Preview

TD60 – TD70 – TD80 – TD90 – TD95
STRADDLE MOUNT MODEL TRACTORS

SERVICE MANUAL
SECTIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TRANSMISSION OF MOTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
FRONT MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REAR MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
POWER TAKE–OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
AXLE AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
S E R V I C E
INTRODUCTION
◊ This manual is divided into sections identified by two–figure numbers. Each section has independent page
numbering.
For ease of reference, these sections have the same numbers and names as the Repairs Rate Book sections.
◊ The different sections can easily be found by consulting the table of contents on the following pages.
◊ The document number of the manual and the edition/update dates are given at the bottom of each page.
◊ Pages updated in the future will be identified by the same document number followed by a two–figure update
number (for example: 1st update 603.54.331.01; 2nd update 603.54.331.02; etc.) and the corresponding is-
sue date.
These pages will be supplemented by a reprint of the updated contents page.
◊ The information contained in this manual was current on the date printed on each section. As NEW HOLLAND
constantly improves its product range, some information may be out of date subsequent to modifications im-
plemented for technical or commercial reasons or to meet legal requirements in different countries.
In the event of conflicting information, consult the NEW HOLLAND Sales and Service Departments.
IMPORTANT WARNINGS
◊ 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 who performs the operations described herein without strictly following the instructions is personally
responsible for resulting injury or damage to property.
◊ The Manufacturer and all organisations belonging to the Manufacturer’s distribution network, including but
not restricted to national, regional or local distributors, will accept no responsibility for personal injury or dam-
age to property caused by abnormal function of parts and/or components not approved by the Manufacturer,
including those used for maintenance and/or repair of the product manufactured or marketed by the Manufac-
turer.
In any case, the product manufactured or marketed by the Manufacturer is covered by no guarantee of any
kind against personal injury or damage to property caused by abnormal function of parts and/or components
not approved by the Manufacturer.
TEXT AND ILLUSTRATIONS ARE THE PROPERTY

OF NEW HOLLAND ???????????????
No part of the text or illustrations

may be reproduced
PRINTED IN ?????
NEW HOLLAND ????????. – ??????????????????????????????????

SERVICE – Technical Publications & Special Tools
Print no. ???.??.???.?? – 06 – 2002
NEW
HOLLAND
Repair Manual–TD Straddle Mount Series Tractors
CONTENTS
GENERAL SECTION 00
General Instructions and Health and Safety Chapter 1
Section Description Page
00 000 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Notes for spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Notes for equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINE SECTION 10
Engine System Chapter 1
10 000 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cross–sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lubrication and cooling system diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10 001 Removal – Installation – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Checks, dimensions and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
CLUTCH SECTION 18
Clutches Chapter 1
18 000 General Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
18 110 10 Removal – Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–15
18 110 30 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–19
Checks, measurements and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–21
18 100 40 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–23
GEARBOX SECTION 21
Mechanical Transmission (12x4) Chapter 1

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

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
21 110 Removal – Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see sect 27
Reverser (12x12) Chapter 2

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

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
21 110 Removal–Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Reverser and Creeper (20x12) Chapter 3

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

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
21 110 Removal–Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DRIVE LINES SECTION 23
Drive Lines Chapter 1

23 000 Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Torque settings and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cross–Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
23 101 26 Transmission shafts and guard (Disassembly – Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
23 101 40 Drive gear housing (Removal – Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
23 101 42 Drive gear housing removed (Disassembly – Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FRONT AXLE MECHANICAL TRANSMISSION SECTION 25
Front Axle Mechanical Transmission Chapter 1

25 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cross–sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
25 100 30 Complete front axle. Removal – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
25 100 38 Front axle. Removal – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
25 108 46–47 Steering knuckle bearing pins. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Stub axle adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wheel hub bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bevel drive adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
25 102 24 Front axle differential. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
25 100 27 Front axle differential with LIM–SLIP. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Front axle differential with NO SPIN. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
44 511 80 Leading drive wheels toe–in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REAR AXLE AND TRANSMISSION SECTION 27
Rear Axle And Transmission Chapter 1


Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
27 100 Removal–Refitting–Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
POWER TAKE–OFF SECTION 31
Mechanical Power Take – Off Chapter 1

31 000 Main specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal – Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
31 101 Bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BRAKING SYSTEM SECTION 33
Braking System Chapter 1

31 000 Main specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal – Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
31 101 Bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HYDRAULIC SYSTEM SECTION 35
Rear Mechanical Hydraulic Lift Chapter 1


Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
35 114 Removal – Refitting – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Open Centre System Auxiliary Control Valves Chapter 2

35 000 Main data – Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see ‘lift’ in chapter 1
35 204 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Trailer Brake Auxiliary Control Valve Chapter 3

35 000 Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Trailer brake remote control valve linkage adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
STEERING SECTION 41
Steering Chapter 1
41 000 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
41 204 Hydrostatic steering control valve – Removal–Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydrostatic steering control valve – Disassembly–Assembly . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydrostatic steering control valve – Bench testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
41 206 Hydrostatic steering oil pump – Disassembly–Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
41 216 Steering cylinder – Removal–Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FRONT AXLE AND WHEELS SECTION 44
Front Axle And Wheels Chapter 1

44 000 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment – Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
44 101 Removal–Refitting–Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
44 101 Wheel hub disassembly–assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
44 101 Stub axle overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ELECTRICAL SYSTEM SECTION 55
Instruments Chapter 1
Section Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
55 418 Analogue instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Components Chapter 2
55 500 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Starting System Chapter 3

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

Trouble–shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
System tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
55 201 Removal and re–installation of starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bench tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Charging System Chapter 4


System testing and trouble–shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
55 301 Removal, re–installation and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Battery Chapter 5

55 301 Removal and re–installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Battery checking and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery problems – Frequent causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Circuits Chapter 6

55 100 Fuses (all versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Symbols used in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Electrical wire colour coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical diagrams
Generall diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Start–up circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Side lights, main and dipped headlights, parking light circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Direction indicator and hazard warning light circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Work lamp circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Windscreen and rear window wiper/washer circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Heating and air–conditioning system circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Analogue instrument circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BODYWORK AND DRIVER POSITION SECTION 90
Bodywork And Driver Position Chapter 1

90 000 Disassembly–Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SECTION 00 – GENERAL – CHAPTER 1 1
GENERAL INSTRUCTIONS
IMPORTANT NOTICE
All maintenance and repair operations described in this manual should be carried out exclusively by the FIATA-
GRI authorised workshops. All instructions detailed should be carefully observed and special equipment indi-
cated should be used if necessary.
Everyone who carries out service operations described without carefully observing these prescriptions will be
directly responsible of deriving damages.
SHIMMING
At each adjustment, select adjusting shims, measure them individually using a micrometer and then sum up
recorded values. Do not rely on measuring the whole shimming set, which may be incorrect, or on rated value
indicated for each shim.
ROTATING SHAFT SEALS

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

Use exclusively genuine NEW HOLLAND spare parts, the only ones bearing this logo.
Only genuine parts guarantee same quality, life, safety as original components as they are the same as mounted
in production.
Only the NEW HOLLAND genuine spare parts can offer this guarantee.
All spare parts orders should be complete with the following data:
– tractor model (commercial name) and frame number;
– engine type and number;
– part number of the ordered part, which can be found on the “Microfiches” or the “Spare Parts Catalogue”,
which is the base for order processing.
NOTES FOR EQUIPMENT

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

Cables from the external power supply should be connected exclusively to the respective terminals of the tractor
positive and negative cables using pliers in good condition which allow proper and steady contact.
Disconnect all services (lights, etc.) before starting the tractor.
If it is necessary to check the tractor electrical system, check it only with the power supply connected. At check
end, disconnect all services and switch the power supply off before disconnecting the cables.
????
SAFETY RULES
PAY ATTENTION TO THIS SYMBOL

This warning symbol points out important messages involving personal safety.
Carefully read the safety rules contained herein and follow advised precautions to
avoid potential hazards and safeguard your safety and personal integrity.
In this manual you will find this symbol together with the following key–words:
WARNING – it gives warning about improper repair operations and deriving potential
consequences affecting the service technician’s personal safety.
DANGER – it gives specific warning about potential dangers for personal safety of the
operator or other persons directly or indirectly involved.
TO PREVENT ACCIDENTS if they are certified operators to assist in the

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

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

ELECTRICAL SYSTEMS
tractor wheels. Raise the tractor and install safe
◊ If it is necessary to use auxiliary batteries, cables and stable supports under the tractor in accor-
must be connected at both sides as follows: (+) to dance with regulations in force.
(+) and (–) to (–). Avoid short–circuiting the termi-
nals. GAS RELEASED FROM BATTERIES IS ◊ Deflate the tyre before removing any object
HIGHLY FLAMMABLE. During charging, leave caught into the tyre tread.
the battery compartment uncovered to improve
ventilation. Avoid checking the battery charge by ◊ Never inflate tyres using flammable gases as they
means of “jumpers” made by placing metallic may originate explosions and cause injuries to
objects across the terminals. Avoid sparks or bystanders.
flames near the battery area. Do no smoke to pre-
vent explosion hazards.
REMOVAL AND INSTALLATION
◊ Lift and handle all heavy components using lifting
◊ Prior to any service, check for fuel or current equipment of adequate capacity. Ensure that
leaks. Remove these leaks before going on with parts are supported by appropriate slings and
the work. hooks. Use lifting eyes provided to this purpose.
Take care of the persons near the loads to be
lifted.
◊ Do not charge batteries in confined spaces. En-
sure that ventilation is appropriate to prevent acci- ◊ Handle all parts with great care. Do not place your
dental explosion hazard due to build–up of gases hands or fingers between two parts. Wear
releaved during charging. approved protective clothing such as safety
goggles, gloves and footwear.
◊ Always disconnect the batteries before perform- ◊ Do not twine chains or metal cables. Always wear
ing any type of service on the electrical system. protection gloves to handle cables or chains.
???
CONSUMABLES
QUANTITY NEW HOLLAND
COMPONENT TO BE FILLED OR INTERNATIONAL
RECOMMENDED
TOPPED UP litres/dm3 US gal IMP gal SPECIFICATION
PRODUCTS
Cooling system:
Water & liquid
AMBRA AGRIFLU
models TD60, TD70 . . . . . . . . . . . 12 3.2 2.64 –
50% + 50%
models TD80, TD90, TD95 . . . . . 14 3.7 3.08
(NH 900 A)
Decanted and
Fuel tank........................................... 77 20.34 16.94 filtered –
diesel fuel
Engine sump:
without filter : AMBRA Supergold
TD60 and TD70............................... SAE 15W – 40
7.6 1.98 1.67 (NH 330G)
TD80, TD90andTD95...................... 10.5 2.77 2.31 API CF–4/SG
AMBRA Supergold
with filter : CCMC D4
SAE 10W – 30..
MIL–L–2104E
TD60 and TD70 HP models . . . . . . . 8.3 2.19 1.83 (NH 324G)
TD80, TD90 andTD95models.......... 11.2 2.96 2.46
Hydrostatic steering circuit . . . . . . . . . . 2.0 0.5 0.44
Front axle:
– axle housing:
models TD60, TD70 . . . . . . . . . . . 4.5 1.2 0.99
models TD80, TD90, TD95 . . . . . 7.0 1.8 1.54
– final drives (each):
models TD60, TD70 . . . . . . . . . . 0.8 0.2 0.18
models TD80, TD90, TD95 . . . . . 1.25 0.3 0.28
Rear transmission (bevel drive and Oil API GL4
brakes), gearbox, hydraulic lift and AMBRA MULTI G ISO 32/46
PTO (NH 410B) SAE 10W–30
models TD60,TD70, TD80, TD90,
TD95 . . . . . . . . . . . . . . . . . . . . . . . . 46 12.15 10.12
– with synchro–reverser:
models TD60, TD70, TD80, TD90,
TD95 . . . . . . . . . . . . . . . . 46 12.15 10.12
Rear final drives (each) . . . . . . . . . . . .
models TD60, TD70 . . . . . . . . . . . . 3.9 1.03 0.86
models TD80, TD90 and TD95 . . 5.3 1.40 1.17
Front wheel hubs . . . . . . . . . . . . . . . . . . – – – Grease
AMBRA GR9 NLGI 2
Grease fittings . . . . . . . . . . . . . . . . . . . . – – – (NH 710A)
WARNING
In order to correctly fill the oil and water tanks observe the existing level indications (e.g.: the level on
the oil dipstick). Park the tractor on level ground and, where possible, ensure that all of the hydraulic
cylinders are fully extended before checking oil levels.
????
SECTION 10 – ENGINE – CHAPTER 1 1
SECTION 10 – ENGINE
Chapter 1 – Engine
CONTENTS
10 000 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cross–sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Lubrication and cooling system diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10 001 Removal – Installation – Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Checks, dimensions and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
603.54.471.00 – 03 – 2004
2 SECTION 10 – ENGINE – CHAPTER 1
GENERAL SPECIFICATION 3–cylinder 4–cylinder

Engine type:
– TD 60 model normally aspirated – type 8035.05D.639/939 – –
(BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– TD 70 model turbocharged – type 8035.25C.639/939 – –
(BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– TD 80 model normally aspirated – type 8045.05R.639/939 – –
(BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– TD 90 model turbocharged – type 8045.25.639/939 – –
(BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– TD 95 model turbocharged – type 8045.25L.639/939 – –
(BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel, 4–stroke
Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct
Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4
Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dry force–fitted in dry force–fitted in
cylinder block cylinder block
Piston diameter
– TD 60 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 mm –
– TD 70 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 mm –
– TD 80 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 104 mm
– TD 90 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 104 mm
– TD 95 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 104 mm
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 mm
Total displacement:
– TD 60 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2931 cm3 –
– TD 70 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2931 cm3 –
– TD 80 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 3908 cm3
– TD 90 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 3908 cm3
– TD 95 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 3908 cm3
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 to 1 normally aspirated
16.5 to 1 turbocharged
Maximum power 2000/25 EC at 2500 rpm:
– TD 60 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.4 kW (59 HP) –
– TD 70 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.7 kW (69 HP) –
– TD 80 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 58.8 kW (80 HP)
– TD 90 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 65.5 kW (89 HP)
– TD 95 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 69.1 kW (94 HP)
Maximum power ECE R 24 at 2500 rpm:
– TD 60 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 kW (56 HP) –
– TD 70 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47.8 kW (65 HP) –
– TD 80 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 55.9 kW (76 HP)
– TD 90 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 63.3 kW (86 HP)
– TD 95 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 66.9 kW (91 HP)
Fast idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500 rev/min
Maximum torque (daNm) at 1500 rpm: TD 60 model . . . . . . . . . 20.7 –
Maximum torque (daNm) at 1500 rpm: TD 70 model . . . . . . . . . 25.0 –
Maximum torque (daNm) at 1500 rpm: TD 80 model . . . . . . . . . – 27.9
Maximum torque (daNm) at 1500 rpm: TD 90 model . . . . . . . . . – 32.0
Maximum torque (daNm) at 1500 rpm: TD 95 model . . . . . . . . – 33.7
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5
Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Structural, cast iron
603.54.471.00 – 03 – 2004
(continued)
GENERAL SPECIFICATION 3–cylinder 4–cylinder
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced, with gear pump
Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . camshaft
Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . 2:1
Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mesh filter on oil intake and

cartridge filter on delivery line
Normal oil pressure, with engine hot and at fast idling speed: . 2.9 to 3.9 bar (3 to 4 kg/cm2)
Lube pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . built into pump housing
Valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 bar (3.6 kg/cm2)
For further lubrication data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 23
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . coolant circulation
Radiator on TD60, TD70, TD80 and TD90 models . . . . . . . . . . 3–row vertical pipes with copper fins
Radiator on TD95 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . four–row vertical pipes with

copper fins
Fan, attached to coolant pump pulley . . . . . . . . . . . . . . . . . . . . . 4–blade steel exhauster fan
6–blade steel exhauster fan (TD95)
Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal vane–type
Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . . 1:1,403
Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat
Coolant temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . coloured scale divided into 3 sections
Temperature ranges corresponding to each section:
– initial white section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . from 30° to 65° C
– middle green section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . from 65° to 105° C
– final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . from 105° to 115° C
For further cooling system data . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 23
Rev counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . incorporated in control panel
Rev counter drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . from gear on camshaft
Hour counter calibrated for engine speed of . . . . . . . . . . . . . . . . 1800 rev/min

(continued)
603.54.471.00 – 03 – 2004
(continued)
GENERAL SPECIFICATIONS 3–cylinder 4–cylinder
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by a camshaft
located in the engine block through tap-
pets, pushrods and rockers. Camshaft is
driven by the crankshaft through helical
gears.
Intake:
– start: before T.D.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12°
– end: after B.D.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31°
Exhaust:
– start: before B.D.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50°
– end: after T.D.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16°
Valve clearance for timing check . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 mm
Valve clearance for normal running (engine cold):
– intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 " 0.05 mm
– exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 " 0.05 mm
For further timing data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 20
Fuel System
Air cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dual cartridge dry air filter with clogged
filter indicator, centrifugal pre–filter and
automatic dust ejector
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . double diaphragm
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mesh filter in fuel supply pump and

replaceable cartridge on delivery line to
injection pump.
Minimum fuel flow rate with pump shaft rotating

at 1600 rev/min. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 litres/hour
Operated by eccentric cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . on camshaft
BOSCH injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . distributor type
All–speed governor, incorporated in pump: BOSCH centrifugal counterweights
Automatic advance regulator, incorporated in pump: BOSCH hydraulic
For further fuel system data: see pages 5 to 15
For fixed advance (pump setting for start of delivery before refer to the data for the relevant engine
TDC) – Pressure setting – Injection order, and other informa- type in the table on pages 5 to 15
tion regarding the BOSCH pump
603.54.471.00 – 03 – 2004
DATA
Turbocharger (TD95 Model):
– . . . . . GARRETT type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T25
Fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . distributor type with incorporated speed

governor and automatic advance regulator
BOSCH pump:
– . . . . . TD 60 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 3/12 F 1250 L 976
– . . . . . TD 70 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 3/12 F 1150 L 977
– . . . . . TD 80 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 4/12 F 1250 L 980
– . . . . . TD 90 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 4/12 F 1250 L 982
– . . . . . TD 95 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VE 4/12 F 1150 L 972
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . anti–clockwise
Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2–3 (TD60 and TD70 Models)

1–3–4–2 (TD80, TD90 and TD95 Models)
Fuel Injectors:
BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– Nozzle holder type . . . . . . . . . . . . . . . . . .
– Nozzle type . . . . . . . . . . . . . . . . . . . . . . . .
Number of nozzles 5 6
Diameter of nozzle orifices
Pressure setting 248–272 bar 248–272 bar
TD70 TD95 TD60 TD80 TD90
Fuel delivery lines – BOSCH pump
– Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– Dimensions . . . . . . . . . . . . . . . . . . . . mm – – – – –
603.54.471.00 – 03 – 2004
TD60 MODEL – CALIBRATION DATA FOR BOSCH INJECTION PUMP

TYPE VE 3/12 F 1250 L 976
ASSEMBLY DATA CALIBRATION TEST CONDITIONS

Pump timing on engine: delivery start 4°" 0.5 before
TDC of cylinder 1 compression stroke. Test bench conforming to ISO 4008/1.../2
Plunger pre–lift for timing on engine: 1 mm from BDC Injectors conforming to ISO 7440–A61 –
(with tools 291754 – 291755) (1688901027 with pad ∅ 0.5 mm)
Cylinder no. 1 delivery line union on pump: marked Injector setting pressure: 250 bar (254 kg/cm2).
with letter A.
ASSEMBLY DIMENSIONS Fuel supply pressure: 0.35 ±0.05 bar (kg/cm2).

Delivery pipes (conforming to ISO 4093.2):
SYMBOL SVS KF MS ya yb 6 x 2 x 450 mm
(max)
Graduate drain time: 30 seconds
mm – – 36,9–40,9 41,5–46,5 Test liquid: ISO 4113 at a temperature of 40° " 2°C.
1. START OF DELIVERY
Plunger pre–lift from TDC: Pump rotation (viewed from drive side): Injection order: 1–2–3
mm anti–clockwise
2. ADVANCE REGULATOR STROKE

Rev/min: 1250 Setting: mm 2.3 ± 0.2
3. FUEL SUPPLY PUMP PRESSURE

Rev/min: 800 Internal pressure: 6.3 ÷ 6.9 bar
4. FULL–LOAD DELIVERY WITHOUT BOOSTER PRESSURE

Rev/min: 750 Delivery: 78.5 – 79.5 mm3 per crank cycle Spread: – mm3
5. ADJUSTMENT AT IDLING SPEED

Rev/min: 325 Delivery: 13 – 17 mm3 per crank cycle Spread: – mm3
6. ADJUSTMENT AT FAST IDLING SPEED

7. DELIVERY AT STARTING
Rev/min: 100 Delivery: 80 – 110 mm3/per crank cycle
8. TRANSFER PRESSURE PROGRESSION

Rev/min. 800 500 1250
Transfer pump pressure bar 6,3 – 6,9 4,8 – 5,4 8,2 – 8,8
9. INJECTION ADVANCE PROGRESSION

Rev/min – – –
Advance stroke mm – – –
10. BACKFLOW
Rev/min – –
Backflow cm3 /10 sec – –
(continued)
Note: the values shown above in brackets must be used for checking purposes only.
603.54.471.00 – 03 – 2004
(cont)
11. DELIVERY PROGRESSION

Rev/min. Delivery: mm3 per crank cycle
1365 <3
1300 41 – 45
1000 69,5 – 73,5
750 78,5 – 79,5
500 69,5 – 73,5
12. DELIVERY CHECK AT IDLE SPEED

Rev/min. 250 325
Delivery: mm3 per crank cycle 43 – 47 13 – 17
BENCH TEST PERFORMANCE DATA

Test Conditions
Fixed advance before TDC with cylinder No.1 on compression Relative humidity 70% ± 5.
stroke: (see previous page).
Engine without fan, air filter and exhaust silencer. Ambient temperature 25° C.
Atmospheric pressure: 990 mbar Specific gravity of diesel fuel
830 ± 10 g/litre.
Fuel
Throttle Engine speed Power output with engine run–in for a total of:
consumption
lever Braking load applied
position 2 hours 50 hours
rev/min kW) kW kg/h
Maximum For maximum torque 2500 – 39,5 – 42,0 9,1 – 9,7
Maximum For maximum torque 1500 – 31,5 – 33,5 6,8 – 7,2
Maximum None (no–load) 2770"25 – – –
Minimum None (no–load) 650"25 – – –
603.54.471.00 – 03 – 2004

TYPE VE 3/12 F 1150 L 977

Pump timing on engine: delivery start 0° " 0.5 be-
fore TDC of cylinder 1 compression stroke.
Plunger pre–lift for pump timing on engine: 1 mm Test bench conforming to ISO 4008/1.../2
from BDC (with tools 291754 – 291755). Injectors conforming to ISO 7440–A61 –
Cylinder no. 1 delivery line union on pump: marked (1688901027 with pad ∅ 0.5 mm)
with letter A. Injector setting pressure: 250 bar (254 kg/cm2).
ASSEMBLY DIMENSIONS Fuel supply pressure: 0.35 ±0.05 bar (kg/cm2).
Delivery pipes (conforming to ISO 4093.2):
SYMBOL SVS KF MS ya yb 6 x 2 x 450 mm
(max)
mm – – – 35,5–39,5 Test liquid: ISO 4113 at a temperature of 40° " 2°C.
Plunger pre–lift from TDC: Pump rotation (viewed from drive side): Injection order: 1–2–3
mm anti–clockwise

Rev/min: 1250 Advance stroke: mm 2.8 – 3.2

Rev/min: 800 Internal pressure: 6.2 – 6.8 bar

Rev/min: 600 Delivery: 61.5 – 62.5 mm3 per crank cycle Spread: –mm3


Rev/min: 1350 Delivery: 25 – 29 cm3 per crank cycle Spread: – mm3
Rev/min: 100 Delivery: 80 – 110 mm3 per crank cycle

Rev/min. 800 500 1250
Transfer pump pressure bar 6,2 – 6,8 4,7 – 5,3 8,2 – 8,8

Rev/min. 1000 1250
Advance stroke mm 1,0 – 1,4 2,8 – 3,2
10. BACKFLOW
Rev/min. – –
Backflow cm3 /10 sec – –
(continued)
603.54.471.00 – 03 – 2004
(continued)

Rev/min. Delivery mm3 per crank cycle Booster pressure kPa
1380 <3 100
1300 55–59 100
1250 58–62 100
1000 66–70 100
750 73–74 100
500 80–84 100
600 68–72 30
600 60–64 0

Rev/min. 325 250

Test Conditions
Engine without fan, air filter and exhaust silencer. Ambient temperature 25° C.
830 ± 10 g/litre.
Fuel
consumption
rev/min kW kW kg/h
For maximum
Maximum 2500 – 47.5 – 50.5 11.1 – 11.8
torque
Maximum For maximum torque 1500 – 37.0 – 39,5 8.2 – 8.7
603.54.471.00 – 03 – 2004

TYPE VE 4/12 F 1150 L 980

Pump timing on engine: delivery start 1° " 0.5 be-
fore TDC of cylinder 1 compression stroke. Test bench conforming to ISO 4008/1.../2.
Plunger pre–lift for pump timing on engine: 1 mm Injectors conforming to ISO 7440–A61 –
from BDC (with tools 291754 – 291755) (1688901027 with pad ∅ 0.5 mm).
Cylinder no. 1 delivery line union on pump: marked Injector setting pressure: 250 bar (254 kg/cm2).
with letter A.
Fuel supply pressure: 0.35 ±0.05 bar (kg/cm2).
ASSEMBLY DIMENSIONS Delivery pipes (conforming to ISO 4093.2):
6 x 2 x 450 mm.
SYMBOL SVS KF MS ya yb Graduate drain time: 30 seconds.
(max)
mm – – 36,9–40,9 40,1–45,5 Test liquid: ISO 4113 at a temperature of 40° " 2°C.
Plunger pre–lift from TDC: Pump rotation (viewed from drive side): Injection order: 1–3–4–2
mm anti–clockwise


Rev/min: 800 Internal pressure: from 5.7 to 6.3 bar


Rev/min: 325 Delivery: 10 – 14 mm3 per crank cycle Spread:– mm3


Rev/min. 800 500 1150
Transfer pump pressure bar from 5.7 to 6.3 from 4.9 to 5.5 6.7 – 7.3

Rev/min. 1000 1150
Advance stroke mm 1.3 – 1.7 2.4 – 2.6
10. BACKFLOW
Rev/min. – –
Backflow cm3 – –
(continued)
603.54.471.00 – 03 – 2004
(continued)

1290 <3
1200 72 – 76
1150 75 – 79
1000 81 – 85
700 94 –95
500 87 – 91

Rev/min. 350 250

Test Conditions
Engine without fan, air filter and exhaust silencer. Ambient temperature 25°C.
830 ± 10 g/litre.
Fuel
consumption
rev/min kW kW kg/h
For maximum
Maximum 2500 – 54.0 – 57.5 12.3 – 13.1
torque
Maximum For maximum torque 1500 – 39.5 – 42 8.5 – 9.0
603.54.471.00 – 03 – 2004

TYPE VE 4/12 F 1250 L 982

Pump timing on engine: delivery start 1° " 0.5° be-
fore TDC of cylinder 1 compression stroke. Test bench conforming to ISO 4008/1.../2
from BDC (with tools 291754 – 291755). (1688901027 with pad ∅ 0.5 mm)
Cylinder no. 1 delivery line union on pump: marked Injector setting pressure: from 250 to 253 bar
with letter A. (from 255 to 258 kg/cm2).
SYMBOL K KF MS SVS ya yb 6 x 2 x 450 mm
(max)
mm – – – 37.9–40.9 39.7–44.7 Test liquid: ISO 4113 at a temperature of 40° " 2°C.
Plunger pre–lift from TDC: Pump rotation (viewed from drive side): Injection order: 1–3–4–2
mm anti–clockwise


Rev/min: 800 Internal pressure: 6.7 to 7.3 bar




Rev/min. 800 500 1250
Transfer pump pressure bar 6.2 – 6.8 4.9 – 5.5 8.2 – 8.8

Rev/min. 1100 1250
Advance stroke mm 1.1 – 1.9 2.7 – 3.2
10. BACKFLOW
Rev/min. – –
Backflow cm3 – –
(continued)
603.54.471.00 – 03 – 2004
(continued)

1375 <3
1300 58 – 62
1250 71 – 75
1000 78 – 82
750 88 – 89
500 81 – 85

Rev/min. 350 250
Delivery mm3 per crank cycle 13 – 17 63 – 67

Test Conditions
830 ± 10 g/litre.
Fuel
consumption
rev/min kW kW kg/h
For maximum
Maximum 2500 – 60.0 – 64.0 13.7 – 14.6
torque
Maximum For maximum torque 1500 – 46.0 – 48.8 9.8 – 10.4
603.54.471.00 – 03 – 2004

TYPE VE 4/12 F 1250 L 972

Pump timing on engine: delivery start 0° " 0.5° be-
Test bench conforming to ISO 4008/1.../2
fore TDC of cylinder 1 compression stroke.
from BDC (with tools 291754 – 291755) (1688901027 with pad ∅ 0.5 mm)
Cylinder no. 1 delivery line union on pump: marked Injector setting pressure: from 250 to 253 bar
with letter A. (from 255 to 258 kg/cm2).
6 x 2 x 450 mm
SYMBOL K MS ya yb
mm – – 35.5–39.5 39.7–46.7 Test liquid: ISO 4113 at a temperature of 40° " 2°C.
Plunger pre–lift from TDC: mm Pump rotation (viewed from drive side): Injection order: 1–3–4–2
anti–clockwise


Rev/min: 800 Internal pressure: from 7.2 to 7.8 bar

5. FULL–LOAD DELIVERY WITH BOOSTER PRESSURE

Rev/min.: 700 (100 kPa) Delivery: 90.5 – 91.5 mm3 per crank cycle



Rev/min. 800 500 1150
Transfer pump pressure bar from 7.2 to 7.8 from 6.2 to 6.8 8,2 – 8,8

Rev/min. 1000 1150
Advance stroke mm from 0.9 to 1.3 from 2.3 to 2.7
11. BACKFLOW
Rev/min.
Backflow cm3
(continued)
603.54.471.00 – 03 – 2004
(continued)

Rev/min. Delivery mm3 per crank cycle Booster pressure kPa
1250 <3 100
1200 38 – 42 100
1150 73 – 77 100
1000 78 – 82 100
700 90.5 – 91.5 100
500 97 – 101 100
600 78 – 82 35
600 69.5 – 73.5 0

Rev/min. 275 325 430
Delivery per 1000 shots: cm3 27.4 to 33.4 5.8 to 9.8 0 to 3

Test Conditions
830 ± 10 g/litre.
Fuel
consumption
rev/min kW kW kg/h
For maximum
Maximum 2500 – 66 – 70 15.5 – 15.9
torque
Maximum For maximum torque 1500 – 51 – 54 11 – 11.7
603.54.471.00 – 03 – 2004
FUEL SUPPLY PUMP DATA mm
Eccentricity of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Diameter of drive shaft at bushings . . . . . . . . . . . . . . . . . . . . . . . . . 31.975 to 32.000
Internal diameter of installed and reamed bushings . . . . . . . . . . . 32.050 to 32.075
Interference between bushings and seats . . . . . . . . . . . . . . . . . . . . 0.063 to 0.140
Assembly clearance between shaft and bushings . . . . . . . . . . . . . 0.050 to 0.100
Thickness of internal washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45 to 1.50
Thickness of external washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.93 to 3.00
CRANKCASE/CYLINDER BLOCK DATA mm
Cylinder block (4–cylinder engines) . . . . . . . . . . . . . . . . . . . . . . . . . cast–iron monobloc with replaceable

dry–fitted cylinder liners, incorporating
seatings for crankshaft bearings, cam-
shaft and pushrod/tappet assemblies
Internal diameter of cylinder liners (4–cylinder engines) . . . . . . . . 104.000 to 104.024 (1)

External diameter of cylinder liners (4–cylinder engines) . . . . . . . 107.020 to 107.050
Diameter of cylinder bores (4–cylinder engines) . . . . . . . . . . . . . . 106.850 to 106.900
Interference fit between cylinder liners and bores
(4–cylinder engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.120 to 0.200
Liner internal diameter oversizes (4–cylinder engines) . . . . . . . . . 0.4 to 0.8
Liner external diameter oversizes (4–cylinder engines) . . . . . . . . 0.2
Maximum permissible liner ovality or taper due to wear (2)
(4–cylinder engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12
Diameter of main shell bearing seats . . . . . . . . . . . . . . . . . . . . . . . 84.200 to 84.230
Diameter of camshaft bearing seats:
– front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.780 to 54.805
– middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.280 to 54.305
– rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.780 to 53.805
Diameter of standard tappet bores in crankcase . . . . . . . . . . . . . . 15.000 to 15.018
Spare tappet oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 – 0.2 – 0.3
(1) Measured after press–fitting and reaming.
(2) Measure in the area swept by piston rings, both parallel and perpendicular to the crankshaft axis.
603.54.471.00 – 03 – 2004
CRANKSHAFT AND BEARINGS DATA mm
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . balanced with integral counterweights
Standard journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.791 to 79.810 (1)
Journal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254 – 0.508 – 0.762 – 1.016
Standard main bearing shell thickness . . . . . . . . . . . . . . . . . . . . . . 2.168 to 2.178
Main bearing shell undersizes (internal diameter) . . . . . . . . . . . . . 0.254 – 0.508 – 0.762 – 1.016
Bearing shell to journal clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.034 to 0.103
Maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . . . . . . . 0,180
Standard crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.725 to 63.744 (1)
Crankpin undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254 – 0.508 – 0.762 – 1.016
Standard big–end bearing shell thickness . . . . . . . . . . . . . . . . . . . . 1.805 to 1.815
Big–end bearing shell undersizes (internal diameter) . . . . . . . . . . 0.254 – 0.508 – 0.762 – 1.016
Big–end bearing shell to crankpin clearance . . . . . . . . . . . . . . . . . . 0.033 to 0.087
Maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . . . . . . . 0.180
Standard crankshaft thrust washer thickness . . . . . . . . . . . . . . . . . 3.378 to 3.429
Thrust washer oversizes (thickness) . . . . . . . . . . . . . . . . . . . . . . . . 0.127 – 0.254 – 0.381 – 0.508
Width of main bearing including thrust washers . . . . . . . . . . . . . . . 31.766 to 31.918
Width of corresponding crankshaft journal . . . . . . . . . . . . . . . . . . . 32.000 to 32.100
Crankshaft assembly endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.082 to 0.334
Maximum permitted wear endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40

Maximum ovality or taper of journals and crankpin after
regrinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.01
Maximum ovality or taper of journals and crankpin . . . . . . . . . . . . 0.05
Maximum tolerance for alignment of crankshaft journals with

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

(3–cylinder engines) or each pair of crankpins
(4–cylinder engines) relative to crankshaft journals . . . . . . . . . . . . 0.25
Maximum tolerance for run–out between the outer surfaces of

the crankshaft journals and the crankshaft centreline . . . . . . . . . . ± 0.10
(continued)
(1) Crankshafts with 0.1 mm undersize journals and crankpins and consequently undersize bearing shells may be fitted in
factory production.
603.54.471.00 – 03 – 2004
(continued)
BENCH TEST PERFORMANCE DATA mm
Maximum permitted tolerance on run–out of flywheel mounting

flange surface relative to the crankshaft centreline, measured
with 1/100 mm scale dial gauge resting on front flange surface at
a diameter of 108 mm (total gauge reading). . . . . . . . . . . . . . . . . . 0.025
Maximum permitted tolerance on co–axial alignment of flywheel

centering seat relative to the crankshaft journals (total gauge
reading) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.04
CONNECTING ROD DATA mm
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cast–iron with oil way
Diameter of small end bushing seat . . . . . . . . . . . . . . . . . . . . . . . . . 41.846 to 41.884
Outside diameter of small end bushing . . . . . . . . . . . . . . . . . . . . . . 41.979 to 42.017
Interference between small end bushing and seat . . . . . . . . . . . . . 0.095 to 0.171
Inside diameter of small end bushing (measured after fitting) . . . 38.004 to 38.014
Diameter of big end shell bearing seats . . . . . . . . . . . . . . . . . . . . . . 67.407 to 67.422
Maximum tolerance for parallelism between the small end and

big end axes measured at 25 mm . . . . . . . . . . . . . . . . . . . . . . . . . . ± 0,07
Maximum weight difference between con rods in same engine . . 25 grams
603.54.471.00 – 03 – 2004
mm
PISTON DATA
TD60, TD80 TD70, TD90,
TD95
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light alloy with two compression and

one oil control rings
Standard piston diameter, measured at 57 mm from base and 103.852 to 103.870

perpendicularly to the gudgeon pin axis . . . . . . . . . . . . . . . . . . . . . .
Piston clearance in cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.130 to 0.172
Piston oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6
Piston protrusion at TDC from cylinder block face . . . . . . . . . . . . . 0.355 to 0.761
Gudgeon Pin Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.983 to 37.990
Diameter of gudgeon pin seat in piston . . . . . . . . . . . . . . . . . . . . . . 37.994 to 38.000
Gudgeon pin to seat clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004 to 0.017
Gudgeon pin to small end bearing clearance . . . . . . . . . . . . . . . . . 0.014 to 0.031
Maximum weight difference between pistons in same engine . . . 20 grams
Piston ring groove clearance (measured vertically):
– Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 to 0.122 0.105 to 0.155

– Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060 to 0.092
– Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 to 0.075

Maximum permissible clearance (wear limit):
– Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50
– Second and bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20
Piston ring end gap (fitted):
– Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 to 0.65 0.40 to 0.65
– Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.55 0.30 to 0.55
– Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.55
Maximum permissible gap (wear limit) . . . . . . . . . . . . . . . . . . . . . . . 1.20
603.54.471.00 – 03 – 2004
VALVE TIMING GEAR DATA mm
Timing gear tooth backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,160

Inside diameter of intermediate gear bushings
(fitted and reamed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.050 to 37.075
Diameter of intermediate gear journal . . . . . . . . . . . . . . . . . . . . . . . 36.975 to 37.000
Journal to bushing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.100
Maximum permissible clearance (wear limit) . . . . . . . . . . . . . . . . . 0.15
Bushing interference fit in seat in intermediate gear . . . . . . . . . . . 0.063 to 0.140
Outside diameter of camshaft bearings:
– front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.875 to 54.930
– middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.375 to 54.430
– rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.875 to 53.930
Interference between bearings and seats in cylinder block . . . . . 0.070 to 0.150
Inside diameter of camshaft bearings (fitted and reamed):
– front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.080 to 51.130
– middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.580 to 50.630
– rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.080 to 50.130
Diameter of camshaft journals:
– front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.970 to 51.000
– middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.470 to 50.500
– rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.970 to 50.000
Clearance between camshaft journals and bearings . . . . . . . . . . . 0.080 to 0.160
Camshaft endfloat between thrust plate and seat on camshaft . . 0.070 to 0.220
For further valve timing gear data . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 4
TAPPET DATA mm
Tappet bore in crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.000 to 15.018

Outside diameter of standard tappet . . . . . . . . . . . . . . . . . . . . . . . . 14.950 to 14.970
Tappet running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 to 0.068
Spare tappet oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 – 0.2 – 0.3
603.54.471.00 – 03 – 2004
ROCKER ARM – VALVE DATA mm
Diameter of shaft bores in rocker arms . . . . . . . . . . . . . . . . . . . . . . 18.016 to 18.034
Rocker–arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.982 to 18.000

Rocker shaft to rocker arm bore clearance . . . . . . . . . . . . . . . . . . . 0.016 to 0.052
Rocker arm spacing springs:
– free spring length ...................................... 59.5
– length under load of 46 to 52 N (4.7 to 5.3 kg) . . . . . . . . . . . . . . 44
Valve clearance for timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45
Cam lift:
– inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.97
– exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.25
(*) installed on 4–cylinder

BALANCER DATA (FIG. 108, page 67) ((*)) engines only
mm
Interference fit between bushings (28) and seat in gear (26) . . . . 0.063 to 0.140
Clearance between intermediate gear journal (27)
and bushings (28) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.100
Interference fit between bushings and carrier (20) . . . . . . . . . . . . . 0.063 to 0.140
Clearance between gear shaft (22) and bushings . . . . . . . . . . . . . 0.050 to 0.100
Tooth backlash between splined sleeve (17) connecting drive
gear (22) and counterweight drive gear (13) . . . . . . . . . . . . . . . . . . 0.038 to 0.106
Interference fit between front bushing (16) and bore in
housing (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.063 to 0.140
Clearance between counterweight drive shaft (13) and front
bushing (16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.100
Interference fit between rear bushing of counterweight drive gear
(13) and seat in carrier (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.037 to 0.101
Clearance between counterweight drive shaft (13) and rear bushing 0.013 to 0.061
Interference fit between bushing and seat in counterweight (8) . . 0.040 to 0.100
Clearance between counterweight rotation shaft (4) and bushing . . 0.020 to 0.073
Interference fit between intermediate gear bushing (9) and re-
lated seat in housing (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.037 to 0.101
Clearance between intermediate gear shaft (9) and related bushing 0.013 to 0.061
Tooth backlash between meshed gears . . . . . . . . . . . . . . . . . . . . . . 0.080
603.54.471.00 – 03 – 2004
CYLINDER HEAD DATA mm
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with valve seats cut directly in the

casting and press–fitted steel valve
guides.
Original height of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Maximum surface regrinding depth . . . . . . . . . . . . . . . . . . . . . . . . . 0.5
Diameter of standard valve guide bores in head . . . . . . . . . . . . . . 13.950 to 13.983
Outside diameter of standard valve guides . . . . . . . . . . . . . . . . . . . 13.993 to 14.016
Guide interference fit in bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 to 0.066
Inside diameter of valve guide (fitted in head) . . . . . . . . . . . . . . . . 8.023 to 8.043
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.985 to 8.000
Assembly clearance between valve stem and guide . . . . . . . . . . . 0.023 to 0.058
Maximum run–out of valve guide on its stem measured through
360 with dial gauge contact point resting on valve head contact
band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03
Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2
Valve seat angle in head:
– inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60° ± 5’
– exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° ± 5’
Valve face angle:
– inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60° 30’ ± 7’
– exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45° 30’ ± 7’
Valve head diameter:
– inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.300 to 45.500
– exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.500 to 37.750
Valve stand–in relative to cylinder head face . . . . . . . . . . . . . . . . . 0.7 to 1.0
Maximum permissible valve stand–in . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Inlet and exhaust valve springs:
– free spring length ...................................... 44.6
– length with valve closed, under load of 256 to 284 N
(26.1 to 28.9 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
– length with valve open, under load of 502 to 544 N
(51.2 to 56.6 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.8
Injector protrusion relative to head face:
BOSCH injector 0.3 to 1.1
603.54.471.00 – 03 – 2004
mm
LUBRICATION SYSTEM DATA TD60, TD80 TD70, TD90 and
TD95
Assembly clearance between oil pump drive shaft and bushing . 0.016 to 0.055 –
Clearance between shaft and driven gear . . . . . . . . . . . . . . . . . . . . 0.033 to 0.066 –
Tooth backlash between drive and driven gears . . . . . . . . . . . . . . . 0.100 –
Radial clearance between drive and driven gears and housing . 0.060 to 0.170 –
Thickness of drive and driven gears . . . . . . . . . . . . . . . . . . . . . . . . . 40.961 to 41.000 –
Height of gear seat in pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.025 to 41.087 –
Endfloat between gears and gear housing in pump . . . . . . . . . . . . 0.025 to 0.126 –
Pressure relief valve spring: –
– free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 35.9
– length under load of 45 to 49 N (4.6 to 5 kg) . . . . . . . . . . . . . . . 37.5 –
– length under load of 88 to 94 N (9 to 9.6 kg) . . . . . . . . . . . . . . . 30.5 –
– length under load of 127.8 to 141.2 N (130 to 144 kg)
(2, fig. 182) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 29
– length under load of 233.4 – 258 N (238 to 263 kg) (2, fig. 182) – 23.2
For further lubrication system data . . . . . . . . . . . . . . . . . . . . . . . . . . See page 3
COOLING SYSTEM DATA mm
Interference fit between pump impeller and shaft . . . . . . . . . . . . . 0.017 to 0.059

Interference fit between fan hub and shaft . . . . . . . . . . . . . . . . . . . 0.024 to 0.058
Interference fit between front seal bushing and impeller . . . . . . . . 0.012 to 0.058
For further cooling system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 3
603.54.471.00 – 03 – 2004
ANGLE TIGHTENING TORQUE DATA
Preliminary torque
PART Th d
Thread A l
Angle
Nm kgm
Cylinder head bolts (2) fig. 3 or 5 . . . . . . . . . . . . . . . . M 12 x 1.25 70 7.1 90° + 90°
Main bearing cap bolts (4) fig. 3 or 5 . . . . . . . . . . . . . M 14 x 1.5 80 8.2 90°
Big–end cap bolts (5) fig. 3 or 5 . . . . . . . . . . . . . . . . . M 11 x 1.5 40 4.1 60°
Flywheel mounting bolts (3) fig. 3 or 5 . . . . . . . . . . . . M 12 x 1.25 40 4.1 60°
TIGHTENING TORQUE DATA
Tightening torque
PART Thread
Nm kgm
Rocker shaft pedestal bolts (1) fig. 3 or 5 . . . . . . . . . . . . . . . . . . . . M8 25 2.5
Crankshaft hub retaining nut (7) fig. 3 or 5 . . . . . . . . . . . . . . . . . . . M 30 x 1.5 294 30
Fan and alternator pulley bolts (6) fig. 3 or 5 . . . . . . . . . . . . . . . . . M 10 x 1.25 55 5.6
Additional counterweight retaining bolts (1) fig. 6 for TD80, TD90
and TD95 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 110 11,2
Inlet manifold retaining bolts (1) fig. 68 . . . . . . . . . . . . . . . . . . . . . . M8 25 2.6
Alternator and belt tension adjustment nut (1) fig. 54 . . . . . . . . . . M 10 x 1.25 55 5.6
Coolant pump retaining bolts (1) fig. 59 . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 55 5.6
Nuts for injector mounting studs (1) fig. 138 . . . . . . . . . . . . . . . . . . M8 25 (*) 2.6 (*)
Rocker cover nuts (1) fig. 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 15 1.5
Rocker shaft pedestal bolts (2) fig. 81 . . . . . . . . . . . . . . . . . . . . . . . M8 25 2.5
Oil pump and pump cover retaining bolts (1) fig. 89 . . . . . . . . . . . M8 25 2.6
Timing gear case and cover bolts (1) fig. 93 . . . . . . . . . . . . . . . . . . M8 25 2.6
Intermediate flanged journal bolts (1) fig. 96 . . . . . . . . . . . . . . . . . . M 10 x 1.25 55 5.6
Camshaft thrust plate retaining bolts (4) fig. 97 . . . . . . . . . . . . . . . M8 35 3.6
Rear crankcase cover bolts (2) fig. 117 . . . . . . . . . . . . . . . . . . . . . . M8 25 2.6
Tappet adjuster screw locknuts (1) fig. 137 . . . . . . . . . . . . . . . . . . . M8 22 2,2
Exhaust manifold retaining bolts (1) fig. 64 . . . . . . . . . . . . . . . . . . . M8 25 2.6
Injection pump mounting nuts (1) fig. 70 . . . . . . . . . . . . . . . . . . . . . M8 25 2.6
Sump pan retaining bolts (4) fig. 86, to
– inner rear timing cover and gear case . . . . . . . . . . . . . . . . . . . . . M 10 X 1.25 39 to 49 4 to 5
– cylinder block and flywheel case
• TD60, TD70, TD80 and TD90 models . . . . . . . . . . . . . . . . . . . . M 10 X 1.25 49 to 59 5 to 6
• TD95 models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 X 1.25 49 to 69 5 to 7
(*) Tighten the nuts in two stages: see the operation in figure 141.
603.54.471.00 – 03 – 2004
TOOLS X 291046 Punch for valve guide extraction /

installation.
X 294027 Twist bit for enlarging valve guide

WARNING: The operations described in this section bore.
can only be carried out with the ESSENTIAL tools
indicated by an (X).
X 294028 8° Tapered grinder for swaging ex-
To work safely and efficiently and obtain the best haust valve guides
results, it is also necessary to use the recommended
specific tools listed below and certain other tools X 293231 Bush for valve guide installation
which are to be made according to the drawings (with 291046).
included in this manual.
X 291177 Valve guide reamer.
X 291050 Valve spring compressor.

