25167 67 -.CHAPTER 1 SYNCHRONISING THE TIMING GEARS (Disassembly operations 32 to 36) Proceed as follows: -.

2 25177 74 . fig. Using the angular tightening tool 292248 (1) tight- en each bolt (2) in sequence through 90o (3rd 1 stage) and then through a further 90o (4th stage) in the sequence indicated above. -. SECTION 10 -. 73) on 4--cylinder engines to be followed for tightening stages (A = fan end). Lower the cylinder head onto the block and screw in the cylinder head bolts (1. carefully clean and degrease the mating surface of the cylinder block. 73) so that the heads are brought into contact with the cylinder head.ENGINE -. 25173 71 FITTING AND TIGHTENING THE CYLINDER HEAD (Disassembly operation 21) Proceed as follows: -. Locate the cylinder head gasket (1) with the word ALTO uppermost.CHAPTER 1 53 FITTING THE CYLINDER HEAD GASKET 1 (Disassembly operation 22) Proceed as follows: -. Tighten the bolts (1) to a torque of 70 Nm (51 lfb. Tightening sequence for cylinder head bolts (1.lb) in the sequence indicated above (1st stage). 72 -. 25174 -. fig.Before fitting the cylinder head. Check the torque of all the bolts in the sequence indicated above (2nd stage). 1 25176 73 -.

Tighten the rocker arm adjuster screw locknuts (1) to the torque specified on page 20.CHAPTER 1 ADJUSTING VALVE / ROCKER ARM CLEARANCE 1 (Disassembly operation 18) -. tighten nuts to 10 Nm (7 lfb. -. -. using a torque wrench. 2 2nd stage. 1 tighten to the torque specified on page 20 in two stages: 1st stage. tighten nuts to 25 Nm (19 lfb. 76 -. -.Position the injector support brackets and fit the spherical washers.Before refitting the rocker cover.ENGINE -.Insert the injectors (2) in their respective bores.Screw the bracket retaining nuts (1) up to the spherical washers then. ADJUSTING BELT TENSION ON THE COOLING SYSTEM (Disassembly operations 9) NOTE: Tension the belt correctly.Tighten the leak--off pipe unions.54 SECTION 10 -. .Tighten the high--pressure fuel line unions. as shown on page 68.lb). adjust the valve clearances as described on pages 76 and 77. 25179 -. 25178 75 FITTING THE INJECTORS (Disassembly operation 17) Proceed as follows: -.lb).

Wear suitable safety clothing -.D. DIMENSIONS AND REPAIRS -- CYLINDER BLOCK AND CYLINDER LINERS) WARNING Handle all parts carefully. the 0. remove and install the liners in cylinder block cold using a press as follows: 77 . NOTE: If one of the liners is re--bored.3 mm (0. After boring.12 mm (0.0047 in. measure the inside diameter at the upper and lower ends of this area both parallel to the crank- shaft centre line (a) and perpendicular to the crankshaft centre line (b). NOTE: Cylinder liner dimensions must only be mea- sured when the liner is installed in the cylinder bore. gloves and shoes. 1 25307 In case of replacement. all of the liners in the engine must also be re--bored to the same over- size.ENGINE -. Check line wear as follows: -. fig. To check piston running clearance. Then pair up the cylinder liners with the pistons of the same dimensions (see page 12). 79). fig. 79) only along the axis (b) perpendicular to the crankshaft centre line.CHAPTER 1 55 CHECKS. Do not put your hands or fingers between parts. SECTION 10 -.safety goggles.0197 in.). Clean all parts carefully before proceeding with the operations described below. -.0118 in. of each liner in the area (Z.) a 30o champfer must be restored on the liner (1). measure the inside diameter in the area swept by the piston rings (X. re-- bore and grind (or change) the liners. -.) or pis- ton coupling play exceeds 0.5 mm (0. as they are subject to deformation when not fitted. to bring them up to one of the sizes shown in the table on page 12. measure the I. compare these measurements to determine liner ovality and taper. If ovality or taper exceed 0.

-.56 SECTION 10 -.CHAPTER 1 -. using the appropriate plate. E. 25308 78 25310 79 Standard dimensions (mm) of cylinder liners and bores in the cylinder block and positions for checking liner wear A. Positions of dial gauge to measure liner I.D. axes (A. Re--bore and ream the liner to the specified I.0. Press the worn liner out of the block operating from the bottom of the crankcase using the ap- propriate plate. Dimension to obtain after press--fitting and reaming and taper (measure along axes a and b. respectively of liner. D. liner (area swept by piston rings) to determine ovality C. along the two perpendicular sured along axis b perpendicular to crankshaft).2 mm -.ENGINE -. parallel and perpendicular to the crankshaft). Check the ovality of the bore in the block and re-- bore if necessary to 0. Positions of dial gauge to measure liner I. Planes of measurement of the internal diameter of liner to determine piston running clearance (mea. Press--fit the new liner (0. -. -. Area for measurement of inside diameter of used 1. .) oversize.0078 in.2 mm (0. new and ground liners.D. Area for measurement of inside diameter of worn B. (see page 12).D. -- oversize if necessary) from the top of the block.0078 in. B).

safety goggles. and check that: -.0004 in. MAIN BEARINGS AND FLYWHEEL WARNING Handle all parts carefully. main bearing journal and crankpin ovality does not exceed 0. slight scoring or seizure marks can be removed with very fine grade emery cloth.008 mm (0. Crankpin rounds and fillets. After regrinding.05 mm (0. Do not put your hands or fingers between parts.0003 in.). gloves and shoes. Any cracks. DIMENSIONS AND REPAIRS -- CRANKSHAFT. 80 A B C 81 Standard dimensions (mm) of main bearing journals and crankpins. Rounds and fillets of crankshaft journal with thrust B. Normal crankshaft journal rounds and fillets. C. Carefully inspect the crankshaft.). If scoring. .).0020 in. main bearings and semi--circular thrust washers A.ENGINE -. Measure journal diameter to determine the nearest undersize (see page 13). Wear suitable safety clothing -. ovality or taper exceeds 0. SECTION 10 -. main bearing journal and crankpin taper does not exceed 0. even slight. 25311 -. restore the journal and crankpin rounds and fillets as shown in the details below. Crankshaft Clean all parts carefully before proceeding with the operations described below. washers. Inspect the crankshaft journals and crankpins. will necessitate replacement of the crankshaft.01 mm (0. the crankshaft will have to be reground.CHAPTER 1 57 CHECKS.

CHAPTER 1 -.2 psi).25 mm (0. A B 25314 82 Maximum tolerance for alignment of main bearing journals and crankpin relative to crankshaft centreline and alignment of crankpins relative to main bearing journals A. with -.) bar (213. the centrelines of each pair of crankpins lie in the same plane as the main journal centrelines.0039 in. 3 -.10 mm -. point resting on surface (A) or (B) does not ex- ceed the value specified in the table on page 14.10 mm (0. punch--lock in position and re--check oil tightness with the system pressur- -. Bearings Check the clearance between the crankshaft journals and the bearing shells using a calibrated wire gauge 1 2 as follows: -. Maximum permissible main bearing journal alignment B.fit the caps (1) complete with half--shells (2) to the 25316 respective journals.7 a maximum deviation of ± 0. 6 5 4 -. as measured perpendicularly to the same plane.ENGINE -.0039 in.). pendicular run--out of flywheel mounting flange.locate the half--shells in their respective seats (5). -. Dial gauge contact point positions for checking per. C. -. the oil plugs seal against an oil pressure of 14. the maximum misalignment of the main to a tolerance of ± 0. 83 . 82. -. the run--out measured with the dial gauge contact (0.) (C) fig.position lengths of calibrated wire (6) on the crankshaft journals (4) in correspondence with the crankshaft centreline (6).0098 in.install the crankshaft. -.make sure that all parts are perfectly clean and remove all traces of oil. if new plugs are fitted. the distances between the outer surfaces of the ised. with the crankshaft resting on parallel gauge crankpins and the crankshaft centreline are equal blocks. Dial gauge contact point positions for checking cen. bearing journals does not exceed 0. deviation. tering of flywheel mounting flange.58 SECTION 10 -.

at the penultimate bearing. check crankshaft endfloat. if not.CHAPTER 1 59 -. -. 25317 1 85 . Main bearing cap bolts (4. lubricate the screws (4. fig. Remove the caps and determine the bearing clearance by comparing the width of the cali- brated wire at the widest point against the scale printed on the packet (3) fig. If the endfloat exceeds the specified value (see page 13). 25318 84 -. 3) If the bolts are to be re--used. SECTION 10 -. 3) fixing the main bearing caps with engine oil and tighten them to the prescribed torque using a torque wrench (see page 20). -. 83 containing the wire.5 mm (0.ENGINE -.5315 in. using a dial gauge (1). check that diameter d (measured in area a shown in the figure) is greater than 13.). After refitting the crankshaft and the bearing caps and bolts. replace the existing thrust washers with oversize washers. replace the bolts. fig.

if not.5 ± 0. heat in oil to 80o to 90o C before fitting. Flywheel bolts (3. check that diameter d 25319 (measured in area a shown in the figure) is greater than 11. If the ring gear is to be replaced.60 SECTION 10 -. If the flywheel is overhauled.0197 in. 3) with engine oil.).ENGINE -. the external re--facing will need to be re--set to 0.0394 in. fig. 3) If the bolts are to be re--used. Once terminated.) in rela- tion to the nominal thickness of 38. The starter ring gear is force--fitted after pre--heating to the register on the engine side of the flywheel.).0079 in.2 mm (1.CHAPTER 1 Flywheel The flywheel is fixed to the crankshaft flange by means of self--locking bolts. and position with the bevel on the teeth facing inward towards the starter motor. re--facing by 1 mm (0. fig.). replace the bolts. the friction surfaces can be reground. The flywheel mounting holes are offset so that the fly- wheel can only be mounted in one position. as shown in the fig- ure. 25714 86 -. and tighten them to the pre- scribed torque using a torque wrench (see page 20). Lubricate the engine flywheel fixing screws (3. 87 .5 mm (0.4528 in.5 mm (0.5157 ± 0.

Maximum permitted tolerance is ± 0.) from the longi- tudinal axis of the connecting rod. fig. 25321 Also check that the oil ways (L and M. Dimensions to obtain by reaming after fitting bush- ings -.L.ENGINE -. 89 . M. Severely deformed rods should be replaced.07 mm (0.9213 in. bearing shells. bushings and gudgeon pins A. 88 Check parallelism of small end and big end axes. 88) are not obstructed by scale or impurities. New con rods must be marked with the number of the cylinder in which they are to be fitted. 25320 Dimensions (mm) of standard connecting rods. Check that the difference in weight of the connecting rods in the same engine does not exceed 25 grams.CHAPTER 1 61 CHECKS.0028 in. Slightly twisted con rods can be straightened using a press. Oil ports. Check that the bushings in the connecting rod small ends are tight in their bores and are flush with the sides of the rods. SECTION 10 -. replace the bushings and ream after fit- ting to the specified diameter (A) described in the fig- ure. gloves and shoes.) measured at 125 mm (4. Clean all parts carefully before proceeding with the operations described below. If necessary.safety goggles. Do not put your hands or fingers between parts. Wear suitable safety clothing -. DIMENSIONS AND REPAIRS -- CONNECTING RODS WARNING Handle all parts carefully.

DIMENSIONS AND REPAIRS -- PISTONS WARNING Handle all parts carefully.30 mm (0. Checking the end gap with ring in cylinder bore. re--bore and ream the liners and fit over- size pistons and rings (see pages 12 and 15). Wear suitable safety clothing -.CHAPTER 1 CHECKS. Checking piston diameter at a distance (L) from the C.). base of the skirt. D. Do not put your hands or fingers between parts. Checking piston ring groove clearance.ENGINE -. In case of piston replacement.). 90 and the end gap (c) are within the tolerances spe- cified on page 15. Distance from the base of the piston skirt: 57 mm B.2441 in. Check that the differ- ence in weight between pistons in the same engine does not exceed 20 grams. . Check that the piston ring groove clearance (b) fig. gloves and shoes.0118 in. If the piston running clearance exceeds 0. Clean all parts carefully before proceeding with the operations described below. Determine the degree of piston and liner wear in the manner described on pages 12 and 15 and the figures below.62 SECTION 10 -.safety goggles. correct by grinding the ends of the piston ring. (2. If the end gap is less than that spe- cified. A B C 25322 90 Checking pistons and rings A.

CHAPTER 1 63 25323 91 Dimensions (mm) of standard pistons. Measurement to be obtained with ring inserted in B.ENGINE -. Fit rings in grooves in the order indicated in fig. SECTION 10 -. If not. To remove or fit piston rings (1) use pliers 291160 (2). check that the clearance between the gudgeon pin and its bore in the piston is within the tolerance specified on page 15. the base of the skirt.) from cylinder bore. 25108 93 . 2 25324 92 Check that the piston / connecting rod assembly is perfectly square. gudgeon pins and rings A. Piston diameter measured at 57 mm (2.2441 in. replace parts causing the problem. 91. 1 When fitting pistons on connecting rods.

ENGINE -. 2 25326 94 Big end cap bolts (5. check that the ring end gaps are offset by an angle of 180o. -.5 mm (0.64 SECTION 10 -. NOTE: It is advisable to replace the big end cap bolts 25327 each time the connecting rods are dismantled.4134 in. replace the bolts.CHAPTER 1 Note: 1 -. check that diameter d (measured in the area a shown in the figure) is greater than 10. fig. Before fitting the ring clamp 291048 (1) to com- press the rings for piston (2) insertion in the liner. rings and liners before inserting the pistons in their bores. if not. 95 .). Oil the pistons. 3) If the bolts are to be re--used.

96 Tappets Check that the tappets slide freely in their bores with- out excessive play. SECTION 10 -. check that the step below the valve contact band is no less than 0. and the concave surface with the rocker arm adjuster screw must not show signs of seizure or excessive wear. TAPPETS AND VALVES WARNING Handle all parts carefully. 25329 In case of re--facing of the contact surfaces. remove as little material as possible. re--bore the seats and fit oversize tappets (see page 16).ENGINE -. Wear suitable safety clothing -. B.CHAPTER 1 65 CHECKS. In case of more serious defects. Discharge.). gloves and shoes. In the case of minor sealing faults. otherwise the rod must be replaced. 97 . Valves Use tool 291050 for valve removal and installation. Clean all parts carefully before proceeding with the operations described below.safety goggles.0197 in. S.5 mm (0. DIMENSIONS AND REPAIRS -- CAMSHAFT. Dimensions (mm) of valves and valve guides A. After grinding. the valves and their seats in the cylinder head may be re--faced using a pneumatic grinder or universal grinder. re--face the seats and grind the valves as shown in the relative chapter. Do not put your hands or fingers between parts. Distance to be obtained by reaming the fitted valve guide. Inlet. Pushrods must be perfectly straight. In the case of excessive tappet--to--bore clearance.

6.66 SECTION 10 -. Check cam lift using a dial gauge.) exhaust valve.CHAPTER 1 Camshaft Position the camshaft on two parallel V blocks and. 98 Replace worn bushings using suitable extractors and drifts.2350 in.2 mm (0.The value indicated for the bushing inside diameter refers to the fitted part. which should be as follows: -.). 25328 -. .0079 in.02 mm (0. using a dial gauge with 1/100 mm scale. the camshaft may be straightened using a press. and ream to obtain the inside diameter indi- cated in figure 98. check that journal run--out relative to the axis of rotation does not exceed 0.97 mm (0. If run--out does not exceed 0.0079 in. 25331 99 Dimensions (mm) of camshaft journals and relative seats in cylinder block Note -.ENGINE -.25 mm ()0.2461 in.). 5. other- wise replace the camshaft.) inlet valve.

45 mm (0. Provisionally set valve clearances to 0.). set the valve clearances for normal running. Discharge. . 25333 2. Valve timing diagram.0177 in. check that valves open and close and the angles indicated in the timing diagram. as specified on pages 76 and 77. Fixed advance (*). 4. 100 (*) See page 2. BDC. On completion of the timing check. Inlet. 3. A. Injection. using a graduated timing disk. 1. Turn the crankshaft and. TDC.CHAPTER 1 67 Valve timing check To check the valve timing after dismantling/assembly or overhaul of the valve timing gear. proceed as fol- lows: Check that the timing reference marks on the timing gears are aligned as indicated on page 49. SECTION 10 -.ENGINE -. 5.

the head must be refaced. gloves and shoes. Wear suitable safety clothing -.68 SECTION 10 -. 1 2 Use valve spring compressor 291050 to remove and refit valve springs. 25940 102 .) are found. 101 imum depth of material that can be ground from the cylinder head is 0.5 mm (0.ENGINE -.15 mm (0. Do not put your hands or fingers between parts. Clean all parts carefully before proceeding with the operations described below. check the run--out of the valve head (2) in the guide and the 1 2 clearance between the valve stem and guide.0059 in. If deviations of more 0.safety goggles. if necessary. 25108 NOTE: remove as little material as possible: the max. the valve guide.CHAPTER 1 CHECKS. replace the valve and. If the clearance exceeds the specified value (see page 18). Check that the cylinder head mating surface is flat us- ing a straight edge (2) and feeler gauge (1).). DIMENSIONS AND REPAIRS -- CYLINDER HEAD WARNING Handle all parts carefully.0197 in. Using a dial gauge with magnetic base (1).

(B) 25344 104 . Depth of taper. 1. Wear suitable safety clothing -.CHAPTER 1 69 VALVE SEATS IN CYLINDER HEAD -- Re--facing 1 WARNING Handle all parts carefully. SECTION 10 -. A. Discharge.safety goggles.ENGINE -. Do not put your hands or fingers between parts. gloves and shoes. Inlet. If the valve seats need re--facing to improve valve sealing. 103 Dimensions (mm) of valve seats and valve guides. S. B. use the universal valve grinder (1) and 25343 remove as little material as possible.

Cross--sectional view of engine lubricating oil pump. 2.safety goggles. 2 4. gloves and shoes.ENGINE -. 4 3 26109 106 . In case of replacement. 5. Pressure relief valve. When servicing the pump. DIMENSIONS AND REPAIRS -- LUBRICATION SYSTEM WARNING Handle all parts carefully.CHAPTER 1 CHECKS. Wear suitable safety clothing -. check component wear against the dimensions specified in the table on page 4 19. 1 Clean all parts carefully before proceeding with the operations described below. 2 OIL PUMP -.Overhaul 3 To access the oil pump. 4. model TN 70 and TN 75 1 1. remove the sump pan. Bushing. External drive gear. 3. 2. Pump body. models TN 55 and TN 65 25354 1. Drive shaft and gear. note that the drive shaft (3) and drive gear are supplied ready assembled. 3. Do not put your hands or fingers between parts. Spring. Internal gears. with 5 the gear hot force--filled on the shaft. Pressure relief valve.70 SECTION 10 -. 105 Cross--sectional view of engine lubricating oil pump. Driven shaft and gear.

the possible causes are: in order to drain the solution through the drain plug. If the red lamp fails to illuminate when the engine is stopped and the ignition switch is turned to the power Run the engine for about an hour (with the engine off) ON position. 5) is of the full--flow. whichever comes sooner. mixture consisting of water and “AMBRA AGRIFLU” suring that the engine continues to be lubricated. interruption in wire to the control switch.98 bar (14. against the mounting. antifreeze (up to 50% in volume). oil the outer part of the seal in contact with the ”AMBRA 20 30 40 50 mounting on the crankcase. -. two minutes (repeat the -.ENGINE -. LOW OIL INDICATOR -. remembering to: Degrees oC --8 --15 --25 --35 % in volume of -. blowing air into the radiator at a pressure of 0. tighten the cartridge. control switch malfunction. thus en. The same mixture can be kept in the cooling system for a maximum of 2 years or 1600 operating hours. al. blown fuse. only -. the radiator by means of a solution of water and nates in normal conditions. pression valve and one depression valve.CHAPTER 1 71 OIL FILTER -. vents freezing down to the following temperatures: Replace the cartridge periodically (every 400 operat- ing hours).always extend this operation to the entire cool- ing circuit. the safety valve (2) The cooling system is fitted with a permanent coolant will open to allow the oil to by--pass the filter. anti--corrosion. through a long--term protection of the cooling system.Flushing and checks The indicator consists of a control switch (4. DIMENSIONS AND REPAIRS -- COOLING SYSTEM The oil filter (3. screw on the new cartridge until the seal is up This mixture also has anti--oxidant. 40 °C. 5) Two valves are built into the radiator cap. by hand only. . AGRIFLU” -. If the system is leaking.Functional checks RADIATOR -. Top up the engine with the solution referred to above. This mixture pre- though with unfiltered oil. speed). SECTION 10 -. without signifying a descaling agent in the proportions shown on the fault. fig. one com- and a red warning lamp on the dashboard. which illu. further 3/4 turn. Should the line become clogged. It is never advisable to limit flushing to the radiator -. when the engine is hot and idling at low container. after which it must be changed. and is installed on the pump delivery Clean all parts carefully before proceeding with the line. Check the minates in the following conditions: correct operation of the valves periodically. remove deposits of lime scale in -. fig. test at least three times). anti--foaming and anti--scaling properties to ensure -. blown lamp. check the radiator seal by im- mersing it in a tank of water at a temperature of 20 to -. low oil pressure (the warning lamp also illumi. When overhauling. operations described below.2 psi) for approx. integral paper cartridge type.Replacement CHECKS.

check the tension 22631 again after one hour of running. Note -. 10 414 10 The fan/coolant pump/alternator drive belt is ten- sioned correctly when it deflects 10 to 11 mm (0. The thermostat cannot be adjusted and therefore must be replaced if it does not meet the temperature specifications in the table on page 3.64 to 22. 107 .ENGINE -. fig. move the alternator to achieve correct belt ten- sion.3937 to 0.Testing If malfunction is suspected.) when a force of 78 to 98 N (8 to 10 kg -.CHAPTER 1 COOLANT THERMOMETER -. THERMOSTAT -. slacken the nut (1) securing the alternator to the tensioner bracket.when fitting a new belt.4331 in.Replacement The thermostat (1. COOLANT PUMP AND ALTERNATOR DRIVE BELT Tension adjustment Op. 6) is fitted in the cylinder head coolant outlet union.72 SECTION 10 -. Check the tension using the belt tension tester 296118. 3.) is applied at the mid--point of the run between the alternator and coolant pump pulleys.05 lb. immerse the bulb of the thermometer in water and check the readings against a test thermometer (repeat the test a number of times with different water temperature to be sure).17. Adjust tension if necessary as follows: 1 2. then tighten nut (1).

2 1 25335 109 4. 25334 2. 2 1 25336 110 . NEVER USE YOUR FINGERS OR HANDS. Make sure that assemblies or parts are supported by means of suitable slings and hooks.CHAPTER 1 73 Op. SECTION 10 -. With the cylinder head on the test bench.ENGINE -. Place the cylinder head on a suitable support and remove the valve guide to be replaced. Turn the head upside down. 108 3. using drift 291046 (2) and bush 293231(1). Ream out the valve guide bore (1) using reamer 291177 (2). Make sure that no--one is standing in the vicinity of the load to be lifted. proceed as follows: 1. using drift 291046 (1). and force fit the new valve guide with the enlarged bore. Enlarge the bore of the valve guide to be fitted. 1 WARNING Always use appropriate tools to align fixing holes. using twist drill 294027. 10 101 53 VALVE GUIDES Replacement DANGER Lift and handle all heavy parts using suitable lifting equipment.

C = (43.L = C where: B = depth of taper relative to cylinder head face (see fig.1 to 9. Measure the distance (L) between the cylinder head face and the base of the valve guide.7165) -. Depth of taper milling. Example B = 43.3780 in.7165 in. using a calliper gauge and the special plate (1) on tool 294028.1 to 43. 1 2 25339 113 . 1 The depth of taper milling is given by: B -.3583 to 0.74 SECTION 10 -.1.3386 = 0. 6. From the upper side of the cylinder head. pro- ceed with the following operations.6) -. C = depth of taper milling. 142).6968 to 1. L = 34 mm (1. fit guide bush (1) of tool 294028 on the guide valve to be milled (2). Slide the cutter (1) of tool 294028.ENGINE -.34 = 9. 5. into the previously located guide bush until the cutting head is in contact with the valve guide.CHAPTER 1 NOTE: when replacing exhaust valve guides.].1 to 43. 25337 L = distance measured between cylinder head face 111 and valve guide base. complete with depth stop (2).). 1 2 25109 112 7.).3386 in.6 mm. Distance measured. [(1.6 mm (1.6968 to 1.

C 1 where: D = the distance that determines the end of the taper milling.6) = 35. with the plate flush against the 25341 cylinder head.). Example A = 45.7913 -.5 -. 115 C = the depth of taper milling.3780 in. Turn the cutting tool (2) until the plate (3).ENGINE -.4134 to 1.4 mm. D = 45.3583 to 0. 1 2 3 25340 114 9. C = 9. 10.9 to 36. A = the distance between the end of the cutter shank and the depth stop. 1 2 NOTE: before fitting the cylinder head.4331 in.9 to 36.6 mm (0. Distance (D) is given by: D = A -.) = 1.) from the end of the cutter shank and fix in place with its set screw.4331 in.5 mm (1.1 to 9.CHAPTER 1 75 8. Position the plate (3) of tool 294028 flush against the cylinder head face and slide the depth stop (2) up to the plate. [1. clean thor- oughly to remove all residue from the milling opera- tion. 25342 3 116 .). Position the depth stop (1) at a distance of (D) = 35.(9.4134 to 1.7913 in.3583 to 0. SECTION 10 -. Measure the distance (A) between the depth stop and the end of the cutter shank (1).(0. is brought up to the cylinder head face by the depth stop (1).4 mm (1.1 to 9.].3780 in.

securing it in position by turning the ring nut (8) clockwise. Fit seals (6. in the new sleeve (12. and dress with dressing tool 293861 (5). 117 If injector stand--out exceeds the specified limit. Fit guide bush 293746 (9). 3 4.0393 in. 5. 8. 3. fig. Checking injector and valve height relative to the cylinder head face. 1. re- place the injector sleeve using tool kit 293270.0511 in. Insert reamer 293747 (7) in guide bush (9) and then ream the lower part of the sleeve.7 to 1. 120) fully into the previously 5 cut thread and turn nut (1) to withdraw the injector sleeve (12) from the head.Replacement WARNING Handle all parts carefully. making sure that the thread is cut only in the sleeve. .3 mm. Cut an internal thread in the sleeve (2) to be re. 120) to the injector mount- ing studs on the cylinder head by means of nuts 4 (3) (M 8 x 1. Checking valve stand--in: 0. 1 2 moved using tap 292240 (3) M 12 x 1.safety goggles. 7.76 SECTION 10 -. Screw part (11. fig. Checking injector stand--out (see page 18). Fit tool 293784 (2. Set distance (A) on tap (3) 292240 to 9 mm (0.) (max. 120). 120). Do not put your hands or fingers between parts.0276 to 0. check the injector stand--out is within the toler- ance limits specified on page 18.) by means of ring nut (5) and fix the ring nut in position by tightening the set screw (4). onto the new injector sleeve and fit the sleeve into its bore.75. Remove any copper residue from inside the head 118 using tool 292243 (4.). b.3543 in. If the cylinder head face has been reground. a. fig.ENGINE -. fig. gloves and shoes. 120). 25346 6. 10 101 60 INJECTOR SLEEVES -. permissible stand in = 1. 25345 0.25). making sure that the sleeve butts up against the bottom of the seating in the cylinder head. Wear suitable safety clothing -.0 mm (0. fig. pro- ceeding as follows: 2.CHAPTER 1 Op.

8. 12. 10. installation and reaming of injector sleeve in cylinder head using tool kit 293270 1. 3. 4. fig. if not. 120) to remove ma.ENGINE -. 120) and check that stand--out is as specified on page 18. 120) in the bush. 120) and unscrew the ring nut (8) by approx. Injector sleeve extractor 293784. Cutter 293790. 7. . 10. 119 1 2 3 4 5 6 7 8 9 10 12 11 25348 120 Disassembly. fig. SECTION 10 -. 10 mm. fig. fig. and fit the milling cutter 293790 (10. 6. Injector sleeve dressing tool 293861. Install the bush in the sleeve (12) and fix in position by turning the ring nut (8) clockwise. O--ring seals. Once completed. use new bolts. 5. Waste removal tool 292243.5 mm. 9. Cylinder head bolts (2. Injector sleeve. fig. Injector sleeve extractor 293784. 120) or tap gently with a rubber mallet. fig.25 injector retaining nuts. M 8 x 1. 3) If the bolts are to be re--used. check that diameter d 25343 (measured in area a shown in the figure) is greater than 11. 2. Reamer 293747. fit the injec- tor in the sleeve (12. 13. 12. 1 terial until the seating is perfectly smooth and free from all marks. Remove the guide bush.CHAPTER 1 77 9. Press by hand on the ring nut (8. to release the inside of the guide bush (9) 293746. Work with the cutter (10. 11. Injector sleeve extractor 293784. Remove the reamer (7. remove the cutter. 11. Guide bush 293746. removal of residue. Guide bush 293746.

Loosen the pulley hub locknut (2). Loosen the retaining bolts and remove the fan (1) recovering the spacer. 3. 25690 4. Carry out operation 90 100 22: Bonnet opening. Carry out operation 90 100 80: Safety guard. only removal (see sect. 10 102 70 CRANKSHAFT FRONT OIL SEAL Removal -. remove the bolts (1) and extract the pulley (2). Loosen the alternator locknuts (3). only re- moval (see sect. and recover the pulley (1) and belt (2). Make sure that assemblies or parts are supported by means of suitable slings and hooks. Make sure that no--one is standing in the vicinity of the load to be lifted. 1 Proceed as follows: 1.Installation DANGER Lift and handle all heavy parts using suitable lifting equipment. Carry out operation 10 406 10: Radiator.CHAPTER 1 Op. only removal (see sect. 90). 121 5. 1 2 25693 123 . 1 2 3 25691 122 6. 90).78 SECTION 10 -. 90).ENGINE -. 2.

-. . -. 1 25695 125 9. only 126 installation (see sect. WARNING 1 Always use appropriate tools to align fixing holes. 25696 -. see page 22 and a striker (1). Respect the tightening torques prescribed on page 20. -. 90). -. 1 2 25694 124 8. To install the front oil seal. Carry out operation 90 100 22: Bonnet opening. Fit the hub. SECTION 10 -. using tool 291504 (1) recovering the woodruff key. Carry out operation 10 406 10: Radiator. Carry out operation 90 100 80: Safety guard.CHAPTER 1 79 7.ENGINE -. Extract the crankshaft pulley hub (2). 90). Fit the fan and spacer. NEVER USE YOUR FINGERS OR HANDS. Install the oil seal using tool (50138. 90). Assemble the pulley and the fan drive belt. -. locknut and pulley. -. proceed as follows. only installation (see sect. Remove the seal (1) from the seat. only installation (see sect. -.

80 SECTION 10 -. 2 and 3) and remove the inlet manifold. 90). Remove the flywheel inspection window cover (1). 4.safety goggles. 5. only removal (see sect. 10 106 12 ADJUSTING VALVE/ROCKER ARM CLEAR- ANCE WARNING Handle all parts carefully. Proceed as follows: 1. 127 3. only removal (see page 86). Carry out operation 90 100 22: Bonnet opening.CHAPTER 1 Op. 27180 2. 90). Loosen the retaining bolts and remove the cover (1). only removal (see sect. Do not put your hands or fingers between parts. Wear suitable safety clothing -. Carry out operation 10 254 44: Exhaust pipe. Loosen the clamps (1. 25704 129 . Carry out operation 90 100 84: Bonnet guard.ENGINE -. gloves and shoes. 27752 128 6.

Refit the parts that were removed.CHAPTER 1 81 7. returning the TDC 1 to the previous position. -. 90). Repeat this operation for the other valve pairs. 90). Carry out operation 90 100 84: Bonnet guard. -. proceeding as follows. Refit the flywheel inspection window cover. 8. 1 are balanced (start of induction stroke). Carry out operation 90 100 22: Bonnet opening. Carry out operation 10 254 44: Exhaust pipe. SECTION 10 -. 130 -. wrench (3) and rocker arm adjustment tool 291883 (2) bear- ing in mind the following recommendations. -. Rotate the crankshaft through 3600. only installation (see sect. Adjust the clearance between the valves and the rocker arms using a feeler gauge (1). -. Refit the inlet hose. NEVER USE YOUR FINGERS OR HANDS. only installation (see sect. Refit the rocker cover. -. WARNING Always use appropriate tools to align fixing holes.ENGINE -. -. -. -. . bearing in mind that the TDC 2 and TDC 3 refer- ence marks for pistons 2 and 3 are not present on the flywheel. only installation (see page 86). In this position the pointer will be aligned with the reference mark TDC 1 on the flywheel. Rotate the crankshaft so that the inlet and ex- haust valves of cylinder No. check that the clearances between valves and rocker arms cor- 27753 respond with the values specified in the table on page 17.

133 . 1. Do not put your hands or fingers between parts. 131 4.CHAPTER 1 Op. Loosen the clamp and detach the fuel intake pipe (1). position a support stand under the left-- hand lateral gear casing. Lock the front wheels using chocks. slightly raise the rear part of the tractor. 2.Installation WARNING Handle all parts carefully. 3.17 gal.82 SECTION 10 -. 10 216 10 FUEL TANK Removal -.safety goggles. Disconnect the two unions (1) and the fuel return line (2) from the fuel gauge.ENGINE -. gloves and shoes. Unscrew the plug (1) and drain the fuel from the 27792 tank into a suitable container (capacity 65 litres--17. then remove the rear left hand wheel. Proceed as follows.). Using a hoist. Wear suitable safety clothing -. 27946 132 5.

Loosen the retaining screw and remove the rear clamp (1). Connect the fuel intake pipe.ENGINE -. Position and secure the tank. Fit the left--hand wheel and remove the support stand.CHAPTER 1 83 6. lower the jack and remove the fuel tank. -. loosen the retaining screw and remove the front clamp (1). -. Position and secure the fuel inlet nozzle. Connect the fuel return pipe. 134 7. Position a hydraulic jack under the tank. WARNING Always use appropriate tools to align fixing holes. . Fill up with fuel (capacity 65 litres). 135 8. -. NEVER USE YOUR FINGERS OR HANDS. Unscrew the clamp (1) and remove the fuel inlet nozzle (2). -. 136 -. 9. -. Connect the fuel gauge connections. proceed as follows. To refit the fuel tank. SECTION 10 -. -.

84 SECTION 10 -. 27181 138 4.ENGINE -.CHAPTER 1 Op. Unscrew the return lines connecting union (1) and the injector fuel supply lines (2). 27182 139 . Loosen the injector retaining bolts (1). Loosen the clamps (1. 90). 2 and 3) and remove the inlet manifold. Proceed as follows: 1. 10 218 30 FUEL INJECTORS Removal--Installation WARNING Handle all parts carefully.safety goggles. 27180 2. 137 3. Wear suitable safety clothing -. Do not put your hands or fingers between parts. Carry out operation 90 100 22: Bonnet opening. only removal (see sect. gloves and shoes.

ENGINE -. Carry out operation 90 100 22: Bonnet opening. -.CHAPTER 1 85 5. . NEVER USE YOUR FINGERS OR HANDS. Tighten the union on the fuel supply lines and the 27183 return lines. -. -. Extract the injector (2) using a suitable extracting tool (1). SECTION 10 -. WARNING Always use appropriate tools to align fixing holes. proceed as follows. Refit the inlet hose. 6. 140 -. 90). only installation (see sect. -. Insert and secure the injector in the seat. Respect the tightening torques prescribed on page 20. To install the fuel injector.

CHAPTER 1 Op. 2. 90). timing and air bleeding WARNING Handle all parts carefully.ENGINE -. 27755 142 5. 3. Make two reference marks (1) on the two gears to facilitate the subsequent injection pump instal- lation and timing operations.86 SECTION 10 -. gloves and shoes. Wear suitable safety clothing -.safety goggles. Carry out operation 90 100 80: Safety guard. detach the compressor support bracket (1). Unscrew the retaining bolts and remove the housing (2) on the injection pump drive gear box. NEVER USE YOUR FINGERS OR HANDS. Proceed as follows: 1. WARNING Always use appropriate tools to align fixing holes. 27754 If the conditioning system compressor is fitted. only removal of right--hand guard (see sect. 27756 143 . 141 4. 10 246 14 BOSCH INJECTION PUMP Removal--Installation. Raise the engine hood. Do not put your hands or fingers between parts. Detach the throttle lead (1) from the injection pump lever and the electrical lead from the engine stop electromagnet.

Make sure that the reference marks (2) are indi- cated for injection pump timing (1). (2) the fuel return line and (3) the pump supply line. Unscrew the locknut that holds the injection pump to the drive gear (1). 27758 146 10. 2 1 27761 145 9. 27757 144 8. Disconnect the pipe that connects the LDA de- vice to the inlet manifold (only models TN 70 and TN 75). SECTION 10 -. Loosen the unions: (1) of the injection pump sup- ply line.CHAPTER 1 87 6. 7. Unscrew the injection pump retaining bolts (1). 27759 147 .ENGINE -.

Assemble the LDA device connection pipe to the inlet manifold (for models TN 70 and TN 75). To install the injection pump.ENGINE -. Lower the engine bonnet. -. Refit the injection pump drive gear box access cover. Connect the throttle lead to the injection pump. then fix in 148 position by means of the bolts. Connect the fuel supply and return lines to the in- jection pump. 12. Respect the tightening torques prescribed on page 20. -. proceed as follows. 27760 making sure that the reference marks (made pre- viously) for timing operations coincide. -. -. us- ing the nut. . Lock the injection pump drive gear in position. -.88 SECTION 10 -. -.CHAPTER 1 11. Using tool 295042 (1) detach the injection pump from the gear and recover the injection pump with the woodruff key. Assemble the injection pump complete with key. WARNING Always use appropriate tools to align fixing holes. NEVER USE YOUR FINGERS OR HANDS. -. -. Connect the engine stop electromagnet electrical lead. Connect the injection pump fuel supply lines. -. -.

25710 152 . Unscrew the unions of the fuel supply lines (1). Rotate the crankshaft to bring cylinder No.ENGINE -. disconnect the injection pump sup- ply lines (2 and 3) and. 17.CHAPTER 1 89 BOSCH INJECTION PUMP Timing If the engine does not run evenly. or doubts arise concerning their ac- curacy. detaching them from the injection pump. 1 to TDC of the compression stroke. if the timing marks (1) are not visible. for models TN 70 and TN 75. SECTION 10 -. Remove the injection pump gear cover. 15. time the injection pump as follows: 25709 149 13. 25704 151 16. If necessary. Remove the flywheel inspection window cover (1). 27757 150 14. the connection pipe between the LDA de- vice and the inlet manifold. Check that the “4” timing marks on gears (1) and (2) are aligned.

21.90 SECTION 10 -. With the injection pump in position but with the mounting bolts loose. Refit other parts in the reverse of the dismantling order. 20. fix 155 the pump in position by tightening the mounting nuts to the torque specified on page 20. Turn the pump counter--clockwise if the plunger has completed a stroke of less than 1 mm (0. Check on the dial gauge that the plunger has completed a stroke of 1 mm (0. Stamp pump timing marks (1.0394 1 2 in.) up to this point.CHAPTER 1 18. 25711 154 22. 23.0984 in. 24. Having obtained the correct plunger stroke. .0394 in. distance piece and housing. 28.ENGINE -. 25712 25. and clockwise if the stroke is greater than 1 mm (0.5 mm (0. 26107 153 19. Zero--set the dial gauge and slowly turn the fly- wheel clockwise (as viewed from the fan end of the engine). until the pointer lines up with the “9” reference marks for models TN 55 and TN 65 or the “6” marks for models TN 70 and TN 75. as shown in figure 201) on the pump mounting flange. so as to bring the plunger to BDC at the start of the deliv- ery stroke (the point at which the dial gauge needle stops falling). 27.). remove the plug (1) on the pump housing. repeating the test until the cor- rect stroke is obtained. 26.). Fit dial gauge 291754 (1) fig. Turn the flywheel slowly backwards. Remove the dial gauge 291754 (1) and relative tool 291755 (2) and replace the plug and tighten to a torque of 8 to 10 Nm (6 to 7 ft-lbs).0394 in. 147 and relative tool 1 291755 (2).). slacken off the pump mounting bolts. pre--loading the shaft by approxi- mately 2. if not. Check through the inspection window that the pointer is aligned with the “9” reference marks for models TN 55 and TN 65 or the “6” marks for models TN 70 and TN 75.

fig. 27508 156 32.CHAPTER 1 91 BOSCH INJECTION PUMP Fuel circuit air bleeding 29. SECTION 10 -. 27561 157 33. Operate the priming lever (1. Loosen the fuel supply lines unions on the three injectors. Unscrew the bleeder plug (1) by approx. until the fuel coming out of the injectors is free of air bubbles. Start the engine and check that it runs evenly.ENGINE -. 30. 2 turns. 34. 150) until the fuel coming out of the hole in the plug is free of air bubbles. Tighten the plug (1). 27509 158 . Operate the priming lever (1) again. 31. then tighten the injector unions.

Fit the exhaust pipe. Remove the two retaining bolts (2). NEVER USE YOUR FINGERS OR HANDS. 159 haust pipe bracket (1). -. washer and retaining bolt. gloves and shoes.safety goggles. Wear suitable safety clothing -. 160 . To refit the exhaust pipe. Proceed as follows. 27645 1. and the ex.92 SECTION 10 -. washer and ex- haust pipe (1). 3. WARNING Always use suitable tools to align holes in parts. Fit the exhaust pipe bracket and the two retaining bolts. proceed as follows.CHAPTER 1 Op. 10 254 44 EXHAUST PIPE Removal--Installation. 2. Do not put your hands or fingers between parts. 27646 -. WARNING Handle all parts carefully. Remove the retaining bolt (2).ENGINE -.

ENGINE -. only removal (see sect. Fit the coolant pump and connect the lower lines to the pump. SECTION 10 -. Fit the fan and spacer. 5. installation (see sect 90). DANGER Lift and handle all heavy parts using suitable lifting 1 equipment. -. Carry out operation 10 406 10: Radiator. -. . Respect the tightening torques prescribed on page 20. only installation (see sect. only 25690 removal (see sect. 10 402 11 COOLANT PUMP -. WARNING Always use appropriate tools to align fixing holes. Loosen the retaining bolts and remove the fan (1) recovering the spacer. Carry out operation 90 100 80: Safety guard. 161 moval (see sect. remove the bolts and the pump.Removal--Installation with the radiator removed. Proceed as follows: 1. proceed as follows. only -. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Loosen the alternator locknuts (3). Carry out operation 90 100 22: Bonnet opening. 90). Carry out operation 90 100 22: Bonnet opening. installation (see sect. 25692 -.CHAPTER 1 93 Op. 1 7. 90). NEVER USE YOUR FINGERS OR HANDS. Assemble the pulley and the fan drive belt. 90). To install the coolant pump. 90). 3. 2. Make sure that no--one is standing in the vicinity of the load to be lifted. 1 2 3 25691 162 6. -. 4. Carry out operation 90 100 80: Safety guard. 90). Carry out operation 10 406 10: Radiator. only -. Unscrew the retaining bolts and remove the pump lines (1). and recover the pulley (1) and belt (2). 163 -. only re.

fig. Heat the rotor (1) in an air oven. it is a sealed unit and re. 5976 165 Note -.94 SECTION 10 -.ENGINE -. fig. In the event of replacement. Fit the seal (3. after having spread a film of LOCTITE 242.Overhaul 1 2 3 WARNING 4 Always use appropriate tools to align fixing holes. 166 -. using tool 293280 (1. replacing parts that are in poor condition. from the pump housing (6. fig. 14262 quires no lubrication during running. Fit the shaft (10. 164 Overhaul the pump as follows: -.Remove the front seal bushing (7. -.0197 to 0. -. 1 ture difference of 130 to 150 °C (266 to 302 °F) in relation to the shaft (2).0276 in. -. fig. 156) and the cover (4) securing in position with the relevant screws. fig. complete with bearing (9) and fan hub (1). 156). Refit the parts. 156) and the screw (2) retaining the shaft(10) and bearing (9).Gently tap the end of the shaft (10. 156) when it needs to be replaced. 156) forms a single piece 10 9 8 7 with the control shaft (10). fit the seal (8) into the seat.Only remove the seal (8. fig. until ob- taining an operating clearance of G = 0. 156). 1 Check components for wear. -. 2 21663 167 .7 mm (0. proceeding as follows: -.5 to 0. NEVER USE YOUR FINGERS OR HANDS. Place the rotor (1) on the shaft (2). -. 158).Remove the cover (4. to reach a tempera. fig. 21662 cure with the retaining screw (2). 10 402 28 COOLANT PUMP -.The bearing (9.) (see fig. 5 6 Note -. 156). 156) complete with bearing (9) and hub (1) on the pump housing (6) and se.CHAPTER 1 Op. easing it onto the end so as not to damage the bearing. 156) on the rotor side (5) to break the film of oxide between the shaft and the rotor. -. fig.Use a punch to extract the shaft (10). fig. fit extractor 291182 (1) 1 and remove the rotor.

SECTION 10 -. Loosen the band clamps (1. 90). gloves and shoes. Carry out operation 90 100 22: Bonnet opening. 4. Unscrew the retaining bolts and remove the bracket (1). 27750 170 6. 27751 171 . drain off a few litres of cool- ant and then tighten the plug. 27180 2. only removal of the left--hand guard (see sect. Loosen the band clamp (2) and remove the hose (1). Do not put your hands or fingers between parts. 10 402 30 COOLING SYSTEM THERMOSTAT Removal--Installation WARNING Handle all parts carefully. 3. Proceed as follows: 1. 27749 169 5.CHAPTER 1 95 Op. Carry out operation 90 100 80: Safety guard. Unscrew the plug (1).ENGINE -. 2 and 3) and remove 168 the inlet hose. 90). only removal (see sect. Wear suitable safety clothing -.safety goggles.

section 00 for prescribed products and quantities). Make sure that the drainage plug is tightened. only installation (see sect. Extract the thermostat valve (1) from the seat.ENGINE -. -.96 SECTION 10 -. then fill up the engine cooling system with coolant (see page 6.CHAPTER 1 7. 90). Fit and secure the bracket to the radiator. 25700 -. NEVER USE YOUR FINGERS OR HANDS. -. Connect and secure the hose to the housing seat. Position the thermostat valve in the seat. 173 -. Respect the tightening torques prescribed on page 20. . Carry out operation 90 100 22: Bonnet opening. 1 25699 172 8. Assemble the valve housing--seat. -. -. 9. To refit the thermostat valve. Fit and secure the inlet manifold. only installation of the left--hand guard (see sect. -. 1 WARNING Always use appropriate tools to align fixing holes. Loosen the retaining bolts and detach the hous- ing--seat (1) of the thermostat valve. proceed as follows. -. -. Carry out operation 90 100 80: Safety guard. 90).

then tighten the plug. 90). 10 406 10 RADIATOR Removal--Installation DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that no--one is standing in the vicinity of the load to be lifted. drain off the coolant. Unscrew the plug (1). and remove the relevant support bracket. Unscrew the retaining bolts and extract the POW- ER SHUTTLE heat exchanger (1). 4. if neces- sary.CHAPTER 1 97 Op. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Loosen the retaining bolts (1 and 2) that connect the power steering piping to the radiator. 27749 2. 3. Carry out operation 90 100 22: Bonnet opening.ENGINE -. 27762 175 5. only 174 removal (see sect. only removal (see sect. if fitted. 27763 176 . Proceed as follows: 1. Carry out operation 90 100 80: Safety guard. SECTION 10 -. 90).

27765 178 8. Unscrew the band clamp and remove the pipe (3) that connects the radiator to the expansion tank. 27767 180 .ENGINE -. Unscrew the radiator retaining bracket (2).CHAPTER 1 6. Disconnect the horn connection (1). 27764 177 7. 10. 11. Unscrew the clamp (1) and remove the oil vapour recovery hose (2). Remove the clogged air filter sensor connection (1).98 SECTION 10 -. Unscrew the clamp and disconnect the inlet hose (1). 12. 27766 179 9. Unscrew the retaining clamp and disconnect the upper (4) and lower hoses.

-. -. proceed as follows. Fit the power steering piping to the radiator. 90). see 00. -.radiator connecting pipe. -. Carry out operation 90 100 22: Bonnet opening. Tighten the coolant drainage plug and fill up the system (for quantities and products.ENGINE -. -.CHAPTER 1 99 13. page 6). Connect and secure the upper and lower hoses and the expansion tank -. -. Carry out operation 90 100 80: Safety guard. Assemble the POWER SHUTTLE heat exchang- er. Fit the air filter and inlet hose. Connect the air filter and horn connectors. WARNING Always use appropriate tools to align fixing holes. complete with air filter (2) and inlet hose. Unscrew the retaining bolts and remove the ra- diator (1). 15. 181 -. Unscrew the retaining bolts and detach the air fil- ter from the radiator. only installation (see sect. Fit the inlet hose and vapour recovery hose. Respect the tightening torques prescribed on 27768 page 20. . -. -. -. only installation (see sect. NEVER USE YOUR FINGERS OR HANDS. Fit the tank retaining bracket. 14. Position the radiator and secure with the relevant bolts. To refit the radiator. 90). SECTION 10 -. -. -.

100 SECTION 10 -.ENGINE -.CHAPTER 1 .

. . . . . . mm 0. . . . . . . . . . . . . . . . . .2874 to 0.151 (in. . . . . . . . . .3110) -. . . . . . . . . .050 to 0. SECTION 18 -. . . . . . . . . . . . . . . . . . . . . . . . . . . ” 9. . . . . . . . . . . . . . . 1127769) . . . . . ” see pages 21 and 22 Clearance between main clutch release sleeve and housing . . . . 2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . (in.3779 to 0. . .mm 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 modification . . . . . . . hand lever operated PTO clutch Engagement and release mechanism . . . . 2 Cross--sectional views . . . . . .060 to 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . fig. . . . . . . . . . . . . . . . . .Test bench overhaul . . . . . . . 1): premodification models and models TN 55 and TN 65 post. . . . . 19 LUK 11”/11” CLUTCH -. . . . . . . . . premodification models and models TN 55 and TN 65 postmodi. . .4 (0. . . . .Removal--Installation . . . . . . . PTO clutch (11. . . . . . . . 5 18 110 10 Clutch -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 18 110 30 11”/11” Dual disk clutch -. . . . . . . .136 (in. . . . . . . . . . . . . . . . . . .0023 to 0053) Release lever height adjustment . -. main clutch (9. . . . . . . .) (0. . . . . . . . . . . . . . . . . . . . . . . .3818 to 0. . . . . . . . . . . . . . . . . .4094) -. . . . . . . .0019 to 0. . . single Belleville spring disk Driven plate lining material for main clutch: . . . . . . . . . .0059) Clearance between PTO clutch release sleeve and housing . . . . . . . . . .Clutch CONTENTS Section Description Page 18 000 General specifications . . . . . . . . . . . . . . . . . . . . . . . . 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 to 10. single disk. .4055) models TN 70 and TN 75 (from frame no. . . . . . . . . 1 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ” 7. . see page 24 . . . . . . . . . . . . . .) (0. . . . . . .3 to 7. 1127769) . . . . . . . . wear limit . 15 18 100 40 Clutch adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . organic agglomerate fication . . . . . . . . . . . . . 3 Troubleshooting . . . . . . . . . . . . . . . . . . . mm 0. . . . . . mechanical: pedal operated main clutch. . . . . . . . . . . . see pages 22 and 23 Clutch control adjustment . . . dry plate dual clutch unit Operating system . . . . . . . . . . . . . cerametallic Driven plate lining material for PTO clutch . . . . . . . . . . . . . . . . . . . . . fig. . . . . . . . . . . . .CLUTCH Chapter 1 -. . . . .) (0.CLUTCH -. . . . . .CHAPTER 1 1 SECTION 18 -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 (0. . . . . . . . . . . . .GENERAL SPECIFICATIONS Type . . . . . . . . . . . . . . . . . -. . . . . . . . .Test bench overhaul . . . . . . . . . . . . .6 to 10. . . . . . . . . . . . . . models TN 70 and TN 75 (from frame no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 18 110 30 11” Single disk clutch (Version with Power--Shuttle) -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cerametallic Driven plate thickness: -. . . .

. . . . . . . . . . . . . . . . . . . Belleville spring disk Driven plate lining material for PTO clutch . . . cerametallic pads Driven plate thickness for PTO clutch (1. . . . . . . . .0059) TIGHTENING TORQUES Tightening torque PARTS TO TIGHTEN Thread Nm ft lbs 11”/11” clutch/flywheel retaining bolts . M 16 x 1. . . . . . . . . . . . . . . . . . . . . . . .The operations described in this section can only be carried out with ESSENTIAL tools indi- cated by an (X). . . . . . M 12 x 1. . . . . . . . . .GENERAL SPECIFICATIONS” Type . . . . fig. . . . . . Driven plate wear limit . . . . . . . . . . . . . . which are to be made according to the drawings in- cluded in this manual. . . . 1) . . . M 8 x 1. . X 295023 Clutch adjustment gauge (with 294073). 1) .2 SECTION 18 -. . . . . . . .0019 to 0. . . . . . . . . . . . fig. . . . . X 294073 Pin for centering and adjustment of 11”/11” clutches. . . . . .151 (in) (0. . .CLUTCH -.25 117 to 129 86 to 95 Nut for sleeve cover fixing stud (6.3 to 7. . . . . . .9 (in) (0. . . . To work safely and efficiently and obtain the best re- sults. single dry plate clutch Operating system . . . . . M 8 x 1. List of specific tools required for the various operations described in this section.25 20 to 25 15 to 18 TOOLS Warning -. . . . . . . . . . . . 293763 Set of wrenches for adjustment of levers in 11”/11” LUK clutches. . . . .5 136 to 165 100 to 122 Clutch casing/engine retaining nuts (3. . . it is also necessary to use the recommended specific tools listed below and certain other tools. . . . . . 1) . 2) mm 7. . . . . . . . . . .2874 to 0. .CHAPTER 1 LUK 11” CLUTCH -. . . . . . . . . . . . . . . . . . . . . . mechanical: pedal operated Engagement and release mechanism . .25 20 to 25 15 to 18 Release command fork securing bolt (7. . . . fig. . . .3110) -. . . mm 0. . . . . . . .050 to 0. . fig. . . . . . . . . . . . . . . . . . . . . ” see page 21 Clearance between clutch release sliding sleeve and support . . . . . . . . . . .