List of specific tools required for the various
operations described in this section. X 293270 Set of grinding tools for regrinding
injector seat.
X 292320 Tractor dismantling stand.

X 291182 Puller for coolant pump impeller.
290740 Engine lifting hook.

X 293280 Drift for installation of coolant pump
impeller seal.
290090 Rotating engine service stand.
293786 Wrench for injection pump delivery

293860 Engine mounting brackets for rotat-
line unions.
ing stand 290090.
X 291309 Compression test kit (complete with 293671 Injector cleaning kit.
dummy injector 293862).
293760 Injector splitting support.
291966 Digital rev counter.
X 293761 Wrench set for injector dismantling.
291979 Digital temperature gauge.
293780 Injection check hand pump.
292870 Engine oil pressure test kit.
290284 Hand pump for injector calibration
293240 Check set, turbocharger (TD95 test.
model).
293830 Adaptor for injector removal (with

293679 Filter cartridge removal tool
292927).
X 296118 Drive belt tension test tool.
292927 Slide hammer.
X 291160 Piston ring pliers.
Injection pump bench test
X 291048 Piston ring clamp.
291754 Dial gauge (1/100 mm scale, 5 mm
X 292248 Protractor for angular torque stroke, ∅ 40 mm with 291755).
measurement.
291755 Device for BOSCH injection pump
X 291504 Puller for crankshaft pulley hub. timing on engine.
X 291883 Wrench for valve clearance adjust- X 295042 Extractor for injection pump drive
ment. gear.
603.54.471.00 – 03 – 2004
Splining tool to be manufactured for assembling the

crankshaft front seal (print on the tool no. 50138 –
values in mm).
Material UNI C40.
26102
603.54.471.00 – 03 – 2004

crankshaft rear seal (print on the tool no. 50139 –
values in mm).
Material UNI C40.
26103
603.54.471.00 – 03 – 2004
MIG0491A
3
Longitudinal section of 3–cylinder TD60 and TD70 Models
1. Rocker shaft pedestal bolts 5. Big–end cap bolts

2. Cylinder head bolts 6. Fan and alternator pulley bolts
3. Flywheel bolts 7. Crankshaft hub bolts
4. Main bearing cap bolts
603.54.471.00 – 03 – 2004
MIG0492A
4
Cross–section of 3–cylinder TD60 and TD70 Models
603.54.471.00 – 03 – 2004
MIG0493A
5
Longitudinal section of 4–cylinder model TD80, TD90 and TD95 Models

3. Flywheel bolts 7. Crankshaft hub bolts
603.54.471.00 – 03 – 2004
MIG0494A
6
Cross–section of 4–cylinder model TD80, TD90 and TD95
1. Counterweight retaining bolts
603.54.471.00 – 03 – 2004
32
603.54.471.00 – 03 – 2004
SECTION 10 – ENGINE – CHAPTER 1
7
Lubrication system of normally aspirated 3–cylinder engines
1. Oil filler cap 2. Filter safety valve (opens when oil pressure at filter inlet exceeds the outlet pressure by 1.5–1.7 bar/cm2)
3. Filter. 4. Switch for low engine oil pressure warning (on dashboard). 5. Dipstick.
6. Pump. 7. Oil pressure limiting valve. 8. Screen filter on pick–up pipe
Lubrication system of normally aspirated 4–cylinder engines 8

1. Oil filler cap 2. Filter safety valve (opens when oil pressure at filter inlet exceeds the outlet pressure by 1.5–1.7 bar/cm2)
3. Filter. 4. Switch for low engine oil pressure warning (on dashboard). 5. Dipstick.
6. Pump. 7. Oil pressure limiting valve. 8. Screen filter on pick–up pipe
603.54.471.00 – 03 – 2004
33
1 2
3
4
25363
5
6
1
d
2
3
4
25364 6 5
Engine cooling system. 9
a. Coolant circulation with thermostat valve closed 2. Coolant pump

b. Coolant circulation with thermostat valve open 3. Temperature gauge for engine coolant
c. 3–cylinder models temperature
d. 4–cylinder models 4. Temperature sender
1. Thermostat 5. Fan
6. Radiator
603.54.471.00 – 03 – 2004
ENGINE TROUBLESHOOTING
Faults Possible Cause Correction
Engine does not start. 1. Batteries partially discharged. Check and recharge battery. Replace
if necessary.
2. Battery terminal connections Clean, inspect and tighten terminal

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

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

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

necessary.
Engine stalls. 1. Idle speed too low. Adjust idle speed.
2. Irregular delivery from injection Check injection pump delivery on test

pump. bench.

4. Fuel filters clogged. Renew filter cartridges.

5. Incorrect valve clearances. Adjust valve clearance.
6. Burnt or cracked valves Replace the valves.
8. Injection pump drive mechanism Replace damaged parts.

damaged.
(continued)
603.54.471.00 – 03 – 2004
(continued)
Engine overheats. 1. Coolant pump malfunction. Overhaul or replace pump.
2. Faulty thermostat. Replace the thermostat.
3. Radiator inefficient. Remove internal deposits by flushing.

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

crankcase coolant passages.
5. Coolant pump and fan drive belt Check and adjust belt tension.
slack.
6. Coolant level low. Top up expansion tank with specified
coolant mixture.
7. Incorrect timing. Check and adjust.
8. Injection pump calibration Calibrate pump on test bench to va-

incorrect – delivering too much or lues specified in calibration tables.
too little fuel.
9. Air cleaner restricted. Clean filter unit and replace filter ele-
ment if necessary.
Engine lacks power and 1. Incorrect injection pump timing. Adjust pump timing.
runs unevenly.
2. Auto advance regulator in injection Overhaul injection pump and adjust

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

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

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

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

damaged. just pressure setting.

(continued)
603.54.471.00 – 03 – 2004
(continued)
8. Fuel supply pump damaged. Replace fuel supply pump.

9. Incorrect valve clearances. Adjust valve clearance.
10. Cylinder compression low. Test compression and overhaul engi-
ne if necessary.
11. Air cleaner restricted. Clear air filter unit and replace ele-
ment if necessary.
12. Tie–rod in linkage between acce- Adjust to correct length.
lerator and injection pump incor-
rectly adjusted.
13. Maximum speed screw on injec- Adjust fast idling speed screw.
tion pump incorrectly adjusted.
Engine produces abnormal 1. Injectors partially obstructed or Clean and overhaul injectors and ad-
knocking noises. damaged. just pressure setting.
2. Impurities accumulating in fuel Clean fuel lines and replace severely

lines. dented pipes. Clean injection pump if
necessary.
4. Crankshaft knocking due to Re–grind crankshaft journals and
excessive play in one or more crankpins. Fit oversize shell bearings
main or big–end bearings or and thrust washers.
excessive endfloat.
5. Crankshaft out of balance. Check crankshaft alignment and ba-
lance; if necessary, replace.
6. Flywheel bolts loose. Replace any bolts that have worked
loose and tighten all bolts to the speci-
fied preliminary and angular torque
values.
7. Connecting rod axes not parallel. Straighten connecting rods, check
axes parallelism; replace con rods if
necessary.
8. Piston knock due to excessive Rebore cylinder liners and fit oversize
wear. pistons.
9. Noise caused by excessive play Fit oversize gudgeon pin, rebore pi-
of gudgeon pins in small–end and ston seats and small–end bushings.
piston bushings, or loose fit of Replace bushings.
small–end bushing.
10. Excessive tappet/valve noise. Check for broken springs or excessi-
ve play between valve stems and gui-
des, cam followers and bores. Adjust
valve clearance.
(continued)
603.54.471.00 – 03 – 2004
(continued)
Engine produces excessive 1. Maximum delivery of injection Adjust injection pump on test bench to
black or dark grey smoke. pump too high. the values specified in calibration
chart.
2. Injection pump delivery Adjust injection pump/engine timing

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

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

obstructed or incorrectly just pressure setting; replace if ne-
adjusted. cessary.
5. Air cleaner restricted. Clean air cleaner and replace filter

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

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

nes.
Blue, grey–blue or grey– 1. Injection pump delivery Adjust injection pump/engine timing
white smoke. excessively retarded or or check automatic advance regula-
automatic advance regulator tor.
damaged.
2. Injectors obstructed or damaged. Clean and overhaul injectors and ad-

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

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

operating temperature (thermostat
faulty).
Engine runs on after swit- 1. Engine stop solenoid damaged. Replace solenoid.
ching off.

603.54.471.00 – 03 – 2004
ENGINE
Removal – Installation (Operation 10 001 10)
DANGER
Lift and handle all heavy parts using suitable lifting
equipment.
Make sure that assemblies or parts are supported by
means of suitable slings and hooks.
Check that no one is in the vicinity of the load to be
lifted.
WARNING
Always use suitable tools to align holes in parts.
NEVER USE FINGERS OR HANDS.
1. Disconnect the battery negative cable.

2. Drain oil from the transmission/gearbox.
3. Drain the cooling system.
25621
10
4. Unscrew the nut (1) from the weight retaining pin.
TRE0601A
11
603.54.471.00 – 03 – 2004
5. Remove the weights (1) from the front support.
TRE0602A
12
6. Remove the exhaust pipe, attach lifting chains to
the bonnet (1) and attach the chain to the hoist. 1
24872
13
7. Disconnect the electrical leads (1) from
headlamps (2).
1
2
24873
14
8. Detach the gas struts (1) from the bonnet.
1
TRE0603A
15
603.54.471.00 – 03 – 2004
9. Remove the four bonnet hinge bolts (1) and lift

the bonnet clear.
1
TRE0604A
16
10. Remove the wire mesh guard (1) from right–
hand side of the fan.
1
25028
17
11. Disconnect the tachometer cable (1) and

remove the retaining ring and sleeve.
25046
18
12. Detach the throttle control spring (1) and remove
the throttle lever (2). 1
25183
19
603.54.471.00 – 03 – 2004
13. Detach the cab air–conditioning pipes (1) and

(2). 1
24892
20
14. Detach the cab heating pipes (1) and (2).

1
25411
21
15. Disconnect the electrical connectors (1).
TRE0605A
22
603.54.471.00 – 03 – 2004
16. Detach the fusebox by unscrewing the nut (1) 1
TRE0606A
23
17. Disconnect the delivery and return lines (1) to the

power steering cylinders.
TRE0607A
24
18. Remove the hose (1) from the lift pump suction
pipe.
1
TRE0608A
25
603.54.471.00 – 03 – 2004
19. Detach the lift pump delivery pipe (1).
TRE0609A
26
20. Detach the fuel pipes from the injection pump

and fuel pump and the pipe connecting the tank
to the sedimentation filter.
TRE0610A
27
21. Remove the fuel filter (1) complete with its sup-
port.
25035
28
603.54.471.00 – 03 – 2004
22. Remove the front, centre and rear retaining bolts

from the front axle drive shaft guard and remove
the guard.
25038
29
23. Remove the circlip (2) from the front of the prop
1 2
shaft and slide the sleeve (1), in the direction
shown by the arrow, until it is free of the splines
on the front axle.
25039
30
24. Remove the circlip (2) from the rear of the prop
shaft and slide the sleeve (1), in the direction 1
shown by the arrow, until it is free of the spines
on the crankshaft.
25040
31
25. Remove the middle support bolts (1) from the

propeller shaft and remove the shaft complete
with support.
25041
32
603.54.471.00 – 03 – 2004
26. Withdraw the pin securing the differential lock

knob, remove the knob and remove the mat from
the floor.
TRE0611A
33
27. Unscrew the nuts (1) and the bolts securing the
engine to the transmission. Access is through
the two slots in the cab floor.
1
TRE0612A
34
28. Unscrew the four lower bolts (1) securing the

engine to the transmission.
25049
35
603.54.471.00 – 03 – 2004
29. Position stand 292320 underneath the tractor

and insert a wedge (1), either side of the axle, to
prevent the axle from pivoting.
25050
36
30. Insert a wooden block between the stands and
the tractor.
25051
37
31. Place a fixed stand (1) underneath the drawbar
support and apply the handbrake.
1
25052
38
32. Unscrew the four remaining bolts securing the

engine to the transmission. 1
33. Separate the engine from the transmission.
34. Remove the distance collar (1) between the
engine and the transmission.
25055
39
603.54.471.00 – 03 – 2004
35. Place a fixed stand (1) underneath the front

weight support and chock the wheels with
wooden wedges (2).
1 2
25056
40
36. Insert tool 295022 (1) in the clutch centre hole.

Unscrew the six bolts (2) securing the clutch to
the flywheel and remove complete clutch as-
sembly.
25057 2
41
37. Remove the radiator mounting bolt (1).
TRE0613A
42
603.54.471.00 – 03 – 2004
38. Attach the engine to the hoist using an

adjustable chain (1) attached to the lifting 1
points provided on the engine.
25060
43
39. Remove the lift pump (1) complete with its filter
by unscrewing the four retaining bolts.
TRE0614A
1
44
40. Disconnect all electrical connectors and remove

the complete wiring harness (1).
TRE0615A
45
603.54.471.00 – 03 – 2004
41. Slacken of the hose clamp and detach hose (1)

from the inlet manifold.
1
TRE0616A
46
42. Remove the left–hand side fan guard (1).

1
TRE0617A
47
43. Unscrew the bolts (1) securing the silencer to its
bracket.
1
TRE0618A
48
44. Undo the hose clamp and disconnect the top
radiator hose (1). 1
45. Unscrew the three nuts securing the silencer to
the manifold and lift off the entire silencer assem-
bly.
TRE0619A
49
603.54.471.00 – 03 – 2004
46. Using the hoist, raise the engine slightly and

position the moveable stand (1) under the front
axle.
1
25068
50
47. Undo the hose clamp and disconnect the bottom

48. Unscrew the four bolts (2) securing the engine to
the front axle support, and lower the engine onto
a wooden platform.
25069
51
To re–install the engine, proceed as follows: — Reconnect all electrical leads: thermostart
— Attach the three hooks of an adjustable lifting glow plug, coolant temperature sensor, ‘air
chain to the three eye bolts on the engine. Raise filter blocked’ sensor, horn, front axle support
the engine from the platform and position it in earth, engine stop on injection pump, leads to
front of the front axle support. Join the two units the alternator and relay, oil pressure sensor,
using the four securing bolts. starter motor, fuel dryer filter. Secure all leads
with plastic ties.
— Reposition the moveable stand from under the
front axle differential housing to under the engine — Refit the clutch using tool 295022. Fix the
sump, inserting a suitably shaped block of wood clutch to the engine flywheel using the six
between the stand and the sump pan. retaining bolts.
— Attach the top radiator hose to the thermostat — Reconnect the oil delivery pipe to the 4WD
housing and secure with an adjustable hose control valve. Tighten the pipe union on the
clamp. anti–cavitation accumulator; fix the bracket on
the left–hand side near the engine oil filter.
— Connect the bottom radiator hose to the coolant
pump and secure at both ends with adjustable — Clean the distance collar and the mating surfa-
hose clamps. ces of the overdrive clutch housing; scrape
away all traces of old sealing compound.
— Refit the fuel pump.
— Apply LOCTITE sealing compound to the
— Detach the lifting chain from the engine. mating surfaces of engine and distance collar.
— Connect the rigid pipe from the air cleaner to the Fit the distance ring on the engine studs.
inlet manifold and secure with the relative clamp.
603.54.471.00 – 03 – 2004
— Apply LOCTITE sealing compound to the mating — Connect the two flexible power steering pipes to
surfaces of the overdrive clutch housing. the union on the left–hand side of the front axle.
Secure the two pipes with the special clamp and
— Remove the fixed stand from under the front screw the clamp to the tractor.
weight support. Remove the wooden wedges from
under the front wheels. — Fit the tachometer cable and secure the sleeve
with the retaining ring.
— Attach the adjustable lifting chain to the eyebolts
on the engine. — Fit the silencer onto the exhaust manifold,
remembering to replace the gas seal. Fix the
— Place wooden wedges under the rear wheels, front of the silencer to the vertical support
check that the handbrake is fully on and that the bracket. Attach the flexible DONASPIN pipe.
fixed and moveable stands are firmly in place.
— Attach the bonnet stay bracket to the radiator
— Detach the lifting chain from the engine. Connect bracket.
the two wires still attached to the cab handrail to
the hook of the hoist. Raise the front part of the — Refit the 4WD propeller shaft and the guard.
cab about 6 cm.
— Re–connect the throttle cable to the accelerator
— Replace and tighten all the bolts securing the pedal. It may be necessary to adjust the cable at
engine to the overdrive clutch housing. the injection pump lever end.
— Bolt the brake pipe support bracket to the right– — Refit the clutch cable to the clutch pedal. Fix the
hand side of the engine. Lower the hoist and de- sleeve to the travel stop.
tach the cables from the cab handrail.
— Replace the plastic plugs in the holes in the cab
— Lower the stands under the engine sump and the floor. Replace the mat.
clutch housing. Remove tool 292320 and the
— Refit the steering column cover panels.
stand from under the drawbar support.
— Replace the wire mesh fan guards.
— Fix the cab in place with the two front securing
bolts. — Attach slings to the bonnet in the manner descri-
bed previously in the engine removal instruc-
— Connect the injector leak–off pipe. Connect the tions. Screw the bonnet hinge to its bracket. At-
pipes to the glowplug and to the fuel dryer filter. tach the gas strut, the electrical leads to the
headlamps and then remove the slings.
— Refit the fuel filter mounting to the engine. Connect
the two semi–rigid pipes to the mounting. — Refit the secondary bracket (battery support) to
the overdrive clutch housing. Fit the rotating
— Connect the oil suction pipes to the pumps;
bracket with the battery to the fixed support.
secure the rubber hoses with hose clamps.
— Refit the front weights and secure with the lock
— Connect the rigid lift control valve supply pipe to the pin.
relative pump, remembering to first fit the O–ring.
— Refit the tool box support bracket and then the
— Secure the three pipes with the adjustable hose tool box.
clamp.
— Fill the transmission/gearbox with oil.
— Connect up all the electrical leads to the
connectors on the vertical support bracket. — Fill the radiator with coolant.
— Fit the cab heater pipe union on the engine/ — Connect the battery positive and negative leads.
clutch distance collar. Connect the rubber heater Replace the plastic battery cover.
hoses to the union.
603.54.471.00 – 03 – 2004
ENGINE
Removal – Installation (Operation 10 001 54) 1
WARNING
Handle all parts carefully. Do not put your hands or
fingers between parts.
Wear suitable safety clothing, safety goggles, gloves
and footwear.
1. Remove the front and rear retaining screws from

the bonnet stay bracket (1). 25070
52
2. Remove the bonnet catch support side retaining
bolts (1) and back retaining bolts (2) take off the
bonnet catch and the bonnet stay bracket.
1
25071
53
3. Loosen the alternator pivot bolt.
1
4. Loosen the belt tension adjustment bolt (1).
5. Release the belt tension adjustment arm by
unscrewing the retaining nut.
6. Remove the alternator and coolant pump drive
belt.
25072
54
7. Unscrew the bolts securing the fan (1) and pulley
to the coolant pump. Remove the fan and pulley.
25073
55
603.54.471.00 – 03 – 2004
8. Unscrew the union (1) from the water supply pipe

to the cab heater.
25074
56
9. Loosen the hose clamp (1) and detach the hose
from the coolant pump. Remove the curved hose
and flexible cab heater hoses.
25075
57
10. Remove the union (1) in order to gain access to
the pump retaining bolt.
25077
58
11. Unscrew the coolant pump retaining bolts (1)
and remove the pump. 1
25076
59
603.54.471.00 – 03 – 2004
12. Unscrew the pump support bolts (1) and the

silencer support bolt. Remove the two supports.
25078
60
13. Fit mounting bracket (1) of the set 293860 to
permit attachment of the engine to the rotary
stand 290090.
25079
61
14. Fit an eyebolt (1) on the front of the engine in
place of the silencer support.
15. Raise the engine from the wooden platform and 1
move it to the rotary stand 290090 (2). Secure it
to the stand by means of the bracket (3) of the set
293860.
3 2
25080
62
16. Undo the alternator support retaining bolts (1)
and remove the complete alternator assembly.
1
25081
63
603.54.471.00 – 03 – 2004
17. Unscrew the bolts (1) securing the exhaust

manifold to the cylinder head and remove the
manifold.
25082
64
18. Detach the throttle control lever (1) from the
injection pump.
1
25083
65
19. Remove the thermostat housing retaining bolts
(1) and remove the thermostat housing.
25084
66
20. Unscrew the high pressure fuel line unions (1) on
the injection pump and remove the fuel lines.
1
25085
67
603.54.471.00 – 03 – 2004
21. Unscrew the bolts (1) securing the inlet manifold

to the cylinder head and remove the manifold. 1
25086
68
22. Unscrew the unions (1) on the fuel supply pump
and detach the fuel lines.
25087
69
23. Unscrew the nuts (1) securing the injection pump
to the timing gear case. 1
25088
70
24. Undo screws (1) and remove the injection pump
drive gear cover. 1
25089
71
603.54.471.00 – 03 – 2004
25. Unscrew the nut (1) securing the injection pump

drive gear to the pump shaft. 1
25090
72
26. Extract the injection pump gearing using tool
295942 (1) and remove the injection pump.
NOTE: If the injection pump does not require any

specialist work it must be removed following the in-
structions given on page 118. 1
25091
73
27. Undo the fuel line unions (1) on the fuel
sedimentation filter.
25092
74
28. Unscrew the bolts securing the sedimentation
1
filter support to the engine block and recover the
complete filter assembly.
25093
75
603.54.471.00 – 03 – 2004
29. Unscrew the retaining nut (1) and remove the

fuel pump support complete with the pump.
Retain the gasket for re–use, if undamaged.
25094
76
30. Unscrew the power steering pump retaining
bolts (1) and remove the pump complete with
filter and accumulator on the delivery line.
25095
77
31. Remove spacer (3), gasket (2) and the pump
drive connector (1).
1
2
25096
3
78
32. Unscrew the starter motor retaining bolts (1) and
remove starter motor.
25097
79
603.54.471.00 – 03 – 2004
33. Remove the injector mounting nuts and the

spherical washers beneath, then the supports 1
and the injectors themselves.
34. Remove the rocker cover bolts (1), washers and
seals and then the rocker cover and its gasket.
25098
80
35. Remove the rocker shaft retaining bolts (2), then
remove the entire rocker shaft assembly (1).
2
1
25099
81
36. Remove the valve collets (1) and withdraw the
pushrods (2). Retain the collets and pushrods for 1
re–installation later. 2
25100
82
37. Unscrew the cylinder head bolts (1) and remove
the head using a hoist and lifting hook 290740.
38. Remove the cylinder head gasket.
25101 1
83
603.54.471.00 – 03 – 2004
39. Turn the engine upside down on the rotary stand.

Remove the sump pan bolts, the sump pan (1)
and its gasket (2).
1
25102
2
84
40. Unscrew the retaining bolts and remove the oil
1
pick–up pipe (1) complete with the strainer and
seal.
41. Unscrew the retaining bolts (2) and free the
counterweight housing (3) by moving it outward. 4
Remove the sleeve coupling (4) and housing.
NOTE: Operations 39, 40 and 41 are to be carried

out on 4–cylinder models only. To disassemble and
reassemble the rotating counterweight dynamic
balance, see pages 67 and 68. 3 2
25103
85
42. Unscrew the sump pan retaining bolts (4) and 1 2
remove the sump pan using a hoist, lifting hook
290740 and lifting chain with eyeholes.
43. Remove the half–gaskets (1) and (3) between
the crankcase and sump pan and the gasket (2)
between the timing gear carrier and sump pan.
3
25104
86
44. Remove the gasket (1) between the flywheel
carrier and the sump pan.
NOTE: When fitting the gaskets (1) and (3) (fig. 86),
apply RHODORSIL CAF1 silicone sealing com-
pound to the mating surfaces.
1
25105
87
603.54.471.00 – 03 – 2004
45. Remove the rotating counterweight oil seal

O–ring (1) installed on the crankcase mating
surface.
25106
88
46. Undo the retaining bolts (1) and remove the
complete oil pump assembly.
1
NOTE: For TD90 and TD95 models see fig. 106 on

page 66.
25107
89
47. Unscrew the retaining bolts (2) and remove the
crankshaft pulley (1). 1
25108
90
48. Straighten the lock tab, preventing rotation of the
crankshaft and unscrew nut (1).
25109
91
603.54.471.00 – 03 – 2004
49. Pull the pulley hub off the crankshaft using tool
291504 (1) and retain the woodruff key for re–
use.
25110
92
50. Unscrew the retaining bolt (1) and remove the
timing cover and its gasket.
25111
93
51. Unscrew the retaining bolts and remove the lift
pump drive gear carrier (1).
1
25112
94
52. Remove the circlip (1) and remove the thrust
washer and the intermediate gear (2).
1 2
NOTE: When refitting the intermediate gear see

engine timing instructions on page 73.
25113
95
603.54.471.00 – 03 – 2004

intermediate gear journal.
1
25114
96
54. Unscrew the retaining bolts (4) and withdraw the
camshaft (2) complete with the camshaft gear
(1) and the end plate (3).
1
2
4
25115
97
55. Remove the circlip (1) and the thrust washer.
Withdraw the gear with fuel supply pump
camshaft (2) from the opposite side.
1
NOTE: This gear transmits drive to the injection

pump. On re–assembly see timing instructions on
page 73.
25108
98
56. Unscrew the bolts (1) and remove the timing
gear case.
25109
99
603.54.471.00 – 03 – 2004
57. Renew the O–ring seal (1) installed in the lift

pump drive shaft lubrication line.
58. Remove the crankcase – timing gear case
gasket.
25118
100
59. Rotate the engine on the stand through 90.
Unscrew the big–end cap bolts (2) and remove 1
the big–end caps (1), complete with their half
shell bearings.
25119
101
60. Slide the pistons (1), complete with rings,
gudgeon pins and connecting rods, out of the
cylinder liners.
25108
102
61. Rotate the engine on the stand through 90 back
to the horizontal position. Unscrew the flywheel
bolts and remove the flywheel with the aid of a 1
hoist and hook 290740.
62. Unscrew retaining bolts and remove the rear oil
seal carrier (1) complete with gasket.
25109
103
603.54.471.00 – 03 – 2004
63. Unscrew the main bearing cap bolts (1) and

remove the main bearing caps with related
bearing shells. Remove the thrust washers
located on the penultimate main bearing, as
shown in the figure.
64. Lift the crankshaft clear of the crankcase using
a hoist and nylon sling. Remove the bearing
shells, thrust washers and tappets. 1
25122
104
65. Turn the engine on the stand 290090 (2) through
180. Attach the lifting chain with eye holes to the
1
crankcase as shown in the figure. Raise the hook
290740 with the hoist so that the lifting chain is
under slight tension. Unscrew the bolts securing
the crankcase to the stand (2) and mounting
bracket (3) (from set 293860).
66. Lift the engine clear of the stand. 3 2
67. Unscrew retaining bolts and remove the rear
crankcase housing (1) and its gasket.
25123
105
NOTE: The figure shows the oil pump for the TD90
and TD95 models
68. Remove the retaining screws (4), take off the

washers (3) and the engine lubrication oil pump 1
(2) complete with pressure relief valve (1).
2
4
26106
106
603.54.471.00 – 03 – 2004
NOTE: Operations 68 to 76, relative to the disman- 2

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

69. Remove the circlip (18).
70. Remove the circlip (25) and cover (23) with relati- 6
ve O–ring seal (24). 4
71. Withdraw gear (22) from sump. 5
3
72. Remove the circlip (2), gear (26) and the two 25159
thrust washers (1).
107
73. Inspect shaft (27). If it shows signs of scoring or
wear it must be replaced.
74. Extract the roll pins and remove the
counterweight shafts (8) using a suitable drift.
75. Disassemble the counterweight gear unit (1)
fig. 107 by removing the circlip (5) and the
support retaining bolts (6).
76. Remove the circlip (3) and the intermediate gear
(4) fig. 107.
1 2 3 4 5 6 7
28 8
27
26
25
24
23
22 21 11
25160
20 19 18 17 16 15 14 13 12 10 9
Sectional view of dynamic balancer 108
1. Thrust washers. 15. Mesh filter retaining bolt.

2. Circlip. 16. Bushing.
3. Lubricating oil pipe for bushing (28). 17. Rigid coupling sleeve.
4. Counterweight rotation shaft. 18. Circlip.
5. Shaft retaining spring pin. 19. Thrust washer.
6. Carrier for counterweight drive gear (13). 20. Carrier for gear (22).
7. Thrust washer. 21. Thrust washer.
8. Rotating counterweights. 22. Counterweight drive gear.
9. Counterweight intermediate gear. 23. Cover.
10. Bolts securing counterweight housing to sump. 24. O–ring seal.
11. Circlip. 25. Circlip.
12. Counterweight housing. 26. Intermediate gear.
13. Counterweight drive gear. 27. Shaft for gear (26).
14. Mesh filter. 28. Bushing.
603.54.471.00 – 03 – 2004
GENERAL NOTES AND INFORMATION

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

— Replace all seals and gaskets at each complete
or partial engine rebuild.
— Lubricate all rotating parts and oil seals with
engine oil prior to installation.
— Lubricate the oil filter mounting seal prior to fitting
the filter.
WARNING
and footwear.
INSTALLING THE BALANCER GEARS WITH

COUNTER–ROTATING WEIGHTS (Disassembly 1
operations 68 – 76)
Proceed as follows:
— Assemble the counterweight components in the

housing (2) carrying out dismantling operations
74 to 76 in reverse order. Align the positioning
marks on the gear (4) and counterweights (1)
(indicated by arrows in figure 127).
24913
4 3 2
109
— The intermediate gear (3) fig. 109 must be

installed with the longer side of its hub towards 1
the casing side;
— The holes for the roll pins (1) in the counterweight
shafts (2) must be aligned with corresponding
holes in the casing.
— Install the counterweight assembly on the sump
carrying out operations 68 to 76 (page 67) in 2
reverse order.
24914
110
603.54.471.00 – 03 – 2004
INSTALLING THE TAPPETS AND CRANKSHAFT

WITH MAIN BEARING CAPS, BEARINGS AND
THRUST RINGS; CHECKING CRANKSHAFT
END FLOAT (Disassembly operations 63 – 64)
Proceed as follows:
— Install the tappets in their crankcase bores.
— Lubricate the main bearing seats (2) with engine
oil and install the half shell bearings (1).
— Stick the semi–circular thrust washers (3) to both
sides of the penultimate main bearing with
grease.
25109
111
— Lubricate the upper surfaces of the main bearing

shells with engine oil and lower the crankshaft (1) 1
into position taking care not to dislodge the
semi–circular thrust washers installed
previously.
24718
112
— Lubricate the crankshaft journals with engine oil

and fit the main bearing caps (3) with the
half–shells (4), fitting the top semi–circular thrust 1 2
3
washers (2) to the penultimate bearing cap.
— Rotate the crankshaft (1) a few times to allow the
parts to settle into position.
— Insert the main bearing cap bolts and screw in
until the head of the bolt is up against the cap. 4
25108
113
603.54.471.00 – 03 – 2004
— Tighten all cap bolts (1) to a torque of 80 Nm (8.2

kgm). 1
24720
114
— Tighten each cap bolt (1) through a further 90°
using tool 292248 (2).
1
2
24744
115
— Check that crankshaft endfloat does not exceed
the value specified on page 17.
24760
116
603.54.471.00 – 03 – 2004
INSTALLING THE REAR COVER WITH SEAL,

AND ENGINE FLYWHEEL
1
(Disassembly operation 62)
Proceed as follows:
— Fit the rear oil seal carrier (3) with the outer seal.
Tighten retaining bolts (2) to the torque specified
3
on page 24. Using a feeler gauge (1), check that 2
the crankshaft flange is coaxial with the carrier.
24752
117
— Fit the inner rear oil seal using installer and hand
grip 50139 (1).
1
24761
118
— Fit the flywheel and tighten the retaining bolts (1)
to a torque of 40 Nm (4.1 kgm).
24762
119
— Using tool 292248 (1), tighten each flywheel bolt
(2) through a further 60°.
1
24763
120
603.54.471.00 – 03 – 2004
INSTALLING THE PISTONS COMPLETE WITH

RINGS, PINS, CONNECTING RODS, BIG END
CAPS AND BEARINGS – CHECKING PROTRU-
SION IN RELATION TO CYLINDER BLOCK FACE
(Disassembly operations 59 and 60)
Proceed as follows:
— Lubricate pistons, rings and cylinder liners with
engine oil prior to fitting.
— Fit the piston rings using piston ring pliers
291160. Make sure that the piston ring gaps are
offset 180° apart.
— Fit piston ring clamp 291048 (1) to compress the 25163
rings, making sure that the piston ring gaps
121
remain 180° apart.
— Insert the piston/connecting rod into the cylinder
liner. Ensure that the connecting rod number
corresponds with the cylinder number and that
the number stamped on the connecting rod is
facing away from the camshaft. 1 2
— Fit the big–end caps (2) complete with shells to
the crankpins and tighten the cap bolts (1) to a
torque of 40 Nm (4.1 kgm).
25164
122
— Using tool 292248 (1), tighten each big–end cap
bolt (2) through a further 60°. 1 2
25165
123
— Rotate the engine on the stand through 180° and
clean the upper face of the cylinder block. Bring
the pistons (2) up to TDC and, using a dial gauge 1 2
with a magnetic base (1), check that the piston
protrusion from the cylinder block face is within
the tolerance limits specified on page 19.
25166
124
603.54.471.00 – 03 – 2004
SYNCHRONIZING THE TIMING GEARS

(Disassembly operations 51 – 55)
Proceed as follows:
— Remove the cover and gasket from the flywheel

housing inspection window.
25167
125
— The flywheel is marked in degrees BTDC. Rotate
the crankshaft to bring cylinder no. 1 to TDC of
the compression stroke. Look through the in-
spection window and check that the notch aligns
with the appropriate index mark, according to the
type of BOSCH pump installed on the tractor
(see pages 6, 8, 10, 12 and 14).
26107
126
— Fit the timing gears making sure that the various
reference marks on the mating gears (indicated
by the arrows in the figure) are aligned.
25169
127
603.54.471.00 – 03 – 2004
REFITTING THE COUNTER–ROTATING WEIGHT

BOX TO THE OIL SUMP
When refitting the counter–rotating weight box, syn-

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

— Position the rotating counterweights so that the
timing reference marks are aligned as shown in
the figure.
25170
128
— Turn the rotating counterweight unit over and
insert the locating pin (2) in its hole. The pin 1 2
serves to hold the counterweights in the correct
timing position during installation of the unit.
— Using the hoist and a lifting chain, lower the
counterweight unit onto its seating in the sump.
25171
129
— Slide the coupling sleeve (1) over the splines of
the counterweight drive gear as shown in figure
85.
1
— Slide the other end of the coupling sleeve (1)
over the splined shaft of the counterweight drive
gear, so that the master spline in the sleeve
coincides with the master spline (3) on the shaft
(2).
— Tighten the dynamic balancer housing retaining
bolts (1) fig. 129 to the torque specified on page
24. 2
3
25172
130
603.54.471.00 – 03 – 2004
REFITTING THE BOSCH INJECTION PUMP

— Fit the BOSCH injection pump and proceed with

the injection pump timing in the manner
described on pages 121 to 123.
1
2
25181
131
FITTING THE CYLINDER HEAD GASKET

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

and degrease the mating surface of the cylinder 1
block. Locate a new cylinder head gasket (1)
with the word ALTO uppermost.
25173
132
603.54.471.00 – 03 – 2004
FITTING AND TIGHTENING THE

CYLINDER HEAD
Proceed as follows:
— Lower the cylinder head onto the block and
screw in the cylinder head bolts (1) fig. 135,
finger tight.
— fig. 133 – Tightening sequence for cylinder head
bolts on 3–cylinder engines to be followed for
each of the four tightening stages (A = fan end).
25174
133
— Fig. 134 – Tightening sequence for cylinder head
25175
134
— First phase – Tighten the bolts (1) to a torque of
70 Nm (7.1 kgm) in the sequence shown in the
above figures (fig. 133/134).
— Second phase – Recheck the torque of all the
bolts in the sequence indicated above (fig.
133/134).
1
25176
135
99. Using the angular tightening tool 292248 (1),
tighten each bolt (2) in sequence through 90° 1
(third phase) and then through a further 90°
(fourth phase) in the sequence indicated above
(figures 133/134).
2
25177
136
603.54.471.00 – 03 – 2004
ADJUSTING VALVE/ROCKER ARM

CLEARANCE
— Before refitting the rocker cover, adjust the valve

clearances as described on pages 128 – 130. 1
— Tighten the rocker arm adjuster screw locknuts
(1) to the torque specified on page 24.
25178
137
FITTING THE INJECTORS

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

— Position the injector support brackets and fit the
spherical washers. 1
— Screw the bracket retaining nuts (1) up to the
spherical washers, then tighten to the torque 2
specified on page 24, in two stages:
first stage – tighten nuts to 10 Nm (1 kgm); 25179
second stage – tighten nuts to 25 Nm (2.6 kgm). 138
— Tighten the leak–off pipe unions.

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

NOTE: Tension the belt correctly as described on pa-

ge 101.
603.54.471.00 – 03 – 2004
CHECKS, MEASUREMENTS AND REPAIRS –

CYLINDER BLOCK and CYLINDER LINERS
WARNING
and footwear.
Clean all parts carefully before proceeding with the

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

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

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

liners in the engine must be rebored to the same
oversize.
After reboring, the 0.5 mm 30 chamfer must be
restored on the liner (1).
In case of replacement, remove and install the
liners in cylinder block cold using a press as fol-
lows:
1
25307
139
603.54.471.00 – 03 – 2004
— Press the worn liner out of the block, operating

from the bottom of the crankcase, using a
stepped plate of appropriate diameter.
— Check the ovality of the bore in the block and
rebore if necessary to 0.22 mm oversize.
— Press–fit the new liner (0.22 mm oversize if
necessary) from the top of the block, using the
stepped plate referred to above.
— Rebore and ream the liner to the specified inside
diameter (see page 16).
25308
140
25310
141
Standard dimensions (mm) of cylinder liners and bores in cylinder block

and positions for checking liner wear.
a,b. Position of dial gauge to measure liner inside X. Area for measurement of inside diameter of
diameter. worn liner (area swept by piston rings) to
c. TD70, TD90 and TD95 Models. determine ovality and taper (measure along
C. Dimension to achieve after press–fitting and axes a and b, respectively parallel and at right
reaming of liner. angles to crankshaft).
Z. Area for measurement of inside diameter of 1,2,3. Points at which to measure inside diameter
used liner to determine piston running of new or rebored liners along axes a and b.
clearance (measured along axis b at right
angles to crankshaft).
603.54.471.00 – 03 – 2004

CRANKSHAFT, MAIN BEARINGS AND FLYWHEEL
WARNING:
fingers between parts. Wear suitable safety clothing,
safety goggles, gloves and footwear.
Crankshaft
Clean parts carefully before proceeding with
Carefully inspect the crankshaft. Any cracks, even
minor ones, will necessitate replacement of the
crankshaft.
Inspect the crankshaft journals and crankpins;
slight scoring or seizure marks can be removed with
very fine grade emery cloth.
If scoring, ovality or taper exceeds 0.05 mm, the
crankshaft will have to be reground.
Measure journal diameter, fig. 142 to determine the
nearest undersize (see page 17).
After regrinding, restore the journal and crankpin
radii and fillets as shown in the details in fig. 143 and
check that:
— main bearing journal and crankpin ovality does
not exceed 0.008 mm;
— main bearing journal and crankpin taper does 25311
not exceed 0.01 mm;
142
a
b
d
d
e e
25312 25313
143
Standard dimensions (mm) of main bearing journals and crankpins, main bearings
and semi–circular thrust washers.
a. TD60 and TD70 models. d. Normal crankshaft journal radii and fillets.
b. TD80, TD90 and TD95 models. e. Radii and fillets of crankshaft journal with
c. Crankpin radii and fillets. thrust washers.
603.54.471.00 – 03 – 2004
— with the crankshaft resting on parallel gauge — the run–out measured with the dial gauge
blocks, the maximum misalignment of the main contact point resting on surface (A) or (B),
bearing journals does not exceed 0.10 mm (D) fig. 144, does not exceed the measurement
fig. 161; given in the chart on page 18;
— the centrelines of the crankpins (mod. TD70) or
of each pair of crankpins (TD70, TD80, TD90
— the oil plugs seal against an oil pressure of 14.7
and TD95 models) lie in the same plane as the
bar (15 kg/cm2);
main journal centrelines, with a maximum
deviation of"0.25 mm as measured perpen-
dicularly to the same plane (see fig. 143);
— the distances between the outer surfaces of the — if new plugs are fitted, punch–lock in position
crankpins and the crankshaft centreline are and re–check oil tightness with the system
equal with a tolerance of " 0.10 mm; pressurised.
b
B
a
25314
c
B
a
25315
144
Maximum tolerances for alignment of main bearing journals and crankpin relative to
crankshaft centreline and alignment of crankpins relative to main bearing journals (a)
b. TD60 and TD70 models D. Maximum permissible main bearing journal

c. TD80, TD90 and TD95 models alignment deviation
A. and B. Dial gauge contact point positions for .
checking run–out of flywheel mounting flange.
603.54.471.00 – 03 – 2004
Bearings
Check the clearance between the crankshaft
journals and bearing shells using a calibrated wire
1 2
gauge as follows:
— make sure that all parts are perfectly clean and 3
remove all traces of oil;
— locate the half–shells in their respective seats (5); 6
— install the crankshaft; 4
— position lengths of calibrating wire (6) on the 5
crankshaft journals (4) corresponding with the
crankshaft centreline.
25316
— fit the caps (1) complete with half–shells (2) to
the respective journals; 145
— lubricate the bolts (4, fig. 3 and 5) securing the

main bearing caps with engine oil and tighten
them to the prescribed torque using a torque
wrench (see page 24);
Main bearing cap bolts (4, figs. 3 and 5)

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

clearance by comparing the width of the calibrat-
ing wire at the widest point against the scale
printed on the packet (3) fig. 145, containing the
wire;
— after refitting the crankshaft and the bearing
caps and bolts, check crankshaft endfloat about
the penultimate bearing with a dial gauge (1);
— if the endfloat exceeds the specified value (see
page 17), replace the existing thrust washers
with oversized ones.
25317
1
147
603.54.471.00 – 03 – 2004
Flywheel
The flywheel is fixed to the crankshaft flange by

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

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

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

25.
— lubricate the screws securing the engine fly-

wheel with engine oil, then tighten them to the
prescribed torque (see page 24) using a torque
wrench.
Flywheel bolts (3, figs. 3 and 5)

(measured in area “a” shown in figures 148 e 149) is 25318
greater than 13.5 mm. If not, replace the bolts.
148
25319
149
603.54.471.00 – 03 – 2004

CONNECTING RODS
CAUTION
Handle all parts carefully. Do not place hands or fin-
gers between one part and another. Wear the recom-
mended safety clothing such as goggles, gloves and
safety boots.
Clean all parts carefully before carrying out the

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

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

ting to the specified diameter (A) shown in the draw-
ing.
Dimensions (mm) of standard connecting rods,

bearing shells, bushings and gudgeon pins.
A = Dimension required by reaming after fitting
bushings – L, M = Oil ports.
25320
150
Check parallelism of small end and big end axes.

Maximum permitted tolerance is " 0.07 mm
measured at 125 mm from longitudinal axis of the
connecting rod.
Slightly twisted con rods can be straightened using

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

cylinder in which they are to be fitted. Check that the 25321
difference in weight of connecting rods in the same

151
engine does not exceed 25 grams.
Also check that the oil ways (L and M) fig. 150 are
not obstructed by scale or impurities.
603.54.471.00 – 03 – 2004

PISTONS
WARNING

Determine the degree of piston and liner wear in the

manner described on pages 16 and 19 and the fig-
ures below.
If the piston running clearance exceeds 0.30 mm,

rebore and ream the liners and fit oversize pistons
and rings (see pages 16 e 19).
In case of piston replacement, check that the weight

difference between pistons in the same engine does
not exceed 20 grams.
Check that the piston ring groove clearance (b, fig.

152) and the end gap (c, fig. 152) are within the
tolerances specified on page 19. If the end gap is less
than that specified, correct by grinding the ends of
the piston ring.
25322
Checking pistons and rings 152
a. Checking piston diameter at a distance (L) from c. Checking the end gap with ring in cylinder bore.
the base of the skirt. L. Distance from base of piston skirt: 12 mm.
b. Checking piston ring groove clearance.
603.54.471.00 – 03 – 2004
MIG0495A
153
Dimensions (mm) of standard pistons, gudgeon pins and rings.
a. TD60 and TD80 models. E Piston diameter measured at 12 mm from the

b. TD70, TD90 and TD95 models. base of the skirt.
A. Measurement to be obtained with rings inserted
in cylinder liners.
To remove or fit piston rings (1), use pliers 291160

(2).
1
Fit rings in grooves in the order indicated in fig. 153.
When fitting pistons on connecting rods, check that

the clearance between the gudgeon pin and its bore
in the piston is within the tolerance specified on page
2
19. 25324
154
603.54.471.00 – 03 – 2004
Check that the piston/connecting rod assembly is

perfectly square.
If not, replace parts causing the problem.
25108
155
NOTES:
1
— Oil the pistons, rings and liners before inserting
the pistons in their bores.
— Before fitting the ring clamp 291048 (1) to
compress the rings for insertion in the liner,
check that the ring end gaps are offset by an
angle of 180° i.e., opposite one another.
This will ensure better compression and better oil

sealing.
2
25326
156
Big end cap bolts (5, fig. 3 and 5)

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

each time the connecting rods are dismantled.
25327
157
603.54.471.00 – 03 – 2004

CAMSHAFT, TAPPETS AND VALVES
WARNING

Valves
Use tool 291050 for valve removal and installation.
In the case of minor sealing faults, the valves and
their seats in the cylinder head may be re–faced
using a pneumatic grinder or universal grinder. In
case of more serious defects, re–face the seats and
grind the valves as shown in the relative chapter.
After grinding, check that the step below the valve
contact band is no less than 0.5 mm.
Dimensions (mm) of valves and valve guides
A. Intake.
B. Distance to be obtained by reaming fitted valve
guide.
S. Exhaust.
25330
158
Tappets
Check that the tappets slide freely in their bores
without excessive play.
In the case of excessive tappet–to–bore clearance,
rebore the seats and fit oversize tappets (see page
20).
Pushrods must be perfectly straight, and the con-
cave contact surface with the rocker arm adjuster
screw must not show signs of seizure or excessive
wear, otherwise the rod must be replaced.
In case of refacing of the contact surfaces, remove
as little material as possible.
25329
159
603.54.471.00 – 03 – 2004
Camshaft
Place the camshaft on two parallel V blocks, as

shown. Using a dial gauge with 1/100 mm scale,
check that journal run–out relative to the axis of
rotation does not exceed 0.02 mm.
If run–out does not exceed 0.2 mm, the camshaft

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

as follows: 25328
– inlet valves = 5.97 mm; 160
– exhaust valves = 6.25 mm.
Replace worn bushings using suitable extractors and

drifts. Ream to obtain the inside diameter indicated
in figure 161.
25331
161
Dimensions (mm) of camshaft journals and relative seats in cylinder block.
a. TD60 and TD70 models. b. TD80, TD90 and TD95 models.
NOTE: The value indicated for the bushing inside diameter is for an installed bush.
603.54.471.00 – 03 – 2004
Valve timing check
To check the valve timing after dismantling/assembly

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

gears are aligned as indicated on page 73.
Provisionally set valve clearances to 0.45 mm.
Turn the crankshaft and, using a graduated timing

disc, check that valves open and close at the angles
25333
indicated in the timing diagram.
162
On completion of timing check, set the valve clear-

ances for normal running as detailed on pages 126
to 128.
Valve timing diagram.

A. Fixed advance (*).
1. TDC.
2. BDC.
3. Inlet.
4. Exhaust.
5. Injection.
(*) According to pump type and engine model (see page 2).
603.54.471.00 – 03 – 2004

CYLINDER HEAD
WARNING
Use valve spring compressor 291050 to remove and

refit valve springs. 1 2

Check that the cylinder head mating surface is flat

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

25108
head must be refaced.
163
NOTE: Remove as little material as possible: the

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

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

page 22), replace the valve and, if necessary, the
valve guide.
25108
164
603.54.471.00 – 03 – 2004
VALVE GUIDES
Replacement (Operation 10 101 53)
WARNING
equipment.
lifted.
WARNING
With the cylinder head on the test bench, proceed as

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

using twist drill 294027.
2. Place the cylinder head on a suitable support and

remove the valve guide to be replaced, using drift
291046 (1).
25334
165
3. Turn the head upside down, and force fit the new
valve guide with the enlarged bore using drift
291046 (1) and bush 293231 (2).
25335
166
4. Ream out the valve guide bore (2) using reamer
(1) 292177.
25336
167
603.54.471.00 – 03 – 2004
NOTE: When replacing exhaust valve guides you

must also carry out the following further operations.
5. Measure the distance (L) between the cylinder
head face and the base of the valve guide using
a caliper gauge and the special plate of tool
294028. 1
25337
168
The depth of taper milling is given by:
B–L=C
where:
B = depth of taper relative to cylinder head face (see

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

and valve guide base.
C = depth of taper milling.
Example (4–cylinder engine)
B = 43.1 to 43.6 mm
L = 34 mm (distance measured). 1 2
C = (43.1 to 43.6) – 34 = 9.1 to 9.6 mm.

Depth of taper milling.
6. From the upper side of the cylinder head, fit

guide bush (1) of tool 294028 on the guide valve
to be milled (2).
25109
169
7. Slide the cutter (1) of tool 294028, complete with
depth stop (2), into the previously located guide
bush until the cutting head is in contact with the
valve guide.
1
2
25339
170
603.54.471.00 – 03 – 2004
8. Position the plate (3) of tool 294028 flush against

the cylinder head face and slide the depth stop
(2) up to the plate. Measure the distance (A)
2
between the depth stop and the end of the cutter 1 3
shank (1).
25340
171
9. Position the depth stop (1) at a distance (D) =
35.9 to 336.4 mm from the end of the cutter
shank and fix in place with its set screw.
Distance (D) is given by:
D=A–C 1
where:
D = the distance determining the end of the taper

milling.
25341
A = the distance between the end of the cutter shank 172

and the depth stop, with the plate flush against the
cylinder head.
C = the depth of taper milling.
Example
A = 45.5 mm
C = 9.1 to 9.6 mm
D = 45.5 – (9.1 to 9.6) = 35.9 to 36.4 mm.
10. Turn the cutting tool (2) until the plate (3) is
brought up to the cylinder head face by the depth
stop (1). 2
NOTE: Before fitting the cylinder head, clean it 1

thoroughly to remove all residue from the milling
operation.
25342
3
173
603.54.471.00 – 03 – 2004
VALVE SEATS IN CYLINDER HEAD.

Reboring
CAUTION
11. If the valve seats need refacing to improve valve

sealing, use the universal valve grinder 294006
(1) and remove as little material as possible.
1
25343
174
Dimensions (mm) of valve seats and guide

valves.
A. Inlet.
B. Depth of taper on 3 and 4–cylinder engines.
S. Exhaust.
C. Engines for TD60 and TD80 models.
D. Engines for TD70, TD90 and TD95 models
MIG0496A
175
603.54.471.00 – 03 – 2004
INJECTOR SLEEVES – Replacement

(Operation 10 101 60).
WARNING
1. If the cylinder head face has been reground,

check that injector protrusion is within the
tolerance limits specified on page 22.
Checking injector and valve height relative to

the cylinder head face.
a. Checking injector protrusion (see page 22)
b. Checking valve stand–in: 0.7 to 1.0 mm (max.
permissible stand–in = 1.3 mm).
25345
176
If injector protrusion exceeds the specified limit,

replace the injector sleeve using tool kit 293270 and
proceed as follows:
2. Set distance (A) on tap (3) 292240 to 9 mm by 1
means of the ring nut (5). Fix the ring nut in posi-
tion by tightening the set screw (4).
3
2
3. Cut an internal thread (2) in the sleeve to be re-
moved using tool 292240 (M12 x 11.75) making 4
sure that the thread is cut only in the sleeve.
5
4. Fit tool 293784 (2) fig. 179 to the injector mount-
ing studs on the cylinder head by means of the
nuts (3) (M8 x 1,25). 25346
177
5. Screw part (11) fig. 179) fully into the previously
cut thread and turn nut (1) to withdraw the injec-
tor sleeve (12) from the head.
6. Remove any copper residue from inside the

head using tool 292243.
7. Fit seals (6, fig.179) onto the new injector sleeve

and fit the sleeve into its bore, making sure that
the sleeve butts up against the bottom of the
seating in the cylinder head, and dress with
dressing tool 293861 (5).
603.54.471.00 – 03 – 2004
8. Fit guide bush 293746 (10) fig.179 in the new

sleeve (12), securing it in position by turning the
ring nut (9) clockwise. Insert reamer (7) 293747
in guide bush (10) and ream the lower part of the
sleeve.
9. Remove the reamer (7) fig. 179 and back–off the
ring nut (9) by about 10 mm.
10. Press by hand on the ring nut (or tap gently with
a rubber mallet) to release the inside of the guide
bush 293746 (10) fig. 179.
11. Remove the guide bush, and fit the milling cutter
293790 (8) fig. 179 in the bush. Install the bush
in the sleeve (12) and fix in position by turning the
ring nut (9) clockwise.
12. Work with the cutter to remove material until the
seating is perfectly smooth and free from all
marks.
13. This done, remove the cutter, fit the injector and
check that stand–out is as specified on page 22.
Cylinder head bolts (2, fig. 3 and 5)

(measured in area a, as shown in fig. 178) is greater
than 11.5 mm. If not, replace the bolts.
25343
178
7 8
2
5 9
1 4
3 6 10
12 11
25348
Disassembly, removal of residue, installation and reaming 179

of injector sleeve in cylinder head using tool kit 293270.
1, 2, and 11. Injector sleeve extractor 293784. 6. O–ring seals.
3. M8 x 1.25 retaining nuts. 7. Reamer 293747.
4. Waste removal tool 292243. 8. Cutter 293790.
5. Injector sleeve dressing tool 293861. 9. Ring nut
10. Guide bush 293746.
12. Injector sleeve.
603.54.471.00 – 03 – 2004

ROTATING COUNTERWEIGHT DYNAMIC
BALANCER
WARNING
safety goggles, gloves and footwear

Check component wear and replace any defective
parts.
If the bushings of the counterweights are to be
replaced, pre–heat the counterweights in oil to a
temperature of 140° to 160°C (or dip the bushings in
nitrogen) before shrink–fitting in their bores.
Ream the new bushings after fitting using a reamer
with expanding cutters to the inside diameter
specified in the table on page 21.
1 2 3 4 5 6 7 8 9
28
27
26
25
24
23 22 21 20 19 18 17 16 15 14 13 12 11 10
22605
Cross–sectional view of rotating counterweight dynamic balancer. 180
1. Thrust washers. 15. Mesh filter retaining bolt.

3. Bushing lubrication tube. 17. Sleeve coupling.
4. Rotation shaft for counterweight (8). 18. Circlip.
5. Retaining spring pin for shaft (4). 19. Thrust washer.
8. Counterweights. 22. Drive box gear for dynamic balancer.
10. Circlip. 24. O–ring seal.
11. Bolts securing balancer housing to sump. 25. Circlip.
12. Dynamic balancer housing. 26. Intermediate gear.
13. Counterweight drive gear. 27. Rotation shaft for intermediate gear (26).
14. Mesh filter. 28. Bushing.
603.54.471.00 – 03 – 2004

LUBRICATION SYSTEM
WARNING
safety goggles, gloves and footwear. 1

operations described below. 3
OIL PUMP – Overhaul
To access the oil pump, remove the sump pan. 4

When servicing the pump, check component wear
against dimensions specified in the table. 5
In case of replacement, note that the drive shaft (3)

and drive gear are supplied ready assembled, with
the gear hot shrink–fitted on the shaft.
25354
Cross–sectional view of engine lubrication oil
181
pump models TD60 and TD80 Models
1. External drive gear.
2. Bushing.
3. Drive shaft and gear. 1
4. Driven shaft and gear.
5. Pressure relief valve.
2
pump models TD90 and TD95 Models
2. Spring.
3. Pump housing.
4. Internal gears.
4 3
26109
182

pump models TD70 Model
1. Pump housing.
2. Internal gears.
MIG0497A
183
603.54.471.00 – 03 – 2004
OIL FILTER – Replacement CHECKS, MEASUREMENTS AND REPAIRS –

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

paper cartridge type, and is installed in the pump Clean all parts carefully before proceeding with the
delivery line. operations described below.
Should the filter become clogged, the safety valve (2)
will open to allow the oil to by–pass the filter, thus
ensuring that the engine continues to be lubricated, The cooling system is filled with a permanent coolant
although with unfiltered oil. mixture consisting of water and “AMBRA
AGRIFLU” antifreeze (up to 50% in volume). This
mixture prevents freezing down to the following
Replace the cartridge periodically (every 400 temperatures:
operating hours), remembering to:
— oil the outer part of the seal in contact with the Degrees °C –8 –15 –25 –35
mounting on the crankcase; % in volume of
“AMBRA 20 30 40 50
— screw on the new cartridge until the seal is up AGRIFLU”
against the mounting;
— tighten the cartridge, by hand only, through a

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

for a maximum of 2 years or 1600 operating hours,
whichever comes sooner; after which it must be
changed.
LOW OIL PRESSURE INDICATOR – Functional

checks
The indicator consists of a control switch (4) figs. 7

and 8 and a red warning lamp in the instrument panel, RADIATORS – Flushing and checks
which illuminates in the following conditions:
— low oil pressure (the warning lamp also Two valves are built into the radiator cap, one
illuminates in normal conditions, with no faults compression valve and one depression valve. Check
present, when the engine is hot and idling at low periodically that they are working correctly.
speed);
When overhauling, remove deposits of lime scale in
— control switch malfunction. the radiator by means of a solution of water and
de–scaling agent in the proportions shown on the
If the red lamp fails to illuminate when the engine is container.
stopped and the ignition switch is turned to the power
on position, the possible causes are: It is never advisable to limit flushing to the radiator
only – always extend it to the entire cooling circuit
— blown fuse; and top up the engine with the solution referred to
above.
— blown lamp;
Run the engine for about an hour. With the engine off,
— interruption in wire to the control switch. drain the solution through the drain plug aperture.
In the event of leakage, the radiator is checked by

immersing it in a tank of water at a temperature of
20–40°C, introducing air into the radiator at a
pressure of 0.98 bar (1 kg/cm2) for approximately
two minutes (repeat the test at least three times).
603.54.471.00 – 03 – 2004
COOLANT THERMOMETER – Testing

If malfunction is suspected, immerse the bulb of the
thermometer in water and check the readings
against a test thermometer (repeat the test a number
of times with different water temperatures to be
sure).
THERMOSTAT – Replacement
The thermostat (1), fig. 9 is fitted in the cylinder head
coolant outlet union. The thermostat cannot be
adjusted and therefore must be replaced if does not
meet the temperature specifications in the table on
page 3.
COOLANT PUMP AND ALTERNATOR DRIVE

BELT – Tension adjustment (Operation 10 414
10).
The fan/coolant pump/alternator drive belt is

tensioned correctly when it deflects 10 to 11 mm
when a force of 78 to 98 N (8 to 10 kg) is applied at
the mid–point of the run between the alternator and
coolant pump pulleys.
1. Check the tension using the belt tension tester

296118. Adjust tension if necessary as follows:
2. Slacken the nut (1) securing the alternator to the

tensioner bracket;
3. Move the alternator to achieve the required belt

tension and lock the nut (1).
NOTE: When fitting a new belt, check the tension

22631
again after one hour of running.
184
603.54.471.00 – 03 – 2004
RADIATOR
Removal – Installation (Operation 10 406 10)
DANGER
equipment.
lifted.
1. Remove the exhaust pipe and open the bonnet.

1
3. Remove the left and right–hand safety guards
(1) from around the fan.
25028
185
4. Remove the hose clamp, detach the bottom radi-
ator hose (1) and drain off the coolant.
1
25124
186
5. Unscrew the front axle earth cable fixing bolt (1).
6. Disconnect electrical leads from the horn.
1
25125
187
603.54.471.00 – 03 – 2004
7. Disconnect electrical leads from air filter restric-

tion sensor (1).
TRE0620A
188
8. Remove the clamp (1) on the inlet manifold hose.
189
9. Remove the clamp (1) on the air filter hose.
25129
190
10. Remove the air filter restriction sensor (1) and re-
cover the pipe.
TRE0620A
191
603.54.471.00 – 03 – 2004
11. Unscrew the clamp and disconnect the pipe (1)

connecting the air filter to the exhaust aspirator.
1
25131
192
12. Unscrew the hose clamp (1) and remove the top
radiator hose. 1
TRE0619A
193
13. Unscrew the clamp and remove the pipe (1) from
the radiator cap.
1
25133
194
14. Unscrew the two bolts (1) securing the radiator
to the front axle support and remove the bolts,
rubber mountings and spacers.
1
25134
195
603.54.471.00 – 03 – 2004
15. Remove the radiator (1) and the upper rubber

mountings.
1
To refit the radiator proceed as follows:
— Replace the radiator and secure with the two
bolts. 25135
— Refit the two rubber hoses to the coolant pump 196

and the thermostat housing. Reconnect the
pipe to the radiator cap.
— Reconnect the bonnet stay bracket to the brac-
ket mounted on the radiator and replace the re-
taining bolts.
— Refit the hose to the exhaust aspirator.
— Refit the hose connecting the air cleaner to the
inlet manifold. Refit the air filter clogging sensor.
— Reconnect the electrical leads to the horn, air
filter restriction sensor and the front axle earth
lead.
— Refit the two wire mesh guards around the fan.
— Fill the radiator with coolant.
— Reconnect the battery negative lead; close the
bonnet.
603.54.471.00 – 03 – 2004
CRANKSHAFT FRONT OIL SEAL

Removal/installation (Operation 10 102 70)
DANGER
equipment. Make sure that assemblies or parts are
supported by means of suitable slings and hooks.
lifted.

1
3. Remove the left and right–hand wire mesh
guards (1) from around the fan.
25028
197
4. Remove the hose clamp, detach the bottom
hose (1) and drain off the coolant.
1
25124
198
1
25125
199
603.54.471.00 – 03 – 2004
7. Disconnect electrical leads from air filter restric-

tion sensor (1).
TRE0620A
200
201
25129
202
10. Remove the air filter restriction sensor (1) and
pipe.
TRE0620A
203
603.54.471.00 – 03 – 2004

1
25131
204
12. Unscrew the hose clamp remove the top radiator
hose (1). 1
TRE0619A
205
13. Unscrew the clamp and remove the pipe (1) from
the radiator cap.
1
25133
206
1
25134
207
603.54.471.00 – 03 – 2004

mountings.
25135
208
25136
209
17. Loosen the belt tension adjuster bolt (1) and re-
move the belt. 1
25137
210
18. Remove the radiator fan (1).
1
25138
211
603.54.471.00 – 03 – 2004

crankshaft pulley.
25139
212
20. Straighten the tab on the lock washer, hold the

crankshaft against rotation and unscrew nut (1).
25140 1
213
21. Remove the pulley hub from the crankshaft

using tool 291504 (1) and retrieve the woodruff
key.
25141
214
603.54.471.00 – 03 – 2004
22. Remove the oil seal (1) from it seat.
To install the front oil seal, proceed as follows:

— Install the oil seal.
— Refit the crankshaft hub and retaining nut; bend
tab over on lock washer.
— Refit fan.
— Refit the drive belt, adjust tension and tighten 25142
1
alternator bolts.
— Replace the radiator and secure with the two 215
bolts.
— Refit the two rubber hoses to the coolant pump
and the thermostat housing.
— Reconnect the pipe to the radiator cap.
— Reconnect the bonnet stay bracket to the
bracket mounted on the radiator and replace the
retaining bolts.
inlet manifold. Refit the air filter restriction
sensor.
— Reconnect the battery negative lead; close the
bonnet.
603.54.471.00 – 03 – 2004
COOLANT PUMP
Removal–Installation (Operation 10 402 10) 1
WARNING
NEVER USE YOUR FINGERS OR HANDS.

3. Remove the wire mesh guards (1) from the left
25028
and right–hand sides of the fan.
216
radiator hose (1) and drain off the coolant.
1
25124
217
5. Remove the fan shroud (1) retaining bolts.
25143
218
6. Remove the two strips (1) from the sides of the
radiator.
1
25144
219
603.54.471.00 – 03 – 2004
7. Move the fan shroud towards the engine.

8. Unscrew the three bolts securing the fan to the
coolant pump shaft. Remove the fan and the fan
cowling.
25145
220
9. Loosen the alternator pivot bolt (2).
25146
221
11. Remove the coolant pump pulley (1).
25147
222
from the coolant pump.
25148
223
603.54.471.00 – 03 – 2004
13. Unscrew the belt tension adjustment arm

retaining nut (1) and move the alternator
outward.
1
25149
224
14. Remove pump connection pipe (1) to gain
access to the coolant pump retaining bolt (2). 2
1
25150
225
15. Unscrew the four bolts (1) fig. 226 securing the
coolant pump to its mounting.
16. Disconnect the hose from the coolant pump to

the thermostat housing, then remove the pump
(1) fig. 227.
1
To refit the coolant pump proceed as follows:
— Refit the coolant pump. Take care not to lose the
seals on the upright hose connecting the pump
to the thermostat body.
— Refit the connection pipe to the pump, and repla- 25151
ce the two retaining bolts.
— Refit the coolant pump pulley and the fan. Refit 226
the fan shroud and the two vertical side strips to
the radiator. Fix the belt tension adjustment arm.
Tighten the alternator pivot bolt.
— Refit the bottom radiator hose to the connection
pipe on the coolant pump and the radiator.
— Refit the right–hand wire mesh guard. 1
— Refit the left–hand wire mesh guard.
— Fill the cooling system from the radiator cap.
— Reconnect the negative battery lead and refit the
exhaust pipe.
25152
227
603.54.471.00 – 03 – 2004
COOLING SYSTEM THERMOSTAT

Removal–Installation 1
(Operation 10 402 30)
WARNING

the bonnet (1) and attach the chains to the hoist.
228
3. Disconnect the electrical leads (1) from headlamps
(2).
1
2
24873
229
1
TRE0603A
230
the bonnet clear.
1
TRE0604A
231
603.54.471.00 – 03 – 2004
6. Drain the cooling system from the drain plug on

the engine block.
24804
232
7. Remove the wire mesh guard (1) from the right–
1
hand side of the radiator.
25028
233
8. Unscrew the hose clamp and disconnect the
hose (1) connecting the radiator to the 1
thermostat housing.
TRE0619A
234
9. Remove the thermostat housing cover screws
(1).
1
25156
235
603.54.471.00 – 03 – 2004
10. Lever the cover (1) off the housing using a

screwdriver and remove the cover.
1
25157
236
11. Remove the thermostat valve (1).
1
25158
237
To refit the thermostat proceed as follows:

— Fit the thermostat in its housing and locate the
gasket. Refit the cover to the housing.
— Connect the top radiator hose to the thermostat
housing and secure with a hose clamp.
— Refit the bonnet stay.
— Refit the right–hand wire guard to the fan.
— Refit the bonnet.
— Fill the cooling system. Top up as necessary.
— Reconnect the battery negative lead. Close the
bonnet and refit the exhaust pipe.
603.54.471.00 – 03 – 2004
Op. 10 246 14
BOSCH INJECTION PUMP Removal–Instal-
lation, timing and air bleeding
CAUTION
fingers between parts. Wear the prescribed safety
clothing, including goggles, gloves and safety foot-
wear.
CAUTION
Always use appropriate tools to align fixing holes.
Proceed as follows:
1. Raise the bonnet.

2. Unscrew the retaining bolts and take off the injec-
tion pump gearbox cover (2); if there is an air–
conditioning system compressor, remove the 27754
bracket (1) supporting the compressor.
3. Unscrew and remove the fuel filter. 238

4. Remove the flywheel inspection window cover
(1) and the tappet cover.
5. Rotate the crankshaft to bring cylinder no. 1 to
T.D.C. and make sure the valves are closed
(compression stroke).
25704
239
6. Disconnect the throttle control cable (1) from the
lever on the injection pump, the engine cut–out
electromagnet connection and the connection of
the thermometric circuit breaker cutting out star-
ting advance according to temperature (KSB).
27756
240
603.54.471.00 – 03 – 2004
7. Unscrew the unions of the fuel supply lines (1)

from the injection pump, from the fuel return pipe
(2) and from the pump fuel supply line (3).
8. Disconnect the L.D.A. device connecting pipe to
the inlet manifold (only TD70 and TD95 models).
27757
241
9. Unscrew the injection pump locknut on the relati-
ve gearing (1).
27759
242
10. Using tool X295042 (1) remove the injection
pump from the gearing and recover the pump.
27760
243
11. Unscrew the bolts (1) securing the injection
pump.
27758
244
603.54.471.00 – 03 – 2004
12. To refit the injection pump, proceed as follows.
CAUTION
– Respect the tightening torques prescribed on

page 24.
– Check that cylinder no. 1 is at T.D.C. and the
valves are closed (compression stroke).
– Position the injection pump in its seat and secure
it with the bolts, checking they are in the middle
of the slot.
– Lock the injection pump drive gear with the nut
tightened to a torque of 90 Nm, making sure the
crankshaft does not turn.
– Loosen the screw stopping the injection pump
from turning. Insert the relevant spacer and
tighten the screw back. In these conditions, the
pump spindle can turn freely.
– Refit the injection pump drive gear box access
cover.
– Assemble the LDA device connection pipe to the
inlet manifold (TD70 and TD95 models only).
– Connect the fuel supply and return lines to the in-
jection pump.
– Connect the engine cut–out electromagnet cable
and the cable of the thermometric circuit breaker
cutting out starting advance according to tem-
perature (KSB).
– Connect the delivery pipes to the injectors, to the
injection pump.
– Connect the throttle lead to the injection pump.
– Fit the fuel filter.
– Close the bonnet.
603.54.471.00 – 03 – 2004
BOSCH INJECTION PUMP

Timing
13. Using an external cable, supply 12 V to the ther-
mometric circuit breaker cutting out starting ad-
vance according to temperature (KSB) (1)
attaching the positive terminal to the connection
and earth to the pump housing.
245
14. Make sure that the KSB fork (1) is free to move.
MIG0498A
246
15. Unscrew the unions of the fuel supply lines (1),
detaching them from the injection pump.
If necessary, disconnect the injection pump sup-
ply and return lines (2 and 3) and the LDA/intake
manifold connecting pipe.
27757
247
(1) and the tappet cover.
17. Rotate the crankshaft to bring cylinder no. 1 at
T.D.C. and make sure the valves are closed
(compression stroke).
25704
248
603.54.471.00 – 03 – 2004
18. Check through the inspection window that the

pointer is aligned with reference marks 4 for
mod. TD60, 0 for mod. TD70 and TD95, or 1
for mod. TD80 and TD90.
26107
249
19. With the injection pump in its seat, remove the
plug (1) on the pump cover.
20. Fit dial gauge 291754 (1) fig. 251 and the asso-
ciated tool 291755 (2), pre–loading the shaft by 1
approximately 2.5 mm.
21. Turn the flywheel slowly backwards, so as to
bring the plunger to B.D.C. at the start of the deli-
very stroke (the point at which the dial gauge ne-
edle stops falling).
25711
250
22. Zero–set the dial gauge and slowly turn the
flywheel clockwise (as viewed from the fan end
of the engine) until the pointer lines up with
reference marks 4 for TD60 models, 0 for
TD70 and TD95 models, or 1 for TD80 and
TD90 models.
23. Check on the dial gauge that the plunger has
completed a stroke of 1 mm up to this point, if not,
slacken off the pump mounting bolts.
If the plunger stroke is checked with the pointer
at the T.D.C. there must be a stroke of: 1.47 mm 1 2
for mod. TD60 or 1.00 mm for mod. TD70 and
TD95, or 1.12 mm for mod. TD80 and TD90. 25712
24. Turn the pump anti–clockwise if the plunger has
251
completed a shorter stroke and clockwise if the
stroke is longer, repeating the test until the cor-
rect stroke is obtained.
25. Having obtained the correct plunger stroke, fix
the pump in position by tightening the mounting
nuts to the torque specified on page 24.
26. Remove the dial gauge 291754 (1) and relative
tool 291755 (2) and replace the plug and tighten
to a torque of 8 – 10 Nm (0.8 – 1 kgm).
27. Disconnect the KSB external power supply unit.
28. Refit other parts in the reverse of the dismantling
order.
603.54.471.00 – 03 – 2004

Air bleeding
1. Unscrew the plug (1) on the first filter. 1
25198
252
2. Operate the priming lever (1) fig. 253 on the fuel
supply pump until the fuel coming out of the filter
orifice is free of bubbles, then replace and tighten
plug (1) fig. 252.
25199
253
3. Slacken the fuel line unions (1) on the injectors,
start the engine and then re–tighten the union (1)
when the fuel flows out free of bubbles.
25200
254
603.54.471.00 – 03 – 2004
FUEL INJECTORS
Removal–Installation (Operation 10 218 30) 1
WARNING

2. Attach lifting chains to the bonnet (1) and then
attach the chains to the hoist.
24872
255
3. Disconnect the electrical leads (1) from head-
lamps (2).
1
2
24873
256
1
TRE0603A
257
the bonnet clear.
1
TRE0604A
258
603.54.471.00 – 03 – 2004
6. Unscrew the fuel leak–off pipe union (1) on the

injector. 1
25301
259
7. Unscrew the union (1) of the high–pressure fuel
line on the injector.
25302
1
260
8. Unscrew the two retaining nuts (1) and withdraw
the injector. 1
To refit the injector, proceed as follows:

— Insert the injector into its seat.
— Replace and tighten the two retaining nuts in two
stages. 1st stage: tighten nuts to 10 Nm (1 kgm)
2nd stage: tighten nuts to 25 Nm (2.6 kgm).
25303
— Reconnect the fuel leak–off pipe union.
261
— Reconnect the high–pressure fuel line union.
— Replace the bonnet.
— Reconnect the battery negative lead.
603.54.471.00 – 03 – 2004
ADJUSTING VALVE CLEARANCE

(Operation 10 106 12)
1
WARNING

2. Attach lifting chains to the bonnet (1) and then at-
tach them to the hoist.
24872
262
headlamps (2).
1
2
24873
263
1
TRE0603A
264
the bonnet clear.
1
TRE0604A
265
603.54.471.00 – 03 – 2004
6. Undo the hose clamp and detach the hose from

the silencer ejector. 1
7. Unscrew the two screws securing the silencer
front support.
8. Unscrew the retaining nuts securing the silencer
to the exhaust manifold and remove the silencer.
TRE0618A
266
9. Unscrew the four rocker cover nuts (1) and
remove cover.
25305
267
(1).
25190
268
11. Adjust the clearance between the valves and the
rocker arms using a feeler gauge, wrench (1) and
the special tool 291883 (2). 1
NOTE: Before proceeding with adjustment
operations, position the valves as described on the 2
following page.
25306
269
603.54.471.00 – 03 – 2004
To adjust valve clearances on the 3–cylinder TD60

and TD70 engines, proceed as follows:
— Turn the crankshaft so that the inlet and exhaust
valves of cylinder no. 1 are balanced (start of
induction stroke). In this position the pointer will
be aligned with the reference mark PMS 1 (TDC
1) on the flywheel.
— Rotate the crankshaft through a full revolution,
returning to TDC 1, then check that the valve
clearances correspond with the values specified
in the table on page 4.
— Repeat this operation for the other valve pairs.
Note that the TDC positions of cylinders 2 and 3
are not marked on the flywheel.
To check valve clearances on 4–cylinder TD80,
TD90 and TD95 models, proceed as follows:
valves of cylinder no. 1 are balanced (start of in-
duction stroke). In this position the pointer will be
aligned with the reference mark PMS 1 (TDC 1)
on the flywheel.
— Check that the clearance between valves and
rocker arms on cylinder no. 4 corresponds with
the values specified in the table on page 4.
Rotate the crankshaft through 360 and check
valve clearances on the opposing cylinder (No.
1).
Note that the opposing cylinders are 1–4 and
2–3.
To reassemble proceed as follows:
— Refit the rocker cover.
— Refit the flywheel inspection window cover.
— Refit the exhaust silencer.
— Refit the bonnet.
— Reconnect the battery negative lead.
603.54.471.00 – 03 – 2004
WATER PUMP – Overhaul

(Operation 10 402 28) 1 2 G
3
WARNING
Use suitable tools for aligning holes. NEVER USE 4
FINGERS OR HANDS.
5
NOTE: The bearing (9) forms a single piece with the
control shaft (10). It is a sealed unit and requires no
6
lubrication during running. 10 9 8 7
14262
Overhaul the pump as follows: 270

— Remove the cover (4) fig. 270, and the shaft
screw (2) retaining the shaft (10) and bearing (9).
— Gently tap the end of the shaft (10) fig. 270 on the
rotor side (5) to break the film of oxide between
the shaft and the rotor. Install the extractor
291182 (1) fig. 271 and take out the rotor.
1
— Remove the front sealing bushing (7) fig. 270.
— Use a punch to extract from the pump housing
(6) fig. 270 the shaft (10) complete with bearing
(9) and the fan hub (1).
5976
271
NOTE: Remove the seal (8) fig. 270 only when it

needs to be changed.
1
Check components for wear, and change any that
are in poor condition.
Refit the parts, proceeding as follows:

— Fit the shaft (10) fig. 270 complete with bearing
(9) and hub (1) on the pump housing (6) and se-
cure it with the retaining screw (2), having first
coated it with LOCTITE 242.
21662
— If changing the seal (8) fig. 270, fit the seal into
the seat using tool 293280 (1) fig. 272. 272
— Heat the rotor (1) fig. 270 in an air oven, until it
reach a temperature of 130–150°C higher than
the shaft (2). 1
— Place the rotor (1) on the shaft (2), easing it onto
the end so as not to damage the bearing, until
you obtain the operating clearance of G =
0.5–0.7 mm (see fig. 270).
— Fit the seal (3) fig. 270 and the cover (4), secu-
ring it with the relevant screws.
2
21663
273
603.54.471.00 – 03 – 2004
ENGINE 5) Turn the engine over a few times with the starter
motor in order to expel any carbon residue.
Compression test (Operation 10 001 30)
6) Fit the dummy injector 293862 in place of the injec-
In case of poor engine performance, in addition to tor removed previously, inserting the copper sealing
checking the fuel injection system (injector nozzles washer.
and injection pump), also test the compression on
each cylinder. 7) Connect the compression tester 291309/1 and
take readings while turning the engine over with the
starter motor.
DANGER
Do not use matches, lighters, blow torches or any On engines in perfect working order, with the sump
naked flame as a source of light when inspecting the oil at approx. 40C, at sea level (760 mm mercury)
engine due to the presence of inflammable fluids and and at an engine speed of 200 – 280 rev/min, the
compression should be 25.5 – 27.5 bar (26 to 28 kg/
vapour.
cm2).
8) Test the compression on the other cylinders, re-

peating steps 4, 5, 6 and 7, bearing in mind that:
Compression ratio
The minimum permissible compression on a used
The compression ratio is a measure of the quantity engine is 21.6 bar (22 kg/cm2).
of air drawn into the cylinder and provides an indica-
tion of the efficiency of the sealing elements in the The maximum permissible compression difference
cylinder (piston rings and valves). between cylinders is 3 bar (3 kg/cm2).
Uniform compression in all the cylinders ensures that Every 100 metres above sea level corresponds to a
they all perform an equal amount of work, provided reduction in compression by about 1%.
of course that each cylinder is injected with the same
quantity of fuel at the right time.
CONSIDERATIONS:
Low compression not only reduces engine perform-
ance, it also causes incomplete fuel combustion due
to the lack of available combustion air. Uniform compression
The engine therefore gives poor performance with Although high compression is important, it is more
excessive fuel consumption, and consequently ex- important as regards smooth running that the com-
haust smoke and restriction of the exhaust pass- pression is the same in all cylinders.
ages.
Low compression readings
As the compression ratio also varies with the tem-
perature of the engine (cold engines produce lower If very low compression readings are obtained on
compression values than hot engines) the compres- one cylinder it is advisable to repeat the test.
sion should only be tested when the engine is at nor-
mal operating temperature. Before testing this time, pour about a spoonful of en-
gine oil into the cylinder through the injector bore.
Compression should be tested using the compres-
sion test kit 291309 as follows: Turn the engine over a few times to distribute the oil
evenly over the cylinder walls, and then repeat the
test.
1) Run the engine until it reaches normal operating
temperature. If the second test readings are significantly higher,
suspect worn piston rings, out–of–round or damaged
2) Switch off the engine. pistons or liners.
3) Disconnect the lead from the engine stop solenoid If the second test readings are not higher, the prob-
on the injection pump in order to close the solenoid lem will be the valves.
valve and block the flow of fuel to the injectors.
On the other hand, if the second test reading shows
4) Remove the injector from the cylinder to be tested. only a slight improvement, the problem will be due to
both the valves and the rings.
603.54.471.00 – 03 – 2004
Chapter 1 – Engines Before PIN HFJ013287
CONTENT

10 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10 001 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Checks, Dimensions and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Cylinder Block and Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Crankshaft, Main Bearings and Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Camshaft, Tappets and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Rotating Counterweight Dynamic Balancer (TD80, TD90, and TD95 Models) . . 83
Engine Lubrication Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Low Oil Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Radiators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Valve Seats in Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Coolant Pump and Alternator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Cooling System Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
SPECIFICATIONS

Engine type:
– TD60 (BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally aspirated
– TD90 (BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally aspirated
– TD95 (BOSCH pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . turbocharged
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel, 4–stroke

Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct
No. of in–line cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4
Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dry force–fitted in cylinder block
Piston diameter
– TD60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm (3.937 in.) –
– TD70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 mm (4.094 in.) –
– TD80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 100 mm (3.937 in.)
– TD90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 104 mm (4.094 in.)
– TD95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 104 mm (4.094 in.)
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 mm
Total displacement:
– TD60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2710 cm3 (165 in3) –
– TD70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2931 cm3 (175 in3) –
– TD80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 3613 cm3 (220 in3)
– TD90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 3908 cm3 (238 in3)
– TD95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 3908 cm3 (238 in3)
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 to 1 naturally aspirated
16.5 to 1 turbocharged
Maximum power:
– TD60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.4 kW (TD60) –
– TD70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44,1 kW (TD70) –
– TD80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 51,5 kW (TD80)
– TD90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 58,8 kW (TD90)
– TD95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 70 kW (TD95)
Max. power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500 rev/min
Max. torque speed: TD60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 rev/min –
Max. torque speed: TD70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 rev/min –
Max. torque speed: TD80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 1500 rev/min
Max. torque speed: TD90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 1500 rev/min
Max. torque speed: TD95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 1500 rev/min
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5
Sump pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Structural, cast iron
(continued)
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced, with gear pump
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, warm engine running at max. speed: . . . . 2.9 to 3.9 bar (42 – 56 psi)
Pressure relief valve ................................... built into pump housing
Valve opening pressure 3.5 bar (50 psi)
For further lubrication data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 13
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . water circulation
Radiator on TD60, TD70, TD80 and TD90 . . . . . . . . . . . . . . . . . 3–row vertical pipes with copper fins
Radiator on TD95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–row vertical pipes with copper fins
Fan, attached to coolant pump pulley . . . . . . . . . . . . . . . . . . . . . 4–blade steel exhauster fan
6–blade steel exhauster fan (TD95)
Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . centrifugal vane–type
Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . . 1:1.403
Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat
Coolant temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . coloured scale divided into 3 sections
Temperature ranges corresponding to each section:

– initial white section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30o to 65o C (86o – 149o F)
– middle green section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65o to 105o C (149o – 221o F)
– final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105o to 115o C (221o – 239o F)
For further cooling system data . . . . . . . . . . . . . . . . . . . . . . . . . . . See page 13
Rev counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . incorporated in control panel
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . from gear on camshaft
Hour counter calibrated for engine speed of . . . . . . . . . . . . . . . . 1800 rev/min

(continued)

located in the 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 (.017 in.)
– inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.05 mm (0.012 – 0.002 in.)
– exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.05 mm (0.012 – 0.002 in.)
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mesh screen in fuel supply pump, and

injection pump.
Minimum fuel flow rate with pump shaft rotating at 1600 rev/min 100 litres/hour (.44 gpm)
All–speed governor, incorporated in pump: BOSCH

centrifugal counterweights
Automatic advance regulator, incorporated in pump: BOSCH
hydraulic
For further fuel system data:
TDC) – Pressure setting – Injection order, and other type in the table in chapter 2.
information regarding the BOSCH pump
FUEL SUPPLY PUMP DATA mm (in.)
Eccentricity of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Diameter of drive shaft at bushings . . . . . . . . . . . . . . . . . . . . . . . . . 31.975 to 32.000 (1.258 – 1.26)
Internal diameter of installed and reamed bushings . . . . . . . . . . . 32.050 to 32.075 (1.261 – 1.262)
Interference between bushings and seats . . . . . . . . . . . . . . . . . . . . 0.063 to 0.140 (0.002 – 0.005)
Assembly clearance between shaft and bushings . . . . . . . . . . . . . 0.050 to 0.100 (0.001 – 0.003)
Thickness of internal washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45 to 1.50 (0.057 – 0.059)
Thickness of external washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.93 to 3.00 (0.115 – 0.118)
mm (in.)
CRANKCASE/CYLINDER BLOCK DATA 100 mm 104 mm
(3.93 in.) bore (4.09 in.) bore
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cast–iron monobloc with replaceable
dry–fitted cylinder liners, incorporating
seatings for crankshaft bearings,
camshaft and pushrod/tappet
assemblies
Internal diameter of cylinder liners (1) . . . . . . . . . . . . . . . . . . . . . . . 100.000 to 100.024 104.000 to 104.024
(3.937 – 3.938) (4.094 – 4.095)
External diameter of cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . 103.020 to 103.050 107,020 to 107.050
(4.055 – 4.057) (4.213 – 4.214)
Diameter of cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.850 to 102.900 106.850 to 106.900
(4.049 – 4.051) (4.206 – 4.208)
Interference fit between cylinder liners and bores . . . . . . . . . . . . . 0.120 to 0.200 (0.004 – 0.007)
Liner internal diameter oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 to 0.8 (0.015 – 0.031)
Liner external diameter oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 (0.007)
Maximum permissible liner ovality or taper due to wear (2) . . . . . 0.12 (0.004)
Diameter of main shell bearing seats . . . . . . . . . . . . . . . . . . . . . . . . 84.200 to 84.230(3.314 – 3.316)
Diameter of camshaft bearing seats:
– front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.780 to 54.805(2.156 – 2.157)
– center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.280 to 54.305(2.137 – 2.138)
– rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.780 to 53.805(2.117 – 2.118)
Diameter of standard tappet bores in crankcase . . . . . . . . . . . . . . 15.000 to 15.018(0.590 – 0.591)
Tappet oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 – 0.2 – 0.3(0.003 – 0.007 – 0.011)
(1) Measured after press–fitting and reaming.