Main clutch release lever. Fork lever retaining bolts. a Clutch (up to frame no. 2. 6. PTO clutch release levers. Bearing on flywheel.8386 in. SECTION 18 -. 1127769). NOTE:During assembly apply sealing compound on surfaces marked with an X as shown in Section 21. Release sleeves for main and PTO clutch. Nuts for sleeve cover fixing studs. 11.). 4.5 mm (3. Bolts or nuts securing clutch casing to the engine. page 30.4921 in.5 mm (5. 10. PTO clutch release lever adjuster. Nominal distance of release levers (8) from clutch contact surface on flywheel.CLUTCH -. Main clutch disk. 12. Main clutch release lever adjuster. 8. Nominal distance of release levers (4) from clutch contact surface on flywheel. D = 97. 1127768). complete with thrust bearings.CHAPTER 1 3 Longitudinal section of 11”/11” LUK clutch 1. Belleville spring disk. X Chapter 1. 1 D 3 4 5 5. 12 11 10 9 8 7 6 a 25961 b 1 . PTO clutch disk. 9. b Clutch (from frame no. 2 D1 3.). 7. D1 = 139.

check that the clutch disks are positioned as in the drawing.5 mm (5. a Clutch (up to frame no. NOTE:When refitting the clutch. Fork lever retaining bolt. 3. Main clutch disk. 6. complete with D1 thrust bearing. Nuts for sleeve cover studs. 1127768). 5. 1 2 3 2.CLUTCH -. NOTE:During assembly apply sealing compound on X surfaces marked with an X as shown in Section 21.CHAPTER 1 Longitudinal section of 11” LUK clutch” 1.4921 in. D1 = 139.4 SECTION 18 -.). 1127769). 4. Chapter 1. Nominal distance of release levers (2) from clutch contact surface on flywheel. Screws and bolts securing the clutch casing to the engine. b Clutch (from frame no. 6 5 4 25962 a b 2 . page 30. Release sleeves. PTO clutch release levers.

2) clean the friction surfaces. 2 pressure plates and fly.the pages indicated. the clutch housing and thoroughly fig. Partial seizure of pedal pivot. 1) and disk (1. replace any wheel worn. control linkage. 2) deformed. identify and elimi- the friction lining of disks (11 nate the source of the lubricant inside and 9. 2. distorted or damaged. . 2.CHAPTER 1 5 CLUTCH TROUBLESHOOTING Problems Possible causes Remedies Clutch slips 1. fig. Belleville spring disk (2. cate. 3. Oil or grease contaminating Replace the disks. fig. 1) Replace the Belleville spring disk. 4. control linkage. fig.Replace the disk. Clutch noisy when engaged 1. SECTION 18 -. fig. fig. Partial seizure of the external Check rod pivots and lubricate. Clutch disk (9. Controls incorrectly adjusted. Clutch disk (9. control lever. replace faulty parts and lubri- linkage. 1) with hub Replace the disk. 2. Seizure of external control Check. Partial seizure of the external Check rod pivots and lubricate. fig. aged hub springs or loose hub rivets. Thrust bearing worn. Oil or grease contaminating Replace the disks. page 1) de. 2. fig. Replace bearing and/or disengaged 2. parts which are worn up to or over the limit and adjust levers and clutch con- trol linkage. Clutch disk (9. 2) clean the friction surfaces. Adjust the controls (see page 19). identify and elimi- the friction lining of disks (11 nate the source of the lubricant inside and 9. Disks 11 and 9. disk 1. 1) and disk (1. Clutch jerks 1. fig. 1. the clutch housing and thoroughly fig.CLUTCH -. Check pivot and lubricate. springs damaged. 1) Replace and adjust the disks. 3. Check and compare the data given on fig. Clutch sticks and drags 1. Clutch disks (11 and 9. Clutch pedal too stiff 1. 3.Replace the disk and adjust the clutch formed. and disk (1. 3) with dam.

095 gallons). extract the pin (2) and remove the ballast. Disconnect the engine oil pressure sensor con- nection (1). 3 3. Make sure that assemblies or parts are supported by means of suitable slings and hooks. 2. NEVER USE YOUR FINGERS OR HANDS. only removal (see section 90). using a hoist 27786 and two steel cables (1). Unscrew the plug and drain the oil from the rear transmission casing (the prescribed quantity is 42 litres. 11. Make sure that no--one is standing in the vicinity of the load to be lifted.6 SECTION 18 -. 5 . WARNING Always use appropriate tools to align fixing holes.CLUTCH -. 18 110 10 CLUTCH Removal--Installation DANGER Lift and handle all heavy parts using suitable lifting equipment. Proceed as follows: 1.CHAPTER 1 Op. Remove the front ballast (3). if fitted. 25628 4 4. Carry out operation 90 100 22: Bonnet opening.

6 7. Unscrew the screw that holds the exhaust pipe to the left--hand steps. Unscrew the brake oil reservoir (2) retaining screws. 6. Unscrew the speedometer/tachometer (2) con- trol cable and relative retaining clamp (1). 7 8.CLUTCH -. remove the reservoir and attach to the right--hand handrail (1). SECTION 18 -. Remove the two flexible hoses (1) on the power steering control. 8 9.CHAPTER 1 7 5. Loosen the relative retaining clamps and remove the thermostarter and fuel pump pipes (1 and 2). 9 .

CHAPTER 1 10.CLUTCH -. Disconnect the thermostarter connection (1). loosen the relative clamp and detach the pipe (2). 10 11. 11 12.8 SECTION 18 -. Disconnect the electric motor connectors (1). Disconnect the filter pipe (1). 13 . Disconnect the power steering oil delivery pipes (1). 12 13.

NEVER USE YOUR FINGERS OR HANDS. 15 18. Using tool 294073 (1). 16 19. Using the front wheels. separate the clutch hous- ing from the engine. Wedge the front axle assembly to prevent the en- gine from oscillating. 17 . Apply the torque settings listed on page 2. 14 16. proceed as follows. connect a hoist with a chain to the rear hook on the engine and tighten the chain. 17. Position a fixed stand under the front part of the clutch box. unscrew the retaining bolts and remove the clutch (2).CLUTCH -. To refit the engine to the clutch box. WARNING Always use appropriate tools to align fixing holes. 20. 15. only removal (see section 23). then unscrew the bolts that hold the clutch housing to the engine.CHAPTER 1 9 14. SECTION 18 -. 27785 -. Carry out operation 23 101 26: Transmission shafts and guard. Remove the accelerator control cable (1) from the control lever.

-. Position and secure the ballasting. fully clean the mating surfaces and apply sealing compound (2 mm diameter). Connect the power steering oil delivery pipes. section 00 connections. -. Refit the clutch to the flywheel.CHAPTER 1 -. using tool 294073. pump piping. -. trol lever. Before refitting the engine to the clutch box care. -. Using a hoist. position the engine--front axle as. -. Carry out operation 23 101 26: Transmission ter control cable. Attach the exhaust pipe to the left--hand steps. -.10 SECTION 18 -. for prescribed products and quantities). tor. -. shafts and guard. Connect and secure the thermostarter and fuel gram shown Section 21. Connect the engine oil pressure sensor connec- -. -. only installation (see section 23). according to the dia. Connect the power steering control pipes.CLUTCH -. . sembly and secure in position. -. -. -. page 33. Connect and secure the speedometer/tachome- -. Carry out operation 90 100 22: Bonnet opening. -. -. Chapter 1. Connect the accelerator control cable to the con. only installation (see section 90). Connect the thermostarter and engine electrical housing and fill up with oil (see page 6. Tighten the plug on the rear gear transmission -. Connect the lift delivery and return lines to the transmission oil filter. Attach the brake oil reservoir to the inlet manifold.

18 2. Unscrew the three PTO clutch lever adjustment nuts (1). Proceed as follows: 24791 1. Extract the six spring retaining pins (1) from their seats.CLUTCH -. Take off the pressure plate (1) with the three coil springs (2) and the three washers. 1 24794 21 . 18 110 30 11”/11” DUAL CLUTCH 1 Test bench overhaul WARNING Always use appropriate tools to align fixing holes. SECTION 18 -.CHAPTER 1 11 Op. 1 24793 20 4. NEVER USE YOUR FINGERS OR HANDS. Position three clamps (1) at intervals of 120o on the clutch body and gradually and carefully squeeze the Belleville spring disk. 1 2 24792 19 3.

1 24975 22 6. 1 24977 24 8. Loosen the three locknuts (1) of the main clutch lever adjustment screws.12 SECTION 18 -. Remove the three clamps and extract the Belle- ville spring disk (1). Remove the three the main clutch lever adjust- ment screws (1).CHAPTER 1 5. 1 24976 23 7.CLUTCH -. Extract the main clutch pressure plate (1). 1 24978 25 .

SECTION 18 -- CLUTCH -- CHAPTER 1 13

9. Extract the main clutch disk (1).
1

24979

26
10. Remove the springs (1) of the PTO clutch control
levers.
1

24980

27
11. Extract the pivot pins (1) of the PTO clutch control
levers. 1

24981

28
12. Remove the springs (1) of the main clutch control
levers. 1

24982

29

14 SECTION 18 -- CLUTCH -- CHAPTER 1

13. Extract the pivot pins (1) of the main clutch control
levers. 1
14. To refit the clutch, proceed as follows.

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

-- Refit the lever pivot pins and the relative springs.
-- Refit the main clutch disk in the housing.
-- Install the main clutch pressure plate , securing to
the pins with the bolts. 24983

-- Install the Belleville spring disk, carefully position 30
the three clamps and evenly and progressively
compress the spring. Insert the six pins, making
sure that they are securely inserted in their re-
spective seats, then remove the clamps.
-- Install the PTO clutch disk; fit the three washers
and the coil springs on the pins and secure with
the three nuts.

SECTION 18 -- CLUTCH -- CHAPTER 1 15

Op. 18 110 30
11” SINGLE CLUTCH (Fitted with the Pow-
er-Shuttle gearbox) Test bench overhaul
WARNING
Always use appropriate tools to align fixing holes.
NEVER USE YOUR FINGERS OR HANDS.

Proceed as follows:
1. Unscrew the three clutch lever adjustment nuts
(1).
25963

31
2. Remove the pressure plate (1) with the coil
springs (2) on the levers.

25964

32
3. Unscrew the six retaining bolts (1) of the Power
Shuttle gear control disk and remove (2).

4. To refit the clutch, proceed as follows.

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

-- Refit the Power Shuttle gear control disk in the
clutch housing. 25965

-- Install the pressure plates and secure to the 33
spring coils.

-- Tighten the lever adjustment nuts.

16 SECTION 18 -- CLUTCH -- CHAPTER 1

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

Minimum permissible dimensions after re--facing of
parts subject to wear in the 11”/11” dual clutch
A ≥ 15.5 mm (0.6102 in.); B ≥ 22.7 mm (0.8937 in.);
D ≥ 15.8 mm (0.6220 in.).
1. Flywheel. 25966

2. PTO clutch pressure plate. 34
3. Main clutch pressure plate.
4. Clutch cover.

Minimum permissible dimensions after re--facing of
parts subject to wear in the 11” single clutch
A ≥ 15.5 mm (0.6102 in.); C ≥ 15.8 mm (0.6220 in.).
1. Flywheel.
2. PTO clutch pressure plate.
3. Clutch cover.

-- Check the degree of wear on the PTO disks (11,
fig. 1 and 1, fig. 2) and gear (9), replacing them
if the linings have worn down (or are nearly worn
down) to the rivet heads.
-- Replace the disk when the oil has soaked into the
organic agglomerate surfaces. 25967

Minimum permissible dimensions after re--fac- 35
ing of parts subject to wear in the 11”/11” dual
clutch and 11” single clutch.
-- Check the friction surface conditions of the pres-
sure plates and the clutch cover.
Generally, by means of turning, up to 1 mm of ma-
terial can be removed from the cast iron friction
surfaces of the clutch cover (3), the pressure
plate ring (2) and the flywheel (see Section 10,
Chap. 1, page 56).
When parts (1), (2), (3) and (4 figs. 34 and 35), are
to be repaired by removing material, proceed as fol-
lows:

SECTION 18 -- CLUTCH -- CHAPTER 1 17

-- If it is necessary to reface the friction surfaces on
the PTO clutch pressure plate (2, fig. 34 and 35),
remember that the amount removed in relation to
the nominal thickness (A), must also be removed
from the base of the flywheel housing (4, fig. 34
and 35) in order to regain the original position of
the pressure plate (2) in relation to the flywheel.

The position indicated by (C) of the clutch cover
(4, see fig. 34 and 35) must be calculated using
the following formula:

C = 71.4 + A

Where:

A = Thickness of the pressure plate after refacing.

C = Height of the clutch cover after refacing.

-- When the friction surfaces of the main clutch
pressure plate ring (3, fig. 34) or the clutch cover
(4), need refacing, remember that the removal of
material cannot be compensated by turning the
clutch cover (4) on the flywheel side.

-- Therefore the least possible material should be
removed from parts (3 and 4), for longer clutch
life.

NOTE:If, after having refaced parts (3 and 4, fig. 34),
several times, the main clutch disk starts to slip, the
entire clutch assembly must be replaced.

-- Refit the clutch assembly as shown on page 6).

RELEASE LEVER HEIGHT ADJUSTMENT
OF 11”/11” DUAL CLUTCH RELEASE

1. After overhauling the clutch, fit centering pin
25968
294073 (1) and fit the entire clutch assembly to
the flywheel, then tighten the bolts (2). 36

18 SECTION 18 -- CLUTCH -- CHAPTER 1

2. Fit gauge 295023 (1) on the centering pin and,
using a feeler gauge, adjust the clutch release
levers (2) to obtain a clearance of 0.1 mm (0.0039
in.).

25969

37
3. Rotate the gauge 295023 (1) and, using a feeler
gauge, adjust the PTO clutch release levers (2)
to obtain a clearance of 0.1 mm (0.0039 in.).

25970

38
COPLANARITY OF 11” SINGLE PLATE
CLUTCH RELEASE LEVERS”
4. After overhauling the clutch, fit centering pin
294073 (1), gauge 295023 (2), and fit the entire
clutch assembly to the flywheel, then tighten the
bolts (3).

25971

39
5. Using a feeler gauge, adjust the coplanarity of the
clutch release lever to obtain a clearance of 0.1
mm (0.0039 in.).

25972

40

SECTION 18 -- CLUTCH -- CHAPTER 1 19

Op. 18 100 40
CLUTCH ADJUSTMENTS

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

1. If the clutch pedal (1) position becomes uncom-
fortable or when the clutch is overhauled, check
that height (A), from the centre of the main gear
clutch pedal in relation to the platform, is 140 ± 2
mm (5.5118 ± 0.0787 in). If not, adjust as follows: 41

-- Loosen the locknut (2) and turn the nut (1)
counter--clockwise.

-- Check that the height of the pedal is 140 ± 2 mm
(5.5118 ± 0.0787 in.).

-- Tighten the locknut (2).

-- Operate the unit four or five times.

-- Check that the height of the clutch pedal (1, fig. 41)
is as prescribed.

-- If necessary, reset to the correct value (A, fig. 41)
as previously described. 42

20 SECTION 18 -- CLUTCH -- CHAPTER 1

PTO CLUTCH CONTROL ADJUSTMENTS

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

1. With the PTO lever (1) disengaged, using the ex-
ternal lever (4, fig. 44) (located on the clutch cas-
ing), move the internal lever into contact with the
PTO clutch engagement sleeve. 43

2. Loosen the locknut (2), extract the pin (5), tighten
the fork (1) on the control cable (3) until the cable
is slightly tensioned, whilst making sure that the
external lever (4) has not moved.

3. Carry out 5 engage/disengage manoeuvers and
check that the conditions (in the points previously
mentioned) have not changed.

4. Unscrew the fork (1) by half a turn (180o).

5. Tighten the locknut (2). 44
6. With the lever (1) disengaged, check that it is in
contact with the relative stop (2).

45
7. Check that the clearance (L) between the lever
(1) and the relative sector (2) is 3 to 5 mm (.118
to .196 ins).
If not, unscrew the sector (2) retaining bolts and
position correctly.

46

SECTION 21 -- TRANSMISSIONS -- CHAPTER 1 1

SECTION 21 -- TRANSMISSIONS

Chapter 1 -- Mechanical Transmission (8 x 8),
(16 + 16) Synchro-Command, and 8 x 8 Non-Synchronized Transmissions

CONTENTS

Section Description Page

21 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cross-sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

21 118 10 Rear Transmission/Gearbox, Removal--Installation

21 118 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
21 118 85 Rear Transmission/Gearbox, Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Rear Transmission/Gearbox, driving and driven shafts clearance adjustments . . . . . . . . 31

21 130 10 Gearbox Control Lever, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
21 130 11 Range Gear Control Lever, Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

SHUTTLE UNIT MAIN DATA

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical type with spur
gearing, located between the
main clutch and the gearbox.

Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hand lever located on left--hand
side of operator

GEARBOX AND RANGE GEAR MAIN DATA

Gearbox (8 x 8 non-synchronized) BSN: 1279632 . . . . . . . . . . . . 4-speed constant mesh,
non-synchronized gears
with non-synchronized
F/R shuttle shift.

ASN: 1279632 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-speed constant mesh,
non-synchronized gears with
synchronized F/R shuttle shift.
(continued overleaf)

2 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

GEARBOX AND RANGE GEAR MAIN DATA
(continued)

Gearbox (Synchro-Command) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--speed constant mesh,
synchronized on all gears with
synchronized F/R shuttle shift.
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helical
Range gear (16 x 16 version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ordinary gear train with 4 ranges
for a total of 16 gears.
Range gear (8 x 8 version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ordinary gear train with 2 ranges
for a total of 8 gears.
-- Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . spur gears
Gearbox and range gear operating system . . . . . . . . . . . . . . . . . . independent, by means of lever
located on right--hand side of
operator
Thickness of gearbox driving shaft adjustment ring
(4, figs. 7 and 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.5 -- 0.75 -- 1.0 -- 1.25 -- 1.5 --
1.75 -- 2.0 -- 2.25
(in.) (0.0197 -- 0.0295 -- 0.0393 --
0.0492 -- 0.0591 -- 0.0689 --
0.0787 -- 0.0886)
Thickness of gearbox driven shaft adjustment ring
(12, figs. 7 and 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.5 -- 0.75 -- 1.0 -- 1.25 -- 1.5 --
1.75 -- 2.0 -- 2.25
(in.) (0.0197 -- 0.0295 -- 0.0393 --
0.0492 -- 0.0591 -- 0.0689 --
0.0787 -- 0.0886)
Springs for detent balls on gearbox and range gear control rods:
-- spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 42
(in.) (1.6535)
-- length of springs under load of 75.5 to 83.3 N (7.7 to 8.5 kg;
16.98 to 18.74 lb.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 35
(in.) (1.3780)
Springs (1, page 10) for gearbox and range gear control levers:
-- spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 44
(in.) (1.7323)
-- length of springs under load of 31.4 to 35.3 N (3.2 to 3.6 kg;
7.05 to 7.94 lb.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 35
(in.) (1.3780)

TORQUE SETTINGS
Tightening torque
PART Thread
Nm ft. lbs.
Sleeve cover retaining nuts (C1, fig. 1) . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 20 to 25 14 to 18
Gearbox driving and driven shafts bearing cover screws (C2) . . . M 10 x 1.25 84 to 93 62 to 69
Retaining bolts securing creeper clutch casing to rear transmis-
sion/gearbox (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 117 to 129 86 to 95
Driven gear shaft locknut (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 32 x 1.5 280 to 309 206 to 228
Drive gear housing cover retaining screws (C5) . . . . . . . . . . . . . . . -- 43 to 51 32 to 38
Pressure switches (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 51 to 72 38 to 53
Parking brake inspection cover, gearbox and range control relay
levers support cover retaining screws (C7) . . . . . . . . . . . . . . . . . . . M 10 x 1.25 43 to 51 32 to 38
Bolts or nuts securing creeper clutch casing to the engine (C8) . M 12 x 1.25 117 to 129 86 to 95

SECTION 21 -- TRANSMISSIONS -- CHAPTER 1 3
TORQUE SETTINGS

C1 -- 20 to 25 Nm C3 -- 117 to 129 Nm C4 -- 280 to 309 Nm C5 -- 43 to 51 Nm
(14 to 18 ft. lbs.) (86 to 95 ft. lbs.) (206 to 228 ft. lbs.) (32 to 38 ft. lbs.)

25612 C2 -- 84 to 93 Nm
(62 to 69 ft. lbs.)

C6 -- 51 to 72 Nm
(38 to 53 ft. lbs.)

25614 C8 -- 117 to 129 Nm C7 -- 43 to 51 Nm
(86 to 95 ft. lbs.) 27928
(32 to 38 ft. lbs.)

1

4 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

SPECIAL TOOLS 290090 Rotating stand for overhaul opera-
tions.
X 294074 Tool for gearbox driving and driven
shafts adjustment.
Warning -- The operations described in this section
X 294087 Driving shaft rod for lifting unit.
can only be carried out with ESSENTIAL tools indi-
cated by an (X). X 294075 Driven shaft retaining tool.
To work safely and efficiently and obtain the best re- X 294076 Pliers for gearbox shafts circlips.
sults, it is also necessary to use the recommended X 294090 Driving shaft fitting guides.
special tools listed below and certain other tools
X 294091 Driven shaft fitting guides.
which are to be made according to the drawings in-
cluded in this manual. X 294099 Adjuster handle (with 294100 and
294145).
X 294100 Power take--off drive shaft seal splin-
List of special tools required for the various opera- ing tool (with 294099).
tions described in this section. X 294145 Power take--off drive shaft roller bear-
291517 Clutch casing lift hook. ings splining tool (with 294099).

24663

2
Tool to be made for disassembly--assembly of the final drives, to be used with 50114.
(Stamp No. 50091 on the tool -- Measurement in mm [ins])

1. Make 2 tie--rods in C 40 bon material. -- Make in Aq 42 D material.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 1 5

(1.57)

(11.81)
(9.84)
(7.87)

(1.96)
(1.57)

(3.54)
(.787) (.787)
26258

3

Tool to be made for lateral gear removal--installation, use with a part of 50091.
(Mark tool No. 50114 -- Measurement in mm [ins])

Make in Fe 42 C material -- (*) Measurement according to hoist seat.

6 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

4
Bracket to be made for gearbox overhaul on rotating stand
(Mark tool No. 50160 -- Measurement in mm [ins])
1. Rotating stand axis.
Make in Fe 42C material.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 1 7

5
Bracket to be made for gearbox overhaul on rotating stand
(Mark tool No. 50157 -- Measurement in mm [ins])

Make in Fe 42C material.

150 (5.905)

20 15
(.787) (.590)
M12x1.25

7 (.275)

25618

6

Guide pin for re--fitting the gearbox in the casing
(Mark part with no. 50158 -- Measurement in mm [ins])

Make in C 40 material.

8 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

1 2 3 4 5 6 7 8

X
X

25619 13 12 11 10 9

7
Longitudinal cross--sectional view of gearbox and gear range (16 + 16 Synchro-Command)

1. Seal. 8. Bevel pinion shaft.
2. Power take--off shaft support roller bearings. 9. Selector sleeve for low or medium--high speeds.
3. Shuttle control synchroniser. 10. Synchroniser for 1st and 2nd speed.
4. Gearbox driving gear clearance adjusting thickness. 11. Synchroniser for 3rd and 4th speed.
5. Power take--off shaft. 12. Gearbox driven shaft gear clearance adjusting thick-
6. Gearbox driving gear. ness.
7. Selector sleeve for high or medium--low speeds. 13. Gearbox driven shaft.

NOTE: When fitting apply sealing compound to surfaces X as shown on 33.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 1 9

8
Longitudinal cross--sectional view of gearbox and gear range (8 x 8 Synchro-Command)

1. Low speed intermediate gears. 2. Selector sleeve for high speeds.

10 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

2

1

50032165

9
Longitudinal cross--sectional view of gearbox and gear range
(8 x 8 Non-Synchronized with Synchronized Mechanical Shuttle)

1. Low speed intermediate gears. 2. Selector sleeve for high speeds.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 1 11

3 4
2

1

50032166

10
Longitudinal cross--sectional view of gearbox and gear range (8 x 8 Non-Synchronized)

1. Low speed intermediate gears. 3. Selector sleeve for low speeds.
2. Selector sleeve for high speeds. 4. Bevel pinion.

12 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

11

Cross--sectional view of gearbox and range gear

1. Shuttle control external rod. 4. Gear selector internal rod.
2. Gear control external rod spring. 5. Shuttle selector internal rod.
3. Gear control external rod.

NOTE: When fitting apply sealing compound to surfaces X as shown on 33.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 1 13

1 2 3

4

8
5

7

25621

25622

6

25623

12

Cross--sectional view of gearbox and range gear

1. Range gear control external rod spring. 5. Shuttle relay gear (reverse gear)
2. Range gear control external rod. 6. Detent ball and spring.
3. Shuttle control fork. 7. Lubricating oil external pipes.
4. Shuttle selector synchroniser. 8. Lubricating oil internal pipes.

NOTE: When fitting apply sealing compound to surfaces X as shown on 33.

14 SECTION 21 -- TRANSMISSIONS -- CHAPTER 1

DESCRIPTION AND OPERATION

Gearbox and shuttle (Synchro-Command) Gearbox and shuttle (Non-Synchronized)

4--speed gearbox with constant--mesh helical gears 4-speed gearbox with constant-mesh helical gears
controlled by two synchronisers. controlled by two non-synchronized selection
sleeves.
The range gear has cascade--type constant--mesh
spur gears. The range gears provide 2 gears -- 8 x 8 version.
The range gear provides: 2 gears (8 x 8 version) or The gearbox and range gears are controlled by two
4 gears (16 + 16 version). independent levers located on the right hand side of
The gearbox and the range gears are controlled by the operator.
two independent levers located on the right--hand The shuttle is a mechanical device providing 8 for-
side of the operator. ward and 8 reverse gears (8 x 8). It is controlled by a
The shuttle is a mechanical device, providing: 8 for- lever located on the left hand side of the operator.
ward gears and 8 reverse gears (8 x 8 version) or 16
forward gears and 16 reverse gears (16 + 16 version). The shuttle is composed of three spur gears and
It is controlled by a lever located on the cab platform shuttle driving gear, shuttle driven gear, and inter-
to the left of the operator. mediate gear. Engagement is by means of non-syn-
chronized selection sleave. After SN 1279632 en-
The shuttle is composed of a group of three spur gagement is by means of a synchronizer located in
gears: shuttle driving gear, shuttle driven gear and in- the gear unit.
termediate gear, engagement is by means of a syn-
chroniser located in the gear unit. The shuttle is installed inside the clutch casing, be-
tween the clutch and the gearbox.
The shuttle is installed inside the clutch casing be-
tween the clutch and the gearbox. Lubrication is by Lubrication is by means of the oil in the rear transmis-
means of the oil in the rear transmission. sion/gearbox.

GEARBOX, GEAR RANGE AND SHUTTLE TROUBLESHOOTING

Problems Possible causes Remedies

Spontaneous disengagement of 1. Levers and relay rods incor- Adjust correctly.
gearbox. rectly adjusted.

2. Control levers retaining Replace springs.
springs damaged.

3. Synchroniser teeth or selec- Remove the transmission--gearbox
tion sleeves damaged. casing and replace the synchronisers
or the sleeves.

4. Incomplete engagement Eliminate the cause and reset the
stroke. complete stroke.
(continued overleaf)

Adjust correctly.CHAPTER 1 15 GEARBOX. Main clutch dragging. Synchronisers or selection Remove the transmission--gearbox sleeves damaged. easily: rods. parts. 3. 4. 5.TRANSMISSIONS -. SECTION 21 -. Worn or damaged internal Remove the transmission--gearbox shuttle. . 2. casing and replace the synchronisers or the sleeves. See Section 18. Stiffness and/or partial seizu. GEAR RANGE AND SHUTTLE TROUBLESHOOTING (continued) Problems Possible causes Remedies Difficulty in engaging the gearbox. Levers and relay rods incor.Check rod pivots and lubricate. casing and replace the damaged parts. rectly adjusted. re of external levers and relay rods. 1. forks and slee- ves. Excessive noise in gearbox or 1. Internal controls do not slide Overhaul the controls.

Remove the top link of the third point. Carry out operation 90 110 50: Control panel. 8. Chapter 1). Carry out operation 90 116 24: Rear guard.CHAPTER 1 Op. 21 118 10 -. Carry out operation 90 114 26: Rear roll bar. then remove the right--hand (2) and left hand wheels. only removal (see Section 90. 3. 13 9.10 gallons). only re- moval (see Section 10. Chapter 1). only removal (see Section 23. Lock the front wheels using chocks. 5. Chapter 1). Make sure that no--one is standing in the vicinity of the load to be lifted.16 SECTION 21 -. position a fixed support stand under the 27837 towing hook. 25628 14 . Make sure that the units or parts are supported by means of suitable slings and hooks. Carry out operation 23 101 26: Transmission shafts and guard. only removal (see Section 90. 7. 4. 6. Proceed as follows: 1.TRANSMISSIONS -. Chapter 1). only removal (see Section 90. 2. 11. Carry out operation 10 216 10: Fuel tank.21 118 12 REAR TRANSMISSION--GEARBOX Removal--Installation DANGER Lift and handle all heavy parts using suitable lifting equipment. Using a hoist and sling (1) raise the rear part of the tractor. Unscrew the plug and drain the oil from the rear transmission casing (the prescribed quantity is 42 litres. Chapter 1).

25627 18 .CHAPTER 1 17 10. unscrew the retaining bolts and. 27840 15 11. SECTION 21 -. complete with the lower arms. 13.TRANSMISSIONS -. Detach and remove the vertical rods. 27841 16 12. loos- 1 2 en the retaining bolts and detach the hook. to the hoist. Position a hydraulic jack (2) under the gear unit. remove the right--hand gear unit (1) and the spacer. 27842 17 14. connect the pick--up hitch hook (2). using the jack (2). Unscrew the stabiliser strut bracket retaining bolts (1). using a chain (1). Remove the pick--up bar. Attach tool 50091 (1) and adapter 50114 (2) to the lateral gear unit body.

TRANSMISSIONS -.CHAPTER 1 15.18 SECTION 21 -. 1 25450 20 17. 25449 19 16. Attach the lifting hook 291517 (1) to the lift (2) and. 25452 22 . Unscrew the retaining bolts and extract the Lift-- O--Matic control lever (1). 1 25451 21 18. raise and remove the 1 2 lift. by means of the hoist. Disconnect and remove the lift auxiliary control valve control pipes (1) and trailer brake control 1 2 (2). Unscrew the retaining bolts on the lift (1) and re- cover the trailer brake control pipes support bracket. Disconnect the power take--off speed sensor connections. if necessary.

then re- move the pipes (2). Disconnect the unions on the heat exchanger pipes (1). Disconnect the union (3) on the front differential lock control pipes and loosen the clamp.TRANSMISSIONS -. detach and remove the two transmission gearbox casing pipes. 1 25640 26 . Unscrew the union and the retaining bolt. unscrew the union (2) and re- move the lift oil feed pipes. 20. 23. SECTION 21 -.CHAPTER 1 19 19. 27795 23 21. Unscrew and remove the filter pipes (2) and the transmission--gearbox casing pipes. 25 24. Disconnect the brake control pipes (1) from the brake block and the rear transmission casing and remove. 27796 24 22. Unscrew the clamp (1) and detach the sleeve on the oil intake pipes.

Position a fixed stand (1) under the engine. 27944 29 29. using a chain. connect them to a hoist. unscrew the retaining 1 bolts that secure the clutch casing to the engine and detach the engine.CHAPTER 1 25. 25642 27 27. Screw on the four hooks (1) and. Disconnect the unions (2) and remove the pipes (1 and 3). Unscrew the retaining bolts and re- 1 cover the services control valve (1). 25654 30 . 1 2 3 26.TRANSMISSIONS -. together with the rear transmission.20 SECTION 21 -. Unscrew the retaining bolts and remove the cab support bracket (on both sides). Position the rear transmission--clutch unit on a workbench. 1 27943 28 28.

complete with control lever. -. 3 25655 31 31. 2 and 3). Respect the tightening torques prescribed on page 2. unscrew the retaining bolts and remove the sup. To refit the rear transmission--gearbox case. thor- oughly clean and degrease the mating surfaces and apply a strip of sealing compound of about 2 mm (0. 33 -. supports and covers. 1 2 ing bolts that secure the clutch casing to the transmission casing and remove. the drive gear oil union and the parking brake control external lever. . Fit the electric sensors. Position two nylon slings (1) under the clutch cas- ing (2) and attach to the hoist. pro- ceed as follows. 11. Extract the pin (3). SECTION 21 -. WARNING Always use appropriate tools to align fixing holes. 12. 13 25657 and 14. 33. -. 1 2 port (2). Unscrew the retain. the drive gear control oil union (4) and the electric 3 1 2 sensors (1. -. detach the external lever (1). Re--fit the clutch casing on the rear transmission-- gearbox case. NEVER USE YOUR FINGERS OR HANDS. 4 5 25656 32 32. re- fer to the illustrations on pages 8. For the correct orientation of the various parts.TRANSMISSIONS -. Before refitting boxes.CHAPTER 1 21 30. 9. Remove: the parking brake control lever (5). 10.0787 inches) diameter as shown in the diagram on page 33. -.

Connect all of the services control valve pipes. section 00 for prescribed products and quantities). -. Chapter 1). only installation (see Section 90. -. Fit the hitch--hook and pick--up bar. Fit the brake disks. only installation (see Section 23. -. 27945 -. -. Carry out operation 90 116 24: Rear guard. -. remembering to attach the lever (2) to the bracket (1) and to insert the unit positioned 1 in a counter--clockwise direction. Carry out operation 90 114 26: Rear roll bar. only installation (see Section 90. only installation (see Section 10. Assemble and connect the auxiliary control valve support and trailer brake valve pipes. Chapter 1). -. -. Carry out operation 90 110 50: Control panel. Fit the Lift--O--Matic control lever. -. -. -. Assemble the creeper--shuttle external control le- ver. Fit the services control valve. Connect the brake and services control pipes. the differential axle shafts and side gears. Chapter 1). Connect the heat exchanger pipes. Refit the rear transmission--gearbox case and clutch casing to the engine. Carry out operation 23 101 26: Transmission shafts and guard. -.TRANSMISSIONS -. . Connect the trailer brake and lift control pipes.22 SECTION 21 -. -. -. only installation (see Section 90. Connect all of the lateral filter and front differential lock control pipes. Chapter 1). -. Tighten the rear transmission--gearbox oil drain- age plug. then straight- en--up the unit when it comes into contact with the 2 casing to facilitate the insertion of the lever (2) in the relative teeth. Carry out operation 10 216 10: Fuel tank. Attach the cab mounting. -. Fill up the rear transmission--gearbox casing (see page 6.CHAPTER 1 -. -. Re--connect the vertical rods to the lift arms. 34 -. Assemble the hydraulic lift. Chapter 1). Fit the support complete with creeper--shuttle control lever. -. -. Fit the rear wheels and remove the support stands. -. -. Fit the rear transmission--gearbox case oil intake pipes. -. -.

Remove the parking brake casing cover and ex- tract the circlip (1) that secures the parking brake control lever. 21 118 85 REAR GEARBOX TRANSMISSION Disassembly-. 35 5. 3. Unscrew the retaining bolts and remove the cover (1) with the gearbox lever and gear unit. Fix the gearbox --transmission casing to the rotat- ing stand 290090 using brackets 50157 (see Figs. 1. 2. 25721 37 . only removal (see Section 23. Carry out operation 23 101 40 or 23 202 50 Drive gear casing assembly.TRANSMISSIONS -. Proceed as follows.Assembly WARNING Handle all parts carefully. Extract the parking brake control lever(2) and re- cover the sleeve--cam (1). gloves and shoes. Chapter 1).CHAPTER 1 23 Op. 25718 36 6.safety goggles. 4 and 5). SECTION 21 -. Detach the power take--off control shaft following 25717 the instructions in section 31. Wear suitable safety clothing -. 4. Do not put your hands or fingers between parts.

) washer and 3 mm (0. 25735 39 9. Remove the circlip (2) and recover the unit (1) composed of the brake disk and the relative fric- tion sectors. instead of tool 294075 (2). Remove the circlip from the front side of the cas- ing and.CHAPTER 1 7.1181 in.24 SECTION 21 -. NOTE: If the gearbox in question is a standard fitting.25 x 40 screw together with a ∅ 12 x ∅ 45 (0. 25736 40 10.) shim. insert tool 294075 (2) on the gearbox driven shaft and tighten.7717 in. Fit tool 294087 (1) on the driving shaft and lock in position. extract the final drive driven shaft and recover the driven gears (1).4724 x 1. Loosen the retaining bolt and remove the cover (1). 25737 41 . using an extracting tool.TRANSMISSIONS -. 25734 38 8. fit a M 12 x 1.

25738 42 12. Unscrew the lubrication union (1) from the left-- hand side of the casing. 25739 43 13. Remove the circlip (1) and the union (2). 25741 45 . Extract the lubrication pipe (1) from the gearbox. 25740 44 14.CHAPTER 1 25 11. com- plete with the lubrication pressure adjustment valve.TRANSMISSIONS -. SECTION 21 -. Remove the union (2) and the lubrication sleeve (1).

using a hoist. enlarge the circlip (1) that secures the gearbox driven shaft. 25744 47 17. Unscrew the gearbox retaining bolts (1) and re- move. 25774 49 .CHAPTER 1 15. 25742 46 16. Fit tool 294074 (2) in a vice and remove the mo- bile part (1) of the tool.26 SECTION 21 -.TRANSMISSIONS -. Enlarge the circlip (1) that secures the gearbox driving shaft. From the drive gear case. 25743 48 18.

Remove the pins (1) to free the gearbox control forks (on one side). 25777 52 22.CHAPTER 1 27 19. Extract the pins (1) on the other side of the gear- box and remove: the upper part (1) of tool 294074. SECTION 21 -.TRANSMISSIONS -. 25778 53 . tool 294087 (2) from the driving shaft and the retaining tool 294075 from the driven shaft. Remove the driving (1) and driven (2) shafts. Fit the gearbox unit to the tool 294074 (1) and re-- fit the mobile part (2) of the tool. 25776 51 21. 25775 50 20.

CHAPTER 1 23. remove the rod stop ring (2). Extract the circlip (1) and recover the synchronis- er (2). Unscrew the retaining bolt (2) and recover the pin (3). 25779 54 24.28 SECTION 21 -.TRANSMISSIONS -. Enlarge the circlip (3) that secures the driven gear (1) to the gearbox support (2) and remove the gear (1). From the opposite side. 25781 56 26. 25782 57 . relay gear (1) and relative bearings and thrust washers. 25780 55 25. extract and recover the shuttle control fork (1).

fork and stop circlip. 59 . 11. SECTION 21 -. -. 58 -. -. thor- oughly clean and degrease the mating surfaces and apply a strip of sealing compound of about 2 mm (0. -. -. WARNING Always use appropriate tools to align fixing holes. Detach the mobile part of the tool 294074 and re- move the gearbox unit from the tool. 28. fit the mobile part of tool 294074. -.TRANSMISSIONS -. 9. Fit tools 294090 and 294091 (1) on the driving 25784 shaft lock circlip and the driven shaft lock circlip (respectively). 25783 NEVER USE YOUR FINGERS OR HANDS. Enlarge the circlip (1) and extract the gearbox driven shaft (2).CHAPTER 1 29 27. Respect the tightening torques prescribed on page 2. 10. Assemble the driven and driving shafts. 12. Fit the reverse drive gear complete with thrust washer. -. -. -. Fit the gearbox driving shaft on the relative sup- port. supports and covers. To re--fit the transmission--gearbox casing. Before refitting boxes.) diameter as shown in the dia- gram on page 33. Fit the gearbox driven gear on the relative sup- port. Carry out the gearbox driven and driving shaft ad- justments noted on page 32. 13 and 14.0787 in. -. Assemble the synchroniser and circlip. Fit the shuttle control rod. For the correct orientation of the various parts. bearing and retaining bolt. Fit the control forks to the rods using the pins. the con- trol forks and lock in position by means of tools 294075 and 294087. re- fer to the illustrations on pages 8. pro- ceed as follows. -. -. -.

-. -. Assemble the power take--off control shaft. -. 60 -. only installation (see Sec- tion 23.TRANSMISSIONS -. -.). Using a hoist. -.CHAPTER 1 -. Fit the lubrication union and sleeve. -. Secure in position with the bolts. fol- lowing the instructions in Section 31. -. -. NOTE: Apply Loctite 242 thread locker to the thread on bolt (2) and tighten to a torque setting of 19.6 Nm (15 ft. complete with the union and circlip. . Fit the driven shaft and gears. Chapter 1). Fit the parking brake cover. -. Assemble the lubrication pipes. Fit the parking brake unit. lbs. Carry out operation 23 101 40 or 23 202 50 Drive gear casing assembly. comprising brake disks and friction sectors. -. -. 61 -. Assemble the parking brake control lever. Fit the lubrication pressure adjustment valve. Remove tools 294087 and 294075 from the driv. Fit the cover with the gearbox control lever and 25786 final drive. com- plete with cam sleeve and circlip. fit the gearbox unit in the casing and recover the tools 294090 (1) and 294091 (the latter must be recovered from the drive gear cas- ing). Fit the cover (1) and secure with the bolt (2). 25785 ing and driven shafts. Detach the transmission--gearbox casing from the rotating stand.30 SECTION 21 -.

the driving and driven shaft gears must provide an axial clearance of 0. 30. S1 = 37..8 mm (1.8 mm (S = 1.032 ins)(adjustment shim 12. measurement read 46.0 mm (1.8 mm (0.1.417 -.1.039 ins) = synchronizers operating clearance. The adjustment shim (12. NEVER USE YOUR FINGERS OR HANDS.) in order to guarantee correct synchronizer operation.5 -.039 ins) = synchronizer operating clearance. The adjustment shim (4.1.. measure the distance (L) between the top of the tool 294074 (1) and the cir- clip (3) on the driving shaft bearing.921 -. page 8).488 ins).039 = . .0 mm (1.830 ins) = theoretical measurement of tool 294074 1. 33.5 mm (1.5 mm (1. Using a depth gauge. 31.CHAPTER 1 31 TRANSMISSION--GEARBOX CASING Gearbox driving and driven shafts clearance adjustment. Measure the distance (L1) between the top of the tool 294074 (1) and the circlip (2) on the driven shaft bearing.830 -. fit the mobile part (2) on the tool.3 mm (S = 1. S = 48. Proceed as follows. page 8) to fit on the driven shaft is given by: S1 = L1 -. 32. page 8) to fit on the driv- ing shaft is given by: S = L -..1.417 -.417 ins) = theoretical measurement of tool 294074 1.052 ins) (adjustment shim 4.1. 25787 29.8 -.921 ins). Round down the value Example: L = 48.039 = . page 6).36 -.039 ins) 25788 L1 = measurement read 36 mm (1.039 ins) = synchronizer operating clearance.488 -.5 -.830 -.1.46. Round down the value. Round down the value.0 mm (.0314 in.0 mm (. SECTION 21 -.417 ins) = theoretical measurement of 63 tool 294074 1. NOTE: When fitted.8 -.0 = 0. Using tool 294074 (1) clamped in the vice. The adjustment shims are listed on page 2. page 6).0 mm (. attach 62 the gearbox support complete with the driving and driven shafts without the respective adjust- ment shims (4 and 12.TRANSMISSIONS -.46.830 ins) = theoretical measurement of tool 294074 36 mm (1.0 = 1. WARNING Always use appropriate tools to align fixing holes.36 -. measurement read L1 = 37.8 mm (1..039 ins) where L = measurement read 46.

TRANSMISSIONS -.CHAPTER 1 27152 64 Sealing compound application diagram for transmission--gear box casing The types of sealing compounds to be applied are specified on page 1. section 00.32 SECTION 21 -. .

Fit the gearbox control lever (1. 3. NEVER USE YOUR FINGERS OR HANDS. SECTION 21 -. complete with guard (2) on the control sleeve. fit the four guard retaining flange retaining bolts.TRANSMISSIONS -. 1.Installation WARNING Handle all parts carefully. 2. NOTE: If a POWER SHUTTLE gearbox is fitted. -. -. proceed as follows. . Raise the guard (2). NOTE: If a POWER SHUTTLE gearbox is fitted.CHAPTER 1 33 Op. Fit the lever retaining bolt to the control sleeve. remove the gearbox control lever retaining bolt and the gearbox control lever (1).safety goggles. Do not put your hands or fingers between parts. Unscrew the four retaining bolts and the guard retaining flange. Proceed as follows. disconnect the electrical contact located on the gear lever. lower the guard. Wear suitable safety clothing -. 65 WARNING Always use appropriate tools to align fixing holes. Figure 65). gloves and shoes. 21 130 10 GEARBOX CONTROL LEVER Removal -. To refit the gearbox control lever. disconnect the electrical contact located on the gear lever.

Fit the range control lever (1. Unscrew the four retaining bolts and the guard retaining flange. Fit the lever retaining bolt to the control sleeve. proceed as follows. lower the guard. Figure 66). 1. 3. gloves and shoes. NEVER USE YOUR FINGERS OR HANDS. To refit the range control lever.safety goggles. fit the four guard retaining flange retaining bolts. Do not put your hands or fingers between parts. complete with guard (2) on the control sleeve. Proceed as follows. WARNING Always use appropriate tools to align fixing holes.34 SECTION 21 -. -.Installation WARNING Handle all parts carefully. disconnect the electrical contact located on the gear lever. 66 NOTE: If a POWER SHUTTLE gearbox is fitted. Raise the guard (2). . 21 130 11 RANGE GEAR CONTROL LEVER Removal -. 2.TRANSMISSIONS -.CHAPTER 1 Op. remove the range control lever retaining bolt and the range control lever (1). -. Wear suitable safety clothing -.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clutch pedal potentiometer and status switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Diagnosis during operation . 10 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 H5 -. . 36 Calibration and diagnostics unit use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TRANSMISSIONS Chapter 2 -. . . . . . . . . . . . 59 HA -. . . . .Stored error codes . . . . . . . . . . . . . . . . . . . . . . . . . .Clutches A and B calibration error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 21 118 85 Transmission--Gearbox. . . . . . . . . . . . . . 33 Fault codes indication . . . . . . . . . . . 49 H6 -. . . 67 HE -. . . . . . . . . . . . . . . . . . . . . . . . .Clutches A and B calibration values display . . . . . . . . . . . . . . . . . . . . 22 21 154 34 21 154 60 Clutch casing. . . . . . . . . . . . . . . . . . . . . . . . 16 21 134 46 Power shuttle control valve. . . . . .TRANSMISSIONS -. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hi/Lo Synchronizer operation (not used in standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltmeter functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 HH menu access . . . 54 H7 -. . . . . . . . . . . . . . . Removal--Installation . . . . . . . . . . . . . . . . . . SECTION 21 -. . . . . . . . . 58 H9 -. . . . . . . . . . . . . . . . . . 72 Power Shuttle (8 x 8 and 16 x 16) electronic control unit input/output wiring diagram . . .CHAPTER 2 1 SECTION 21 -. . . . .Clutch A fill time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Automatic self-diagnosis (ECM) . . . 21 21 134 70 Dump valve solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Power Shuttle Transmission (8 + 8 and 16 + 16 versions) CONTENTS Section Description Page 21 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 HF -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 HD -. . . . . . . . . . . . . . . . . . . . 23 Description of systems (ECM and CDU) . . . . . . . . . . . . Removal--Installation . . 63 Clutch pedal potentiometer replacement . . . . . . . . . . . . . . . 5 Cross-sectional views . . . . 2 Torque values . . . . . . . . . . . . . . . . . . . . . . 70 Troubleshooting fault codes . . . . . . . . . . . . . . 29 ECM First start up . . . . . 276 . . . . . . . . . Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Calibration and diagnostic unit (CDU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transmission oil temperature sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 21 134 70 A + B Clutch valve solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . 65 HC -. . . . . . . . . . .Erasure of data stored in NVM . . . . . . . . . . . . . 46 H4 -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gear change adjustments . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control switch diagnosis . . . .Power shuttle hardware and software revision levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Clutch B fill time . . . . . . . . . . . . . . . . . . . . . . . . 45 H3 -. Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 H1 -. . . . . . . . . . . . .System configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 H2 -. . . . . . . . . . . . . . . . . . . . . Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 H8 -. . . . . . . . . . . . . 32 Power shuttle fault code priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-. . . . . Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating system . . . . . . . . . . . . . . . independent. . . . . . . . ordinary gear train with 2 ranges for a total of 8 gears. . . . . . . . . . . . by means of lever located on right--hand side of operator For missing data see Chapter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical type with spur gearing. . . . . . . . . . . . . . ordinary gear train with 4 ranges for a total of 16 gears. synchronised on all gears Gearing type . . . . . . . . . . . . . . . Range gear (8 + 8 version) . .2 SECTION 21 -. helical Range gear (16 + 16 version) . located between the main clutch and the gearbox. . . . . . . . . . . . . . . . . . . 4--speed constant mesh. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . spur gears Gearbox and range gear operating system . . . . . . . . . . . . .TRANSMISSIONS -. . . . . . . . . . . . . . . . . . . . . . hand lever located on left-hand side of the steering wheel GEARBOX AND RANGE GEAR MAIN DATA Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CHAPTER 2 SHUTTLE MAIN DATA Type . . . . . . . . . . . . . . . . . . . . page 2. .

. . . . . . . . . .2. . . . . . . . . . . . . . . . . . .1299) -. . . comprising 3 control solenoid valves Power Shuttle and services transmission working pressure . . . . .) (1. . . . . . . . . . . . . . . . . . . . . .1 (1) (in. . . . . .57 lb. .2 lb. . .1031) Hydraulic control valve . . . . . . . . . 359. . .) (0. . . . . . . . sintered Number of driving plates in each clutch . . . . . . . . . . . .30 (in. . . . mm 2. . . . . . . . . . . . . . . mm 2. . . .) . pages 7 and 8): -. . the same as used for the hydrostatic steering system (see Section 41.) . . . . . . . . . . . . . . . . .8 to 4. . . . . . . . . . . . . . . . . . . . . . . . . . .9882) Clutch piston return spring (4. . . . Chapter 2) (1) Value to obtain by varying the thickness of the driving plates. . . . .0787 -. . mm 3. .0. . . . . . . . . . . . . . . . . . . . . . . . . . .TRANSMISSIONS -. .00 -. . . . . . 282. . . 6 Thickness of driven plates . . . . . .0819) Driven plates material . . . . . . . . . . . .CHAPTER 2 3 POWER SHUTTLE MAIN DATA Number of driven plates in each clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 to 25. . . .5 (in. . . . . . . . . . . . . . . . . . . . . . .0866) Driving plates material . . . .) (0. .19 lb. mounted on the outer left--hand side of the transmission--rear--gearbox casing. . no. . . . . . . . . . . . 6 Thickness of driving plates . . .1 kg. . . . 8. . number of springs for each clutch . . . . . .) (0. . . no.0039) Filter . . . . . . . . mm 24. . . . . . . . . . . . . . . . . . . . bar 15. . . . . . mm 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .) (0. . . . . . . . . . .) . . . . spring free length . . . . . . . . . .2 to 41. . . . . . . . steel Thickness of clutch assembly under a load of 1600 N (163. . page 11): -. . .00 to 2. . .0787 to 0. . . . . . . .08 (in. . 7 -. . . . . . . . . . . . . . . . . . . . . . . . . . .) (1. . . . . . .62 (in. mm 35. . paper cartridge Location . . . spring length under load of 37. . . . . . . . . . . .2 kg.5 (in. . . . . .9803 to 0. . . . . . . . . SECTION 21 -. . . . . . . . . . . . . . . . . mm 2. . . . . . . . . . .7 (psi) (227. spring free height . . .) (0. . .3976) -. . . . . . . . .2 N (3. . . . . . . . . . no. . . . . . . fixed to the pump housing on suction side Pump . . . . .7) By--pass valve spring (6. . . spring height under a load of 1255 N (128 kg. . . . . . .4 to 9.20 (in. . .