(2) Measure in the area swept by piston rings, both parallel and perpendicular to the crankshaft axis.
mm (in.)
CRANKSHAFT AND BEARINGS DATA 100 mm 104 mm
(3.93 in.) bore (4.09 in.) bore
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . balanced with integral counterweights
Standard journal diameter (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.791 to 79.810 (3.141 – 3.142)
Journal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254 – 0.508 – 0.762 – 1.016

(0.01 – 0.02 – 0.03 – 0.04)
Standard main bearing shell thickness . . . . . . . . . . . . . . . . . . . . . . 2.168 to 2.178 (0.0853 –0.0857)
Main bearing shell undersizes (internal diameter) . . . . . . . . . . . . . 0.254 – 0.508 – 0.762 – 1.016
(0.01 – 0.02 – 0.03 – 0.04)
Bearing shell to journal clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.034 to 0.103 (0.001 – 0.004)
Maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . . . . . . . 0.180 (0.007)
Standard crankpin diameter (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.725 to 63.744 (2.508 – 2.509)
Crankpin undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.254 – 0.508 – 0.762 – 1.016

(0.01 – 0.02 – 0.03 – 0.04)
Standard big–end bearing shell thickness . . . . . . . . . . . . . . . . . . . . 1.805 to 1.815 (0.0710 – 0.0714)
Big–end bearing shell undersizes (internal diameter) . . . . . . . . . . 0.254 – 0.508 – 0.762 – 1.016
(0.01 – 0.02 – 0.03 – 0.04)
Big–end bearing shell to crankpin clearance . . . . . . . . . . . . . . . . . . 0.033 to 0.087 (0.001 – 0.003)
Maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . . . . . . . 0.180 (0.007)
Standard crankshaft thrust washer thickness . . . . . . . . . . . . . . . . . 3.378 to 3.429 (0.132 – 0.135)
Thrust washer oversizes (thickness) . . . . . . . . . . . . . . . . . . . . . . . . 0.127 – 0.254 – 0.381 – 0.508

(0.005 – 0.01 – 0.015 – 0.02)
Width of main bearing including thrust washers . . . . . . . . . . . . . . . 31.766 to 31.918 (1.251 – 1.256)
Width of corresponding crankshaft journal . . . . . . . . . . . . . . . . . . . 32.000 to 32.100 (1.259 – 1.263)
Crankshaft assembly endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.082 to 0.334 (0.003 – 0.013)
Max. permitted wear endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.40 (0.015)
Maximum ovality or taper of journals and crankpin after regrinding 0.01 (0.0004)
Maximum ovality or taper of worn journals and crankpin . . . . . . . 0.05 (0.002)
Maximum tolerance for alignment of crankshaft journals with

crankshaft supported on the two outer journals . . . . . . . . . . . . . . . 0.10 (0.004)
Maximum tolerance for alignment, in both directions, of crankpins
(3–cylinder engines) or each pair of crankpins (4–cylinder
engines) relative to crankshaft journals . . . . . . . . . . . . . . . . . . . . . . 0.25 (0.609)
Maximum tolerance for run–out between the outer surfaces of

the crankshaft journals and the crankshaft centerline . . . . . . . . . . ± 0.10 (± 0.004)
(continued)
(1) Crankshafts with 0.1 mm (.004 in.) undersize journals and crankpins and consequently undersize bearing shells may be
fitted in factory production.
mm (in.)
CRANKSHAFT AND BEARINGS DATA
100 mm 104 mm
(3.93 in.) bore (4.09 in.) bore
Maximum permitted tolerance on run–out of flywheel mounting

flange surface relative to the crankshaft centerline, measured with
1/100 mm scale dial gauge resting on front flange surface at a di-
ameter of 108 mm (total gauge reading). . . . . . . . . . . . . . . . . . . . . . . 0.025 (0.001)
Maximum permitted tolerance on co–axial alignment of flywheel

centering seat relative to the crankshaft journals (total gauge
reading) . . . . . . . . . . . . . 0.04 (0.0015)
mm (in.)
CONNECTING ROD DATA 100 mm 104 mm
(3.93 in.) bore (4.09 in.) bore
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cast–iron with oil way
Diameter of small end bushing seat . . . . . . . . . . . . . . . . . . . . . . . . . 41.846 to 41.884

(1.647 – 1.648)
Outside diameter of small end bushing . . . . . . . . . . . . . . . . . . . . . . 41.979 to 42.017

(1.652 – 1.654)
Interference between small end bushing and seat . . . . . . . . . . . . . 0.095 to 0.171

(0.003 – 0.006)
Inside diameter of small end bushing (measured after fitting) . . . 38.004 to 38.014
(1.496 – 1.50)
Diameter of big end shell bearing seats . . . . . . . . . . . . . . . . . . . . . . 67.407 to 67.422

(2.653 – 2.654)
Max. tolerance for parallelism between the small end and big end
axes measured at 25 mm (.984 in.) . . . . . . . . . . . . . . . . . . . . . . . . . ± 0.07 (± 0.002)
Max. weight difference between con rods in same engine . . . . . . 25 grams (.88 oz)
mm (in.)
PISTON DATA 100 mm 104 mm
(3.93 in.) bore (4.09 in.) bore
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light alloy with two compression and

one oil control rings
Standard piston diameter, measured at 57 mm (2.24 in.) from

base and perpendicularly to the gudgeon pin axis . . . . . . . . . . . . . 99.827 to 99.841 103.812 to 103.826
(3.9301 – 3.9307) (4.0870 – 4.0876)
Piston clearance in cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.159 to 0.197 0.174 to 0.212

(0.006 – 0.007) (0.007 – 0.008)
Max. permissible clearance due to wear . . . . . . . . . . . . . . . . . . . . . 0.30 (0.012)
Piston oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 – 0.8 (0.015 – 0.031)
Piston protrusion at TDC from cylinder block face . . . . . . . . . . . . . 0.355 to 0.761 (0.013 – 0.029)
Gudgeon pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.983 to 37.990 (1.4953 – 1.4956)
Diameter of gudgeon pin seat in piston . . . . . . . . . . . . . . . . . . . . . . 37.993 to 38.000 (1.4957 – 1.4960)
Gudgeon pin to seat clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.003 to 0.017 (0.0001 – 0.0006)
Gudgeon pin to small end bearing clearance . . . . . . . . . . . . . . . . . 0.014 to 0.031 (0.0005 – 0.001)
Max. permissible clearance due to wear . . . . . . . . . . . . . . . . . . . . . 0.06 (0.002)
Max. weight difference between pistons in same engine 20 grams (0.7 oz)
Piston ring groove clearance (measured vertically): . . . . . . . . . . .
– Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.090 to 0.122 (0.0003 – 0.005)

– Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.060 to 0.092 (0.002 – 0.004)
– Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 to 0.075 (0.0015 – 0.0029)

Max. permissible clearance (wear limit):
– Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 (0.019)
– Second and bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 (0.008)
Piston ring end gap (fitted):
– Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 to 0.55 0.40 to 0.65

(0.013 – 0.021) (0.015 – 0.025)
– Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.45 0.30 to 0.55

(0.011 – 0.017) (0.011 – 0.021)
– Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.60

(0.011 – 0.023)
Max. permissible gap (wear limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 (0.047)

mm (in.)
VALVE TIMING GEAR DATA 100 mm 104 mm
(3.93 in.) bore (4.09 in.) bore
Timing gear tooth backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.160 (0.006)
Inside diameter of intermediate gear bushings (fitted and

reamed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.050 to 37.075 (1.4586 – 1.4596)
Diameter of intermediate gear journal . . . . . . . . . . . . . . . . . . . . . . . 36.975 to 37.000 (1.4557 – 1.4566)
Journal to bushing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.100 (0.002 – 0.004)

Max. permissible clearance (wear limit) . . . . . . . . . . . . . . . . . . . . . . 0.15 (0.006)
Bushing interference fit in seat in intermediate gear . . . . . . . . . . . 0.063 to 0.140 (0.002 – 0.005)
Outside diameter of camshaft bearings:
– front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.875 to 54.930 (2.160 – 2.162)
– center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.375 to 54.430 (2.140 – 2.142)
– rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.875 to 53.930 (2.121 – 2.123)
Interference between bearings and seats in cylinder block . . . . . 0.070 to 0.150 (0.002 – 0.006)
Inside diameter of camshaft bearings (fitted and reamed):
– front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51.080 to 51.130 (2.011 – 2.012)
– center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.580 to 50.630 (1.991 – 1.993)
– rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.080 to 50.130 (1.971 – 1.973)
Diameter of camshaft journals:
– front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.970 to 51.000 (2.006 – 2.007)
– center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.470 to 50.500 (1.987 – 1.988)
– rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49.970 to 50.000 (1.963 – 1.968)
Clearance between camshaft journals and bearings . . . . . . . . . . . 0.080 to 0.160 (0.003 – 0.006)

Camshaft endfloat between thrust plate and seat on camshaft . . 0.070 to 0.220 (0.002 – 0.008)
For further valve timing gear data . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 5
mm (in.)
TAPPET DATA 100 mm 104 mm
(3.93 in.) bore (4.09 in.) bore
Tappet bore in crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.000 to 15.018 (0.59 – 0.591)
Outside diameter of standard tappet . . . . . . . . . . . . . . . . . . . . . . . . 14.950 to 14.970 (0.5885 – 0.5893)
Tappet running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.030 to 0.068 (0.001 – 0.002)
Tappet oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 – 0.2 – 0.3 (0.004 – 0.008 – 0.012)

mm (in.)
ROCKER ARM – VALVE DATA 100 mm 104 mm
(3.93 in.) bore (4.09 in.) bore
Diameter of shaft bores in rocker arms . . . . . . . . . . . . . . . . . . . . . . 18.016 to 18.034 (0.709 – 0.710)
Diameter of rocker arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.982 to 18.000 (0.707 – 0.708)

Rocker shaft to rocker arm bore clearance . . . . . . . . . . . . . . . . . . . 0.016 to 0.052 (0.0006 – 0.002)
Maximum permissible clearance (wear limit) 0.15 (0.006)
Rocker arm spacing springs:
– free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59.5 (2.34)
– length under load of 46 to 52 N (10.36 – 11.68 lbs) . . . . . . . . . . 44 (1.73)
Valve clearance for timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.45 (1.77)
Cam lift:
– inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.67 (.223)
– exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.95 (.234)
(*) installed on 4–cylinder

ROTATING COUNTERWEIGHT DYNAMIC engines only
BALANCER DATA (fig.
(fig 104
104, page 57) (*)
mm (in.)
Interference fit between bushings (28) and seat in gear (26) . . . . 0.063 to 0.140 (.002 – .005)
Clearance between intermediate gear journal (27) and
bushings (28) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.100 (.002 – .004)
Interference fit between bushings and carrier (20) . . . . . . . . . . . . . 0.063 to 0.140 (.002 – .005)
Clearance between gear shaft (22) and bushings . . . . . . . . . . . . . 0.050 to 0.100 (.002 – .004)
Tooth backlash between splined sleeve (17) connecting drive
gear (22) and counterweight drive gear (13) . . . . . . . . . . . . . . . . . . 0.038 to 0.106 (.001 – .004)
Interference fit between front bushing (16) and bore in
housing (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.063 to 0.140 (.002 – .005)
Clearance between counterweight drive shaft (13) and front
bushing (16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.050 to 0.100 (.002 – .004)
Interference fit between rear bushing of counterweight drive gear
(13) and seat in carrier (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.037 to 0.101 (.001 – .004)
Clearance between counterweight drive shaft (13) and rear bushing 0.013 to 0.061 (.0004 – .002)
Interference fit between bushing and seat in counterweight (8) . . 0.040 to 0.100 (.0015 – .004)
Clearance between counterweight rotation shaft (4) and bushing . . 0.020 to 0.073 (.0007 – .0028)
Interference fit between intermediate gear bushing (9) and re-
lated seat in housing (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.037 to 0.101 (.0014 – .0039)
Clearance between intermediate gear shaft (9) and related bushing 0.013 to 0.061 (.0004 – .002)
Tooth backlash between meshed gears . . . . . . . . . . . . . . . . . . . . . . 0.080 (.003)
mm (in.)
CYLINDER HEAD DATA 100 mm 104 mm
(3.93 in.) bore (4.09 in.) bore
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with valve seats cut directly in the
casting and press–fitted steel valve
guides.
Original height of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 (3.62)
Max. face re–grinding depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 (.019)
Diameter of standard valve guide bores in head . . . . . . . . . . . . . . 13.950 to 13.983 (.549 – .550)
Outside diameter of standard valve guides . . . . . . . . . . . . . . . . . . . 13.993 to 14.016 (.550 – .551)
Guide interference fit in bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 to 0.066 (.0004 – .0025)
Inside diameter of valve guide (fitted in head) . . . . . . . . . . . . . . . . 8.023 to 8.043 (.315 – .316)
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. 985 to 8.000 (.314 – .315)
Assembly clearance between valve stem and guide . . . . . . . . . . . 0.023 to 0.058 (.001 – .002)
Maximum permissible clearance (wear limit) . . . . . . . . . . . . . . . . . 0.13 (.005)
Maximum run–out of valve guide on its stem measured through
360 with dial gauge contact point resting on valve head contact
band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 (.001)
Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 (.0078)
Valve seat angle in head:
– inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60o ± 5’
– exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45o ± 5’
Valve face angle:
– inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60o 30’ ± 7’
– exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45o 30’ ± 7’
Valve head diameter:
– inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.300 to 45.500 (1.783 – 1.791)
– exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.500 to 37.750 (1.476 – 1.486)
Valve stand–in relative to cylinder head face . . . . . . . . . . . . . . . . . 0.7 to 1.0 (.027 – .039)
Max. permissible valve stand–in . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 (.051)
Inlet and exhaust valve springs:
– free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.6 (1.755)
– length with valve closed, under load of 256 to 284 N (57.5 to
63.7 lbs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 (1.338)
– length with valve open, under load of 502 to 544 N (112 to 124
lbs) . . . . . . . . . . . . . . . . . 23.8 (.937)
Injector protrusion relative to head face:
BOSCH injector part 0.05 to 0.7 (.002 – .027)
0.3 to 1.1 (.011 – .043)
mm (in.)
LUBRICATION SYSTEM DATA TD60, TD70, TD80 TD95
and TD90
Assembly clearance between oil pump drive shaft and bushing . . . 0.016 to 0.055 –
(.0006 – .002)
Clearance between shaft and driven gear . . . . . . . . . . . . . . . . . . . . 0.033 to 0.066 –
(.001 – .0025)
Tooth backlash between drive and driven gears . . . . . . . . . . . . . . . 0.100 (.004) –
Radial clearance between drive and driven gears and housing . . 0.060 to 0.170 –
(.002 – .006)
Thickness of drive and driven gears . . . . . . . . . . . . . . . . . . . . . . . . . 40.961 to 41.000 –
(1.612 – 1.614)
Height of gear seat in pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.025 to 41.087 –
(1.615 – 1.617)
Endfloat between gears and gear housing in pump . . . . . . . . . . . . 0.025 to 0.126 –
(.001 – .005)
Pressure relief valve spring: –
– free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 (1.77) 35.9 (1.41)
– length under load of 45 to 49 N (10.1 to 11 lbs) . . . . . . . . . . . . . 37.5 (1.47) –
– length under load of 88 to 94 N (9.8 to 21 lbs) . . . . . . . . . . . . . . 30.5 (1.2) –
– length under load of 127.8 to 141.2 N (286 to 317 lbs)
(2, fig. 185) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 29 (1.14)
– length under load of 233.4 to 258 N (525 to 580 lbs)
(2, fig. 185) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . – 23.2 (.913)
For further lubrication system data . . . . . . . . . . . . . . . . . . . . . . . . . . see page 4
mm
COOLING SYSTEM DATA
100 mm bore 104 mm bore
Interference fit between pump impeller and shaft . . . . . . . . . . . . . 0.017 to 0.059
(.0006 – .002)
Interference fit between fan hub and shaft . . . . . . . . . . . . . . . . . . . 0.024 to 0.058
(.001 – .002)
Interference fit between front seal bushing and impeller . . . . . . . . 0.012 to 0.058
(.0004 – .002)
For further cooling system data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 4
TIGHTENING TORQUES
ANGULAR TORQUE DATA
Preliminary torque
PART Thread size Angle
Nm ft-lbs
Cylinder head bolts (2) fig. 6 or 8 . . . . . . . . . . . . .

M 12 x 1.25 70 51 90o + 90o
Main bearing cap bolts (4) fig. 6 or 8 . . . . . . . . . . M 14 x 1.5 80 59 90o
Big–end cap bolts (5) fig. 6 or 8 . . . . . . . . . . . . . . M 11 x 1.5 40 29 60o
Flywheel mounting bolts (3) fig. 6 or 8 . . . . . . . . . M 12 x 1.25 40 29 60o
TIGHTENING TORQUE DATA

Tightening torque
PART Thread size
Nm ft-lbs
Rocker shaft pedestal bolts (1) fig. 6 or 8 M8 25 18
Crankshaft hub retaining nut (7) fig. 6 or 8 . . . . . . . . . . . . . . . . . . . M 30 x 1.5 294 216
Fan and alternator pulley bolts (6) fig. 6 or 8 . . . . . . . . . . . . . . . . . M 10 x 1.25 55 40
Additional counterweight retaining bolts (1) fig. 9
for models TD80, TD90, TD95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 110 81
Inlet manifold retaining bolts (1) fig. 64 . . . . . . . . . . . . . . . . . . . . . . M8 25 18
Alternator and belt tension adjustment nut (1) fig. 52 . . . . . . . . . . M 10 x 1.25 55 40
Coolant pump retaining bolts (1) fig. 55 . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 55 40
Nuts for injector mounting studs (1) fig. 134 . . . . . . . . . . . . . . . . . . M8 25 (*) 18
Rocker cover nuts (1) fig. 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M8 15 11
Rocker shaft pedestal bolts (2) fig. 77 . . . . . . . . . . . . . . . . . . . . . . . M8 25 18
Oil pump and pump cover retaining bolts (1) fig. 85 . . . . . . . . . . . M8 25 18
Timing gear case and cover bolts (1) fig. 89 . . . . . . . . . . . . . . . . . . M8 25 18
Intermediate flanged journal bolts (1) fig. 92 . . . . . . . . . . . . . . . . . . M 10 x 1.25 55 40
Camshaft thrust plate retaining bolts (4) fig. 93 . . . . . . . . . . . . . . . M8 35 26
Rear crankcase cover bolts (2) fig. 113 . . . . . . . . . . . . . . . . . . . . . . M8 25 18
Tappet adjuster screw locknuts (1) fig. 133 . . . . . . . . . . . . . . . . . . . M8 22 16
Exhaust manifold retaining bolts (1) fig. 60 . . . . . . . . . . . . . . . . . . . M8 25 18
Injection pump mounting bolts (2) fig. 73 . . . . . . . . . . . . . . . . . . . . . M8 25 18
Sump pan retaining bolts (4) fig. 82, to
– inner rear timing cover and gear case . . . . . . . . . . . . . . . . . . . . . M 10 X 1.25 39 to 49 28 to 36
– cylinder block and flywheel case
• models TD60, TD70, TD80 and TD90 . . . . . . . . . . . . . . . . . . . . M 10 X 1.25 49 to 59 36 to 43
• model TD95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 X 1.25 49 to 69 36 to 51
(*) Tighten nuts in two stages: see operation on page 66
SPECIAL TOOLS
X 380000226 Puller for crankshaft pulley hub.

Warning – The operations described in this section
can only be carried out with ESSENTIAL tools indi-
cated by an (X). X 380000232 Wrench for valve clearance adjust-
To work safely and efficiently and obtain the best re- ment.
sults, 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- X 380000219 Drift for valve guide extraction / in-
cluded in this manual. stallation.
List of specific tools required for the various X 380000276 Twist bit for enlarging valve guide
operations described in this section. bore.
380000236 Tractor disassembly stand. X 380000277 Twist bit for enlarging valve guide
bore 8°.
380000216 Engine lifting hook.

X 380000242 Bush for valve guide installation
(with 380000219).
380000301 Revolving engine service stand.
X 380000222 Engine valve guide reamer.

380000313 Engine mounting brackets for rotat-
ing stand 380000301.
X 380000302 Engine valve spring disassembly–
assembly compressor.
380000240 Engine oil lubrication pressure test
kit.
X 380000223 Puller for coolant pump impeller.
X 380000303 Compression test kit (complete

with dummy injector 293862). X 380000247 Drift for installation of coolant pump
impeller seal.
X 380000328 Device for engine belt tension

check. X 380000259 Extractor for regulator unit centri-
fuge weights.
X 380000221 Piston ring pliers.

X 380000292 Pin for clutch assembly.
X 380000220 Clamp for fitting pistons in cylin-

ders. X 380000322 Tool for disassembly of injection
pump gear unit.
X 380000304 Protractor for angular torque

measurement. X 8824959 Brackets for lifting engine
(Quantity = 2).
Mounting for engine lifting hook (No. 50075 – mea-
surements in mm).
Make with UNI C40 material.
26101

crankshaft front seal (print on the tool no. 50138 –
values in mm).
Material UNI C40.
26102
2
crankshaft rear seal (print on the tool no. 50139 – val-
ues in mm).
Material UNI C40.
26103
3
26104
4
Rear mountings for lifting hood (No. 50131 – measurements in mm).
Make with UNI Fe 42C – Quantity = 2.
Front hook for lifting hood (50132 – Measurements
in mm).
Make with UNI C40.
26105
5
5 4 3
25355
6
Longitudinal section of 3–cylinder models TD60 and TD70

3. Flywheel mounting bolts 7. Crankshaft hub retaining bolts
25356
7
Cross–section of 3–cylinder models TD60 and TD70
5
6 4 3
25357
8
Longitudinal section of 4–cylinder models TD80, TD90 and TD95

3. Flywheel mounting bolts 7. Crankshaft hub retaining bolts
25358
9
Cross–section of 4–cylinder models TD80, TD90 and TD95
1. Counterweight retaining bolts

22
Lubrification system of 3–cylinder engine 10
1. Oil filler cap 2. Filter safety valve (opens when oil pressure at filter inlet exceeds the pressure at the outlet by 1.5 – 1.7 bar/cm2(21.7 – 24.6 psi) 3. Filter.
4. Switch for low engine oil pressure warning (on dashboard). 5. Dipstick. 6. Pump. 7. Oil pressure limiting valve. 8. Screen filter on pick–up pipe.
11
Lubrification system of 4 – cylinder engine
1. Oil filler cap 2. Filter safety valve (opens when oil pressure at filter inlet exceeds the pressure at the outlet by 1.5 – 1.7 bar/cm2(21.7 – 24.6 psi) 3. Filter.
4. Switch for low engine oil pressure warning light (on dashboard). 5. Dipstick. 6. Pump. 7. Oil pressure limiting valve. 8. Screen filter on pick–up pipe.
23
1 2
3
4
25363
5
6
1
d
2
3
4
25364 6 5
Engine cooling system. 12
a. Coolant circulation with thermostat valve closed 2. Coolant pump

b. Coolant circulation with thermostat valve open 3. Temperature gauge for engine coolant
c. 3–cylinder models temperature
d. 4–cylinder models 4. Temperature sender
1. Thermostat 5. Fan
6. Radiator
TROUBLESHOOTING
Problem Possible Cause Remedy
Engine does not start. 1. Battery partially discharged. Check and recharge battery. Replace
if necessary.
2. Battery terminal connections Clean, inspect and tighten terminal

corroded or loose. nuts. Replace terminals and nuts if
excessively corroded.
3. Injection pump timing incorrect. Adjust injection pump timing.

5. No fuel in tank. Fill tank.
6. Fuel supply pump malfunction. Check and replace pump if necessary.

8. Starter motor faulty. Repair or replace starter motor.
9. Thermostart faulty. Check and replace thermostart, if

necessary.
Engine stalls. 1. Idle speed too low. Adjust idle speed.
2. Irregular delivery from injection Check injection pump delivery on test

pump. bench.

4. Fuel filters clogged. Renew filter cartridges.

5. Incorrect valve clearances. Adjust valve clearances.
6. Burnt or cracked valves Replace valves.
8. Injection pump drive mechanism Replace damaged parts.

damaged.
(continued)
Engine overheats. 1. Coolant pump malfunction. Overhaul pump or replace.
2. Thermostat faulty. Replace thermostat.
3. Radiator inefficient. Remove internal deposits by flushing.

Check for leaks and repair.
4. Deposits in cylinder head and Flush out coolant system.

crankcase coolant passages.
5. Coolant pump and fan drive belt Check and adjust belt tension.
slack.
6. Coolant level low. Top up expansion tank with specified
coolant mixture.
7. Incorrect timing. Check and adjust.
8. Injection pump calibration incorrect Calibrate pump on test bench to val-

– delivering too much or too little ues specified in calibration tables.
fuel.
9. Air filter blocked. Clean filter unit and replace filter ele-
ment if necessary.
Engine lacks power and 1. Injection pump timing incorrect. Adjust pump timing.
runs unevenly.
2. Auto advance regulator in injection Overhaul injection pump and adjust

pump damaged. on test bench to the values specified
3. Distributor journal worn. Overhaul injection pump and adjust

4. Injection pump delivery irregular. Overhaul injection pump and adjust


6. Injectors partially obstructed or Clean, overhaul and calibrate injectors.

damaged.

(continued)
8. Fuel supply pump damaged. Replace fuel supply pump.

9. Incorrect valve clearances. Adjust valve clearances.
10. Cylinder compression low. Test compression and overhaul engine
if necessary.
11. Air filter blocked. Clear air filter unit and replace element
if necessary.
12. Tie–rod in linkage between accel- Adjust to correct length.
erator and injection pump incor-
rectly adjusted.
13. Maximum speed screw on injection Adjust max. speed screw.
pump incorrectly adjusted.
Engine produces abnormal 1. Injectors partially obstructed or Clean, overhaul and calibrate injectors.
knocking noises. damaged.
2. Impurities accumulating in fuel Clean fuel lines and replace severely
lines. dented pipes. Clean injection pump if
necessary.
4. Crankshaft knocking due to Re–grind crankshaft journals and
excessive play in one or more main crankpins. Fit oversize shell bearings
or big–end bearings or excessive and thrust washers.
endfloat.
5. Crankshaft out of balance. Check crankshaft alignment and bal-
ance; replace if necessary.
6. Flywheel bolts loose. Replace any bolts that have worked
loose and tighten all bolts to the speci-
fied preliminary and angular torque
values.
7. Connecting rod axes not parallel. Straighten connecting rods, check
axes parallelism; replace con rods if
necessary.
8. Piston knock due to excessive Rebore cylinder liners and fit oversize
wear. pistons.
9. Noise caused by excessive play Fit oversize gudgeon pin, rebore pis-
of gudgeon pins in small–end and ton seats and small–end bushings.
piston bushings, or loose fit of Replace bushings.
small–end bushing.
10. Excessive tappet/valve noise. Check for broken springs or exces-
sive play between valve stems and
guides, cam followers and bores. Ad-
just valve clearances.
(continued)
Engine produces excessive 1. Maximum delivery of injection Adjust injection pump on test bench to
black or dark grey smoke. pump too high. the values specified in calibration
chart.
2. Injection pump delivery excessively Adjust injection pump/engine timing or
retarded or automatic advance check automatic advance regulator.
regulator damaged.
3. Injection pump delivery excessively Adjust injection pump/engine timing.
advanced.
4. Injectors partially or totally Clean and overhaul injectors and ad-
obstructed or incorrectly adjusted. just pressure setting; replace if nec-
essary.
5. Air filter blocked. Clean air cleaner and replace filter

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

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

lines.
Blue, grey–blue or grey– 1. Injection pump delivery Adjust injection pump/engine timing or
white smoke. excessively retarded or automatic check automatic advance regulator.
advance regulator damaged.
2. Injectors obstructed or damaged. Clean and overhaul injectors and ad-

just pressure setting; replace if nec-
essary.
3. Oil leaking past piston rings due Replace damaged parts or, if neces-
to sticking rings or cylinder liner sary, recondition engine.
wear.
4. Oil leaking through the inlet valve Recondition cylinder head.

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

operating temperature (thermostat
faulty).
Engine runs on after switch- 1. Engine stop solenoid damaged. Replace solenoid.
ing off.
2. All–speed governor damaged. Recondition injection pump and ad-

just on test bench to values specified
in calibration data chart.
OVERHAUL
ENGINE
Removal
DANGER
equipment.
Make sure that the load is supported by means of
suitable slings and hooks.
Make sure that no–one is standing in the vicinity of
the load to be lifted.
CAUTION
1. Disconnect the negative lead from the battery.

2. Drain oil from the transmission/gearbox.
3. Drain the cooling system.
25621
13
4. Unscrew the nuts (1) from the weight retaining pin.
1
TRE3107A
14
5. Remove the weights (1) from the front support
(2).
1
2
TRE3107A
15
the hood (1) using tools 50131 and 50132 and 1
attach the chain to the hoist.
24872
16
7. Detach the electrical leads (1) from the
headlamps (2).
1
2
24873
17
8. Detach the gas struts (1) from hood.
1
TRE0603A
18
9. Remove the four hood hinge bolts (1) and lift the
hood clear.
1
TRE0604A
19
10. Remove the wire mesh guard (1) from right–
hand side of the fan.
TRE1319B
20
11. Disconnect the tachometer cable and remove

the retaining ring and sleeve.
1
25046
21
25183
22
13. Detach the fusebox by unscrewing the nut (1) 1
TRE0606A
23
14. Disconnect the delivery and return lines (1) to the

power steering cylinders.
TRE0607A
24
15. Remove the hose (1) from the lift pump suction
pipe.
1
TRE0608A
25
16. Detach the lift pump delivery pipe (1).
TRE0609A
26
17. Detach the fuel pipes from the injection pump

fuel pump and the pipe connecting the tank to the
TRE0610A
27
18. Remove the fuel filter (1) complete with its
support.
25035
28
19. Remove the front, center and rear retaining bolts
from the front axle drive shaft guard and remove
the guard.
25038
29
20. Remove the circlip (2) from the front of the prop
1 2
shaft and slide the sleeve (1), in the direction
shown by the arrow, until it is free of the splines
on the front axle.
25039
30
21. Remove the circlip (2) from the rear of the prop
shaft and slide the sleeve (1), in the direction 1
shown by the arrow, until it is free of the spines
on the drive shaft.
2
25040
31
22. Remove the retaining bolts from the central drive

shaft support (1) and recover the shaft complete
with support.
25041
32
23. Unscrew the four lower bolts (1) securing the
engine to the transmission.
TRE3048A
33
24. Position stand 380000236 underneath the trac-
tor and insert a wedge (1), either side of the axle,
to prevent the axle from pivoting.
25050
34
25. Insert a wooden block between the stands and
the tractor.
25051
35
26. Place a fixed stand (1) underneath the drawbar
support and apply the handbrake.
1
25052
36
28. Unscrew the four remaining bolts securing the
engine to the transmission. 1
29. Separate the engine from the transmission.
27. Remove the distance collar (1) between the

engine and transmission.
25055
37
30. Place a fixed stand (1) underneath the front

weight support and chock the wheels with
wooden wedges (2).
1 2
25056
38
31. Insert tool 295022 (1) in the clutch center hole.
Unscrew the six bolts (2) securing the clutch to
the flywheel and remove complete clutch as-
sembly.
25057 2
39
32. Remove the radiator mounting bolt (1).
TRE0613A
40
33. Attach the engine to the hoist using an

adjustable chain (1) attached to the lifting 1
points provided on the engine.
25060
41
34. Remove the lift pump (1) complete with its filter
by unscrewing the four retaining bolts.
TRE0614A
1
42
35. Disconnect all electrical connectors and remove
the complete wiring harness (1).
TRE0615A
43
36. Slacken of the hose clamp and detach hose (1)
from the inlet manifold.
1
TRE0616A
44
37. Remove the left–hand side fan guard (1).

1
TRE0617A
45
38. Unscrew the bolts (1) securing the silencer to its
bracket.
1
TRE0618A
46
39. Undo the hose clamp and disconnect the top
40. Unscrew the three nuts securing the silencer (2) to
the manifold and lift off the entire silencer assem-
bly.
TRE0619A
47
41. Using the hoist, raise the engine slightly and
position the moveable stand (1) under the front
axle.
1
25068
48
42. Undo the hose clamp and disconnect the bottom
43. Unscrew the four bolts (2) securing the engine to
the front axle support, and lower the engine onto
a wooden platform.
25069
49
Installation — Reconnect all electrical leads: thermostart
glow plug, coolant temperature sensor, ‘air
To re–install the engine, proceed as follows:
filter blocked’ sensor, horn, front axle support
— Attach the three hooks of an adjustable lifting earth, engine stop on injection pump, leads to
chain to three eye bolts on the engine. Raise the the alternator and relay, oil pressure sensor,
engine from the platform and position it in front starter motor, fuel dryer filter. Secure all leads
of the front axle support. Join the two units using with plastic ties.
the four securing bolts.
— Refit the clutch Fix clutch to the engine fly-
— Move the mobile stand from under the front axle wheel using the six retaining bolts.
differential housing to under the engine sump,
inserting a suitably shaped block of wood — Reconnect the oil delivery pipe to the DT control
between the stand and the sump pan. valve. Tighten the pipe union on the
anti–cavitation accumulator; fix the bracket on
— Attach the top radiator hose to the thermostat the left–hand side near the engine oil filter.
housing and secure with an adjustable hose
clamp. — Clean the distance collar and the mating sur-
faces of the overdrive clutch housing; scrape
— Connect the bottom radiator hose to the coolant away all traces of old sealing compound.
pump and secure at both ends with adjustable
hose clamps. — Apply LOCTITE sealing compound to the mat-
ing surfaces of engine and distance collar. Fit
— Refit the lift pump. the distance ring on the engine studs.
— Detach the lifting chain from the engine.
— Connect the rigid pipe from the air cleaner to the
inlet manifold and secure with the relative clamp.
— Apply LOCTITE sealing compound to the mating — Connect the two flexible power steering pipes to
surfaces of the overdrive clutch housing. the union on the left–hand side of the front axle.
Secure the two pipes with a special clamp and fix
— Remove the fixed stand from under the bfront the clamp to the tractor with a screw.
weight support. Remove the wooden wedges from
under the front wheels. — Fit the tachometer cable and secure the sleeve
with the retaining ring.
— Attach the adjustable lifting chain to the eyebolts
on the engine. — Fit the silencer onto the exhaust manifold,
remembering to replace the gas seal. Fix the
— Place wooden wedges under the rear wheels, front of the silencer to the vertical support
check that the handbrake is fully on and that the bracket. Attach the flexible DONASPIN pipe.
fixed and moveable stands are firmly in place.
— Attach the hood stay bracket to the radiator
— Detach the lifting chain from the engine. Attach bracket.
the two cables still attached to the cab handrail
to the hook of the hoist. Raise the front part of the — Refit the 4WD transmission shaft and the guard.
cab about 6 cm. (2.36 in.)
— Re–connect the throttle cable to the accelerator
— Replace and tighten all the bolts securing the pedal. It may be necessary to adjust the cable at
engine to the overdrive clutch housing. the injection pump lever end.
— Bolt on the brake pipe support bracket on the — Refit the clutch cable to the clutch pedal. Fix the
right–hand side of the engine. Lower the hoist sleeve to the travel stop.
and detach the cables from the cab handrail.
— Refit the steering column cover panels.
— Lower the stands under the engine sump and the
— Replace the wire mesh fan guards.
clutch housing. Remove tool 292320 and the
stand from under the drawbar support. — Attach slings to the hood in the manner described
previously in the engine removal instructions.
— Connect the injector leak–off pipe. Connect the
Screw the hood hinge to its bracket. Attach the gas
pipes to the glowplug and to the fuel dryer filter.
strut, the electrical leads to the headlamps, and
— Refit the fuel filter mounting to the engine. Connect then remove the slings.
the two semi–rigid pipes to the mounting. — Refit the secondary bracket (battery support) to
the overdrive clutch housing. Fit the rotating
— Connect the oil suction pipes to the pumps;
bracket with the battery to the fixed support.
secure the rubber hoses with hose clamps.
— Refit the front weights and secure with the lock
— Connect the rigid lift control valve supply pipe to the
pin.
relative pump, remembering to first fit the O–ring.
— Refit the tool box support bracket and then the
— Secure the three pipes with the adjustable hose
tool box.
clamp.
— Fill the transmission/gearbox with oil.
— Connect up all the electrical leads to the
connectors on the vertical support bracket. — Fill the radiator with coolant mixture.
— Connect the positive and negative battery leads.

Replace the plastic battery cover.
Compression Test On engines in perfect working order, with the sump oil
at approx. 40C (104F), at sea level (760 mm of
In case of poor engine performance, in addition to mercury) and at an engine speed of 200 to 280 rpm,
checking the fuel injection system (injector nozzles the compression should be 25.5 to 27.5 bar (370 to 400
and injection pump), also test the compression on psi).
each cylinder.
DANGER 8) Test the compression on the other cylinders, re-
Do not use matches, lighters, blow torches or any peating steps 4, 5, 6 and 7, bearing in mind that:
naked flame as a source of light when inspecting the
The minimum permissible compression on a used
engine due to the presence of inflammable fluids and engine is 21.6 bar (313 psi).
vapour.
The maximum permissible compression difference
between cylinders is 3 bar (43 psi).
Compression Ratio
Every 100 meters (328 ft) above sea level corre-
The compression ratio is a measure of the quantity sponds to a reduction in compression by about 1%.
of air drawn into the cylinder and provides an
indication of the efficiency of the sealing elements in
the cylinder (piston rings and valves). CONSIDERATIONS:
Uniform compression
Uniform compression in all the cylinders ensures that
they all perform an equal amount of work, provided
of course that each cylinder is injected with the same Although high compression is important, it is more
quantity of fuel at the right time. important as regards smooth running that the
compression is the same in all cylinders.
Low compression not only reduces engine
performance, it also causes incomplete fuel
combustion due to the lack of available combustion Low compression readings
air.
If very low compression readings are obtained on
The engine therefore gives poor performance with one cylinder it is advisable to repeat the test.
excessive fuel consumption, and consequently
exhaust smoke and restriction of the exhaust Before testing this time, pour about a spoonful of
passages. engine oil into the cylinder through the injector bore.
As the compression ration also varies with the tem- Turn the engine over a few times to distribute the oil
perature of the engine (cold engines produce lower evenly over the cylinder walls, and then repeat the
compression values than hot engines) the compres- test.
sion should only be tested when the engine is at nor-
mal operating temperature. If the second test readings are significantly higher,
suspect worn piston rings, out–of–round or damaged
Compression should be tested using the compression pistons or liners.
test kit 380000303 as follows:
1) Run the engine until it reaches normal operating If the second test readings are not higher, the problem
temperature; will be the valves.
2) Switch off the engine;
3) Disconnect the lead from the engine stop solenoid On the other hand, if the second test reading shows
on the injection pump in order to close the valve and only a slight improvement, the problem will be due to
block the flow of fuel to the injectors; both the valves and the rings.
4) Remove the injector from the cylinder to be tested;
5) Turn the engine over a few times with the starter
motor in order to expel any carbon residue;
6) Fit the dummy injector 293862 in place of the
injector removed previously, inserting the copper
sealing washer.
7) Connect the compression tester 380000303/1 and
take readings while turning the engine over with the
starter motor.
Disassembly
1
CAUTION
Wear suitable safety clothing – safety goggles,
gloves and shoes.
1. Remove the front and rear retaining screws from

the hood stay bracket (1). 25070
50
2. Remove the hood catch lever retaining screw (1)
and take off the hood catch and the hood stay
bracket.
1
25071
51
1
5. Release the belt tension adjustment arm by
unscrewing the retaining nut.
6. Remove the alternator and coolant pump drive
belt.
25072
52
7. Unscrew the bolts securing the fan (1) and pulley
to the coolant pump. Remove the fan and pulley.
25073
53
8. Remove the union (1) in order to gain access to
the pump retaining bolt.
25077
54
9. Unscrew the coolant pump retaining bolts (1)
and remove the pump. 1
25076
55
10. Unscrew the pump support bolts (1) and the
silencer support bolt. Remove the two supports.
25078
56
11. Fit mounting bracket (1) of the set 380000313 to
permit attachment of the engine to the rotary
stand 380000301.
25079
57
12. Fit an eyebolt (1) on the front of the engine in
place of the silencer support.
13. Raise the engine from the wooden platform and 1
move it to the rotary stand 380000301 (2). Se-
cure it to the stand by means of the bracket (3)
of the set 380000313.
3 2
25080
58
14. Undo the alternator support retaining bolts (1)
and remove the complete alternator assembly.
1
25081
59
15. Unscrew the bolts (1) securing the exhaust
manifold to the cylinder head and remove the
manifold.
25082
60
16. Detach the throttle control lever (1) from the
injection pump.
1
25083
61
17. Remove the thermostat housing retaining bolts
(1) and remove the thermostat housing.
25084
62
18. Unscrew the high pressure fuel line unions (1) on
the injection pump and remove the fuel lines.
1
25085
63
19. Unscrew the bolts (1) securing the inlet manifold
to the cylinder head and remove the manifold. 1
25086
64
20. Unscrew the unions (1) on the fuel supply pump
and detach the fuel lines.
25087
65
25088
66
22. Undo screws (1) and remove the injection pump
drive gear cover. 1
25089
67
shaft to the drive gear. 1
25090
68
24. Withdraw the injection pump drive gear using
tool 295942 (1) and remove the injection pump
and the woodruff key.
25091
69
25. Undo the fuel line unions (1) on the fuel
25092
70
26. Unscrew the bolts securing the sedimentation
1
filter support to the engine block and recover the
complete filter assembly.
25093
71
27. Unscrew the retaining nut (1) and remove the
fuel pump support complete with the pump.
Retain the gasket for re–use, if undamaged.
25094
72
28. Unscrew the power steering pump retaining
bolts (1) and remove the pump complete with
filter and accumulator on the delivery line.
25095
73
29. Remove spacer (3), gasket (2) and the pump
drive connector (1).
1
2
25096
3
74
30. Unscrew the starter motor retaining bolts (1) and
remove starter motor.
25097
75
31. Remove the injector mounting nuts and the
spherical washers beneath, then the supports 1
and the injectors themselves.
32. Remove the rocker cover bolts (1), washers and
seals and then the rocker cover and its gasket.
25098
76
33. Remove the rocker shaft retaining bolts (2), then
remove the entire rocker shaft assembly (1).
2
1
25099
77
34. Remove the valve collets (1) and withdraw the
pushrods (2). 1
2
25100
78
35. Unscrew the cylinder head bolts (1) and remove
the head using a hoist and lifting hook
380000216.
36. Remove the cylinder head gasket.
25101 1
79
37. Turn the engine upside down on the rotary stand.
Remove the sump pan bolts, the sump pan (1)
and its gasket (2).
1
25102
2
80
38. Unscrew the retaining bolts and remove the oil
1
pick–up pipe (1) complete with the strainer and
seal.
39. Unscrew the retaining bolts (2) and free the coun-
terweight housing (3) by moving it outward. Re- 4
move the sleeve coupling (4) and housing.
NOTE: Operations 37., 38. and 39. are to be carried

out on 4–cylinder models only. For dismantling and
assembly of the rotating counterweight dynamic
balancer see pages 56 to 58. 3 2
25103
81
40. Unscrew the sump pan retaining bolts (4) and 1 2
remove the sump pan using a hoist, lifting hook
290740 and lifting chain with eyeholes.
41. Remove the half–gaskets (1) and (3) between
the crankcase and sump pan and the gasket (2)
between the timing gear carrier and sump pan.
3
25104
82
42. Remove the gasket (1) between the flywheel
carrier and the sump pan.
NOTE: When relocating gaskets (1) and (3) (fig. 82),

apply RHODORSIL CAF1 silicone sealing compound
to the mating surfaces.
1
25105
83
43. Remove the rotating counterweight oil seal O–ring
(1) installed on the crankcase mating surface.
25106
84
44. Unscrew retaining bolts (1) and remove the
complete oil pump unit.
1
NOTE: For TD95 see fig. 102 page 56.
25107
85
crankshaft pulley (1). 1
25108
86
46. Straighten the lock tab, preventing rotation of the
crankshaft and unscrew nut (1).
25109
87
47. Pull the pulley hub off the crankshaft using tool
380000226 (1) and retain the woodruff key for
re–use.
25110
88
48. Unscrew the retaining bolt (1) and remove the
timing cover and its gasket.
25111
89
49. Unscrew the retaining bolts and remove the lift
pump drive gear carrier (1).
1
25112
90
50. Remove the circlip (1) and remove the thrust
washer and the intermediate gear (2).
1 2
NOTE: When refitting the intermediate gear see

engine timing instructions on page 63.
25113
91
intermediate gear journal.
1
25114
92
52. Unscrew the retaining bolts (4) and withdraw the
camshaft (2) complete with the camshaft gear
(1) and the end plate (3).
1
2
4
25115
93
53. Remove the circlip (1) and the thrust washer.
Withdraw the gear with fuel supply pump
camshaft (2) from the opposite side.
1
NOTE: This gear transmits drive to the injection

pump. On re–assembly see timing instructions on
page 63.
25108
94
54. Unscrew the bolts (1) and remove the timing
gear case.
25109
95
55. Renew the O–ring seal (1) installed in the lift
pump drive shaft lubrication line.
56. Remove the crankcase – timing gear case gasket.
25118
96
57. Rotate the engine on the stand through 90.
Unscrew the big–end cap bolts (2) and remove 1
the big–end caps (1), complete with their half
shell bearings.
25119
97
58. Slide the pistons (1), complete with rings, wrist
pins and connecting rods, out of the cylinder
liners.
25108
98
59. Rotate the engine on the stand through 90 back
to the horizontal position. Unscrew the flywheel
bolts and remove the flywheel with the aid of a 1
hoist and hook 380000216.
60. Unscrew retaining bolts and remove the rear oil
seal carrier (1) complete with gasket.
25109
99
61. Unscrew the main bearing cap bolts (1) and
remove the main bearing caps with related
bearing shells. Remove the thrust washers
located on the penultimate main bearing, as
shown in the figure.
62. Lift the crankshaft clear of the crankcase using
a hoist and nylon sling. Remove the bearing
shells, thrust washers and tappets. 1
25122
100
63. Turn the engine on the stand 38000301 (2)
through 180. Attach the lifting chain with eye
1
holes to the crankcase as shown in the figure.
Raise the hook 380000216 with the hoist so that
the lifting chain is under slight tension. Unscrew
the bolts securing the crankcase to the stand (2)
and mounting bracket (3) (from set 380000313).
64. Lift the engine clear of the stand. 3 2
65. Unscrew retaining bolts and remove the rear
crankcase housing (1) and its gasket.
25123
101
NOTE: Oil pump for TD95 model.
66. Remove the retaining screws (4), take off the

washers (3) and the engine lubrication oil pump 1
(2) complete with pressure relief valve (1).
2
4
26106
102
NOTE: Operations 1. to 9. relative to the dismantling 2
of the rotating counterweight dynamic balancer only 1
apply to 4–cylinder models.
1. Remove the lubricating oil pipe (3) fig. 104.