. . . . . . . -.4 to 8. .2 to 2 Solenoid valve spool retaining bolt (C2) .3 Nm C2 --1. .1 Nm (35 to 40 ft. .) C3 --47 to 54 Nm (35 to 40 ft. . . . . . . . . . -.4 to 8. .4 SECTION 21 -. . . . .) C4 --5. . . . . . . .) 27951A (4 to 6 ft.3 10 to 15 Solenoid valve spool retaining bolts (C3) . . . .9 to 20. .2 to 2 ft. . . .4 to 8. . .9 to 20. lbs. . . . . lbs. .) C1 --14. . . . . . .8 1. . .TRANSMISSIONS -. lbs. . . .1 Nm C3 --47 to 54 Nm C4 --5. . .) 25792 1 .1 4 to 6 (•) Apply 1 or 2 drops of LOCTITE 542 before tightening (10 to 15 ft. Solenoid valve retaining nut (C1) (•) . . 47 to 54 35 to 40 Solenoid valve retaining nut (C4) (•) . . page 2.) (4 to 6 ft. -. . .7 to 2. . . . . . lbs. lbs. 5. lbs. . 14. 1.7 to 2. . . . . . . . For missing data see Chapter 1. . . -. . . . . lbs. . . .CHAPTER 2 TORQUE VALUES Tightening torque PART Thread Nm ft. .8 Nm (1.

ings splining tool (with 294099). List of specific tools required for the various opera. X 294076 Pliers for gearbox shafts circlips. (Stamp No. Make 2 tie--rods in C 40 bon material. . 50091 on the tool -. X 294075 Driven shaft retaining tool. X 294145 Power take--off drive shaft roller bear- cluded in this manual. X 294100 Power take--off drive shaft seal splin- sults. X 292870 Hydraulic pressure testing kit.TRANSMISSIONS -. 294145). X 295021 Tool for hydraulic clutch piston springs (with 294077). to be used with 50114. 290090 Rotating stand for overhaul opera- tions.The operations described in this section can only be carried out with SPECIAL tools indicated X 294099 Adjuster handle (with 294100 and by an (X). it is also necessary to use the recommended ing tool (with 294099). X 294091 Driven shaft fitting guides. tions described in this section. Warning -. 24663 2 Tool to be made for disassembly--assembly of the final drives. X 294090 Driving shaft assembly guide. SECTION 21 -.Measurement in mm [ins]) 1. X 294077 Adapter (with 295021). -.CHAPTER 2 5 SPECIAL TOOLS X 294086 Driving shaft rod for lifting unit. To work safely and efficiently and obtain the best re. 291517 Clutch casing lift hook. specific tools listed below and certain other tools which are to be made according to the drawings in.Make in Aq 42 D material. X 294074 Tool for gearbox driving and driven shafts adjustment.

787) 26258 3 Tool to be made for lateral gear removal--installation. 50114 -.57) (3.TRANSMISSIONS -.57) (11.6 SECTION 21 -.(*) Measurement according to hoist seat.87) (1.Measurement in mm [ins]) Make in Fe 42 C material -.81) (9.84) (7.54) (. .96) (1.CHAPTER 2 (1. use with a part of 50091.787) (. (Mark tool No.

.CHAPTER 2 7 4 Bracket to be made for gearbox overhaul on rotating stand.SECTION 21 -.Measurement in mm [ins]).TRANSMISSIONS -. Make in Aq 42 material. 50157 -. (Mark part with no.

CHAPTER 2 5 Bracket to be made for gearbox overhaul on rotating stand.TRANSMISSIONS -. (Mark part with no.8 SECTION 21 -.Measurement in mm [ins]) 1. Rotating stand axis -.Make in Aq 42 material. 50157 -. .

905) 20 15 (. . SECTION 21 -.25 7 (.TRANSMISSIONS -.787) (.590) M12x1.275) 25618 6 Guide pin for re--fitting the gearbox in the casing.Measurement in mm [ins]) Make in C 40 material. (Mark part with no.CHAPTER 2 9 150 (5. 50158 -.

Forward gear drive shaft. Forward gear clutch control piping. NOTE: For missing data see Chapter 1. 7. Reverse gear clutch control piping. 9. Reverse gear control clutch piston.10 SECTION 21 -. Piston return Belleville washer. . Forward gear control clutch piston. 11. Reverse driven shaft. Reverse gear control clutch. Reverse drive shaft. Lubrication control pipes. 4. 5.TRANSMISSIONS -. 3. 2. 8. 6.CHAPTER 2 7 Longitudinal cross--sectional view of Power Shuttle gearbox (16 + 16 version) 1. Forward gear control clutch. 10.

4. Gear control internal rod. 5. 6. Roller bearing. 3.CHAPTER 2 11 4 7 6 5 8 Cross--sectional views of Power Shuttle gearbox 1. . 8. Dump solenoid valve. Gear control external lever. Reverse return gear. SECTION 21 -. 2. Pin retaining bolt (4). Operating pressure testing plugs.TRANSMISSIONS -. 9. Pin. Power Shuttle control valve. 7.

Bevel pinion. . Low gear intermediate gears. 2. 3. NOTE: For missing data see Chapter 1.TRANSMISSIONS -.CHAPTER 2 9 Longitudinal cross--sectional view of Power Shuttle gearbox (8 + 8 version) 1.12 SECTION 21 -. Selector sleeve for high gears. 4. Selector sleeve for low gears.

Dump solenoid valve.TRANSMISSIONS -. high. Start the engine and check the pressure (see page 2). Forward clutch control solenoid valve. 2. 5. Forward gears clutch working pressure control plug. Reverse gears clutch working pressure control plug. SECTION 21 -. 4. increase if the pressure is low and decrease if too tive hole. CLUTCHES CONTROL PRESSURE TEST Unscrew plug (4) or (5) on the clutch to be tested and If the pressure is incorrect adjust the shims (3. 1. 3. fig. . Reverse clutch control solenoid valve.CHAPTER 2 13 5 4 MDE0067A 10 Power Shuttle control valve. 11). connect a pressure gauge from kit 292870 to the rela.

2. valve.CHAPTER 2 1 2 3 4 27804A 6 5 11 Cross--sectional view of services control valve 1. Four wheel drive release solenoid valve. . By--pass valve spring. 4. 6.TRANSMISSIONS -. Services control oil pressure adjustment shims. 3. Services control pressure adjustment valve.14 SECTION 21 -. Spring for services control oil pressure adjustment 5. By--pass valve.

both forward and in reverse. GEARBOX AND GEAR RANGE TROUBLESHOOTING See Chapter 1. Gear reversal is obtained by means of the lever (1) located on the left--hand side of the steering wheel. the rear clutch controls the reverse gears. It is not necessary to press the clutch pedal.CHAPTER 2 15 DESCRIPTION AND OPERATION Gears 4--speed gearbox with constant--mesh helical gears controlled by two synchronizers. but the en- gine rpm and tractor speed must be reduced. pages 15 and 16. Power Shuttle unit The Power Shuttle gearbox is controlled by two multi-- disk clutches in an oil bath. Lubrication is by means of the oil in the rear trans- mission/gearbox. The gearbox and the range gears are controlled by two independent levers located on the right--hand side of the operator. . 12 Gear and range selection is performed by pressing the clutch pedal and operating the control levers lo- cated on the right--hand side of the operator. The range gear has cascade--type constant--mesh spur gears. The range gear provides 2 gear ranges (8 + 8 version) or 4 gear ranges (16 + 16 version). The front clutch controls the forward gears.TRANSMISSIONS -. SECTION 21 -. This provides hydraulic control of 4 gears for each range.

CHAPTER 2 Op. Do not put your hands or fingers between parts. Proceed as follows: 1. Unscrew the retaining bolts and detach the Pow- er Shuttle (1) control valve. 4. Attach the transmission--gearbox casing on the rotating stand 290090 using brackets 50160 (see pages 5 and 6). 1 25654 13 3. 2. Unscrew the retaining bolts and recover the ser- vices control valve (1).TRANSMISSIONS -. gloves and shoes.16 SECTION 21 -.safety goggles. only removal (see Chapter 1). Wear suitable safety clothing -. Carry out operation 21 118 10: Rear transmis- sion--gearbox casing. 27087 14 . 21 118 85 TRANSMISSION--GEARBOX Disassembly--Assembly WARNING Handle all parts carefully.

27091 18 . 27088 15 6. 10. SECTION 21 -. 27089 16 7. 27090 17 8.CHAPTER 2 17 5. 9. following the instructions in Chapter 1. To refit the unit. Remove the clutch control pipes (1) by means of rotation. carry out the disassembly opera- tions in reverse order. Unscrew the unions (1 and 2) on the clutch con- trol pipes and recover the internal unions. page 24.TRANSMISSIONS -. Unscrew the retaining bolts (1) on the clutch con- trol pipes (2). Complete the gearbox removal operations by fol- lowing the instructions in Chapter 1. Loosen the shuttle control pin (1).

27110 20 3. Unscrew the nut (1) and extract the solenoid valve (2). 19 2. proceed as follows. Extract the creeper unit control lever (1) and re- cover the internal lever (2). Do not put your hands or fingers between parts. gloves and shoes. 21 134 46 POWER SHUTTLE CONTROL VALVE Disassembly--Assembly WARNING Handle all parts with extreme care.TRANSMISSIONS -. With the Power Shuttle control valve on the work- bench. 1.safety goggles. Wear suitable safety clothing -. Extract the pin (1) that retains the creeper unit 27109 control lever (2). 27111 21 .CHAPTER 2 Op.18 SECTION 21 -.

CHAPTER 2 19 4. Unscrew the solenoid valve pin (1). 27112 22 6. Repeat operations 6 and 7 with solenoid valves (2 and 3). Unscrew the solenoid valve pin (1). 27115 25 . 27114 24 9. 5. Repeat operations 3 and 4 with solenoid valve (2). SECTION 21 -. Unscrew the nut (2) and extract the solenoid valve (1). 27113 23 7. Remove the circlip (1).TRANSMISSIONS -. 8.

proceed as follows. Fit the pins and relative solenoid valves then. the creeper unit con- trol lever and the pin. For the correct orientation of the various parts. NEVER USE YOUR FINGERS OR HANDS. 27117 -. Assemble the internal lever. -. Respect the tightening torque values prescribed on page 3. plug and circlip. . Remove the switch (1). 12. tighten the nuts.TRANSMISSIONS -. -. Remove the plug (1) and recover the shuttle con- trol pin (2). -. re- fer to the illustrations on page 10.CHAPTER 2 10. Assemble the control pin. To refit the Power Shuttle control valve. 27116 26 11. 20 SECTION 21 -. WARNING Always use appropriate tools to align fixing holes. -. af- ter having applied 1 or 2 drops of Loctite 542. Fit the switch. 27 -.

Chapter 1). To refit the control valve solenoid. gloves and shoes. . Wear suitable safety clothing -. -. only re- moval (see Section 10. Carry out operation 10 216 10 Fuel tank. proceed as fol- lows. WARNING Always use appropriate tools to align fixing holes. Proceed as follows. In order to remove a control solenoid valve from the two clutches. Chapter 1). the working area must be kept clean. Screw the pin on the solenoid valve. SECTION 21 -.TRANSMISSIONS -.Installation WARNING Handle all parts carefully. 28 3.CHAPTER 2 21 Op. 5. 21 134 70 A + B CLUTCH VALVE SOLENOIDS Removal -. Connect the electrical connection.safety goggles. Do not put your hands or fingers between parts. -. 1. only installation (see Section 10. NEVER USE YOUR FINGERS OR HANDS. Disconnect the solenoid valve connection (1). Loosen the nut and remove the solenoid valve (1). -. Unscrew the solenoid valve pin (1). Carry out operation 10 216 10 Fuel tank. 2. 30 -. 29 4. Fit and secure the solenoid valve.

Fit and secure the solenoid valve. Unscrew the solenoid valve pin (1). 1. Wear suitable safety clothing -. Chapter 1).TRANSMISSIONS -. proceed as fol- lows. Screw the pin on the solenoid valve. -. 22 SECTION 21 -.CHAPTER 2 Op. only installation (see Section 10. 32 4. Do not put your hands or fingers between parts. NEVER USE YOUR FINGERS OR HANDS. Carry out operation 10 216 10 Fuel tank. gloves and shoes. Pro- ceed as follows. 2.safety goggles. In order to remove a control solenoid valve from the gearbox. Connect the electrical connection. WARNING Always use appropriate tools to align fixing holes. -. Carry out operation 10 216 10 Fuel tank. Chapter 1). To refit the control valve solenoid. 31 3. Remove the solenoid valve (1). . -. only re- moval (see Section 10.Installation WARNING Handle all parts carefully. 21 134 70 DUMP VALVE SOLENOID Removal -. the working area must be kept clean. 33 -. Disconnect the solenoid valve connection (1) and unscrew the retaining nut. 5.

Wear suitable safety clothing -. Carry out operation 21 118 12 : Rear transmis- sion--gearbox casing.TRANSMISSIONS -. fork (2) lever (3) and spring (4). 27092 3. Proceed as follows. Do not put your hands or fingers between parts. 2. Attach the clutch casing to the rotating stand 290090 using brackets 50157 (see figs. SECTION 21 -. Unscrew the rear bearing support retaining bolts (1). 21 154 34 -. 1.safety goggles.21 154 60 CLUTCH CASING Disassembly--Assembly WARNING Handle all parts carefully. gloves and shoes. only removal (see Chapter 1).CHAPTER 2 23 Op. 34 4. 27093 35 5. 27094 36 .NO TAG and NO TAG). Unscrew the retaining bolt and recover the sleeve (1). Unscrew the retaining bolts and remove the clutch control pipes (1).

Position the clutch unit (1) on a workbench.24 SECTION 21 -. using a hoist. Unscrew the front bearing support retaining bolts (1). Insert tool 294086 (1) on the clutch unit (2).CHAPTER 2 6. Unscrew the retaining bolts and remove the sleeve (1) for the power take--off clutch engage- ment sleeve. 27096 38 8. se- cure in position and remove. 27097 39 9.TRANSMISSIONS -. re- move tool 294086 (2) and separate the unit into two parts. 27098 40 . 27095 37 7.

27103 44 . SECTION 21 -. 27100 41 11.CHAPTER 2 25 10. 27101 42 12.TRANSMISSIONS -. 27102 43 13. Remove the circlip (1) and remove the front bear- ing support (2). Remove the circlip (1) and remove the shaft (2). Remove the circlip (1) that secures the clutch disk assembly. Extract the gear (1) and recover the clutch disk assembly (2) and the relative springs (3).

Remove the sto ring (1) and extract the clutch body (2). Remove the circlip (1) and remove the bearing (2). Remove the front bearing support (1). 271106 47 17. WARNING Always use appropriate tools to align fixing holes. To refit the clutch casing. see cross-sectional views earlier in this chapter. 27105 46 16.CHAPTER 2 14. 27104 45 15. For the correct orientation of the various parts. proceed as follows. NEVER USE YOUR FINGERS OR HANDS.TRANSMISSIONS -. Using an extractor (1) and tool 295021 (2) com- press the Belleville washer (3). 27107 -. 18. Respect the tightening torque values prescribed earlier in this chapter. 48 . remove the sto ring (4) and recover the washer and piston. -. 26 SECTION 21 -.

-. only installation (see gagement sleeve. -. fit the clutch control pipes. Carry out operation 21 118 12: Rear trans- -. -.CHAPTER 2 27 -. Insert the piston and fit the Belleville washer and circlip. Fit the shaft and stop ring. -. as described previ- ously. Insert the clutch unit in the casing. means of tool 294086. Fit the front bearing support. Assemble the clutch disk assembly complete with springs and gear. Detach the casing from the rotating stand. Assemble the front bearing and circlip on the -. -. Assemble the front bearing support and circlip. -. Assemble the lever. -. -. Fit the front bearing support by means of the bolts. -. SECTION 21 -. Assemble the other clutch. . Chapter 1). Unite the two clutch units and lock in position by shaft. mission--gearbox casing. -. -. Fit the sleeve for the power take--off clutch en. Fit the rear bearing support by means of the bolts.TRANSMISSIONS -. -. Insert the clutch body and stop ring. -. -. fork and the power take--off clutch engagement sleeve. spring.

The failure management logic will signal error codes according to their priority. start calibrations. the ECM error logic will 1 signal an error code. “RUN” posistion (B). This transmission has an Electronic Control Module (ECM) for commanding. The ECM has two modes of “Auto Self-Diagnostic” functions to detect abnormal operating conditions in the ECM itself or in the ECM controls or monitors. The “up arrow” (B) and “down arrow” (C) are used to scroll through list in each menu.CHAPTER 2 DESCRIPTION OF SYSTEMS (ECM and CDU) The TN standard series tractor has various electro-hydraulic components for controlling the Power Shuttle transmission. 51 . The “H Menu” button (A) is used to scroll through different menus and for initial access to the calibration and diagnostic systems.TRANSMISSIONS -. Because of this. an operating software program is required to monitor and control the system. and saving/erasing. This self-diagnosis could continue up to 30 seconds if abnormal conditions are detected. 49 The CDU has three operating buttons. operating. tool #CNH294084). The software program is in a tool called C the Calibhration/Diagnostic Unit (CDU. causing the alarm lamp (1) on the instrument panel to flash a code. 50 If the ECM detects a system error or abnormal condition in either mode. The second mode is real-time self-diagnosis while the tractor is running. and troubleshooting certain B A input and output sensors.28 SECTION 21 -. A diagnostic software program is used to indicate when and where a system fault occurs. The first mode is when the key switch (1) is turned from the “OFF” (A) position to the “RUN” position (B) when starting the tractor. The ECM will detect failures or abnormal conditions and once detected will switch to error logic and failure management logic circuitry in the ECM.

During the self-diagnosis period the trasmission status light will remain on. “RUN” position (B). If an error of higher priority occurs while an error of lower priority is being signaled. the transmission status light will be turned off and error codes may not be displayed. the lower priority error will be stored until the error of higher priority has been removed. . The self-diagnosis process could continue for up to 30 seconds if abnormal conditions are detected. The configuration of these parts is already stored in the non-volatile memory. NOTE: If an attempt is made to move the tractor prior to the completion of self diagnosis the self diagnosis will 52 be terminated.CHAPTER 2 29 AUTOMATIC SELF-DIAGNOSIS (ECM) The ECM automatically does a self-diagnosis of the different system parts when the key switch (1) is turned from the “OFF” position to the “ON” position (B). the higher priority error will be displayed after the lower priority error sequence has been displayed. The ECM also performs real-time self diagnosis of system components while the tractor is running. SECTION 21 -.TRANSMISSIONS -. causing the alarm lamp on the instrument panel to flash a code. If the ECM detects a system error or abnormal condition while the tractor is running. The failure management logic will signal error codes according to their priority. If an error with lower priority occurs while an error of higher priority is already being signaled. The ECM will perform this at regular intervals to check for possible system failures or abnormal conditions. or the transmission status light will begin flashing alerting the operator that there is a problem. the ECM error logic will signal an error code. alerting the operator that there is a problem. the ECM will cause the alarm lamp on the instrument panel to flash a code. Once the self-diagnosis is completed and if there is an abnormal condition or failure in one or more of the ECM controlled systems.

: rapid flashing. -. MDD3231A 54 . Following ECM replacement. fig.TRANSMISSIONS -. -. -. At the end of the production line. followed by 1 flash.i. 30 SECTION 21 -.e. Following manual configuration (see H3 MENU). Following erasure of the Non--Volatile memory (NVM) (see H8 MENU). after a while the indicator will flash to repeat the recognised configuration code -. 53) to OFF for a few seconds: the configuration is now saved in the Non--Volatile memory (NVM). Indicator (1) (fig. -. 54) will be illuminated (non--flash- ing). 53 Turn switch (1) to B (ON) without switching on the en- gine. Turn the key (1.CHAPTER 2 ECM -. -.FIRST START--UP (Self Configuration) The ECM will require configuration when any one of the following circumstances has occurred.

55). the the event of incompatibility between the different faults display logic and the anomalous conditions corrections. if possible. tiple anomalous condition effect/condition is provided played.TRANSMISSIONS -. The anomalous conditions management logic con- siders the effect of the faults that effect tractor oper- ation. the display logic functional bodies and their configuration. by the diagnostics (start--up diagnosis and diagnosis subdivided into the aforementioned fields. The TROUBLESHOOTING FAULT CODES head- This logic processes the faults information provided ing contains the definitions of the system errors. whilst the functional software is 4 -. in order to detect ”system faults” and ”anomalous conditions”.Fault code Numerical value. FAULT DISPLAY LOGIC The logic also manages the correction procedure for a fault condition.Priority Numerical value. In the event of multiple anomalous conditions. functional change of the sys- tem after this correction. PRIORITY agement logic also diagnoses ECM and external cir- cuit anomalies. .Effects The eventual effect of the fault working. it creates a fault which is processed by the by superimposing each individual effect/correction. it checks the coherence of the plained in the following heading.CHAPTER 2 31 DIAGNOSIS DURING OPERATION 2 -. played by the indicator lamp (1. the fault code will be dis.Not displayed in Cab Test mode: this mode is ac- The start--up and functional code also includes the cessed by sending a series of ”commands” to the faults detection and anomalous conditions manage. as ex- nosed directly. FAULT DETECTION AND ANOMALOUS 6 -. uses the “Priority” field to establish the code to dis- Each time the faults logic detects a ”system error” or play. Diagnosis during operation is in real time and checks 3 -. regular intervals. i.Detection Group of conditions creating for the eventual presence of anomalous conditions at the fault. Unless otherwise specified. the correction linked with the highest management logic. in faults buffer logic in the non--volatile memory. it must be dis- 1 -. MULTIPLE ANOMALOUS CONDITIONS -- The faults detection and anomalous conditions man. The diagnosis should check all conditions shown 5 -.e. priority fault is used. CONDITIONS MANAGEMENT LOGIC 7 -. fig. on the system. and the headings. during operation) and functional bodies. ment logic. through the serial connection. the resulting mul- an ”anomalous condition”.Correction The condition that corrects under the DIAGNOSIS MINIMUM CONDITIONS the fault. where the hardware can not be diag. Introduction Each fault is described using the following fields: As soon as a problem is detected. SECTION 21 -.Not displayed during calibration. indicating the condition of the system. ECM.

tions must be diagnosed (independently of the ECM AN6 Not used. and in the event of microprocessor AN1 Clutch pedal potentiometer. -. . AN10 Not used. b) nominal range deviation. are enabled. there is an ECM fault. fault conditions relative to the HH menu. The unit must be provided with a watchdog for ECM Anomalous condition description and reset anomalous conditions).short to 5V or 12V or circuit open. there is an ECM fault. short to ground or circuit open. c) nominal range deviation. tester mode” or ”calibration mode”. short to 5V or 12V. apart from when The length of the software cycle should be 10 ms. AN8 Not used. (CDU) a) short to +12. fig.g. DIAGNOSIS MINIMUM CONDITIONS INPUT DIAGNOSTICS ECM and relative circuits fault. AN4 Oil temperature sensor. For each ulterior current supply. 5V SENSORS SUPPLY. 55). Anomalous condition description and reset AN7 Fuse 20. anomalous conditions.32 SECTION 21 -.5 ms tions must be diagnosed (independently of the ECM (longer pauses are not recommended). apart from when AN3 Reverse gear lever switch. AN5 Shuttle mode switch. none of the solenoid valves AN2 Forward gear lever switch. At start--up. Other fault conditions. AN9 Not used. are flashed on the illuminated signal lamp (1. This check must be carried out at least every 10 ms Reaction to fault.TRANSMISSIONS -. AN12 LO push button. the watchdog AN11 HI pushbutton. status). and reset circuit must guarantee that the ECM does not excite the solenoid valves. POWER SUPPLY DIAGNOSTICS -. e. -. the following anomalous condi- whereas the watchdog pause should be 16. This check must be carried out at least every 10 ms (longer pauses are not recommended). the following anomalous condi. For each of the following inputs.CHAPTER 2 CALIBRATION AND DIAGNOSTICS UNIT 8V SENSORS SUPPLY. (longer pauses are not recommended). -. Follow--up reaction. The Calibration and Diagnostics Unit (CDU) indicates b) short to ground or open circuit. tion Uxx codes. short to ground or circuit open. unless masked by the ”cab 12VD CLUTCH DRIVERS SUPPLY. -.short to ground. a) short to ground or open circuit. status).: calibra. 12VF KEY SUPPLY. In the event of an anomalous condition.

SECTION 21 -.CHAPTER 2 33 POWER SHUTTLE FAULT CODE PRIORITY CODES FAULT PRIORITY CORRECTION EFFECT 11 CPDL_POT_LO_DISABLING_ERR 14 SL Dis 11 CPDL_POT_LO_ERR 75 Fixed Lim 12 CPDL_POT_HI_DISABLING_ERR 15 SL Dis 12 CPDL_POT_HI_ERR 74 Fixed Lim 13 UD_SW_ON_ERR 67 Auto None 14 C1_SW_HI_DIS_ERR 22 CP/SL Dis 14 C1_SW_HI_ERR 83 Fixed Model 15 C1_SW_LO_DIS_ERR 23 CP/SL Dis 15 C1_SW_LO_ERR 84 Fixed Model 16 G1_SW_HI_DIS_ERR 24 CP/SL Dis 16 G1_SW_HI_ERR 85 Fixed Model 17 G1_SW_LO_DIS_ERR 25 CP/SL Dis 17 G1_SW_LO_ERR 86 Fixed Model 18 CREEPER_ENG_SW_HI_ERR 47 Fixed Model 19 CREEPER_ENG_SW_LO_ERR 48 Fixed Model 21 CH_HARN_ERR 1 Fixed Crit.Dis .Dis 36 SOL_DUMP_OPEN_OR_GND_DIS_ERR 34 CP/SL Dis 36 SOL_DUMP_OPEN_OR_GND_ERR 99 Fixed Lim 37 CL_SW_OC_ERR 13 CP/SL Dis 38 SOL_B_SHORT_12V_ERR 9 Fixed Crit.TRANSMISSIONS -.Dis 22 SOL_A_SHORT_DIS_ERR 39 CP/SL Dis 22 SOL_A_SHORT_ERR 97 Fixed Lim 23 SOL_B_SHORT_DIS_ERR 37 CP/SL Dis 23 SOL_B_SHORT_ERR 95 Fixed Lim 24 CL_UNCAL_ERR 100 Fixed Model 26 ERPM_HI_ERR 65 Fixed Model 27 ERPM_LO_ERR 66 Fixed Model 28 B_CL_UNCAL_ERR 101 Fixed Model 29 A_CL_UNCAL_ERR 102 Fixed Model 31 SOL_SHTL_SHORT_DIS_ERR 31 CP/SL Dis 31 SOL_SHTL_SHORT_ERR 90 Fixed Lim 32 SOL_HL_SHORT_DIS_ERR 33 CP/SL Dis 32 SOL_HL_SHORT_ERR 92 Fixed Lim 33 SOL_DUMP_SHORT_DIS_ERR 35 CP/SL Dis 33 SOL_DUMP_SHORT_ERR 98 Fixed Lim 35 SOL_DUMP_SHORT_12V_ERR 8 Fixed Crit.

34 SECTION 21 -.Dis 55 FORWARD_SW_HI_ERR 57 Auto None 56 FORWARD_SW_LO_ERR 58 Auto None 57 REVERSE_SW_HI_ERR 61 Auto None 58 REVERSE_SW_LO_ERR 62 Auto None 59 FNR_SW_DISAGREE_ERR 43 Auto Dis 61 HI_LO_SYNCRO_SW_HI_DIS_ERR 16 CP/SL Dis 61 HI_LO_SYNCRO_SW_HI_ERR 76 Fixed Lim 62 HI_LO_SYNCRO_SW_LO_DIS_ERR 17 CP/SL Dis 62 HI_LO_SYNCRO_SW_LO_ERR 77 Fixed Lim 63 SYNCRO_HL_ENG_ERR 40 SL/HI Dis 64 SYNCRO_SHTL_ENG_ERR 41 SL Dis 65 SOL_HL_OPEN_OR_GND_DIS_ERR 32 CP/SL Dis 65 SOL_HL_OPEN_OR_GND_ERR 91 Fixed Lim 66 SOL_SHTL_OPEN_OR_GND_DIS_ERR 28 CP/SL Dis 66 SOL_SHTL_OPEN_OR_GND_ERR 89 Fixed Lim 67 SOL_HL_SHORT_12V_DIS_ERR 27 CP/SL Dis 67 SOL_HL_SHORT_12V_ERR 87 Fixed Lim 68 SOL_SHTL_SHORT_12V_DIS_ERR 26 CP/SL Dis 68 SOL_SHTL_SHORT_12V_ERR 88 Fixed Lim 69 WHLSPD_SNRLO_ERR 64 Fixed Model .Dis 43 SHTL_SYNCRO_SW_HI_DIS_ERR 18 CP/SL Dis 43 SHTL_SYNCRO_SW_HI_ERR 81 Fixed Lim 44 SHTL_SYNCRO_SW_LO_DIS_ERR 21 CP/SL Dis 44 SHTL_SYNCRO_SW_LO_ERR 82 Fixed Lim 46 FUSE_20_ERR 51 Auto Lim 47 CL_SW_HI_ERR 55 Fixed Model 48 CL_SW_LO_ERR 56 Fixed None 49 WHLSPD_SNR_HI_ERR 63 Fixed Model 51 TEMP_SNDR_OC_ERR 53 Auto Model 52 TEMP_SNDR_SC_ERR 54 Auto Model 53 V5_VREF_FAILED_HIGH 6 Fixed Crit.Dis 54 V5_VREF_FAILED_LOW 7 Fixed Crit.TRANSMISSIONS -.CHAPTER 2 CODES FAULT PRIORITY CORRECTION EFFECT 39 SOL_B_OPEN_OR_GND_DIS_ERR 36 CP/SL Dis 39 SOL_B_OPEN_OR_GND_ERR 94 Fixed Lim 41 SOL_A_OPEN_OR_GND_DIS_ERR 38 CP/SL Dis 41 SOL_A_OPEN_OR_GND_ERR 96 Fixed Lim 42 SOL_A_SHORT_12V_ERR 11 Fixed Crit.

the gears are critically disabled by this fault. . the ”correction” column explains how the gears can be enabled. Hi the fault is no longer displayed pressing the pushbutton (Hi).g. e. EFFECT column Dis. Mod.Dis 78 V8_VREF_FAILED_LOW 5 Fixed Crit.: there are faults that disable certain functions. Dis. SL the fault is no longer displayed by using the Shuttle (SL) and/or the clutch pedal (CP).Dis 74 V_12VF_FAILED_LOW 3 Fixed Crit.: there are faults that make the tractor move slowly or abruptly. SECTION 21 -. Combinations of the aforementioned symbols are possible. Crit. Auto the fault is no longer displayed when the conditions that generated the fault are no longer present (RESET).Dis 76 NVM_RD_ERR 68 Fixed Model 77 V8_VREF_FAILED_HIGH 4 Fixed Crit.Dis 81 PRESS_SW_OC_ERR 49 Fixed Model 82 PRESS_SW_SC_ERR 50 Fixed Model SYMBOLS USED CORRECTION column Fixed the fault continues to be displayed (NO RESET). CODE column Contains the numerical code to display. CP the fault is no longer displayed using the clutch pedal (CP). the gears are disabled.g. LIM the fault condition limits tractor operation. This fault can only be deleted by switching off the ECM.TRANSMISSIONS -. PRIORITY column The apostrophe indicates that the CODE has already been used by a previously listed fault condition. the fault condition effects tractor operation.CHAPTER 2 35 CODES FAULT PRIORITY CORRECTION EFFECT 71 SYNC_START_UP_INIT_ERROR 93 Auto Dis 72 SYNC_POPPED_OUT_ERR 42 CP/SL Dis 73 V_12VF_FAILED_HI 2 Fixed Crit. e.

To check for the presence of other codes the fault must be eliminated.. 4. FAULTS CODE DECODING The indicator (1) identifies the error code in six phases: 1. any eventual anomalous conditions are indicated by the illumination of an indicator lamp (1). -.. 55 5. 5 flashes in rapid succession to indicate imminent transmission of the error code. 3.TRANSMISSIONS -.. 3 second pause. 6. giv- ing priority to the most serious faults. If a higher priority fault occurs whilst a lower priority fault is being displayed. 1 second pause.. n. flashes to indicate the first figure of the fault MDD3231A code. 2 second pause. the corresponding code will take precedence over other codes that were previously indicated.Example of the interpretation of fault code number 21 -- 1st phase 2nd phase 3rd phase 4th phase 5th phase 6th phase FFFFF pause FF pause F pause code second transmission 2s first digit 2 1s 3s digit 1 warning fault code composition p 21 . allowing the control unit to pro- ceed to the following fault.CHAPTER 2 FAULT CODES INDICATION In the event of an electrical or electronic fault. n. these codes will be saved by the system. IMPORTANT: If a fault disables the lift control func- tion. The control unit only indicates one code at a time.36 SECTION 21 -. before becoming active. flashes to indicate the second figure of the fault code. 2. the display sequence of higher priorities will wait until the sequence in prog- ress ends.

TRANSMISSION OIL TEMPERATURE DIS- PLAY HD -.GEAR CHANGE ADJUSTMENT HF -. If tractor movement is detected whilst these menus are in use. If the menu allows tractor movement. fig.CLUTCHES A and B CALIBRATION) H2 -. the menu will be interrupted and trans- mission will be enabled. to re--enter the HH MENU. press key (1.CLUTCH B FILL TIME MODIFICATION AND DISPLAY H8 -.DELETE DATA SAVED IN THE NON--VOL- ATILE MEMORY (EEPROM) H9 -. HA. 58) to return to the HH MENU. Errors code If the Faults Detection Logic reads a fault condition.SHUTTLE SYNCHRONISER POSITION NOT ACCESSIBLE ON TN STANDARD HE -. HC and HE menus. certain faults may be masked. .SYSTEM CONFIGURATION H4 -.CONTROL SWITCHES DIAGNOSTICS H6 -. To exit from an active MENU. The CDU CNH294084 gives access to the following menus: H1 -.TRANSMISSIONS -.CHAPTER 2 37 CALIBRATION AND DIAGNOSTIC UNIT USE Calibration unit use (CDU) Specific remote diagnosis operations can be carried out with the Calibration and Diagnosis Unit (CDU). the code will flash on the indicator.FAULTS SAVED IN THE ECM NON--VOLATI- LE MEMORY NOTE: The tractor can only be used in the H6.SOFTWARE REVISION LEVEL H5 -. In this manner. Whilst other menus are being used the transmission is disabled.CLUTCH PEDAL POSITION AND SWITCH DISPLAY HC -. H7.CLUTCH A FILL TIME MODIFICATION AND DISPLAY H7 -. stop the tractor (speed = 0).CLUTCHES A and B CALIBRATION VALUES DISPLAY) H3 -. 58). fig. During calibration (H1 menu). SECTION 21 -. the fault condition can be displayed whilst in HH mode.VOLTMETER FUNCTIONS HA -. H9. stop the tractor and press key (1.

the CDU display (2) shows “H MENU”.CHAPTER 2 HH MENU ACCESS WARNING Put all gearshift levers in their neutral positions. consult Section 55. (see fig. Now the H Menu button can be released. This is required because some H Menus allow operation of the transmission.TRANSMISSIONS -. NOTE: Align the outer left ad right pins between the male and female connector. consult the electrical diagrams as to which fuse provides power to the diagnostic tool. Turn the key switch to the “ON” position (B) (see fig. Lift the hood (1) of the tractor. If the warning lights display an error code. electrical diagrams as to which fuse provides power to the instrument panel. This also occurs if the “H Menu” button is not held while turning the key switch to the “ON” position. They have a flat side to orient the connector. . 2. If the button was not held long enough the CDU may display “NO COMM”. 1. If the instrument panel is not on. Identify the CDU connector (2) located underneath the hood at the right side of the tractor forewall. but the CDU does not light up and the H Menus can not 57 be accessed again. NO TAG) while pressing down the “H Menu” button (1). 4.38 SECTION 21 -. 58). 5. After a few seconds. Turn the switch (1) to A (OFF) and connect the CDU device 294084 to the black diagnosis connector. 2 1 10007083 56 3.

unless otherwise specifically noted. After a brief pause (2 seconds) the ECM enters H MENU the procedure of the selected menu. the remote control valve levers in neutral and switch off the engine. e. five times to access H5. Set the Shuttle control lever in neutral. Remember that after the HF MENU. MDB0751A If the operator presses key (1) whilst an H menu is in use.Shuttle. Check that the transmission oil temperature is between 20 to 50 °C (68 to 122 °C).TRANSMISSIONS -. the hy- draulic lift lower arms down. switch off all electrical switches and the air conditioning system. Engage the handbrake.e. the levers: . H2 etc. the display (2) returns to HH and waits for an ulterior selection.: once to access H1. 59 structed area (in case of sudden movement).Range gear. . WARNING Park the tractor on level ground in an unob. if on. Consult the description of the individual HH menus in order to un- derstand why the functional software is disabled. Unless otherwise specified.: H1. NOTE: The functional software is always disabled when the CDU is connected to the diagnosis connec- tion. 1 2 3 4 Explanations of the relative menus are noted on the following pages. the display (2) H5 shows the H code obtained. the menu is abandoned and the display 58 (2) returns to the HH selection phase.Gear shift.CHAPTER 2 39 6.g. are in the NEUTRAL position. Turn the key switch (1) to the “off” position (A) and wait approximately 5 seconds to store the revised data.Creeper. Select the required H menu by pressing the H MENU key (1) the correct number of times to dis- play the relative code on the display (2). the count re- starts from HH. etc. SECTION 21 -. If the H code does not correspond with an active H menu. i. 7. The CDU can be re-entered by repeating step #4. . . Put safety wedges under the front and rear wheels. Each time key (1) is pressed. .

3. The ECM reads engine RPM from the alternator to accomplish this. While holding the “HMENU” button (1) on the CDU display (2). The calibration of the clutches is necessary when the following has occurred: • Poor transmission performance • Solenoid valve has been replaced • Erasure of non--volatile memory in the ECM (using the H8 menu) • ECM has been replaced • After initial break-in period -. “CALIBR” will appear momentarily on MENU 1 2 3 4 the CDU display (2) and then change to the transmission fluid temperature. Make sure the parking brake is firmly set and increase the engine speed to 1300 + 100 RPM. 60 2. 61 .CHAPTER 2 H1 -.CLUTCHES A and B CALIBRATION The H1menu provides access to Power Shuttle clutches (A) and (B) calibration.40 SECTION 21 -. turn the key to the “START” position (C). release the “HMENU” button (1).first 50 hrs. reducing the engine speed when the clutches start engaging. Press the “HMENU” button (1) once. H1 “HMENU” should appear on the CDU display (2). After a few H seconds. Make sure the key switch (1) is in the “OFF” position (A) and connect the CDU to the Power Shuttle ECM as described previously in this manual. 1.TRANSMISSIONS -. After the tractor has gone through self diagnosis and has started. Use the following procedure to calibrate the clutches. 4. “H1” should appear on the CDU display (2). MDB0751A 5.

SECTION 21 -. 62 7. 10. 8.TRANSMISSIONS -. Slowly release the clutch pedal. Position the Power Shuttle FNR lever (1)to the forward position. 64 . making sure the tractor does not move. Fully depress the clutch pedal (1). Place the range lever (2) into the highest range (B). 63 9. Place the gear selection lever into first gear (1).CHAPTER 2 41 6.

4 bar (40 -. An example would be : A=286mA NOTE: The tractor may lurch. Press and hold the down arrow (1) on the CDU. 2. Initially the CDU will display “STAB. refer to the table at the end of this procedure in this section to identify and remedy the problem. A = 286 mA 3 10006107 66 . but not move.CHAPTER 2 CLUTCH A CALIBRATION NOTE: If the diagnostic instrument displays an “U” error code during the calibration procedure . This value and lurch represent the point the energized PWM 1 solenoid has provided enough hydraulic fluid to engage 2 the clutch pack. Release the down arrow (1) and the CDU display should display the transmission oil temperature. 10006107 65 3.TRANSMISSIONS -.7 -. 1.50 psi). An example of an error code would be U21 (engine speed lower than 1200 RPM).RPM” (2).3. Hydraulic pressure at this point is not full but approximately 2. RPM final calibration setting flashes continuously (3). Continue holding the down arrow (1) until the engine speed reduces about 50 RPM and the STAB. then the initial value of the setting in milli--amps (mA) (3).42 SECTION 21 -.

the clutch calibration and fill times will need adjusted accordingly. the main (C1) and range (G1) shift levers are not in neutral.3.CHAPTER 2 43 CLUTCH B CALIBRATION NOTE: If the diagnostic instrument displays an “U” error code during the calibration procedure .7 -. Calibration can go on only 10006107 if the tractor is stationary. an “U” code will be displayed on the CDU. Hydraulic pressure at this point is not full but approximately 2. RPM calibration setting flashes continuously (3).RPM” (2). NOTE: If the tractor operation is abrupt after calibrating the clutches. clutch pedal position. 3 NOTE: Transmission output speed. 4. Press and hold the up arrow (1) on the CDU. this will be displayed and the associated error code will be flashed on the instrument panel. This value and lurch represent the point the energized PWM 2 solenoid has provided enough hydraulic fluid to engage the clutch pack.TRANSMISSIONS -. . the Power Shuttle FNR 68 lever is not in neutral. Release the down arrow (1) and the CDU display should display the transmission oil temperature. If the fault condition is relevant to calibration. If calibration conditions have not been met.50 psi). Turn the key switch to the “OFF” position (A) to store the (4) and (8) clutch values. NOTE: As clutch components wear. gear and range lever positions are constantly monitored. SECTION 21 -. Continue holding the up arrow (1) until the engine speed reduces about 50 RPM and the final STAB. Initially the CDU will display “STAB. refer to the table at the end of this procedure in this section to identify and remedy the problem. 5. engine RPM. 10006107 67 6. 7. refer to the H6 and H7 menus A = 286 mA to adjust the fill times for the clutches. An example would be : A=286mA NOTE: The tractor may lurch. but not move.4 bar (40 -. then the initial value of the setting in milli--amps 1 (mA) (3). and the clutch pedal is released. An example of an error code would be U21 (engine speed lower than 1200 RPM).

the calibration will continue. . replace mA as necessary U28 Clutch pack (B) value higher than 480 Check solenoid value circuit and solenoid valve. Test reverse solenoid hydraulic pressure circuit. U24 Range selector in neutral Place range lever into highest range U25 Gear selector in neutral Place gear lever into first gear U26 Clutch pedal not fully raised Release clutch pedal fully U27 Clutch pack (B) value lower than 230 Check solenoid value circuit and solenoid valve.CHAPTER 2 Calibration Error Codes Code Cause Remedy U19 Transmission oil temperature lower Drive tractor to increase transmission oil temperature than 10_ C (50_ F) ∗ U20 Incorrect starting procedure Press and release clutch pedal U21 Engine speed lower than 1200 RPM Increase engine speed U22 Engine speed over 1400 RPM Decrease engine speed U23 Power Shuttle control lever in neutral Place Power Shuttle control lever into the forward or reverse position as required.44 SECTION 21 -.TRANSMISSIONS -. However. U31 Tractor is moving Engage parking brake U32 Hi/Lo synchronizer not engaged Check synchronizer using the HD menu (*) Between 10_ C (50_ F) and 20_ C (68_ F) the CDU display will show “COLD OIL”. Test reverse solenoid hydraulic pressure circuit. replace mA as necessary U30 Clutch pack (A) value higher than 480 Check solenoid value circuit and solenoid valve. U29 Clutch pack (A) value lower than 230 Check solenoid value circuit and solenoid valve. replace mA as necessary. when continuing to hold the up arrow or the down arrow key. replace mA as necessary.

will be displayed.CHAPTER 2 45 H2 -. expressed in mA. Press the “HMENU” button (2) twice. Press the down arrow (4) on the CDU to obtain a 2 B = 290 mA value for the “A” clutch. The current stored value. for the “A” and “B” hydraulic clutch solenoid valves. SECTION 21 -. as described previously in this manual. Release the “HMENU” button. Press the up arrow (3) on the CDU to obtain the value for the “B” clutch. “H2” should appear on the CDU. 4 7. 2. These values were obtained by the ECM during the clutch calibration in the H1 menu. Make sure the key switch (1) is in the “OFF” (A) position and connect the CDU to the Power Shuttle ECM.TRANSMISSIONS -. turn the key switch to the “ON” (B) position. Once the tractor has gone through diagnostics. The mA range for each clutch must be between 230 mA and 480 mA (for either clutch). Turn the key switch (1) to the “OFF” (A) position 71 or enter another menu by pressing the “HMENU” button on the diagnostic instrument. 3 6. The current stored value. 69 4. “HHMENU” should appear on the display. NOTE: The display automatically shows the “A” 3 clutch value. in mA. 10006107 8. Use the following procedure to obtain the values: 1.CLUTCHES A and B CALIBRATION VALUES DISPLAY) The H2 menu displays the calibration values expressed in milli-amps (mA). will be displayed. An example would be: A=286 mA. An example would be B=290 mA. 3. While holding the “HMENU” button on the CDU. 2 H2 4 10006107 70 5. .

H3 also allows the transmission to be configured manually.CHAPTER 2 H3 -. Hold the “HMENU” button (2) on the CDU and turn the key switch (1) to the “ON” position (B). stored in the non-volatile memory (NVM) menu after a tractor with a new ECM has been initially started up.Power Shuttle Transmission with Hi/Lo and Creeper (44X16) • None .Power Shuttle Transmission (8X8 or 16X16) 3 • Hi/Lo (does not apply to TN Standard) - Power Shuttle Transmission with Hi/Lo 10006107 (32X16) • Hi/Lo CR (does not apply to TN Standard) 73 . 72 3. Only detected at first power on of ECM. Press the “HMENU” button (2) three times.TRANSMISSIONS -. After the tractor has gone through the diagnostics. After several seconds the configuration stored will be 2 H3 displayed. occurs with the ECM replacement or erasure of non-volitile memory (H8). “H3” will appear on the CDU display (3). Put the key switch (1) into the “OFF” position (A) and connect the CDU to the Power Shuttle ECM connector. 2.46 SECTION 21 -.No configuration stored in memory. 2 PSHUTTLE 3 10006107 74 .SYSTEM CONFIGURATION The H3 menu displays the tractor’s system configuration. 1. 4. One of the following configurations will be shown: • Pshuttle . Release the “HMENU” button (2). “HMENU” will appear on the display. as described previously in this manual.

8. NOTE: If the down arrow (5) is released during the store countdown.TRANSMISSIONS -. press the “HMENU” button (2) on the CDU. The self-con- figuration check always gets performed when a different ECM is installed. STORE 2s. and solenoids. the configuration can be modified manually by 2 PSHUTTLE pressing the up arrow (4) until the correct configuration is shown on the CDU. after H8 is cleared. 5. Selection of the “NONE” will cause the ECM to conduct a self-configuration at the next start-up. . 7. SECTION 21 -. 4 6. and whenever H3 configuration is set to “NONE”. The ECM performs the self test by sending a signal out through the harness and receives acknowledgement of signs in from various sensors. After the configuration has 75 been stored. STORED”. When the correct configuration is shown. The display (3) on 3 the CDU will start this sequence: “STORE 5s. the latest changes to configuration will not be stored and the CDU displays the previous setting. To quit the menu without modifying the configuration. This shows the new configuration is 10006107 stored in the ECM. switches. STORE 1s. STORE 4s. Turn the key switch (1) to the “OFF” position (A) and wait for at least two seconds to save the configuration into the non-volatile memory. If the configuration displayed does not match the configuration the tractor is equipped with. release the down arrow (5) on the CDU. press 5 and hold the down arrow (5).CHAPTER 2 47 NOTE: It is possible to select any configuration available. STORE 3s. Selection of the wrong configuration can cause Error Codes to be displayed through the PS Alarm lamp or causes tractor malfunctions.

76 3. Make sure the key switch is in the “OFF” (A) position and connect the CDU to the Power Shuttle ECM connector.01])) • Hardware Level: (02. 4.POWER SHUTTLE HARDWARE AND SOFTWARE REVISION LEVELS The H4 menu will display the revision level of the software that is installed in the ECM. Once the tractor has gone through diagnostics. 6.00) 10006107 • Manufacturer -. press the “HMENU” button to enter another menu or turn the key switch to the “OFF” (A) position. The instrument will display the following H4 information in a 8 second interval.48 SECTION 21 -. “HHMENU” should appear on the display. Each parameter will be displayed for 2 seconds and then revert back to “HH MENU”. “H4” should appear on the instrument display. module serial number and batch number. as described previously in this manual.TRANSMISSIONS -.CHAPTER 2 H4 . • Product Identity (MA) • Software Revision Level: (Release [00. Release the “HMENU” button. . When finished viewing. 2. 5.set valves (40) 77 NOTE: It is also a good practice to remove the instrument panel in order to record the ECM part number. Press the “HMENU” button four times. Use the following procedure to display the revision levels: 1. turn the key switch to the “ON” (B) position. While holding the “HMENU” button on the CDU.

either switch or analogue type. Neutral and Reverse button inconsistencies. Proceed as follows to guarantee adequate checking. clutch pedal potentiometer calibration values are checked and also button adjustment is checked. The neutral button is not tested separately through its own “d” number. the message displayed changes to “d0” when the second transition takes place. which is used to test the clutch pedal button. If same circuit has two subsequent transitions. Following interaction among these buttons: • The Forward and Reverse buttons should be tested with the clutch pedal applied (down). “transition” means that a certain threshold was exceeded. SECTION 21 -. • The clutch pedal button should be tested with the shuttle lever engaged (not in neutral). the neutral safety switch will originate a transition also on the 12VD line. as the operator cannot induce neutral safety switch transition in any manner without inducing it at the same time on the Forward or Reverse buttons. With reference to analogue inputs. a button inconsistency error may occur (exclusive- ly in this diagnostic mode). • If the keystart switch is turned to the engine-on position with the shuttle lever in neutral and the clutch pedal down (normal start-up procedure). The number displayed indicates in which circuit the transition occurred. When a clutch pedal button transition occurs (pedal is released). The H5 menu allows inspection of each one of these circuits for continuity and to check for transitions on ECM inputs.CHAPTER 2 49 H5 -.CONTROL SWITCH DIAGNOSIS The H5 menu is for checking the status of the circuits and control switches that are connected to the ECM. for diagnostic purposes. .TRANSMISSIONS -. The letter “d” and a number are displayed each time a transition occurs. If the shuttle lever is moved with the clutch pedal released. This routine also checks for Forward.

79 .50 SECTION 21 -. Make sure the key switch is in the “OFF” (A) position and connect the CDU to the Power Shuttle ECM.TRANSMISSIONS -. Once the tractor has gone through diagnostics. 2. in the forward position. Place the Power Shuttle FNR lever.CHAPTER 2 NOTE: It is important to follow each of the procedures as described. 4. 78 NOTE: The clutch pedal should be up (released). Release the “HMENU” button. turn the key switch to the “ON” (B) position. as described previously in this manual. “HHMENU” should appear on the display. While holding the “HMENU” button on the CDU. 1. otherwise the display on the diagnostic instrument will not show the correct reading. 1. 3.

Leave the tractor in neutral for a few seconds while observing the display. Slowly release the clutch pedal while observing the display on the CDU. Removing the gear selector lever from a gear should cause a second transition in that circuit and the display should show d0. 12. Press the “HMENU” button five times. d20. The display should appear like this as the clutch pedal is being 10006107 depressed: d0 > d20 > d21 . The display will change from d21 > d22. This verifies conditions related to Error Codes 11. d21. The display should continue to show d22 . The CDU display should show d33.CHAPTER 2 51 5. the display will return to d20. and then to the potentiometer. SECTION 21 -. 47. To obtain the readings in the following procedures the clutch pedal must be released and the FNR lever must be in forward before entering H5 d0 menu. or another control or switch is moved while the gear lever is engaged the readings may be opposite from step 10. place the Power Shuttle lever into reverse. take the Power Shuttle lever from forward and return the lever to neutral.TRANSMISSIONS -. If the clutch pedal is completely released. and 48. NOTE: If the gear lever is in gear when H5 menu is entered. this helps to verify Error Code 59. The display should change from d22 to d23. 82 . 8. The status of the potentiometer and clutch switch is displayed. NOTE: d0 is always displayed first when H5 menu is entered. The display should change from reverse. 9. 7. With the clutch pedal depressed. to the clutch switch. Observe the display on the CDU while slowly depressing the clutch pedal (at least two seconds). Place the gear selector lever (1) from neutral into any gear. While the clutch pedal is depressed. 81 10. “H5” should appear on the CDU display. 6. d21 is displayed when the clutch pedal “clicks” on the depressed 80 movement. d23.

NOTE: If any other control or switch is moved during the shift. 12.CHAPTER 2 11. code Switch and Analogue Inputs d. The CDU should display 1 d34.29 Hydraulic oil temperature circuit (unplugged versus plugged in) d. This can be accomplished by viewing the CDU as the sensor is unplugged and plugged back together. SUMMARY OF SWITCH AND ANALOGUE INPUTS d.33 Main (C1) gear shift lever (in gear versus neutral) d. For d29 (Transmission Oil Temperature Sensor). and when a second transition occurs on the same switch d.52 SECTION 21 -. d30 (Transmission Oil Pressure Sensor).21 Clutch pedal switch (Power Shuttle FNR lever must be in forward or reverse) d. 83 13.36 Operator’s seat presence switch (stand-up) . a transition must be manually induced.34 Range (G1) gear shift lever (in gear versus neutral) d.30 Hydraulic oil pressure circuit (engine off versus engine started) d.23 Power Shuttle FNR lever in reverse position (Clutch must be depressed) d. This should cause the CDU display to change to d36.35 Wheel speed detection circuit (tractor moving) d. the “d” values may occur opposite as listed above.32 Fuse supply to CDU (tool will not work if fuse is removed) d.0 When H5 menu is first entered.20 Clutch pedal potentiometer d. Stand up from the operator’s seat. Sitting down on the seat will cause a second transition and the display to change back to d0. Place the range control lever (1) from the neutral position to any range.TRANSMISSIONS -.22 Power Shuttle FNR lever in forward position (Clutch must be depressed) d. and d35 (Transmission Wheel Speed Sensor) to be displayed on the CDU.