3. Remove the circlip (25) and cover (23) with rela-
tive O–ring seal (24). 6 4
4. Withdraw gear (22) from sump.
5
5. Remove the circlip (2), gear (26) and the two 3
thrust washers (1). 25159
6. Inspect shaft (27). If it shows signs of scoring or 103

wear it must be replaced.
7. Extract the roll pins and remove the
counterweight shafts (8) using a suitable drift.
8. Remove the counterweight drive gear (1) fig. 103
by removing the circlip (5) and the carrier
retaining bolts (6).
9. Remove circlip (3) and intermediate gear (4) fig.
103.
1 2 3 4 5 6 7
28 8
27
26
25
24
23
22 21 11
25160
20 19 18 17 16 15 14 13 12 10 9
Sectional view of dynamic balancer. 104
1. Thrust washers. 15. Screen filter retaining bolt.

3. Lubricating oil pipe for bushing (28). 17. Rigid coupling sleeve.
4. Counterweight rotation shaft. 18. Circlip.
5. Shaft retaining spring pin. 19. Thrust washer.
8. Counterweight. 22. Counterweight drive gear.
10. Bolts securing counterweight housing to sump. 24. O–ring seal.
12. Counterweight housing. 26. Intermediate gear.
13. Counterweight drive gear. 27. Shaft for gear (26).
14. Screen filter. 28. Bushing.
Assembly
General Notes and Information

— After dismantling the engine, clean all parts
carefully.
— To re–assemble the engine, carry out the
dismantling operations described on pages 43 to
57 in reverse order.
— The following pages 58 to 67 concern those
assembly operations requiring particular atten-
tion.
— Tightening torques are specified on page 14.
In addition, make sure to:

— Replace all seals and gaskets at each complete
or partial engine rebuild.
— Lubricate all rotating parts and oil seals with
engine oil prior to installation.
— Lubricate the oil filter mounting seal prior to fitting
the filter.
CAUTION
gloves and shoes.
Counter-Rotating Balancer Assembly

(Disassembly operations 1 – 9) 1
Proceed as follows:
— Assemble the counterweight components in the

housing (2) carrying out dismantling operations
7. to 9. in reverse order. Align the positioning
marks on the gear (4) and counterweights (1)
(indicated by arrows in fig. 127).
24913
4 3 2
105
— The intermediate gear (3) fig. 105 must be
installed with the longer side of its hub towards 1
the casing side;
— The holes for the roll pins (1) in the counterweight
shafts (2) must be aligned with corresponding
holes in the casing.
— Install the counterweight assembly on the sump
carrying out on page 58. 2
24914
106
Tappets, Main Bearings and Crankshaft
Proceed as follows:
— Install the tappets in their crankcase bores.
— Lubricate the main bearing seats with engine oil
and install the half shell bearings (3).
— Stick the semi–circular thrust washers to both
sides of the penultimate main bearing with
grease.
25109
107
— Lubricate the upper surfaces of the main bearing
shells with engine oil and lower the crankshaft (1) 1
into position taking care not to dislodge the
semi–circular thrust washers installed previously.
24718
108
— Lubricate the crankshaft journals with engine oil
and fit the main bearing caps (3) with the
half–shells (4), fitting the top semi–circular thrust 1 2
3
washers (2) to the penultimate bearing cap.
— Rotate the crankshaft (1) a few times to allow the
parts to settle into position.
— Insert the main bearing cap bolts and screw in
until the head of the bolt is up against the cap. 4
25108
109
— Tighten all cap bolts (1) to a torque of 80 Nm

(59 ft-lbs). 1
24720
110
— Tighten each cap bolt (1) through a further 90o
using tool 380000304 (2).
1
2
24744
111
— Check that crankshaft endfloat does not exceed
the value specified on page 7.
24760
112
Installing Rear Cover Seal, and Flywheel
1
Proceed as follows:
— Fit the rear oil seal carrier (3) with the outer seal.
Tighten retaining bolts (2) to the torque specified
on page 14. Using a feeler gauge (1), check that
3
the crankshaft flange is coaxial with the carrier. 2
24752
113
— Fit the inner rear oil seal using installer and hand
grip 50139 (1).
1
24761
114
— Fit the flywheel and tighten the retaining bolts (1)
to a torque of 40 Nm (29 ft-lbs).
24762
115
— Using tool 380000304 (1), tighten each flywheel
bolt (2) through a further 60o.
1
24763
116
Piston Assembly and Installation
(Disassembly operations 59 and 60)
Proceed as follows:
— Lubricate pistons, rings and cylinder liners with
engine oil prior to fitting.
— Fit the piston rings using piston ring pliers
291160. Make sure that the piston ring gaps are
offset 180o apart.
— Fit piston ring clamp 380000220 (1) to compress
the rings, making sure that the piston ring gaps
remain180o apart.
— Insert the piston/connecting rod into the cylinder 25163
liner. Ensure that the connecting rod number 117

corresponds with the cylinder number and that
the number stamped on the connecting rod is
facing away from the camshaft.
— Fit the big–end caps (2) complete with shells to
the crankpins and tighten the cap bolts (1) to a
torque of 40 Nm (29 ft-lbs).
1 2
25164
— Using tool 380000304 (1), tighten each big–end
cap bolt (2) through a further 60o. 118
1 2
25165
— Rotate the engine on the stand through 180o and
clean the upper face of the cylinder block. Bring 119
the pistons (2) up to TDC and, using a dial gauge
with a magnetic base (1), check that the piston
protrusion from the cylinder block face is within 1 2
the tolerance limits specified on page 9.
25166
120
Synchronizing the Timing Gears
Proceed as follows:
— Remove the cover and gasket from the flywheel

housing inspection window.
25167
121
— The flywheel is marked in degrees BTDC. Turn
the drive shaft so as to bring cylinder No. 1 to
TDC on the compression stroke. Look through
the inspection window and check that the notch
aligns with the appropriate index mark, accord-
ing to the type of BOSCH pump installed on the
tractor (see chapter 2)
26107
122
— Fit the timing gears making sure that the various
reference marks on the mating gears (indicated by
the arrows in the figure) are aligned.
25169
123
Counter–Rotating Balancer Installation/Timing
When refitting the counter–rotating weight box, syn-

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

1
— Position the rotating counterweights so that the
timing reference marks are aligned as shown in
the figure.
25170
124
— Turn the rotating counterweight unit over and
insert the locating pin (2) in its hole. The pin 1 2
serves to hold the counterweights in the correct
timing position during installation of the unit.
— Using the hoist and a lifting chain, lower the
counterweight unit onto its seating in the sump.
25171
125
— Slide the coupling sleeve (1) over the splines of
the counterweight drive gear as shown in figure
133.
1
— Slide the other end of the coupling sleeve (1)
over the splined shaft of the counterweight drive
gear, so that the master spline in the sleeve
coincides with the master spline on the shaft (3).
— Tighten the dynamic balancer housing retaining
bolts (1) fig. 125 to the torque specified on page
14.
2
3
25172
126
Injection Pump Installation/Timing
— Fit the BOSCH injection pump and proceed with

the injection pump timing in the manner
described in Chapter 2 of this section.
1
2
25181
127
Cylinder Head Gasket
Proceed as follows:
— Before fitting the cylinder head, carefully clean

and degrease the mating surface of the cylinder 1
block. Locate a new cylinder head gasket (1)
with the word ALTO uppermost.
25173
128
Cylinder Head Installation
Proceed as follows:
— Lower the cylinder head onto the block and
screw in the cylinder head bolts (1) fig. 131,
finger tight.
25174
129
25175
130
— 1st. stage – Tighten the bolts (1) to a torque of
70 Nm (51 ft-lbs) in the sequence indicated
above (figs. 129/130).
— 2nd. stage – Recheck the torque of all the bolts
in the sequence indicated above (figs. 129/130).
25176
131
100. Using the angular tightening tool 380000304
(1), tighten each bolt (2) in sequence through 1
90o (3rd. stage) and then through a further 90o
(4th. stage) in the sequence indicated above
(figs. 129/130).
2
25177
132
Adjusting Valve/Rocker Arm Clearance
— Before refitting the rocker cover, adjust the valve

clearances as described on pages 128 – 97. 1
— Tighten the rocker arm adjuster screw locknuts
(1) to the torque specified on page 14.
25178
133
Fitting the Injectors
Proceed as follows:
— Insert the injectors (2) in their respective bores.

— Position the injector support brackets and fit the
spherical washers. 1
— Screw the bracket retaining nuts (1) up to the
spherical washers, then tighten to the torque 2
specified on page 14 in two stages:
1st. stage – tighten nuts to 10 Nm (73 ft-lbs); 25179
2nd stage – tighten nuts to 25 Nm (18 ft-lbs). 134

— Tighten the leak–off pipe unions.
— Tighten the high–pressure fuel line unions.
Adjusting Cooling System Belt Tension

NOTE: Tension the belt correctly as described on

page 98.
CHECKS, DIMENSIONS AND REPAIRS
Cylinder Block and Liners
CAUTION
gloves and shoes.

NOTE: Cylinder liner dimensions must only be mea-

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

— measure the inside diameter in the area swept
by the piston rings X (fig.137);
— measure the inside diameter at the upper and
lower ends of this area both parallel to the
crankshaft center line (a) and perpendicular to
the crankshaft center line (b);
— compare measurements thus obtained to
determine liner ovality and taper.
To check piston running clearance, measure the I.D.
of each liner in the area Z (fig.137) along the axis per-
pendicular to the crankshaft center line.
If ovality or taper exceed 0.12 mm or piston coupling
play exceeds 0.3 mm (.011 in.), rebore and grind (or
change) the liners, to bring them up to one of the
sizes shown in the table on page 6.
Then pair up the cylinder liners with the pistons of the
same dimensions (see page 9).
NOTE: If one of the liners requires reboring, all the

liners in the engine must be rebored to the same
oversize.
After reboring, the 0.5 mm (.019 in.) 30 chamfer

must be restored on the liner (1).
In case of replacement, remove and install the lin-
ers in cylinder block cold using a press as follows:
25307
135
— Press the worn liner out of the block, operating
from the bottom of the crankcase, using a
stepped plate of appropriate diameter.
— Check the ovality of the bore in the block and
rebore if necessary to 0.22 mm (.008 in.)
oversize.
— Press–fit the new liner (0.22 mm (.008 in.)
oversize if necessary) from the top of the block,
using the stepped plate referred to above.
— Rebore and ream the liner to the specified inside
diameter (see page 6).
25308
136
25309
25310
Standard dimensions (mm) of cylinder liners and bores in cylinder block 137
and positions for checking liner wear.
a,b. Perpendicular positions of dial gauge to mea- X. Area for measurement of inside diameter of
sure liner inside diameter. worn liner (area swept by piston rings) to
c. Models TD60 and TD80. determine ovality and taper (measure along
d. Models TD70, TD90 and TD95. axes a and b, respectively parallel and
C. Dimension to obtain after press–fitting and perpendicular to crankshaft).
reaming of liner. 1,2,3. Points at which to measure inside diameter
Z. Area for measurement of inside diameter of used of new or rebored liners along axes a and b.
liner to determine piston running clearance
(measured along axis b perpendicular to
crankshaft).
Crankshaft, Main Bearings and Flywheel
CAUTION
fingers between parts. Wear suitable safety clothing
– safety goggles, gloves and shoes.
Crankshaft
Clean parts carefully before proceeding with
Carefully inspect the crankshaft. Any cracks, even
minor ones, will necessitate replacement of the
crankshaft.
Inspect the crankshaft journals and crankpins;
slight scoring or seizure marks can be removed with
very fine grade emery cloth.
If scoring, ovality or taper exceeds 0.05 mm (.002
in.), the crankshaft will have to be reground.
Measure journal diameter, fig.138, to determine the
nearest undersize (see page 7).
After regrinding, restore the journal and crankpin ra-
dii and fillets as shown in the details in fig.139 and
check that:
— main bearing journal and crankpin ovality does
not exceed 0.008 mm (.0003 in.);
— main bearing journal and crankpin taper does 25311
not exceed 0.01 mm (.0004 in.);

138
a
b
d
d
e e
25312 25313
139
Standard dimensions (mm) of main bearing journals and crankpins, main bearings
and semi–circular thrust washers.
a. Models TD60 and TD70. d. Normal crankshaft journal radii and fillets.
b. Models TD80, TD90, and TD95. e. Radii and fillets of crankshaft journal with
c. Crankpin radii and fillets. thrust washers.
— with the crankshaft resting on parallel gauge — the run–out measured with the dial gauge contact
blocks, the maximum misalignment of the main point resting on surface (A) or (B), fig.140, does
bearing journals does not exceed 0.10 mm not exceed the value specified in the table on
(.0004 in.) (D) fig. 161; page 8;
— the centerlines of the crankpins (TD70) or of
each pair of crankpins (models TD70, TD80,
— the oil plugs seal against an oil pressure of 14.7
TD90 and TD95) lie in the same plane as the
bar (213 psi);
main bearing journal centerlines, with a maxi-
mum deviation of "0.25 mm (.009 in.) as
measured perpendicularly to the same plane
(see fig.139); — if new plugs are fitted, punch–lock in position and
— the distances between the outer surfaces of the re–check oil tightness with the system
crankpins and the crankshaft centerline are pressurised.
equal with a tolerance of " 0.10 mm (.0004 in.);
b
B
a
25314
c
B
a
25315
140
Maximum tolerances for alignment of main bearing journals and crankpin relative to
crankshaft centerline and alignment of crankpins relative to main bearing journals (a).
b. Models TD60 and TD70. D. Maximum permissible main bearing journal

c. Models TD80, TD90, and TD95. alignment deviation.
A. e B. Dial gauge contact point positions for checking
run–out of flywheel mounting flange.
Bearings
Check the clearance between the crankshaft
journals and bearing shells using a calibrated wire
1 2
gauge as follows:
— make sure that all parts are perfectly clean and 3
remove all traces of oil;
— locate the half–shells in their respective seats (5); 6
— install the crankshaft; 4
— position lengths of calibrating wire (6) on the 5
crankshaft journals (4) corresponding with the
crankshaft centerline.
25316
— fit the caps (1) complete with half–shells (2) to
the respective journals; 141
— lubricate the screws (4, figs. 6 and 8) securing

the main bearing caps with engine oil and tighten
them to the prescribed torque using a torque
wrench (see page 14);
Main bearing cap bolts (4, figs. 6 and 8)

(measured in area a shown in fig.142) is greater than
13.5 mm (.531 in.). If not, replace the bolts.
25318
142
— remove the caps and determine the bearing

clearance by comparing the width of the calibrat-
ing wire at the widest point against the scale
printed on the packet (3) fig.141, containing the
wire;
— after refitting the crankshaft and the bearing
caps and bolts, check crankshaft endfloat about
the penultimate bearing with a dial gauge (1);
— if the endfloat exceeds the specified value (see
page 7), replace the existing thrust washers
with oversizes ones.
25317 1
143
Flywheel
The flywheel is fixed to the crankshaft flange by

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

90o C before fitting and position with the bevel on the
teeth facing inward towards the starter motor.
The flywheel mounting holes are offset so that the

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

25.
— lubricate the screws securing the engine fly-

wheel with engine oil, then tighten them to the
prescribed torque (see page 14) using a torque
wrench.
Flywheel bolts (3, figs. 6 and 8)

(measured in area a shown in figs.144 and 145) is 25318
greater than 13.5 mm (.531 in.). If not, replace the
144
bolts.
25319
145
Connecting Rods
WARNING
Handle all parts with great care. Do not put your
hands or fingers between one part and another.
Wear the recommended safety clothing, i.e. goggles,
gloves and protective shoes.

Check that the bushings in the connecting rod small

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

fitting, to the specified diameter (A).
Dimensions (mm) of standard connecting rods,

bearing shells, bushings and gudgeon pins
A = Dimension required by reaming after fitting
bushings – L, M = Oil ports.
25320
146
Check parallelism of small end and big end axes.

Maximum permitted tolerance is " 0.07 mm (.002
ins) measured at 125 mm (4.92 ins) from longitudinal
axis of the connecting rod.
Slightly twisted con rods can be straightened using a

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

cylinder in which they are to be fitted. Check that the
difference in weight of connecting rods in the same 25321
engine does not exceed 25 grams (.88 oz).

147
Also check that the oil ways (L and M) fig.146 are not
obstructed by scale or impurities.
Pistons
CAUTION

Determine the degree of piston and liner wear in the

manner described on pages 16 and 19 and the fig-
ures below.
If the piston running clearance exceeds 0.30 mm

(.011 in.), rebore and ream the liners and fit oversize
pistons and rings (see pages 6 and 9).
In case of piston replacement, check that the weight

difference between pistons in the same engine does
not exceed 20 grams (.7 oz).
Check that the piston ring groove clearance (b, fig.

148) and the end gap (c, fig. 148) are within the
tolerances specified on page 9. If the end gap is less
than that specified, correct by grinding the ends of
the piston ring.
25322
Checking pistons and rings 148
a. Checking piston diameter at a distance (L) from c. Checking the end gap with ring in cylinder bore.
the base of the skirt. L. Distance from base of piston skirt: 57 mm (2.24 in.).
b. Checking piston ring groove clearance.
25323
149
Dimensions (mm) of standard pistons, gudgeon pins and rings.
a. Models TD60 and TD80. E. Piston diameter measured at 57 mm (2.24 in.)

b. Models TD70, TD90, and TD95. from the base of the skirt.
A. Measurement to be obtained with ring inserted in
cylinder bore.
To remove or fit piston rings (1), use pliers 380000221

(2).
1
Fit rings in grooves in the order indicated in fig. 149.
When fitting pistons on connecting rods, check that the

clearance between the gudgeon pin and its bore in the
piston is within the tolerance specified on page 9.
2
25324
150
Check that the piston/connecting rod assembly is
perfectly square.
If not, replace parts causing the problem.
25108
151
NOTES:
— Oil the pistons, rings and liners before inserting

1
the pistons in their bores.
— Before fitting the ring clamp 380000220 (1) to

compress the rings for insertion in the liner,
check that the ring end gaps are offset by an
angle of 180o i.e., opposite one another.
This will ensure better compression and better oil

sealing.
2
25326
152
Big end cap bolts (5, figs. 6 and 8)

(measured in the area a shown in figure153) is
greater than 10.5 mm (.41 in.). If not, replace the
bolts.
NOTE: It is advisable to replace the big end cap bolts

each time the connecting rods are dismantled.
25327
153
Camshaft, Tappets and Valves
CAUTION
Valves
Use tool 380000302 for valve removal and installa-
tion.
In the case of minor sealing faults, the valves and
their seats in the cylinder head may be re–faced us-
ing pneumatic grinder or universal grinder. In case of
more serious defects, re–face the seats and grind
the valves as shown in the relative chapter.
After grinding, check that the step below the valve
contact band is no less than 0.5 mm (.019 in.).
Dimensions (mm) of valves and valve guides

A. Inlet.
B. Distance to be obtained by reaming fitted valve
guide.
S. Exhaust.
25330
154
Tappets
Check that the tappets slide freely in their bores

without excessive play.
In the case of excessive tappet–to–bore clearance,

rebore the seats and fit oversize tappets (see page 10).
Pushrods must be perfectly straight, and the con-

cave contact surface with the rocker arm adjuster
screw must not show signs of seizure or excessive
wear, otherwise the rod must be replaced.
25329
In case of refacing of the contact surfaces, remove
as little material as possible. 155
Camshaft
Place the camshaft on two parallel V blocks, as

shown. Using a dial gauge with 1/100 mm scale,
check that journal run–out relative to the axis of
rotation does not exceed 0.02 mm (.0007 in.).
If run–out does not exceed 0.02 mm (.0007 in.), the

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

as follows: 25328
– inlet valve = 5.97 mm (.235 in.); 156
– exhaust valve = 6.25 mm (.246 in.).
Replace worn bushings using suitable extractors and

drifts. Ream to obtain the inside diameter indicated
in figure 157.
25331
157
Dimensions (mm) of camshaft journals and relative seats in cylinder block.
a. Model TD60 and TD70. b. Models TD80, TD90, and TD95
NOTE: The value indicated for the bushing inside diameter is for an installed bush.
Valve timing check
To check the valve timing after dismantling/assembly

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

gears are aligned as indicated on page 63.
Provisionally set valve clearances to 0.45 mm (.017

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

25333
disc, check that valves open and close at the angles
indicated in the timing diagram. 158
On completion of timing check, set the valve clear-

ances for normal running as detailed on pages 95
and 97.
Valve timing diagram

A. Fixed advance (*).
1. TDC.
2. BDC.
3. Inlet.
4. Exhaust.
5. Injection.
(*) According to pump type and engine model (see page 2).
Cylinder Head
CAUTION
Use valve spring compressor 380000302 to remove

and refit valve springs. 1 2

Check that the cylinder head mating surface is flat

using a straightedge (2) and feeler gauge (1).
If deviations of more than 0.15 mm (.006 in.) are

25108
found, the head must be refaced.
159
NOTE: Remove as little material as possible: the
maximum depth of material that can be ground from
the cylinder head is 0.5 mm (.019 in.).
Using a dial gauge with magnetic base (1), check the

run–out of the valve head (2) in the guide and the
1
clearance between the valve stem and guide. 2
If the clearance exceeds the specified value (see
page 12), replace the valve and, if necessary, the
valve guide.
25108
160
Rotating Counterweight Dynamic Balancer

(TD80, TD90, and TD95 models)
CAUTION
– safety goggles, gloves and shoes

Check component wear and replace any defective
parts.
If the bushings of the counterweights are to be
replaced, pre–heat the counterweights in oil to a
temperature of 140o to 160oC (284o – 320oF) (or dip
the bushings in nitrogen) before shrink–fitting in their
bores.
Ream the new bushings after fitting using a reamer
with expanding cutters to the inside diameter specified
1 2 3 4 5 6 7 8 9
28
27
26
25
24
23 22 21 20 19 18 17 16 15 14 13 12 11 10
22605
Cross–sectional view of rotating counterweight dynamic balancer. 161
1. Thrust washers. 15. Screen filter retaining screw.

3. Bushing lubrication tube. 17. Sleeve coupling.
4. Counterweight (28) rotation shaft. 18. Circlip.
5. Shaft (4) retaining spring pin. 19. Thrust washer.
6. Counterweight drive gear (13) carrier. 20. Carrier for gear (22).
8. Counterweights. 22. Drive box gear for dynamic balancer.
9. Intermediate counterweight drive gear. 23. Cover.
10. Bolts securing balancer housing to sump. 24. O–ring seal.
12. Dynamic balancer housing. 26. Intermediate gear.
13. Counterweight drive gear. 27. Intermediate gear (26) rotation shaft.
14. Wire screen filter. 28. Bushing.
ENGINE LUBRICATION COMPONENTS
CAUTION

Oil Pump
To access the oil pump, remove the sump pan.
When servicing the pump, check component wear
against dimensions specified in the table. 1
In case of replacement, note that the drive shaft (3) 2

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

pump models TD60, TD70, TD80, and TD90 4
1. External drive gear.
2. Bushing. 5
3. Drive shaft and gear.
4. Driven shaft and gear.
25354
162

pump model TD95. 1
1. Pressure relief valve
2. Spring 2
3. Pump housing
4. Internal gears
4 3
26109
163
Oil Filter COOLING SYSTEM
The oil filter (3) figs. 10 and 11 is of the full–flow, Clean all parts carefully before proceeding with the
integral paper cartridge type, and is installed in the operations described below.
pump delivery line.
Should the filter become clogged, the safety valve (2) The cooling system is filled with a permanent coolant
will open to allow the oil to by–pass the filter, thus mixture consisting of water and ”AKCELA Premium
ensuring that the engine continues to be lubricated, Anti Freeze” antifreeze (up to 50% in volume). This
although with unfiltered oil. mixture prevents freezing down to the following
temperatures:
Replace the cartridge periodically (every 400
operating hours), remembering to: Degrees oF 17.6 5 –13 –31
Degrees oC –8 –15 –25 –35
— oil the outer part of the seal in contact with the
mounting on the crankcase; % in volume of
— screw on the new cartridge until the seal is up ”AKCELA Premium 20 30 40 50
against the mounting; Anti Freeze”
— tighten the cartridge by hand only through a
further 3/4 turn. This mixture also has anti–oxidant, anti–corrosion,
anti–foaming and anti–scaling properties to ensure
long–term protection of the cooling system.
The same mixture can be kept in the cooling system
Low Oil Pressure Indicator
for a maximum of 2 years or 1600 operating hours,
The indicator consists of a control switch (4) figs. 10 whichever comes sooner, after which it must be
and 11 and a red warning lamp in the instrument changed.
panel, which illuminates in the following conditions:
— low oil pressure (the warning lamp also illuminates Radiators
in normal conditions, without signifying a fault,
Two valves are built into the radiator cap, one
when the engine is hot and idling at low speed);
compression valve and one depression valve. Check
— control switch malfunction. periodically that they are working correctly.
If the red lamp fails to illuminate when the engine is When overhauling, remove deposits of lime scale in
stopped and the ignition switch is turned to the power the radiator by means of a solution of water and
on position, the possible causes are: de–scaling agent in the proportions shown on the
— blown fuse; container.
— blown lamp; It is never advisable to limit flushing to the radiator
— interruption in wire to the control switch. only – always extend it to the entire cooling circuit
and top up the engine with the solution referred to
above.
Run the engine for about an hour. With the engine off,
drain the solution through the drain plug aperture.
If the system is leaking, check the radiator seal by
immersing it in a tank of water at the temperature of
20–40oC (68o – 104oF), blowing air into the radiator
at a pressure of 0.98 bar (14 psi) for approximately
two minutes (repeat the test at least three times).
VALVE GUIDES
CAUTION
equipment.
CAUTION
With the cylinder head on the test bench, proceed as

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

using twist drill 294027.
2. Place the cylinder head on a suitable support and

remove the valve guide to be replaced using drift
380000219 (1).
25334
164
3. Turn the head upside down, and force fit the new
valve guide with the enlarged bore using drift
380000219 (1) and bush 380000242 (2).
25335
165
4. Ream out the valve guide bore (2) using reamer
292177 (1).
25336
166
NOTE: When replacing exhaust valve guides you

must also carry out the following further operations.
5. Measure the distance (L) between the cylinder
head face and the base of the valve guide using
a caliper gauge and the special plate of tool
294028. 1
25337
167
The depth of taper milling is given by:
B–L=C
where:
B = depth of taper relative to cylinder head face (see

fig. 174).
L = distance measured between cylinder head face

and valve guide base.
C = depth of taper milling.
Example (4–cylinder engine)
B = 43.1 to 43.6 mm (1.696 to 1.716 in.)

1 2
L = 34 mm (1.338 in.) (distance measured).
C = (1.696 to 1.716) – 1.338 = .358 to .377 ins.
C = (43.1 to 43.6) – 34 = 9.1 to 9.6 mm.

Depth of taper milling.
6. From the upper side of the cylinder head, fit

guide bush (1) of tool 294028 on the guide valve
25109
to be milled (2).
168
7. Slide the cutter (1) of tool 294028, complete with
depth stop (2), into the previously located guide
bush until the cutting head is in contact with the
valve guide.
1
2
25339
169
8. Position the plate (3) of tool 294028 flush against
the cylinder head face and slide the depth stop
(2) up to the plate. Measure the distance (A)
2
between the depth stop and the end of the cutter 1 3
shank (1).
25340
170
9. Position the depth stop (1) at a distance
(D) = 35.9 to 36.4 mm (1.414 to 1.433 in.) from
the end of the cutter shank and fix in place with
its set screw.
Distance (D) is given by:
D=A–C 1
where:
D = the distance determining the end of the taper

milling.
25341
A = the distance between the end of the cutter shank 171

and the depth stop, with the plate flush against the
cylinder head.
C = the depth of taper milling.
Example
A = 45.5 mm (1.791 in.)
C = 9.1 to 9.6 mm (.358 to .377 in.)
D = 45.5 – (9.1 to 9.6) = 35.9 to 36.4 mm.
D = 1.791 – (.358 to .377) = 1.414 to 1.433 ins.

10. Turn the cutting tool (2) until the plate (3) is
brought up to the cylinder head face by the depth
stop (1). 2
NOTE: Before fitting the cylinder head, clean it 1

thoroughly to remove all residue from the milling
operation.
25342
3
172
VALVE SEATS IN CYLINDER HEAD
CAUTION
11. If the valve seats need refacing to improve valve

sealing, use the universal valve grinder 294006
(1) and remove as little material as possible.
1
25343
173
Dimensions (mm) of valve seats and guide

valves.
A. Inlet.
B. Depth of taper on 3 and 4–cylinder engines.
(relative to cylinder head face)
S. Exhaust.
25344
174
CRANKSHAFT FRONT OIL SEAL
Removal
DANGER
equipment. Make sure that the load is 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. Remove the exhaust pipe and open the hood.

2. Disconnect the negative battery lead.
3. Remove the left and right–hand wire mesh
guards (1) from around the fan.
TRE1319B
175
1
25124
176
1
25125
177
7. Disconnect electrical leads (1) from air filter
restriction sensor.
TRE0620A
178
179
25129
180
pipe.
TRE0620A
181

1
25131
182
hose (1). 1
TRE0619A
183
13. Unscrew the clamp and remover the pipe (1)
from the radiator cap.
1
25133
184
1
25134
185
mountings.
25135
186
25136
187
17. Loosen the belt tension adjuster bolt (1) and re-
move the belt. 1
25137
188
18. Remove the radiator fan (1).
1
25138
189
crankshaft pulley.
25139
190
20. Straighten the tab on the lock washer, hold the
crankshaft against rotation and unscrew nut (1).
25140 1
191
21. Remove the pulley hub from the crankshaft using
tool 380000226 (1) and retrieve the woodruff key.
25141
192
22. Remove the oil seal (1) from it seat.
Installation
To install the front oil seal, proceed as follows:
— Install the oil seal.
— Refit the crankshaft hub and retaining nut; bend
tab over on lock washer.
— Refit fan.
— Refit the drive belt, adjust tension and tighten
alternator bolts.
— Replace the radiator and secure with the two 25142
1
bolts.
— Refit the two rubber hoses to the coolant pump 193
and the thermostat housing.
— Reconnect the pipe to the radiator cap.
— Reconnect the hood stay bracket to the bracket
mounted on the radiator and replace the
retaining bolts.
inlet manifold. Refit the air filter restriction
sensor.
— Reconnect the negative battery lead; close the
hood.
VALVE CLEARANCE
Adjustment
1
CAUTION

2. Attach lifting chains to the hood (1) using tools
50131 and 50132 and attach the chains to the
hoist.
24872
194
3. Disconnect the electrical leads (1) from headlamps
(2).
1
2
24873
195
4. Detach the gas struts (1) from the hood.
1
TRE0603A
196
hood clear.
1
TRE0604A
197
6. Undo the hose clamp and detach the hose from
the silencer ejector. 1
7. Unscrew the two screws securing the silencer front
support.
8. Unscrew the retaining nuts securing the silencer
to the exhaust manifold and remove the silencer.
TRE0618A
198
9. Unscrew the four rocker cover nuts (1) and
remove cover.
25305
199
10. Remove the flywheel inspection window cover (1).
25190
200
11. Adjust the clearance between valves and rocker
arms using a feeler gauge, spanner (1) and
special tool 380000232 (2). 1
NOTE: Prior to adjustment, position the valves as
described on the following page. 2
25306
201
To adjust valve clearances on the 3–cylinder TD60
and TD70, proceed as follows:
valves of cylinder no.1 are balanced (start of
induction stroke). In this position the pointer will
be aligned with the reference mark PMS 1 (TDC
1) on the flywheel.
— Rotate the crankshaft through a full revolution,
returning to TDC 1, then check that the valve
clearances correspond with the values specified
Note that the TDC positions of cylinders 2 and 3
are not marked on the flywheel.
To check valve clearances on 4–cylinder models
TD80, TD90, and TD95, proceed as follows:
valves of cylinder no. 1 are balanced (start of in-
duction stroke). In this position the pointer will be
aligned with the reference mark PMS 1 (TDC 1)
on the flywheel.
— Check that the clearance between valves and
rocker arms on cylinder no. 4 corresponds with the
values specified in the table on page 5. Rotate the
crankshaft through 360 and check valve
clearances on the opposing cylinder (No. 1).
Note that the opposing cylinders are 1–4 and
2–3.
To reassemble proceed as follows:
— Refit the rocker cover.
— Refit the flywheel inspection window cover.
— Refit the exhaust silencer.
— Refit the hood.
— Reconnect the negative battery lead.
Thermostat – Replacement
The thermostat (1) fig. 12 is fitted in the cylinder head
coolant outlet union. The thermostat cannot be
adjusted and therefore must be replaced if does not
meet the temperature specifications in the table on
page 4.
COOLANT PUMP AND ALTERNATOR

DRIVE BELT
Tension Adjustment
The fan/coolant pump/alternator drive belt is

tensioned correctly when it deflects 10 to 11 mm
(.393 – .433 in.) when a force of 78 to 98 N (17.6 –
22 lbs) is applied at the mid–point of the run between
the alternator and coolant pump pulleys.
1. Check the tension using the belt tension tester

296118. Adjust tension if necessary as follows:
2. Slacken the nut (1) securing the alternator to the

tensioner bracket; 10 to 11 mm
(.393 – .433 in.)
1
3. Move the alternator to achieve correct belt

tension, then tighten nut (1).
NOTE: When fitting a new belt, check the tension

again after one hour of running.
22631
202
WATER PUMP
Removal
CAUTION
1. Remove the exhaust pipe and open the engine

hood.
3. Remove the wire mesh guards (1) from the left
and right–hand sides of the fan. 25028
203
1
25124
204
5. Remove the fan shroud (1) retaining bolts.
25143
205
6. Remove the two strips (1) from the sides of the
radiator.
1
25144
206
7. Move the fan shroud towards the engine.
8. Unscrew the three bolts securing the fan to the
water pump shaft. Remove the fan and the fan
cowling.
25145
207
25146
208
11. Remove the water pump pulley (1).
25147
209
from the water pump.
25148
210
13. Unscrew the belt tension adjustment arm retaining
nut (1) and move the alternator outward.
25149
211
14. Remove pump connection pipe (1) to gain access
to the water pump retaining bolt (2). 2
1
25150
212
15. Unscrew the four bolts (1) fig. 220 securing the
water pump to its mounting.
16. Disconnect the hose from the coolant pump to the

thermostat housing, then remove the pump (1) fig.
218.
1
25151
213
Disassembly
1 2
3
CAUTION
Use the appropriate tools for aligning the holes. NEV- 4
ER USE YOUR HANDS OR FINGERS.
5
NOTE: The bearing (9) forms a single piece with the
control shaft (10). It is a sealed unit and requires no
6
lubrication during running. 10 9 8 7
14262
Overhaul the pump as follows: 214

— Remove the cover (4) fig. 221 and the shaft
screw (2) retaining the shaft (10) and bearing (9).
— Gently tap the end of the shaft (10) fig. 221 on the
rotor side (5) to break the film of oxide between
the shaft and the rotor. Fit extractor 380000223
(1) fig. 222 and take out the rotor. 1
— Remove the front sealing bushing (7) fig. 221.
— Use a punch to extract from the pump housing
(6) fig. 221 the shaft (10) complete with bearing
(9) and the fan hub (1).
5976
NOTE: Remove the seal (8) fig. 221 only when it 215
needs to be changed.
Check components for wear, and change any that 1

are in poor condition.
Assembly
Refit the parts, proceeding in the following way:
— Fit the shaft (10) fig. 221 complete with bearing
(9) and hub (1) on the pump housing (6) and se-
cure it with the retaining screw (2), having first
21662
coated it with LOCTITE 242.
— If changing the seal (8) fig. 221, fit the seal into 216
the seat using tool 38000247 (1) fig. 223.
— Heat the rotor (1) fig. 221 in an air oven, until it 1
reach a temperature of 130–150oC higher than
the shaft (2).
— Place the rotor (1) on the shaft (2), easing it onto
the end so as not to damage the bearing, until
you obtain the operating clearance of G =
0.5–0.7 mm (.019 – .027 in.) (see fig. 221).
— Fit the seal (3) fig. 221 and the cover (4), secur-
ing it with the relevant screws.
21663
2
217
Installation
To refit the water pump proceed as follows:
— Refit the water pump. Be careful not to lose the
seals on the vertical hose connecting the pump
to the thermostat housing. 1
— Refit the connection pipe to the pump, and re-
place the two retaining bolts.
— Refit the coolant pump pulley and the fan. Refit
the fan shroud and the two vertical side strips to
the radiator. Fix the belt tension adjustment arm.
Tighten the alternator pivot bolt.
25152
— Refit the bottom radiator hose to the connection
pipe on the water pump and the radiator. 218
— Refit the right–hand wire mesh guard.
— Refit the left–hand wire mesh guard.
— Fill the cooling system from the radiator cap.
— Reconnect the negative battery lead and refit the
exhaust pipe.
COOLING SYSTEM THERMOSTAT

Removal 1
CAUTION

2. Remove exhaust pipe, attach lifting chains to the
hood (1) using tools 50131 and 50132 and attach
the chains to the hoist.
219
3. Disconnect the electrical leads (1) from headlamps (2).
1
2
24873
220
4. Detach the gas struts (1) from hood.
1
TRE0603A
221
hood clear.
1
TRE0604A
222
6. Drain the cooling system from the drain plug on
the engine block.
24804
223
7. Remove the wire mesh guard (1) from the right–
1
hand side of the radiator.
25028
224
8. Unscrew the hose clamp and disconnect the hose
(1) connecting the radiator to the thermostat 1
housing.
TRE0619A
225
9. Remove the thermostat housing cover screws
(1).
1
25156
226
10. Lever the cover (1) off the housing using a
screwdriver and remove the cover.
1
25157
227
11. Remove the thermostat valve (1).
Coolant Thermometer – Testing

If malfunction is suspected, immerse the bulb of the
thermometer in water and check the readings
against a test thermometer (repeat the test a
number of times with different water temperatures to
be sure). 1
25158
228
Installation
To refit the thermostat proceed as follows:
— Fit the thermostat in its housing and locate the
gasket. Refit the cover to the housing.
— Connect the top radiator hose to the thermostat
housing and secure with a hose clamp.
— Refit the hood stay.
— Refit the right–hand wire guard to the fan.
— Refit the hood.
— Fill the cooling system. Top up if necessary.
— Reconnect the negative battery lead. Close the
hood and refit the exhaust pipe.
RADIATOR
Removal
DANGER
equipment.
1. Remove the exhaust pipe and open the engine

hood. 1
3. Remove the left and right–hand safety guards
(1) from around the fan.
25028
229
1
25124
230
1
25125
231
7. Disconnect electrical leads (1) from air filter

restriction sensor.
TRE0620A
232
233
25129
234
recover the pipe.
TRE0620A
235

1
25131
236
hose. 1
TRE0619A
237
13. Unscrew the clamp and remover the pipe (1)
from the radiator cap.
1
25133
238
1
25134
239
mountings.
25135
Installation 240
To refit the radiator proceed as follows:
— Replace the radiator and secure with the two
bolts.
— Refit the two rubber hoses to the coolant pump
and the thermostat housing. Reconnect the
pipe to the radiator cap.
— Reconnect the hood stay bracket to the bracket
mounted on the radiator and replace the retaining
bolts.
inlet manifold. Refit the air filter clogging sensor.
— Reconnect the electrical leads to the horn, air
filter restriction sensor and the front axle earth
lead.
— Reconnect the negative battery lead; close the
hood.
Chapter 2 – Fuel Injection System
CONTENT

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10 101 60 Injector Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Checking Injector Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10 218 30 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
10 246 14 Bosch Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIFICATIONS
located in the 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 (.017 ins)
– inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.05 mm (.011 – .002 ins)
– exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 to 0.05 mm (.011 – .002 ins)
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mesh screen in fuel supply pump, and

injection pump.
Minimum fuel flow rate with pump shaft rotating at 1600 rev/min 100 litres/hour (.44 gal/min)
All–speed governor, incorporated in pump: BOSCH

centrifugal counterweights
Automatic advance regulator, incorporated in pump: BOSCH
hydraulic
For further fuel system data:
TDC) – Pressure setting – Injection order, and other type in the table on page 3
information regarding the BOSCH pump
FUEL SYSTEM DATA
Turbocharger (95 hp):
– GARRETT type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TA 3118–0.82 A/R–57
Injection pump (BOSCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . distributor type with incorporated speed

governor and automatic advance regulator
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . anti–clockwise
Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2–3 (55 hp and 60 hp)

1–3–4–2 (70 hp, 80 hp and 95 hp)
100 mm 104 mm
Injectors:
BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– Nozzle holder type . . . . . . . . . . . . . . . . . . . . . .
– Nozzle type . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number of nozzles 5 5
Diameter of nozzle orifices

260 272 bar
260–272 260 272 bar
260–272
Pressure setting (3770 – 3945 psi) (3770 – 3945 psi)
Fuel delivery lines – BOSCH pump
– type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
– Dimensions . . . . . . . . . . . . . . . . . . . . . . . . mm 6x1.5x475 6x1.5x475 6x1.75x530 6x1.75x530 6x1.75x530

TIGHTENING TORQUES
Nuts for injector mounting studs (1. fig. 11) . . . . . . . . . . . . . . . . . . . M8 25 Nm (*) 18 ft-lbs
Injection pump retaining bolts (1, fig. 24) . . . . . . . . . . . . . . . . . . . . . M8 25 Nm 18 ft-lbs

(*) Tighten the nuts in two stages – see operations described in fig. 251.
SPECIAL TOOLS
380000310 Hand pump for injector calibration

Warning – The operations described in this section test.
can only be carried out with ESSENTIAL tools indi-
cated by an (X).
To work safely and efficiently and obtain the best re-
sults, 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- Injection pump bench test
cluded in this manual.
380000228 Dial gauge 0.039/3.94 in., 0.197 in.

stroke, ∅ 1.57 in. (1/100 mm, 5 mm
List of specific tools required for the various stroke, ∅ 40 mm with 380000229).
operations described in this section.
X 380000246 Set of grinding tools for regrinding 380000229 Device for BOSCH injection pump
injector seat. timing on engine (with 380000228).
380000311 Wrench for injection pump delivery

line unions. 380000322 Puller for injection pump drive gear.
380000254 Injector cleaning kit.