Clutch pedal pushbutton adjustment is checked (E47 and E48). d21 With the clutch pedal lowered.TRANSMISSIONS -. move the Shuttle lever from the Forward position 3 to neutral. d0 Slowly press the clutch pedal (time > 2 seconds). d30 18 Carry out a status change on the operator seat switch. d29 15 Carry out a status change on the gear lever pushbutton. The potentiometer status d20 2 change should be read first. move the Shuttle lever from the neutral position to 5 Reverse. to check the relative pushbutton. SECTION 21 -. d22 Leave the Shuttle lever in the neutral position for at least 1 second to check for 4 disagreement between the Forward/Neutral/Reverse pushbuttons (E59). the potentiometer status change is read. The pushbutton status change should be read first. Finally. followed by the pushbutton. d21 6 Clutch pedal calibration is checked (E10. E11 and E12). d20 13 Carry out a status change on the oil temperature sensor.CHAPTER 2 53 Action Description Display 1 Enter the H5 menu with the clutch pedal released and the Shuttle lever in Forward. d36 . d34 17 Carry out a status change on the pressure switch. (d22) Holding down the clutch pedal. d23 Release the clutch pedal slowly (time > 2 seconds). to check the Forward selection pushbutton. d33 16 Carry out a status change on the Range lever pushbutton.

to the “ON” (B) position. use the following guidelines. tractor should be properly ballasted or configured according to what tractor will be used for. • Increase the clutch filling time if the tractor “jerks” abruptly and then takes off. then hesitates. as described previously in this manual.CHAPTER 2 H6 -. if necessary. the clutch calibration and clutch fill time will need to be adjusted accordingly.CLUTCH (A) FILL TIME MODIFICATION AND DISPLAY IMPORTANT: The transmission is functional during this menu.TRANSMISSIONS -. The H6 menu displays the (A) clutch filling time and allows change of the clutch filling time. and then takes off. NOTE: As clutch components wear. 2. 84 . turn the key switch. The solenoid coil will receive full voltage.) If adjusting the clutch filling time due to poor or abrupt tractor take off when the clutch is released. IMPORTANT: For best results. While holding the “HMENU” button on the CDU. • Decrease the clutch filling time if the tractor “jerks”. Vehicle mass will affect shift characteristics. 1. 1. Make sure the key switch is in the “OFF” (A) position and connect the CDU to the Power Shuttle ECM.54 SECTION 21 -. (Full open solenoid valve for maximum flow of oil to fill up clutch pack.

5.150 milli-seconds. “H6” should appear on the CDU display. NOTE: Fill time can also be adjusted by operating the CDU while the tractor is running. 7. if necessary. Press the “HMENU” button six times. Adjust the clutch fill time again. so ensure the gears are neutral and parking brake set. 4. To change the filling time. 85 IMPORTANT: The clutch must be fully released to properly store the clutch filling time in the tractor ECM. The clutch filling time must be between 30 . SECTION 21 -. Turn the key switch to the “OFF” (A) position to save the clutch fill time in the ECM. the display may read: A=80ms. 6. “HHMENU” should appear on the display. . Release the “HMENU” button. 9.TRANSMISSIONS -. the CDU will display a value A = 80ms in milli-seconds (1/1000 second). place the Power Shuttle control lever in the forward position to store the new value. 8. Once the tractor has gone through diagnostics. 10. be sure the Power Shuttle control lever is in neutral and use the up and down buttons to change the clutch filling time 10006107 by multiples of 10 ms. Return the Power Shuttle control lever to the neutral position. the factory default setting is 70 ms. With the clutch released. NOTE: The first fill time after adjustment may not be reliable. After a few seconds. For example.CHAPTER 2 55 3. Disconnect the CDU from the tractor and test the new clutch filling time by test driving the tractor in a variety of situations. The value is changed and saved in the same manner as stated. but the tractor is running. Fill time should be tried several times to accurately evaluate performance.

CHAPTER 2 H7 . If adjusting the clutch filling time due to poor or abrupt tractor take off when the clutch is released. 1. 3. 2. tractor should be properly ballasted or configured according to what tractor will be used for. then hesitates. “HHMENU” should appear on the display. IMPORTANT: For best results. turn the key switch. the clutch calibration and clutch fill time will need to be adjusted accordingly.CLUTCH (B) FILL TIME IMPORTANT: The transmission is functional during this menu. The H7 menu displays the (B) clutch filling time and allows change of the clutch filling time. and then takes off. Once the tractor has gone through diagnostics. to the “ON” (B) position. if necessary. Vehicle mass will affect shift characteristics. as described previously in this manual. Release the “HMENU” button.TRANSMISSIONS -. NOTE: As clutch components wear. 86 . 1. • Decrease the clutch filling time if the tractor “jerks”. Make sure the key switch is in the “OFF” position and connect the CDU to the Power Shuttle ECM. While holding the “HMENU” button on the CDU. use the following guidelines.56 SECTION 21 -. • Increase the clutch filling time if the tractor “jerks” abruptly and then takes off.

Fill time should be tried several times to accurately evaluate performance. place the Power Shuttle control lever in the forward position to store the clutch fill time. Return the Power Shuttle control lever to the neutral position. .CHAPTER 2 57 4. SECTION 21 -. “H7” should appear on the CDU. 9. be sure the Power Shuttle control lever is in neutral and use the up and down buttons to change the clutch filling time by multiples of 10 ms. Adjust the clutch fill time again. but the tractor is running. Press the “HMENU” button seven times. the factory default setting is 70 ms. After a few seconds. To change the filling time. With the clutch released. the display may read: B=80ms. The clutch filling time must be between 30 . the CDU will display a value in milli-seconds (1/1000 second). For example. 5. 8. IMPORTANT: The clutch must be fully released to 10006107 properly store the clutch filling time into the tractor ECM. NOTE: The first fill time after adjustment may not be reliable. Turn the key switch to the “OFF” (A) position to save the clutch fill time in the ECM. NOTE: Fill time can also be adjusted by operating the CDU while the tractor is running. so ensure the gears are neutral and parking brake set.150 milli-seconds.TRANSMISSIONS -. if necessary. B = 80ms 6. 87 7. Disconnect the CDU from the tractor and test the new clutch filling time by test driving the tractor in a variety of situations. The value is changed and saved in the same manner as stated. 10.

1. 4. 9. To erase the non-volatile memory. and if necessary. H6 and H7. Press the “HMENU” button eight times. Allow the ECM to self-configure by disconnecting the CDU and turning the key switch to the “OFF” (A) position. ERASED. Then turn the key switch to the “ON” (B) position and leave the switch on for at least 5 seconds. This is useful in the case of replacing the ECM from another tractor. The ECM will find the tractor configuration. Release the “HMENU” button.TRANSMISSIONS -. to the “ON” (B) position. “HHMENU” should appear on the display. 89 7. 5. Turn the key switch to the “OFF” (A) position to store the tractor configuration in the ECM.CHAPTER 2 H8 . 6. as described previously in this manual. After a few seconds “ERASE?” will be displayed ERASE? on the on the CDU display. ERASE 2s. ERASE 3s. clutch fill times should be adjusted. 88 3. . “H8” should appear on the CDU display. Also double check configuration in H3 menu. Once the tractor has gone through diagnostics. ERASE 4s. turn the key switch. 8. 1. The display will show the following countdown sequence: ERASE 5s. H9. Releasing the up button at anytime during this countdown will abort the 10006107 erasure of the non-volatile memory and revert back to beginning of H8 mode. ERASE 1s. (A) and (B) clutches must be calibrated (H1). While holding the “HMENU” button on the CDU. Make sure the key switch is in the “OFF” (A) position and connect the CDU to the Power Shuttle ECM. Error code(s) should have been erased. The ECM’s data from the previous tractor can be erased for the tractor the ECM is going into. 2.58 SECTION 21 -. press and hold the down button on the CDU. Use the following procedure to erase the data stored in the ECM’s non-volatile memory.ERASURE OF DATA STORED IN THE NON-VOLATILE MEMORY (NVM) The H8 menu allows erasure of the data stored in the non-volatile memory.

Ground CN2-29 20 Engine Speed Sensor Frequency (Alternator + W) Signal CN2-15 Use the following procedures to access the voltmeter functions: 1. Signal CN2-26 10 Power Shuttle FNR Lever Reverse Switch Voltage CN2-20. Ensure the parking brake is set. When a a channel number that corresponds to a particular channel measures frequency. Signal CN2-24. SECTION 21 -. Ground CN2-29 12 Synchronizer Reverse (Shuttle) Solenoid NOT USED TN Standard 13 Synchronizer Forward (Hi/Lo) Solenoid NOT USED TN Standard 14 ECM 5V Input Sensor Supply Voltage CN2-20. Ground CN2-29 3 ECM 12V Key On Supply Voltage CN2-10 and CN2-34. Ground CN2-13 and CN2-14 16 Main (C1) Gear Shift Lever Position Switch Voltage CN2-20. 90 . Signal CN1-6 9 Power Shuttle FNR Lever Forward Switch Voltage CN2-20. or ohm measurements. Signal CN2-28 18 Creeper Engagement Switch NOT USED TN Standard 19 Wheel Speed Sensor Frequency Signal CN2-36. switches. An example of how the diagnostic tool H9 Power Shuttle Channel Description Channel/Description Circuit/Connector--Pin Information 1 Clutch Pedal Potentiometer Voltage CN2-20.CHAPTER 2 59 H9 -. as described previously in this manual.VOLTMETER FUNCTIONS would display this is: 1 > 538. actual voltage. Signal CN2-27 11 Wheel Speed sensor Signal CN2-36. Make sure the key switch is in the “OFF” position (A) and connect the CDU to the Power Shuttle ECM. The values are not The H9 menu allows inspection of individual circuits. amperage. Signal CN1-5 8 Clutch “A” PWM Solenoid Voltage CN1-10. turn the key switch (1) to the “ON” position (B). Ground CN2-13 and CN2-14 15 ECM 12V Fuse Supply Voltage CN2-1. the value is measured circuit and a value which corresponds into a in “Hertz” (Hz). senders. Signal CN2-4 17 Range (G1) Gear Shift Lever Position Switch Voltage CN2-20. Ground CN2-13 and CN2-14 4 ECM 12V Key START Supply Voltage CN1-15. measurement. Ground CN2-13 and CN2-14 5 Synchronizer Forward (Hi/Lo) Position Switch NOT USED TN Standard 6 Synchronizer Reverse (Shuttle) Position Switch NOT USED TN Standard 7 Clutch “B” PWM Solenoid Voltage CN1-11. Ground CN2-29 2 Transmission Oil Temperature Sensor Signal CN2-25. While holding the “HMENU” button on the CDU. 2.TRANSMISSIONS -. and solenoids showing The values are analogue/digital counts. sensors.

prolonged cranking) 428 • Battery charge at 12V (normal) 595 • Battery charge at 16V (overcharge) 762 4. may be displayed by using the up and down buttons on the CDU.CHAPTER 2 3. 6. “H9” should appear on the CDU display. or “START” (engine running) position) is listed behind the channel title in parenthesis. (ON) 1 → 538 NOTE: “HC Menu” will display transmission oil temperature in degrees Celsius. • Battery charge at 9V (low charge) 428 • Battery charge at 12V (normal) 595 • Battery charge at 16V (overcharge) 762 b) Power Shuttle FNR lever in the neutral posi- tion or clutch pedal depressed 0-95 . Transmission Oil Temperature Sensor. (START) a) Clutch pedal released and Power Shuttle FNR lever in the forward or reverse position. (pedal down). “HMENU” should appear on the display. After a few seconds the first channel will be H9 indicated on the CDU display. ECM +12VD Keyed Battery Voltage. Once the tractor has gone through diagnostics. up to 24. Press the “HMENU” button nine times. (pedal up). This is because the Power Shuttle FNR lever may be stated in a certain position. 542 (maximum) • depressed. 1. The clutch pedal depressed is the same as the Power Shuttle FNR lever in neutral. 4.60 SECTION 21 -. NOTE: Sometimes the clutch pedal position is not stated. (ON) • Battery charge at 9V (low charge. 10006107 NOTE: The status of the tractor (with key switch in the 91 “OFF”. The channels. 38 (minimum) 2.TRANSMISSIONS -. Release the “HMENU” button. Clutch Pedal Potentiometer. • At 0_ C (32_ F) 463 + 69 • At 30_ C (86_ F) 225 + 33 • At 60_ C (140_ F) 136 + 20 10006107 • At 90_ C (194_ F) 53 + 8 92 3. ECM +12 VF Keyed Battery Supply Voltage. “ON” (engine off). IMPORTANT: Transmission operation in enabled in this menu. 5. Listed below are the channels and their values. (ON) • released.

5V input Sensor Supply Voltage. • Display will read (200 min-400 max) 350 (ON) 9. (NOT USED TN Standard) • Place range control lever into “A” 14.4 mph) 16 12. (ON) • Place the gear selector lever into first • (521 min. Synchronizer Reverse (Shuttle) Position • Neutral (21 min – 323 max) 170 Switch. (536 min – 831 max) 600 While Driving NOTE: Allow at least six seconds for the CDU to indicate an actual reading as solenoids ramp up to • 4 kph (2.4 mph) 3 proper amperage. Synchronizer in Reverse (Shuttle) Solenoid.9 mph) 6 operating temperature of hydraulic fluid. (NOT USED TN Standard) (ON) 6. otherwise bodily injury. death or • Place the Power Shuttle FNR lever into the damage may occur. 12V Fuse Sensed Voltage.) 670 • Place the Power Shuttle FNR lever into reverse for all transmissions 15. (START) WARNING The tractor will move when checking channels 7 NOTE: The tractor will not be moved during this test. 7. (START) 13. Power Shuttle FNR Lever Forward Switch. Clutch (B) PWM Solenoid Driver Versus (NOT USED TN Standard) Status Sensed. (ON) • Display will read (200 min-400 max) 350 • Battery charge at 9V (low charge) 428 8. NOTE: For channels 7 and 8. • 20 kph(12. – 849 max. SECTION 21 -. Power Shuttle FNR Lever Reverse Switch. Be sure the area around the tractor is clear • Place range control lever into highest range of people and objects before performing the • Place gear selector lever into first following test. and 8. reading will vary • Display with wheels not moving depending upon clutch calibration values. forward position. • Place range control lever into “A” (ON) • Place the gear selector lever into first • In neutral (516 min – 900 max) 680 • Place the Power Shuttle FNR lever into • In gear (21 min – 514 max) 340 forward position for all transmissions 17. Range (G1) Gear Shift Lever Position Switch. Wheel Speed Sensor Voltage. Switch. Synchronizer Forward (Hi/Lo) Position 10. Clutch (A) PWM Solenoid Driver Versus • Battery charge at 12V (normal) 595 Status Sensed.TRANSMISSIONS -. • In neutral (516 min – 900 max) 680 (ON) • In gear (21 min – 514 max) 340 • Neutral (21 min – 323 max) 170 18. (START) • Battery charge at 16 V (overcharge) 762 • Release the parking brake 16. Main (C1) Gear Shift Lever Position Switch. (NOT USED TN Standard) • Forward (326 min – 900 max) 480 11. Ramp up time is dependent upon • 8 kph (4. Creeper Control Lever (NOT USED TN • Forward (326 min – 900 max) 480 Standard) .CHAPTER 2 61 5. Synchronizer in Forward (Hi/Lo) Position • Release the parking brake Solenoid.

• Place range control lever into the highest • With FNR lever in neutral or with clutch pedal range depressed -. Wheel Speed Sensor Frequency.0 515 The tractor will move when checking channel 19.TRANSMISSIONS -. or • 2000 RPM for software 6. NOTE: There is no channel set aside in “H9” to check NOTE: The reading displayed when the Power the dump solenoid. • 2000 RPM for software 4.01 430 following test. Shuttle FNR lever is placed in the forward position is circuit CN1-18 and CN1-2. (ON) 20. CN1-18 and the black lead (-) to ground.62 SECTION 21 -.0 to 5. death. (START) WARNING • 2500 RPM for software prior to 4.0 415 damage may occur. otherwise bodily injury.solenoid not “forward” position 0-3000 energized 0V . Engine Speed Sensor Frequency (Alternator+W).0 33 Be sure the area around the tractor is clear of people and objects before performing the • 2000 RPM for software 5.solenoid energized 12V • Place the gear selector lever into first 0-60 • With FNR lever NOT in neutral and with • Place the Power Shuttle FNR lever into the clutch pedal released -.CHAPTER 2 19. driver versus status sensed. A true test to this solenoid dependent upon tires and the differential gear ratio is with an actual voltmeter with the red lead (+) to the tractor is equipped with.

Press the “HMENU” button until the “HA” appears on the CDU display. The transmission operation is enabled in this menu. “HMENU” should appear on the display. 2. 1.CHAPTER 2 63 HA-CLUTCH PEDAL POTENTIOMETER AND STATUS SWITCH The HA menu displays input values of both the clutch pedal potentiometer and status switch. SECTION 21 -. This menu can also be viewed with the tractor stationary. turn the key switch (1) to the “ON” position (B). as described previously in this manual. Once the tractor has gone through diagnostics. While holding the “HMENU” button on the CDU. The clutch pedal potentiometer position is expressed as a percentage of the entire travel range while the clutch pedal switch status is indicated by ON and OFF during the travel of the pedal. Make sure the key switch is in the “OFF” position (A) and connect the CDU to the Power Shuttle ECM. Ensure the parking brake is set. 93 3. HA 10006107 94 . It is possible to drive the tractor and at the same time record the clutch pedal potentiometer travel and clutch pedal switch status from the CDU display.TRANSMISSIONS -. Release the “HMENU” button. 4.

0% OFF 10006107 97 7. 96 “ON” means the clutch pedal switch is closed so the dump solenoid is energized. disengage the range lever and engage the parking brake. “OFF” means the clutch pedal switch is open so 10006107 the dump solenoid is de-energized. NOTE: To run stationary test (if engine is running). As the clutch pedal is being depressed. the percentage should be 0% or 1% OFF. oil is dumped to sump from the clutch packs. As the clutch pedal is being released. When the clutch pedal is released the percentage should be 100% or 99 % ON. . When the clutch is fully depressed.CHAPTER 2 5. the 100% ON display should change from “ON” to “OFF” before 5%. 95 6.TRANSMISSIONS -. the display should change from “OFF” to “ON” before 15%. oil is supplied to the clutch packs. Place the Power Shuttle FNR lever (1) into the forward position.64 SECTION 21 -. Turn the key switch to the “OFF” position to disconnect the CDU or press the “HMENU” button on the instrument to access another menu.

as described previously in the H1 menu description. Turn the key switch back to the “ON” (B) position. If the readings are not as specified. and moving the switch as needed. Turn the key switch. The clutch pedal potentiometer limit has been calibrated. After a few moments the service transmission light will begin to flash the error code for “non-calibrated clutches”. When the clutch pedal is released (raised). The CDU display should change from “ON” to “OFF” before 5% as the clutch is being depressed and the display should change from “OFF” to “ON” before 15% as the clutch pedal is being released. 9. the percentage should be 100% or 99% ON.TRANSMISSIONS -.CHAPTER 2 65 CLUTCH PEDAL POTENTIOMETER REPLACEMENT AND CLUTCH PEDAL SWITCH ADJUSTMENT If the clutch pedal potentiometer has been replaced. to the “ON” (B) position to allow the ECM to perform the self configuration (first start-up). 2. 8. the previous data for the clutch must be erased using the H8 menu. Release the clutch pedal and allow the clutch to remain at the top travel limit for a few seconds. 3. SECTION 21 -. To adjust the clutch pedal switch. use the following procedure to calibrate the new potentiometer and adjust the switch. 1. the display 50025110 should change from “OFF” to “ON” before 15%. 7. Ignore this error for now. 1. 5. . Turn the key switch to the “OFF” (A) position to disconnect the CDU or press the “HMENU” button to access another menu. the percentage should be O% or 1% OFF. the display should change from “ON” to “OFF” before 5%. Hold the clutch pedal for a few seconds at the bottom travel limit. As the clutch pedal is being released. 1 4. To calibrate the clutch pedal potentiometer limits. The clutch pedal switch will also need adjustment (see step 6--8). adjust the 99 clutch pedal switch by loosening the switch mounting screws. NOTE: The clutch pedal switch is located under the left lower dash cover on the inside of the clutch pedal 1 pivot. access the HA menu using the CDU. 6. Once the data has been erased. 2 As the clutch pedal is being depressed. Turn the key switch to the “OFF” (A) position to save the configuration. 1. 2. fully depress the clutch pedal. Turn the key switch to the “OFF” (A) position to 98 save the potentiometer limit calibration. Now the clutch packs will need calibrated. Make sure the mounting screws are tightened once the clutch pedal switch is adjusted properly. When the clutch is fully depressed.

To display the transmission oil temperature. Make sure the key switch is in the “OFF” (A) position and connect the CDU to the Power Shuttle ECM. Press the “HMENU” button until “HC” appears on the CDU. Release the “HMENU” button. 100 3. use the following procedure: 1. Turn the key switch to the “OFF” (A) position to 10006107 disconnect the CDU or press the “HMENU” button on the CDU to access another menu.66 SECTION 21 -. While holding the “HMENU” button on the CDU. 1. 6. The HC menu displays the temperature transmission oil in degrees Celsius. 2. to the “ON” (B) position. An example is: T = 21° C. “HHMENU” should appear on the display.TRANSMISSION OIL TEMPERATURE SENDER NOTE: The transmission can be operated in this mode. turn the key switch. 4. in degrees Celsius. The temperature range is --40°C to +120°C (--40°F) to +248°F).CHAPTER 2 HC -.TRANSMISSIONS -. T = 21°C 5. 101 . as described previously in this manual. Once the tractor has gone through diagnostics. After a few seconds the display on the CDU will indicate the temperature of the transmission oil.

the ECM is unsure of what position the synchronizer is in.TRANSMISSIONS -. 102 3. Hold the “HMENU” button on the CDU and turn the key switch (1) to the “START” position (C) and start the engine. 1. forward (Hi/Lo) position sensor pressed. Put the key switch (1) into the “OFF” position (A) and connect the CDU to the Power Shuttle ECM. SECTION 21 -. Use the following procedure to inspect the F/R synchronizer operation. If the display indicates Pos = SHTL (or SHUT). 4. means the synchronizer in the rear position ready for forward travel. After the tractor has gone through the diagnostics. The HD menu is used to inspect the operation of the Forward/Reverse (Hi/Lo--Shuttle) Synchronizer and will indicate the status of the synchronizer on the CDU display. because the synchronizer did not engage properly or is malfunctioning in some way. 5. normally Error Code 72. reverse (Shuttle) position sensor not pressed. Press the “HMENU” button until “HD” appears on the CDU display. An example is: Pos = Hi/Lo. Release the “HMENU” button. as described previously in this manual. . 103 forward (Hi/Lo) position sensor not pressed. 2. but ensure the range lever is in neutral and the parking brake is engaged. “HMENU” will appear on the CDU display. After a few seconds the CDU display will indicate HD the status of the synchronizers position.CHAPTER 2 67 HD--HI/LO SYNCHRONIZER OPERATION (NOT USED TN STANDARD) NOTE: The transmission should be disabled. reverse (Shuttle) position sensor pressed. If the display indicates Pos = UNKN. the synchronizer is in the front position for reverse 10006107 travel.

Change the synchronizer position several times to be sure the synchronizer is functioning properly. then it would be moved to the reverse position during self-diagnosis. the F/R synchronizer is always meshed with forward or reverse gear even if the Power Shuttle FNR lever or clutch pedal are in neutral. the message Pos = UNKN could be displayed even if the synchronizer moves and engages correctly. 8. Turn the key switch to the “OFF” position (A) to disconnect the CDU or press the “HMENU” button on the CDU to access another menu. In this case. 7. In normal conditions. If not following a mechanical or electro-hydraulic problem.68 SECTION 21 -. The Power Shuttle FNR lever or clutch pedal are causing the clutch packs to neutralize. For example.CHAPTER 2 NOTE: In case of failure of one or both synchronizer position sensor. Mechanically there is not a neutral synchronizer position. The CDU display will indicate the position of the synchronizer. the F/R synchronizer should never be in the mechanical neutral position. the F/R synchronizer is moved automatically by the ECM to the opposite position from tractor shut down. . 6. In normal conditions at engine start-up and during ECM self-diagnosis. if the synchronizer is in the forward position.TRANSMISSIONS -. the Error Code selected for the particular position sensor should appear flashing on the instrument panel. Increase the engine to 1200 – 1400 RPM and use the up arrow and down arrow buttons on the CDU to change the position of the synchronizer. however.

There are three settings. 4 mph) • Low WST=LOW (approx. 3 mph) 6. 1. SECTION 21 -. Release the “HMENU” button. as listed below. 105 .approximately 3 mph • Med -. 1. 2.GEAR CHANGE ADJUSTMENTS The HE menu displays the speed threshold setting. 4. “HHMENU” should appear on the display. 104 3. use the up 10006107 and down buttons on the CDU until the desired speed is indicated on the CDU display. The ECM uses two shifting tables. one that is used when the transmission is shifted above the speed threshold setting. WST = MID 5. Once the tractor has gone through diagnostics. turn the key switch. The display on the CDU will indicate one of the following settings: • High WST=HI (approx.approximately 8 mph IMPORTANT: This value should not be changed as it was set at the factory.CHAPTER 2 69 HE -. 8 mph) • Medium WST=MID (approx. as described previously in this manual. Turn the key switch to the “OFF” (A) position to store the setting in the ECM. Press the “HMENU” button until “HE” appears on the CDU display. While holding the “HMENU” button on the CDU.approximately 4 mph • High -. 7. To change the engagement speed. Make sure the key switch is in the “OFF” (A) position and connect the CDU to the Power Shuttle ECM. the other is used when the tractor is shifted below the speed threshold setting. • Low -. to the “ON” (B) position.TRANSMISSIONS -.

CHAPTER 2 HF-STORED ERROR CODES When a fault is detected it is stored in the ECM non-volatile memory and signalled by the indicator lamp. “HMENU” will appear on the CDU display. Put the key switch (1) into the “OFF” position (A) and connect the CDU to the Power Shuttle ECM. The following key is used for Error Codes: • E Error • (9) Progressive storage channel of the Error 10006107 • 11 Error Code number 108 . The HF menu allows access to Error Codes that are stored in the non-volatile memory of the ECM. An example would be: E (9) =11. the associated Error Code is saved into the HF memory. Use the following procedure to access the HF menu: MDD3231A 106 1. as described previously in this manual. After the tractor has gone through the diagnostics. Stored errors can be read and erased by using the CDU. HF 5. 4. Release the “HMENU” button. As soon as a fault condition is detected by the ECM.70 SECTION 21 -. The CDU display will indicate the last stored Error Code. 2. Press the “HMENU” button until “HF” appears on the CDU display. (1). Hold the “HMENU” button on the CDU and turn the key switch (1) to the “ON” position (B). 6.TRANSMISSIONS -. 107 3.

E(10) will be the most recent Error Code. ERASED. ERASE4s. Release the down button once the errors have been erased and turn the key switch to the “OFF” position (A) for at least two seconds. ERASE 1s. use the up arrow and down arrow buttons to view Error Codes from other channels. SECTION 21 -. The following will be displayed when there are no Error Codes stored: E (1)=00 There is a maximum of ten stored Error Codes.TRANSMISSIONS -. 10006107 9. 8. ERASE 2s. Stored errors can be erased from the non-volatile memory by pressing and holding the down arrow 109 button on the CDU until the following sequence is displayed: ERASE 5s. If multiple Error Codes are present. otherwise the Error Codes may be E (1) = 00 erased. NOTE: Do not hold the buttons that change the Error Code displayed. 10. NOTE: If the down arrow is released or the “HMENU” is pushed during the erasure countdown. Press them momentarily when changing the Error Code viewed. . ERASE 3s.CHAPTER 2 71 7. the sequence is cancelled and the Error Codes are not erased.

B -.Green electrical wiring diagram.Yellow S -. To facilitate problem solving. paired. memory (see HF MENU). CN1--4 or CN2--25 on the ECM connections (85) refer to the smaller connection (18 pin) or the the H8 MENU function (cancellation of the resi. other requested calibration operations.5 AB (2) 2.72 SECTION 21 -.CHAPTER 2 TROUBLESHOOTING FAULT CODES WARNING calibration of the hydraulic clutches MENU H1 page 40. The fault will be saved (as a ”no temperature of 20 o C (68 oF) (ambient temperature).) are cor. etc.White N -. 9. tance value of less than 5 ohm (Ω). bigger connection (36 pin) and the relative pin dent non--volatile memory). played if the cause has been eliminated or re- resistance. resistance values shown in the manual should vary accordingly. Notes to help the operator make diagnosis and prob- lem--solving easier.Purple 5. switches. The “short to ground” message refers to a resis. also check that the number. 0. AB = wire colour. sensors.TRANSMISSIONS -. must be carried out with a digital tester. 3.Black rect tractor operation. the following operations must be carried out: 8.Pink 4.Grey V -. self--configuration operation at the first start--up (after ECM replacement) is correct. 7. NO FAULT RESET: the fault remains on the alarm lamp when the cause is eliminated or solved. Example: 0. When a fault occurs.Blue Z -. The measurements taken to read: FAULT RESET: the fault will no longer be dis- voltage. Electric Wire Color Coding rectly connected. before carrying out any kind (2) = connection pin number. consult the ECM H -. stop then re- NOTE: the resistance values shown are valid for a start the tractor. but the relative code will be saved in the non--volatile frequency. check that the specific con- nections (ECM. L -. C -.Orange R -. of service operations. even without switching off the tractor.5 = wire diameter. fault reset”) in the non volatile memory (see HF With higher or lower tractor temperatures.Light Blue M -. shown on page 227. The faults are listed in progressive order. ECM LOCATION The ECM (1) controls the POWER SHUTTLE. the relative MENU. and the connection pin number. The connection references indicate: the wire di- mension and colour. A -. . 6. There are two types of faults: 1. If the ECM needs to be replaced.Brown A faulty connection could be the cause of incor.Red G -. To remove the fault display.

CHAPTER 2 73 PAGE LEFT BLANK .TRANSMISSIONS -.SECTION 21 -.

While tractor is being driven. pin 20 and Clutch Pedal Potentiometer. . • Transmission is limited.74 SECTION 21 -. While tractor is in neutral. Tractor can only be moved using the Power Shuttle FNR Lever.053 volts. NOTE: This error may also cause Error Code 37 and Error Code 48 to activate. circuit is shorted to ground or open between ECM connector 2.053 volts. Depressing the Clutch Pedal will stop the tractor and the error will revert back to the first Condition. NOTE: The proper operation of the Power Shuttle FNR Lever and/or Clutch Pedal Switch guarantee activation of the Dump Solenoid in order to safely control the transmission. Recovery: • Cause must be resolved and error must be cleared using the CDU. Or common 5 volt sensor supply wire from ECM connector 2. pin 24. or between potentiometer terminals. • The clutch pedal doesn’t work. • HA. signal voltage at ECM connector 2. but can be re-enabled by cycling the Power Shuttle FNR Lever. Channel 1 value is below 30 counts. pin 24 drops below 0. Conditions: 1.CHAPTER 2 FAULT CODE 11 – CLUTCH PEDAL POTENTIOMETER (1) SIGNAL VOLTAGE SHORT TO GROUND OR OPEN CIRCUIT. HF Menu. Causes: • Faulty wiring. pin 20 is shorted to ground or open between potentiometer and any other 5 volt sensor.TRANSMISSIONS -. doesn’t read the correct percentage. NOTE: On all Transmissions the Status Lamp (Gear with a Slash) will flash in a alternating manner. • Transmission is disabled. signal voltage at ECM connector 2. or between Clutch Pedal Potentiometer and ECM connector 2. Effects of Condition 1: • The Transmission Status Lamp is flashing. • H5. doesn’t display transition between d0 and d20. pin 24 drops below 0. 2. inching the tractor with the Clutch Pedal is not possible. • Faulty ECM. • Faulty Clutch Pedal Potentiometer (1). Effects of Condition 2: • An intermittent error is the same as the operator abruptly popping the Clutch Pedal. Tests: • H9.

is the value between NO Is connection (87) or the clutch pedal po. NO nection (87) (S) on the potentiometer? YES Replace the ECM. SECTION 21 -. Is there electrical continuity between pin CN2--24 (S) on connections (85) and con. NO Using a digital tester. Is wire (S) (wiring side) in short to ground? NO YES Disconnect the control panel and the con- nections (85) on the ECM.CHAPTER 2 75 Replace the potentiometer. 1 50025110 . Turn the starter key to the OFF position.TRANSMISSIONS -. Disconnect the potentiometer connection Remove the left--hand panel under the (87).8 kΩ? YES YES Connect the connection and/or wiring. Eliminate the cause of the short to ground. Check the wiring and eliminate the cause of the open circuit. dashboard. wires (V) and (N) (potentiometer side with tentiometer wiring disconnected? the pedal released) ∼ 3. Check the wiring between pin CN2--24 (S) on connections (85) and connection (87) on the potentiometer.

TRANSMISSIONS -.76 SECTION 21 -.CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 110 Art Shown As If Sitting In Operator’s Seat .

5 L (8) 0. SECTION 21 -.5 A (27) 1 N (16) 0.5 BG (7) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 VN (3) 1 N (3) 1 ZB (18) 1 SN (17) 1 GN (16) 0.TRANSMISSIONS -.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.CHAPTER 2 77 FAULT CODE 11 Tractor Side of Connector Potentiometer Side of Connector 87 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 RN (15) 0.5 AB (20) 0.5 AN (26) 1 HM (25) 0.5 BC (13) 0.5 R (15) 0.5 S (24) 0.5 M (12) 1 ZN (2) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 G (33) 85B 1 MN (34) 0.5 AB (2) 1 C (2) 0.5 LB (12) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 V (19) 0.5 S (1) 1 V (1) 0.5 MB (1) .5 LN (8) 0.

Or common 5 volt sensor supply wire from ECM connector 2. pin 24 goes above 0. circuit is shorted to 12 volts between ECM connector 2. inching the tractor with the Clutch Pedal is not possible. While tractor is in neutral. HF Menu. • Faulty ECM Tests: • H9. NOTE: The proper operation of the Power Shuttle FNR Lever and/or Clutch Pedal Switch guarantee activation of the Dump Solenoid in order to safely control the transmission. Causes: • Faulty wiring.CHAPTER 2 FAULT CODE 12 – CLUTCH PEDAL POTENTIOMETER (1) SIGNAL VOLTAGE SHORT TO 5 OR 12 VOLTS. • Transmission is limited. Depressing the Clutch Pedal will stop the tractor and the error will revert back to the first Condition. • Transmission is disabled. pin 20 is shorted to 12v between potentiometer and any other 5 volt sensor. voltage at ECM connector 2. Tractor can only be moved using the Power Shuttle FNR Lever. or short to 5v across potentiometer terminals.TRANSMISSIONS -. • The clutch pedal doesn’t work. pin 24. • Faulty Clutch Pedal Potentiometer (1).78 SECTION 21 -. pin 24 goes above 0. pin 20 and Clutch Pedal Potentiometer. but can be re-enabled by cycling the Power Shuttle FNR Lever. While tractor is being driven. NOTE: This error may also cause Error Code 38 and Error Code 47 to activate. • H5. Channel 1 value is above 545 counts. . doesn’t read the correct percentage. or short to 5 or 12v between Clutch Pedal Potentiometer and ECM connector 2.96 volts. Conditions: 1.96 volts. • HA. NOTE: On all Transmissions the Status Lamp (Gear with a Slash) will flash in a alternating manner. 2. Effects of Condition 1: • The Transmission Status Lamp is flashing. voltage at ECM connector 2. Recovery: • Cause must be resolved and error must be cleared using the CDU. doesn’t display transition between d0 and d20. Effects of Condition 2: • An intermittent error is the same as the operator abruptly popping the Clutch Pedal.

Is there a reading of +5V or +12V between NO CN2--24 (S) on connections (85) and ground? YES Check the wiring and eliminate the cause of the short to +5V or +12V. SECTION 21 -. Turn the starter key to the OFF position. Is there electrical continuity between pin NO CN2--29 (VN) on connections (85) and con- nection (87) (VN) on the potentiometer? YES Turn the starter key to the OFF position. disconnected? the pedal released) ∼ 3. Replace the ECM. Disconnect the control panel and the con- nections (85) on the ECM. is the value between NO Is connection (87).CHAPTER 2 79 Replace the potentiometer. wires (V) and (N) (potentiometer side with tentiometer wiring.8 kΩ? YES YES Connect the connection and/or wiring. Check the wiring and eliminate the cause of the open circuit. or the clutch pedal po. NO Using a digital tester. dashboard. Disconnect connection (87) on the poten- Remove the left--hand panel under the tiometer. 1 50025110 .TRANSMISSIONS -.

CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 111 Art Shown As If Sitting In Operator’s Seat .80 SECTION 21 -.TRANSMISSIONS -.

5 S (1) 1 V (1) 0.TRANSMISSIONS -.5 RN (15) 0.5 AB (2) 1 C (2) 0.5 LN (8) 0.5 A (27) 1 N (16) 0.5 S (24) 0.5 BG (7) 0.CHAPTER 2 81 FAULT CODE 12 Tractor Side of Connector Potentiometer Side of Connector 87 0.5 LB (12) 0.5 MB (1) . SECTION 21 -.5 G (33) 85B 1 MN (34) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 AB (20) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 AN (26) 1 HM (25) 0.5 V (19) 0.5 R (15) 0.5 BC (13) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 L (8) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 M (12) 1 ZN (2) 0.5 VN (3) 1 N (3) 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.

CHAPTER 2 FAULT CODE 13 – HI AND LO BUTTONS PRESSED SIMULTANEOUSLY. Tests: • H5. NOTE: On a 32x16 the Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. but will be stored in HF. doesn’t display transition between d0 and d24 for Lo(Turtle) or d25 for Hi(Rabbit). They will flash in a alternating manner.82 SECTION 21 -. • Hi or Lo Button Switch is stuck closed while the other button is pressed.5 seconds. HF Menu. when the opposition button is pressed. H1. • Faulty wiring. . Conditions: • While driving or stationary. (NOT USED TN Standard) NOTE: Error Code is not triggered during clutch pack calibration. • Speed shift will not take place. both Hi and Lo buttons pressed simultaneously longer than 0. (broken switch). circuit is shorted to 12 volts between Hi or Lo Button Switch and ECM connector 2.TRANSMISSIONS -. • Transmission operates normally but not when Hi or Lo speed shift is conducted. Recovery: • Error will self-clear when Condition or Causes stop. • Cause must be resolved and cleared using the CDU. Effects: • The Transmission Status Lamp is flashing. Causes: • Operator pressed Hi and Lo Buttons at the same time. pin 3 or 22. Error is only shown on 32x16 transmissions.

SECTION 21 -. Replace the ECM. Disassemble the HI and LO pushbuttons Remove the rear right--hand wheel. Disconnect the HI and LO pushbuttons con- NO NO Using a digital tester check the operation nection (89). of the two pushbuttons. Is there a short circuit between the wires? Is one of the two buttons in short? YES YES Check the wiring and eliminate the cause of Replace the faulty pushbutton.5 MB (3) . the short circuit.5 AV (1) 1 C (2) 0.TRANSMISSIONS -. 89 0.CHAPTER 2 83 Turn the starter key to the OFF position. knob.

. then transmission attempt to move is conducted. • Transmission is disabled.TRANSMISSIONS -. pin 4 goes above 4. so ECM assumes position is in gear. If Wheel Speed Sensor signal is reliable. voltage at ECM connector 2. While tractor is being driven. While tractor is in neutral.84 SECTION 21 -. Effects of Condition 2: • Transmission is modified. (no error). voltage at ECM connector 2.2 volts. (Error Code 49). Or common 5 volt sensor supply wire from ECM connector 2. and Main (C1) Gear Shift Lever. (no increase in wheel rotation when the Clutch Pack is at maximum pressure causes the Dump Solenoid to be energized which returns oil to sump). NOTE: On all Transmissions the Status Lamp (Gear with a Slash) will flash in a alternating manner. Channel 16 value is above 860 counts. pin 20 is shorted to 12v between switch and any other 5 volt sensor. Conditions: 1. (Wheel Speed Sensor signal not reliable or tractor is not moving). Clutch Packs are at maximum pressure but no movement seen while Main (C1) Gear Shift Switch reports to be engaged. • H5. (when the Clutch Pedal released and Power Shuttle FNR Lever engaged into a direction).2 volts. • Faulty Main (C1) Gear Shift Switch. • Faulty ECM. If Wheel Speed Sensor signal is not reliable. circuit is shorted to 12 volts between ECM connector 2. 2. • Main (C1) Gear Shift Switch neutral position can not be detected. Effects of Condition 1: • The Transmission Status Lamp is flashing. pin 4 goes above 4. HF Menu. pin 20 and Main (C1) Gear Shift Switch. Recovery: • Cause must be resolved and error must be cleared using the CDU. pin 4. then transmission is critically disabled. Tests: • H9. or short 5 or 12v between switch and ECM connector 2. doesn’t display transition between d0 and d33. but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal.CHAPTER 2 FAULT CODE 14 – MAIN (C1) GEAR SHIFT SWITCH SIGNAL VOLTAGE SHORT TO 5 OR 12 VOLTS. or short to 5v volts between switch terminals. Causes: • Faulty wiring. Main (C1) Gear Shift Switch neutral position can not be detected.

SECTION 21 -. replace the pushbutton. a digital tester. Replace the ECM. Does the fault persist? YES Disconnect the control panel and the con- nections (85) on the ECM. Eliminate the cause of the short circuit. Check the wiring between pins CN2--4 (GL) and CN2--20 (AB) on connections (85) with pins (A7) (GL) and (C6) (AB) on connection (69). Is the resistance ∼ 550 Ω? YES YES Check the wiring and eliminate the cause of the short circuit. using NO (C1). Are wires (GL) and (AB) (wiring side) in NO short? YES Check the wiring and eliminate the cause of the short circuit between connection (71) on the pushbutton and pins (C6) and (A7) on the connection (69). 71 1 AB 1 GL . Turn the starter key to the OFF position.CHAPTER 2 85 (Gear position sensor X) If in short circuit. measure the electrical resist- Is there a short circuit between the wires? ance on the pushbutton. Disconnect connection (71) on pushbutton Remove the rear right--hand wheel and (C1).TRANSMISSIONS -. check connection (71) on pushbutton NO Position the gear lever in neutral and.

86 SECTION 21 -.TRANSMISSIONS -.CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 112 Art Shown As If Sitting In Operator’s Seat .

5 MB (1) 1 GN (C5) 1 BV (C4) 1 AB (C6) 1 B (C3) 1 HL (C7) 1 S (C2) 1 BR (C8) 1 G (C1) 69 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 H (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HG (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 LR (9) 1 AV (22) 1 HL (23) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 LN (8) 0.5 AN (26) 1 HM (25) 0.5 RN (15) 0.5 G (33) 85B 1 MN (34) 0.TRANSMISSIONS -.5 M (12) 1 ZN (2) 0.5 L (8) 0.5 LB (12) 0.5 A (27) 1 N (16) 0.5 R (15) 0.5 V (19) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 BG (7) 0.5 BC (13) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.CHAPTER 2 87 FAULT CODE 14 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 AB (20) 0. SECTION 21 -.5 S (24) 0.

• Main (C1) Gear Shift Switch neutral position can not be detected. pin 20 and Main (C1) Gear Shift Switch. (when the Clutch Pedal released and Power Shuttle FNR Lever engaged into a direction). Conditions: 1. pin 4 goes below 0. and Main (C1) Gear Shift Lever. pin 20 is shorted to ground or open between Main (C1) Gear Shift Switch and any other 5 volt sensor. • Faulty Main (C1) Gear Shift Switch. • Faulty ECM. 2. Or common 5 volt supply wire from ECM connector 2. While tractor is being driven. then transmission attempt to move is conducted. While tractor is in neutral. (Error Code 49).TRANSMISSIONS -. then transmission is critically disabled. voltage at ECM connector 2. HF Menu 1. (no increase in wheel rotation when the Clutch Pack is at maximum pressure causes the Dump Solenoid to be energized which returns oil to sump). Causes: • Faulty wiring.7 volts. (Wheel Speed Sensor signal not reliable or tractor is not moving). Tests: • H9.88 SECTION 21 -. circuit is short to ground or open between ECM connector 2. Clutch Packs are at maximum pressure but no movement seen while Main (C1) Gear Shift Switch reports to be engaged. pin 4 goes below 0. If Wheel Speed Sensor signal is reliable. . If Wheel Speed Sensor signal is not reliable. • H5. Recovery: • Cause must be resolved and error must be cleared using the CDU. (no error). or between Main (C1) Gear Shift Switch and ECM connector 2. Channel 16 value is below 143 counts. so ECM assumes position is in gear. • Transmission is disabled. or across switch terminals.7 volts. but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal.CHAPTER 2 FAULT CODE 15 – MAIN (C1) GEAR SHIFT SWITCH SIGNAL VOLTAGE SHORT TO GROUND OR OPEN CIRCUIT. Main (C1) Gear Shift Switch neutral position can not be detected. Effects of Condition 1: • The Transmission Status Lamp is flashing. voltage at ECM connector 2. Effects of Condition 2: • Transmission is modified. NOTE: On all Transmissions the Status Lamp (Gear with a Slash) will flash in a alternating manner. doesn’t display a transition between d0 and d33. pin 4.

measure the electri. pin (C6) NO (AB) on connection (69) and connection (71) on the pushbutton? YES Replace the ECM.TRANSMISSIONS -. Wire (GL) (wiring side) in short to ground? NO Is there electrical continuity between pin NO YES CN2--4 (GL) on connections (85). Check the wiring and eliminate the cause of the open circuit. SECTION 21 -. Is the resistance ∼ 550 Ω? YES Disconnect the control panel and the con- nections (85) on the ECM. (C1). Remove the rear right--hand wheel and check connection (71) on pushbutton NO Connect the wires. cal resistance on the pushbutton. pin (A7) (GL) on connection (69) and connection Check the wiring and eliminate the cause (83) on the pushbutton? of the short to ground. Are the relative wires connected? YES Position the gear lever in neutral. Using a digital tester. 71 1 AB 1 GL .CHAPTER 2 89 (Range position sensor X) Turn the starter key to the OFF position. YES Is there electrical continuity between pin CN2--20 (AB) on connections (85). NO Replace the pushbutton if interrupted.

CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 113 Art Shown As If Sitting In Operator’s Seat .TRANSMISSIONS -.90 SECTION 21 -.

5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 MB (1) 1 GN (C5) 1 BV (C4) 1 AB (C6) 1 B (C3) 1 HL (C7) 1 S (C2) 1 BR (C8) 1 G (C1) 69 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 H (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HG (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 RN (15) 0.5 BG (7) 0. SECTION 21 -.5 LB (12) 0.5 AN (26) 1 HM (25) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 A (27) 1 N (16) 0.5 S (24) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 V (19) 0.TRANSMISSIONS -.5 BC (13) 0.CHAPTER 2 91 FAULT CODE 15 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 L (8) 0.5 G (33) 85B 1 MN (34) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 LN (8) 0.5 M (12) 1 ZN (2) 0.5 AB (20) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 R (15) 0.

Causes: • Faulty wiring. then transmission is critically disabled. . Effects of Condition 2: • Transmission is modified. pin 28 goes above 4. • H5. pin 20 is shorted to 12v between switch and any other 5 volt sensor. Tests: • H9. then transmission attempt to move is conducted. Recovery: • Cause must be resolved and error must be cleared using the CDU. Effects of Condition 1: • The Transmission Status Lamp is flashing. Range (G1) Gear Shift Switch neutral position can not be detected. • Faulty ECM. (no increase in wheel rotation when the Clutch Pack is at maximum pressure causes the Dump Solenoid to be energized which returns oil to sump). doesn’t display transition between d0 and d34. and Range (G1) Gear Shift Lever. pin 28 goes above 4. circuit is shorted to 12 volts between ECM connector 2. (no error). (when the Clutch Pedal released and Power Shuttle FNR Lever engaged into a direction). Clutch Packs are at maximum pressure but no movement seen while Range (G1) Gear Shift Switch reports to be engaged.92 SECTION 21 -. HF Menu. voltage at ECM connector 2.TRANSMISSIONS -. • Range (G1) Gear Shift neutral position can not be detected. • Transmission is disabled. voltage at ECM connector 2. While tractor is in neutral. pin 20 and Range (G1) Gear Shift Switch. pin 28. Conditions: 1. or short 5 or 12v between switch and ECM connector 2. or short to 5 volts between switch terminals.CHAPTER 2 FAULT CODE 16 – RANGE (G1) GEAR SHIFT SWITCH SIGNAL VOLTAGE SHORT TO 5 OR 12 VOLTS.2 volts. While tractor is being driven. NOTE: On all Transmissions the Status Lamp (Gear with a Slash) will flash in a alternating manner. Channel 17 value is above 860 counts. Or common 5 volt sensor supply wire from ECM connector 2.2 volts. 2. (Error Code 49). but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal. (Wheel Speed Sensor signal not reliable or tractor is not moving). • Faulty Range (G1) Gear Shift Switch. If Wheel Speed Sensor signal is reliable. so ECM assumes position is in gear. If Wheel Speed Sensor signal is not reliable.

Are wires (BG) and (AB) (wiring side) in NO short? YES Check the wiring and eliminate the cause of the short circuit between connection (70) on pushbutton and pins (B5) (GB) and (C6) (AB) on connection (69). Turn the starter key to the OFF position. Replace the ECM. check connection (70) on pushbutton NO Position the range lever in neutral and. 70 1 BG 1 AB .TRANSMISSIONS -. SECTION 21 -. Disconnect connection (70) on pushbutton Remove the rear right--hand wheel and (G1). Use a digital tester. Does the fault persist? YES Disconnect the control panel and the con- nections (85) on the ECM. ing a digital tester.CHAPTER 2 93 (Range position sensor Y) If in short circuit. Check the wiring between pins CN2--28 (BG) and CN2--20 (AB) on connections (85) with pins (B5) (GB) and (C6) (AB) on con- nection (69). us- NO (G1). measure the electrical re- Is there a short circuit between the wires? sistance on the pushbutton. YES Is the resistance ∼ 550 Ω? YES Check the wiring and eliminate the cause of the short circuit. Eliminate the cause of the short circuit. replace the pushbutton.

94 SECTION 21 -.TRANSMISSIONS -.CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 114 Art Shown As If Sitting In Operator’s Seat .

5 L (8) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0. SECTION 21 -.5 AB (20) 0.5 AN (26) 1 HM (25) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 LB (12) 0.5 BC (13) 0.5 V (19) 0.5 LN (8) 0.5 A (27) 1 N (16) 0.5 S (24) 0.5 G (33) 85B 1 MN (34) 0.5 RN (15) 0.5 R (15) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 VN (29) 1 N (14) 1 BG (28) 0.TRANSMISSIONS -.5 BG (7) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 MB (1) 1 GN (C5) 1 BV (C4) 1 AB (C6) 1 B (C3) 1 HL (C7) 1 S (C2) 1 BR (C8) 1 GR (C1) 69 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 H (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HG (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 M (12) 1 ZN (2) 0.CHAPTER 2 95 FAULT CODE 16 1 ZB (18) 1 SN (17) 1 GN (16) 0.

• H5.7 volts. HF Menu. so ECM assumes position is in gear. Channel 17 value is below 143 counts.TRANSMISSIONS -. Conditions: 1. but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal. (Error Code 49). Tests: • H9. (Wheel Speed Sensor signal not reliable or tractor is not moving).96 SECTION 21 -. Effects of Condition 2: • Transmission is modified. While tractor is being driven. (when the Clutch Pedal released and Power Shuttle FNR Lever engaged into a direction). pin 20 and Range (G1) Gear Shift Switch. • Faulty ECM. (no error). then transmission is critically disabled. Effects of Condition 1: • The Transmission Status Lamp is flashing. . pin 28. Or common 5 volt supply wire from ECM connector 2.7 volts. voltage at ECM connector 2. Causes: • Faulty wiring. pin 20 is shorted to ground or open between Range (G1) Gear Shift Switch and any other 5 volt sensor. If Wheel Speed Sensor signal is not reliable. Clutch Packs are at maximum pressure but no movement seen while Range (G1) Gear Shift Switch reports to be engaged. NOTE: On all Transmissions the Status Lamp (Gear with a Slash) will flash in a alternating manner. doesn’t display transition between d0 and d34. or across switch terminals. Recovery: • Cause must be resolved and error must be cleared using the CDU. • Transmission is disabled. circuit is short to ground or open between ECM connector 2. voltage at ECM connector 2. While tractor is in neutral. or between Range (G1) Gear Shift Switch and ECM connector 2. and Range (G1) Gear Shift Lever. If Wheel Speed Sensor signal is reliable. 2. (no increase in wheel rotation when the Clutch Pack is at maximum pressure causes the Dump Solenoid to be energized which returns oil to sump). then transmission attempt to move is conducted. • Faulty Range (G1) Gear Shift Switch.RANGE (G1) GEAR SHIFT SWITCH SIGNAL VOLTAGE SHORT TO GROUND OR OPEN CIRCUIT. Range (G1) Gear Shift Switch neutral position can not be detected. pin 28 goes below 0. pin 28 goes below 0.CHAPTER 2 FAULT CODE 17 . • Range (G1) Gear Shift neutral position can not be detected.

Is wire (BG) (wiring side) in short to NO Is there electrical continuity between pin ground? NO CN2--28 (BG) on connections (85).CHAPTER 2 97 (Range position sensor Y) Turn the starter key to the OFF position.TRANSMISSIONS -. Are the relative wires connected? YES Position the gear lever in neutral. cal resistance on the pushbutton. pin (C6) NO (AB) on connection (69) and connection (70) on the pushbutton? YES Replace the ECM. SECTION 21 -. Remove the rear right--hand wheel and check connection (70) on pushbutton NO Connect the wires. Using a digital tester. (G1). Is there electrical continuity between pin CN2--20 (AB) on connections (85). NO Replace the pushbutton if interrupted. pin (B5) YES (BG) on connection (69) and connection (70) on the pushbutton? Check the wiring and eliminate the cause YES of the short to ground. measure the electri. Is the resistance ∼ 550 Ω? YES Disconnect the control panel and the con- nections (85) on the ECM. 70 1 BG 1 AB . Check the wiring and eliminate the cause of the open circuit.

TRANSMISSIONS -.CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 115 Art Shown As If Sitting In Operator’s Seat .98 SECTION 21 -.

5 LN (8) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 MB (1) 1 GN (C5) 1 BV (C4) 1 AB (C6) 1 B (C3) 1 HL (C7) 1 S (C2) 1 BR (C8) 1 G (C1) 69 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 H (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HG (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) . SECTION 21 -.5 BG (7) 0.5 G (33) 85B 1 MN (34) 0.5 M (12) 1 ZN (2) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 R (15) 0.TRANSMISSIONS -.5 V (19) 0.5 BC (13) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 RN (15) 0.5 S (24) 0.5 L (8) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 LB (12) 0.5 AN (26) 1 HM (25) 0.5 A (27) 1 N (16) 0.CHAPTER 2 99 FAULT CODE 17 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 AB (20) 0.

TRANSMISSIONS -.2 volts. • ECM failure Effects: • Creeper lever neutral position cannot be detected • The ECM will assume the creeper is engaged and the tractor will attempt to move when the shuttle lever is in the forward or reverse position and the clutch pedal is raised. pin 21. (NOT USED TN Standard) Conditions/Detection: • Voltage at ECM connector 2. . Causes: • Short circuit to +5 or +12 volts between creeper switch and ECM connector 2. Recovery: • Error must be cleared using diagnostic tool.100 SECTION 21 -. pin 21 goes above 4.VOLTAGE FROM CREEPER (N) SWITCH (CREEPER LEVER) TOO HIGH. • Short circuit at switch terminals or switch failure.CHAPTER 2 FAULT CODE 18 -.

Does the fault persist? YES Disconnect the control panel and the con- nections (129) on the ECM. * * 97 0. Eliminate the cause of the short circuit. SECTION 21 -. Are wires (HG) and (AB) (wiring side) in NO short circuit? YES Check the wiring between connection (97**) on pushbutton and pins (C7) (HG) and (C6) (AB) on connection (158). Eliminate the cause of the short circuit. button. Replace the ECM.TRANSMISSIONS -. Remove the rear left--hand wheel and the Move the creeper lever to the engaged posi- solenoid valves unit guard. measure the electrical pushbutton. NO NO tion. Check the wiring between pins CN2--21 (HG) and CN2--20 (AB) on connections (129) with pins (C7) (HG) and (C6) (AB) on connection (158). Is there a short circuit between the wires? Is the resistance ∼ 550 Ω? YES YES Check the wiring and eliminate the cause of the short circuit.5 AB 0. replace the pushbutton.5 HG . Disconnect connection (97**) on the push- Turn the starter key to the OFF position. Check connection (97**) on the creeper Using a digital tester. resistance on the pushbutton.CHAPTER 2 101 If in short circuit.

CHAPTER 2 PAGE LEFT BLANK .TRANSMISSIONS -.102 SECTION 21 -.

5 BC (13) 0. SECTION 21 -.5 AN (26) 1 HM (25) 0.5 G (33) 1 MN (34) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 1 SG (3) 0.5 HB (36) 1 BV (30) 1 N (13) 0.5 RN (15) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 BG (7) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 L (8) 0.5 R (15) 0.CHAPTER 2 103 FAULT CODE 18 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 AB (20) 0.5 S (24) 0.5 MB (1) 1 C (C5) 1 SG (C4) 1 AB (C6) 1 HL (C3) 1 HG (C7) 1 AV (C2) 1 AR (C8) 1 GR (C1) 158 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 GN (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HV (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 LN (8) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 A (27) 1 N (16) 0.5 LB (12) 0.5 M (12) 1 ZN (2) 0.5 V (19) 0.TRANSMISSIONS -.5 VN (29) 1 N (14) 1 BG (28) 0.

goes below 0. . • Open circuit or short to ground between switch terminals or faulty switch. Recovery: • Error must be cleared using diagnostic tool. (NOT USED TN Standard) Conditions/Detection: • Voltage at ECM connector 2.TRANSMISSIONS -. • ECM failure Effects: • Creeper lever neutral position cannot be detected • The ECM will assume the tractor is in gear and the tractor will attempt to move when the shuttle lever is in the forward or reverse position and the clutch pedal is raised.104 SECTION 21 -. pin 21. Causes: • Open circuit or short to ground between creeper switch and ECM connector 2.7 volts. pin 21.VOLTAGE FROM CREEPER (N) SWITCH (CREEPER LEVER) TOO LOW.CHAPTER 2 FAULT CODE 19 -.

* * 97 0. NO tion. pin NO (C6) (AB) on connection (158) and connec- tion (97**) on the pushbutton? YES Replace the ECM. Remove the rear left--hand wheel and the Move the creeper lever to the engaged posi- solenoid valves unit guard.5 HG . Is there electrical continuity between pin CN2--21 (HG) on connections (129).5 AB 0. Disconnect the control panel and the con- nections (129) on the ECM. Disconnect connection (97**) on the creep- Turn the starter key to the OFF position.TRANSMISSIONS -. resistance on the pushbutton.CHAPTER 2 105 Replace the pushbutton if interrupted. er pushbutton. pin NO (C7) (HG) on connection (158) and connec- tion (97**) on the pushbutton? YES Is there electrical continuity between pin CN2--20 (AB) on connections (129). Is the wiring disconnected? Is the resistance ∼ 550 Ω? YES YES Connect the wiring. NO Check connection (97**) and the creeper Using a digital tester. Check the wiring and eliminate the cause of the open circuit. measure the electrical pushbutton wiring. Is wire (HG) (wiring side) in short to ground? NO YES Check the wiring and eliminate the cause of the short to ground. SECTION 21 -.

106 SECTION 21 -.CHAPTER 2 PAGE LEFT BLANK .TRANSMISSIONS -.

5 BG (7) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 MB (1) 1 C (C5) 1 SG (C4) 1 AB (C6) 1 HL (C3) 1 HG (C7) 1 AV (C2) 1 AR (C8) 1 GR (C1) 158 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 GN (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HV (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) . SECTION 21 -.5 L (8) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 AB (20) 0.5 R (15) 0.TRANSMISSIONS -.5 LN (8) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 G (33) 1 MN (34) 0.5 RN (15) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 1 SG (3) 0.5 AN (26) 1 HM (25) 0.5 A (27) 1 N (16) 0.5 M (12) 1 ZN (2) 0.5 BC (13) 0.5 S (24) 0.5 HB (36) 1 BV (30) 1 N (13) 0.5 VN (29) 1 N (14) 1 BG (28) 0.CHAPTER 2 107 FAULT CODE 19 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 V (19) 0.5 LB (12) 0.

F/R Synchronizer Position Sensors. (shutting off the tractor).108 SECTION 21 -.TRANSMISSIONS -. Connectors and pins are pinched. . Causes: • Faulty wiring. and F/R Synchronizer Solenoids doesn’t display the correct transition between d0 and the corresponding d value. and F/R Synchronizer Solenoids will not display the correct count. HF Menu. PS ECM Harness to PS Transmission Side Harness connected at CN 9 A-D or CN 9 (24 pins).CHAPTER 2 FAULT CODE 21 – CHASSIS HARNESS (NOT USED TN Standard) NOTE: The 32x16 transmission will use this FAULT CODE for F/R Synchronizer circuit and dump circuit. F/R Synchronizer Position Sensors. or corroded. Effects: • Transmission is critically disabled. and F/R Synchronizer Solenoids. loose. Tests: • H9. but can be re-enabled by cycling the Ignition Switch. The 16x16 & 8x8 transmissions will use this FAULT CODE for just the dump circuit. (at firewall). connector between PS ECM Harness and PS Transmission Side Harness disconnected. open circuit between Power Shuttle ECM Harness and Power Shuttle Transmission Side Harness hinders communication. would display open circuit FAULT CODEs related to the dump solenoid. located under the hood on engine side of firewall. channels related to the dump solenoid. Conditions: • While tractor is being driven or in neutral. • HF. F/R Synchronizer Position Sensors. NOTE: Power Shuttle ECM to PS ECM Harness connected at CN1 and CN2. Connector between Dump Solenoid and Transmission Side Harness is disconnected. PS Transmission Side Harness to Dump Solenoid and F/R Synchronizer Position Sensors located on left side of transmission by the Power Shuttle Control Valve. • H5. located under the instrument panel. Recovery: • Cause must be resolved and error must be cleared using the CDU. Connector between F/R Synchronizer Position Sensors and Transmission Side Harness is disconnected. Connector between F/R Synchronizer Solenoids and Transmission Side Harness is disconnected. related to the dump solenoid.

NO Connect connection (158). Is the wiring on the solenoid valve connected? YES Disconnect the control panel. Raise the engine hood.TRANSMISSIONS -. NO (129).CHAPTER 2 109 Turn the starter key to the OFF position. . SECTION 21 -. Connect the connections correctly Are connections (129) on the ECM correctly con. Is connection (158) connected? YES Remove the rear left--hand wheel and the solenoid valves unit guard. nected? YES Replace the ECM. NO Connect the wiring.

TRANSMISSIONS -.110 SECTION 21 -.CHAPTER 2 PAGE LEFT BLANK .

CHAPTER 2 111 FAULT CODE 21 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 BC (13) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 RN (15) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 V (19) 0.5 S (24) 0. SECTION 21 -.5 HR (11) 1 MN (10) 1 HG (21) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 1 SG (3) 0.5 R (15) 0.5 AB (20) 0.5 LN (8) 0.5 L (8) 0.TRANSMISSIONS -.5 MB (1) 1 C (C5) 1 SG (C4) 1 AB (C6) 1 HL (C3) 1 HG (C7) 1 AV (C2) 1 AR (C8) 1 GR (C1) 158 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 GN (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HV (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 M (12) 1 ZN (2) 0.5 LB (12) 0.5 A (27) 1 N (16) 0.5 G (33) 1 MN (34) 0.5 BG (7) 0.5 AN (26) 1 HM (25) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 HB (36) 1 BV (30) 1 N (13) 0.

controlled by the top. horizontal solenoid on the Power Shuttle Control Valve Assembly. PWM Solenoid can not be electrically controlled to pressurize and de-pressurize the Clutch Pack. Clutch Pack (B) is the rear pack. CN1-6 without going through the solenoid coil. Effects of Condition 2: • Transmission is limited. the Clutch Pack (A) PWM Solenoid has a short circuit. NOTE: On all transmissions Clutch Pack (A) is the front pack.CHAPTER 2 FAULT CODE 22 – CLUTCH PACK (A) PULSE WIDTH MODULATED SOLENOID COIL SHORT CIRCUIT. Clutch Pack (A) becomes inoperable. Causes: • Faulty wiring. used for reverse movement.112 SECTION 21 -. Tests: • H9. horizontal solenoid on the Power Shuttle Control Valve Assembly. 2. HF Menu. Channel 8 value is below 200 counts.TRANSMISSIONS -. the Clutch Pack (A) PWM Solenoid has a short circuit. . • Clutch Pack (A) becomes inoperable. CN1-10 sends voltage to the input signal ECM. pin 6 wires. controlled by the bottom. • Faulty ECM. • Faulty Clutch Pack (A) PWM Solenoid Coil. Effects of Condition 1: • The Transmission Status Lamp is flashing. • Transmission is disabled. or across the two solenoid coil terminals. Transmission will only operate in Reverse. While tractor is being driven in Reverse. used for forward movement. Recovery: • Cause must be resolved and error must be cleared using the CDU. circuit is shorted between the ECM connector 1. but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal. While tractor is being driven in Forward. pin 10 and ECM connector 1. Conditions: 1. meaning the output signal from ECM.

Eliminate the cause of the short circuit. Is the electrical resistance on the solenoid valve coil. ∼ 10 Ω? YES Wires (AR) and (AN) (wiring side) are in short. measured with a digital tester. short. YES Check the wiring between connection (75) on the solenoid valve and pins (C8) (AR) and (B7) (AN) on connection (69).TRANSMISSIONS -. Does the fault persist? YES Disconnect the control panel and the connections (85) on the ECM.CHAPTER 2 113 Turn the starter key to the OFF position. NO Replace the ECM. SECTION 21 -. Eliminate the cause of the short circuit. Disconnect connection (75) on the clutch solenoid NO Replace the solenoid valve coil if in valve (A). 75 . Check the wiring between pins CN1--10 (AR) and CN1--6 (AN) on connections (85) with pins (C8) (AR) and (B7) (AN) on connection (69). Remove the rear left--hand wheel and the solenoid valves unit guard.

CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 116 Art Shown As If Sitting In Operator’s Seat .TRANSMISSIONS -.114 SECTION 21 -.

SECTION 21 -.5 AN (26) 1 HM (25) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 V (19) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 BC (13) 0.5 S (24) 0.CHAPTER 2 115 FAULT CODE 22 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 G (33) 85B 1 MN (34) 0.5 R (15) 0.5 L (8) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 AB (20) 0.5 LN (8) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 BG (7) 0.TRANSMISSIONS -.5 VN (29) 1 N (14) 1 BG (28) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 M (12) 1 ZN (2) 0.5 LB (12) 0.5 A (27) 1 N (16) 0.5 MB (1) 1 GN (C5) 1 BV (C4) 1 AB (C6) 1 B (C3) 1 HL (C7) 1 S (C2) 1 BR (C8) 1 G (C1) 69 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 H (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HG (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 RN (15) 0.

Recovery: • Cause must be resolved and error must be cleared using the CDU. circuit is shorted between ECM connector 1. 2. • Effects of Condition 1: • The Transmission Status Lamp is flashing. Tests: • H9. • Faulty ECM. NOTE: Two Conditions/Detection will trigger this error code. PWM Solenoid can not be electrically controlled to pressurize and de-pressurize the Clutch Pack. Conditions: 1. pin 11 and ECM connector 1. Causes: • Faulty wiring. .TRANSMISSIONS -. CN1-11 sends voltage to the input signal ECM. the Clutch Pack (B) PWM Solenoid has a short circuit. the Clutch Pack (B) PWM Solenoid has a short circuit. Channel 7 value is below 200 counts. or across the two solenoid coil terminals. HF Menu. CN1-5 without going through the solenoid coil. meaning the output signal from ECM. • Clutch Pack (B) becomes inoperable. Effects of Condition 2: • Transmission is limited. • Faulty Clutch Pack (B) PWM Solenoid Coil. While tractor is being driven in Reverse.116 SECTION 21 -. but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal. • Transmission is disabled.CHAPTER 2 FAULT CODE 23 – CLUTCH PACK (B) PULSE WIDTH MODULATED SOLENOID COIL SHORT CIRCUIT. pin 5 wires. Clutch Pack (B) becomes inoperable. Transmission will only operate in Forward. While tractor is being driven in Forward.

short. Disconnect connection (74) on the clutch solenoid NO Replace the solenoid valve coil if in valve (B). Eliminate the cause of the short circuit. YES Check the wiring between connection (74) on the solenoid valve and pins (A5) (BN) and (A8) (BR) on connection (69). Is the electrical resistance on the solenoid valve coil. Remove the rear left--hand wheel and the solenoid valves unit guard. Check the wiring between pins CN1--11 (BN) and CN1--5 (BR) on connections (85) with pins (A5) (BN) and (A8) (BR) on connection (69).CHAPTER 2 117 Turn the starter key to the OFF position. 74 . measured with a digital tester.TRANSMISSIONS -. Does the fault persist? YES Disconnect the control panel and the connections (85) on the ECM. Eliminate the cause of the short circuit. SECTION 21 -. ∼ 10 Ω? YES Wires (BN) and (BR) (wiring side) are in short. NO Replace the ECM.

TRANSMISSIONS -.118 SECTION 21 -.CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 117 Art Shown As If Sitting In Operator’s Seat .

5 LB (12) 0.5 M (12) 1 ZN (2) 0.5 LN (8) 0.5 V (19) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 G (33) 85B 1 MN (34) 0.CHAPTER 2 119 FAULT CODE 23 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 RN (15) 0.5 R (15) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 AN (26) 1 HM (25) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 A (27) 1 N (16) 0.5 AB (20) 0.5 BC (13) 0.5 BG (7) 0. SECTION 21 -.TRANSMISSIONS -.5 MB (1) 1 GN (C5) 1 BV (C4) 1 AB (C6) 1 B (C3) 1 HL (C7) 1 S (C2) 1 BR (C8) 1 G (C1) 69 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 H (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HG (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 L (8) 0.5 S (24) 0.

Effects: • Transmission is modified. (EEPROM) and Non-Volatile Memory. Tests: • H2.CHAPTER 2 FAULT CODE 24 – CLUTCH PACK (A) AND (B) PULSE WIDTH MODULATED SOLENOIDS ARE NOT CALIBRATED. Recovery: • Cause must be resolved and error must be cleared using the CDU. (NVM). HF Menu. jerky. Directional modulation between forward and reverse using the Power Shuttle FNR Lever will be poor. . or impossible. Clutch Pack Calibration values are corrupt in the Electrically Erased Programmable Read Only Memory. doesn’t display calibration values within range 230 to 480 mA. • During Clutch Pack Calibration procedure. using the CDU. (H1) a Calibration “U” Error occurs preventing the completion of a Calibration procedure. (H8). NOTE: This error code will mask Errors Code 28 and Error Code 29 to prevent ECM memory saturation. (H1).TRANSMISSIONS -. Causes: • Clutch Pack Calibration procedure. is completed. or impossible. • Faulty ECM. • Clutch Pack Calibration procedure.120 SECTION 21 -. (H1) has not been performed after replacing the Clutch Pack (A and B) PWM Solenoids. Conditions: • Clutch Pack Solenoid Calibration Values are out of acceptable range or are not registered. [H8]. (H1) has not been performed after conducting a Non-Volatile Memory Erasure. feathering with the Clutch Pedal will be poor. (H1) has not been performed after replacing a Power Shuttle ECM. jerky. • Clutch Pack Calibration procedure. • Error code will remain active until a Clutch Pack Calibration procedure.

CHAPTER 2 121 H1 H MENU 1 2 3 4 MDB0751A .SECTION 21 -.TRANSMISSIONS -.

the Engine RPM is greater than 3500. • Frequency between alternator W+ terminal and ECM connector 2. NOTE: This error will NOT self-clear even if the engine RPM is returned to correct speed. • Faulty Engine high idle setting. pin 15 is too high. ECM assumes 2300 Engine RPM. Conditions: • For 3 consecutive seconds. channel 20 is higher than given value. Tests: • H9. . • Transmission is modified. Effects: • Unable to conduct Calibration of Clutch Packs (H1). Faulty alternator.CHAPTER 2 FAULT CODE 26 – ENGINE RPM FREQUENCY SIGNAL TOO HIGH.TRANSMISSIONS -. HF menu. Causes: • Faulty alternator drive belt. while a Clutch Pack receives full pressure. with Wheel Speed Sensor indicating movement. so engine performance may be reduced at other RPM levels. Recovery: • Cause must be resolved and error must be cleared using the CDU.122 SECTION 21 -.

SECTION 21 -. Is the frequency ∼ 200 Hz? YES Replace the ECM (1). Is wire (R) on alternator socket (W) correctly con. NO Connect the wire correctly. nected? YES Start the engine and accelerate to 1000 rpm (make sure that the recharging lamp is off). . Using a digital tester measure the frequency at the Replace the alternator if the frequen- NO alternator output between la socket (W) and cy value is much higher. ground.CHAPTER 2 123 Turn the starter key to the OFF position.TRANSMISSIONS -.

so engine performance may be reduced at other RPM levels. • Faulty Engine low idle setting. or short to ground between ECM connector 2. HF menu. while a Clutch Pack receives full pressure. circuit open between Alternator W+ terminal and ECM connector 2. Recovery: • Cause must be resolved and error must be cleared using the CDU. the Engine RPM is less than 500.CHAPTER 2 FAULT CODE 27 – ENGINE RPM FREQUENCY SIGNAL TOO LOW. pin 15 and alternator (W+) terminal. pin 15 and alternator {W+) terminal. pin 15. • Faulty wiring. Tests: • H9. NOTE: This error will NOT clear even if the engine RPM is throttle down to correct speed. with Wheel Speed Sensor indicating movement. ECM assumes 2300 Engine RPM. . Effects: • Unable to conduct Calibration of Clutch Packs (H1) • Transmission is modified. • Faulty Alternator. or short to 12 volts between ECM connector 2. Conditions: • For 3 consecutive seconds. Causes: • Faulty Alternator Drive Belt.124 SECTION 21 -.TRANSMISSIONS -. channel 20 is lower than given value.

CHAPTER 2 125 Turn the starter key to the ON position. Is the alternator recharge lamp ON? YES Start the engine and accelerate to 1200 Check the recharge system. Using a digital tester. CN2--15 (R) (wiring side) and the alterna- tor socket (W)? YES Replace the ECM. SECTION 21 -.TRANSMISSIONS -. . NO Replace the alternator. Check the wiring and eliminate the cause of Is there electrical continuity between pin NO the open circuit. NO Replace the lamp bulb. NO Does the fault persist? Is the recharge lamp OFF? YES YES Is wire (R) on the alternator socket (W) Connect the wire correctly NO correctly connected? YES Is the alternator socket (W) wire (R) in NO short to ground? YES Check the wiring and eliminate the cause of the short to ground. rpm. measure the fre- quency at the alternator output between the socket (W) and ground. Does the fault persist? YES Bring engine speed to 1000 rpm. Is the frequency ∼ 200 Hz? YES Disconnect the control panel and the con- nections (85) on the ECM.

CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 118 Art Shown As If Sitting In Operator’s Seat .126 SECTION 21 -.TRANSMISSIONS -.

CHAPTER 2 127 FAULT CODE 27 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 M (12) 1 ZN (2) 0. SECTION 21 -.5 R (15) 0.5 LN (8) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 VN (29) 1 N (14) 1 BG (28) 0.TRANSMISSIONS -.5 BG (7) 0.5 AB (20) 0.5 L (8) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 G (33) 85B 1 MN (34) 0.5 BC (13) 0.5 A (27) 1 N (16) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 MB (1) .5 RN (15) 0.5 V (19) 0.5 AN (26) 1 HM (25) 0.5 S (24) 0.5 LB (12) 0.

• Error code will remain active until a Clutch Pack Calibration procedure. • Clutch Pack (B) Calibration procedure. (H8). is completed. doesn’t display calibration values within range 230 to 480 mA. Tests: • H2. HF Menu. • During Clutch Pack (B) Calibration procedure.TRANSMISSIONS -.128 SECTION 21 -. NOTE: This error code will not be displayed during clutch calibration procedure. Effects: • Transmission is modified. (H1). • Clutch Pack (B) Calibration procedure. . using the CDU. Reverse will be affected by the poor performance of Clutch Pack (B). Use tool 294084 to access the H1 menu. • Faulty ECM. (H1) has not been performed after replacing the Clutch Pack (A and B) PWM Solenoids. (NVM). Causes: • Clutch Pack (B) Calibration procedure. Clutch Pack (B) Calibration values are corrupt in the Electrically Erased Programmable Read Only Memory. (H1) has not been performed after replacing a Power Shuttle ECM. (H1) a Calibration “U” Error occurs preventing the completion of a Calibration procedure. Recovery: • Cause must be resolved and error must be cleared using the CDU. “U” codes are used during H1 procedure for notification of incorrect calibration values. (H1). (EEPROM) and Non-Volatile Memory. Conditions: • While key switch is in the “ON” position the ECM detects that the Clutch Pack (B) is not calibrated. (H1) has not been performed after conducting a Non-Volatile Memory Erasure. [H8].CHAPTER 2 FAULT CODE 28 – CLUTCH PACK (B) NOT CALIBRATED.

CHAPTER 2 129 H1 H MENU 1 2 3 4 MDB0751A .TRANSMISSIONS -.SECTION 21 -.

(H1) has not been performed after replacing a Power Shuttle ECM. Forward will be affected by the poor performance of Clutch Pack (A). using the CDU. is completed. (H1). (EEPROM) and Non-Volatile Memory. NOTE: This error code will not be displayed during clutch calibration procedure.TRANSMISSIONS -. • Clutch Pack (A) Calibration procedure. • Faulty ECM. Causes: • Clutch Pack (A) Calibration procedure. . (H8).CHAPTER 2 FAULT CODE 29 – CLUTCH PACK (A) NOT CALIBRATED. Tests: • H2. [H8]. • Error code will remain active until a Clutch Pack Calibration procedure. HF Menu. (NVM). Use tool 294084 to access the H1 menu. doesn’t display calibration values within range 230 to 480 mA. • Clutch Pack (A) Calibration procedure. (H1) has not been performed after replacing the Clutch Pack (A and B) PWM Solenoids. (H1). (H1) a Calibration “U” Error occurs preventing the completion of a Calibration procedure. • During Clutch Pack (A) Calibration procedure. Conditions: • While key switch is in the “ON” position the ECM detects that the Clutch Pack (A) is not calibrated. Effects: • Transmission is modified.130 SECTION 21 -. Clutch Pack (A) Calibration values are corrupt in the Electrically Erased Programmable Read Only Memory. Recovery: • Cause must be resolved and error must be cleared using the CDU. “U” codes are used during H1 procedure for notification of incorrect calibration values. (H1) has not been performed after conducting a Non-Volatile Memory Erasure.

SECTION 21 -.TRANSMISSIONS -.CHAPTER 2 131 H1 H MENU 1 2 3 4 MDB0751A .

While the tractor is in neutral the Reverse (Shuttle) Synchronizer Solenoid has a short circuit. Recovery: • Cause must be resolved and error must be cleared using the CDU. but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal. • Transmission is disabled. pin 3 wires. Conditions: 1. • Faulty ECM. or across the two coil terminals. Reverse Side of the F/R Synchronizer Piston becomes inoperable. channel 13 value is below 0 counts. HF Menu. • Faulty Reverse (Shuttle) Synchronizer Solenoid Coil. pin 17 and ECM connector 1.TRANSMISSIONS -.CHAPTER 2 FAULT CODE 31 – REVERSE (SHUTTLE) SYNCHRONIZER SOLENOID COIL SHORT CIRCUIT. circuit shorted between ECM connector 1. If the Synchronizer was already in the reverse position then the tractor will move in reverse. (NOT USED TN Standard) NOTE: Error is only for 32x16. Tests: • H9. Causes: • Faulty wiring. Effects of Condition 1: • The Transmission Status Lamp is flashing. But once the Synchronizer is moved into the forward position it will not be able to shift it back into reverse. The Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. While the tractor is being driven in reverse the Reverse (Shuttle) Synchronizer Solenoid has a short circuit. 2. Effects of Condition 2: • Transmission is limited. . meaning the solenoid can not hydraulically pressurize and de-pressurize the piston. They will flash in a alternating manner.132 SECTION 21 -.

Check the wiring between pins CN1--17 (SN) and CN1--3 (SG) on connections (129) with pins (B4) (SN) and (C4) (SG) on connection (158).CHAPTER 2 133 Turn the starter key to the OFF position. short. measured with a digital tester. . SECTION 21 -. Is the solenoid valve coil electrical resistance. NO Replace the ECM.TRANSMISSIONS -. Does the fault persist? YES Disconnect the control panel and the connections (129) on the ECM. Replace the solenoid valve coil if in NO chroniser solenoid valve. cuit? YES Check the wiring between connection (65) on the solenoid valve and pins (B4) (SN) and (C4) (SG) on connection (158). Remove the rear left--hand wheel and the solenoid valves unit guard. Eliminate the cause of the short circuit. Disconnect connection (65) on the Shuttle syn. Eliminate the cause of the short circuit. ∼ 7 Ω? YES Are wires (SN) and (SG) (wiring side) in short cir.

134 SECTION 21 -.CHAPTER 2 PAGE LEFT BLANK .TRANSMISSIONS -.

5 L (8) 0.5 V (19) 0.5 G (33) 1 MN (34) 0.5 M (12) 1 ZN (2) 0.5 A (27) 1 N (16) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 LN (8) 0.5 R (15) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 1 SG (3) 0.5 HB (36) 1 BV (30) 1 N (13) 0.5 HR (11) 1 MN (10) 1 HG (21) 0. SECTION 21 -.5 BC (13) 0.5 S (24) 0.TRANSMISSIONS -.5 BG (7) 0.5 AB (20) 0.5 AN (26) 1 HM (25) 0.5 MB (1) 1 C (C5) 1 SG (C4) 1 AB (C6) 1 HL (C3) 1 HG (C7) 1 AV (C2) 1 AR (C8) 1 GR (C1) 158 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 GN (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HV (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 LB (12) 0.5 RN (15) 0.CHAPTER 2 135 FAULT CODE 31 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.

• Faulty ECM. But once the Synchronizer is moved into the Reverse position it will not be able to shift it back into forward. While the tractor is in neutral the Forward (Hi-Lo) Synchronizer Solenoid has a short circuit. While the tractor is being driven in forward the Forward (Hi-Lo) Synchronizer Solenoid has a short circuit. If the Synchronizer was already in the Forward position then the tractor will move in forward. pin 4 wires. meaning the solenoid can not hydraulically pressurize and de-pressurize the piston. Tests: • H9.CHAPTER 2 FAULT CODE 32 – FORWARD (HI-LO) SYNCHRONIZER SOLENOID COIL SHORT CIRCUIT. • Transmission is disabled. Causes: • Faulty wiring. or across the two coil terminals. HF Menu. Effects of Condition 2: • Transmission is limited. but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal. pin 16 and ECM connector 1. Effects of Condition 1: • The Transmission Status Lamp is flashing. circuit shorted between ECM connector 1. The Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps.136 SECTION 21 -. • Faulty Forward (Hi-Lo) Synchronizer Solenoid Coil. (NOT USED TN Standard) NOTE: Error is only for 32x16. They will flash in a alternating manner.TRANSMISSIONS -. 2. . channel 12 value is below 0 counts. Conditions: 1. Recovery: • Cause must be resolved and error must be cleared using the CDU. Forward Side of the F/R Synchronizer Piston becomes inoperable.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 137

Turn the starter key to the OFF position.
Remove the rear left--hand wheel and the solenoid
valves unit guard.
Disconnect connection (67) on the Shuttle syn- Replace the solenoid valve coil if in
NO
chroniser solenoid valve. short.
Is the electrical resistance of the solenoid valve
coil, measured with a digital tester, ∼ 7 Ω?
YES

Are wires (GN) and (GR) (wiring side) in short cir- NO Replace the ECM.
cuit?
YES

Check the wiring between connection (67) on the
solenoid valve and pins (B2) (GN) and (C1) (GR)
on connection (158).
Eliminate the cause of the short circuit.
Does the fault persist?
YES

Disconnect the control panel and the connections
(129) on the ECM.
Check the wiring between pins CN1--16 (GN) and
CN1--4 (GR) on connections (129) with pins (B2)
(GN) and (C1) (GR) on connection (158).
Eliminate the cause of the short circuit.

138 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

PAGE LEFT BLANK

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 139
FAULT CODE 32
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4)
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33)
1 MN (34)
0.5 HB (36)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)

1 C (C5) 1 SG (C4)
1 AB (C6) 1 HL (C3)
1 HG (C7) 1 AV (C2)
1 AR (C8) 1 GR (C1)

158

1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 GN (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HV (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)

140 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

FAULT CODE 33 – DUMP SOLENOID COIL SHORT CIRCUIT.
NOTE: On all Transmissions the Status Lamp (Gear with a Slash) will flash in a alternating manner.

Conditions:
1. While the tractor is being driven in forward or reverse the Dump Solenoid has a short circuit.
2. While the tractor is in neutral the Dump Solenoid has a short circuit.

Causes:
• Faulty wiring; circuit is shorted between ECM connector 1, pin 18 and ECM connector 1, pin 2 wires, or across
the two coil terminals.
• Faulty Dump Solenoid Coil.
• Faulty ECM.

Tests:
• No H Menu for diagnostic check.

Effects of Condition 1:
• The Transmission Status Lamp is flashing.
• Transmission is disabled, but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal.

Effects of Condition 2:
• Transmission is limited; Dump Solenoid stays energized, meaning the output signal from ECM, CN1-18
sends voltage to the input signal ECM, CN1-2 without going through the solenoid coil. The Clutch Packs (A
or B) can not be hydraulically de-presserised. Transmission will still operate by using other Clutch Pack
solenoids to bleed off hydraulic pressure when shuttle or speed shift is conducted.

Recovery:
• Cause must be resolved and error must be cleared using the CDU, HF Menu.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 141

Turn the starter key to the OFF position.
Remove the rear left--hand wheel and the solenoid
valves unit guard.
Disconnect connection (77) on the dump solenoid Replace the solenoid valve coil if in
NO
valve. short.
Is the electrical resistance of the solenoid valve
coil, measured with a digital tester, ∼ 7 Ω?
YES

Are wires (ZB) and (ZN) (wiring side) in short cir- NO Replace the ECM.
cuit?
YES

Check the wiring between connection (66) on the
solenoid valve and pins (B8) (ZB) and (B3) (ZN) on
connection (69).
Eliminate the cause of the short circuit.
Does the fault persist?
YES

Disconnect the control panel and the connections
(85) on the ECM.
Check the wiring between pins CN1--18 (ZB) and
CN1--2 (ZN) on connections (85) with pins (B8)
(ZB) and (B3) (ZN) on connection (69).
Eliminate the cause of the short circuit.

77

142 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

ECM PIN REFERENCE

PIN 1 PIN 1

CN1 CN2

PIN 7 PIN 13 PIN 13 PIN 25

50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B)

119
Art Shown As If Sitting In Operator’s Seat

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 143
FAULT CODE 33
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)

1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)

69

1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)

144 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

FAULT CODE 35 – DUMP SOLENOID OR ECM DRIVER SHORT CIRCUIT TO 12 VOLTS.

Conditions:
• While the tractor is being driven in forward or reverse, the Dump Solenoid becomes energized by a short
to 12 volts.

Causes:
• Faulty wiring; circuit short to 12 volts between ECM connector 1, pin 18 and the solenoid coil terminal, or
across solenoid coil terminals, or between ECM connector 1, pin 2 and solenoid coil terminal.
• Faulty Dump Solenoid Coil.
• Faulty ECM; internal ECM driver is shorted to 12 volts.

Tests:
• No H Menu for diagnostic check.

Effects:
• Dump Solenoid short circuit to 12 volts instead of being 0 volts; therefore keeping the Dump Solenoid
energized which causes Clutch Pack (A or B) to be de-pressurized.
• Transmission is critically disabled; but can be re-enabled by cycling the Ignition Switch, (shutting off the
tractor).

Recovery:
• Cause must be resolved and error must be cleared using the CDU, HF Menu.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 145

Turn the starter key to the OFF position.
Disconnect the control panel and the con-
nections (85) on the ECM. Is there a reading of +12V between pin
Turn the starter key to the ON position. NO CN1--2 (ZN) on connections (85) (wiring NO
Is there a reading of +12V between pin side) and ground?
CN1--18 (ZB) on connections (85) (wiring YES
side) and ground?
YES Check the wiring between CN1--2 (ZN) on
connections (85), pin (B3) (ZN) on connec-
Check the wiring between pin CN1--18 tion (69) and connection (77) on the sole-
(ZB) on connections (85), pin (B8) (ZB) on noid valve.
connection (69) and connection (77) on
the solenoid valve.
Eliminate the cause of the short circuit to
+12V. Replace the ECM.

77

146 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

ECM PIN REFERENCE

PIN 1 PIN 1

CN1 CN2

PIN 7 PIN 13 PIN 13 PIN 25

50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B)

120
Art Shown As If Sitting In Operator’s Seat

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 147
FAULT CODE 35
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)

1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)

69

1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)

148 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

FAULT CODE 36 – DUMP SOLENOID SHORT CIRCUIT TO GROUND OR OPEN CIRCUIT OR
ECM DRIVER OPEN.
NOTE: On all Transmissions the Status Lamp (Gear with a Slash) will flash in a alternating manner.

Conditions:
1. While the tractor is being driven in forward or reverse, the Dump Solenoid has a short to ground or open
circuit.
2. While the tractor is in neutral the Dump Solenoid has a short to ground or open circuit.

Causes:
• Faulty wiring; circuit short to ground or open between ECM connector 1, pin 18 and the solenoid coil terminal,
or across the two coil terminals, or between ECM connector 1, pin 2 and the solenoid coil terminal.
• Faulty Dump Solenoid Coil.
• Faulty ECM; internal ECM driver is open or short to ground.

Tests:
• No H Menu for diagnostic check.

Effects of Condition 1:
• The Transmission Status Lamp is flashing.
• Transmission is disabled, but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal.

Effects of Condition 2:
• Transmission is limited; Dump Solenoid stays de-energized. The Clutch Packs (A or B) can not be
hydraulically de-pressurized. Transmission will still operate by using other Clutch Pack solenoids to bleed
off hydraulic pressure when shuttle or speed shift is conducted.

Recovery:
• Cause must be resolved and error must be cleared using the CDU, HF Menu.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 149

Check the wiring and eliminate the cause of
Turn the starter key to the OFF position. the open circuit.
Remove the rear left--hand wheel and the
solenoid valves unit guard.
Disconnect connection (77) on the dump Replace the solenoid valve coil if inter-
NO
solenoid valve. rupted.
Using a digital tester, measure the electri-
cal resistance of the solenoid valve coil.
Is the resistance ∼ 7.5 Ω?
YES
Disconnect the control panel and the con-
Is wire (ZB) on the solenoid valve wiring in NO nections (85) on the ECM.
NO
short to ground? Is wire (ZN) on the solenoid valve wiring in
YES short to ground?
YES
Check the wiring and eliminate the cause
of the short to ground?

Lift the engine bonnet and disconnect con-
nection (69).
Is there electrical continuity between pin NO
(B8) (ZB) and connection (77) on the sole-
noid valve?
YES

Is there electrical continuity between pin
NO
(B3) (ZN) and connection (77) on the sole-
77 noid valve?
YES

Is there electrical continuity between pin
CN1--18 (ZB) on connections (85) and pin
(B8) (ZB) on connection (69)? NO
YES

Is there electrical continuity between pin
CN1--2 (ZN) on connections (85) and pin NO
(B3) (ZN) on connection (69)?
YES

Replace the ECM.

150 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

ECM PIN REFERENCE

PIN 1 PIN 1

CN1 CN2

PIN 7 PIN 13 PIN 13 PIN 25

50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B)

121
Art Shown As If Sitting In Operator’s Seat

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 151
FAULT CODE 36
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)

1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)

69

1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)

152 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

FAULT CODE 37 – CLUTCH PEDAL SWITCH (1) OPEN CIRCUIT.
NOTE: This error may be triggered by Error Code 11.

NOTE: On all Transmissions the Status Lamp (Gear with a Slash) will flash in a alternating manner.

Conditions:
• For 1 second, when Clutch Pedal is released, (switch closed), the Clutch Pedal Potentiometer is above 30%,
while Power Shuttle FNR Lever is not in neutral, (Voltage is being supplied to ECM connector 2, pin 18), and
with 12 volts not present at ECM connector 1, pin 15.

Causes:
• Faulty wiring; circuit open between ECM connector 1, pin 15 and Clutch Pedal Switch.
• Faulty Clutch Pedal Switch (1).
• Clutch Pedal Switch (1) is sticking, (cold weather condition).
• Clutch Pedal Switch (1) is miss adjusted.

Tests:
• H9, channel 4 is too low.
• H5, does not change from “d0” to “d21”.
• HA, doesn’t display correct values.

Effects:
• The Transmission Status Lamp is flashing.
• Transmission is disabled, but can be re-enabled by cycling the Clutch Pedal.

Recovery:
• Cause must be resolved and error must be cleared using the CDU, HF Menu.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 153

(Clutch pedal double switch 1)
Turn the starter key to the OFF position.
Remove the left--hand panel under the dashboard. Connect the connection and/or wiring.
Is connection (86) and/or the switch wiring con- NO
nected?
YES

Disconnect connection (86) on the switch.
Using a digital tester, check the double switch. NO Replace the switch.
Does it work?
YES

Disconnect the control panel and the connections
(85) on the ECM.
Check the wiring and eliminate the
Is there electrical continuity between pin CN1--15 NO
cause of the open circuit.
(RN) on connections (85) and connection (86) on
the switch?
YES

Replace the ECM.

1

50025110

154 SECTION 21 -.CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 122 Art Shown As If Sitting In Operator’s Seat .TRANSMISSIONS -.

5 V (19) 0.CHAPTER 2 155 FAULT CODE 37 86 1 ZB (18) 1 SN (17) 1 GN (16) 0.TRANSMISSIONS -.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 LB (12) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 M (12) 1 ZN (2) 0.5 MB (1) .5 AN (26) 1 HM (25) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 BC (13) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 L (8) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 AB (20) 0.5 LN (8) 0.5 A (27) 1 N (16) 0. SECTION 21 -.5 G (33) 85B 1 MN (34) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 RN (15) 0.5 R (15) 0.5 S (24) 0.5 BG (7) 0.

Causes: • Faulty wiring. (neutral PS FNR Lever or depressed Clutch Pedal). but can be re-enabled by cycling the Ignition Switch. pin 11 and the solenoid coil terminal or across solenoid coil terminals. pin 5 and solenoid coil terminal.156 SECTION 21 -. • Faulty ECM. Tests: • H9. (shutting off tractor). internal ECM driver is shorted to 12 volts. Effects: • The Clutch Pack (B) PWM Solenoid Coil remains energized. keeping clutch engaged. Conditions: • While tractor is being operated the Clutch Pack (B) Pulse Width Modulated Solenoid becomes energized by a short circuit to 12 volts.TRANSMISSIONS -. or between ECM connector 1.CHAPTER 2 FAULT CODE 38 – CLUTCH PACK (B) PULSE WIDTH MODULATED SOLENOID OR ECM DRIVER SHORT CIRCUIT TO 12 VOLTS. . • Faulty Clutch Pack (B) PWM Solenoid Coil. The transmission is disabled to ensure the operator is not placed in a dangerous situation where the tractor can not be stopped. circuit shorted to 12 volts between ECM connector 1. Non authorized 12 volt can only be stopped by activating the Dump Solenoid. Channel 7 value stays constant and is above 480 counts. HF Menu. • Transmission is critically disabled. Recovery: Cause must be resolved and error must be cleared using the CDU.

Eliminate the cause of the short circuit to +12V. Is there a reading of +12V between pin Turn the starter key to the ON position. pin (A8) (BR) on connec- Check the wiring between pin CN1--11 tion (69) and connection (74) on the sole- (BN) on connections (85). Replace the ECM. pin (A5) (BN) noid valve.CHAPTER 2 157 Turn the starter key to the OFF position.TRANSMISSIONS -. SECTION 21 -. Disconnect the control panel and the con- nections (85) on the ECM. on connection (69) and connection (74) on the solenoid valve. NO CN1--5 (BR) on connections (85) (wiring NO Is there a reading of +12V between pin side) and ground? CN1--11 (11) (BN) on connections (85) YES (wiring side) and ground? YES Check the wiring between CN1--5 (BR) on connections (85). 74 .

158 SECTION 21 -.CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 123 Art Shown As If Sitting In Operator’s Seat .TRANSMISSIONS -.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 159
FAULT CODE 38
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)

1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)

69

1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)

160 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

FAULT CODE 39 – CLUTCH PACK (B) PULSE WIDTH MODULATED SOLENOID SHORT
CIRCUIT TO GROUND OR OPEN CIRCUIT OR ECM DRIVER OPEN.
NOTE: On all Transmissions the Status Lamp (Gear with a Slash) will flash in a alternating manner.

Conditions:
1. While tractor is being driven Reverse, the Clutch Pack (B) PWM Solenoid has a short to ground or open
circuit.
2. While tractor is being driven Forward, the Clutch Pack (B) PWM Solenoid has a short to ground or open
circuit.

Causes:
• Faulty wiring; circuit is short to ground or open between ECM connector 1, pin 11 and the solenoid coil
terminal, or across the two solenoid coil terminals, or between ECM connector 1, pin 5 and the solenoid coil
terminal.
• Faulty Clutch Pack (B) PWM Solenoid Coil.
• Faulty ECM; internal ECM driver is open or short to ground.

Tests:
• H9, Channel 7 value is below 200 counts

Effects of Condition 1:
• The Transmission Status Lamp is flashing.
• Transmission is disabled, but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal.

Effects of Condition 2:
• Transmission is limited; Clutch Pack (B) becomes inoperable; meaning the PWM Solenoid can not
hydraulically pressurize and de-pressurize the Clutch Pack. Transmission will only operate in Forward.

Recovery:
• Cause must be resolved and error must be cleared using the CDU, HF Menu.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 161

Turn the starter key to the OFF position. Check the wiring and eliminate the cause of
Remove the rear left--hand wheel and the the open circuit.
solenoid valves unit guard.
Disconnect connection (74) on the clutch
solenoid valve (B). Replace the solenoid valve coil if inter-
NO
Using a digital tester, measure the electri- rupted.
cal resistance of the solenoid valve coil.
Is the resistance ∼ 10 Ω?
YES
Disconnect the control panel and the con-
Is wire (BN) on the solenoid valve wiring nections (85) on the ECM.
NO NO
in short to ground? Is wire (BR) on the solenoid valve wiring in
YES short to ground?
YES
Check the wiring and eliminate the cause
of the short to ground?
Lift the engine bonnet and disconnect con-
nection (69).
Is there electrical continuity between pin
(A5) (BN) and connection (74) on the sole- NO
noid valve?
YES

Is there electrical continuity between pin
(A8) (BR) and connection (74) on the sole- NO
noid valve?
YES

Is there electrical continuity between pin
CN1--11 (BN) on connections (85) and pin NO
(A5) (BN) on connection (69)?
74 YES

Is there electrical continuity between pin
CN1--5 (BR) on connections (85) and pin NO
(A8) (BR) on connection (69)?
YES

Replace the ECM.

162 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

ECM PIN REFERENCE

PIN 1 PIN 1

CN1 CN2

PIN 7 PIN 13 PIN 13 PIN 25

50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B)

124
Art Shown As If Sitting In Operator’s Seat

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 163
FAULT CODE 39
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)

1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)

69

1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)

164 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

FAULT CODE 41 – CLUTCH PACK (A) PULSE WIDTH MODULATED SOLENOID SHORT
CIRCUIT TO GROUND OR OPEN CIRCUIT OR ECM DRIVE OPEN.
NOTE: On all Transmissions the Status Lamp (Gear with a Slash) will flash in a alternating manner.

Conditions:
1. While tractor is being driven Lo-Forward, the Clutch Pack (A, Lo-Forward) PWM Solenoid has a short to
ground or open circuit.
2. While tractor is being driven Hi-Forward or Reverse, the Clutch Pack (A, Lo-Forward) PWM Solenoid has
a short to ground or open circuit.

Causes:
• Faulty wiring; circuit short to ground or open between ECM connector 1, pin 10 and the solenoid coil terminal,
or across the two solenoid coil terminals, or between ECM connector 1, pin 6 and the solenoid coil terminal.
• Faulty Clutch Pack (A, Lo-Forward) PWM Solenoid Coil.
• Faulty ECM; internal ECM Driver is open or short to ground.

Tests:
• H9, Channel 8 value is below 200 counts

Effects of Condition 1:
• The Transmission Status Lamp is flashing.
• Clutch Pack (A) becomes inoperable; meaning the PWM Solenoid can not hydraulically pressurize and
de-pressurize the Clutch Pack.
• Transmission is disabled, but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal.

Effects of Condition 2:
• Transmission is limited; Clutch Pack (A) becomes inoperable; meaning the PWM Solenoid can not
hydraulically pressurize and de-pressurize the Clutch Pack. Transmission will only operate in Hi-Forward or
Reverse.

Recovery:
• Cause must be resolved and error must be cleared using the CDU, HF Menu.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 165

Turn the starter key to the OFF position. Check the wiring and eliminate the cause of
Remove the rear left--hand wheel and the the open circuit.
solenoid valves unit guard.
Disconnect connection (75) on the clutch Replace the solenoid valve coil if inter-
NO
solenoid valve (A). rupted.
Using a digital tester, measure the electri-
cal resistance of the solenoid valve coil.
Is the resistance ∼ 10 Ω?
YES
Disconnect the control panel and the con-
Is wire (AR) on the solenoid valve wiring nections (85) on the ECM.
NO NO
in short to ground? Is wire (AN) on the solenoid valve wiring in
YES short to ground?
YES
Check the wiring and eliminate the cause
of the short to ground?

Lift the engine bonnet and disconnect con-
nection (69).
Is there electrical continuity between pin NO
(C8) (AR) and connection (75) on the sole-
noid valve?
YES

Is there electrical continuity between pin
(B7) (AN) and connection (75) on the sole- NO
noid valve?
YES

Is there electrical continuity between pin
CN1--10 (AR) on connections (85) and pin
(C8) (AR) on connection (69)? NO

75 YES

Is there electrical continuity between pin
CN1--6 (AN) on connections (85) and pin NO
(B7) (AN) on connection (69)?
YES

Replace the ECM.

166 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

ECM PIN REFERENCE

PIN 1 PIN 1

CN1 CN2

PIN 7 PIN 13 PIN 13 PIN 25

50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B)

125
Art Shown As If Sitting In Operator’s Seat

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 167
FAULT CODE 41
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)

1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)

69

1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)

168 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

FAULT CODE 42 – CLUTCH PACK (A) PULSE WIDTH MODULATED SOLENOID OR ECM
DRIVER SHORT CIRCUIT TO 12 VOLTS.

Conditions:
• While tractor is being operated the Clutch Pack (A) Pulse Width Modulated Solenoid becomes energized
by a short circuit to 12 volts.

Causes:
• Faulty wiring; circuit shorted to 12 volts between ECM connector 1, pin 10 and the solenoid coil terminal or
across solenoid coil terminals, or between ECM connector 1, pin 6 and solenoid coil terminal.
• Faulty Clutch Pack (A) PWM Solenoid Coil.
• Faulty ECM; internal ECM driver is shorted to 12 volts.

Tests:
• H9, Channel 8 value stays constant and is above 480 counts.

Effects:
• The Clutch Pack (A) PWM Solenoid Coil remains energized, keeping clutch engaged. Non authorized 12
volt can only be stopped by activating the Dump Solenoid, (neutral PS FNR Lever or depressed Clutch
Pedal). The transmission is disabled to ensure the operator is not placed in a dangerous situation where the
tractor can not be stopped.
• Transmission is critically disabled, but can be re-enabled by cycling the Ignition Switch, (shutting off tractor).

Recovery:
• Cause must be resolved and error must be cleared using the CDU, HF Menu.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 169

Turn the starter key to the OFF position.
Disconnect the control panel and the con-
nections (85) on the ECM. Is there a reading of +12V between pin
Turn the starter key to the ON position. NO CN1--6 (AN) on connections (85) (wiring NO
Is there a reading of +12V between pin side) and ground?
CN1--10 (AR) on connections (85) (wiring YES
side) and ground?
YES Check the wiring between CN1--6 (AN) on
connections (85), pin (B7) (AN) on connec-
Check the wiring between pin CN1--10 tion (69) and connection (75) on the sole-
(AR) on connections (85), pin (C8) (AR) noid valve.
on connection (69) and connection (75) on
the solenoid valve.
Eliminate the cause of the short circuit to
+12V. Replace the ECM.

75

170 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

ECM PIN REFERENCE

PIN 1 PIN 1

CN1 CN2

PIN 7 PIN 13 PIN 13 PIN 25

50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B)

126
Art Shown As If Sitting In Operator’s Seat

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 171
FAULT CODE 42
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4) 85A
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33) 85B
1 MN (34)
0.5 HB (36) SN (31)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)

1 GN (C5) 1 BV (C4)
1 AB (C6) 1 B (C3)
1 HL (C7) 1 S (C2)
1 BR (C8) 1 G (C1)

69

1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 H (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HG (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)

172 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

FAULT CODE 43 – SYNCHRONIZER SHUTTLE (REVERSE) POSITION SWITCH (T) SIGNAL
VOLTAGE SHORT TO 5 OR 12 VOLTS.

(NOT USED TN Standard)
NOTE: On a 32x16 the Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. They will flash in a
alternating manner. On 16x16 & 8x8 the Transmission Status Lamp is the Gear with a Slash lamp. It will flash.

NOTE: On the 32x16 transmission, the Synchronizer Shuttle (Reverse) and Hi-Lo (Forward) Position Switches
are located on the left side of the transmission between the Power Shuttle Control Valve and the Service Control
Valve. The Synchronizer Shuttle (Reverse) Position Switch is toward the rear of the tractor. The Synchronizer
Hi-Lo (Forward) Position Switch is toward the front of the tractor.

Conditions:
1. While the Power Shuttle FNR Lever is in the reverse position, voltage at the ECM connector 2, pin 23 is above
4.2 volts.
2. While the Power Shuttle FNR Lever is in the neutral position, voltage at the ECM connector 2, pin 23 is above
4.2 volts.

Causes:
• Faulty wiring; short to 12 volts between ECM connector 2, pin 20 and Synchronizer Shuttle (Reverse)
Position Switch, or short to 5 v across switch terminals, or short to 5 or 12 v between Synchronizer Shuttle
(Reverse) Position Switch and ECM connector 2, pin 23. Or common 5 volt sensor supply wire from ECM
connector 2, pin 20 is shorted to 12v between switch and any other 5 volt sensor.
• Faulty Synchronizer Shuttle (Reverse) Position Switch (T).
• Faulty ECM.

Tests:
• H9, channel 6 is above 860 counts.
• H5 doesn’t display “d27”.
• HD displays “unkn”.

Effects of Condition 1:
• The Transmission Status Lamp is flashing.
• Transmission is disabled, but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal.

Effects of Condition 2:
• Transmission is limited; only Synchronizer Hi-Lo (Forward) Position Switch is available (forward movement).
Any shuttle into reverse will not work. Transmission is neutralized whenever Power Shuttle FNR is put into
reverse position. Then ECM will look for detection of Synchronizer Hi-Lo (Forward) Position Switch and move
synchronizer to forward position.