INJECTOR SLEEVES
CAUTION
1. If the cylinder head face has been reground, check

that injector protrusion is within the tolerance limits
specified in chapter 1, page 11.
Checking Injector Protrusion

a. Checking injector protrusion
b. Checking valve stand–in: 0.7 to 1.0 mm (.027 –
.039 ins) (max. permissible stand–in = 1.3 mm
[0.051 ins]).
25345
Removal
241
If injector protrusion exceeds the specified limit, the
injector sleeve must be replaced using tool kit
380000246 and proceeding as follows:
13. Set distance (A) on tap (3) 292240 to 9 mm (.354

ins) by means of the ring nut (5). Fix the ring nut
in position by tightening the set screw (4). 1
14. Cut an internal thread in the sleeve to be 3

removed using tap 292240 (M12 x 11.75),
2
making sure that the thread is cut in the sleeve 4
only.
5
15. Fit tool 293784 (2) fig. 244 to the injector mounting
studs on the cylinder head by means of nuts (3)
(M8 x 1.25). 25346
242
16. Screw part (11) fig. 244 fully into the previously
cut thread and turn nut (1) to withdraw the injec-
tor sleeve (12)from the head.
17. Remove any copper residue from inside the

head using tool 292243. (4) fig. 4.
Installation
1. Fit seals (6) fig. 244 onto the new injector sleeve
and fit the sleeve into its bore, making sure that
the sleeve butts up against the bottom of the
seating in the cylinder head, and dress with
dressing tool 293861 (5).
2. Fit guide bush 293746 (10) fig.244 in the new
sleeve (12), securing it in position by turning the
ring nut (9) clockwise. Insert reamer (7) 293747
in guide bush (10) and ream the lower part of the
sleeve.
3. Remove the reamer (7) fig. 244 and back–off the
ring nut (9) by about 10 mm (.393 ins).
4. Press by hand on the ring nut (or tap gently with

a rubber mallet) to release the inside of the guide
bush 293746 (10) fig. 244 .
5. Remove the guide bush, and fit the milling cutter
293790 (8) fig. 244 in the bush. Install the bush
in the sleeve (12) and fix in position by turning the
ring nut (9) clockwise.
6. Work with the cutter to remove material until the
seating is perfectly smooth and free from all
marks.
7. This done, remove the cutter, fit the injector and
check that stand–out is as specified on page 16.
Cylinder head bolts (fig. 3)

(measured in area a shown in fig. 243) is greater than
11.5 mm (.452 ins). If not, use new bolts.
25343
243
7 8
2
5 9
1 4
3 6 10
12 11
25348
244
Disassembly, removal of residue, installation and reaming of injector sleeve
in cylinder head using tool kit 293270.
1, 2, and 11. Injector sleeve extractor 293784. 7. Reamer 293747.

3. M8 x 1.25 retaining nuts. 8. Cutter 293790.
4. Waste removal tool 292243. 9. Ring nut.
5. Injector sleeve dressing tool 293861. 10. Guide bush 293746.
6. O–ring seals. 12. Injector sleeve.
FUEL INJECTORS
1
Removal
CAUTION

2. Attach lifting chains to the hood (1) using tools
and attach the chains to the hoist.
24872
245
headlamps (2).
1
2
24873
246
4. Detach the gas struts (1) from the hood.
1
TRE0603A
247
hood clear.
1
TRE0604A
248
6. Unscrew the fuel leak–off pipe union (1) on the
injector. 1
25301
249
7. Unscrew the union (1) of the high–pressure fuel
line on the injector.
25302
1
250
8. Unscrew the two retaining nuts (1) and withdraw
the injector. 1
Installation
To refit the injector, proceed as follows:
— Insert the injector into its seat.
— Replace and tighten the two retaining nuts in two
stages. 1st stage: tighten nuts to 10 Nm
(7.3 ft-lbs)
(1 kgm) 2nd stage: tighten nuts to 25 Nm
(18 ft-lbs) (2.6 kgm).
— Reconnect the fuel leak–off pipe union. 25303
— Reconnect the high–pressure fuel line union. 251

— Replace the hood.
Removal
CAUTION
CAUTION
1. Remove the exhaust pipe and open the hood.

25621
252
3. Unscrew the three retaining bolts, and remove the
wire mesh guard (1) from the right–hand side of the
fan.
1
25182
253
25183
254
5. Unscrew the hose clamp (1) and disconnect the
flexible pipe (2) connected to the thermostart. 1
2
25184
255
6. Disconnect the electrical lead (1) from the engine
stop solenoid.
1
25185
256
7. Unscrew union (1) on the fuel supply pump and 1
union (2) on the injection pump.
25186
257
8. Unscrew the unions on the fuel filter and recover
the fuel lines (1) and (2).
1
2
25187
258
9. Unscrew the unions (1) of the high–pressure fuel
1
lines from the injection pump to the injectors and
remove the fuel lines.
25188
259
10. Unscrew the retaining bolts (1) of the injection
pump gear cover (2). 1
25189
260
11. Remove the cover from the flywheel ring gear
inspection window (1).
25190
261
12. Rotate the flywheel, using a screwdriver as a
lever, until the two 4 reference marks stamped
on the gears (1) and (2) coincide.
1
25191
262
drive gear to the pump shaft.
25192
263
25193
264
15. Withdraw the injection pump drive gear (1) using
puller 295942 (2).
1
2
25194
265
16. Lift off the injection pump (1).
1
NOTE: On engine model TD70, the fuel filter must be
removed prior to removing the injection pump.
25195
266
17. Recover gasket (1), spacer (2) and gasket (3).
2
3
1
22650
267
Installation
To refit the injection pump, proceed as follows:
— Refit the drive gear and the injection pump, fitting
the gear in its tapered housing and securing with
the nut. Secure the pump with the three retaining
nuts.
— Refit the gear cover.
— Refit the two semi–rigid pipes connecting the
injection pump to the filter and the fuel supply
pump to the filter. This job is made easier if you
tighten the unions on the filter first.
— Reconnect the engine stop solenoid lead.
Reconnect the high–pressure fuel lines to the
injection pump and the injectors.
— Refit the throttle control lever spring on the
injection pump. Reconnect all the flexible hoses
previously removed.
— Replace the flywheel inspection window cover.
— Refit the wire meshguard to the right–hand side
of the fan.
— Refit the power steering control valve delivery
pipe to the anti–cavitation accumulator.
— Reconnect the negative battery lead. Close the
hood and refit the exhaust pipe.
Timing
If the engine does not run evenly, if the timing marks
(1) are not visible, or should you be in doubt as to
whether the marks are correct, time the injection 1
pump as follows:
2
25181
268
1. Unscrew the unions of the high–pressure fuel
lines connecting the pump to the injectors and 1
remove the fuel lines.
25188
269
2. Remove the injection pump gear cover.
3. Check that 4 timing marks on gears (1) and (2)
are aligned. 1
25191
270
4. Remove the flywheel inspection window cover (1).
5. Turn the crankshaft to bring cylinder no. 1 to TDC
of the compression stroke. 1
25190
271
6. Check through the inspection window that the
pointer is aligned with the BOSCH reference
mark.
26107
272
7. With the injection pump in position but with the
mounting bolts loose, remove the plug (1) fig.
273 on the pump housing.
8. Fit dial gauge 380000230 (1) fig. 274 and related 1
tool 380000229 (2) and pre–load the shaft by
about 2.5 mm (0.098 ins).
9. Turn the flywheel slowly backwards so as to
bring the plunger to BDC at the start of the
delivery stroke (the point at which the dial gauge
needle stops falling).
25196
273
10. Set the dial gauge to zero and slowly turn the
flywheel clockwise (as viewed from the fan end
of the engine) until the pointer lines up with the
BOSCH reference mark.
11. Check on the dial gauge that the plunger has
completed a stroke of 1 mm (0.039 ins) up to this
point. If not, slacken off the pump mounting bolts.
12. Turn the pump anti–clockwise if the plunger
stroke is less than 1 mm (0.039 ins) and clock-
wise if the stroke is greater than 1 mm (0.039 1 2
ins), and repeat test until the correct stroke is ob-
tained.
25197
13. Having obtained the correct plunger stroke, fix the
pump in position by tightening the securing nuts (1) 274
(fig. 264)
14. Stamp pump timing marks (1) fig. 27 on the
pump mounting flange, distance piece and
casing.
15. Remove the dial gauge 380000230 (1) fig. 274
and the related tool 380000229 (2). Replace the
plug and tighten to a torque of 8 to 10 Nm (6 to
7.3 ft-lbs).
16. Refit other parts in the reverse of the dismantling
order.
Air Bleeding
1. Unscrew the plug (1) on the first filter.
1
25198
275
2. Operate the priming lever (1) fig. 276 on the fuel
supply pump until the fuel coming out of the filter
orifice is free of bubbles, then replace and tighten
plug (1) fig. 275.
25199
276
3. Slacken the fuel line unions (1) on the injectors,
start the engine and then re–tighten the union (1)
when the fuel flows out free of bubbles.
25200
277
SECTION 18 – CLUTCH – CHAPTER 1 1
SECTION 18 – CLUTCH
Chapter 1 – Clutch
CONTENTS
18 000 General Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6
Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
18 110 10 Removal – Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–15
18 110 30 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16–19
Checks, measurements and repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–21
18 100 40 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–23
GENERAL CHARACTERISTICS 11”/11” CLUTCH
( TD60,TD70, TD80 and TD90 Models )
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual clutch consisting of two

single dry plate clutches
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical : pedal operated
main clutch; hand lever operated
PTO clutch
Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . . single Belleville spring disc
Driven plate lining material for main clutch (11”) . . . . . . . . . . . . . . .
TD60 and TD70 Models ....................... Organic agglomerate

TD80 and TD90 Models ....................... cerametallic
Driven plate lining material for PTO clutch (11”)
TD60, TD70, TD80 and TD90 Models . . . . . . . . . . . . . . . . . . Organic agglomerate
Driven plate thickness:
. main clutch (9, fig. 1)

. VALEO
. Organic agglomerate and cerametallic . . . . . . . . . . . . . . . . . mm 10.2 to 10.8
. LUK
. Organic agglomerate and cerametallic . . . . . . . . . . . . . . . . . mm 10.2 to 10.8
. PTO clutch (11, fig. 1)

. VALEO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 7.3 to 7.9
. LUK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 7.3 to 7.9
. wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ” see pages 18 and 19
Clearance between main clutch release sleeve and housing . . . mm 0 050 to 0

0.050 0.151
151
Clearance between PTO clutch release sleeve and housing . . . mm 0.050 to 0.151
Release lever coplanarity adjustment . . . . . . . . . . . . . . . . . . . . . . . see page 22
Clutch control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 23
603.54.411.00–07–2002
2 SECTION 18 – CLUTCH – CHAPTER 1
GENERAL CHARACTERISTICS 12” CLUTCH
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual clutch consisting of two

single dry plate clutches
Operating system
– Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical: Pedal operated
– PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical: Manual Lever
Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . . Single Belleville spring disc
Driven plate lining material for main clutch (12”)

TD95 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cerametallic pads
Driven plate lining material for PTO clutch (12”)
TD95 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Organic agglomerate
Driven plate thickness for main clutch (2, fig. 9)

VALEO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 10.2 to 10.8
LUK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 10.2 to 10.8
Driven plate thickness for PTO clutch (2, fig. 11)
VALEO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 7.9 to 8.5
LUK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 7.9 to 8.5
. wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ” see page 18–19
Clearance between clutch release sliding sleeve and support . . mm 0.050 to 0.151
Clearance between PTO clutch release sleeve and support mm 0.060 to 0.180
Release lever coplanarity adjustment . . . . . . . . . . . . . . . . . . . . . . . mm see page 20
Clutch controls adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm see page 21
TIGHTENING TORQUE
Tightening torque
PART Thread
Nm kgm
11”/11” clutch/flywheel retaining bolts(1, fig. 46) . . . . . . . . . . . . . . . M 8 x 1.25 25 2.6
Release command fork securing bolt (7, fig. 1) . . . . . . . . . . . . . . . M 16 x 1.5 157 16
12”/12” clutch/flywheel retaining bolts (1, fig. 46) . . . . . . . . . . . . . . M 10 x 1.25 59 6
Clutch housing/engine retaining nuts (3, fig. 1) . . . . . . . . . . . . . . . M 12 x 1.25 98 10
Nut for sleeve cover fixing stud (6, fig. 1) . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 17 1.7
603.54.411.00–07–2002
TOOLS
List of specific tools required for the various
operations described in this section.
292320 Tractor dismantling stand.
291184 Dowel for centering and adjust-
ment of 11”/11
295022 Dowel for centering and adjust-
ment of, 12”, 12”/12” clutches.
295023 Clutch adjustment gauge (with
295022)
293763 Set of wrenches for adjustment of
levers in 11”/11” , VALEO
clutches.
2294078 Locating dowel for assembly of
clutch housing on engine.
Longitudinal section of clutch VALEO 11”/11”
–C2–Clutch housing capscrews
–C3. Fork Iever capscrews

–C4. Sleeve cover retaining nuts
–D = 97.5 to 98.5 mm
Nominal distance of transmission clutch Ievers from
flywheel face
–D1 = 122.5 to 123.5 mm . Nominal distance of
P.T.O. clutch release Ievers (2) from flywheel face
–L1 = 2,5 mm . Nominal P.T.O. clutch release Ievers
clearance
–L2= 2 mm . Nominal transmission clutch release
Iever clearance

Iever clearance
–1. PTO clutch dishspring

–2. . PTO clutch release Ievers
–3. Transmission clutch release Ievers

–4and 5 Release control sleeves with thrust
bearings TRE0409A
–6 and 7. PTO clutch release Iever Iocknut and 1

adjusting Iink
–8. PTO clutch plate
–9. Transmission clutch plate

–10. Flywheel bearing
–11 and 12. Sleeve control forks

–13.Main clutch release lever adjuster.
–14 and 15. Trans–mission clutch release Iever

adjusting screw and Iocknut –
603.54.411.00–07–2002
Longitudinal section of clutch VALEO 12”/12”

–C2–Clutch housing capscrews
–C3. Fork Iever capscrews

–C4. Sleeve cover retaining nuts
–D = 97.5 to 98.5 mm
Nominal distance of transmission clutch Ievers from
flywheel face
–D1 = 122.5 to 123.5 mm . Nominal distance of
P.T.O. clutch release Ievers (2) from flywheel face
–L1 = 2,5 mm . Nominal P.T.O. clutch release Ievers
clearance
Iever clearance
–1. PTO clutch dishspring

–2. . PTO clutch release Ievers
–3. Transmission clutch release Ievers

–4and 5 Release control sleeves with thrust
bearings
–6 and 7. PTO clutch release Iever Iocknut and
adjusting Iink
–8. PTO clutch plate

–9. Transmission clutch plate
TRE0409A
–10. Flywheel bearing
–11 and 12. Sleeve control forks 2
–13.Main clutch release lever adjuster.
–14 and 15. Trans–mission clutch release Iever
adjusting screw and Iocknut –
603.54.411.00–07–2002
Longitudinal section of the

LUK 11”/11” clutch D1
1 2 D 3 4 5
1. PTO clutch release lever adjuster.
2. Belleville spring disc.
3. Clutch housing/engine securing nuts and bolts.
4. PTO clutch release levers.
5. Main and PTO clutch release sleeves, complete
with thrust bearings.
6. Nuts for sleeve cover studs.
7. Fork lever securing bolts.
8. Main clutch release levers.
9. Main friction disc.
10. Main clutch release lever adjuster.
11. PTO friction disc. 12
12. Bearing on flywheel.
D = 98 mm. Nominal distance of release levers (8)
from clutch contact surface on flywheel.
D1 = 123 mm. Nominal distance of release levers (4)
25371 11 10 9 8 7 6
3
603.54.411.00–07–2002
Longitudinal section of the

LUK 12”/12” clutch D1
1 2 D 3 4 5
1. PTO clutch release lever adjuster.
2. Belleville spring disc.
3. Clutch housing/engine securing nuts and bolts.
4. PTO clutch release levers.
5. Main and PTO clutch release sleeves, complete
with thrust bearings.
6. Nuts for sleeve cover studs.
7. Fork lever securing bolts.
8. Main clutch release levers.
9. Main friction disc.
10. Main clutch release lever adjuster.
11. PTO friction disc. 12
12. Bearing on flywheel.
D = 103 mm. Nominal distance of release levers (8)
D1 = 137 mm. Nominal distance of release levers (4)
25371 11 10 9 8 7 6
4
Warning – On refitting the clutch, check that the fric-

tion discs are oriented as shown in the figure.
603.54.411.00–07–2002
CLUTCH TROUBLESHOOTING
Problems Possible causes Remedies
Clutch slips 4. Worn friction discs (8 and 9, Check and compare the data given in
page 3–4), woflywheel pres- the pages indicated; replace any
sure plates, and flywheel parts which are worn up to or over the
worn. limit and adjust levers and clutch con-
trol linkage.
5. Belleville spring disc (1, page Replace the Belleville spring disc.
3–4) distorted or otherwise da-
maged.
6. Friction linings of discs (8 and Replace friction discs; identify and
9, page 3– 4) disc contami- eliminate the source of lubricant in-
nated with oil and grease. side the clutch housing and thorough-
ly clean the friction surfaces.
Fierce clutch 1. Partial seizure of the external Check linkage pivots and lubricate.
control linkage.
2. Friction disc (9, page 3–4) dis- Replace disc and adjust clutch control
torted. lever.
3. Friction disc (9, page 3–4) with Replace friction disc.
damaged hub springs or loose
hub rivets.
4. Oil or grease contaminating Replace the discs, identify and elimi-
the friction lining of discs nate the source of lubricant inside the
(8 and 9, page 3–4) clutch housing and thoroughly clean
the friction surfaces.
Clutch sticks and drags 1. Clutch disc friction linings (8 Replace discs and adjust the disks.
and 9, page 3–4) or disc de-
formed.
2. Seizure of external control lin- Check, replace faulty parts and lubri-
kage. cate.
3. Controls badly adjusted. Adjust controls (see page 21).
Clutch noisy when engaged 1. Worn thrust bearing. Replace bearing.

and/or disengaged
2. Friction disc (9, page 3–4) with Replace the friction disc.
hub springs damaged.
Clutch pedal too stiff 1. Partial seizure of external con- Check linkage pivots and lubricate.
trol linkages.
2. Partial seizure of pedal pivot. Check pivot and lubricate.
603.54.411.00–07–2002
CLUTCH
Removal–Refitting (Op. 18 110 10)
To access the clutch it is necessary to separate the
engine complete with the front axle from the trans-
mission.
DANGER
equipment.
make sure that the load is held and supported by suit-
able slings and hooks. Make sure that no–one is
standing in the vicinity of the load.
WARNING
Use suitable tools to align holes. NEVER USE FIN-
GERS OR HANDS.
Proceed as follows:
2. Drain off the oil from the gearbox/transmission 1
casing.
25621
3. Drain off the coolant from the engine cooling sys-

tem.
4. Disconnect two flexible houses from the power
steering control cylinder and drain off the oil from 1
the steering system
5. Remove the front end weights
TRE0159A
603.54.411.00–07–2002
6. To access the engine the hood must be

opened.
TRE0159A
7
7. Remove the electrical connections (1)
TRE185A
8
8. Disconnect the oil pipes (1) to the hydrostatic
steering control valve unit.
1
TRE0028A
9. Disconnect the multimeter cable (1) from the en-

gine and undo the mounting retaining bolt (2). 1 2
TRE0410A
30
603.54.411.00–07–2002

TRE0411A
11
25183
11. Undo the hose clamp (1) from around the rigid
pump and lift delivery pipes. 1
25029
14
12. Disconnect the rubber connecting hose (1) of the

hydraulic pump .
TRE0184A
15
603.54.411.00–07–2002
13. Disconnect the lift pump delivery line (1).
TRE0183A
16
14. Disconnect the fuel line (1) from the glow plug.
1
TRE0183A
17
15. Remove the front, centre and rear screws secur-
ing the front axle prop shaft guard and remove 1
the guard (1).
25038
18
16. Remove circlip (2) and move sleeve (1) in the di-
rection shown by the arrow to disengage it from 1 2
the splined shaft of the front axle.
25039
19
603.54.411.00–07–2002
17. Remove circlip (2) and move sleeve (1) in the di-
rection shown by the arrow to disengage it from 1 2
the splined shaft of the drive.
25040
20
18. Remove the retaining bolts of the central support

(1) of the prop shaft and recover the shaft com- 1
plete with support.
25041
21
19. Remove the four lower engine to transmission

mounting bolts (1).
TRE3048A
24
603.54.411.00–07–2002
20. Position two wedges (3) on the front axle to pre-

vent any movement of the engine about the axle 3
pivot. Position the tractor dismantling stand
292320, so that the fixed support (1) is under the
rear transmission housing in the area of the en-
gine coupling flange and the mobile support (2)
under the engine in the area of the flange at-
tached to the transmission housing, as shown in
fig. 41.
2 1
25050
25
21. Position another mobile stand 292320 under the
front ballast carrier to prevent any possibility of 1
the engine turning or tipping forwards when the
transmission housing is removed.
22. Interpose wooden blocks (1) between the stands

and the tractor, and turn the stand height adjust-
ment screws to bring the blocks (1) into contact
with the tractor.
25051
26
23. Position a fixed stand (1) under the draw bar sup-
port and pull on the hand brake. 1
25052
27
24. Remove the distance collar (1) between the en-
gine and the transmission. ( TD95 Model ) 1
25055
28
603.54.411.00–07–2002
25. Using tool 295022 (1) ,unscrew the retaining

bolts and remove the clutch 1
25055
29
603.54.411.00–07–2002
To refit the engine, proceed as follows:
Check condition of ball bearings pressed in flywheel; Remove the stands of tool 292320 from under the
replace in the event of excessive noise or binding. engine and the gearbox/transmission and the stand
To install a new bearing,pack lubricate with grease under the draw bar.
Position the clutch using tool 295022 (TD95 mod. ) Connect the flexible power steering pipes of the
Fix the clutch to the flywheel with the six bolts. front axle and add oil to the system.
Connect the flexible pipe to the injector fuel leak–off

Adjust the coplanarity of the clutch release levers as pipe
described on page 20.
Refit the multimeter and secure the sleeve with the
Clean the distance collar and the mating surfaces of relative clamp.
the clutch housing, and also scrape all residue of old
sealing compound from the mating surface of the en- Connect all the electrical connections
gine.
Connect the throttle cable to the injection pump.

Spread LOCTITE sealing compound on the mating
surfaces of the engine and distance collar.Fit the dis-
Refit the 4WD transmission shaft and the relative
tance collar on the studs screwed into the engine.
guard.
Before Connecting tranmission casing to engine – Refit the front ballast and secure with the vertical
front axle assembly, grease discs hubs. lock pin.
Chock up the rear wheels with wooden wedges, Fiil oil to gearbox/transmission.
check that the hand brake is fully on and that the
fixed and mobile stands are well positioned.
Fill the coolant to engine cooling system.
Fit and tighten the bolts securing the clutch housing Connect the negative battery lead
to the engine.
Make sure that no electrical leads or cables are

trapped between the two units.
Next rotate the crankshaft by turning the cooling fan,

so as to allow the sleeve to engage the splines on the
power take–off shaft.
603.54.411.00–07–2002
11” and 12” DUAL CLUTCH

Bench overhaul (Op. 18 110 30) 1
1. Unscrew the three PTO clutch lever adjustment

nuts (1).
24791
30
2. Recover the pressure plate (1) with the three coil
springs (2) and the three washers. 1
24792
31
3. Position three clamps (1) at intervals of 120° on
the clutch body and evenly and progressively
compress the Belleville spring disc.
1
24793
32
4. Remove the spring retaining clips (1) from their
seatings. 1
24794
33
603.54.411.00–07–2002
5. Remove the three clamps and recover the Belle-

ville spring disc (1). 1
24975
34
6. Slacken off the three locknuts (1) of the main
clutch lever adjustment screws. 1
24976
35
7. Unscrew the three main clutch lever adjustment
screws (1). 1
24977
36
8. Recover the main clutch pressure plate (1).
1
24978
37
603.54.411.00–07–2002
9. Recover the main clutch friction disc (1).

1
24979
38
10. Remove the springs (1) of the PTO clutch control
levers. 1
24980
39
11. Withdraw the pivot pins (1) of the PTO clutch
control levers. 1
24981
40
12. Remove the springs (1) of the main clutch control
levers. 1
24982
41
603.54.411.00–07–2002
13. Withdraw the pivot pins (1) of the main clutch

control levers. 1
24983
42
For assembly, proceed as follows:
Refit the lever pivot pins and the relative springs.
Refit the main clutch disc in the clutch housing.
Install the main clutch pressure plate, fixing it to

the pins with the bolts.
Install the Belleville spring disc, carefully position

the three clamps and evenly and progressively
compress the spring.; insert the six clips, making
sure they are firmly inserted in their respective
seatings, then remove the clamps..
Install the PTO clutch friction disc; fit the three

washers and the coil springs on the pins and se-
cure with the three nuts.
603.54.411.00–07–2002
CHECKS, MEASUREMENTS AND REPAIRS

– DUAL CLUTCH–
WARNING
Handle all parts with great care.
Never put your hands or fingers between one part
and another. Wear suitable safety clothing, i.e. safety
Dimensions of components of the 11”/11”

VALEO dual clutch
A w 12.5 mm; B w 17 mm; C w 87mm; D w 69mm

1 2 3 4
0,5
LUK dual clutch
A w 18 mm; B w 24.2 mm; C w 88.2 mm;
D w 71.2 mm
1. Flywheel
2. PTO clutch pressure plate. D
3. Main clutch pressure plate. A B C
25365
4. Clutch cover.
Dimensions of components of the 12”/12” 43
VALEO dual clutch
A w 14mm; B w 16.8 mm ; C w 87 mm; D w 69 mm

1 2 3 4
0,5

LUK dual clutch
A w 18.7mm; B w 24.6 mm ; C w 94.3 mm;

D w 71.3 mm
1 Flywheel.
D
2. PTO clutch pressure plate. A B C
3. Main clutch pressure plate.
26164
4. Clutch cover.
44
Check the degree , (fig. 1 and 3) and main clutch fric-
tion disc and replace them if the linings have worn
down – or nearly down – to the rivet heads.
Replace the disc when oil has soaked into the friction
linings.
Minimum permissible dimensions after refacing

of parts subject to wear in the 11”/11” and
12”/12” dual clutches.
Check conditions of friction surface of the pressure

plates and the clutch cover.
In general it is permissible to remove, by turning, up
to 1 mm of material from the cast iron friction sur-
faces of the clutch cover (4) and the pressure plates
(3 and 2) and the flywheel (1).
603.54.411.00–07–2002
When parts (1), (2), (3) and (4) ( figs. 43 and 44) are
to be repaired by removing material, proceed as fol-
lows:
A
If it is necessary to reface the friction surfaces on the B

flywheel (1, figs. 43 and 44), bear in mind that the
maximum permissible depth of refacing relative to
the nominal thickness * (see fig. 45 ) is 1 mm.
C
For flywheels with 11”/11” and 12”/12” (see fig. 45)
dual clutches, after refacing, it will also be necessary
to restore the external recess of 0.5 mm as shown in
the figure.
26166
11’’ flywheel
flywheel 45
Valeo
A = 340 mm B = 290 mm C = 78.5 mm
Luk
A = 327 mm B = 285 mm C = 78.5 mm
12’’ flywheel
Valeo
A =360 mm B = 321 mm C = 73.5 mm
Luk
A = 352 mm B = 313 mm C = 73.5 mm
When the friction surfaces of the main clutch pres-

sure plate (3, fig. 43 and 44) or the clutch cover (4)
are to be refaced, remember that any removal of ma-
terial cannot be compensated for by turning the fly-
wheel contact side of the clutch cover (4).
For this reason only the minimum possible amount

of material should be removed from parts 3 and 4 in
order to prolong the working life of the clutch.
Note – When, after parts (3 and 4 fig. 43 and 44)

have been refaced a number of times, the main
clutch friction disc starts to slip, the entire clutch as-
sembly should be replaced.
Refit the clutch assembly as shown on page 17.
603.54.411.00–07–2002
COPLANARITY ADJUSTMENT OF DUAL

CLUTCH RELEASE LEVERS 1 2 3
1. After overhauling the clutch, fit the centering

dowel 295022 (3), fit the clutch complete with
PTO disc to the engine flywheel and tighten the
bolts (1) to the torque specified on page 3. Fit the
gauge 295023 (2) and, using a feeler gauge, ad-
just the main clutch release levers (4) to obtain
a clearance of 0.1 mm on all levers.
4
25366
46
2. Rotate the gauge 295023 (2) and, with the aid of

a feeler gauge, adjust the PTO clutch release 1 2
levers (1) to obtain a clearance of 0.1 mm on all
levers. Remove tools n. 295023 and295022.
Note – For TD60, TD70, TD80 and TD90 model trac-

tors,do the same adjustments explained above,with
using special toll 291184. 25367
295022 and 295023 are just used for TD95 model. 47
603.54.411.00–07–2002
ADJUSTMENT OF THE MAIN CLUTCH CON-

TROL LINKAGE (Op. 18.100.40)
Check that pedal free travel before clutch release is
approximately 40 mm . When free travel is down to
25 mm , adjust clutch as follows:
TRE3101A
48
– Back off locknut (1) and rotate sleeve (2) counter-

clockwise ( each sleeve turn is equivalent to 12 mm
in pedal displacement ).
– Tighten locknut (1) ;

1
– Ensure that pedal free travel is 25 mm
2
TRE0044A
49
PTO CLUTCH LINKAGE ADJUSTMENT

A
The only clutch adjustment required is to check and,
if necessary, adjust the clutch pedal free travel. This
is the amount of pedal movement from fully released
position (B) to the point where resistance is first en-
countered.
The clutch free travel (C) should be 2.5–4.5 mm.
When free travel is down to 2.5 mm. adjust it as
follows: B
–Move the PTO clutch lever (A) to position (B) (fully
lowered). TRE0171A
50
–Loosen the locknut, (1) and remove the split pin (2).
–Turn the sleeve (3) to lenghten or shorten the oper-
ating rod, as required. 1
–Secure the split pin (2), and tighten the locknut (1).
2
3
C
TRE0173A
51
603.54.411.00–07–2002
603.54.411.00–07–2002
SECTION 21 – TRANSMISSIONS – CHAPTER 1 1
SECTION 21 – TRANSMISSIONS
Chapter 1 – Mechanical Transmission (12 x 4)
CONTENTS
21 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
21 110 Removal – Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see sect 27
21 000 – MAIN DATA – TIGHTENING TORQUES – SECTIONS – TOOL – DESCRIPTION AND

OPERATION – FAULT DIAGNOSIS
MAIN DATA – GEARBOX AND RANGE GEAR
TRANSMISSION AND RANGE GEAR MAIN DATA
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–speed, constant–mesh with

synchronisers on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helical gears
Range gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordinary gear train with 3 forward

ranges and 1 reverse range those
giving a total of 12 forward and 4
reverse speeds
– Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . spur gears
– Reduction ratios :
D Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23x17
= 1:(5.49)
43x50
D Normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23x27
= 1:(2.35)
43x34
D Fast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Gearbox and range gear controls . . . . . . . . . . . . . . . . . . . . . . . . . Independent, hand operated lev-

ers located on
right–hand side of operator
Thickness of gearbox driving shaft adjustment ring (5, page 5) . mm 3.00–3.25–3.50–3.75–4.00
Inside diameter of gearbox driven gears . . . . . . . . . . . . . . . . . . . . mm 50.050 – 50.075
Outside diameter of bushings (17) . . . . . . . . . . . . . . . . . . . . . . . . . . mm 49.925 – 49.950
Clearance between gears and bushings . . . . . . . . . . . . . . . . . . . . . mm 0.100 – 0.150
Diameter of gearbox driven shaft (19) . . . . . . . . . . . . . . . . . . . . . . . mm 39.175 – 39.191
Inside diameter of bushings (17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 39.200 – 39.239
Clearance between shaft and bushings . . . . . . . . . . . . . . . . . . . . . mm 0.009 – 0.064

(continued overleaf)
???.??.???.?? – ?? – ????
2 SECTION 21 – TRANSMISSIONS – CHAPTER 1
TRANSMISSION AND RANGE GEAR MAIN DATA

(continued)
Diameter of power take off (PTO) clutch shaft (4, page. 5) . . . . . mm 24.979 – 25.000
Inside diameter of fitted bushing (1) . . . . . . . . . . . . . . . . . . . . . . . . . mm 25.040 – 25.092 (1)
Clearance between PTO clutch shaft and relative bushing . . . . . mm 0.040 – 0.113
Interference fit between bushing on driving shaft . . . . . . . . . . . . . . mm 0.037 – 0.091
Springs (16, page 7) for detent balls on gearbox and range gear
control rods :
– Spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 30
– Length of spring under load of 50–56 N (5.13–5.67 kg) . . . . . . mm 25.5
Gearbox and range gear control lever retaining springs :
– Spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 75
– Length of spring under load of 94–104 N (9.6–10.6 kg) . . . . . . mm 42
(1) Measurement to obtain after fitting without reaming.
TORQUE VALUES
Torque settings
PARTS Thread
Nm kgm
Retaining bolts for upper cover of rear transmission / gearbox

(C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 59 6
Bolts for securing lift to rear transmission box (C2) . . . . . . . . . . . . M 12 x 1.25 98 10
Bolts for securing PTO box to transmission / gearbox (C3) . . . . . M 16 x 1.5 221 22.5
Bolts for securing flexion bar to transmission / gearbox case (C4) M 16 x 1.5 221 22.5
Nuts for stud bolt securing final drive to transmission / gearbox

(C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 10
Nuts for securing steel plate disc to wheel drive hub (C6) . . . . . . M 18 x 1.5 255 26
Nuts for bolts securing steel plate disc to drive wheel rim (C7) . . M 16 x 1.5 245 25
Ring bevel gear retaining bolts (C8) ........................ M 12 x 1.25 123 12.5
Bevel gear pair support retaining bolts (C9) . . . . . . . . . . . . . . . . . . M 10 x 1.25 59 6
???.??.???.?? – ?? – ????
C1 59 Nm C2 98 Nm
C4 221 Nm C3 221 Nm
C9 59 Nm
C7 245 Nm
C6 255Nm
C8 123 Nm
C5 98 Nm
TRE0550A
TOOLS List of special tools required for the various opera-

tions described in this Section :
Warning – The operations described in this Section 292320 Tractor dismantling trolley.
can only be carried out using the ESSENTIAL tools
marked on the right side with an (X). 291517 Clutch casing lifting hook.
However, for greater safety and to obtain the best re- 290090 Rotating overhaul stand.
sults while saving time and effort, it is recommended
that these essential tools are used together with the 293971 Front bracket (with 290090).
special tools listed here as well as certain tools which 293972 Rear bracket (with 290090).
are to be made following the sectional drawings giv-
en in this manual. X 293940 Adaptor for removal of reverse gear
pin (with 292927).
???.??.???.?? – ?? – ????
Drift to be made for removal of gearbox driving shaft

(tool to be stamped no. 50006 – measurement in
mm).
Make in material UNI C40.
26215
Tool to be made for adjustment of gearbox driving

shaft bearings (tool be stamped no. 50007 – mea-
surement in mm).
Make in material Aq 45.
26216
26217
4
Tool to be made for removal of rear bearing of range gear driving shaft and the driving gear for the slow
speeds (tool to be stamped no. 50028 – Measurements in mm).
Make in UNI C40.
Note – Make two parts from the tool shown at Figure 4, uppermost one .
???.??.???.?? – ?? – ????
5
Longitudinal cutaway section through gearbox and range gear.
1. Power take–off (PTO) shaft support bushing. 11. Retaining half–rings.
2. Seal. 12. Driven gear for reverse speeds.
3. Gearbox driving shaft. 13. Driven gear for low speeds.
4. PTO shaft. 14. Selector sleeve for high and low speeds.
5. Driving shaft adjustment ring. 15. Circlip.
6. Range gear driving shaft. 16. Synchroniser for 1st and 2nd speeds.
7. Control gear for reverse and middle speeds. 17. Support bushings for gearbox driven gears.
8. Upper cover. 18. Synchroniser for 3rd and 4th speeds.
9. Driving gear for middle speeds. 19. Gearbox driven shaft.
10. Bevel pinion shaft.
Note – On assembly apply sealant to surfaces X following the indications given on page 6 in this Section.
???.??.???.?? – ?? – ????
TRE0556A
Sealing compound application diagram for mating surfaces between engine, clutch casing and rear
transmission–gearbox.
The types of sealing compound to use are indicated on page 1, Sect. 00.
???.??.???.?? – ?? – ????
TRE0557A
Cross–section through gearbox and range gear
1. Range gear control relay rod. 14. Circlip.

2. Gearbox control relay rod. 15. Upper cover of transmission / gearbox.
3. Low and high speeds selector rod. 16. Spring.
4. Normal and reverse speeds selector rod. 17. Detent ball.
5. 3rd and 4th speed selector rod. 18. Speed control safety pawl.
6. 1st and 2nd speed selector rod. 19. Plug.
7. Range gear driving shaft. 20. Speed control safety pawl.
8. Intermediate gear for reverse speeds. 21. Range control safety pawl.
9. Control gear for normal and reverse speeds. 22. Plug.
10. Driving gear for normal speeds. 23. Selector rod for low and high speeds.
11. Journal of intermediate gear (8). 24. Selector rod for middle and reverse speeds.
12. Journal bolt (11). 25. 3rd and 4th speed selector rod.
13. Bearings. 26. 1st and 2nd speed selector rod.
Note –Before plugs (19 and 22) are bolted in, they must be covered with one of the sealants listed on page 1,
Sect. 00.
???.??.???.?? – ?? – ????
DESCRIPTION AND OPERATION
4–speed gearbox with constant–mesh helical gears The range gear provides 3 forward ranges and 1 re-
controlled by two synchronisers. verse range.
The range gear has cascade–type constant–mesh The gearbox and the range gears are controlled by
spur gears, excluding reverse. two independent levers located on the right–hand
The driven gears of the range gear are keyed directly side of the operator.
onto the bevel pinion shaft.
GEARBOX AND RANGE GEAR TROUBLESHOOTING
Spontaneous disengagement of 3. Levers and relay linkages in- Adjust correctly.

gearbox and range gear. correctly adjusted.
4. Selector rod retaining springs Replace the springs.

defective.
5. Defective teeth on synchro- Remove the transmission/gearbox

niser or engagement sleeve. and replace the synchronisers or the
engagement sleeves.
6. Incomplete engagement trav- Eliminate the cause and restore full

el. engagement travel.
Difficulty in engaging the gearbox 1. Control levers and linkages in- Adjust correctly.
and range gear. correctly adjusted.
2. Stiffness and / or partial sei- Check pivot points and lubricate.

zure of control levers and link-
ages.
3. Main clutch drag. See page 10, Sect. 6001.
4. Synchronisers or engage- Remove the transmission / gearbox

ment sleeves defective. and replace the synchronisers or en-
gagement sleeves.
5. Internal controls do not slide Perform the checks and overhaul for
freely : rods, forks and needed parts.
sleeves.
Gearbox or range gear unduly 1. Internal component/s worn or Remove the transmission / gearbox
noisy. defective. and replace the worn / defective
parts.
???.??.???.?? – ?? – ????
SECTION 21 – TRANSMISSIONS
Chapter 2 – Reverser
CONTENTS
21 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
21 110 Removal–Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
21 000 – MAIN DATA – TIGHTENING TORQUES – SECTIONS – TOOLS – DESCRIPTION AND

OPERATION – FAULT DIAGNOSIS
SYNCHRONISER REVERSER MAIN DATA
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical type spur gear unit,

located between the main clutch
and the gearbox. Comprises 1
driving gear, 1 intermediate gear
and
1 idle gear.
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand lever located on left–hand

side of the operator
GEARBOX MAIN DATA
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 speed, constant–mesh, with

synchronisers on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helical
Reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordinary gear train with 3 ranges

providing a total of 12 gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . spur
Gearbox and reduction unit controls . . . . . . . . . . . . . . . . . . . . . . . . Independent, with two hand levers
located on right–hand side of the
operator
For other main data see chapter 1.
???.??.???.?? – ?? – ????
TORQUE VALUES
Torque Settings
PARTS Thread
Nm kgm
Bolt or nut securing clutch / reverser casing to engine (C1) . . . . . M 12 x 1.25 98 10
Sleeve cover retaining nuts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 17 1.7
Reverser driven shaft cover retaining bolts (C3) . . . . . . . . . . . . . . . M 8 x 1.25 28 2.9
Reverser driven shaft plate retaining bolts (C4) . . . . . . . . . . . . . . . M 10 x 1.25 64 6.5
Bolts securing clutch / reverser housing to gearbox / rear tran-

smission (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 10
C1 98 Nm
C2 17 Nm
C3 28 Nm
C4 6 Nm
C5 98 Nm
TRE0558A
???.??.???.?? – ?? – ????

tions described in this Section :
Warning – The operations described in this Section
can only be carried out using the ESSENTIAL tools 292320 Tractor dismantling trolley.
marked with an (X).
However, for greater safety and to obtain the best re- 291517 Clutch casing lifting hook.
that these essential tools are used together with the 290090 Rotating overhaul stand.
special tools listed here as well as certain tools which 293971 Front support bracket (with
are to be made following the sectional drawings given
in this manual. 290090).
293972 Rear support bracket (with 290090).
4 5 6
3 7
10
9 8
TRE0559A
Longitudinal cutaway section of synchroniser reverser
1. Synchroniser reverser control shaft 6. Reverser control synchroniser.

2. Seal 7. Seal.
3. Roller bearing. 8. Synchroniser reverser driven gear.
4. Synchroniser reverser driving gear. 9. Journal for driven gear (8).
5. Roller bearing. 10. Seal.
Note – On assembly apply jointing compound to surfaces X as indicated on page 6, chapter 1.
???.??.???.?? – ?? – ????
TRE0560A
10
Synchroniser reverser sectional views
1. Synchroniser reverser selector fork. 11. Journal of idle gear (7).

2. Reverser synchroniser. 12. Stop plate for journals (11 and 13).
3. External reverser control lever. 13. Synchroniser reverser driven gear.
4. Seal. 14. Synchroniser reverser control rod.
5. Circlip. 15. Spacer.
6. Thrust washer. 16. Reverser synchroniser.
7. Synchroniser reverser idle gear. 17. Detent ball.
8. Roller bearing. 18. Spring for detent ball (17).