Recovery:
• Cause must be resolved and error must be cleared using the CDU, HF Menu.

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 173

Turn the starter key to the OFF position.
Remove the rear left--hand wheel and the solenoid
valves unit guard.
Disconnect connection (59) on pushbutton. NO If in short, replace the pushbutton.
Using a digital tester, measure the electrical resist-
ance on the pushbutton.
Is the resistance 500 ÷ 3000 Ω?
YES

Are wires (AB) and (HL) (wiring side) in short cir- NO Replace the ECM.
cuit?
YES

Check the wiring between connection (59) on
pushbutton , pin (C3) (HL) and pin (C6) (AB) on
connection (158).
Eliminate the cause of the short circuit.
Does the fault persist?
YES

Disconnect the control panel and the connections
(129) on the ECM.
Check the wiring between pin CN2--23 (HL) on
connections (129) and pin (C3) (HL) on connection
(158) or between pin CN2--20 (AB) and pin (C6)
(AB).
Eliminate the cause of the short circuit.

59

0,5 AB

0,5 HL

174 SECTION 21 -- TRANSMISSIONS -- CHAPTER 2

PAGE LEFT BLANK

SECTION 21 -- TRANSMISSIONS -- CHAPTER 2 175
FAULT CODE 43
1 ZB (18)
1 SN (17)
1 GN (16)
0.5 RN (15)
0.5 BC (13)
0.5 BG (7)
0.5 LN (8) 0.5 AG (9)
1 AN (6) 1 AR (10)
1 BR (5) 1 BN (11)
1 GR (4)
1 SG (3) 0.5 M (12)
1 ZN (2)
0.5 G (33)
1 MN (34)
0.5 HB (36)
1 BV (30)
1 N (13) 0.5 VN (29)
1 N (14) 1 BG (28)
0.5 R (15) 0.5 A (27)
1 N (16) 0.5 AN (26)
1 HM (25)
0.5 LB (12)
0.5 HR (11)
1 MN (10) 1 HG (21)
0.5 LR (9) 1 AV (22)
1 HL (23)
0.5 L (8) 0.5 S (24)
0.5 AB (20)
0.5 V (19)
0.5 B (18)
1 GL (4)
1 C (3)
1 HV (2)
0.5 MB (1)

1 C (C5) 1 SG (C4)
1 AB (C6) 1 HL (C3)
1 HG (C7) 1 AV (C2)
1 AR (C8) 1 GR (C1)

158

1 ZB (B8) 1 N (B1)
1 BR (A8) 1 MB (A1)
1 AN (B7) 1 GN (B2)
1 GL (A7) 1 HM (A2)
1 VN (B6) 1 ZN (B3)
1 HV (A3)
1 BG (B5) 1 SN (B4)
1 BN (A5)

Any shuttle into reverse will not work. • Transmission is disabled. only Synchronizer Hi-Lo (Forward) Position Switch is available (forward movement). On 16x16 & 8x8 the Transmission Status Lamp is the Gear with a Slash lamp. While the Power Shuttle FNR Lever is in the neutral position. Conditions: 1. channel 6 is below 143 counts. voltage at the ECM connector 2. They will flash in a alternating manner. pin 23 is below 0. It will flash. Causes: • Faulty wiring. or between Synchronizer Shuttle (Reverse) Position Switch and ECM connector 2. Or common 5 volt sensor supply wire from ECM connector 2. Recovery: • Cause must be resolved and error must be cleared using the CDU. pin 20 and Synchronizer Shuttle (Reverse) Position Switch. voltage at the ECM connector 2. While the Power Shuttle FNR Lever is in the reverse position. • Faulty ECM. Effects of Condition 2: • Transmission is limited. pin 20 is shorted to ground or open between switch and any other 5 volt sensor. NOTE: On the 32x16 transmission.CHAPTER 2 FAULT CODE 44 – SYNCHRONIZER SHUTTLE (REVERSE) POSITION SWITCH (T) SIGNAL VOLTAGE IS SHORT TO GROUND OR OPEN CIRCUIT. Effects of Condition 1: • The Transmission Status Lamp is flashing. (NOT USED TN Standard) NOTE: On a 32x16 the Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. circuit shorted to ground or open between ECM connector 2. • H5 doesn’t display “d27”.7 volts. Transmission is neutralized whenever Power Shuttle FNR is put into reverse position. Then ECM will look for detection of Synchronizer Hi-Lo (Forward) Position Switch and move synchronizer to forward position. • HD displays “unkn”. or between switch terminals.176 SECTION 21 -. but can be re-enable by cycling the Power Shuttle FNR Lever or Clutch Pedal. 2. pin 23.7 volts. The Synchronizer Hi-Lo (Forward) Position Switch is toward the front of the tractor. the Synchronizer Shuttle (Reverse) and Hi-Lo (Forward) Position Switches are located on the left side of the transmission between the Power Shuttle Control Valve and the Service Control Valve. The Synchronizer Shuttle (Reverse) Position Switch is toward the rear of the tractor.TRANSMISSIONS -. Tests: • H9. . HF Menu. • Faulty Synchronizer Shuttle (Reverse) Position Switch (T). pin 23 is below 0.

pin (C3) (HL) on connection (158) nection (59) on pushbutton (AB) and pin NO and pin CN2--23 (HL) on connections (C6) (AB) on connection (158)? (129).CHAPTER 2 177 Check the wiring and eliminate the cause of the open circuit. Check the wiring between connection Is there electrical continuity between con- (59).5 AB 0. cal resistance on the pushbutton. YES Eliminate the cause of the short to ground. Is the resistance 500 ÷ 3000 Ω? YES Raise the engine hood. measure the electri. Turn the starter key to the OFF position. YES tions (129) on the ECM. Is wire (HL) (wiring side) in short to NO Is there electrical continuity between con. NO ground? nection (59) on pushbutton (HL) and pin YES (C3) (HL) on connection (158)? Disconnect the control panel and connec. NO Replace the pushbutton if interrupted.5 HL . Disconnect connection (158). Remove the rear left--hand wheel and the solenoid valves unit guard. Is there electrical continuity between pin NO CN2--23 (HL) on connections (129) and pin (C3) (HL) on connection (158)? YES Is there electrical continuity between pin CN2--20 (AB) on connections (129) and pin NO (C6) (AB) on connection (158)? YES Replace the ECM.TRANSMISSIONS -. SECTION 21 -. Using a digital tester. Is the wiring and connection (59) on the pushbutton connected? YES Disconnect connection (59) on the push- button. 59 0. Disconnect the control panel and connec- tions (129) on the ECM. NO Connect the connection and/or wiring.

CHAPTER 2 PAGE LEFT BLANK .TRANSMISSIONS -.178 SECTION 21 -.

5 G (33) 1 MN (34) 0.5 BC (13) 0.5 R (15) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.CHAPTER 2 179 FAULT CODE 44 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 RN (15) 0.5 AB (20) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 AN (26) 1 HM (25) 0. SECTION 21 -.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 1 SG (3) 0.5 HB (36) 1 BV (30) 1 N (13) 0.5 V (19) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 BG (7) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 MB (1) 1 C (C5) 1 SG (C4) 1 AB (C6) 1 HL (C3) 1 HG (C7) 1 AV (C2) 1 AR (C8) 1 GR (C1) 158 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 GN (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HV (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 LN (8) 0.5 S (24) 0.5 L (8) 0.5 M (12) 1 ZN (2) 0.5 LB (12) 0.TRANSMISSIONS -.5 A (27) 1 N (16) 0.

• Faulty ECM. channel 15 is below 428. pin 1 is low while voltage at ECM connector 2. pin 1 circuit. The circuit is keyed 12 volts. . • H5. pin 10 is high. Recovery: • Cause must be resolved and error must be cleared using the CDU.180 SECTION 21 -. The actual fuse number is 15.TRANSMISSIONS -. ECM Calibration / Diagnostic Unit (CDU) will not work. Effects: • Transmission will be limited. Cause: • Faulty wiring. circuit open between battery and key switch or between key switch and fuse. or across fuse. Conditions: • When tractor on. • Faulty Fuse. The fuse is a 5 amp. won’t show “d20”. or between fuse and ECM connector 2. pin 1. ECM detects voltage at ECM connector 2.CHAPTER 2 FAULT CODE 46 – FUSE ERROR NOTE: This fuse protects the ECM connector 2. Tests: • H9. HF Menu.

5 MB (1) .5 RN (15) 0.5 V (19) 0. Turn the starter key to the ON position. der the control panel. Chapter 5.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 BG (7) 0. Remove the left--hand guard located un.5 AN (26) 1 HM (25) 0.CHAPTER 2 181 Disconnect the control panel and the con- Turn the starter key to the OFF position.5 S (24) 0.5 AB (20) 0. page CN2--21 (HG) on connections (85) and 2 blown)? ground? YES YES Replace the fuse.5 A (27) 1 N (16) 0. nections (85) on the ECM. Eliminate the cause of the open circuit.5 G (33) 85B 1 MN (34) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 LB (12) 0.5 L (8) 0.5 HR (11) 1 MN (10) 1 HG (21) 0. 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 M (12) 1 ZN (2) 0.5 BC (13) 0.TRANSMISSIONS -.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0. NO Is there a reading of +12V between pin NO Is fuse F15 (Section 55.5 LN (8) 0.5 R (15) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0. Check the wiring between connection (85) and the fusebox. Replace the ECM. SECTION 21 -.

Recovery: • Cause must be resolved and error must be cleared using the CDU. pin 15. won’t show “d21”. (Error Code 37.182 SECTION 21 -. Conditions: • For 1 second. with the clutch pedal released and the clutch pedal switch isn’t open. • H5. Tests: • H9. HF Menu. • Improperly adjusted switch (1). pin 18 should have 12 volts). (Error Code 37. when pedal is released). channel 1 is higher than 542 during release. while the Power Shuttle FNR lever not in neutral. pin 15 should have 12 volts).CHAPTER 2 FAULT CODE 47 – CLUTCH PEDAL SWITCH (1) SET TOO HIGH. when pedal is released). clutch pedal inching maneuver may be jerky and occur at a higher clutch pedal position. when Clutch Pedal Potentiometer is above 15%. the Clutch Pedal Switch (1) changes from off to on after 15%. open circuit between Power Shuttle FNR Lever. during clutch pedal release. Effects: • Transmission is modified. (neutral switch) and ECM connector 1. . • HA. Causes: • Faulty wiring.TRANSMISSIONS -. (ECM connector 1. (ECM connector 2. • Faulty Clutch Pedal Switch (1).

NO NO Move the Shuttle lever to forward gear Is the wiring and connection (86) con- and fully press down the clutch pedal. NO Does it work? YES Disconnect the control panel and the con- nections (85) on the ECM. YES Replace the ECM. Replace the switch.TRANSMISSIONS -.CHAPTER 2 183 (Clutch pedal double switch 1) Connect the connection and/or wiring. nected? When the clutch pedal is released. Remove the left--hand panel under the tion. lease slowly. 1 50025110 . so that the message switches be- “ON” in correspondence to a percentage tween “OFF” and “ON” in correspondence value of 10 to 15? to a set value (10 to 15 %). Check the wiring and eliminate the cause of the open circuit. press the H MENU key and turn the starter switch to the ON posi. Is there electrical continuity between pin NO CN1--15 (RN) on connections (85) and con- nection (86) on the switch? YES Remove the left--hand panel under the Press the clutch pedal fully down and re. dashboard. then select the HA MENU. Position the double switch on the relative The message switches from “OFF” a NO slots. Connect tool 294084 to the diagnosis socket (black). SECTION 21 -. the YES message switches from “OFF” to “ON”? YES Disconnect connection (86) on the switch and check. dashboard.

TRANSMISSIONS -.CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 127 Art Shown As If Sitting In Operator’s Seat .184 SECTION 21 -.

5 BG (7) 0.5 R (15) 0.TRANSMISSIONS -.5 S (24) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 VN (29) 1 N (14) 1 BG (28) 0.CHAPTER 2 185 FAULT CODE 47 86 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 AB (20) 0.5 MB (1) .5 L (8) 0.5 RN (15) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 LN (8) 0.5 M (12) 1 ZN (2) 0.5 A (27) 1 N (16) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 LB (12) 0.5 G (33) 85B 1 MN (34) 0. SECTION 21 -.5 V (19) 0.5 BC (13) 0.5 AN (26) 1 HM (25) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.

circuit short to 12 volts between Power Shuttle FNR Lever. Recovery: • Cause must be resolved and error must be cleared using the CDU. (ECM connector 2. the Clutch Pedal Switch (1) changes from on to off after 5%. won’t show “d21”. (neutral switch) and ECM connector 1. .CHAPTER 2 FAULT CODE 48 – CLUTCH PEDAL SWITCH (1) SET TOO LOW. with the clutch pedal depressed and the clutch pedal switch is open. pin 15 shouldn’t have 12 volts).186 SECTION 21 -. channel 1 is lower than 38 during depression. • HA. during clutch pedal depression. pin 15. • H5. while the Power Shuttle FNR lever in neutral. The Power Shuttle FNR Lever will have to be used to make tractor move. when Clutch Pedal Potentiometer is below 5%.TRANSMISSIONS -. (ECM connector 1. pin 18 shouldn’t have 12 volts). • Improperly adjusted / sticky switch (1). Conditions: • For 1 second. Causes: • Faulty wiring. • Faulty Clutch Pedal Switch (1). (de-energize the clutch pack solenoids). Tests: • H9. HF Menu. Effects: • No effect to normal operation except using the clutch pedal will not neutralize the transmission.

NO ative slots.TRANSMISSIONS -. switches from “ON” to “OFF” in correspondence to a percentage value of 5 to 8? YES Replace the ECM. then select the HA the dashboard. Position the double switch on the rel- Move the Shuttle lever to forward gear. press the H MENU key and turn the starter Remove the left--hand panel under switch to the ON position. SECTION 21 -. the message 8%).CHAPTER 2 187 (Clutch pedal double switch 1) Connect tool 294084 to the diagnosis socket (black). MENU. the percentage switches between “ON” and “OFF” in value displayed is∼ 100 with the “ON” message. so that the message Press and release the clutch pedal. correspondence to a set value (5 to By slowly pressing the clutch pedal. 1 HA H MENU 1 2 3 4 MDB0751A 50025110 .

. • Faulty ECM. or short to 5v across sensor terminals. or short to 5 or 12v between Wheel Speed Sensor (Aa) and ECM connector 2. channel 19 is above 3000 counts. • H5. Acceleration or tractor movement may not be sensed by ECM during Automatic Take Off (ATO). Causes: • Faulty wiring.188 SECTION 21 -.TRANSMISSIONS -. • Faulty Wheel Speed Sensor.CHAPTER 2 FAULT CODE 49 – WHEEL SPEED SENSOR (Aa) VOLTAGE SHORT TO 5 OR 12 VOLTS. Power Shuttle FNR lever may not shuttle directions correctly. Conditions: • The ECM detects voltage is above 4. pin 36 and Wheel Speed Sensor (Aa) terminal. pin 29. doesn’t display “d35”. Tests: • H9. Recovery: • Cause must be resolved and error must be cleared using the CDU.25 volts at ECM connector 2. pin 36. HF Menu. circuit shorted to 12 volts between ECM connector 2. Effects: • Transmission is modified.

(VN) (wiring side) on connections (85) and ground? YES (Speed sensor Aa) Check the wiring and eliminate the cause of the short to +12V. NO Connect the connection and/or Is connection (76) and the sensor wiring con. nected? YES Disconnect sensor connection (76). cal resistance. Is the resistance ∼ 700 Ω? YES Raise the engine hood. nection (69)? YES Is there electrical continuity between connection (76) (VN) on the sensor and pin (A4) (VN) on con. Is there a reading of +12V between pin CN2--29 NO Replace the ECM. cause of the open circuit. Is there electrical continuity between pin (B3) (HB) NO on connection (69) and pin CN2--36 (HB) on con- nections (85)? YES Is there electrical continuity between pin (A4) (VN) on connection (69) and pin CN2--29 (VN) on con.TRANSMISSIONS -. SECTION 21 -. NO Replace the sensor if interrupted. wiring. Is there electrical continuity between connection NO Check the wiring and eliminate the (76) (HB) on the sensor and pin (B3) (HB) on con.CHAPTER 2 189 Turn the starter key to the OFF position. Remove the rear left--hand wheel. 76 VN . NO nection (69)? YES Disconnect the control panel and the connections (85) on the ECM. NO nections (85)? YES Turn the starter key to the ON position. measure the sensor electri. Using a digital tester.

CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 128 Art Shown As If Sitting In Operator’s Seat .TRANSMISSIONS -.190 SECTION 21 -.

5 LB (12) 0.5 G (33) 85B 1 MN (34) 0. SECTION 21 -.CHAPTER 2 191 FAULT CODE 49 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 RN (15) 0.5 LN (8) 0.5 A (27) 1 N (16) 0.5 BC (13) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 M (12) 1 ZN (2) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 BG (7) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 S (24) 0.TRANSMISSIONS -.5 R (15) 0.5 AN (26) 1 HM (25) 0.5 AB (20) 0.5 MB (1) 1 GN (C5) 1 BV (C4) 1 AB (C6) 1 B (C3) 1 HL (C7) 1 S (C2) 1 BR (C8) 1 G (C1) 69 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 H (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HG (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 L (8) 0.5 V (19) 0.

then cause must be resolved and error must be cleared using the CDU. • Temperature is below --40_C (--40_F).192 SECTION 21 -. above --30_C (--22_F)]. circuit shorted to 12 volts between ECM connector 2. pin 29. • Faulty ECM. Recovery: • If temperature increases but error remains. . Tests: • H9. won’t show “d29” if Transmission Temperature Sender (Bb) is disconnected. pin 25 and Transmission Temperature Sender terminal. won’t show an accurate temperature. pin 25. • Faulty Transmission Oil Temperature Sender (Bb). or short to 5v across sender terminals. channel 2 is above 925 counts.CHAPTER 2 FAULT CODE 51 – TRANSMISSION TEMPERATURE SENDER (Bb) OPEN CIRCUIT. Error may be self-resolved as voltage reaches normal range. or open circuit between Transmission Temperature Sender and ECM connector 2. resulting in sluggish operation and clutch pedal inching occurs at a higher level. • HC. • H5. Conditions: • The ECM detects voltage is above 4. HF Menu. [once the transmission oil temperature warms up.TRANSMISSIONS -. pin 25. extreme low temperature is assumed so clutch pack pressures will be low. Effects: • Transmission is modified.5 volts at ECM connector 2. or short to 5 or 12v between Transmission Temperature Sender and ECM connector 2. Causes: • Faulty wiring.

Is there electrical continuity between pin (A2) (HM) NO on connection (69) and pin CN2--25 (HM) on con- nections (85)? YES Is there electrical continuity between pin (B6) (VN) on connection (69) and pin CN2--29 (VN) on con. (HM) (wiring side) on connections (85) and ground? (Transmission oil temperature sensor Bb) YES Check the wiring and eliminate the cause of the short to +12V.TRANSMISSIONS -. Remove the rear left--hand wheel and the solenoid NO Connect the connection and/or valves unit guard. wiring. (72) (HM) on the sensor and pin (A2) (HM) (trans- mission side) on connection (69)? YES Is there electrical continuity between connection NO (72) (VN) on the sensor and pin (B6) (VN) on con- nection (69)? YES Disconnect the control panel and the connections (85) on the ECM. With the oil temperature at 20°C (68°F). NO nections (85)? YES Turn the starter key to the ON position. measure the sensor electri- cal resistance. is the resistance ∼ 500 Ω? YES Lift the engine bonnet and disconnect connection (69). Is connection (72) and the sensor wiring con- nected? YES Disconnect sensor connection (72).CHAPTER 2 193 Turn the starter key to the OFF position. Is there a reading of +12V between pin CN2--25 NO Replace the ECM. NO Check the wiring and eliminate the Is there electrical continuity between connection cause of the open circuit. Using a digital tester. NO Replace the sensor if interrupted. 72 . SECTION 21 -.

CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 129 Art Shown As If Sitting In Operator’s Seat .TRANSMISSIONS -.194 SECTION 21 -.

5 AN (26) 1 HM (25) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 BC (13) 0.5 BG (7) 0. SECTION 21 -.5 G (33) 85B 1 MN (34) 0.5 M (12) 1 ZN (2) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.CHAPTER 2 195 FAULT CODE 51 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 S (24) 0.5 AB (20) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 R (15) 0.5 V (19) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 RN (15) 0.5 MB (1) 1 GN (C5) 1 BV (C4) 1 AB (C6) 1 B (C3) 1 HL (C7) 1 S (C2) 1 BR (C8) 1 G (C1) 69 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 H (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HG (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .TRANSMISSIONS -.5 LN (8) 0.5 A (27) 1 N (16) 0.5 L (8) 0.5 LB (12) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.

then cause must be resolved and error must be cleared using the CDU. won’t show an accurate temperature. • H5. pin 29. • Transmission oil temperature is above 130_C (266_F). Tests: • H9. • Faulty ECM. . circuit shorted to ground between ECM connector 2. below 130_C (266_F)]. pin 25. won’t show “d29” if Transmission Temperature Sender (Bb) is disconnected. [once the transmission oil temperature cools down.196 SECTION 21 -. Recovery: • If temperature decreases but error remains. extreme high temperature is assumed so clutch pack pressures will be low resulting in sluggish operation and clutch pedal inching occurs at a higher level. Causes: • Faulty wiring. or between Transmission Temperature Sender and ECM connector 2. • Faulty Transmission Temperature Sender (Bb). • HC.CHAPTER 2 FAULT CODE 52 – TRANSMISSION TEMPERATURE SENDER (Bb) SHORT CIRCUIT. or across sender terminals. HF Menu. Conditions: • The ECM detects voltage is below 0.TRANSMISSIONS -. channel 2 is below 70 counts.34 volts at ECM connector 2. pin 25 and Transmission Temperature Sender. Error may be self-resolved as voltage reaches normal range. Effects: • Transmission is modified.

TRANSMISSIONS -.CHAPTER 2 197 Replace the sensor if in short. NO Is wire (HM) on sensor connection (72) in short to ground? YES Check the wiring between sensor connec- tion (72). pin (A2) (HM) on connection (69) and pin CN2--25 (HM) on connections (85). NO Is connection (72) and the temperature sensor wiring in short? With the oil temperature at 20° C (68° F). Remove the rear left--hand wheel. SECTION 21 -. (Transmission oil temperature sensor Bb) 72 . is the resistance ∼ 500 Ω? YES YES Check the wiring and eliminate the cause of the short circuit. Does the fault persist? YES Replace the ECM. Using a digital tester. Disconnect sensor connection (72). Disconnect the control panel and the con- nections (85) on the ECM. measure the sensor NO electrical resistance. Turn the starter key to the OFF position.

198 SECTION 21 -.TRANSMISSIONS -.CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 130 Art Shown As If Sitting In Operator’s Seat .

5 S (24) 0.5 R (15) 0.CHAPTER 2 199 FAULT CODE 52 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 LB (12) 0.5 V (19) 0. SECTION 21 -.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 G (33) 85B 1 MN (34) 0.5 LN (8) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 M (12) 1 ZN (2) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 BC (13) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 A (27) 1 N (16) 0.5 MB (1) 1 GN (C5) 1 BV (C4) 1 AB (C6) 1 B (C3) 1 HL (C7) 1 S (C2) 1 BR (C8) 1 G (C1) 69 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 H (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HG (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 L (8) 0.5 RN (15) 0.5 AN (26) 1 HM (25) 0.5 AB (20) 0.5 BG (7) 0.TRANSMISSIONS -.

Recovery: • Cause must be resolved and error must be cleared using the CDU. . Tests: • H9. [Clutch Pedal Potentiometer. Main (C1) Gear and Range (G1) Gear Position Switches. circuit shorted to 12 volts between ECM connector 2. Conditions: • The ECM detects voltage is above 4.200 SECTION 21 -. (shutting off the tractor). Power Shuttle FNR lever.8 volts at ECM connector 2. but can be re-enabled by cycling the Ignition Switch. HF Menu. Causes: • Faulty wiring. • This error may be displayed instead of showing errors for the different individual circuits. Effects: • Transmission is critically disabled. pin 20 and any other 5 volt sensor.TRANSMISSIONS -.CHAPTER 2 FAULT CODE 53 – 5 VOLTS SENSOR SUPPLY SHORT TO 12 VOLTS. pin 20. channel 14 is above 849 counts. • Faulty ECM.

5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 MB (1) .5 A (27) 1 N (16) 0.5 AB (20) 0.5 M (12) 1 ZN (2) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 V (19) 0.CHAPTER 2 201 Turn the starter key to the OFF position.5 LN (8) 0. Is there a reading of +12V between pin CN2--20 (AB) (wiring side) and ground? YES Check the wiring and eliminate the cause of the short on pin CN2--20 (AB) to +12V.5 G (33) 85B 1 MN (34) 0.5 S (24) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 RN (15) 0.5 AN (26) 1 HM (25) 0. NO Replace the ECM. 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0. Disconnect the control panel and the connections (85) on the ECM.5 LR (9) 1 AV (22) 1 HL (23) 0.5 BC (13) 0. SECTION 21 -.5 R (15) 0.5 BG (7) 0.5 LB (12) 0.5 L (8) 0.TRANSMISSIONS -.

circuit shorted to ground between ECM connector 2. Causes: • Faulty wiring. Conditions: • The ECM detects voltage is below 4. .TRANSMISSIONS -. Main (C1) Gear and Range (G1) Gear Position Switches. • Faulty ECM. Tests: • H9.202 SECTION 21 -. (shutting off the tractor). pin 20. Power Shuttle FNR lever. Effects: • Transmission is critically disabled.2 volts at ECM connector 2. channel 14 is below 521 counts. • This error may be displayed instead of showing errors for the different circuits. HF Menu. pin 20 and any other 5 volt sensor. Recovery: • Cause must be resolved and error must be cleared using the CDU.CHAPTER 2 FAULT CODE 54 – 5 VOLTS SENSOR SUPPLY SHORT TO GROUND OR OPEN. [Clutch Pedal Potentiometer. but can be re-enabled by cycling the Ignition Switch.

CHAPTER 2 203 Turn the starter key to the OFF position.5 V (19) 0.5 G (33) 85B 1 MN (34) 0. Disconnect the control panel and the connections (85) on the ECM.5 AB (20) 0.5 AN (26) 1 HM (25) 0.5 HR (11) 1 MN (10) 1 HG (21) 0. Is pin CN2--20 (AB) (wiring side) in short to ground? YES Check the sensors voltage wire (AB) on the wiring: Shuttle lever.TRANSMISSIONS -.5 A (27) 1 N (16) 0. clutch pedal potentiometer.5 RN (15) 0. range and gear neutral position sensor push- buttons and the creeper position sensor pushbut- ton. forward and reverse gear synchroniser position pushbut- ton.5 LB (12) 0. 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 BG (7) 0.5 S (24) 0. NO Replace the ECM.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0. use the diagram shown in Section 55.5 LN (8) 0. Eliminate the cause of the short to ground.5 L (8) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 BC (13) 0. To facilitate this search.5 M (12) 1 ZN (2) 0.5 MB (1) . page 141.5 R (15) 0.5 LR (9) 1 AV (22) 1 HL (23) 0. SECTION 21 -. Chapter 5.

204 SECTION 21 -. pin 26. pin 20 is shorted to 12v between switch and any other 5 volt sensor. or short to 5v across switch terminals. pin 26. circuit shorted to 12 volts between ECM connector 2. Tests: • H9. or short to 5 or 12v between PS FNR Lever Forward Position Switch and ECM connector 2. except there will be a slight delay whenever the forward position is selected. channel 9 is above 860 counts. • H5. • ECM will determine shuttle position by using the PS FNR Lever Neutral and Reverse Position Switches. pin 20 and PS FNR Lever Forward Position Switch. Causes: • Faulty wiring. • Faulty ECM.2 volts at ECM connector 2.TRANSMISSIONS -. Conditions: • The ECM detects voltage is above 4. Effects: • Transmission will operate normally. won’t display “d22”. • Faulty PS FNR Lever Forward Position Switch (1). . Recovery: • Cause must be resolved and error must be cleared using the CDU.CHAPTER 2 FAULT CODE 55 – POWER SHUTTLE FNR LEVER (1) FORWARD POSITION SWITCH SHORT TO 5 OR 12 VOLTS. HF Menu. Or common 5 volt sensor supply wire from ECM connector 2.

Replace the Shuttle lever if a short When the Shuttle lever (1) is positioned in forward NO circuit is found. (Shuttle lever 1) .CHAPTER 2 205 Turn the starter key to the OFF position. between pin CN2--20 (AB) and pin CN2--26 (AN) (wiring side). SECTION 21 -. gear. Disconnect the control panel and the connections (85) on the ECM.TRANSMISSIONS -. is the reading ∼ 600 Ω? YES Replace the ECM.

CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 131 Art Shown As If Sitting In Operator’s Seat .TRANSMISSIONS -.206 SECTION 21 -.

5 LR (9) 1 AV (22) 1 HL (23) 0.5 MB (1) .5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 G (33) 85B 1 MN (34) 0.5 LB (12) 0.5 A (27) 1 N (16) 0.5 S (24) 0.CHAPTER 2 207 FAULT CODE 55 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 BC (13) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 LN (8) 0.5 VN (29) 1 N (14) 1 BG (28) 0.TRANSMISSIONS -.5 BG (7) 0.5 V (19) 0.5 AN (26) 1 HM (25) 0.5 M (12) 1 ZN (2) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0. SECTION 21 -.5 L (8) 0.5 R (15) 0.5 RN (15) 0.5 AB (20) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.

pin 26. or across switch terminals. pin 26.TRANSMISSIONS -.208 SECTION 21 -. Tests: • H9. • ECM will determine shuttle position by using the PS FNR Lever (1) Neutral and Reverse Position Switches. Causes: • Faulty wiring. pin 20 and PS FNR Lever Forward Position Switch.CHAPTER 2 FAULT CODE 56 – POWER SHUTTLE FNR LEVER (1) FORWARD POSITION SWITCH SHORT TO GROUND OR OPEN CIRCUIT.7 volts at ECM connector 2. HF Menu. • H5. Or common 5 volt sensor supply wire from ECM connector 2. pin 20 is shorted to ground or open between switch and any other 5 volt sensor. . • Faulty PS FNR Lever Forward Position Switch (1). won’t display “d22”. Effects: • Transmission will operate normally. except there will be a slight delay whenever the forward position is selected. circuit is shorted to ground or open between ECM connector 2. Conditions: • The ECM detects voltage is below 0. • Faulty ECM. or between PS FNR Lever (1) Forward Position Switch and ECM connector 2. channel 9 is below 143 counts. Recovery: • Cause must be resolved and error must be cleared using the CDU.

SECTION 21 -. Disconnect the control panel and the con. NO (AN) on connections (85) and connection nection (90) (AN) on the Shuttle lever? (90) on the Shuttle lever. Check the wiring and eliminate the cause of the open circuit. NO Is wire (AN) on pin CN2--26 in short to nection (90) (AB) on the Shuttle lever? ground? YES YES Is there electrical continuity between Check the wiring between pin CN2--26 CN2--26 (AN) on connections (85) and con. NO CN2--20 (AB) on connections (85) and con. (Shuttle lever 1) . YES Eliminate the cause of the short to ground. Is there electrical continuity between nections (85) on the ECM.TRANSMISSIONS -.CHAPTER 2 209 Turn the starter key to the OFF position. Does the fault persist? YES Replace the ECM. Replace the Shuttle lever.

CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 132 Art Shown As If Sitting In Operator’s Seat .TRANSMISSIONS -.210 SECTION 21 -.

5 LN (8) 0.5 AN (26) 1 HM (25) 0. SECTION 21 -.5 LR (9) 1 AV (22) 1 HL (23) 0.5 HV (2) 0.5 AB (6) 0.TRANSMISSIONS -.5 B (1) .5 V (19) 0.5 LB (12) 0.5 S (24) 0.5 MN (3) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 A (4) 0.CHAPTER 2 211 FAULT CODE 56 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 BC (13) 0.5 MB (1) 90 0.5 L (8) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 BG (7) 0.5 M (12) 1 ZN (2) 0.5 AB (20) 0.5 AN (5) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 RN (15) 0.5 G (33) 85B 1 MN (34) 0.5 R (15) 0.5 A (27) 1 N (16) 0.

channel 10 is above 860 counts. . pin 27. pin 27. pin 20 is shorted to 12v between switch and any other 5 volt sensor. Conditions: • The ECM detects voltage is above 4. except there will be a slight delay whenever the reverse position is selected.212 SECTION 21 -. Effects: • Transmission will operate normally. Recovery: • Cause must be resolved and error must be cleared using the CDU. • Faulty ECM.CHAPTER 2 FAULT CODE 57 – POWER SHUTTLE FNR LEVER (1) REVERSE POSITION SWITCH SHORT TO 5 OR 12 VOLTS. Causes: • Faulty wiring. • Faulty and PS FNR Lever Reverse Position Switch (1). Tests: • H9. or short to 5v across switch terminals. circuit is shorted to 12 volts between ECM connector 2.2 volts at ECM connector 2. • H5. won’t display “d23”. Or common 5 volt sensor supply wire from ECM connector 2. or short to 5 or 12v between PS FNR Lever Reverse Position Switch and ECM connector 2. • ECM will determine shuttle position by using the PS FNR Lever Neutral and Forward Position Switches. pin 20 and PS FNR Lever Reverse Position Switch.TRANSMISSIONS -. HF Menu.

TRANSMISSIONS -. between pin CN2--20 (AB) and pin CN2--27 (A) on connections (85) (wiring side). is the reading ∼ 600 Ω? YES Replace the ECM. (Shuttle lever 1) . Replace the Shuttle lever if a short Move the Shuttle lever to the reverse gear position. Disconnect the control panel and the connections (85) on the ECM.CHAPTER 2 213 Turn the starter key to the OFF position. NO circuit is found. SECTION 21 -.

TRANSMISSIONS -.214 SECTION 21 -.CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 133 Art Shown As If Sitting In Operator’s Seat .

5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 A (27) 1 N (16) 0.5 LB (12) 0.5 RN (15) 0.5 BG (7) 0.5 M (12) 1 ZN (2) 0.CHAPTER 2 215 FAULT CODE 57 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 MB (1) .5 R (15) 0.5 AN (26) 1 HM (25) 0. SECTION 21 -.5 AB (20) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 S (24) 0.5 L (8) 0.5 LN (8) 0.5 G (33) 85B 1 MN (34) 0.TRANSMISSIONS -.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 BC (13) 0.5 V (19) 0.

CHAPTER 2 FAULT CODE 58 – POWER SHUTTLE FNR LEVER (1) REVERSE POSITION SWITCH SHORT TO GROUND OR OPEN CIRCUIT.216 SECTION 21 -. Causes: • Faulty wiring. or between PS FNR Lever Reverse Position Switch and ECM connector 2.TRANSMISSIONS -. circuit shorted to ground or open between ECM connector 2. Recovery: • Cause must be resolved and error must be cleared using the CDU. Or common 5 volt sensor supply wire from ECM connector 2. pin 20 is shorted to ground or open between switch and any other 5 volt sensor. • Faulty PS FNR Lever Reverse Position Switch (1). . pin 27. except there will be a slight delay whenever the reverse position is selected. HF Menu. Effects: • Transmission will operate normally. or between switch terminals. • H5. Tests: • H9. won’t display “d23”.7 volts at ECM connector 2. • ECM will determine shuttle position by using the PS FNR Lever Neutral and Forward Position Switches. channel 10 is below 143 counts. • Faulty ECM. pin 20 and PS FNR Lever Reverse Position Switch. pin 27. Conditions: • The ECM detects voltage is below 0.

SECTION 21 -.CHAPTER 2 217 Turn the starter key to the OFF position. Is there electrical continuity between nections (85) on the ECM. Disconnect the control panel and the con. NO Is wire (A) on pin CN2--27 in short to nection (90) (AB) on the Shuttle lever? ground? YES YES Is there electrical continuity between Check the wiring between pin CN2--27 (A) CN2--27 (A) on connections (85) and con. NO on connections (85) and connection (90) nection (90) (AN) on the Shuttle lever? on the Shuttle lever.TRANSMISSIONS -. NO CN2--20 (AB) on connections (85) and con. Replace the Shuttle lever. Does the fault persist? YES Replace the ECM. Check the wiring and eliminate the cause of the open circuit. (Shuttle lever 1) . YES Eliminate the cause of the short to ground.

CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 134 Art Shown As If Sitting In Operator’s Seat .TRANSMISSIONS -.218 SECTION 21 -.

5 RN (15) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 LN (8) 0.5 A (4) 0.5 M (12) 1 ZN (2) 0.5 AB (20) 0.TRANSMISSIONS -.5 HV (2) 0.5 MB (1) 90 0.5 G (33) 85B 1 MN (34) 0.5 BG (7) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 B (1) .5 VN (29) 1 N (14) 1 BG (28) 0.5 AB (6) 0.CHAPTER 2 219 FAULT CODE 58 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 S (24) 0.5 AN (26) 1 HM (25) 0.5 BC (13) 0.5 LB (12) 0. SECTION 21 -.5 HR (11) 1 MN (10) 1 HG (21) 0.5 MN (3) 0.5 AN (5) 0.5 L (8) 0.5 V (19) 0.5 A (27) 1 N (16) 0.5 R (15) 0.

or Reverse) are activated at the same time. • Transmission is disabled. for example inputs could be indicated for two switches simultaneously.TRANSMISSIONS -. NOTE: On all Transmissions the Status Lamp (Gear with a Slash) will flash in a alternating manner.220 SECTION 21 -. Causes: • A particular position switch could be sticking. pin 18 and Power Shuttle FNR Lever Neutral Position Switch. (Neutral. Forward. and nothing from neutral. channel 9 and 10 are out of range. & REVERSE POSITION SWITCHES DISAGREE. . (both neutral and forward. Conditions: • The ECM detects that two or none of the Power Shuttle FNR Lever Position Switches. • Faulty ECM. Any voltages recorded out of range will result in displaying separate error codes. • Faulty wiring. • Faulty Power Shuttle FNR Lever Neutral Switch (1). forward. • Faulty Power Shuttle FNR Lever Reverse Switch (1). or reverse). won’t show “d22” or “d23”. Tests: • H9. Effects: • The Transmission Status Lamp is flashing. HF Menu. both neutral and reverse. open circuit between ECM connector 2.CHAPTER 2 FAULT CODE 59 – POWER SHUTTLE FNR LEVER (1) NEUTRAL. FORWARD. both forward and reverse. • H5. but can be re-enabled by cycling the Power Shuttle FNR Lever. Recovery: • Cause must be resolved and error must be cleared using the CDU. • Faulty Power Shuttle FNR Lever Forward Switch (1).

CHAPTER 2 221 (Shuttle lever 1) .SECTION 21 -.TRANSMISSIONS -.

(NOT USED TN Standard) NOTE: The Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. pin 23 is above 4. Conditions: 1. pin 2.CHAPTER 2 FAULT CODE 61 – VOLTAGE FROM SYNCHRONIZER HI-LO (FORWARD) POSITION SWITCH (S) SHORT TO 5 OR 12 VOLTS. Effects of Condition 1: • The Transmission Status Lamp is flashing.TRANSMISSIONS -. 2.2 volts. circuit shorted to 12 volts between ECM connector 2. Transmission is neutralized whenever Power Shuttle FNR is put into forward position. Then ECM will look for detection of Synchronizer Shuttle (Reverse) Position Switch and move synchronizer to reverse position. HF Menu. • H5 doesn’t display “d27”. but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal. • HD displays “unkn”. • Faulty ECM. pin 20 is short to 12v between switch and any other 5 volt sensor. Causes: • Faulty wiring. pin 20 and Synchronizer Hi-Lo (Forward) Position switch. or short to 5v across switch terminals. While the Power Shuttle FNR Lever is in the neutral position. Effects of Condition 2: • Transmission is limited. Tests: • H9. or short to 5 or 12v between Synchronizer Hi-Lo (Forward) Position Switch and ECM connector 2. channel 5 is above 860 counts. voltage at the ECM connector 2. NOTE: On the 32x16 transmission. They will flash in a alternating manner. • Faulty Synchronizer Hi-Lo (Forward) Position Switch (S). Any shuttle into forward will not work. pin 2 is above 4. While the Power Shuttle FNR Lever is in the forward position.2 volts. voltage at the ECM connector 2. Or common 5 volt sensor supply wire from ECM connector 2. • Transmission is disabled.222 SECTION 21 -. the Synchronizer Shuttle (Reverse) and Hi-Lo (Forward) Position Switches are located on the left side of the transmission between the Power Shuttle Control Valve and the Service Control Valve. only Synchronizer Shuttle (Reverse) Position Switch is available (reverse movement). The Synchronizer Shuttle (Reverse) Position Switch is toward the rear of the tractor. The Synchronizer Hi-Lo (Forward) Position Switch is toward the front of the tractor. . Recovery: • Cause must be resolved and error must be cleared using the CDU.

Does the fault persist? nection (158) or between pin (C6) (AB) on connec- tion (158) and connection (97*) on pushbutton. SECTION 21 -. (HV) and (C6) (AB) on connection NO (158) with pins CN2--2 (HV) and Are wires (AB) and (HV) still in short? CN2--20 (AB) on connections (129) YES on the ECM.5 HV . Using a digital tester. measure the electrical resist- ance on the pushbutton. button.5 AB 0. Is the resistance 500 ÷ 3000 Ω? YES Are wires (AB) and (HV) (wiring side) in short cir. cuit? YES YES Lift the engine bonnet and disconnect connection Check the wiring between pins (A3) (158).CHAPTER 2 223 Turn the starter key to the OFF position. Check the wiring between pin (A3) (HV) on con. * 97 0. Disconnect connection (97*) on pushbutton (HI If in short circuit. NO Replace the ECM.TRANSMISSIONS -. replace the push- NO and LO) (grey connection). Eliminate the cause of the short circuit. Remove the rear left--hand wheel and the solenoid valves unit guard.

TRANSMISSIONS -.CHAPTER 2 PAGE LEFT BLANK .224 SECTION 21 -.

5 L (8) 0.5 G (33) 1 MN (34) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 BG (7) 0.5 MB (1) 1 C (C5) 1 SG (C4) 1 AB (C6) 1 HL (C3) 1 HG (C7) 1 AV (C2) 1 AR (C8) 1 GR (C1) 158 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 GN (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HV (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 S (24) 0.5 A (27) 1 N (16) 0. SECTION 21 -.5 AB (20) 0.CHAPTER 2 225 FAULT CODE 61 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 HB (36) 1 BV (30) 1 N (13) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 1 SG (3) 0.5 R (15) 0.5 LN (8) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 LB (12) 0.5 V (19) 0.5 RN (15) 0.5 M (12) 1 ZN (2) 0.TRANSMISSIONS -.5 BC (13) 0.5 AN (26) 1 HM (25) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.

only Synchronizer Shuttle (Reverse) Position Switch is available (reverse movement).CHAPTER 2 FAULT CODE 62 – VOLTAGE FROM SYNCHRONIZER HI-LO (FORWARD) POSITION SWITCH (S) SHORT TO GROUND OR OPEN CIRCUIT. Transmission is neutralized whenever Power Shuttle FNR is put into forward position.7 volts. The Synchronizer Shuttle (Reverse) Position Switch is toward the rear of the tractor. circuit short to ground or open between ECM connector 2. • Faulty ECM. Conditions: 1. (NOT USED TN Standard) NOTE: The Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. 2. pin 2 is below 0. pin 2 is below 0. voltage at the ECM connector 2. Causes: • Faulty wiring. Effects of Condition 2: • Transmission is limited. They will flash in a alternating manner. or across switch terminals. HF Menu. Tests: • H9. voltage at the ECM connector 2. pin 20 and Synchronizer Hi-Lo (Forward) Position Switch. • Transmission is disabled. • H5 doesn’t display “d28”. Effects of Condition 1: • The Transmission Status Lamp is flashing. • HD displays “unkn”. Then ECM will look for detection of Synchronizer Shuttle (Reverse) Position Switch and move synchronizer to reverse position. While the Power Shuttle FNR Lever is in the neutral position. • Faulty Synchronizer Hi-Lo (Forward) Position Switch (S). or between Synchronizer Hi-Lo (Forward) Position Switch and ECM connector 2. but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal. Any shuttle into forward will not work. Or common 5 volt sensor supply wire from ECM connector 2. . The Synchronizer Hi-Lo (Forward) Position Switch is toward the front of the tractor. channel 5 is below 143 counts. Recovery: • Cause must be resolved and error must be cleared using the CDU. pin 2. While the Power Shuttle FNR Lever is in the forward position. the Synchronizer Shuttle (Reverse) and Hi-Lo (Forward) Position Switches are located on the left side of the transmission between the Power Shuttle Control Valve and the Service Control Valve. NOTE: On the 32x16 transmission.TRANSMISSIONS -. pin 20 is short to ground or open between switch and any other 5 volt sensor.226 SECTION 21 -.7 volts.

TRANSMISSIONS -. measure the electri. Is wire (HV) on connection (97*) in short Disconnect connection (158). SECTION 21 -. Using a digital tester. NO to ground? YES nection (97*) on pushbutton (HV) and pin (A3) (HV) on connection (158)? Check the wiring and eliminate the cause YES of the short to ground. cal resistance on the pushbutton. Is there electrical continuity between con- nection (97*) on pushbutton (AB) and pin NO (C6) (AB) on connection (158)? YES Disconnect the control panel and connec- tions (129) on the ECM. NO Connect the connection and/or wiring. NO Is there electrical continuity between con. Is the resistance 500 ÷ 3000 Ω? YES Raise the engine hood.5 HV .5 AB 0. * 97 0. NO Replace the pushbutton if interrupted. Remove the rear left--hand wheel and the solenoid valves unit guard. Is there electrical continuity between pin NO CN2--2 (HV) on connections (129) and pin (A3) (HV) on connection (158)? YES Replace the ECM. Is the wiring and connection (97*) on the pushbutton connected? YES Disconnect connection (97*) on the push- button.CHAPTER 2 227 Check the wiring and eliminate the cause of the open circuit. Turn the starter key to the OFF position.

TRANSMISSIONS -.228 SECTION 21 -.CHAPTER 2 PAGE LEFT BLANK .

5 BC (13) 0.5 MB (1) 1 C (C5) 1 SG (C4) 1 AB (C6) 1 HL (C3) 1 HG (C7) 1 AV (C2) 1 AR (C8) 1 GR (C1) 158 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 GN (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HV (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 AB (20) 0.5 LN (8) 0.5 V (19) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.CHAPTER 2 229 FAULT CODE 62 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 LB (12) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 1 SG (3) 0.5 HB (36) 1 BV (30) 1 N (13) 0.5 BG (7) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 G (33) 1 MN (34) 0. SECTION 21 -.TRANSMISSIONS -.5 AN (26) 1 HM (25) 0.5 R (15) 0.5 A (27) 1 N (16) 0.5 S (24) 0.5 L (8) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 M (12) 1 ZN (2) 0.5 RN (15) 0.

• HD displays “unkn”. NOTE: The Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. Conditions: • During directional change (a shuttle). channel 5 is not within allowable range. NOTE: On the 32x16 transmission. (NOT USED TN Standard) NOTE: This is the same as the synchronizer not disengaging from reverse.230 SECTION 21 -. The Synchronizer Hi-Lo (Forward) position is toward the rear of the tractor. Causes: • Faulty F/R Synchronizer. • Once the error has been cleared. • Faulty Synchronizer Hi-Lo (Forward) Position Switch (S). • Transmission is disabled. but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal. the ECM will attempt to put the F/R Synchronizer into the Hi-Lo (Forward) position again. Effects: • The Transmission Status Lamp is flashing. • H5 doesn’t display “d28”. . They will flash in a alternating manner. moving the PS FNR Lever to forward position. HF Menu. the Shuttle (Reverse) and Hi-Lo (Forward) Synchronizer is located on the left side of the transmission behind the Power Shuttle Control Valve. The Synchronizer Shuttle (Reverse) position is toward the front of the tractor.TRANSMISSIONS -. the F/R Synchronizer did not engage the forward position within the time allowed. This error will be triggered until an attempt to shift the F/R Synchronizer into forward position has been successful. Recovery: • Cause must be resolved and error must be cleared using the CDU. • Faulty F/R Synchronizer linkage. Tests: • H9.CHAPTER 2 FAULT CODE 63 – F/R SYNCHRONIZER DID NOT MOVE INTO THE HI-LO (FORWARD) POSITION.

. Does the fault persist? YES Replace the HI and LO forward gears synchroniser solenoid valve. SECTION 21 -.CHAPTER 2 231 Turn the starter key to the OFF position. the synchroniser unit and eliminate the fault. Replace the HI and LO forward gears synchroniser position sensor pushbutton. Remove the rear left--hand wheel and the solenoid valves unit guard. Does the fault persist? YES Check the hydraulic system.TRANSMISSIONS -.

• Faulty Synchronizer Shuttle (Reverse) Position Switch. • Transmission is disabled but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal. • Tests: • H9. moving the PS FNR Lever to reverse position. NOTE: The Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. the Shuttle (Reverse) and Hi-Lo (Forward) Synchronizer is located on the left side of the transmission behind the Power Shuttle Control Valve.TRANSMISSIONS -. • HD displays “unkn”.CHAPTER 2 FAULT CODE 64 – F/R SYNCHRONIZER DID NOT MOVE INTO THE SHUTTLE (REVERSE) POSITION. Conditions: • During directional change (a shuttle). Recovery: • Cause must be resolved and error must be cleared using the CDU. • Faulty F/R Synchronizer linkage. The Synchronizer Hi-Lo (Forward) position is toward the rear of the tractor. This error will be triggered until an attempt to shift the F/R Synchronizer into reverse position has been successful.232 SECTION 21 -. the F/R Synchronizer did not engage the reverse position within the time allowed. channel 6 is not within allowable range. HF Menu. • H5 doesn’t display “d27”. They will flash in a alternating manner. NOTE: On the 32x16 transmission. Causes: • Faulty F/R Synchronizer. . the ECM will attempt to put the F/R Synchronizer into the Shuttle (Reverse) position again. • Once the error has been cleared. (NOT USED TN Standard) NOTE: This is the same as the synchronizer not disengaging from forward. The Synchronizer Shuttle (Reverse) position is toward the front of the tractor. Effects: • The Transmission Status Lamp is flashing.

the synchroniser unit and eliminate the fault. SECTION 21 -.CHAPTER 2 233 Turn the starter key to the OFF position.TRANSMISSIONS -. Remove the rear left--hand wheel and the solenoid valves unit guard. Replace the Shuttle reverse synchroniser position sensor pushbutton. Does the fault persist? YES Check the hydraulic system. . Does the fault persist? YES Replace the Shuttle synchroniser position solenoid valve.

or across the solenoid coil terminals or between solenoid coil terminal and ECM connector 1. channel 12 is not within range. on/off. While the tractor is started and the Power Shuttle FNR Lever is in the neutral position. but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal. HF Menu. Effects of Condition 1: • The Transmission Status Lamp is flashing. The Synchronizer Hi-Lo (Forward) Solenoid is toward the front of the tractor. Both solenoids are 12v. NOTE: On the 32x16 transmission.TRANSMISSIONS -. (NOT USED TN Standard) NOTE: The Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps.CHAPTER 2 FAULT CODE 65 – SYNCHRONIZER HI-LO (FORWARD) SOLENOID CIRCUIT SHORT TO GROUND OR OPEN CIRCUIT OR ECM DRIVER IS OPEN. Recovery: • Cause must be resolved and error must be cleared using the CDU. Effects of Condition 2: • Transmission is limited. Transmission is neutralized whenever Power Shuttle FNR is put into forward position. the Synchronizer Hi-Lo (Forward) Solenoid has a short to ground or open circuit. internal ECM Driver is open or short to ground. • Transmission is disabled. the Synchronizer Shuttle (Reverse) and Hi-Lo (Forward) Solenoids are located on the bottom of the Power Shuttle Control Valve. Then ECM will look for detection of Synchronizer Shuttle (Reverse) Solenoid and move synchronizer to reverse position. The Synchronizer Shuttle (Reverse) Solenoid is toward the rear of the tractor. • Faulty Synchronizer Hi-Lo (Forward) Solenoid Coil.234 SECTION 21 -. pin 4. Conditions: 1. pin 16 and solenoid coil terminal. • Faulty ECM. • HD displays “unkn”. the Synchronizer Hi-Lo (Forward) Solenoid has a short to ground or open circuit. Causes: • Faulty wiring. While the tractor is started and the Power Shuttle FNR Lever is in forward or reverse position. only Synchronizer Shuttle (Reverse) Solenoid is available (reverse movement). 2. . Any shuttle into forward will not work. They will flash in a alternating manner. Tests: • H9. circuit is short to ground or open between the ECM connector 1.

Eliminate the cause of the short to ground. pins (B2) (GN) and (C1) (GR) on connection (158) and pins nection (67) on the solenoid valve? CN1--16 (GN) and CN1--4 (GR) on con. SECTION 21 -. NO Replace the solenoid valve if interrupted. .TRANSMISSIONS -.CHAPTER 2 235 Check the wiring and eliminate the cause of the open circuit. cal resistance of the solenoid valve coil. NO on the solenoid valve. measure the electri. Is wire (GN) on pin CN1--16 on connec. Is there electrical continuity between pin NO CN1--16 (GN) on connections (129) and NO tions (129) or wire (GR) on pin CN1--4 in short to ground? connection (67) on the solenoid valve? YES YES Check the wiring between connection (67) Is there electrical continuity between pin CN1--4 (GR) on connections (129) and con.5 Ω? YES Disconnect the control panel and the con- nections (129) on the ECM. Is connection (67) on the HI and LO for- ward gear synchroniser position control solenoid valve connected? YES Disconnect connection (67) on the sole- noid valve. NO Connect connection. Remove the rear left--hand wheel and the solenoid valves unit guard. Is the resistance ∼ 7. Replace the ECM. Using a digital tester. YES nections (129). Turn the starter key to the OFF position.

CHAPTER 2 PAGE LEFT BLANK .236 SECTION 21 -.TRANSMISSIONS -.

5 LN (8) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0. SECTION 21 -.5 RN (15) 0.5 R (15) 0.5 LB (12) 0.5 AN (26) 1 HM (25) 0.5 V (19) 0.5 BG (7) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 G (33) 1 MN (34) 0.5 A (27) 1 N (16) 0.5 M (12) 1 ZN (2) 0.5 MB (1) 1 C (C5) 1 SG (C4) 1 AB (C6) 1 HL (C3) 1 HG (C7) 1 AV (C2) 1 AR (C8) 1 GR (C1) 158 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 GN (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HV (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 S (24) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 AB (20) 0.5 L (8) 0.CHAPTER 2 237 FAULT CODE 65 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 1 SG (3) 0.5 BC (13) 0.5 HB (36) 1 BV (30) 1 N (13) 0.TRANSMISSIONS -.

. Conditions: 1. NOTE: On the 32x16 transmission. the Synchronizer Shuttle (Reverse) and Hi-Lo (Forward) Solenoids are located on the bottom of the Power Shuttle Control Valve. Tests: • H9. 2. They will flash in a alternating manner. pin 17 and the Synchronizer Shuttle (Reverse) Solenoid Coil terminal. Transmission is neutralized whenever Power Shuttle FNR is put into reverse position. internal ECM driver is open or short to ground. the Synchronizer Shuttle (Reverse) Solenoid has a short to ground or open circuit. but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal. The Synchronizer Shuttle (Reverse) Solenoid is toward the rear of the tractor. (NOT USED TN Standard) NOTE: The Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. Any shuttle into reverse will not work. channel 13 is not within range. • Faulty Synchronizer Hi-Lo (Forward) Solenoid Coil. Causes: • Faulty wiring. circuit is short to ground or open between the ECM connector 1. • Faulty ECM. the Synchronizer Shuttle (Reverse) Solenoid has a short to ground or open circuit. Effects of Condition 1: • The Transmission Status Lamp is flashing. Both solenoids are 12v.TRANSMISSIONS -. • HD displays “unkn”. pin 3. HF Menu. Effects of Condition 2: • Transmission is limited. Recovery: • Cause must be resolved and error must be cleared using the CDU. on/off. While the tractor is started and the Power Shuttle FNR Lever is in forward or reverse position. While the tractor is started and the Power Shuttle FNR Lever is in the neutral position. only Synchronizer Hi-Lo (Forward) Solenoid is available (forward movement).CHAPTER 2 FAULT CODE 66 – SYNCHRONIZER SHUTTLE (REVERSE) SOLENOID CIRCUIT SHORT TO GROUND OR OPEN CIRCUIT OR ECM DRIVER IS OPEN. or between the Synchronizer Shuttle (Reverse) Solenoid Coil terminal and ECM connector 1. or across the solenoid coil terminals. Then ECM will look for detection of Synchronizer Hi-Lo (Forward) Solenoid and move synchronizer to forward position.238 SECTION 21 -. The Synchronizer Hi-Lo (Forward) Solenoid is toward the front of the tractor. • Transmission is disabled.

Turn the starter key to the OFF position. pins (B4) (SN) and nection (65) on the solenoid valve? (C4) (GS) on connection (158) and pins YES CN1--17 (SN) and CN1--3 (GS) on con- nections (129).TRANSMISSIONS -.5 Ω? YES Disconnect the control panel and the con- nections (129) on the ECM. Is the resistance ∼ 7. NO Replace the solenoid valve if interrupted. Using a digital tester. .CHAPTER 2 239 Check the wiring and eliminate the cause of the open circuit. the Shuttle reverse synchroniser position control connected? YES Disconnect connection (65) on the sole- noid valve. NO CN1--17 (SN) on connections (129) and NO tions (129) or Wire (SG) on pin CN1--3 in connection (65) on the solenoid valve? short to ground? YES YES Is there electrical continuity between pin Check the wiring between connection (65) CN1--3 (GS) on connections (129) and con. cal resistance on the pushbutton. Is there electrical continuity between pin Is wire (SN) on pin CN1--17 on connec. NO on the solenoid valve. SECTION 21 -. measure the electri. Is connection (65) on the solenoid valve of NO Connect connection. Remove the rear left--hand wheel and the solenoid valves unit guard. Eliminate the cause of the short to ground. Replace the ECM.

CHAPTER 2 PAGE LEFT BLANK .TRANSMISSIONS -.240 SECTION 21 -.

5 RN (15) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 A (27) 1 N (16) 0.5 AB (20) 0.5 V (19) 0.5 LB (12) 0.5 HB (36) 1 BV (30) 1 N (13) 0.5 LN (8) 0.5 L (8) 0.5 BG (7) 0.5 S (24) 0.5 BC (13) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 M (12) 1 ZN (2) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 G (33) 1 MN (34) 0.5 AN (26) 1 HM (25) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 1 SG (3) 0.5 MB (1) 1 C (C5) 1 SG (C4) 1 AB (C6) 1 HL (C3) 1 HG (C7) 1 AV (C2) 1 AR (C8) 1 GR (C1) 158 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 GN (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HV (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 R (15) 0.CHAPTER 2 241 FAULT CODE 66 1 ZB (18) 1 SN (17) 1 GN (16) 0.TRANSMISSIONS -. SECTION 21 -.

the Synchronizer Shuttle (Reverse) and Hi-Lo (Forward) Solenoids are located on the bottom of the Power Shuttle Control Valve. Hi-Lo speed engagement is operational. but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal. therefore keeping F/R Synchronizer Piston in forward position. Causes: • Faulty wiring. channel 12 is not within range. HF Menu.TRANSMISSIONS -. • Faulty Synchronizer Hi-Lo (Forward) Solenoid Coil. The Synchronizer Hi-Lo (Forward) Solenoid is toward the front of the tractor. Effects: • The Transmission Status Lamp is flashing. Recovery: • Cause must be resolved and error must be cleared using the CDU. Synchronizer Hi-Lo (Forward) Solenoid remains energized. • Transmission is disabled. circuit shorted to 12 volts between the ECM connector 1. Conditions: • While the tractor is started and the Power Shuttle FNR Lever is in forward or reverse position. or across the solenoid coil terminals. • Faulty ECM. internal ECM Driver is shorted to Tests: • H9. on/off. Only forward engagement is operational. • Transmission is limited. The Synchronizer Shuttle (Reverse) Solenoid is toward the rear of the tractor. NOTE: On the 32x16 transmission. pin 4. Any shuttle into reverse will not work. pin 16 and the Synchronizer Hi-Lo (Forward) Solenoid Coil terminal. They will flash in a alternating manner. (NOT USED TN Standard) NOTE: The Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. the Synchronizer Hi-Lo (Forward) Solenoid becomes energized by a short circuit to 12 volts. • HD displays “unkn”.242 SECTION 21 -. Both solenoids are 12v. . or between the Synchronizer Hi-Lo (Forward) Solenoid Coil terminal and ECM connector 1.CHAPTER 2 FAULT CODE 67 – SYNCHRONIZER HI-LO (FORWARD) SOLENOID OR ECM DRIVER IS SHORT TO 12 VOLTS.

CHAPTER 2 243 Turn the starter key to the OFF position. Eliminate the cause of the short circuit to +12V. . Disconnect the control panel and the connections (129) on the ECM. NO Replace the ECM.TRANSMISSIONS -. pin (B2) (GN) on connection (158) and connection (67) on the solenoid valve. Is there a reading of +12V between pin CN1--16 (GN) on connections (129) and ground? YES Check the wiring between pin CN1--16 (GN) on connections (129). SECTION 21 -.

CHAPTER 2 PAGE LEFT BLANK .TRANSMISSIONS -.244 SECTION 21 -.

5 HR (11) 1 MN (10) 1 HG (21) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 LB (12) 0.5 AB (20) 0.5 RN (15) 0.TRANSMISSIONS -.5 BG (7) 0.5 AN (26) 1 HM (25) 0.5 A (27) 1 N (16) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 1 SG (3) 0.5 G (33) 1 MN (34) 0.5 MB (1) 1 C (C5) 1 SG (C4) 1 AB (C6) 1 HL (C3) 1 HG (C7) 1 AV (C2) 1 AR (C8) 1 GR (C1) 158 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 GN (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HV (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 LN (8) 0.CHAPTER 2 245 FAULT CODE 67 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 V (19) 0.5 R (15) 0.5 M (12) 1 ZN (2) 0. SECTION 21 -.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 S (24) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 BC (13) 0.5 L (8) 0.5 HB (36) 1 BV (30) 1 N (13) 0.

(NOT USED TN Standard) NOTE: The Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. Recovery: • Cause must be resolved and error must be cleared using the CDU. therefore keeping F/R Synchronizer Piston in reverse position. • Transmission is limited. NOTE: On the 32x16 transmission. They will flash in a alternating manner. Synchronizer Shuttle (Reverse) Solenoid remains energized. but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal. Any shuttle into forward will not work. pin 3. Both solenoids are 12v. Effects: • The Transmission Status Lamp is flashing. or across the solenoid coil terminal.246 SECTION 21 -. Conditions: • While the tractor is started and the Power Shuttle FNR Lever is in forward or reverse position. pin 17 and the Synchronizer Shuttle (Reverse) Solenoid Coil terminal. the Synchronizer Shuttle (Reverse) and Hi-Lo (Forward) Solenoids are located on the bottom of the Power Shuttle Control Valve. The Synchronizer Hi-Lo (Forward) Solenoid is toward the front of the tractor. Causes: • Faulty wiring. internal ECM Driver is short to 12 volts. Hi-Lo speed engagement is applicable with reverse. • Transmission is disabled. circuit is shorted to 12 volts between the ECM connector 1. The Synchronizer Shuttle (Reverse) Solenoid is toward the rear of the tractor.CHAPTER 2 FAULT CODE 68 – SYNCHRONIZER SHUTTLE (REVERSE) SOLENOID OR ECM DRIVER IS SHORT TO 12 VOLTS. HF Menu. on/off. • Faulty ECM. • Faulty Synchronizer Shuttle (Reverse) Solenoid Coil. the Synchronizer Shuttle (Reverse) Solenoid become energized by a short circuit to 12 volts. .TRANSMISSIONS -. channel 13 is not within range. Only reverse engagement is operational. Tests: • H9. or between the Synchronizer Shuttle (Reverse) Solenoid Coil terminal and ECM connector 1. • HD displays “unkn”.

. SECTION 21 -. Disconnect the control panel and the connections (129) on the ECM. Eliminate the cause of the short circuit to +12V. Is there a reading of +12V between pin CN1--17 (SN) on connections (129) and ground? YES Check the wiring between pin CN1--17 (SN) on connections (129). pin (B4) (SN) on connection (158) and connection (65) on the solenoid valve. NO Replace the ECM.CHAPTER 2 247 Turn the starter key to the OFF position.TRANSMISSIONS -.

248 SECTION 21 -.TRANSMISSIONS -.CHAPTER 2 PAGE LEFT BLANK .

5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 BC (13) 0.5 BG (7) 0.5 LB (12) 0.5 RN (15) 0.5 A (27) 1 N (16) 0.5 V (19) 0.5 LN (8) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 S (24) 0.TRANSMISSIONS -.5 HB (36) 1 BV (30) 1 N (13) 0.5 MB (1) 1 C (C5) 1 SG (C4) 1 AB (C6) 1 HL (C3) 1 HG (C7) 1 AV (C2) 1 AR (C8) 1 GR (C1) 158 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 GN (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HV (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .CHAPTER 2 249 FAULT CODE 68 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 1 SG (3) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 G (33) 1 MN (34) 0.5 M (12) 1 ZN (2) 0.5 L (8) 0.5 AB (20) 0.5 R (15) 0. SECTION 21 -.5 AN (26) 1 HM (25) 0.

• Faulty Wheel Speed Sensor (Aa).TRANSMISSIONS -. is not within range. Recovery: • Cause must be resolved and error must be cleared using the CDU. Tests: • H9. channel 19. circuit shorted to ground or open between ECM connector 2. • Faulty ECM.8 volts.250 SECTION 21 -. . • H5 doesn’t display “d35”. Conditions: • The ECM detects voltage at ECM connector 2. No acceleration feedback monitored during automatic take-off (ATO). Power Shuttle FNR Lever may not work properly. Causes: • Faulty wiring. or across sensor terminals. Effects: • Transmission is modified. HF Menu. pin 36 and Wheel Speed Sensor (Aa).CHAPTER 2 FAULT CODE 69 – WHEEL SPEED SENSOR (Aa) SHORT TO GROUND OR OPEN. pin 36 is below 1.

nection (69). on the sensor and pin (B3) (HB) on con- Eliminate the cause of the short to ground. (Speed sensor wiring Aa) 76 0.CHAPTER 2 251 Turn the starter key to the OFF position.5 VN .TRANSMISSIONS -. connection (69). Eliminate the cause of the short to ground. Replace the ECM. Disconnect the control panel and the con- Lift the engine bonnet and disconnect nections (85) on the ECM. NO NO Is pin CN2--36 (HR) on connections (85) Is pin (B3) (HB) (wiring side) in short to (wiring side) in short to ground? ground? YES YES Check the wiring between pin CN2--36 (HB) Remove the rear left--hand wheel. on connections (85) and pin (B3) (HB) on Check the wiring between connection (76) connection (69). SECTION 21 -.

TRANSMISSIONS -.252 SECTION 21 -.CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 135 Art Shown As If Sitting In Operator’s Seat .

5 AB (20) 0.5 RN (15) 0.5 BC (13) 0.5 R (15) 0.5 S (24) 0.5 AN (26) 1 HM (25) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 MB (1) 1 GN (C5) 1 BV (C4) 1 AB (C6) 1 B (C3) 1 HL (C7) 1 S (C2) 1 BR (C8) 1 G (C1) 69 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 H (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HG (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 L (8) 0.CHAPTER 2 253 FAULT CODE 69 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 BG (7) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 LB (12) 0.5 A (27) 1 N (16) 0.5 HR (11) 1 MN (10) 1 HG (21) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.TRANSMISSIONS -.5 G (33) 85B 1 MN (34) 0.5 V (19) 0.5 M (12) 1 ZN (2) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 LN (8) 0. SECTION 21 -.

The F/R Synchronizer is in the Hi-Lo (forward) position when it is shifted toward rear of tractor. • Faulty F/R Synchronizer Shift Piston in Power Shuttle Control Valve. • H5 doesn’t display “d27” or “d28”.254 SECTION 21 -. The F/R Synchronizer is in the Shuttle (reverse position when it is shifted toward front of tractor. • HD displays “unkn”.TRANSMISSIONS -. (NOT USED TN Standard) NOTE: The Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. Conditions: • The ECM is unable to change the position of the F/R Synchronizer within 30 seconds after the tractor has been started. NOTE: On the 32x16 transmission. • Faulty F/R Synchronizer shift rail or fork.) • Faulty ECM. Causes: • Faulty F/R Synchronizer. HF Menu. . (Transmission oil temperature too cold. Tests: • H9. channel 5 or 6 are not within range. (above 0_C/32_F). Recovery: • Cause must be resolved and error must be cleared using the CDU. Effects: • Transmission is disabled. the ECM will attempt to change position of the F/R Synchronizer each time the key switch is turned to the “ON” or to the “START” position. • Faulty Temperature Sensor.CHAPTER 2 FAULT CODE 71 – F/R SYNCHRONIZER UNABLE TO CHANGE POSITION DURING START UP. this error could correct itself after the F/R Synchronizer has been successfully shifted into a different position. They will flash in a alternating manner. if oil temperature is OK. • Faulty Synchronizer Hi-Lo (Forward) or Shuttle (Reverse) Position Switches (T and S).

TRANSMISSIONS -. Remove the rear left--hand wheel. alternately power--up the two Shuttle and HI -. Disconnect the synchroniser solenoid valves (Shuttle/HI--LO) and the two relative synchroniser position sensor pushbuttons.CHAPTER 2 255 Turn the starter key to the OFF position. . 2.LO solenoid valves. Using an external battery. Start the engine and accelerate to 1000 rpm.7 kΩ pushbutton re- leased). SECTION 21 -. Does the fault persist? YES Check the synchroniser unit and the relative hy- draulic system to eliminate the cause of the fault. Using a digital tester.LO and Shuttle). Replace the two synchroniser position sensor pushbuttons (HI -. Does the fault persist? YES Start the engine and accelerate to 1000 rpm. check that the synchroniser position sensor pushbuttons are pressed alter- nately. (560 Ω pushbutton pressed.

channel 5 or 6 are not within range. the ECM will attempt to change position of the F/R Synchronizer each time the key switch is turned to the “ON” or to the “START” position. Conditions: • The ECM detects a change in the position of the F/R Synchronizer without a command from the PS FNR Lever. . Effects: • The Transmission Status Lamp is flashing. HF Menu.TRANSMISSIONS -. Recovery: • Cause must be resolved and error must be cleared using the CDU. The F/R Synchronizer is in the Hi-Lo (forward) position when it is shifted toward rear of tractor. • Transmission is disabled.256 SECTION 21 -. but can be re-enabled by cycling the Power Shuttle FNR Lever or Clutch Pedal. • Faulty F/R Synchronizer Shift Piston in Power Shuttle Control Valve.CHAPTER 2 FAULT CODE 72 – F/R SYNCHRONIZER DISENGAGED FROM POSITION. NOTE: On the 32x16 transmission. • H5 doesn’t display “d27” or “d28”. • Faulty ECM. They will flash in a alternating manner. • Faulty F/R Synchronizer shift rail or fork. • HD displays “unkn”. (NOT USED TN Standard) NOTE: The Transmission Status Lamp is the Hi(Rabbit) and Lo(Turtle) lamps. • Faulty Synchronizer Hi-Lo (Forward) or Shuttle (Reverse) Position Switches (T and S). Causes: • Faulty F/R Synchronizer. The F/R Synchronizer is in the Shuttle (reverse position when it is shifted toward front of tractor. Transmission will only operate in the previous shuttle direction. Tests: • H9.

(560 Ω pushbutton pressed. Using an external battery. check that the two synchro- niser position sensor pushbuttons are pressed al- ternately. Start the engine and accelerate to 1000 rpm. Replace the two synchroniser position sensor pushbuttons (HI -.CHAPTER 2 257 Turn the starter key to the OFF position. Does the fault persist? YES Start the engine and accelerate to 1000 rpm. Disconnect the synchroniser solenoid valves (Shuttle/HI--LO) and the two relative synchroniser position sensor pushbuttons.LO and Shuttle). Does the fault persist? YES Check the synchroniser unit and the relative hy- draulic system to eliminate the cause of the fault. alternately power--up the two Shuttle and HI -.7 kΩ pushbutton re- leased). SECTION 21 -. 2. . Using a digital tester.LO solenoid valves.TRANSMISSIONS -. Remove the rear left--hand wheel.

but can be re-enabled by cycling the Ignition Switch. Causes: • Faulty Battery. ECM detects that the voltage at ECM connector 2. Tests: • H9.258 SECTION 21 -. (shutting off the tractor). channel 3. • Faulty Alternator. ECM stops sending diagnostic pulses to the sensors. Conditions: • When tractor is on.TRANSMISSIONS -. Dump solenoid stays energized. • Overcharged Battery. is above 762. HF Menu. This error will automatically clear when voltage dropped below 16 volts Recovery: • Cause must be resolved and error must be cleared using the CDU. . or solenoids. Indicator lights will not illuminate when key switch is in the “ON” or “Start” position.3 seconds. Effects: • Transmission is critically disabled. pin 34 or ECM connector 2. pin 10 is above 18 volts for longer that 0.CHAPTER 2 FAULT CODE 73 – ECM (2) SUPPLY VOLTAGE (12VF) IS TOO HIGH. switches.

YES Replace the ECM (1).TRANSMISSIONS -. Check the recharging system and re- NO place the alternator if the voltage is Using a digital tester. SECTION 21 -. measure the battery voltage. (ECM 1) . Is the voltage ∼ 14V? much higher than +14 V. Start the engine and accelerate to 1200 rpm.CHAPTER 2 259 Turn the starter key to the OFF position.

CHAPTER 2 FAULT CODE 74 – ECM SUPPLY VOLTAGE (12VF) IS TOO LOW. but can be re-enabled by cycling the Ignition Switch. HF Menu. ECM detects that the voltage at ECM connector 2. • Faulty Alternator.260 SECTION 21 -. Indicator lights will not illuminate when key switch is in the “ON” or “Start” position. Tests: • H9. This error will automatically clear when voltage raises above 9 volts. or solenoids. Effects: • Transmission is critically disabled. Causes: • Faulty Battery. (shutting off the tractor).3 seconds.TRANSMISSIONS -. Recovery: • Cause must be resolved and error must be cleared using the CDU. switches. ECM stops sending diagnostic pulses to the sensors. • Undercharged Battery. pin 34 or ECM connector 2. . Dump solenoid stays energized. Conditions: • When tractor is on. is below 428. pin 10 is below 9 volts for longer that 0. channel 3.

5 LB (12) 0.5 G (33) 85B 1 MN (34) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 MB (1) . Check the wiring between connec- Turn the starter key to the ON position.5 LR (9) 1 AV (22) 1 HL (23) 0.5 L (8) 0. Remove the left--hand panel located under the dashboard. SECTION 21 -.5 AB (20) 0. on connections (85) and ground.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.CHAPTER 2 261 Turn the starter key to the OFF position.5 BG (7) 0. page 2) Does it work? YES Disconnect the control panel and the connections (85) on the ECM. NO tions (85) and the fusebox and elimi- Between pin CN2--10 (MN) and pin CN2--34 (MN) nate the cause of the open circuit.5 R (15) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 AN (26) 1 HM (25) 0.5 RN (15) 0.5 HR (11) 1 MN (10) 1 HG (21) 0. is the reading +12V? YES Replace the ECM. Fuse F16 (5A) (Section 55. Chapter 5.5 S (24) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.TRANSMISSIONS -.5 A (27) 1 N (16) 0. NO Replace the fuse. 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 LN (8) 0.5 M (12) 1 ZN (2) 0.5 BC (13) 0.5 V (19) 0.

The tractor performance may be affected in the area where setting have been changed to improve characteristics. Tests: • No H Menu for diagnostic check.262 SECTION 21 -. HF Menu.CHAPTER 2 FAULT CODE 76 – ECM TRIPLICATE READ ERROR IN THE NON-VOLATILE MEMORY (NVM). Causes: • Damaged Electrically Erasable Programmable Read Only Memory (EEPROM) micro-chip. & HE). H3. . Effects: • Transmission is modified. H6.TRANSMISSIONS -. Conditions: • It is impossible to recall any data from the NVM because all three stored copies are different. ECM will re-set to default settings. H7. Recovery: • Cause must be resolved and error must be cleared using the CDU. • Faulty ECM (2). (H2. The ECM will try to store any self learned or collected data when tractor is shut down.

TRANSMISSIONS -.SECTION 21 -.CHAPTER 2 263 (ECM 1) .

Causes: • Faulty ECM (2). HF Menu.264 SECTION 21 -.TRANSMISSIONS -. (shutting off the tractor). but can be re-enabled by cycling the Ignition Switch. This is a internal print board circuit error.CHAPTER 2 FAULT CODE 77 – INTERNAL ECM SUPPLY VOLTAGE (8V) IS TOO HIGH. NOTE: This pin is not used externally as an actual output. . Tests: • No H Menu for diagnostic check. Effects: • Transmission is critically disabled. • Internal circuit short to 12 volts. pin 35 is above 8 volts. Conditions: • The ECM detects that the voltage at ECM connector 2. pin 35 is/was shorted by an external 12 volt source. • ECM connector 2. Recovery: • Cause must be resolved and error must be cleared using the CDU.

SECTION 21 -.TRANSMISSIONS -.CHAPTER 2 265 (ECM 1) .

HF Menu.266 SECTION 21 -. pin 35 is below 8 volts. NOTE: This pin is not used externally as an actual output. . Effects: • Transmission is critically disabled. Recovery: • Cause must be resolved and error must be cleared using the CDU. but can be re-enabled by cycling the Ignition Switch. pin 35 is/was shorted to an external ground or 5 volt source. This is a internal print board circuit error. Conditions: • The ECM detects that the voltage at ECM connector 2. Causes: • Faulty ECM (2). Tests: • No H Menu for diagnostic check. • Internal circuit short to ground.TRANSMISSIONS -.CHAPTER 2 FAULT CODE 78 – INTERNAL ECM SUPPLY VOLTAGE (8V) IS TOO LOW. • ECM connector 2. (shutting off the tractor).

CHAPTER 2 267 (ECM 1) .TRANSMISSIONS -.SECTION 21 -.

a signal is sent from the ECM to the dump solenoid.268 SECTION 21 -.CHAPTER 2 FAULT CODE 81 – TRANSMISSION HYDRAULIC OIL PRESSURE SWITCH SHORT TO GROUND OR OPEN. Or common 5 volt sensor supply wire from ECM connector 2. pin 31. Tests: • H5 doesn’t display “d30”. HF Menu. pin 20 is shorted to ground or open between switch and any other 5 volt sensor. the pressure switch reaches a pressure above 11 bar (160 psi). Causes: • Faulty wiring. • Faulty ECM.TRANSMISSIONS -. If this doesn’t happen within 30 seconds the error is registered. allowing the clutch packs to engage. Conditions: • The ECM detects a short to ground or open between Transmission Pressure Switch and ECM connector2. . If the error is present and oil temperature is above 0_(32_F) the transmission is still operational. pin 31. or between the switch terminals. pin 20 and Transmission Pressure Switch. Recovery: • Cause must be resolved and error must be cleared using the CDU. transmission oil pressure information is not available. During the first 30 seconds of start up. Effects: • Transmission is modified. • Faulty Transmission Pressure Switch. or between the Transmission Pressure Switch and ECM connector2. circuit shorted to ground or open between ECM connector 2.

NO Replace the pressure switch. Remove the rear left--hand wheel and the solenoid NO Connect the connections. check: does the pressure NO NO Is the oil pressure ∼ 16 bar (232 psi)? switch open? YES Check the hydraulic system.TRANSMISSIONS -. Check the hydraulic system. NO nection (69)? YES Replace the ECM. valves unit guard. Is there electrical continuity between pin CN2--31 NO (SN) on connections (85) and pin (B4) (SN) on con- nection (69)? YES Is there electrical continuity between pin CN2--20 (AB) on connections (85) and pin (C6) (AB) on con. Is there electrical continuity between wire (AB) on NO Check the wiring and eliminate the the pressure switch connection and pin (C6) (AB) cause of the open circuit. Using a digital tester. Are the pressure switch connections connected? YES Disconnect the pressure switch and the dump so- lenoid valve connections. SECTION 21 -. Using a digital tester. on connection (69)? YES Is there electrical continuity between wire (SN) on the pressure switch connection and pin (B4) (SN) NO on connection (69)? YES Disconnect the control panel and the connections (85) on the ECM.CHAPTER 2 269 Turn the starter key to the OFF position. . check: is the pressure switch normally closed? YES YES Start the engine. Turn the starter key to the OFF position.

270 SECTION 21 -.CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 136 Art Shown As If Sitting In Operator’s Seat .TRANSMISSIONS -.

CHAPTER 2 271 FAULT CODE 81 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 MB (1) 1 GN (C5) 1 BV (C4) 1 AB (C6) 1 B (C3) 1 HL (C7) 1 S (C2) 1 BR (C8) 1 G (C1) 69 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 H (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HG (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.5 LN (8) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.5 AB (20) 0.5 L (8) 0. SECTION 21 -.5 M (12) 1 ZN (2) 0.5 A (27) 1 N (16) 0.5 V (19) 0.5 G (33) 85B 1 MN (34) 0.5 RN (15) 0.5 R (15) 0.TRANSMISSIONS -.5 HR (11) 1 MN (10) 1 HG (21) 0.5 LB (12) 0.5 BG (7) 0.5 VN (29) 1 N (14) 1 BG (28) 0.5 BC (13) 0.5 S (24) 0.5 AN (26) 1 HM (25) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.

or short to 5v across switch terminals. Tests: • H5 doesn’t display “d30”. the pressure switch reaches a pressure above 11 bar (160 psi).CHAPTER 2 FAULT CODE 82 – TRANSMISSION HYDRAULIC OIL PRESSURE SWITCH SHORT TO 5 OR 12 VOLTS. or short to 5 or 12v between the Transmission Pressure switch and ECM connector2. Recovery: • Cause must be resolved and error must be cleared using the CDU.272 SECTION 21 -.TRANSMISSIONS -. pin 20 is shorted to 12v between switch and any other 5 volt sensor. a signal is sent from the ECM to the dump solenoid. pin 31. Conditions: • The ECM detects a short to 5 or 12 volts between Transmission Pressure Switch and ECM connector2. • Faulty Transmission Pressure Switch. Effects: • Transmission is modified. If the error is present and oil temperature is above 0_(32_F) the transmission is still operational. circuit short to 12 volts between ECM connector 2. pin 20 and Transmission Pressure Switch. Or common 5 volt sensor supply wire from ECM connector 2. During the first 30 seconds of start up. Causes: • Faulty wiring. . • Faulty ECM. allowing the clutch packs to engage. If this doesn’t happen within 30 seconds the error is registered. transmission oil pressure information is not available. pin 31. HF Menu.

pin (C6) (AB) and (B4) (SN) on connec- tion (69) and pins CN2--20 (AB) and CN2--31 (SN) on connections (85) on the ECM. Remove the rear left--hand wheel and the solenoid valves unit guard.CHAPTER 2 273 Turn the starter key to the OFF position. Eliminate the cause of the short circuit. .TRANSMISSIONS -. Disconnect the pressure switch connections. Are wires (AB) and (SN) in short circuit? YES Check the wiring between the pressure switch con- nections. NO Replace pressure switch. SECTION 21 -.

CHAPTER 2 ECM PIN REFERENCE PIN 1 PIN 1 CN1 CN2 PIN 7 PIN 13 PIN 13 PIN 25 50032193 CONNECTOR 1 (85A) CONNECTOR 2 (85B) 137 Art Shown As If Sitting In Operator’s Seat .TRANSMISSIONS -.274 SECTION 21 -.

5 VN (29) 1 N (14) 1 BG (28) 0.5 A (27) 1 N (16) 0. SECTION 21 -.5 L (8) 0.5 G (33) 85B 1 MN (34) 0.5 LB (12) 0.5 LN (8) 0.5 R (15) 0.5 RN (15) 0.5 V (19) 0.5 BC (13) 0.5 M (12) 1 ZN (2) 0.5 S (24) 0.5 MB (1) 1 GN (C5) 1 BV (C4) 1 AB (C6) 1 B (C3) 1 HL (C7) 1 S (C2) 1 BR (C8) 1 G (C1) 69 1 ZB (B8) 1 N (B1) 1 BR (A8) 1 MB (A1) 1 AN (B7) 1 H (B2) 1 GL (A7) 1 HM (A2) 1 VN (B6) 1 ZN (B3) 1 HG (A3) 1 BG (B5) 1 SN (B4) 1 BN (A5) .5 AN (26) 1 HM (25) 0.5 LR (9) 1 AV (22) 1 HL (23) 0.5 B (18) 1 GL (4) 1 C (3) 1 HV (2) 0.CHAPTER 2 275 FAULT CODE 82 1 ZB (18) 1 SN (17) 1 GN (16) 0.5 AG (9) 1 AN (6) 1 AR (10) 1 BR (5) 1 BN (11) 1 GR (4) 85A 1 SG (3) 0.5 BG (7) 0.5 AB (20) 0.5 HB (36) SN (31) 1 BV (30) 1 N (13) 0.TRANSMISSIONS -.5 HR (11) 1 MN (10) 1 HG (21) 0.

14 Parking brake ON output signal. 20 Connection for Troubleshooting unit 294084.3b: on power supply control unit circuit. 9 Clutch A (forward gears) solenoid valve.276 SECTION 21 -. 41 Sensors power supply (+5V). 13 Dump solenoid valve (hydraulic neutral safety). 5 Clutch pedal switch for power supply control unit circuit. 43 Battery. 40 Clutch pedal potentiometer signal. 39 Shuttle lever in forward gears selection position. 38 Shuttle lever in reverse gears selection position. 24 Troubleshooting unit 294084. 35 Transmission oil temperature sensor.CHAPTER 2 POWER SHUTTLE (8 + 8 and 16 + 16) ELECTRONIC CONTROL UNIT INPUT/OUTPUT WIRING DIAGRAM 1 Starter switch. 27 Parking brake ON switch. 2 Starter relay. 6 Transmission oil pressure sensor indicator light. 15 Shuttle lever output signal (to 4WD control unit) if reverse gear is selected. 16 Speed sensor amplified signal to instrument panel. 3 Shuttle control lever. for acoustic alarm. 19 Power ground.TRANSMISSIONS -. 21 Pushbutton Y. 30 Speed shift position sensor switch (C1). 4 Clutch pedal switch for engine starting circuit. .1b: gear function. 17 Bodywork ground. 26 Engine revs sensor (from alternator). 3a: on engine starting circuit -. 1a: starter function -. 23 HMENU selection pushbutton. 29 Transmission oil pressure for control unit activation. 42 Emergency cable for ”limp home” after electrics breakdown. 28 Range position sensor switch (G1). 8 Transmission alarm indicator light. 34 Driving seat safety switch. 33 To fuse 15. 25 Speed sensor. 10 Clutch B (forward gears) solenoid valve (reverse gears). 18 Sensors ground. 22 Pushbutton B.

TRANSMISSIONS -.CHAPTER 2 277 POWER SHUTTLE ELECTRONIC CONTROL UNIT INPUT/OUTPUT WIRING DIAGRAM (8 + 8 and 16 + 16) 2 FUSE 16 (5A) 1a 3a 4 5 3b FUSE 14 (5A) 6 FUSE 7 (10A) 41 FUSE 9 (10A) 40 FUSE 15 (5A) 8 FUSE 7 (10A) 1b 39 38 9 43 10 NTC 1140 a 0o -. SECTION 21 -.330 a 40o 35 34 42 33 9 13 30 14 10 29 SW--3 CN2--31 15 28 SW--3 CN2--31 27 16 24 26 680 23 25 22 21 19 18 17 20 MPD2821A .

278 SECTION 21 -.CHAPTER 2 .TRANSMISSIONS -.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 23 101 26 Transmission shafts and guard. . . . . . . . . . . . . . . 2 Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . 9 23 202 50 Drive gear housing assembly. . . . . . . . . . . . 7 Troubleshooting . . . . . . . . . . . . . .Assembly . . . . . . . . . . . . . . . . . . . . . . . .CHAPTER 1 1 SECTION 23 -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive Lines CONTENTS Section Description Page 23 000 Main data . . .Installation . . . . . . . .Assembly . .Installation . . . . . . . . . . . . . 11 23 202 52 Drive gear housing assembly removed. . . . Removal -. . . . . . . . . . . . . . SECTION 23 -. . . 43/28X28/39 = 1:1. . . . . . . . . . . . . . .DRIVE LINES Chapter 1 -. . . . . . . . . . . . .DRIVE LINES -. . . . . . . . . . . . . . . . . . . . . . . . 1 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description. . . . . . . . . . . . . . 9 23 101 42 Drive gear housing assembly removed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . operation and hydraulic diagrams . . . . . . . . . . . . .1 . Disassembly -. . . . . . . . . . . . . . . . Disassembly -. . . . . 13 MAIN SPECIFICATIONS Reduction ratio of drive gear device (on all models) . . . .Assembly . Removal -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly -. . . . . . . . . 8 23 101 40 Drive gear housing assembly. .

. .5 88 65 .DRIVE LINES -. lbs) 27836 1 Tightening torque PART Thread Nm lfb.88 Nm (65 ft.lb Transmission shaft central support retaining bolt (C1) . . .2 SECTION 23 -.CHAPTER 1 TORQUE SETTINGS C1 -. . . . . M 12 x 1. .

X 294049 Key for Ø 50 mm (1.9685 in.DRIVE LINES -. 27827 2 Tool to make for drive gear unit removal. X 294050 Key for Ø 35 mm (1.) piston. (Stamp no. To work safely and efficiently and obtain the best re- sults.) piston.Measurement in mm) Construct in Fe 42C material. . it is also necessary to use the recommended specific tools listed below and certain other tools which are to be made according to the drawings in- cluded in this manual. List of specific tools required for the various op- erations described in this section.The operations described in this section cannot be carried out without the ESSENTIAL tools marked with an (X). SECTION 23 -. X 294098 Drive shaft seal key.3780 in. 50161 on the tool -.CHAPTER 1 3 TOOLS Warning -.

7874 in.DRIVE LINES -.Measurement in mm) Construct in C40 material. (Stamp no.4 SECTION 23 -. .CHAPTER 1 27828 3 Tool to make for drive gear shaft removal.). Pin mm 3 x 20 (0. 50141 on the tool -.1181 to 0.

15. 2. 9. 11. SECTION 23 -. Thrust washer. Circlip. 12. 4. Chapter 1). Bearing. 16. 8. 3. Dust ring. 18. apply sealing compound to the surfaces X (see Section 27. NOTE: On installation. 13. Bearing. . Seal.DRIVE LINES -. Driven shaft. External control lever. Coupling sleeve. Lever return spring (17). 5. Circlip. Circlip. 6. 7. Control pad. Thrust washer.CHAPTER 1 5 1 2 3 4 5 6 7 8 9 10 11 12 13 27832 14 10 13 15 16 17 18 27833 4 Sectional view of drive gear with mechanical coupling 1. 14. Seal. Circlip. Transmission oil drainage plug. Driving gear. 17. 10.

Special screw spring 6. Washer. Spring 9. Handle grip 13. O ring. roll 2. Engagement control fork 3. Pin. M6 18. Bushing .DRIVE LINES -. locking. 2 x 18 8.88 22.CHAPTER 1 20032191 5 Mechanical 4WD Engagement / Disengagement Idler Controls 1. Washer. D=14 10. Ring. Nut. Bushing 5. Pin. Pin. roll 14.62 x 15. 2. Washer. Slide block engagement relay lever 20. Lever 4. Bushing 17. 10 x 21 11. Lock. 14 x 25 7. Screw. split (cotter). M6 x 1 19. M6 x 14 15. Tie-rod 12. CL 8.6 SECTION 23 -. 4WD coupling inner lever 21. Seat/Slot/Spherical bushing 16. Lever.

remove corrosion with emery cloth. Check moving parts affected. axle by means of the transmission shaft that connects MECHANICAL 4WD TROUBLESHOOTING Problems Possible causes Remedies 4WD will not engage or Lever (10) seizing up in 4WD drop Remove drop box and clean lever disengages shortly thereafter. (10). . Any part of engage/disengage Break loose. SECTION 23 -. disassemble parts. Drive gear engagement and disengagement by sion shaft via gear unit (10. means of the mechanical 4WD lever on the floor to Drive is then transmitted from the shaft (1) to the front the left of the seat.CHAPTER 1 7 DESCRIPTION AND OPERATION The drive gear housing is mounted below the rear the two units. Cotter pin (18) missing allowing the bushing lever to come out and hang up on moving parts. transmission gearbox and is driven by the transmis. fig. box. replace worn/damaged parts. upon assembly lubricate all mating surfaces with grease. 4).DRIVE LINES -. linkage damaged/seized up. insert cotter pin. clean any seized area.

Extract the rear circlip and unscrew the sleeve (1) back on the splined shaft. . Unscrew the central support bolts and extract the transmission shaft. To remove. Fit and secure the guard. central and rear retaining bolts and remove the transmission shaft guard (1). -. proceed as follows: 27801 1. 23 101 26 TRANSMISSION SHAFTS AND GUARD Disassembly--Assembly WARNING Handle all parts carefully. pro- ceed as follows: WARNING Always use appropriate tools to align fixing holes. To re--fit the transmission shaft and guard. Unscrew the front. NEVER USE YOUR FINGERS OR HANDS.DRIVE LINES -.safety goggles. 27802 7 -. Do not put your hands or fingers between parts. gloves and shoes. Fit and secure the transmission shaft in position. 4.CHAPTER 1 Op. 3.8 SECTION 23 -. 6 2. Wear suitable safety clothing -.

SECTION 23 -. 23 101 40 -. Carry out operation 23 101 26: Transmission shafts and guard. 25628 2. 1 50030468 9 . Do not put your hands or fingers between parts. 8 3.23 202 50 DRIVE GEAR HOUSING ASSEMBLY Removal--Installation WARNING Handle all parts carefully. 1. Remove the drainage plug and collect the oil in a suitable. Wear suitable safety clothing -. Detach the drive gear engagement control lever (1). gloves and shoes.CHAPTER 1 9 Op.DRIVE LINES -. only removal (see page 10).safety goggles.

10 SECTION 23 -. only installation (see page 10). Carry out operation 23 101 26: Transmission shafts and guard. -. as shown in Section 27. Fit the drive gear housing on the transmission gearbox. Carefully clean the contact surfaces. proceed as fol- lows. WARNING Always use appropriate tools to align fixing holes. 25982 10 5. 25983 -. Respect the tightening torques prescribed on page 2. Remove the drive gear housing (1) from the transmission gearbox. Replace the transmission oil drainage plug. Chapter 1.CHAPTER 1 4. -. -. Connect the drive gear engagement control lever. see Section 00. 6. page 6). Unscrew the eight drive gear housing retaining bolts (1) on the transmission gearbox. -. -.787 in. 11 0. -. -. 2 mm -. . Apply the sealing compound (approx. NEVER USE YOUR FINGERS OR HANDS. To re--fit the drive gear housing. Refill the rear transmission gearbox (for products and quantities.DRIVE LINES -. -.in thickness).

Proceed as follows. Remove the circlip (5) and washer (4). Carry out operation 23 101 40 Drive gear housing assembly. Carry out operation 23 101 26: Transmission shafts and guard. gloves and shoes. SECTION 23 -. 23 101 42 DRIVE GEAR HOUSING ASSEMBLY REMOVED Disassembly--Assembly WARNING Handle all parts carefully. the in- ternal lever (2) and the coupling pad (1).safety goggles. 2. 1.CHAPTER 1 11 Op. Remove the circlips and ball bearings (1) from the seatings. Remove the dust ring (1) and seal (2). 1 2 6 3 4 27834 5 14 .DRIVE LINES -. Do not put your hands or fingers between parts. only removal (see page 11). 25984 3. 25985 13 5. 12 4. extract the pin (3) and remove: the external lever (6). only removal (see page 10). Wear suitable safety clothing -.

Carry out operation 23 101 40 Drive gear housing assembly. Extract the coupling sleeve (1). then assemble the gear unit. 4 -. fit the seal and dust ring (use the spacer to fit the dust ring). washer and circlip.DRIVE LINES -. To refit the drive gear housing. Insert the shaft in the housing.12 SECTION 23 -. only installation (see page 11). Carry out operation 23 101 26: Transmission shafts and guard. -. WARNING 3 Always use appropriate tools to align fixing holes. Fit the bearing and relative circlips. remove the circlip (3) and remove: the washer (4). -. the gear unit (5) 1 and the shaft (2). 27835 5 -. 7. the external lever. -. proceed as fol. 25989 16 . only installation (see page 10). Fit the internal lever. Using tool 294098. -. 2 lows. the cou- 15 pling pad.CHAPTER 1 6. NEVER USE YOUR FINGERS OR HANDS. securing in position by means of the washer and relative circlip.

SECTION 23 -. Remove the pin (1) fitted on the opposite end of the shaft and slide off the oil delivery union. 25986 19 . 1. Carry out operation 23 101 26: Transmission shafts and guard. Wear suitable safety clothing -. Do not put your hands or fingers between parts. 25984 17 4. Remove the circlips and ball bearings (1) from the seatings. gloves and shoes. Proceed as follows. 23 202 52 DRIVE GEAR HOUSING ASSEMBLY REMOVED Disassembly--Assembly WARNING Handle all parts carefully. 3. 25985 18 5. Remove the dust ring (1) and seal (2).DRIVE LINES -. only removal (see page 10). only removal (see page 11). 2. Carry out operation 23 202 50 Drive gear housing assembly.CHAPTER 1 13 Op.safety goggles.

NO TAG) must be 21 inserted in their respective housings as quickly as possible in order to avoid deformation. 3) and an extracting tool applied to the end of the shaft. the 4--WD coupling unit and the oil delivery manifold. . -. -. Carry out operation 23 202 50 Drive gear housing assembly. -. compress the spring.14 SECTION 23 -. only installation (see page 11). -. the oil delivery manifold. remove the gears. fit the seal and dust ring (use the spacer to fit the dust ring)). Fit the oil delivery union and secure the shaft by means of the circlip. Lubricate all parts. -. -. the bearing. 2). NEVER USE YOUR FINGERS OR HANDS. proceed as fol- lows. Check all parts and replace if worn. extract the retaining ring and remove the spring.NO TAG) to remove it from the housing. Carry out operation 23 101 26: Transmission shafts and guard. -. using (respec- tively) tools 294049 and 294050. 25988 X- 20 8. wash- er and retaining ring. -. fig. To refit the drive gear housing. Fit the shaft. fig. only installation (see page 10). Using a press and tool 50161 fit the spring. -. re- placing if necessary. -.CHAPTER 1 6. 25989 NOTE: The seals (13 and 15. 7.DRIVE LINES -. Fit the bearing and relative circlips. Using a hydraulic press and tool 50161 (see fig. Insert the piston in the seating. the 4--WD coupling assembly and the bearing in the drive gear housing. Move the end of the piston (mobile coupling 16. Using tool 294098. -. Using tool 50141 (see fig. manipulating the washer. WARNING Always use appropriate tools to align fixing holes. Check the seals and the metal seal segments.

. . .FRONT AXLE MECHANICAL TRANSMISSION Chapter 1 -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhaul . . . . Disassembly--Assembly . . . . . . . . . . .6 mph): -. . . . . . . . . . . . . . . . model TN 55 . 9/42 = 1:4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . models TN 65. . . . . . . . . . . . models TN 65. . . . . . . . . . . . 10 Description and Operation .CHAPTER 1 1 SECTION 25 -. . . . . . 1 Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . 30 Bevel Drive Adjustments .75 Backlash between bevel drive teeth: -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . load bearing structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 -. . . . . . . . . . . . .6 mph): -. . . . . . mm 0. . . . . . . . TN 65. . . . . . . . . . . . . . TN 70 and TN 75 . . . . . . . . . . . . .378 (continued overleaf) . . . . . . . 8/30 = 1:3. . . . . . . . . . . . . . . . . . .0079) Ratio between front wheel revs and rear wheel bevel drive revs 30 km/h (18. . . . . . . . . . . Removal--Replacement--Installation 22 25 100 38 Bevel Drive and Front Axle Differential Axle Housing. . . . . . . . . . . . . . . . . . SECTION 25 -. . . . . . . . . . . . . . . . . . . . . . . model TN 55 . . . . . . . . Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cross--sectional Views . . . . . . 40 25 102 27 Front Axle Differential with LIM--Slip Unit. . . . . . . . . . . . . . . . . . . . . . . . .differential Pinion--crown gear ratio 30 Km/h (18. . . . . . . . . . . . . . pivoting at centre Bevel drive -. . . . . . . . . . . . . . . 4 Tools . . . . . . . . . . . . . . . . . . . . . . steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FRONT AXLE MECHANICAL TRANSMISSION -. . . . . . . . . . . . . 41 44 511 80 Leading Drive Wheels Toe-in Check . . . . . . . . . . . .402 -. . . . . . . . . . . . . . . . . . . . . . . 12 25 108 30 Front Epicyclic Final Drive. . . . . . . . . . . . . . . . . . . . 22 25 100 38 Wheel Hubs and Steering Knuckle Pins and Bearings. . . . . . . . . . 11 25 100 30 Front Axle. . . . . 33 25 102 24 Front Axle Differential. . . . . . . . . . . . . . . . . . . . . . . . 43 MAIN DATA Type . 16 25 108 46 Steering Knuckle Bearing Pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 (in. . . . . . . models TN 55. . . . . . . 25 25 102 20 Front Axle Bevel Drive. . . . . . . . . . . . . . . . . . . . . . . . . . 1. . . . . . . . . . . . . . 1. . . . . . . . . . . . . Removal--Installation . . . . . . . . . .) 0. . . . . .15 to 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhaul . . . . . . TN 70 and TN 75 . . . . . . . . .0059 to 0. . . . . .Front Axle Mechanical Transmission CONTENTS Section Description Page 25 000 Main Data . . . Replacement . . . . . . . . . . . TN 70 and TN 75 . . . . . . . . Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0. . . . ..5 -. . . .0984 -.2 -.1398 -- 0.3.0.. .0. fig.6 -- 1.25 -.4.0. . .95 -.6 -.0. . .2.. . .3.2 -.200 (in.. . . . .15 (in. .0551 -. . ..00 -.3. .. .0. . . . . . .0670 -.1. . . . . . .. . . .1. . . .8 -.0059 -.0.3. . . mm 2.3.0.0 (in.. . .1. . .3. .0. .1 -.6 -. ..1358 -. .0.. .652 to 52.5 -.) (0. mm 0. . . .9 -. .45 -.0303 to 0.0. .1 (in. . . .175 (1) (in.3. .0579 to 0. .4.5 -.0. . .1. .0051) Thickness of steering knuckle bearing adjuster plates (10) . . .100 to 0. .8 -- 3.2.1181 -.75 -. .77 to 0.0.4 -. . .. . . .. . . .1063 -. mm 1..0. . . . . .9 -.4. . . . .) (0.1220 -.0.2 -. .45 -.1024 -. .2.0.) (0.0354 -. . . . . . . .1457 -. . . . .0.1378 -. . mm 1. . . . .4. . . . . mm 0.530 (in.7717) Inside diameter of installed bushes (8) .3 to 1. . . . . .1181 -. mm 21.0. .) (0. .7 -.65 -.0. . . . . .1496 -. . . .30 (in. .0039 -. . . . . . . . .1752 -- 0. fig.0670 -. . . mm 0.1102 -.83 (in.0025 to 0. . . .2.3 -. .1102 -- 0. ..1122 -. . . . . .0. 28) in correspondence with bushes (8) . .1614 -. . . . . . .1654 -. .0. . .0. .. . . .0.0. . . .6 -. .0 -.0059) Thickness of planet pinion thrust washers .5 -. .2.55 -. .4. .0. . .073 to 2. . .0473 -- 0. . .6 -. .074) (continued overleaf) . .0. . . . . . .15 -.15 -. . .960 (in.1142 -. . . .0.4. .064 to 0.0.2. .7707 to 1. . . . .65 -. . mm 0. . . .1004 -..3. . .4.1280 -.0327) Axle pivot Axle clearance on pivot between body and support . .0.10 -. . . .1299 -. .35 -. .0..1535 -. . mm 0.5 -.35 -.1 -. . .0591 -.0039 to 0. .4.6 -. . fig.4. . . .0118) Epicyclic final drives Reduction ratio . .) (1. . .1260 -. .2. . . . .0433 -.) (0. . .470 to 1. .000 (in. . . .4 -.5 -.85 -.2 SECTION 25 -. . .0. . 28) .0. mm 0. . . ..3.. ..1850 -.1516 -. . . . . .0. . . . . . .1043 -- 0.4 -. . mm 2 (in. .0079 -. .9 -.3.1063 -.3. . . .) (0. mm 45.0.0.75 -.) (0. . .3.) (0. . .1 -.8 (in. . .0098 -- 0.0630 -- 0.0787) Clearance between sides of planet and side pinion teeth . .0. .) (0. . . . .0. . . . .0748 -.3.3..1201 -.0433) Wear limit endfloat . . .0.040 to 22. .0. mm 52. fig. . .7 (in. . . .1. . . ...1457) Thickness of pinion bearing adjustment spacer rings (12) .. . . . . . . . .4.. .0.1. . . .1220 -- 0.0. . . . .55 -. 28) . .080 to 0. mm 0. .95 -. . . . . .100 to 45. . . .0.0.129 (in. . . mm 22. .25 -. . . . .00 -.. .0. .3.1791 -.1870 -. . .2. .75 -.060) Thickness of side gear thrust washers (1) . .15 -.2 (in.7 -.0984 -.0079) Interference fit between bushes and respective bores . .671 (in.1555 -. .1417 -.1142 -.0393 -. . . . . .3.1693 -.7 -. .55 -. . .0.0. . . .1 -..0.1437 -.0.8677 to 0. .4. . . .3 -.2. . .0. . .85 -. . . .1 -.65 -. . .9 -.061 (in. . . . .) (0. .2. mm 44. . . . .) (2. . .3. .) (0. .122 (in.0. .2. . . . . .1594 -.4. .05 -. . .1378 -. . .1260 -. .7785) Clearance between axle shafts and bushes .0. . .939 to 21.1299 -. . .0.0630 -.0. . . . . ... .8685) Clearance between cross pin and bores . .1. . . . . . . . .25 -.0. .0048) Axle shafts and steering knuckles Diameter of outer axle shafts (7. .6 -. .0. .0031 to 0. . .4.1240 -.3.3. . . .0. .3. . . . .4.0709 -.1083 -.0. .4. . . . . .0..975 to 45. .0.0512 -. .0. .1476 -. . .0. .1831 -. . . . . . . .1. .7 -.CHAPTER 1 MAIN DATA (continued) Thickness of bevel pinion position adjustment spacer rings (11. . . .0591 -.FRONT AXLE MECHANICAL TRANSMISSION -. . 12 : (12 + 60) = 1 : 6 Thickness of driven gear shims (9. . .0. . . .2.1. . .0. . . . . . .20 -. .8 -- 2.) (0.1673 -. . 28) . ..1732 -.1417 -.5 -. .. . .7756 to 1. .0709 -- 0. . . .3. .0787) Diameter axle pivot front pin (3.) (0. . .8 -.. .3.3. 29) . .1319 -.2 -. .0118 to 0. . . .) (0.4.1024 -. . . .8 -. .7 -. .1161 -.9 -.1.0. . .0. .8646) Side pinion cross pin bore diameter (3) . . . . . . mm 2. .1634 -.3. . .) (1. . .05 -. . .0.1713 -. . . . . . . . .. .) (0. .9 -. . .. . .0. .1339 -. .3. . .0. .1339 -. . . . . . .3 -.0.3.3 -. .4 -. . .. . . mm 0.2.1772 -. fig. . . .4.7 -. .1890) Thickness of crown wheel position adjustment spacer (4.0.3. . .0787) Diameter of cross pin (14) for planet pinions . .0. .1811 -. .0748 -.8637 to 0. .1.0. . . . . . . .1575 -- 0. . . .1.