19. Detent ball retaining bolt (the bolt must be cov-
9. Thrust washer.
ered in one of the sealants listed on page 1, Sect.
10. Seal. 00).
???.??.???.?? – ?? – ????
The synchroniser reverser is a mechanical device fected by means of a synchroniser located in the
which makes it possible to obtain 12 forward and 12 group of gears.
reverse gears. It is controlled by a specific lever loca-
ted on the platform to the left of the operator. The synchroniser reverser is installed inside the
clutch casing between the clutch and the gearbox.
The synchroniser reverser is comprised of a group
of three spur gears : driving reverser gear, interme- It is lubricated by the oil in the rear transmission /
diate gear and driven reverser gear. Selection is ef- gearbox.
SYNCHRONISER REVERSER TROUBLESHOOTING
Spontaneous disengagement of 2. Incorrect adjustment of exter- Adjust correctly.

the synchroniser reverser nal levers and linkages.
3. Synchroniser engagement Remove the clutch casing and re-

teeth damaged. place the synchroniser.
4. Engagement travel incom- Eliminate the cause and restore full

plete. engagement travel.
Difficulty in engaging the reverser 1. Incorrect adjustment of exter- Adjust correctly.

nal levers and linkages.

zure of external levers and
linkages.
3. Dragging of main clutch. See page 6, Sect. 18.
4. Synchroniser damaged. Remove the clutch casing and re-

place the synchroniser.
5. Internal controls do not slide Perform the checks and overhaul for
freely : rods, forks and needed parts.
sleeves.
Synchroniser reverser unduly noi- 1. Worn or damaged internal Remove the clutch casing and re-
sy part/s. place damaged part/s.
???.??.???.?? – ?? – ????
CLUTCH/REVERSER CASING
Replacement (Op. 21 110 85)
WARNING
Never insert fingers or hands between one piece and
another. Wear suitable safety clothing, i.e., safety
goggles, gloves and shoes.
1. Fix the clutch / reverser casing (1) to stand

290090 (2) using the two brackets 293971 and
1 2
293972.
24984
11
2. Withdraw the spring pin and recover the link le-

ver (1) and the internal lever (2). 1 2
26185
12
3. Unscrew the retaining bolt (1) and recover the
detent ball and spring. 1
24989
13
???.??.???.?? – ?? – ????
4. Remove the circlip (1) and take out : bearing,

thrust washers, synchroniser assembly together 1
with the selector fork and its rod, the reverser
driven gear (2) complete with roller bearings and
spacer. 2
26186
14
5. Remove the reverser driving gear (1) complete
with roller bearings. 1
24994
15
6. Remove the circlip (1) securing the reverser driv-

ing shaft. 1
24995
16
7. Working from the front of the clutch / reverser

casing with an aluminium drift (2), drive out the 1 2
reverser driving shaft (1) and remove it from the
rear of the casing.
24997
17
???.??.???.?? – ?? – ????
8. Detach the retaining springs and withdraw the

sliding sleeves (1). 1
24999
18
9. Unscrew the retaining bolts and remove the
sleeve cover / support (1). 1
25000
19
10. Unscrew the two securing bolts (1) of the sliding
sleeve control forks (2). 1 2
25001
20
11. Withdraw the external clutch control levers (1)
and remove the forks (2). 1
2
25002
21
???.??.???.?? – ?? – ????
12. Relieve the staking and unscrew bolt (1) secur-

ing the stop plate for the journal of the reverser 1
driven shaft (2) and the intermediate gear jour-
nal, removing the latter from the rear of the cas-
ing.
13. Refitting of the synchroniser reverser according

to the following instructions :
— Refer to the illustrations on pages 5 and 6 to
check the correct orientation of the various parts. 2
— Refer to the torque settings on page 2.
— Install the intermediate gear journal complete 25004
with the various associated parts, and the journal 22

of the reverser driven gear and secure with the
relative stop plate and bolt.
— Fit the sliding sleeve control forks on the relative
clutch control levers and fix the previous to the
latter.
— Fit the sliding sleeve cover and its support.
— Fit the sliding sleeve assembly to the relative
support and secure with the springs.
— Insert the reverser driving shaft from the rear of
the casing and fix it to the clutch / reverser casing
with the circlip.
— Position the reverser driving gear complete with
bearings on the driven shaft.
— Fit the reverser driving gear complete with the
bearings and spacers.
— Fit the synchroniser assembly complete with
control forks, rod, thrust washers and bearing,
and fix in position with the relative circlip.
— Fit the detent ball, spring, and bolt in the locked
position after covering the bolt using one of the
sealants listed on page 1, Sect. 00.
— Position the internal lever and link lever and fix
with the relative spring pin.
— Remove the clutch / reverser casing from the
stand 290090.
???.??.???.?? – ?? – ????
???.??.???.?? – ?? – ????
SECTION 21 -- TRANSMISSIONS -- CHAPTER 3 1
SECTION 21 -- TRANSMISSIONS
Chapter 3-- Reverser and creeper unit
CONTENTS
21 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
21 110 Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
21 000 -- MAIN DATA -- TIGHTENING TORQUES -- SECTION VIEWS -- TOOLS -- DESCRIPTION AND
OPERATION -- FAULT DIAGNOSIS
SYNCHRONISER REVERSER--CREEPER UNIT MAIN DATA

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical, spur gears, located
between engine and gearbox.
Comprising 1 driving gear, 1
intermediate gear and 1 idle
gear.
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by hand lever located on
left--hand side of operator
CREEPER UNIT MAIN DATA
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordinary gear train with spur

gears, located between main
clutch and gearbox, in series
with the reverser.
Provides 20 forward speeds and
12 reverse speeds
Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18x26
= 1:5.524
55x47
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by hand lever located on
left--hand side of operator
GEARBOX MAIN DATA

Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--speed constant mesh,
synchronised on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . helical
Range gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ordinary gear train with three
ranges for a total of 12 speeds
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . spur gears
Gearbox and range gear controls . . . . . . . . . . . . . . . . . . . . . . . . . Independent, by two hand levers
For further data see chapter 1.
???.??.???.?? -- ?? -- ????
2 SECTION 21 -- TRANSMISSIONS -- CHAPTER 3
TORQUE VALUES
Torque Settings
PARTS Thread
Nm kgm
Bolt or nut securing clutch casing -- reverser and creeper unit to the
engine (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 10
Sleeve cover nuts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 17 1.7
Synchroniser reverser -- creeper unit driven shaft cover nuts (C3)

M 8 x 1.25 17 1.7
Gearbox driving and driven shaft bearings cover screws (C4) . . M 8 x 1.25 28 2.9
Bolt securing clutch casing -- reverse and creeper unit to the rear
transmission--gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 10
TRE0561A
23
???.??.???.?? -- ?? -- ????

tions in this Section :
Warning -- The operations described in this Section
can only be carried out using the ESSENTIAL tools 292320 Tractor dismantling stand.
marked with an (X).
However, for greater safety and to obtain the best re- 291517 Clutch casing lifting hook.
that these essential tools are used together with the 290090 Rotating overhaul stand.
special tools listed here as well as certain tools which
are to be made following sectional drawings given in 293971 Front bracket (with 290090).
this manual.
293972 Rear bracket (with 290090).
Support bracket for installation of gearbox driving

shaft seal (mark tool 50043) (Dimensions in mm).
Part of kit 50043 -- Make tool in UNI C40.
26191
26192
24
Tool for gearbox driving shaft seal (mark tool 50137)
(Dimensions in mm)
make tool in UNI C40.
???.??.???.?? -- ?? -- ????
2 3 4 5 6
10 8 7
9
TRE0562A
25
Longitudinal section through reverser--creeper unit
1. Reverser and creeper unit control shaft. 6. Gearbox driving shaft control gear.
2. Seal. 7. Creeper unit driven gear.
3. Circlip. 8. Thrust washer.
4. Creeper unit control gear. 9. Reverser driven shaft.
5. Reverser--creeper unit synchroniser. 10. Seal.
Note -- On assembly apply sealing compound to the surfaces X following the indications given on page 6 in chap-
ter 1.
???.??.???.?? -- ?? -- ????
TRE0563A
26
Cross sectional views of synchroniser reverser -- creeper unit
1. Reverser control fork. 12. Roller bearing.

2. Detent ball. 13. Journal for gear (11).
3. Reverser synchroniser. 14. Seal.
4. Seal. 15. Reating screw for journal (13).
5. External reverser control lever. 16. Fast speeds lock pawl.
6. Creeper unit control fork.
17. Reverser and creeper unit control rod.
7. Detent ball.
18. Reverser synchroniser.
8. External creeper control lever.
19. Creeper unit control gear.
9. Seal.
20. Retaining screw for rod (17) (apply one of the
10. Creeper unit control gear. sealing compounds listed on page 1, Sect. 00 to
11. Intermediate gear for reverser. the screw).
???.??.???.?? -- ?? -- ????
The reverser--creeper unit is a mechanical device and is controlled by a hand lever located on the right--
providing the possibility to obtain 20 forward speeds hand side of the operator.
and 12 reverse speeds.
The reverser comprises three spur gears : the re-
The creeper unit engages only in slow and middle verser driving gear, an intermediate gear and the re-
ranges, a mechanical interlock prevents creeper en- verser driven gear; the reverser is engaged by
gagement in the fast ranges. means of a synchroniser located in the gear assem-
bly.
The creeper unit comprises a group of three spurs
gears : a sliding control gear, a synchroniser control The reverser--creeper unit is installed inside the
gear and a driven gear; the unit utilises the same syn- clutch casing between the clutch and the gearbox.
chroniser as the reverser.
Lubrication is provided by the oil contained in the rear
The creeper is installed in series with the reverser transmission--gearbox.
SYNCHRONISER REVERSER--CREEPER UNIT TROUBLESHOOTING
Spontaneous disengagement of 14. External levers and linkages Adjust correctly.

the reverser--creeper unit. incorrectly adjusted.
15. Synchroniser teeth damaged. Remove the clutch casing and re-
place the synchroniser.
16. Engagement travel incom- Eliminate the cause and restore full
plete. travel.
Difficulty in engaging the revers- 1. External levers and linkages Adjust correctly.
er--creeper unit. incorrectly adjusted.

zure of external levers and
linkages.
3. Main clutch drag. See page 6, Sect. 18.
4. Synchroniser defective. Remove the clutch casing--gearbox

and replace the synchroniser.
5. Internal control elements do Perform the checks and overhaul for

not slide freely : rods, forks needed parts.
and sleeves.
Reverser--creeper unit unduly 1. Internal component/s worn or Remove clutch casing and replace
noisy. defective. defective parts.
???.??.???.?? -- ?? -- ????
CLUTCH CASING -- SYNCHRONISER

REVERSER AND CREEPER UNIT
Replacement (Op. 21 110 87)

WARNING
Never place your hands between one part and anoth-
er. Wear suitable safety clothing, i.e. safety goggles,
gloves and shoes.
To gain access to the synchroniser reverser--creeper

unit, first remove the footboards (Refer to section 90)
and remove the clutch casing as described in Sect.
18, and then proceed as follows :
1. Fix the casing to the rotating stand 290090 using
the brackets 293971 and 293972.
22893
27
2. Remove circlip (1) and slide out constant mesh

gear (2).
22894
28
3. Remove circlip (1) of reverser transmission driv-
ing shaft.
26198
29
???.??.???.?? -- ?? -- ????
4. Remove plug and remove the control lever re-

taining pin (1).
26199
30
5. Remove the reverser synchroniser assembly (1)

together with control forks and gears.
26200
31
6. Withdraw the driven shaft gear (1) together with
the roller bearings and remove the thrust wash-
er.
26201
32
7. Remove the control fork retaining springs (2) and
withdraw the clutch pressure plate bearing as-
sembly (1).
26202
33
???.??.???.?? -- ?? -- ????
8. Unscrew the retaining screws (2) and remove

the control forks (1).
26203
34
9. Unscrew the retaining screw (15, page 5) and

withdraw the reverser intermediate gear assem-
bly (1).
26204
35
10. Unscrew the retaining bolts and remove the cov-
er (1).
22902
36
11. From the rear of the casing, withdraw the shaft
(1) complete with the relative bearing.
26205
37
???.??.???.?? -- ?? -- ????
12. Unscrew the retaining bolts and remove the cov-

er--support (1).
26206
38
13. Remove the circlip (2) and withdraw the drive--

shaft (1) complete with bearing.
26207
39
26208
40
15. Remove the driveshaft seal (1) using a suitable
implement.
26209
41
???.??.???.?? -- ?? -- ????
16. To refit all the reverser and creeper components

in the casing follow the instructions below :
— Refer to the illustrations on pages 6 and 7 for the
orientation of the various components.
— Adhere to the torque setting values prescribed
on page 4.
— To install the seal (1, fig. 19) follow the instruc-
tions in steps 17 -- 24.
— Install the driveshaft complete with bearing and
circlips.
— Fit the cover--support.
— Install the reverser and creeper driven gear
shaft.
— Fit the cover for the driven gear shaft and secure
with the relative screws.
— Install the reverser intermediate gear assembly
and secure with the relative screw.
— Install and fix the clutch control forks to the rela-
tive levers.
— Install the pressure plate bearings and hold in
place with the relative springs.
— Install the driven gear complete with bearing and
thrust washer.
— Install the complete synchroniser assembly and
secure with the relative circlip.
— Fit the rod retaining screw coated with one of the
sealing compounds listed on page 1, Sect. 00.
— Install the gear on the reverser driven shaft and
secure with the relative circlip.
— Remove the clutch casing --reverser and creeper
unit from the stand 290090.
WARNING
Always use suitable tools to align holes. NEVER
USE YOUR FINGERS OR HANDS.
17. Fit the circlip (1, fig. 18) in its seat.

18. Make the bracket of tool 50043 (4) and the tool
50137 (5) (see page 5). 1
19. Fit the bracket (3) on the clutch casing, insert the 5
installation drift (4) in the seal seat in contact with 2
the circlip (1, fig. 18).
20. Screw in nut (1) to obtain a distance (H) between 3
the bracket and nut of 3.3 -- 3.6 mm and secure
the latter with the locknut (5). 4
26210
42
???.??.???.?? -- ?? -- ????
Note -- Leave the drift (1) with the nut in the position
reached on completion of the installation operation,
and on future seal installation operations simply
check that the distance (H, fig. 20) is as prescribed.
21. Remove the drift (1), the bracket (2) and the cir-
clip (1, fig. 18).
22. Locate the new seal in its seat (see page 6 for
correct orientation of seal), refit the bracket (2)
on the clutch casing and insert the drift in the
26211
bracket.
43
23. Force the seal in until the nut (1, fig. 20) reaches
up against the bracket (2).
24. Dismantle the bracket (2), remove the drift (1)
and proceed with the installation of the other
components.
???.??.???.?? -- ?? -- ????
SECTION 23 – DRIVE LINES – CHAPTER 1 1
SECTION 23 – DRIVE LINES
Chapter 1 – Drive Lines
CONTENTS
23 000 Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Torque settings and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cross–Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
23 101 26 Transmission shafts and guard (Disassembly – Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . 4
23 101 40 Drive gear housing (Removal – Installation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
23 101 42 Drive gear housing removed (Disassembly – Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MAIN SPECIFICATION
Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34/24x24/34= 1 to 1

Relay lever pad width mm 7.978 – 8.000
Pad seat width in driven gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 8.280 – 8.370
Pad clearance in seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.280 – 0. 460
Relay lever pivot diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 15.973 – 16.000

Pivot housing bore in casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 16.016 – 16.059
Pivot clearance in housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.016 – 0.086
Relay lever detent spring length

– Free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 130
– Under 178.2 to 197.8 N (18.17 to 20.17 kg or 40 to 44 lb ) . . . . mm 142.5
MAIN SPECIFICATION OF DRIVE SHAFT
Front drive sleeve adjustment see page 4
Front drive sleeve shim thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2.2.–2.5–2.8–3– 3.3– 3.7 – 4 –4.3
???
2 SECTION 23 – DRIVE LINES – CHAPTER 1
TORQUE SETTINGS
C12
C13
TRE0401A
TRE0400A
Torque setting
PART TO BE TORQUED Thread
Nm kgm
Transmission shaft central support retaining bolt ( C12 ) . . . . . . . . M 12 x 1.5 98 10
Drive gear housing retaining bolt (C13) . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 10
TOOLS
293836 Drive shaft seal key
???
5
22
6
25
1
x
10
C12 11
30
4
56 39 27
28 2
29 12 3
TRE0402A
TRE0403A
2
Sectional views of transfer box:
C12 = Drive shaft centre bearing capscrew
C13 = Axle drive housing capscrew
X = On assembly,thoroughly clean and degrease
mating surface X .
1. Brake driven discs 12. Four – wheel drive engagement sleeve
2. Brake linings 22. Dentent plunger
25. Roll pin
3. Brake shoe
26. Intermediate shaft
4. Driven gear 27. Dust exculuder
5. Intermediate gear 28. Seal
6. Needle roller bearing 29. Retaining ring
30. Splined driven shaft
10. Driven shaft 39. Drive shaft guard
11. Guide screws 56. Centre bearing
???
Op. 23 101 26
TRANSMISSION SHAFTS AND GUARD
Disassembly – Assembly
WARNING
Do not place hands or fingers between one part and
another.
Always wear the prescribed safety clothing, including
protective glasses, gloves and shoes.
To remove, proceed as follows:
1.Disconnect the negative battery lead. 1
25621
3
2.Remove the front, centre and rear screws securing
the front axle prop shaft guard and remove the 1
guard (1).
3.Remove circlip (2) fig. 5 and move sleeve (1) in the
direction shown by the arrow to disengage it from
the splined shaft of the front axle.
4.To re–fit the transmission shaft and guard, proceed
as follows:
WARNING
Use suitable tools to align holes. NEVER USE FIN- 25038
GERS OR HANDS.
4
1 2
–Fit and secure the transmission shaft in position
NOTE:
Move the front splined sleeve (27) against
retaining ring (28). Using a feeler gauge,
measure gap between the sleeve and the
retaining ring (26) and install shim (S 5) to
obtain sleeve end play (L) of 1 to 1.5 mm (see
Section 25 page 9).
25040
– Fit and secure the guard.
5
???
Op. 23 101 40
DRIVE GEAR HOUSING ASSEMBLY
Removal– Installation
WARNING
another.
To remove, proceed as follows:

1.Carry out operation 23 101 26 Transmission
shafts and guard removal (see page 4)
2.Remove the plug (1) and drain the oil from the 1
transmission box/gearbox.
TRE0404A
3.Detach the drive gear engagement control lever(1)
TRE0405A
7
4.Remove the screws (1) that hold the drive gear
housing (transfer box) to the transmission housing. 1
5.Remove the drive gear housing from the transmis-

sion housing.
TRE0406A
???
6 – To re–fit the drive gear housing, proceed as

follows:
WARNING
Use suitable tools for aligning holes. DO NOT USE
YOUR HANDS OR FINGERS.
–Refer to the tightening torques shown on page 2.
–Carefully clean the contact surfaces.
–Apply sealing compound (approx. 2 mm wide strip)

to the contact surface of the drive gear housing.
–Fit the drive gear housing to the transmission

housing.
–Connect the drive gear engagement control lever
–Replace the transmission oil drain plug.
–Carry out operation 23 101 26 Transmission shafts

and guard installation (see page 4)
–Fit the drive shaft guard.
26283
Mastic application diagram for assembly of

drive gear housing to transmission housing.
???
TRANSFER BOX, UNIT REMOVED

Disassembly – Assembly (Op. 23 101 42)
WARNING
another.
With the transfer box on the bench, proceed as fol-

lows:
1.Carry out operation 23 101 26 Transmission shafts

and guard removal (see page 4)
2.Carry out operation 23 101 40 Drive gear housing
removal (see page 5)
25725
10
3.Use the special punch to withdraw the snap ring
1 2 3
(1), then the pin (2). Remove the roller bearing, the
spacer, the thrust washers and the intermediate
gear (3).
4.Remove the parking brake control lever
TRE0407A
11
5.Use a screwdriver to remove the dust ring (1).
1
6.Remove the splined driven shaft, complete with
parts, parking brake discs and the driven gear,
TRE0408A
12
???
7.To refit the transfer box, proceed as follows:
WARNING
Use suitable tools to align holes. NEVER USE FIN- TRE0119A
GERS OR HANDS.
13
Insert the shaft in the housing, then assemble the

gear unit, washer and circlip.
Fit the internal lever ,the external lever, the cou-
pling pad and secure in position by means of
the washer and relative circlip.
Fit the bearing and relative circlips
–Using tool 293836, fit the seal and dust ring (use
the spacer to fit the dust ring )
–Carry out operation 23101 40 Drive gear housing

installation (see page 5) TRE0118A
Carry out operation 23 101 26 Transmission 14

shafts and guard installation (see page 4)
???
SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1 1
SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION

Chapter 1 -- Front axle mechanical transmission
CONTENTS
25 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cross--sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
25 100 30 Complete front axle. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
25 100 38 Front axle. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
25 108 46--47 Steering knuckle bearing pins. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Stub axle adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Wheel hub bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bevel drive adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
25 102 24 Front axle differential. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
25 100 27 Front axle differential with LIM--SLIP. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Front axle differential with NO SPIN. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
44 511 80 Leading drive wheels toe--in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
MAIN DATA
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . steering, load bearing structure,

pivoting at centre
Bevel gear pair -- differential
Pinion--crown gear ratio: 30 km/h:
-- TD60 and TD70 Models 9/38 = 1:4.2
-- TD80, TD90 and TD95 Models 9/39 = 1:4.3

Pinion--crown gear ratio: 40 km/h:
-- TD60 and TD70 Models 11/38 = 1:3.45
-- TD80, TD90 and TD95 Models 11/39 = 1:3.54
Backlash between bevel gear pair:
-- TD60 and TD70 Models mm 0.18 -- 0.23
-- TD80, TD90 and TD95 Models mm 0.15 -- 0.20

Ratio between front wheel revs and rear wheel bevel drive revs
-- TD60 and TD70 Models mm 1.386

-- TD80, TD90 and TD95 Models mm 1.378
-- TD95 Model 1.398

???
2 SECTION 25 -- MECHANICAL FRONT AXLE -- CHAPTER 1
MAIN DATA
Bevel Drive and Differential
-- Thickness of pinion bearing adjustment spacer
TD60 and TD70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2.5--2.55--2.6--2.65--2.7--2.75--2.8--
2.85--2.9--2.95--3.00--3.05--3.10--
3.15--3.2--3.25--3.3--3.35--3.4--3.45
--3.5--3.55--3.6--3.65-- 3.7
TD80 , TD90 and TD95 Models . . . . . . . . . . . . . . . . . . . . . . . mm 2.2--2.25--2.30--2.35--2.40--2.45--2.
5--2.55--2.6--2.65--2.7--2.75--2.8--2.
85--2.9--2.95--3.00--3.05--3.1--3.15
--3.2--3.25--3.3--3.35--3.4
-- Thickness of crown wheel position adjustment spacer
TD60 and TD70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2.5--2.6--2.7--2.8--2.9--3.00--3.1--
3.2--3.3--3.4--3.5--3.6--3.7
TD80 , TD90 and TD95 Models . . . . . . . . . . . . . . . . . . . . . . . mm 2.2--2.3--2.4--2.5--2.6--2.7--2.8--2.9
--3.0--3.1--3.2--3.3--3.4--3.5
-- Clearance between sides of planet and side pinion teeth . . . . . mm 0.15
-- Thickness of planet pinion thrust washers . . . . . . . . . . . . . . . . . mm 1.470 -- 1.530
-- Thickness of side gear thrust washers . . . . . . . . . . . . . . . . . . . . mm 1.50 to 1.60
-- Diameter of cross pin for planet pinions
TD60 and TD70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 21.939 -- 21.960
TD80 , TD90 and TD95 Models . . . . . . . . . . . . . . . . . . . . . . . mm 23.939 -- 23.960
-- Side diameter cross pin bore diameter
-- Clearance between cross pin and bores . . . . . . . . . . . . . . . . . . . 0.080 -- 0.122
-- Diameter of outer axle shafts and corresponding bushes
-- Inside diameter of installed bushes 0.77 -- 0.83
TD60 and TD70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 38.080 -- 38.199.
-- Clearance between axle shafts and bushes ............... mm 0.080 -- 0.158
MAIN DATA
Axle shafts and steering knuckles

-- Diameter of outer axle shafts and corresponding bushes
-- Inside diameter of installed front bush
TD80 , TD90 and TD95 Models . . . . . . . . . . . . . . . . . . . . . . . mm 42.100 -- 42175
-- Clearance between pin and bush
-- Interference fit between bushes and respective bores mm 0.064 -- 0.129
-- Thickness of steering knuckle bearing adjuster plates . . . . . . . . mm 0.10--0.15--0.20--0.25--0.30
Planetary Final Drives
-- Reduction ratio
TD60 and TD70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 15:(15+54) = 1:4.6
TD80 and TD90 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 16:(16+62) = 1:4.88
-- Driven gear thrust washer thickness 0.77--0.83
Axle pivot
Pivotting angle (on either side ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11o
Centre pivot and support end float . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.3 -- 1.1
Max. wear clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 2
Centre pivot diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 52.652--52.671
Centre pivot front bushing fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 52.720--52.790
Centre pivot working clearance in bushing . . . . . . . . . . . . . . . . . . . mm 0.049--0.138
Rear bevel pinion carrier spigot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99.040--99.72
Rear bushing fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 99.146--99.221
Spigot fitted clearance in bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.074--0.181
Axle front and rear thrust washer thickness . . . . . . . . . . . . . . . . . . 4.95--5.00
Turning radius:
-- Live axle in Brakes on TD60 and TD70 Models . . . . . . . . . . . . mm 3600
Brakes on TD80, TD90 and TD95 Models . . . . . . mm 4100
-- Live axle in Brakes off TD60 and TD70 Models . . . . . . . . . . . . mm 5300
Brakes off TD80, TD90 and TD95 Models . . . . . . mm 5600
-- Live axle out Brakes on TD60 and TD70 Models . . . . . . . . . . . 4200
Brakes on TD80, TD90 and TD95 Models . . . . . . mm 4500
-- Live axle out Brakes off TD60 and TD70 Models . . . . . . . . . . . mm 4900
Brakes off TD80, TD90 and TD95 Models . . . . . . mm 5100
???
TIGHTENING TORQUES
Tightening torque
PART Thread
Nm kgm
Front axle
Lock ring, bevel pinion(C1, page 7)
TD60 and TD70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 35 x 1.5 294 30

TD80 and TD90 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 40 x 1.5 294 30
TD95 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 40 x 1.5 294 30
Capscrew, differential case to axle casing(C2) . . . . . . . . . . . . . . . . M 12 x 1.25 113 11.5
Capscrew, ring gear to differential case (C3) . . . . . . . . . . . . . . . . . M 12 x 1.25 113 11.5
Capscrew, king pin(C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 64 6.5
Steering knuckle capscrew(C5):(page 8)
-- models TD60, TD70, TD80, TD90 and TD95 . . . . . . . . . . . . . . . M 12 x 1.25 113 11.5
Wheel hub bearings lock nut (C6):
-- models TD60, TD70 and TD80 . . . . . . . . . . . . . . . . . . . . . . . . . . . M 45 x 1.5 118 12
-- models TD90 and TD95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 50 x 1.5 118 12

Capscrew, planetary final drive housing (C7) . . . . . . . . . . . . . . . . . M 10 x 1.25 64 6.5
Capscrew, wheel disc to hub (C8)(page 9) . . . . . . . . . . . . . . . . . . . M 16 x 1,5 260 26.5
Nut for rim to disc securing bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 14 x 1.5 216 22

Front axle front and rear pivot support bolt(C9) . . . . . . . . . . . . . . . M 18 x 1.5 392 40
Differential cage support cap bolt(C10) . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 113 11.5
Front axle support to engine retaining bolt (C11) . . . . . . . . . . . . . . M 18 x 1,5 314 32
Capscrew, front brake housing (C12) . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1,25 64 6.5

C3 -- 113 Nm C12 -- 64 Nm
C4 (*) C6 -- 392 Nm
26125
C7 -- 64 Nm
C2 -- 113 Nm C1 -- 294 Nm
26124
C11 -- 314 Nm
C9 -- 314 Nm
26126
C10 -- 113 Nm C9 -- 314 Nm
1
(*) See pages 25 to 26
???
TOOLS
WARNING: The tools marked below with an (X) are

ESSENTIAL for the operations described in this sec-
tion. To work in safety and obtain the best results
whilst saving time and energy, these essential tools
should be supplemented by the specific tools listed
below and other tools which are to be made from the
drawings provided in this manual.
List of specific tools required for the various opera-

tions described in this section.
X 293524/1 Pinion Ring Nut Wrench.
X 293520 Pinion Ring Nut Wrench (models

293460 Front axle overhaul stand. TD60, TD70).
291517 Hook for removal--installation of the X 293782 Front bevel drive pinion lock key.
front differential assembly.
X 293544 Wrench for front differential case
292525 Dowels (M 12x 1.25 ) for front axle bearing adjustment nut (models
and cover TD60, TD70).
293812 Dowels (M 16x 1.25 ) for removal / X 293665 Wrench for front differential case
installation of front axle wheels. bearing adjustment nut (TD80, TD90,
TD95 models).
293743 Overhaul support for front axle diffe-
rential casing. X 293857 Front axle pivot pin removal tool.
293400 Universal gauge for positioning of X 292161 Front axle pivot bearing outer ring
front bevel drive pinion. removal tool.
X 292220 Tool for measurement of rolling drag

X 293438/2 Pinion bearing adjustment tool.
torque of front axle bearings.
X 293878 Wrench for threaded adjustment X 295030 Wheel hub ring nut wrench.(TD60,
ring of front bevel drive pinion. TD70 models)
X 293880 Wheel hub ring nut wrench.(TD80,

TD90 and TD95 models)
TRE0414A
Cross--sectional view of front axle differential

X = 0.5--1 mm
S1 = Bevel pinion bearing shim 1. Bevel pinion
S2 = Bevel pinion position shim 2. Seal
3. Bevel pinion bearing spacer
C1 = Bevel pinion bearing lockring. 4. Ring gear
C2 = Differential carrier capscrew. 5. Axle shaft with universal joint
C3 = Ring gear capscrew. 6. Side gear washers
7. Differential pinion washers
Gd, Gs= R.H. and L.H. Differential bearing lock- 8. Differential pinion journal capscrew
ring. 60. Side gear
61. Side gear
62. Differential pinion
63. Differential pinion journal
???
TRE0415A
Cross--sectional view of front axle steering knuckle and hub
S3 = King pin bearing shim

S4 = Wheel hub bearing shims 11. King pin bearing
12. Seal
C4 = King pin bearing capscrew.. 13. Seal
C5 = Steering knuckle capscrew. 14. Axsule shaft bushing
C6 = Wheel hub bearing lockring 15. Spacer
C7 = Final drive housing capscrew. 16. Thrust washers
C8 = Wheel hub capscrew. 17. Planet wheel journals
9. Bearing carrier capscrew 18. Planet wheel shims
10. Seal 19. Sun gear
TRE0416A
Cross--sectional view of front axle pivot

H = 1 mm 22. Front thrust washer
L = 1 to 1.5 mm 23. Rear thrust washer
S5 = Sleeve position shim 24. Rear bushing
25. Rear axle pivot support
C9 = Axle pivot support capscrew 26. Retaining rings
C10 = Differential bearing cap capscrew. 27. Front splined sleeve
C11 = Capscrews securing front axle support 28. Retaining rings
to engine. 29. Drive shaft guard
20. Front axle pivot support 30. Drive shaft
21. Front bushing

TD60, TD70, TD80, TD90 and TD95 models have a The differential has two planet pinions; drive is
centrally pivoting front axle with the pivot and the transmitted to lateral epicyclic final drive units
drive shaft coaxial with the longitudinal axis of the (installed on the wheel hubs) through universal joints
tractor. The drive shaft has no universal joints. which require no maintenance.
???
COMPLETE FRONT AXLE

Removal-- installation (Op. 25 100 30)
DANGER
equipment with a sufficient lifting capacity.
Check that the assemblies or parts are held firmly
and supported by suitable slings and hooks. Make
sure nobody is standing near to the load.
Proceed as follows:
NOTE: The front axle assembly can be removed
from the tractor either with or without previously re-
moving the drive shaft. The description below refers
to removal of the front axle with the drive shaft instal-
led on the tractor. For removal of the drive shaft refer
to section 23.
1. Disconnect the negative battery lead (1).
25621
5
2. Unscrew bolts (1) and remove the front mud-
guard supports (2). 2
25575
6
3. Attach nylon slings to the front weights (1).

Loosen the locking screw from each weight, lift
the weights clear of the tractor and place them in
a safe position.
1
TRE0159A
4. Unscrew bolts (1) and remove the drive shaft

guard (2).
1 2
25576
8
5. Remove the circlip (1) from the front of the drive
shaft. Slide the sleeve rearwards and detach the 1
drive shaft from the front axle.
25584
9
6. Pass two nylon slings around the front axle and
attach them to a hoist.
TRE3201A
10
???
7. Lift the tractor with the hoist and place a stand

under the sump pan.
TRE0417A
11
8. Unscrew unions (1) of the rigid pipes to the
power steering cylinders and detach the two
flexible hoses
TRE0176A
12
9. Unscrew the wheel bolts and remove the front

wheels.
25582
13
10. Unscrew the front axle rear support retaining
bolts (1).
1
25585
14
11. Unscrew the front axle front support retaining

bolts (1.
25586
15
12. Using a hoist and two nylon cables (one for each
side) detach the front axle from the tractor.
13. Refit the front axle following the instructions
below.
WARNING
— Refit the axle and bolt the front and rear supports TRE3301A
in position.
— Reconnect the the power steering pipes. 16
— Fit the front wheels.
— Raise the front of the tractor using the hoist.
— Remove the fixed stand.
— Detach the nylon cables.
— Reconnect the drive shaft and refit the drive
shaft guard.
— Refit the two front mudguards.
— Attach a nylon cable to the front weights, lift, refit
to the tractor and secure with the locking screws.
— Adhere to the tightening torques indicated on
page 4.
???
FRONT AXLE
Removal--Installation (Op 25 100 38 ) C6 2 1
TD60 and TD70 Models
WARNING
Handle all parts with care.
Do not insert hands or fingers between one part and
another. Wear suitable safety clothing, i.e. safety
TRE0418A
17
1. Unscrew the drain plug and drain the oil from the
axle casing. 7 6
5 4
2. Remove the planetary final drive housing (1)
complete with planet wheels.
3. Remove sun gear (2).
3
4. Remove planetary final drive ring gear--fixed
gear unit , slacken lock ring using wrench 295030
(for TD60 and TD70 models) or 293880 (for
TD80, TD90 and TD95 models).
5. and removing assy from knuckle.
6. Remove wheel hub (6) with taper roller bearing
cups (7) and associated seal. Be careful to TRE0419A
prevent seal damage.
18
7. Remove steering knuckle (10) with wheel hub
support.
8. Remove articulated axle shaft (9) with bearing 6
housing. Back off the capscrew before withdraw-
ing the axle shaft.
9. Replace worn bearings using suitable punches
and universal pullers. Check seal efficiency.
Assembly axle parts referring to

-- Before installing the final drive housing (1)
thoroughly clean and degrease mating surfaces and
apply 2 mm of seaing compound. TRE0420A
19
-- Insert articulated axle shaft (9) in axle case and

install steering knuckle carrier (8)
-- Adjust king pin bearing pre--load as directed in
the appropriate section.
-- Adjust wheel hub bearing pre--load as directed
in the appropriate section.
-- Fill wheel hubs and differential--bevel drive
housing with the specifed oil.
8 9
TRE0421A
10
20
TD80, TD90 and TD95 Models
WARNING
NOTE: For overhaul, the front axle should be moun-

ted on stand No. 293460. 25587
21
1. Unscrewthe plug (1) and drain the oil from the
axle casing.
1
25588
22
2. Unscrew plug (1) on the left--hand epicyclic final
drive casing. Repeat this operation on the 1
right--hand casing.
25589
23
3. Remove the front axle rear support (1). Remove
the front support and retrieve the washer.
25590
24
???
4. Unscrew the two track rod retaining bolts (1).

1
25591
25
5. Using a suitable puller, withdraw the pins from
their bores in the stub axle housing and remove
the track rod.
24080
26
6. Remove the circlips (2) from the cylinder rod
pivot pins, unscrew the pin retaining bolts of the
1 2
cylinder (1), withdraw the pins and detach the
two cylinders.
Retrieve the four pins, washers, spacers and
cylinders, complete with hoses.
25593
27
7. Unscrew the retaining bolts from the left--hand

final drive casing cover (1). Screw in the two 1 2
dowels 293812 (2), as shown. Using a slide
hammer screwed into the oil drain plug hole,
detach the cover (1) from the casing.
25594
28
8. Remove the circlip (1) securing the sun gear (2)

and remove the gear.
1 2
25595
29
9. Remove the inner circlip (1) from the stub axle
shaft.
1
25596
30
10. Remove the staking (1) on the wheel hub bearing
lock ring (2).
1 2
25597
31
11. Remove the wheel hub bearing lock ring using

wrench 295030 (1) for models TD60 ,TD70 or
wrench 293880 (1) for models TD80, TD90 and 1
TD95.
25598
32
???
12. Remove the wheel hub (1) with the ring gear (2).
Retrieve all disassembled parts.
1 2
25599
33
13. Unscrew the three retaining bolts (1) of the lower
pin of the stub axle housing. Recover the lower
pivot pin and the related adjustment shims. 1
25600
34
14. Unscrew the three retaining bolts (1) of the
mudguard bracket (2).
2
1
25601
35
15. Withdraw the upper pivot pin (1) and detach the
stub axle housing (2). Retrieve the disassembled 2
parts. 1
25602
36
16. Unscrew the axle shaft retaining bolt and remove

the axle shaft.
25604
37
17. Remove bracket (1), unscrew the union (3) and
detach the front brake pipe (2). 1 2 3
25605
38
18. Unscrew two of the bolts fixing the bevel
drive--differential support to the axle casing.
Screw in the two dowels 292255 (1). Remove the 2 3
remaining bolts and separate the bevel drive--dif-
ferential support from the axle casing. Attach a 1
cable (2) to the support and take up the strain
with the hoist. Remove the bevel drive--differen-
tial support (3) from the axle casing.
25606
39
19. Install tool 380000255 (1) in the vice on the work
bench. Bolt the bevel drive--differential support
on to the tool. Detach the lifting cable. 1 2
20. Unscrew the bolt (2) and remove the ring nut lock
tab (3).
25607
40
???
21. Remove the front brake bolts (1)
TRE0231A
41
22. Remove the front brake housing (1),

1
TRE0422A
42
23. Remove the front brake hub gear (1),
TRE0233A
25609
43
24. Remove the friction discs (1)and metal discs (2).
1
TRE0234A
44
25. Remove front brake piston (1) and O--rings.
TRE0235A
45
26. Unscrew the two bolts (2) of the crown wheel--dif-
ferential support caps (1).
1
TRE0232A
46
27. Remove the crown wheel--differential assembly 46
(2) from the housing (1). 1 2
TRE0423A
47
28. Remove the circlip (1) from the splined shaft (2).
1 2
25614
48
???
29. Straighten the locking tab on the splined shaft-

lock nut (1). 1
25615
49
30. Unscrew the nut using wrench 293878 (1) while

preventing rotation of the bevel drive pinion shaft 1
using wrench 293782.
25616
50
31. Recover the splined shaft detent ball (1)
1
25617
51
32. Withdraw the bevel drive pinion shaft (1) from the
rear of the casing and recover the spacer, the ad-
justment shims and the bearing.
1
25618
52
33. Using a screwdriver, detach and recover the dust

seal, the oil seal (1) and the rear bearing. 1
25619
53
Reassemble the front axle adhering to the follow-

ing instructions:
--Refer to the illustrations on pages 7, 8 and 9 -- Install the bevel drive--differential housing on the
to check the orientation of the various compo- front axle casing and fit the external front brake
nents. pipe.
--Respect the tightening torques prescribed on --Install the axle shaft and relative bolt.
page 4.
--Fit the stub axle, the adjustment shims, the upper
--Carry out the adjustments described on pages 28 and lower pivot pins, the mudguard bracket and
to 34. related bolts.
--Install the rear bearing, the seal, the dust seal, --Fit the wheel hub, the ring gear of the final drive
the adjustment shims, the spacer and the bevel unit and the lock ring. Tighten to the prescribed
drive pinion shaft complete with front bearing. torque value, while simultaneously turning the
wheel hub, to ensure that the bearings are
--Position the detent ball, screw in the bevel drive correctly seated.
pinion lock nut and secure in position by staking.
Finally, replace the circlip. --Fit the securing and stop circlips, the sun gear
and the cover of the final drive unit.
--Install the crown wheel--differential assembly, the
support caps and tighten the relative bolts --Fit the pins, washers, spacers and steering
cylinders.
--Install the track rod, the front and rear supports

--Install the front brake friction disc, metal disc hub and the oil drain plugs.
gear, piston and front brake housing. Tighten the
respective bolts.
???
STEERING KNUCKLE PINS AND BEARINGS

Replacement (Op. 25 108 46 or 25 108 47)
WARNING
Do not put your fingers or hands between one piece
In the event that the steering knuckle pins prove

difficult to remove, proceed as follows.
1. Remove the grease nipples and the steering

knuckle pin retaining bolts.
2. Fit the bolts (1) of tool 293857.
3. Fit the plate (2) of the tool and fix it to the three
bolts with nuts (5).
4. Fit the central tie bolt (4) screwing it fully into the
grease nipple bore on the pin (6).
5. Screw in the nut (3) to drive the pin out of its bore.
24596
54
6. Using extractor tool 292161 (1) remove the
steering knuckle bearings.
1
7. Re--install the steering knuckle bearings using a
suitable drift.
24599
55
STUB AXLE ADJUSTMENT
WARNING
Do not put your fingers or hands between one piece
Install the front axle on stand 293460 and proceed as

follows.
1. Smear grease AMBRA GR 75MD on the outer

races of the bearings and fit the upper cover,
without the adjustment plate, but with tool 1 2
292220 (2). Tighten the retaining bolts (C5,
page 5) to the following torque values:
TD60 and TD70 64 Nm (6.5 kgm)
TD80, TD90 and TD95 113 Nm (11.5 kgm)
24076
56
2. Fit the lower cover without the adjustment plate

and lubricate the three retaining bolts with
engine oil.
3. Gradually tighten the lower cover bolts in
sequence, while simultaneously rotating the
casing to allow excess grease to escape.
24077
57
4. Using a torque wrench and tool 292220 (1),
check that the torque required to rotate the
casing (ignoring the initial torque) is as follows:
models TD60 and TD70 .2.9 Nm (0.3 kgm) 1
(with torque increment of 0.98 Nm -- 0.1 kgm)
TD80, TD90 and TD95 15 -- 25 Nm

(1,5 -- 2.5 kgm)
If the recorded torque is not as specified,

adjust by way of the lower cover bolts.
5. Measure the gap (H) created between the
lower cover and the casing adjacent to each of 24078
the three bolts.
58
???
6. Calculate the average of the three values

measured. The total thickness of the adjustment
shims (pages 8) to be fitted under the lower
cover is to be calculated as follows:
TD60 and TD70 S3= H

TD80, TD90 and TD95 S3= H -- 0.20 mm
If necessary, round up the value to the next 0.05

mm.
7. Partially unscrew the bolts of the lower cover,

insert the selected shims (S3, page 8). Tighten
the bolts (C4, page 5) to the following torque
values:
TD60 and TD70 64 Nm (6.5 kgm)

TD80, TD90 and TD95 113 Nm (11.5 kgm)
8. After having rotated the casing a few times to

allow the components to bed down, check that
the torque necessary to rotate the casing
(ignoring the initial torque) is follows:
24079
TD60 and TD70 2.9 -- 7.8 Nm
(0.3 -- 0.8 kgm) 59
TD80, TD90 and TD95 118 -- 147 Nm

(12 -- 15 kgm)
9. If the torque value measured is greater than the

prescribed value, increase the thickness of the
shims. If the measured value is less than the
prescribed value, reduce the thickness of the
shims.
10. Fit the grease nipples in the upper and lower

covers and grease the assembly.
WHEEL HUB BEARING ADJUSTMENT: 1
proceed as follows:
-- Install wheel hub and fixed gear unit onto the
steering knuckle;
-- Using a torque wrench and lock ring wrench
295030 (for TD60 and TD70 models) or 293880
(for TD80, TD90 and TD95 models)., progres-
sively tighten the lock ring (C6) (page 8) to147 --
196 Nm (15 -- 20 kgm).While tightening the lock
24093
ring, rotate the hub to settle the bearings.
60
-- Fully slacken the lock ring and retighten to 59 Nm

(6 kgm) while rotating hub.
-- Secure the lock ring by bending over a lockwash-
er tab ( if necessary, further tighten the lock ring to
align a slot with the tab )
-- Turn the hub by hand to check for excessive play
or binding.
???
BEVEL DRIVE ADJUSTMENTS

Adjustment of the preload of the pinion shaft
bearings
M E
WARNING
8 7
goggles, gloves and footwear. 9
TRE0424A
Proceed as follows. 61
1. Install the bevel pinion bearing cones (7) and H4
(9) with spacer (8) on tool 293438 (E) with
centralizer (G) M
2. Fully tighten tool nut (M).
7
E
3. Measure dimension (H4) between the tool pin 8 G
end and top face.
9
TRE0425A
62
4. Remove the bearing cones and spacer from the

tool. Lubricate bearings with engine oil and
re--install onto the tool, inserting differential
carrier (10) with bearing cups. M
5. Fully tighten tool nut (M) while rotating the
differential carier through ten revolutions to settle
the bearings.
E
6. Measure dimension (H3) of the tool in this
condition. 7
10
TRE0426A
63
7. Thickness of shims (S1) will be given by: H3
S1= H3 -- H4 + 0.10 mm S1
M
If necessary, round off (S1) to the nearest 0.05 mm
7
E
NOTE On completing the adjustment, do not remove G
the adjustment tool from the bevel drive--differential 8
housing. Leave in place for adjustment of the drive
pinion position. See following subject matter. 9
TRE0427A 10
64

Determining the thickness of the drive pinion
position adjustment shim
Proceed as follows.
R N R
1. Position the differential bearing caps on the shaft
(P) of tool 293400 with cones (R). Install caps in C10 C10
differential carrier, tightening cap screws (C10) to
113 Nm (11.5 kgm).
2. Tighten or back off tool cones (R) to position 100 P

mm spindle (L) over the bearing cone (11) and
eliminate clearance between cones (R) and the E
differential bearing caps.
10
3. Turn the micrometer depth gauge (N) to bring
L 11
spindle (L) into contact with the bearing cone (11)
TRE0428A
and measure dimension (H7)
H7 = H6 ± C 65
where:
H6 = Nominal distance from ring gear centreline P L G
to pinion larger end R H5 E
-- 100 mm for TD60, TD70 models
-- 115 mm for TD80, TD90, TD95 models N
C = a correction value stamped on the pinion
preceded by a + or -- sign (if other than 0). This H5
value to be added to or subtracted from the
nominal distance (H6) according to the sign. R
4. (H7) is the nominal distance from the ring gear 11
centreline to the back of the bearing. P 10
5. The thickness of the adjustment shim (S2) will be TRE0428A
given by:
S2 = H5 -- H7 66
where:
H5 = the distance measured using the microme-
ter;
H7 = corrected nominal distance between the
crown wheel axis and the large diameter base of
the pinion.
???
Examples (models TD60 and TD70)
Example 1:
-- Distance measured using micrometer H5 = 103.3

mm.
-- Nominal distance between crown wheel axis and

large diameter base of pinion H6 = 100 mm.
-- Correction value C = + 0,2 mm.
-- Corrected nominal distance H7 = 100 + 0.2 =

100.2 mm
-- Thickness of adjustment shim

S2 = 103.3 -- 100.2 = 3.1 mm.
Example 2:

mm.