) (3. .201 (in. . .0054) Outside diameter of rear bush (6) installed in the bevel pinion support . . . . . . . mm 52. . . . . .FRONT AXLE MECHANICAL TRANSMISSION -. . .) (0. .221 (1) (in. .95 to 5. . .00 (in. . . mm 4.) (3.078) Clearance between pin (3) and bush (1) . . . .050 (in.020 to 99. .049 to 0.138 (in. .195 to 0. . . . . . . . . . . . . . . . . .906) Assembly clearance between the two bushes . .197) (1) Measurement to be obtained without reaming . . . . . . . . .) (0. mm 99. 29) . . . . .146 to 99. . . .720 to 52. . .898 to 3. .096 to 0.903 to 3. . fig. . SECTION 25 -.0756 to 2.0019 to 0. .) (2.790 (1) (in. . . .CHAPTER 1 3 MAIN DATA (continued) Installed front bush internal diameter (1. . . . . . .) (0. . . . . . .0079) Thickness of the front (2) and rear (4) front axle thrust washers . . . . . . .900) Inside diameter of rear bush (5) installed in the axle pivot support mm 99. . . . . mm 0. . . mm 0.0038 to 0. . . .

. . . . . . . . M 12X1. . .49 Wheel hub bearing locknut (C14) . . . . . . .25 77 to 93 56 -. . 412 to 451 303 -.FRONT AXLE MECHANICAL TRANSMISSION -. .25 64 47 Rim to hub retaining bolt (C12) . . . . . . . . . . . . . . . M 10X1.106 M 12 X 1. . . . . . . . . . . . M 10X1. . . -. . . . . . . . . . . . . . . . .25 66 to 73 48 -. . . . . . . . . -. . . . .5 170 to 206 125 -. . . -. . . . . . . -. .68 Ring gear to differential cage retaining bolt (C2) . . . . . . . . . .455 Lower pivot pin retaining bolt (C10) . . .151 .53 Differential cage support cap bolt (C5) .25 119 to 144 87 -. . 136 to 165 100 -. . 510 to 617 376 -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .332 Planet support to cover retaining bolt (C13) . . . . . . .25 119 to 144 87 -. . . . . . . . . . . . . . . . . . . . . . . . 73 53 Differential lock control hydraulic fitting (C3) . . . . . .151 Epicyclic final drive case retaining bolt (C13) . . . . M 18X1. .236 Bearing support retaining bolt (C8) . . . . . . . . . . .25 36 to 51 26 -. . . . . . . . . . . . . . . . . . . . . . . .CHAPTER 1 TORQUE SETTINGS Torque setting PART Thread Nm ft-lbs Front axle Nut for axle--shaft retaining bolt (C1) . . . . . . . . . . . . . . . M 12X1. . . M 35X1. . . . . . . . . . . . . . . . . . . M 18X1. . . . 87 -. . .106 Upper pivot bearing locknut (C6) . . . . . . . . . . . . . . . . .106 Rim and cover to hub retaining bolt (C14) . . . . . . . . . . . . .51 Differential lock control hydraulic fitting (C2) . . . M 12X1. . . . . .4 SECTION 25 -. . . . . M 10X1. . . . . . . . . 25 to 27 18 -. . . . . . . . . . . . . . . . . . -. . .5 98 72 Front pivot support retaining bolt (C9) . . . . . . . . . . . . . . . . . . . -. . . .25 119 to 144 87 -. -. .173 Ball joint locknut on tie rod (C10) . . . . . . . . . . . . -. . 20 14 Upper pivot pin locknut (C7) . . . . . . . . . . . . . . . . . M 12X1.19 Tie rod ball joint locknuts (C8) . . . . . . 44 32 Brake control cylinder retaining bolt (C4) . . . . . M 10X1. . . . . . . . . . . . . . 44 32 Pipe unions on manifolds for control hydraulic cylinders (C7) . .25 119 to 144 Bevel pinion shaft locknut (C5) . M 12X1. . . . . . . . . . . . . . -. . . 196 144 Steering knuckle pin retaining bolt (C11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 to 320 213 -. . . . . . . . . . . . . . . . . . . . .37 Final drive assembly support to axle casing retaining bolt (C4) . . . . . . . . . . . . . . . .25 60 to 70 44 -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361 Rear pivot pin retaining bolt (C12) . . . . . M 24 X 2 390 to 490 287 -. . . . . . . . . . . . . . . . . . . . . . . . . . . 206 to 235 151 -. -. -. . . . . . . . . . . . . . . . . . . . .121 Rear pivot bearing support retaining bolt (C11) . .106 Differential locknut safety tab retaining bolt (C3) . . . . . .5 170 to 206 125 -. . . . . M 70 X 2 392 290 Differential lock retaining bolt (C1 page 5) . . . -. . . .25 55 to 67 41 -. 142 104 Tie rod ball joint retaining bolt (C9) .5 294 216 Pipe unions on power control hydraulic cylinders (C6) . . . . . . . . . M 10X1. . . . .

64 Nm (47 ft-lbs) C8 -.44 Nm (87 to 106 ft-lbs) C4 -. SECTION 25 -.77 to 93 Nm (87 to 106 ft-lbs) (26 to 37 ft-lbs) (56 to 68 ft-lbs) (151 to 173 ft-lbs) (144 ft-lbs) (41 to 49 ft-lbs) C9 --206 to 235 Nm C10 -.55 to 67 Nm C11 -.119 to 144 Nm C3 -.196 Nm C13 -.119 to 144 Nm C7 -.142 Nm (104 ft-lbs) C12 -.294 Nm C6 -.170 to 206 Nm (125 to 151 ft-lbs) 25510 C4 -.CHAPTER 1 5 TORQUE SETTINGS (216 ft-lbs) (32 ft-lbs) C5 -.25 to 27 Nm (18 to 19 ft-lbs) 25509 C2 -.FRONT AXLE MECHANICAL TRANSMISSION -.36 to 51 Nm C1 -.66 to 73 Nm (48 to 53 ft-lbs) 1 .

290 to 320 Nm (213 to 236 ft-lbs) 25513 C10 --136to165 Nm (100 to 121 ft-lbs) C9 -.510 to 617 Nm (376 to 455 ft-lbs) (125 to 151 ft-lbs) C14 -.60 to 70 Nm (44 to 51 (48 to 53 ft-lbs) ft-lbs) (87 to 106 ft-lbs) C6 -.CHAPTER 1 C3 --44 Nm (32 ft-lbs) C2 --73Nm (53 ft-lbs) 25512 C4 -.98 Nm C7 -.20 Nm (14 ft-lbs) (72 ft-lbs) C5 -.390 to 490 Nm C12 -.170 to 206 Nm (287 to 361 ft-lbs) (303 to 332 ft-lbs) C11 -.6 SECTION 25 -.FRONT AXLE MECHANICAL TRANSMISSION -.137 Nm 25515 25514 2 .412 to 451 Nm (101 ft-lbs) C13 -.66 to 73 Nm 25511 C1 -.119 to 144 Nm C8 -.

88) 26135 24 . X 293391 Pinion bearing adjustment tool (with X 292220 Tool for measurement of rolling drag 50118 earlier version 50118 needs torque of front axle bearings. X 293878 Wrench for front bevel drive pinion ring X 292161 Front axle pivot bearing outer ring re- nut. bevel drive pinion.The operations described in this section wrench. 293400 Universal gauge for positioning of front To work safely and efficiently and obtain the best re. moval tool.CHAPTER 1 7 TOOLS X 293782 Front bevel drive pinion retaining Warning -. ing retaining nut (TN55 may need modification to tool. 50169 Pins (M10 x 1. see fig. to be used in conjunction with earlier version of tool 293391 [mark tool No. can only be carried out with ESSENTIAL tools indi- cated by an (X). X 295030 Wrench for front axle wheel hub bear- tions described in this section.measurement in mm (ins)]. 50165 Pins (M 16 x 1. cover. Construct in UNI C40 material. Tool to be made for adjustment of bevel drive pin- ion. sults. X 293857 Front axle pivot pin removal tool. tion hook. made see fig. List of specific tools required for the various opera.FRONT AXLE MECHANICAL TRANSMISSION -. 24). SECTION 25 -. (with 293874 and 291318). it is also necessary to use the recommended X 293544 Wrench for front differential case bear- specific tools listed below and certain other tools ing threaded adjustment ring. (. 293460 Front axle overhaul stand.377) (1. 25).25) for front axle and 291517 Front differential unit removal--installa. 292870 Universal kit for testing oil pressure for X 293510 Universal gauge for pinion bearing ad.393) (1. front axle differential lock engagement justment. 294150 Wheel hub seal splining tool.25) for front axle wheels 293743 Front axle differential casing overhaul disassembly/assembly. 50118 -. which are to be made according to the drawings in- cluded in this manual. support.

8 SECTION 25 -.FRONT AXLE MECHANICAL TRANSMISSION -.CHAPTER 1 mm (.05 ins) 3mm (.590 ins) mm (4.120 ins) 25 (TN55 only) Modification to make earlier version of tool 295030 [Measurement in mm (ins)] .

.590) 10 27893 27 Tool to be made for front axle gear unit cover disassembly--assembly.196) (. [Mark tool with No.Measurement in mm (ins)] Construct in UNI C40 material.936) (. 50165 -.196) (.FRONT AXLE MECHANICAL TRANSMISSION -.CHAPTER 1 9 (. (.393) (3.393) (3. [Mark tool with No 50169 -.936) (.Measurement in mm (ins)] Construct in UNI C40 material.SECTION 25 -.787) 27892 26 Tool to be made for front axle wheel disassembly--assembly.

spacer. Side pinions. Cross pin for side pinions. 6. . 11. Ring gear bearings adjustment nut. NOTE: On assembly apply a bead of sealing compound to the surfaces X as indicated on page 29. Bevel gear. 5.FRONT AXLE MECHANICAL TRANSMISSION -. Shims for driven gears of epicyclic final gear. Thickness of side gears thrust washers. 14. Axle shaft. 7. Crown wheel bearing adjustment nut. Thickness of bevel pinion bearing adjustment spacer. Nominal distance between 9. Differential casing. Thickness of bevel pinion position adjustment 3.10 SECTION 25 -. 12. 15.740 ins). Axle shaft bush (7). 4. Steering knuckle adjustment plates. 8. 2. Side gears. 13. crown wheel axis and greater diameter of the pinion. 1.CHAPTER 1 7 8 9 10 26128 X 28 Cross--sectional view of front axle H4 = 95 mm (3. Seal. 10.

Rear bush installed on bevel drive--differential sup- 3. port.CHAPTER 1 11 1 2 3 4 5 6 26131 29 Cross--sectional view of front axle pivot 1. Front thrust washer. shaft is not fitted with universal joints. TN 65.FRONT AXLE MECHANICAL TRANSMISSION -. Axle pivot front pin. DESCRIPTION AND OPERATION TN 55. drive is trans- . SECTION 25 -. 5. The drive require any maintenance. 4. The differential has two planet pinions. TN 70 and TN 75 tractors are provided mitted to lateral epicyclic final drive units (installed on with a centrally pivoting front axle with pivot and drive the wheel hubs) through universal joints which do not shaft coaxial to the tractor longitudinal axis. 2. Rear bush installed on axle support. Axle pivot front bush. Rear thrust washer. 6.

lift the ballasting and remove 1 to a safe position. 25 100 30 FRONT AXLE ASSEMBLY Removal--Installation DANGER Lift and handle all heavy parts using suitable lifting equipment. For removal of the drive shaft refer to section 23. Unscrew the bolts (1) and remove the front mud- guard supports (2).CHAPTER 1 OP. The description below refers to removal of the front axle with the drive shaft installed on the tractor. Make sure that the load is supported by means of suitable slings and hooks. 1 2 25575 30 2. 25577 31 . Attach a nylon sling to the front ballasting (1).FRONT AXLE MECHANICAL TRANSMISSION -. 1.12 SECTION 25 -. Make sure that no--one is standing in the vicinity of the load to be lifted. ex- tract the locking pin. Proceed as follows: NOTE: The front axle assembly can be removed from the tractor either with or without previously removing the drive shaft.

25580 34 6. 25581 35 . 25584 33 5. Attach the front axle to a hoist using two nylon slings. SECTION 25 -.CHAPTER 1 13 3. 1 2 25576 32 4. Raise the tractor and position a fixed stand under the engine sump. slide the sleeve (1) to- wards the rear and free the drive shaft from the 1 2 front axle.FRONT AXLE MECHANICAL TRANSMISSION -. Remove the circlip (2). Unscrew the bolts (1) and remove the drive shaft guard (2).

Allow the slings on the axle to take the strain and remove the front axle rear support retaining bolts 1 (1). Remove the front axle front support retaining bolts (1). Unscrew the retaining bolts and remove the front wheels. 25585 38 11.CHAPTER 1 7. 25582 37 10.14 SECTION 25 -. Unscrew the rigid pipes from the power steering cylinder and disconnect the two hoses. Unscrew the front differential lock control unions (1) and remove the hose (2).FRONT AXLE MECHANICAL TRANSMISSION -. 1 2 8. 25579 36 9. 1 25586 39 .

Refit the two front mudguards. . Re--connect the battery negative lead. -. Attach a nylon sling to the front ballasting. Respect the tightening torque values prescribed on page 3. -. To refit the front axle on the tractor. -. tighten the front and rear sup. -. SECTION 25 -. 13. Using the hoist and the two nylon slings. Fit the front wheels. -. -. Connect the drive shaft and position the guard. Reconnect the differential lock pipe and the pow- er steering pipes. -.CHAPTER 1 15 12. Extract the fixed stand. NEVER USE YOUR FINGERS OR HANDS. WARNING Always use appropriate tools to align fixing holes. -. 25583 ports to the relative support. -. raise the front part of the tractor. Remove the nylon slings from the axle. fit and secure in position with the lock rod. proceed as follows. Using the hoist. detach the front axle.FRONT AXLE MECHANICAL TRANSMISSION -. -. 40 -. Position the axle.

Unscrew the planetary carrier (1) retaining bolts.CHAPTER 1 Op.16 SECTION 25 -. Screw in the two pins 50169 (2) and. 1 25589 42 2. Front epicyclic final drive removal and installation can be carried out with the axle detached and positioned on the stand 293460. a support stand must be positioned under the engine sump. gloves and shoes.Assembly WARNING Handle all parts carefully. or with the axle fitted on the tractor. 70. using an ex. detach the planetary carrier (1) and remove. 25 108 30 FRONT EPICYCLIC FINAL DRIVE Disassembly -.safety goggles. 25594 43 . Turn the epicyclic final drive to position the filler/ drain plug at its lowest point and drain the oil.FRONT AXLE MECHANICAL TRANSMISSION -. 1 2 tractor fitted on the oil drainage plug. 25587 NOTE: TN65. 75 art work shown unless 41 specified. Proceed as follows: 1. If the operation is performed with the axle fitted on the tractor. Wear suitable safety clothing -. Do not put your hands or fingers between parts.

25597 44 2 25598 45 4. 1 NOTE: For TN55. Recover all disassembled 1 2 parts. 25599 46 .CHAPTER 1 17 3.FRONT AXLE MECHANICAL TRANSMISSION -. 295030. SECTION 25 -. see tools. Remove the lock nut (1) on the wheel hub bear- ings using wrench 295030 (2). Remove the wheel hub (1) together with the final drive fixed gear (2).

From inside planetary cover (1). 1 2 20030470 48 3. 2 1 20030471 49 . remove planetary gear support (2). REBUILD. Remove planetary gear (1).18 SECTION 25 -. AND ASSEMBLY OF THE PLANETARY GEARS NOTE: When disassembling planetary carrier assembly. TN 55 Disassembly 1. From outside of the planetary cover (1). remove 2 1 the three cap screws (2) holding the planetary gear support.CHAPTER 1 DISASSEMBLY. and the twenty two needle roller bearings (3).FRONT AXLE MECHANICAL TRANSMISSION -. 20030469 47 2. the two thrust washers (2). keep all parts for each shaft together to facilitate reassembling. 3 Repeat this procedure for remaining planetary gears.

10. Remove the planetary gear (1). and replace in sets if worn or damaged. Inspection and Repair 5. Clean all components in a suitable solvent. . 7. dip pins into liquid nitrogen before assembly. and replace in sets if worn or damaged. 7. Inspect outer tracks inside hub housings. (see arrow). Torque the three cap head screws holding the planetary gear support to 130 N⋅m (95 ft lbs). 9. Allow parts to dry. Assembly of the planetary carrier follows the disassembly procedures in reverse. (see arrows). Replace as necessary. Ensure twenty two needle roller bearings are in each planetary gear. dip pins into liquid nitrogen before assembly. remove planetary pin (2) from the inside out.CHAPTER 1 19 4. observing the following. needle roller bearings. 20030473 4. NOTE: When installing planetary pins. to prevent scoring. 50 Assembly 8. Assembly 6. Assembly of the planetary carrier follows the disassembly procedures in reverse. SECTION 25 -. 1 NOTE: When installing planetary pins. needle roller bearings. the two thrust washers (3). 70. If necessary to replace planetary pins (1). remove pins (1) from the inside out. Ensure nineteen needle roller bearings are in each planetary gear. and planetary pins. Allow parts to dry. TN 65. Repeat this procedure for the remaining planetary gears. To remove planetary gear (1). 3 2. Clean all components in a suitable solvent. 20030472 and planetary pins. Inspection and Repair 1 3. Inspect planetary gears. Inspect outer tracks inside hub housings. observing the following.FRONT AXLE MECHANICAL TRANSMISSION -. Inspect planetary gears. 51 5. and the nineteen needle roller bearings inside the gear. to prevent scoring. AND 75 Disassembly 2 1. Replace as necessary. 6.

) (model TN 55) Rc = Rt -.0787 in.5 to 18. sec- tion 00). Progressively tighten the ring nut. with the torque meter.7 Nm (4. Rc = Rt -.6 to 26.CHAPTER 1 To refit the front epicyclic final drive. rotate the wheel hub to ensure that the bear. -. 2 mm. Carefully secure the ring nut.5 to 41. Progressively tighten the ring nut.9 to 14. -. Assemble the wheel hub and the epicyclic final drive fixed gear. using the torque wrench and wrench 295030 (1) to obtain a torque value of 392 Nm (290 ft-lbs). Before reassembling the epicyclic final drive cas- ing. rotate the wheel hub to ensure that the bear- ings are correctly seated. -.5 lb.FRONT AXLE MECHANICAL TRANSMISSION -. then apply sealing compound (approx.R = 4. -. WARNING Always use appropriate tools to align fixing holes. TN 70 and TN 75) If the value is less than a 5.) (mod- els TN 65. The difference between the two measurements is the rolling torque value of the wheel hub bearings (Rc): Rc = Rt -.R = 5.20 SECTION 25 -. 0.3 ft-lbs) or. -. Measure the rolling resistance (Rt) of the wheel hub using the relative torque wrench.6 lb. -.) (for models TN 65. Assemble the epicyclic final drive casing.5 lb. Fill up the front epicyclic final drive (for recom- mended products and quantities see page 6. TN 70 and TN 75) replace the relevant parts and repeat the test. using the torque wrench and wrench 295030 (1) to obtain a torque value of 392 Nm (290 ft-lbs).R = 7. carefully clean and degrease the mating sur- faces.3 lb.8 to 12 kg (10. 7. at the same time. if measured with a torque meter.5 kg (16. NEVER USE YOUR FINGERS OR HANDS. com- plete with gears.) (for model TN 55) or 4. -.) along the marked line shown on page 30. Fit the track rods. Loosen the ring nut by half a turn and measure the rolling resistance (R) as described previously. -.8 kg (10. at the same time.75 kg (5.3 to 11 ft-lbs) or. 52 ings are correctly seated. -. Respect the tightening torque values prescribed earlier in this section. proceed as follows. . or a torque meter and cord positioned on the base of the wheel disk flange.9 Nm (4.

55 5. NEVER USE YOUR FINGERS OR HANDS. Fit tool 294150 (2) on the hub and fit. To refit the wheel hub parts. Proceed as follows: 1. WARNING Always use appropriate tools to align fixing holes. Remove the worn seal.CHAPTER 1 21 WHEEL HUB SEAL Replacement WARNING Handle all parts carefully. proceed as follows. Do not put your hands or fingers between parts. carefully clean the seat and position the new seal (1) on the seat fitting. 54 4. Carry out operation 25 108 30 Front epicyclic final drive. by a few mm. -. Wear suitable safety clothing -. SECTION 25 -. NOTE: The external surface on the seal (1). Carry out operation 25 108 30 Front epicyclic final drive. indicated by the arrow.FRONT AXLE MECHANICAL TRANSMISSION -. only installation (see page 20). 56 .safety goggles. the seal (3) using a striker (1). 2. Remove the hub casing (1) and the spacer. -. does not require lubrication. Remove tool 294150 from the hub. 53 3. gloves and shoes. only removal (see page 19). Fully fit the seal in position using the ring nut and wrench 295030 (1). 6.

6. Op. Do not put your hands or fingers between parts. gloves and shoes.FRONT AXLE MECHANICAL TRANSMISSION -. 3. Fit the bolts (1) of tool 293857. Remove the grease nipples and the steering knuckle pin retaining bolts. 25 108 46 or 25 108 47) WARNING Handle all parts carefully. If steering knuckle pivot pins present problems during disassembly operations. 5. Wear suitable safety clothing -. gloves and shoes.safety goggles.CHAPTER 1 OP. 1. Fit the plate (2) of the tool and fix it to the three bolts with nuts (5). proceed as follows. 24596 4. 2. Place the stub axle in a nylon sling (1). remove the pin and grease fittings (2) retaining bolts (3). screwing it fully into the grease nipple bore on the pin (6). Wear suitable safety clothing -.safety goggles. 1 2 3 25564 58 . 25 108 46 or 25 108 47 STEERING KNUCKLE PINS AND BEARINGS Replacement WARNING Handle all parts carefully. Do not put your hands or fingers between parts. Wheel hub removal can only be carried out after hav- ing disassembled the front epicyclic final drive. Fit the central tie bolt (4). 57 WHEEL HUBS AND STEERING KNUCKLE PINS AND BEARINGS Removal--Replacement--Installation (Op. Screw in the nut (3) to drive the pin out of its bore.22 SECTION 25 -. 25 108 38.

CHAPTER 1 23 7. Using extractor tool 292161 (1) remove the steering knuckle bearings. -. -. Fit the plate (2) of the tool and secure with the three bolts (1) 2 and nuts (5). 1 10. Refer to the cross section illustrations earlier in this chapter for positioning of various parts. NEVER USE YOUR FINGERS OR HANDS. SECTION 25 -. Respect the tightening torque values prescribed earlier in this chapter. Assemble the steering knuckle on the axle body and adjust the bearings as follows. WARNING Always use appropriate tools to align fixing holes. Screw in the nut (3) to drive the pin out of the bore. Fit the three bolts (1) of tool 293857. Re--install the steering knuckle bearings using a suitable striker. -. Fit the center tie bolt (4). screwing 4 it fully into the grease nipple bore on the pin (6). 5 3 1 25565 59 8. 24599 61 11. Repeat the operation on both pins and recover 6 the adjustment shims. To refit the steering knuckle and wheel hub. 1 25566 60 9. proceed as follows. Detach the wheel hub and steering knuckle (1) and separate the two units. NEVER USE YOUR FINGERS OR HANDS. . WARNING Always use appropriate tools to align fixing holes.FRONT AXLE MECHANICAL TRANSMISSION -.

13. check that the torque required to rotate the casing is 3. while simultaneously rotating the casing to allow the excess grease to escape. Assemble the grease fittings in the upper and 64 lower covers and grease the assembly. After having rotated the casing a few times to allow the components to bed down. adjust by way of the lower cover bolts. Remove tool 292220 and tighten the retaining bolts to a torque value of 64 Nm (47 ft-lbs).8 Nm (34 -. if the measured value is less than the prescribed value. insert the 63 shims (10. 16.5. without the 1 adjustment plate. without considering the initial peak torque. If not. Refit the front epicyclic final drive. lubricate the three retaining bolts with engine oil. but with tool 292220 (1). Gradually tighten the lower cover bolts in sequence. Fit the lower cover without adjustment plate. Using a torque wrench and tool 292220 (1). . 17. page 9) to be fitted under the lower cover will be the average obtained. reduce the thickness of the shims. 20. Measure the gap (H) created between the lower cover and the casing in correspondence with the three bolts.86 ins-lbs).002 ins). 22.3 ins-lbs) without considering the peak starting value. 14.05 mm (.9 Nm (3. 25715 62 15. rounded down 25716 to the next 0. The total thickness of the adjustment shims (10. 21. If the torque value measured is greater than the prescribed value.5 -. page 9) and tighten the bolts to a torque value of 64 Nm (47 ft-lbs).24 SECTION 25 -. Partially unscrew the lower cover bolts. Tighten the retaining bolts to a torque value of 64 Nm (47 ft-lbs). Smear AMBRA GR 9 grease on the outer races of the bearings and fit the upper cover. 18. 23.FRONT AXLE MECHANICAL TRANSMISSION -.9 1 to 5.9 to 9. increase the thickness of the shims.CHAPTER 1 12. check that the torque necessary to rotate the casing is 3. Calculate the average of the three values measured. 19.

Wear suitable safety clothing -. remove the front support and washer.FRONT AXLE MECHANICAL TRANSMISSION -. 1 25590 68 . 1 25588 66 2. NOTE: Front axle overhaul operations must be 25587 carried out on stand No. SECTION 25 -. Remove the front axle rear support (1). Do not put your hands or fingers between parts. Unscrew the plug (1) and drain the oil from the axle casing. gloves and shoes.safety goggles. 25589 67 3.CHAPTER 1 25 OP. 65 1. repeat the same operation on 1 the right--hand housing. 293460. Unscrew the plug (1) on the left--hand epicyclic fi- nal drive housing. 25 100 38 BEVEL DRIVE AND FRONT AXLE DIFFERENTIAL AXLE HOUSING Disassembly--Assembly WARNING Handle all parts carefully.

remove the cover (1). Remove the circlips (2) from the cylinder rod pivot pins. 25593 71 7. Unscrew the left--hand side gear cover (1) retain- ing bolts. 24080 70 6.FRONT AXLE MECHANICAL TRANSMISSION -.CHAPTER 1 4. recovering the track rods. unscrew the cylinder (1) pins retaining bolts. Tighten two pins 50169 (2) and. 25594 72 . washers. extract the pins from the seats on the stub axle housing. using 2 1 an extracting tool screwed into the oil drainage plug hole. extract the pins and remove the two cylinders. spacers and cyl- inders. complete with pipes. 1 25591 69 5. 1 2 Remove the four pins.26 SECTION 25 -. Loosen the two track rod lock nuts (1). Using an extractor.

74 9. 25597 73 2 25598 . see tools 295030. 1 25600 76 . Recover the lower pivot pin and the rela- tive adjusting spacers. Unscrew the three stub axle lower pin retaining bolts (1). SECTION 25 -.FRONT AXLE MECHANICAL TRANSMISSION -. 1 2 25599 75 10. 1 NOTE: For TN55. Remove the lock nut (1) on the wheel hub bear- ings using wrench 295030 (2). Remove the wheel hub (1) together with the epi- cyclic crown (2). Recover all disassembled parts.CHAPTER 1 27 8.

7 to operation No. from opera- tion No. Unscrew the three mudguard support (2) retain- ing bolts (1). Extract the upper pivot pin (1) and remove the stub axle (2). 79).FRONT AXLE MECHANICAL TRANSMISSION -. To disassemble the right hand side gear unit. Using a crowbar. fig. Recover all disassembled parts. ob- serve the order of operations used for the disas- sembly of the left hand side gear unit. 1 2 25601 77 12. 17. remove the axle shaft (1. 1 2 25603 79 14. 15.28 SECTION 25 -. 25604 80 . Unscrew the axle shaft (1) retaining bolt (2). 2 1 25602 78 13.CHAPTER 1 11.

Unscrew the two bevel drive--differential support retaining bolts from the axle casing. 25606 82 . Remove the bevel drive--differential support (3) from the axle casing. screw on the 1 2 3 two pins 50169 (1). Remove the remaining bolts and the bevel drive--differential support.FRONT AXLE MECHANICAL TRANSMISSION -. attach a chain (2) and put the hoist under strain. 1 2 3 25605 81 17. Unscrew the bracket (1). SECTION 25 -. loosen the union (3) and remove the differential lock control rigid pipe (2).CHAPTER 1 29 16.

CHAPTER 1 OP. 1 2 25613 85 5. Remove the bevel drive--differential (2) housing (1). 2 1 25612 84 4. 25607 83 3. 3 2. Remove the differential lock control internal pipe. Remove the circlip (1) from the splined shaft (2). Unscrew the bolt (2) and recover the ring nut lock- ing plate (3). 1 2 25614 86 . 25 102 20 FRONT AXLE BEVEL DRIVE OVERHAUL 1 2 1.30 SECTION 25 -.FRONT AXLE MECHANICAL TRANSMISSION -. Fit tool 293743 (1) in the vice on a work bench. lock the bevel drive--differential support in the tool and remove the chain. Unscrew the bevel drive--differential support cap (1) retaining bolts (2) and remove.

1 25615 87 7. extract the bevel pinion shaft (1) and recover the spacer. Straighten the staking on the splined shaft lock nut (1). 1 25617 89 9. adjusting shims 1 and the bearing. 25618 90 . SECTION 25 -. Acting on the rear part. Remove the splined shaft stop ball (1).CHAPTER 1 31 6. Unscrew the nut. using wrench 293878 (1) hold- ing the bevel pinion shaft in position with wrench 1 293782.FRONT AXLE MECHANICAL TRANSMISSION -. 25616 88 8.

Fit the rear bearing. then position the circlip. proceed as follows: WARNING Always use appropriate tools to align fixing holes. Fit the pins. -. washers. drive gear and side gear cover. To assemble the front axle. Fit the wheel hub. Reconnect the bevel drive--differential support to the front axle casing and fit the differential lock ex- ternal pipe. sup- port caps and tighten the relative screws. -. side gear crown and ring nut and tighten to the prescribed torque. -. mudguard support and screws. lower and upper pivot pins. -. adjusting shims. Fit the track rod. -. dust seal. Carry out the adjustments described in this chap. spacers and steering con- trol cylinder. front and rear supports and the oil drainage plug. the adjusting shims. spacer and bevel pinion shaft.FRONT AXLE MECHANICAL TRANSMISSION -. -. 1 11. complete with front bearing. Fit the circlips.CHAPTER 1 10. -. -. Fit the stub axle. -. detach and remove the dust seal. Respect the tightening torques prescribed earlier in this chapter. Using a screwdriver. tighten and secure the bevel drive nut. Refer to the cross section illustrations earlier in this chapter for the positioning of various parts. -. Position the sto ball. seal. whilst rotat- ing the hub to settle the bearings. 91 ter. NEVER USE YOUR FINGERS OR HANDS. -.32 SECTION 25 -. . Fit the axle shaft and screw. 25619 -. -. Assemble the bevel drive--differential unit. seal (1) and rear bearing.

H1 + 0.2 Nm (10 in. The thickness of the adjustment shim (12) re- quired is given by: 94 S = H2 -. Clamp tool 293391 (1) in a vice. Do not put your hands or fingers between parts.safety goggles. Disassemble the parts mentioned above. 4. Wear suitable safety clothing -. Using micrometer.05 mm . lubri- cate the bearings with engine oil and then reas- semble the parts. Slide 6 a bearing (3) from the bevel assembly onto the tool. lbs). 96) to 1. complete with outer 2 bearing races. torque the nut (7. lbs). Slide the spacer (4) from the bevel assembly 5 onto the tool. 92 2. 7 1.FRONT AXLE MECHANICAL TRANSMISSION -. Slide the remaining bearing (5) from the bevel assembly onto the tool. Slide tool spacer 50118 (2) onto the tool (see tools 293391).CHAPTER 1 33 BEVEL DRIVE ADJUSTMENTS Adjusting the preloading on the bevel drive shaft bearings WARNING Handle all parts carefully. Slide the top cone (6) from the tool onto the tool threads. 6. Tighten the tool nut (7) to 1. 7 6 93 3. On tool 29339. SECTION 25 -. while turning the tool to ensure that the bearings are seated correctly. (excluding only the bearing bevel assembly spacer (4. 5. 96). Using a micrometer. measure distance (H1) be- tween the upper surface of the top cone (6) and the top of the threaded pin (7) of tool 293391 (1). fig. into the bevel 6 drive--differential housing. measure distance (H2) between the upper surface of the top cone (6) and the top of the threaded pin of tool 293391. gloves and shoes.2 Nm (10 in. fig. Proceed as follows.

to be added to or subtracted from the nominal distance (H4) according to the sign. Determine the correct distance (H5) between the 95 differential axis and the large diameter base of the pinion: H5 = H4 ± C where: H4 = 95 mm Nominal distance between the crown wheel axis and the large diameter base of the pinion. round this value up to the nearest 0. circlip and differential housing caps.sign (no mark on the pinion. page 9) will be given by: S = H3 -. C equals 0). Install tool 293400 (1) in the bevel drive--differen. do not remove the adjustment tool 293391 from the bevel drive--dif- ferential housing: leave in place for adjustment of the drive pinion position. Screw the cones (2) of tool 293400 (1) in or out in order to position the micrometer shaft in the direction of the inner bearing ring and eliminate end float between the cones and the outer rings of the differential bearings. C = correction value stamped on pinion preceded by a + or -. 5.CHAPTER 1 If necessary. 1 2 tial housing. 25594 4. NOTE: On completing the adjustment. 1. BEVEL DRIVE ADJUSTMENTS Determining the thickness of the drive pinion position adjustment shim Proceed as follows.FRONT AXLE MECHANICAL TRANSMISSION -. . complete with outer bearing rings. H5 = corrected nominal distance between the differential axis and the large diameter base of the pinion. Adjust the micrometer so that the shaft is in con- tact with the inner bearing ring and measure the distance (H3) obtained. 3.05 mm. The thickness of the adjustment shim (11. differential bearings adjustment shim.34 SECTION 25 -.H5 where: H3 = the distance measured using the microme- ter. 2.

94.8 mm. -. Thickness of adjustment shim S = 98 -.8 mm.95 = 3 mm.2 = 94.95. 7. Thickness of adjustment shim S = 98 -.8 = 3.0. Correction value C = 0 mm. -.0. 25588 96 . -. Distance measured using micrometer H5 = 98 mm. Correction value C = + 0.2 mm. Lubricate all parts before installing.CHAPTER 1 35 Example.2 mm.2 mm -.2 = 95. Thickness of adjustment shim S = 98 -. -. Corrected nominal distance H5 = 95 + 0. -. Install the drive pinion (3) complete with: inner bearing rings.2 mm. adjustment shims of the 1 2 3 previously determined thickness. ball joint and relative bush. -.2 = 2. spacer (1). 6. -. Remove tools 293391 and 293400 from bevel drive housing. Corrected nominal distance H5 = 95 -. Correction value C = -.FRONT AXLE MECHANICAL TRANSMISSION -. SECTION 25 -. -. Corrected nominal distance H5 = H4 = 95 mm. -. Nominal distance between ring gear axis and lar- ge diameter base of H4 = 95 mm. -.

25596 98 . 1 2 9. fit a thinner adjustment shim. Using the torque wrench on wrench 294079 (1). fit a thicker adjustment shim.5 to 1 Nm (4. without oil seal and relative dust seal.4 -.50 Nm (4.8. Finally. 12. tighten the pinion nut to a torque value of 382 Nm (281 ft-lbs) while simulta- neously rotating the pinion shaft to ensure that the bearings are seated correctly. 1 2 with the oil seal and relative dust seal. 11. With torque wrench 293952 (2) fitted on wrench 2934079 (1).4 ins-lbs). With torque wrench 293952 (2) fitted on wrench 294079 (1) check that the pinion rolling torque. Unscrew the nut and fit the oil seal and the rela- tive dust seal ring. is ≤ 0. Tighten the nut to a torque value of 294 Nm (216 ft-lbs) while simultaneously rotating the pinion shaft to ensure that the bear- ings are seated correctly.FRONT AXLE MECHANICAL TRANSMISSION -. 10. whilst holding the pinion in position by means of wrench 294080 (2).36 SECTION 25 -. if the torque 97 is greater than the prescribed value.8 ins-lbs). check that the pinion rolling torque. carefully stake the nut. is 0.CHAPTER 1 8. If the rolling torque is less than the prescribed 25595 value. Position the wrench 294080 (2) for the pinion nut and the wrench 294079 (1) for the splined pinion.

Install the differential assembly (2).15 to 0. rotate the ring gear and.CHAPTER 1 37 BEVEL DRIVE ADJUSTMENTS Adjustment of the differential bearings and 1 2 3 checking the backlash between the pinion and ring gear. fit a thinner adjustment shim. 25598 101 5. SECTION 25 -. With the bearings perfectly lubricated. then loosen and re-- tighten to a torque of 20 Nm (14 ft-lbs). If the measured backlash exceeds the prescribed value. Repeat the measurement in a further two posi- tions 120° apart and compare the average of the 1 three values (Gm) with the prescribed normal backlash: 0. 25597 100 3. Proceed as follows. 4.18 mm. tighten the ring 1 nut using wrench 293544 (1) to a torque value of 39 to 59 Nm (28 -. 1. The thickness of the adjustment shim to be fitted in the bevel drive--differential housing is given by: 25599 102 . 25578 99 2.20 mm (.008 ins. using a 1/100 dial gauge perpendicular to the outer edge of a tooth on the ring gear (1). average valve . adjustment shim (1) and relative circlip in the bevel drive--differential housing. Measure the backlash between pinion and ring gear.43 ft-lbs) to take up the axial play between the components.007 ins) average value 0. Install the differential support caps and the ring nut (2). at the same time.FRONT AXLE MECHANICAL TRANSMISSION -. tighten the relative bolts (1) to a torque 1 2 value of 59 Nm (43 ft-lbs).006 to . complete with bearings.

If the backlash measured is less than the prescribed value.20 mm (.35} (S = Sp + [0.15 to 0. Gm = average backlash measured between the sides of the teeth of the bevel drive. is: A2 = A1 + 1 to 1.0. using wrench 294079 (1) and torque 103 wrench 293952 (2).CHAPTER 1 S = Sp -.{(Gm -.5 Nm (. A1 = rolling resistance torque of pinion only as previously measured. 0.053 ins) where: Sp = thickness of test shim installed in the bevel drive--differential housing. it will be necessary to fit a thicker adjustment shim.35} where: Sp = thickness of test shim installed in the bevel drive--differential housing.Gm) x 1.38 SECTION 25 -.18 ) x 1.Gm] x .18 -. 1 2 25596 104 .007 ins -.008 ins) 7. Using wrench 293544 (1) turn the adjustment ring nut and check using torque wrench 293952 (2). as measured in the same conditions used to check only the pinion.8 to 13 ins-lbs) where: A2 = pinion/differential rolling resistance torque.FRONT AXLE MECHANICAL TRANSMISSION -. the value being given by: S = Sp + {(0.5 Nm (8. check that the backlash between the pinion and the ring gear is within the prescribed toler- ance limits 0. Install a shim of the calculated thickness and with a 1/100 scale dial gauge positioned perpendicu- lar to the outside edge of one of the ring gear teeth.1 to 1.. 1 that the rolling resistance torque of the differential and pinion bearings.8 to 13 ins-lbs) = rolling resistan- ce torque of differential only measured at the end 25598 of the pinion.006 -. Gm = average backlash measured between the sides of the teeth of the bevel drive 6.

to reach the nearest notch. 10. Attach the bevel drive--differential to the axle cas- ing after having carefully cleaned and degreased the mating surfaces and apply sealing compound (approx.106 ft-lbs).078 ins]) along the marked line shown in the figure below. screwing the adjustment ring nut in or out.CHAPTER 1 39 8. section 00. SECTION 25 -. 2 mm [. The types of adhesive to use are listed on page 1. Fit the safety plate.FRONT AXLE MECHANICAL TRANSMISSION -. Tighten the cap bolts (1) to a torque value of 119 to 144 Nm (87 -. 24595 106 . 25597 105 Adhesive application diagram for assembly of bevel drive unit and epicyclic final drive unit. 2 1 9.

0098 in. Fit the planet pinions complete with thrust wash- ers and pins and screw down the pin retaining bolts by a few turns to hold the pins in place. Therefore the shims to be inserted in the differen- tial housing are given by: Ss = Gs -.). 4.25 mm (0.0.25 mm (0. 25 102 24 FRONT AXLE DIFFERENTIAL Overhaul In case of differential assembly overhaul it is neces- sary to adjust the backlash between the teeth of the planet pinions and the side gears. 108 .) for the left--hand side gear.0098 in. Sd = Gd -.0098 in.0. 107 6.) for the right--hand side gear. reading the end- float (Gs) on the dial gauge. Thoroughly clean the components of the differen- tial to remove any traces of oil that would other- wise prevent accurate backlash measurement. The side gear endfloat will be 0. 7. Install the two side gears without thrust washers. Proceed as follows.40 SECTION 25 -. check that the 24598 endfloat of the left and right hand side gears is approximately 0.0098 in.CHAPTER 1 OP. Move the left hand side gear to bring it into full contact with the planet pinion and then push it up 24597 against the differential housing.FRONT AXLE MECHANICAL TRANSMISSION -.25 mm (0.25 mm (0. Position a dial gauge on the differential housing. using a dial gauge and following the previously described procedure. 3. 5. 2. Repeat the above operations to measure the endfloat on the right hand side gear (Gd).). 1. Install shims as near as possible to the calculated value and.

FRONT AXLE MECHANICAL TRANSMISSION -. 110 page 4) and remove the ring gear.SLIP) is of the two planet gear--type. lock in a vice and proceed with disas- sembly operations as follows. . This differential lock device is totally automatic. Remove the right and left--hand bearing adjust- ment ring nuts (Gd) from the ring gear. LIM--SLIP self--locking differential lock OP. 1. 3. and may vary in intensity thereby proportion- ally determining the axial stress on the clutches. al- lowing the side gears to mesh with the differential casing which. permits the axle to overcome the unevenness of the ground. provided with two mul- ti--disk clutch assemblies fitted between the side gears and the differential casing. 2. 6. Remove the bevel drive--differential casing as- sembly from the front axle. 5. Check that the right and left--hand caps (1) are clearly marked. Remove the bolts (C9) caps (1) and separate the ring gear from the bevel pinion support. in turn. according to the nature of the ground and the route followed by the 109 tractor. attach to support 293743 (4). These torque values may be different. It does not require any type of manual operation and significantly reduces (but does not completely elimi- nate) wheel slipping. SECTION 25 -. 4. so as not to interchange the parts during assembly operations. gloves and shoes. Do not put your hands or fingers between parts. The difference in revolutions. Remove the bolts (2) and the right--hand (Gd) and left--hand ring nut lock plates (3).safety goggles. 25 102 27 FRONT AXLE DIFFERENTIAL WITH LIM--SLIP UNIT Overhaul WARNING Handle all parts carefully. If necessary. is impeded by clutch assem- blies that are compressed by axial thrusts from the 27966 bevel drive torque transmitted to the side gears by means of the teeth on the two planet.CHAPTER 1 41 LIM--SLIP SELF--LOCKING DIFFERENTIAL LOCK Operation The differential with limited slip locking (LIM -. between the side gears and the differential casing when a wheel begins to slip as a result of grip loss. unscrew the retaining bolts (C1. Wear suitable safety clothing -.

Remove the half--casing (7) the differential pin (4). the friction disk (11). complete with the planet gears (3). 12. the thrust washers (2) and the pins (9). tightening the bolts to a torque value of 113 Nm (83 ft-lbs). complete with LIM-- SLIP self--locking differential lock. on the bevel drive support. 16.15 (0. the friction disk (11). 15. Remove the retaining bolts (1) from the differen- tial half--casing. apply LOCTITE 270 to the threads on the screws (1) and tighten to a 111 torque value of 50 Nm (37 ft-lbs). Proceed with self--locking differential assembly operations. Refit the crown wheel (if previously disas- sembled) on the half--casing (8). 13. remembering to fit the previously z marked crown wheel bearing support caps in the correct order and assemble and adjust the crown 27967 wheel bearings as indicated earlier in this section.) mm (in. Remove the side gear (5). 8. 7. see table below). Description Quantity mm (in. 10.) 10 Metal disk 10 1. Assemble the crown wheel. Open the differential casing (6).0059) .0039) 12 Friction disk 8 1.1102) 0. the metal disks (10) and the friction disks (12). 112 Friction parts detail LIM--SLIP self--locking differential lock friction disks Thickness Maximum wear per disk Part no. the metal disks (10) and the friction disks (12) from the half--casing (8).0591) -- 11 Friction disk 2 2. Check the rolling torque of the bevel pinion. carrying out the previously described operations in reverse order. as in- dicated earlier in this section.CHAPTER 1 Disassemble the LIM--SLIP self--locking differential lock as follows.FRONT AXLE MECHANICAL TRANSMISSION -.10 (0. 9. Check the wear on the metal disks (10) and the friction disks (11 and 12.42 SECTION 25 -.6 (0. Remove the side gear (5).8 (0. replac- 27966 ing parts that show signs of wear. 11.0630) 0. LIM--SLIP self--locking differential lock 14.5 (0.

After having adjusted the toe--in to within the pre- scribed limits. Loosen lock nut (3) and screw the track rod end (1) in or out to decrease or increase the distance (2. checking that the new measurement is equal to or greater than distance (1) by a maxi- mum of 6 mm (0. 44 511 80 LEADING DRIVE WHEELS TOE--IN CHECK When travelling in a straight line. If wheel toe--in needs to be adjusted. SECTION 25 -. 3 2 24667 114 NOTE: Self--locking nut (2) must be replaced each time it is removed or unscrewed. 2.2362 in. 5. A slight toe--in of the front wheels is permissible -. with one spoke along the longitudinal axis of the tractor.up to a maximum of 6 mm (0. Reposition the track rod end (1) in the housing and check the toe-in as described in steps 4 and 5. proceed as follows. . the wheels on four-- wheel drive models must be parallel to the longitudi- nal axis of the tractor. Turn both front wheels through 180o then. The rotation of the wheels through 180o is required in order to elimi- 24666 nate the effect on the measurement of any even- tual wear on the rims. Measure the distance (1) between the front in- side edges of the rims.lb). Check that the wheels are parallel with the longi- tudinal axis of the tractor. measure the dis- tance (2) between the rear inside edges of the wheel rims.FRONT AXLE MECHANICAL TRANSMISSION -. 113). tighten lock nut (3) to a torque val- ue of 180 Nm (132 lfb. 1 4. as measured at the edges of the wheel rims.CHAPTER 1 43 OP.2362 in. at the 2 height of the wheel hub centres.). 3. Inflate the front tyres to the prescribed pressure. fig.lb) and nut (2) to100 Nm (74 lfb. To check the exact value of the toe--in setting of four-- wheel drive tractors.). 1. 113 6. Position the steering wheel at the middle of its travel. remove nut (2) and extract the track rod end (1) from the 1 housing.

44 SECTION 25 -.CHAPTER 1 .FRONT AXLE MECHANICAL TRANSMISSION -.

. . . . . . . . . . .0071 to 0. . . . .Rear Mechanical Wheel Drive CONTENTS Section Description Page 27 000 Main data . . . . . . . . . . . fig. . .0031 to 0. .0. . . . . . . . . .0. . . . . .50 (in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CHAPTER 1 1 SECTION 27 -. .080 to 44.960 (in. . . . . 12 27 110 10 Differential Lock Engagement Sleeve. . . . . . . . Removal--Installation . . . .158 (in. . . . . . . . . . . . .9465 to 0. pedal operated Side pinion internal seat diameter (5. . . . . . . .) (0. . . . . . . . . . .7354 to 1. . . . . 8) . . . . . . . . . . . 11 27 106 16 Rear Transmission/Gearbox. . . . . . . . . . 18 27 120 10 Final Drive Housing Assembly. 25 27 120 34 Drive Wheel Shaft. . TN 70 and TN 75 . . . . . . . . . . .080 to 0. . . . . . . . . fig. . . . . . . . . . . . . . see pages 21 to 24 Thickness of bearing adjuster rings and bevel gear clearance (21.) (0. . . . . . . . .) (1. . . . . . .) (1. . . mm 0. . . . . . . . . . . . . . . . . 5 Cross-sectional views . . 11 Troubleshooting . . . . . . . . . . . . . . . mm 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9/38 = 1:4. . . . . . . . . . . . . mm 24. . . . . . . . . . . . . . Removal--Installation . . mm 43. . . . . Adjusting . . . . . . . . . . . . 3 Tools . . . . . . .) (0. . . . . . . . . . . . . . . . mm 0. . . . . . . . . . . mm 0. . . . . . 1 Torque settings . . . . . . . . . . . . . .0. . . .15 -. . . . . . . . . . . . .080 to 0. . .) (0. . . . . . . . . . .model TN 55 . . . . . . . .REAR MECHANICAL TRANSMISSION -. . . . . . . . . . . . . .0048) Diameter of crown wheel pinion hub seats on differential housing (3.models TN 65. . . . .BEVEL GEAR PAIR AND DIFFERENTIAL Bevel gear pair ratio: -. . . . .0059 -. . . . . . . . . . . . . . . 8) . . . . . . . .939 to 23. . . . . .7370) Diameter of crown wheel pinion hubs (17. . . . . . . . . . 8) . . . . . . . . . . . . . . . . . . .REAR MECHANICAL TRANSMISSION Chapter 1 -. . . . . .9473) Side pinion pin diameter (19. . . . 8) . . . . . . . . . Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 27 120 32 Epicyclic Final Drive. . . . . 9/40 = 1:4. .) (0. . . . SECTION 27 -. . . . . . . . . . . . . . . . . . . . . .0079 -. . . . . . Removal--Installation 27 120 20 . . .18 to 0. . . with two crown wheel gears Mechanically controlled differential lock . . . . . . . . . .7323) Clearance between crown wheel pinion hubs and seats . mm 44. . . . . . . . . . . . . . . . . . .23 (in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0197) (continued overleaf) . . . . . . . .20 -. . .0062) Bevel gear bearing adjustment and bevel pinion clearance . fig. . .961 to 44.0031 to 0. . . . . . . . . . . . . .0091) Type of differential . . . . . . . . . . . . . . . .061 (in. . . . . . . . . . . . . . . . . .119 (in. .9433) Clearance between side pinions and pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -. . . .122 (in. . . . . . . . . . .7307 to 1. . . . fig. . .9425 to 0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . fig. . . . . . . . . . . . . . . . 29 MAIN SPECIFICATIONS -. . . .4 Clearance between sides of bevel gear pair teeth . . . . . . . . . . 9 Description and operation .0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .) (0. . . . . . . . 8) . . . . . . . . .040 to 24.000 (in. . . . . . . . . . . . . . . . . mm 0.

. . . . . . . . . . .4 -.) (0. . . . . .BEVEL GEAR PAIR AND DIFFERENTIAL (continued) Clearance between sides of planet and side pinion teeth . . .1929 -.) (0.0.5 -. . .) (0. . . . . . . . . . . .15 (in. . . .CHAPTER 1 MAIN SPECIFICATIONS -. . . . . .2126 -. .5 (in. . . . .1. . . . . .2 SECTION 27 -. . . . .3 -. . . .0197) Differential lock control fork spring (Mechanical control): -.0748 -. . . .2008 -. . . .2244 -. mm 1 (in. . .5. . . . . . . . . . . . . . . . 8) . .2205 -.0. . . . . .0579 -. . . . . . . . .REAR MECHANICAL TRANSMISSION -.1. .0. . . fig. . . .1968 -.0. . . .7 -. .1 (in.9 to 43.0.6 -. . . . . . .9 -. . . . . . mm 220 (in. . . . .1 to 19. . . . . .0670 -. . .0. . .TN 70 TN 75 Type . . . .2 -. .2283) . . . .9 lb. . . . . . . . . . . . . .0. . . .0. . .) (8. . . .1. .2. 8) . . mm 1. . mm 1. . . . .5. .2008) MAIN SPECIFICATIONS -.0701 -. . fig. . .4. . . . . .0394) Adjusting axial clearance of side pinion casing .0. .8 -. epicyclic with three side pinions and spur gear Reduction ratio . . . . . . . . . . fig. . .1850 -. . . .1811 -. .1772 -.6 -. .4 -. . . . . fig.) -. 8) .0. .7 -- 5. . . . .6615) -.9 kg. .5. . .0602) Adjustment of clearance between the side pinion and crown wheel teeth . . .) (0. .5 (in. .8 (0. . . . .0 (in.4. .5 -. . . . . . . . . . . . . .) (6. . . mm 0. .5. . . . . . . .0620 -. . . . .0. . . mm 0. . . . .0.6 -. .0.) . . . . . . see page 20 Thickness of differential lock control fork adjuster . . . . .2165 -.5. . . . 39. .0.1. . .4. . . . .0787) Thickness of differential side pinion shim adjustment rings (4.0059) Thickness of differential crown wheel shim adjustment rings (16.1890 -. . . . .5.0. . . . . . . . . . . .5. . . . . . 13:(13+65)=