-- Correction value C = -- 0.2 mm.
-- Corrected nominal distance H7 = 100 -- 0.2 = 99.8

mm.

S2 = 103.3 -- 99.8 = 3.5 mm.
Example 3:

mm.

-- Correction value C = 0 mm.
-- Corrected nominal distance H7 = H6 = 100 mm.

S2 = 103.3 -- 100 = 3.3 mm.
Adjustment of the crown wheel bearings and

checking the backlash between the pinion and
crown wheel.
Proceed as follows.
1. Install the bevel pinion with all parts (less seal

2) but including shims (S1 and S2, fig. 2) into the
differential carrier. Shim sizes to be as deter-
mined in the procedure described on pages
24to 30.
2. Lock the wrench 293524/1 (A) onto the pinion
shaft using screws (1). Check that the torque
required to rotate the shaft is 0 to 0.2 Nm ( 0
to 0.02 kgm).
24590
67
3. Lubricate the bearings with engine oil and

tighten the lock ring (C1 page 5) to 294 Nm
(30 kgm or 217 ft lb ) using wrench 293524/1.
4. Measure the torque using correct torque

wrench (C). Ignore the initial torque reading.
TRE0428A
68
NOTE: This revolving torque is applicable only to

pinions installed without a seal. When the seal is
fitted, this torque should be = 0.5 Nm (0.05 kgm) for
TD60 and TD70 models
These torques may be measured using a spring
balance and a string wound around the ring nut
wrench 293520/2 or 293524/1. On TD80, TD90 and
TD95 models a balance reading of 0 to 6 N (0 to 06
kg) should be obtained for pinions installed without
seal or, when pinions are fitted with seals, 16 N (1.6
kg ) for TD60, TD70 models and 22 N (2.2 kg) for
TD80, TD90 and TD95 models.
???
5. Install the differential unit in the carrier ensur-

ing that ring gear is not forced onto the pinion.
Tighten screws (C10) to 59 Nm (6 kgm) then
slacken and retighten to 20 Nm 2 kgm)
6. Lubricate ring gear bearings, rotate the bevel

drive and tighten the differential bearing lock
ring (GS fig. 2). At the same time, using wrench
293544 for models TD60 or TD70 or 293665
for models TD80, TD90 or TD95 check that the
torque is 39 to 59 Nm (4 to 6 kgm) to establish
the specified axial pre--load. 24591
69
7. Measure bevel drive backlash using a dial

gauge positioned at right angles to a bevel
gear tooth.
8. Repeat the measurement at two other equi--
spaced points, 120o apart. Compare the
average of the three readings with the speci- 1
fied backlash of 0.15 -- 0.20 mm (average
0.18mm).
24592
70
1
If bevel drive blacklash is not within the speci-
fied tolerance range, back off one lock ring and
tighten the other by exactly the same amount
to restore axial pre--load and obtain the speci-
fied backlash.
In these conditions, pinion and differential

bearing revolving torque, measured in the
same conditions as pinion torque, must be:
24593
71
A2 = A1 + 1 -- 1.5 Nm (0.10 -- 0.15 kgm)
where:
A2 = pinion--crown wheel rolling resistance
torque;
A1 = rolling resistance torque of pinion only, as
measured previously;
9. 0 to 02 Nm (0 to 02 kgm ) with pinion installed

without seal (all models )
10. 0.5 Nm ( 0.05 kgm) for TD60 or TD70 models
with pinion installed with seal.
11. 0.75 Nm (0.075 kgm) for TD80, TD90 or TD95

models with pinion installed with seal.
12. 1 to 15 Nm (0.1 to 0.15 kgm) -- ring gear

rotating torque measured at the pinion.
24590
72
NOTE: Should it be required to determine the

revolving torque of the pinion/ring gear assy using
the spring balance and string method on wrench
293524/1, the balance force reading should be
F2 = F1 + F3
Where:
F2 = Pinion/ring gear assy revolving torque deter-
mined by spring balance/string method
24587
F2 =Revolving torque for pinion alone, as mea-
sured earlier by balance/string method, namely: 73
. 0 to 0.6 N ( 0 to 0.06 kg) pinions not fitted with

seal (all models).
. = 16 N ( 1.6 kg ) TD60 or TD70 models, pinions
fitted with seal.
. = 22 N ( 2.2 kg ) TD80, TD90 and TD95 models,
pinions fitted with seal.
F3 = 29 to 43 N (2.9 to 4.3 kg) for TD60 or TD70

models or 31 to 47 N (3.1 to 4.7 kg) for TD80, TD90
and TD95 models (revolving torque for ring gear
alone measured at pinion end using balance/string
method).
13. Finally, tighten the cap retaining screws (C10)

to 113 Nm (11.5 kgm) and secure the lock ring
with the lock plate. If the plate does not
correspond with the notches, tighten the lock
ring further until the notches align.
24596
74
Mastic application diagram for assembly of
bevel drive unit and epicyclic final drive unit.
The types of mastic to use are listed on page 1 of
section 00
???
FRONT AXLE DIFFERENTIAL

Overhaul (Op 25 102 24 )
When overhauling the differential assembly it is nec-

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

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

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

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

contact with the planet pinion and then push it up
against the differential housing, reading the end-
float (Gs) on the dial gauge.
24597
75
6. Repeat the above operations to measure the
endfloat on the right--hand side gear (Gd).
The endfloat should be 0.25 mm.
Therefore the shims to be inserted in the differ-
ential housing are given by:
Ss = Gs -- 0.25 mm for the left--hand side gear;
Sd = Gd -- 0.25 mm for the right--hand side gear.
7. Install shims as near as possible to the calcu-

lated value and, using a dial gauge and following
the procedure described above, check that the
endfloat of the left and right--hand side gears is
approximately 0.25 mm. 24598
76
LIMITED--SLIP, SELF--LOCKING DIFFEREN-

TIAL LOCK
Qperation
The differential with Iimited slip Iocking (LlM--
SLlP) is of the two planet gear--type. It is provided
with two multi--disc clutch assemblies fitted be-
tween the side gears and the differential casing.
This differential Iock device is totally automatic. It
requires no manual operation and significantly
reduces (but does not completely eliminate) wheel
slip.
The difference in speed between the side gears
and the differential casing when a wheel loses grip
and begins to slip, is prevented by the clutch
assemblies that are compressed by axial thrust
from the bevel drive torque transmitted to the side
gears by means of the teeth on the two planet
gears.
These torque values may be different, according
to the nature of the ground and the route followed
by the tractor. Torque may vary in intensity,
thereby proportionally varying the axial thrust on
the clutches. This causes the side gears to mesh 77
with the differential casing which, in turn, permits
the axle to overcome the unevenness of the LIMITED--SLIP self--locking differential lock
ground.
FRONT AXLE DIFFERENTIAL WITH LlMITED--

SLlP UNIT
Overhaul (Op 25 102 27 )
WARNING
Handle all parts with carefully.Do not put your hands
or fingers between parts. Wear suitable safety
clothing, safety goggles, gloves and footwear.
1. Remove the bevel drive--differential casing

assembly from the front axle and attach to the
support 293743 (4). Lock the support in a vice and
proceed with disassembly, as follows.
2. Remove the bolts (2) and the left-- and
right--hand ring nut Iock plates (3).
3. Check that the right and Ieft--hand caps (1) are
clearly marked, so as not to mix the parts during
reassembly.
4. Remove the left-- and right--hand bearing
adjustment ring nuts (Gd) from the crown wheel.
5. Remove the bolts (Cg), securing the caps (1 )
and separate the crown wheel from the bevel 78
pinion support.
6. If necessary, unscrew the retaining bolts (C1)
fig. 1, page 7 and remove the crown wheel.
???
Disassemble the LlM--SLlP self--locking differen-

tial Iock as follows:
7. Remove the retaining bolts (1) from the
differential half--casing.
8. Open the differential casing (6).
9. Remove the half--casing (7) the differential pin
(4), complete with the planet gears (3), the thrust
washers (2) and the pins (9).
10. Remove the side gear (5) the friction disc (11),
the metal discs (1 0) and the friction discs (12) from
the half--casing (8).
11. Check the wear on the metal discs (10) and the
friction discs (11) and (12) -- see table below.
Replace any parts that show signs of wear.
12. Proceed with the self--locking differential
assembly operations, carrying out the previously
described operations in reverse order. Apply
LOCTITE 270 to the threads on the screws (1) and
tighten to a torque value of 50 Nm (5.1 kgm).
79
LIM--SLIP self--locking differential lock
13. Re--install the crown wheel (if previously

disassembled) to the half--casing (8). Tighten the
bolts (C1) fig. 1, page 5, to a torque of 113 Nm
(11.5 kgm)
14. Check the rolling torque of the bevel pinion as
inidicated on pages 31 -- 33.
15. Assemble the crown wheel, complete with
LlM--SLlP self--Iocking differential Iock, onto the
bevel drive support. Do not forget to fit the
previously marked crown wheel bearing support
caps in the correct order. Assemble and adjust the
crown wheel bearings as indicated on page
28--34.
Friction parts detail 80
LIM--SLIP SELF -- locking differential lock friction discs
Part no. Description Quantity Thickness Maximum wear per disc

mm mm
10 Metal discs 10 1.5 --
11 Friction discs 2 2.8 0.10

12 Friction discs 8 1.6 0.15
NO SPIN DIFFERENTIAL (optional)
81
Section through differential with NO--SPIN unit
-- C1 = Case capscrew, tightening torque 56 to 62 Nm (5.7 to 6.3 kgm)
1-- Case, flange half 8-- Retaining ring

2-- Case, cap half 9-- Cam holdout rings
3-- Side gear 10-- Driven clutch
4-- Side gear 11-- Centre cam
5-- Springs 12-- Stop
6-- Spring retainer 13-- Ring gear
7-- Central driven assembly 14-- Axle shafts
15-- Front axle housing
???
NOTE:
Check NO SPIN differential unit operation as When the tractor is in a straight forward or reverse
follows: mode of operation, the NO SPIN allows equal
speed to be distributed to both wheels.
--With the engine off, engage a gear and the front
wheel drive, apply parking brake and raise front of When the tractor makes a turn or a front wheel
tractor. passes over an obstruction, the outer wheel or the
wheel on the obstruction must travel faster and
--Rotate the front wheels in a forward direction to farther than the other. To do this it automatically
eliminate play. Hold the L.H. wheel and rotate the disengages, passes over the obstruction or nego-
R.H. wheel rearwards. The NO SPIN differential tiates the curve and re--engages again automati-
will disengage and the wheel will rotate with an cally.
indexing or metallic clicking sound.
If one wheel should Iose traction momentarily, the
-- Stop the R.H.wheel, then turn forwards slightly. opposite wheel, which still has traction, continues
The NO SPIN differential will engage and stop the to pull the vehicle until traction is regained by both
wheel. Rotate both wheels backwards to eliminate wheels.
play, hold the L.H.wheel and rotate the R.H. wheel
forwards. The NO SPIN differential will disengage Turning: In a left turn, for instance,the right--hand
and the wheel will rotate with an indexing or wheel increases speed. The axle shaft (14) (page
metallic clicking sound. 37), transmits this speed increase to the left side
gear (3) to the left driven clutch (10) and to the
--Stop R.H. wheel, then tum backwards slightly. associated cam holdout ring (9). When the speed
The NO SPIN differential will engage and stop the difference between the two wheels reaches a
wheel. given value, ring (9) and clutch (10) overcome
spring Ioad and disengage from the centre cam
--Repeat the above operations while holding the
(11), remaining in this position until1he end of the
R.H. wheel.
curve.
OPERATlON
NOTE: For correct NO SPIN differential operation,
The NO SPIN differential performs the following key tyres must be equal (within a few millimetres) in
functions: rolling circumference. Small differences may be
corrected by adjusting tyre inflation pressure. To
--Permits full use of tractor pull. check the rolling circumference of a tyre, proceed as
follows:
--Prevents wheel--spin when one wheel Ioses
traction. With the tractor on a hard, level surface, mark the
edge of the tyre, with chalk, at the lowest point
--Compensates for differences in wheel travel which
(where it contacts the ground). Mark the ground at
occur when turning or traveling over uneven ground.
the same spot.
Move the tractor forward so that the tyre rotates

exactly one revolution, i.e., when the chalk mark on
the tyre contacts the ground again. Measure the
distance travelled. This is the rolling circumference
of the tyre.
Repeat on the opposite wheel to check that both

tyres have the same rolling circumference.
FRONT AXLE DIFFERENTIAL WITH NO SPIN

OP. 25 102 26
Overhaul
WARNING
Handle all parts with carefully. Do not put your hands
or fingers between parts.Wear suitable safety clo-
thing, safety goggles, gloves and footwear.
1. Remove the bevel drive--differential casing

assembly from the front axle and attach to the
support 293743 (4). Lock the support in a vice and
proceed with disassembly, as follows.
2. Remove the bolts (2) and the left-- and
right--hand ring nut Iock plates (3).
3. Check that the right and Ieft--hand caps (1) are
clearly marked, so as not to mix the parts during
reassembly.
4. Remove the left-- and right--hand bearing
adjustment ring nuts (Gd) from the crown wheel.
5. Remove the bolts (Cg), securing the caps (1 )
and separate the crown wheel from the bevel
pinion support. 82
6. If necessary, unscrew the retaining bolts (C1)
fig. 1, page 5 and remove the crown wheel.
Disassemble the NO SPIN self--locking differential

Iock as follows.
7. Remove the retaining bolts (1) from the differen-
tial half--casing.
8. Open the differential casing
9. Remove the central driven (7), retaining the
differential half -- casing.
10.Proceed with self--locking the differantial as-
sembly oparations ,carrying out the previously
desciribed operations in reverse order Tighten the
bolts (C1) torgue value of 56--62 Nm (5.7--6.3
kgm)
11. Refit the crown wheel bolts and torque to a

value of 113 Nm (11.5 kgm)
12. Assembfe the crown wheel, complete with no
SPIN seff--Iocking differential Iock, onto the bevel
drive support. Remember to fit the previously
marked crown wheel bearing support caps in the
correct order and assemble and adjust the crown
wheel bearings as indicated on page 30.
83
???
CHECKING THE ALIGNMENT OF STEERING

DRIVE WHEELS (Op 44 511 80 )
When travelling forward in a straight path, the wheels

of four--wheel drive tractors must be parallel to the
longitudinal axis of the tractor, alternatively a slight
toe--in of the front wheels is permissible up to a maxi-
mum of 6 mm as measured at the edges of the wheel
rims.
To check the exact value of the toe--in setting of four--
wheel drive tractors, proceed as follows.
1. Inflate the front tyres to the prescribed pressure.
2. Position the steering at the straight ahead

position (along the longitudinal axis of the
tractor).
3. Check that the wheels are parallel to the

longitudinal axis of the tractor.
4. Make a chalk mark on the front inside edges of

both wheel rims, at the height of the wheel hub
centres. Measure the distance (1) between the 1
chalk marks.
5. Move the tractor forward to turn both front

wheels through 180o. The chalk marks will now
2
be measure between the rear inside edges of the
wheel rims at the height of the wheel hub
centres. Mow measure the distance (2) checking
that this new measurement is equal to or greater
than the distance (1) by a maximum or 6 mm.
The rotation of the wheels through 180o is necessary 24666
to eliminate the effect of wear, misalignment or
distortion of the wheel rims on the measurements 84
obtained.
1
6. If it is necessary to correct the wheel alignment,
remove nut (2) and pull the track rod end (1) out
of its housing. Slacken off locknut (3) and screw
the track rod end (1) in or out to increase or
decrease the distance (2) fig. 84.
Reposition the track rod end (1) in its housing
and re--check alignment as described in points 4
and 5 above.
After having adjusted the alignment to within the
prescribed limits, tighten locknut (3) to a torque 3
of 180 Nm (183 kgm) and nut (2) to 100 Nm 2
(10.2 kgm). 24667
NOTE: The self--locking nut (2) must be renewed
each time it is removed or partially unscrewed. 85
SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1 1
SECTION 27 -- REAR AXLE AND TRANSMISSION
Chapter 1 -- Rear axle and transmission
CONTENTS
27 000 Main specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
27 100 Removal--Refitting--Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
27 000 -- MAIN SPECIFICATION -- TORQUE SETTINGS -- SPECIAL TOOLS -- SECTIONAL VIEWS --

DESCRIPTION AND OPERATION -- FAULT FINDING
MAIN SPECIFICATION OF BEVEL GEAR PAIR AND DIFFERENTIAL
TD60 -- TD70 TD80 -- TD90 --

TD95
Bevel gear pair gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9/43 = 1:4.8 (30 kph)
11/43 = 1:3.9 (40 kph)
Bevel gear pair tooth clearance . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.18 -- 0.23
Type of differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with two planet gears
Mechanical differential lock control . . . . . . . . . . . . . . . . . . . . . . . by means of pedal
Release for mechanically controlled differential lock . . . . . . . . controlled by foot brake pedals
25.040--25.061
24.040 -- 24.061 (for TD80--TD90)
Differential pinion internal seat diameter . . . . . . . . . . . . . . . . . . mm 28.040--28.061
(for TD95)
Differential pinion pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 23.939 -- 23.960 24.939--24.960

(for TD80--TD90)
27.939--27.960
(for TD95)
Clearance between differential pinions and their pins . . . . . . . mm 0.080 -- 0.122 0.080 -- 0.122
Diameter of side gear hub seats on differential box . . . . . . . .

mm 44.080 -- 44.119 51.100 -- 51.146
Diameter of side gear hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 43.961 -- 44.000 50.954 -- 51.000
Clearance between side gears and their seats . . . . . . . . . . . . . mm 0.080 -- 0.158 0.100 -- 0.192
Bevel pinion positioning adjustment . . . . . . . . . . . . . . . . . . . . . . see pages 29 and 30
Adjuster shims for bevel pinion positioning . . . . . . . . . . . . . . . . . mm 1.85 -- 1.90 -- 1.95 -- 2.00 -- 2.05 --
2.10 -- 2.15 -- 2.20 -- 2.40 -- 2.45 --
2.50 -- 2.55 -- 2.60 -- 2.65 -- 2.70
Adjusting bevel pinion bearings . . . . . . . . . . . . . . . . . . . . . . . . . . see page 31

(see over)
???.??.???.?? -- ?? -- ????
2 SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1
MAIN SPECIFICATION OF BEVEL GEAR PAIR AND DIFFERENTIAL

(cont.)
TD60 -- TD70 TD80 -- TD90 --

TD95
Adjusting ring bevel gear bearings and bevel gear pair coupling
clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see pages 32 to 33
Differential pinion and side gear backlash . . . . . . . . . . . . . . . . . mm 0.15 0.18
Thickness of differential side gear clearance adjustment shims mm 1.5--1.6
Thickness of differential pinion thrust bearings . . . . . . . . . . . . . mm 1.47--1.53

Adjusting clearance between pinion and side gear teeth . . . . see pages 34 and 35
Adjusting differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 28
Differential lock control fork adjuster shim . . . . . . . . . . . . . . . . . mm 0.5
Spring for differential lock control fork :

-- free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 220
-- length of spring under load of 177--195 N (1.81--19.9 kg) . mm 157.5
MAIN SPECIFICATIONS OF FINAL DRIVES
TD60 -- TD70 TD80 -- TD90 --

TD95
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pinion type and spur gears
11:67=1:6.1
Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11:62= 1:5.6 (for TD80--TD90)
11:68=1:6.2
(for TD95)
???.??.???.?? -- ?? -- ????
TORQUE SETTINGS -- Refer to fig. 1 on page 4
Torque settings
PART TO BE TIGHTENED Thread
Nm kgm
Retaining bolts for rear transmission/gearbox upper cover (C1) . . . M 10 x 1.25 59 6
Bolts for securing lift to rear transmission box (C2) . . . . . . . . . . . . M 12 x 1.25 98 10
Bolts for securing PTO box to transmission / gearbox case (C3) M 16 x 1.5 221 22.5
Bolts for securing torsion bar to transmission / gearbox case (C4) M 16 x 1.5 221 22.5
Nuts for stud bolt securing final drive box to transmission /

gearbox case (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 10
Nuts for securing steel disc to drive wheel hub (C6) . . . . . . . . . . . M 18 x 1.5 255 26
Nuts for bolts securing steel disc to drive wheel rim (C7) . . . . . . . M 16 x 1.5 245 25
Bevel gear pair retaining bolts (C8) . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 123 12.5
Bevel gear pair support retaining bolts (C9) . . . . . . . . . . . . . . . . . . M 10 x 1.25 59 6
Nut, wheel shaft (C10)

-- TD 60 & TD 70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 55 x 1.5 882 90
-- TD 80, TD 90 &TD95 Models . . . . . . . . . . . . . . . . . . . . . . . . . . M 60 x 2.0 882 90
Bolts for securing clutch box to transmission--gearbox case (C2

Section 18 Page 3, Fig. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 10
???.??.???.?? -- ?? -- ????
SECTIONAL VIEWS
C1 59 Nm C2 98 Nm
C4 221 Nm C3 221 Nm
C9 59 Nm
C7 245 Nm
C6 255Nm
C8 123 Nm
C5 98 Nm
C10 888Nm
TRE0550A
???.??.???.?? -- ?? -- ????
SPECIAL TOOLS 291517 Hook for lifting clutch box.

290090 Rotating stand for overhaul.
293971 Rear mounting (with 290090).
IMPORTANT: The operations described in this Sec- 293972 Front mounting (with 290090).
tion must be performed only with the ESSENTIAL
tools marked with (X). X 293940 Adapter for extracting bevel pinion
To work in complete safety and to ensure optimal (with 292927).
technical results with a minimum of time and effort,
they must be supplemented by the special tools rec- 292927 Slide hammer.
ommended below and with those to be specially
293400 Bevel pinion positioning gauge.
constructed by you and for which the construction
diagrams are given in this manual. 50006 Punch for removing gearbox drive
shaft (see page 4, Sect.21, Chap.
1).
List of special tools required for the various opera-
tions described in this Section : 50007 Tool for adjusting gearbox drive
shaft (see page 4, Section 21,
292320 Trolley for tractor disassembly. Chapter 1).
26259
Tool to be constructed for adjusting the installation position of bevel pinion shaft (Stamp number 50004 on
the tool -- measurement in mm)
Build using Aq 45.
Tool to be constructed for adjusting differential lock

sleeve travel. (Engrave number 50041 on the tool --
measurement in mm).
Build using C40.
26260
???.??.???.?? -- ?? -- ????
TRE0551A
Sectional drawings of transmission--gearbox case

1. Mid--range and reverse gear control rod. 13. Range engagement safety pawl.
2. Slow and fast gear control rod. 14. Plug.
3. 1st and 2nd gear control rod. 15. Reverse gear support pin.
4. Detent balls. 16. Retaining bolt.
5. Spring for ball (4). 17. Reverse idler gear.
6. Gear engagement safety pawl. 18. Thrust bearing.
19. Snap ring.
7. Spring for ball (8).
20. PTO shaft.
8. Detent ball.
21. Reverser drive shaft.
9. 3rd and 4th gear control rod.
22. Engagement gear for mid--range and reverse
10. PTO external control lever. gears.
11. Gear engagement safety pawl. 23. Driving gear for mid--range gears.
12. Plug. 24. Snap ring.
NOTE: Screw in plugs 12 and 14 using one of the sealing compounds listed on page 1, Section 00.
???.??.???.?? -- ?? -- ????
15
10
C3 14 7 9
15 10
C3 14 7 9 3 6
3 6
16
16
4
4
C4
C4
17
17 11
11 13 5
13 2
X
2 5
C5
C5 18 8 19
18
8 19
1 20
1 X 12 X
12
C1 C1
TRE0552A 1
5
Cross--sectional view of final drive
a. TD70 models 7. Ball bearing

b. TD80, TD90, TD95 models
C1. Final drive housing cover capscrews 8. Final drive driven gear
C2. Capscrews securing final drive housing to 9. Axle shaft
transmission housing
10. Final drive casing
C3. Nuts securing disc to wheel rim
11,12.Seals
C4. Capscrews securing disc to wheel hub
13. Seal guard
C5. Nut
T Drain plug 14,15,16.Retaining rings
1. Wheel disc 17. Seal thrust ring

2. Wheel shaft 18. Grease nipple
3. Final drive housing cover 19. Lockwasher
4,5. Ball bearings 20. Seal
6. Roller bearing
NOTE: During installation, apply sealing compound to surfaces X as shown in Section 00, Chapter 1, page 1.
???.??.???.?? -- ?? -- ????
38 38
TRE0554A
Longitudinal and Cross Sectional Views of Pinion and Differential Unit

a. JX55 and JX65 models 13. Planetary gear shim
b. JX75, JX85 and JX95 models 14. Differential box
c. Longitudinal section for all models 15. Pinion shaft
C1. Ring gear retaining screw 16. PTO shaft
C2. Differential support retaining screw 17. PTO control sleeve
S. Pinion shaft positioning shim 18. Fork
1. Differential support 19. Differential lock shaft
2. Differential support 20. Range gear retaining ring
3. Taper roller bearing 21. Pinion securing plate
4. Taper roller bearing 22. Differential bearing ring nut
5. Differential lock sleeve 33. Reverse driven gear
6. Ring gear 34. Driven gear for slow speed gears (low range)
7. Side gear 35. Engagement sleeve for slow and fast speed
8. Side gear gears
9. Planetary gears 36. Transmission driven shaft ring
10. Planetary gears shaft 37. Retaining half--ring
11. Planetary gear shaft retaining screw 38. Lock ring
12. Side gear shim
???.??.???.?? -- ?? -- ????

The rear transmission transmits power from the Final drives are of the pinion type and are controlled
gearbox to the lateral final drives by means of the by the bevel gear pair output half--shafts, the same
bevel gear pair. The bevel gear pair is of the helical shafts that control the footbrakes.
tooth type and is supported by taper--roller bearings.
The differential has two pinions and is equipped with When the differential lock is not in use, it is kept dis-
a mechanically controlled differential lock. engaged by a spring that exerts a force on the fork.
FAULT FINDING FOR BEVEL GEAR PAIR AND DIFFERENTIAL
Transmission noisy while the trac- 1. Incorrect adjustment of bevel Remove the rear transmission box
tor is moving, even when the gear- pinion and / or ring bevel gear and adjust the pinion and ring bevel
box is in neutral (not arising from bearings. gear bearings correctly (page 28).
final drives).
Transmission noisy when tractor 2. Excessive clearance between Remove the rear transmission box
ia operated with or without load. pinion and ring gear teeth. and correctly adjust the pinion and
ring gear bearings (page 28).
Differential repeats noise within 3. An internal component is bro- Remove the rear transmission box,
short intervals. ken or defective. replace the worn parts and correctly
adjust the differential gear clearance
(page 32).
Transmission noisy and assembly 4. Pinion and / or ring gear Remove the rear transmission box
overheats. bearing clearances insuffi- and correctly adjust the pinion and
cient. ring bevel gear bearings (page 28).
5. Insufficient coupling clear- Remove the rear transmission box

ance between the teeth of the and correctly adjust the ring bevel
pinion and the ring gear. gear bearings (page 31).
FAULT FINDING FOR FINAL DRIVES
Final drive noisy when tractor is

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

Removal--Refitting (Op. 21 118 10 -- 21 118 12)
Related service instructions up to item 44 -- see
pages from 10 to 26.
WARNING
Lift and handle all heavy parts using proper equip-
ment of adequate lifting capacity.
Make sure that the assemblies and parts are sup-
ported by appropriate tools and hooks. Keep person-
nel away from the vicinity of the load to be lifted.
To remove the gearbox--rear transmission, proceed

as follows :
1. Disconnect the negative terminal from the
battery. Remove the rear transmission drain plug
(1) and the gearbox drain plug (2). Drain the oil
into suitable containers.
TRE0209A
7
2. Remove the drain plug from the 4WD transfer
box (1) and drain the oil into a suitable container.
TRE0564A
8
3. Place the tractor dismantling stand 292320, so
that the fixed support (1) is beneath the rear
transmission case in supporting the engine
coupling flange and the moveable support (2)
under the engine in supporting the flange
attached to the gearbox case.
25050
9
???.??.???.?? -- ?? -- ????
4. Place another moveable stand 292320 under the

front weight carrier to prevent any possibility of
the engine tipping forwards when the gearbox is
removed. Put wooden blocks (1) between the
stands and the tractor body. Turn the stand
height adjustment lever to bring the blocks (1)
into contact with the tractor.
1
25051
10
5. Remove electrical connections (1) going to the
instrument panel.
TRE0185A
11
6. Remove the socket (1) with its cable that passes
from the instrument panel and over the gearbox
to the rear fender.
TRE0216A
12
7. Remove the support bolt (1) from the injection
pump and disconnect the hand and foot throttle
cables.
TRE0177A
13
???.??.???.?? -- ?? -- ????
8. Disconnect the flexible hoses (1) from the

hydrostatic steering pump. (Mark the hoses,
before removal, to facilitate refitting in the correct
position).
TRE0160A
14
9. Disconnect the proofmeter drive cable from its
adapter (1) and remove the retaining bolt (2).
TRE0501A
15
10. Remove the filter line (1) and pressure pipe (2)
from hydraulic pump.Remove both footboards
as described in section 90.
TRE0201A
16
11. Remove the securing nuts (1) from the brake
pedal retaining bolts. Remove the pedals from
the upper surface of the operator environment/
platform.
TRE0195A
17
???.??.???.?? -- ?? -- ????
12. Disengage the PTO clutch cable removing the

retaining pin (1).
TRE0194A
18
13. Remove the split pins (1) and disconnect the
synchronised PTO engagement lever.
TRE0198A
19
14. Remove the retaining pin (1) of MFD engage-
ment lever and take the lever.
TRE0212A
20
15. Remove the indicator and light connections (1)
on both sides of tractor.
TRE0192A
21
???.??.???.?? -- ?? -- ????
16. Disconnect the retaining bolts (1) of seven--pole

socket electrical connection and remove the
earth cable bolt (2).
TRE0503A
22
17. Take the auxiliary hydraulic valve control rods

out by removing retaining pins (1).
TRE0504A
23
18. Disconnect the auxiliary valve nuts (1) from their
pipes.
TRE0200A
24
19. Remove the split pins (1) and respective draft
and position control levers.
TRE0505A
25
???.??.???.?? -- ?? -- ????
20. Remove the 4WD shaft guard from its front (1),
middle (2) and rear retaining bolts.
TRE0207A
26
21. Remove the snap ring (2) and withdraw the
sleeve (1) from DT transfer box in the direction 2
of the arrow.
1
25039
27
22. Remove the snap ring (2) and withdraw the
sleeve (1) from the DT transfer box in the direc- 1 2
tion of the arrow.
25040
28
23. Remove the middle support bolts (1) from drive
shaft and take the shaft complete with support.
1
25041
29
???.??.???.?? -- ?? -- ????
24. Connect the chain to a final drive assembly and

remove it from the transmission--gearbox case.
Do the same operation for the other side.
TRE0188A
30
25. Remove the retaining bolts and lift the hydraulic

body using the hoist.
TRE0187A
31
26. Use a chain to attach the tow hook and PTO to
the hoist. Remove the three retaining bolts (1) for
both side and remove the unit from rear trans-
mission--gearbox case.
32
27. Unscrew the nut (1), remove the bolt, take the
lower arm (3) out and its spacer (2) by complet-
ing the operations for both side. 1 2 3
25773
33
???.??.???.?? -- ?? -- ????
28. Connect the ends of flexion bar (1) using belt that
strong enough to be lifted the assembly up. Re- 1
move the retaining bolts (2) and take the as-
sembly.
TRE0508A
34
29. Remove the bolts, and then lift the gearbox cover
(1).
TRE0104A
35
30. Remove the bolt (1) and rear transmission case
internal oil tank complete (2). 2
1
25774
36
31. Connect the rear transmission--gearbox case to
the hoist by chain. Begin to remove the rear
transmission--gearbox case using stand
380000236.
TRE0189A
37
???.??.???.?? -- ?? -- ????
18
???.??.???.?? -- ?? -- ????
SECTION 27 -- REAR AXLE AND TRANSMISSION -- CHAPTER 1
TRE0553A
Diagram for application of sealing compound to the rear transmission--gearbox casing 38

The types of sealing compound to be applied are listed on page 1 of Section 00.
Installation 16. Install the rear wheels and remove stand

380000236.
WARNING 17. Install the DT drive shaft and secure it by means

Use appropriate tools to align the holes. NEVER of the middle support and, the front and rear
USE YOUR FINGERS OR HANDS. sleeves.
18. Install the guard onto transfer box shaft.
1. For the correct orientation of the various parts, 19. Screw on the rear transmission--gearbox case oil
refer to the illustrations on pages 5, 7, and 8. discharge plugs and the fuel tank discharge plug.
2. Before installing boxes, supports and covers, 20. Connect the fast raise/lower control cable.
thoroughly clean and degrease the mating sur-
faces and apply a strip of sealing compound of 21. Connect the differential lock mechanical control
about 2 mm (.078 ins) diameter as shown in the rod.
diagram on page 26.
22. Connect the parking brake control rod.
3. Apply the torque settings given on page 4. 23. Install the gearbox and final drive control levers.
4. Using the stand 380000236, install the rear 24. Install the reverser control lever.
transmission--gearbox case onto the clutch box.
25. Connect the PTO speed selection cable.
5. Install the flexion bar support complete with inter-
nal connecting rod. 26. Connect the synchronised PTO control lever.
27. Connect the auxiliary hydraulic valve control lev-

6. Position the left and right brake friction discs.
ers.
Install the brake assembly, and the lateral final
drive assembly. 28. Install the fuel tank together with fixing brackets,
mountings and rear transmission--gearbox
7. Install the PTO cover to the transmission--gear- breather pipes.
box case.
29. Connect the pipes and connections to the fuel
8. Install the internal tank complete with oil dis- tank.
charge pipe.
30. Connect the gearbox clutch control rod.
9. Install the lower arms and spacers.
31. Connect the accelerator control cable.
10. Install the tow hook. 32. Make all electrical socket connections between
the operator environment and the tractor body.
11. Install the hydraulic lift complete.
33. Screw on the engine cooling liquid discharge
12. Insert the springs and poppet balls and install the plug on the base.
gearbox and final drive control rod support cover
on the rear transmission--gearbox case. 34. Fill up the fuel tank, the rear transmission--gear-
box case and cooling circuit; prescribed products
13. Install and connect the lift control and oil filling and their quantities are given in Sect. 00.
pipes.
35. Connect up the front headlights.
14. Install the third--point linkage support together
36. Screw on the engine cooling liquid discharge
with the quick--release installing support plate plug on the base.
and electrical power sockets with respective con-
nections.
37. Fill up the fuel tank, the rear transmission--gear-
15. Install and connect all the hydraulic pump inlet box case and the cooling circuit; the prescribed
and outlet pipes and the connection pipes of the products and quantities are given in Sect. 00.
auxiliary hydraulic valves, hydraulic lift, DT trans-
fer box, etc. 38. Connect the negative terminal of the battery.
???.??.???.?? -- ?? -- ????
TRANSMISSION--GEARBOX CASE
Disassembly
WARNING
Never place your hands or fingers between one part
and another. Wear the prescribed safety clothing, in-
cluding glasses, gloves and protective footwear.
1. Secure the transmission box--gearbox to the

turning stand 380000301 using the front
380000272 and rear 380000271 mountings. TRE0509A
39
2. Turn the box by 180°, undo the bolts (1) and re-
move the transfer box (2).
2
TRE0510A
40
3. Turn the box by 180°, then use a punch to re-
move the elastic pins (1) and take out the shift
rails, the prongs, the gearbox and final drive con-
trol forks.
25783
41
4. Use a punch to remove the elastic pin (2) retain-

ing the differential lock engagement fork (1). 2 3 4
1
Withdraw the rod (4) and remove the helical
spring (3) and the fork.
TRE0511A
42
???.??.???.?? -- ?? -- ????
5. Remove the elastic pin (2) and take out the exter-
nal lever (1) that controls the PTO synchronised
with the gearbox.
1
2
TRE0512A
43
6. Withdraw the internal lever (2) complete with
spring (1) and slide (3). 3
1 2
25791
44
7. Straighten out the notches and undo the driven
shaft locking nut (1).
1
25792
45
8. Remove from the rear the snap ring (1) that re-
tains the final drive driving shaft bearing.
1
25793
46
???.??.???.?? -- ?? -- ????
9. Using a hammer and a brass punch (1) withdraw

the gear (2) for the mid--range speeds together
with the respective bearings and engagement
1 2 3
sleeve (3).
25794
47
10. Withdraw the final drive driving shaft (1).
1
25795
48
11. Remove the snap ring (1) that holds the bearing
(2) onto the gearbox drive shaft.
1 2
25796
49
12. Install the tool 50006 (2) (see Sect. 21) onto the
driving shaft and use the extractor (1) to with- 1 2
draw the driving shaft. Remove the bearings,
gears and respective bushings.
25797
50
???.??.???.?? -- ?? -- ????
13. Straighten out the notches in the washer that re-

tains nut (1) and slacken the nut. 1
25799
51
14. Screw the adapter 293940 (2) onto the pinion (3)
and use the extractor with sliding weight 292927
1 2 3
(1) to move the pinion by a few millimetres in the
direction shown.
25901
52
15. Move the engagement sleeve (1) until it is pos-
sible to gain access with pliers (2) to remove the 1 2
retaining snap ring.
25800
53
16. Move the gear (1) in the direction shown and re-
move the two retaining half--rings (2). Undo the
1 2 3
nut (3) completely and withdraw the pinion, re-
moving all parts.
25902
54
???.??.???.?? -- ?? -- ????
17. Undo the bolts (3), take out the support plate (1)
and remove the bearing (2).
1 2
25903
55
18. Use a brass punch (2) and a hammer to move the
driven shaft (1), withdraw the shaft and remove 2
1
all the parts.
19. Mount the rear transmission--gearbox case by
following sectional views and instructions given.
20. Apply the torque settings listed on page 4.
25904
56
Assembly
1 2
WARNING
Use appropriate tools to align the holes. NEVER
1. Position the box vertically, insert the gearbox

driven shaft gear set (2) and insert the shaft (1).
25907
57
???.??.???.?? -- ?? -- ????
2. Turn the box by 90°, install the front bearing (1)

and the nut (2) and tighten to the prescribed 2
1
torque.
25908
58
3. Install the bearing (2) in its housing on the box
(front end) and lock it using the plate (1).
1 2
25903
59
4. Insert the gear shift forks (1 and 3) on the sliding
rings (2 and 4) of the synchronisers. 1 2 3
5. Install the pinion shaft complete with all the parts
and carry out the adjustments given on pages 4
36, 37 and 38.
25912
60
6. Install the gearbox drive shaft complete with all
parts and the adjuster shim, then position the
bearing (2) and lock it using the snap ring (1).
1 2
25796
61
???.??.???.?? -- ?? -- ????
7. Insert the final drive driving shaft from the rear

end, install the bearing (2) into its seat and lock 1 2
using the snap ring (1).
25913
62
8. Install the lever (1) that controls the PTO syn-

chronised with the gearbox, complete with
spring, pawl and external lever.
1
9. Install the ring gear complete with support and

adjuster shims (see adjustments on pages 38,
39 and 40).
10. Install the differential lock engagement control

fork complete with spring--rod unit, external plate
and the corresponding adjuster shims (see page
37). 25791
63
11. Install the piston and the corresponding differen-
tial lock control union.
12. Install all the rods, forks and gearbox and final
drive control prongs.
13. Install the transfer box assembly.
???.??.???.?? -- ?? -- ????
ADJUSTMENTS
GEARBOX DRIVING SHAFT AXIAL

CLEARANCE
WARNING
Proceed as follows :
Note -- Once installted, the driving shaft gears must

have an axial clearance of 0--0.25 mm (0 -- .009 ins).
The bearings must therefore be adjusted to prevent
them from being mounted with an axial preload.
To perform this adjustment, it is recommended ma-
king a tool in the workshop according to the specifica-
tions given in the drawing in Sect. 21.
1. On the bench mount all the various components
on the drive shaft, replacing the two rear bear- 1 2
ings and the adjuster ring with the tool 50007 (1)
(see Sect. 21).
2. Insert a screwdriver between the gear and its H

bushing and use a feeler gauge to measure the
clearance (H).
3
25910
64
3. Measure the height (C) of the tool 50007 and the
thickness of the internal rings of the two rear
bearings (1 and 2). B
1 2
4. The adjuster shim to be installted is given by :
A C
S = H + C -- A -- B
where :
H = measured clearance
A and B = measured thickness of the bearings
C = height of the tool.
H
Example :
-- measured clearance H = 1.3 mm (.051 ins)
-- height of tool = 43.5 mm (1.712 ins)
25911
-- thickness of ball bearing (1) = 22.9 mm
(.901 ins) 65
-- thickness of roller bearing (2) = 18 mm
(.708 ins)
Thickness of adjuster ring :
S = 1.3 + 43.5 -- 22.9 -- 18 = 3.9 mm
(S = .051 + 1.712 -- .901 -- .708 = .154 ins)
Note -- Since the gears are to be mounted with an ax-

ial clearance of 0--0.25 mm (0 -- .009 ins), in this case
it will be necessary to install a shim (S) of 3.75 mm
(.147 ins) so that to provide an axial clearance of:
3.9--3.75 = 0.15 mm (.154 -- .147 = .006 ins).
???.??.???.?? -- ?? -- ????
DIFFERENTIAL LOCK ENGAGEMENT

SLEEVE POSITION ADJUSTMENT
WARNING
1. Mount the differential release device without the

adjuster shim.
1
2. Insert gauge 50041 (2, see page 5) with the
8.1--8.2 mm (.318 -- .322 ins) shim between the
sleeve and the differential box so that it touches
the sliding surface of the sleeve on the box.
3. Use a suitable lever (2) to bring the sleeve into

contact with the gauge 50041 and the differential
box by acting on the fork (1) at the position of the
gauge. 2
TRE0513A
66
4. Clearance (G) measured between differential
lock sleeve (7) and differential bearing (8) should
be verified according to the models as follows:
TD60 and TD70: 2 mm (.078 ins).
TD80, TD90 and TD95: 0.5 mm (.020 ins).
G. Clearance between sleeve and bearing

C3. Capscrew
1. Differential lock lever
2. Lever support
3. Fork control rod
4. Fork
5. Retun spring
TRE0514A
6. Control pin
67
5. Use a feeler gauge (1) to measure the clearance
between the control pin (2) and its seat on the rod
(3).
6. Place the required shim underneath the differen-

tial release device and secure it by bolts.
TRE0515A
68
???.??.???.?? -- ?? -- ????
PINION SHAFT POSITIONING

ADJUSTMENT RING 1 2
1. On the transmission--gearbox case mount the
external ring of the bearing (1) with the test shim
(2) and the external bearing ring (3, fig. 99).
25915
69
2. Position the bearing (2) on tool 50004 (1, see
page 4), insert the bearing (3) and lock the tool
(1).
1
2 3
25916
70
3. Position the tool 380000249 (2) with two conical
parts in the differential supports and insert the
micrometer (1) with depth rod into its seat and
1 2
lock using the bolt.
25917
71
4. Screw down or unscrew the cones (1 and 2) so
that to move the micrometer rod to the position
of the bearing, adjust the cones (1 and 2) manu-
1
ally to lock the tool on the supports and eliminate
any axial clearance.
H1
5. Move the depth rod of the micrometer into con-
tact with the bearing and measure the value (H1).
2
25918
72
???.??.???.?? -- ?? -- ????
6. Calculate the corrected nominal distance (H3)

between the ring gear axis and the major base of
the pinion shaft :
H3 = H2 + C
where :
H2 = 145.5 mm (5.728 ins). Nominal distance
between the ring gear axis and major base of the
pinion.
C = Correction value stamped on the pinion, ex-
pressed in mm and preceded by a + or -- sign, if
other than 0, to be added to or subtracted from
the nominal distance (H2) respectively.
7. Thickness of the adjuster ring (S) is given by :
S = H1 + Sp -- H3
where :
H1 = Distance measured with the micrometer

gauge.
H3 = Corrected nominal distance between
the ring gear axis and the major base of
the pinion.
Sp = Test ring.
Examples :
Distance measured with the micrometer gauge
H1 = 145.9 mm (5.744 ins).
1
Thickness of test ring Sp = 1.90 mm (.074 ins).
Nominal distance between the ring gear axis and H1
major base of the pinion H2 = 145.5 mm (5.728
ins).
a) Correction value C = + 0.2 mm (.0078 ins).
Corrected nominal distance H3 = 145.5 + 0.2 =
2
145.7 mm (5.728 + .0078 = 5.736 ins).
S = 145.9 + 1.90 -- 145.7 = 2.10 mm (S = 5.744 25918
+ .074 -- 5.736 = .082 ins).

73
b) Correction value C = -- 0.2 mm (.0078 ins).
Corrected nominal distance H3 = 145.5 -- 0.2 =
145.3 mm (H3 = 5.728 -- .0078 = 5.720 ins).
S = 145.9 + 1.90 -- 145.3 = 2.50 mm (S = 5.744
+ .074 -- 5.720 = .098 ins).
c) Correction value C = 0 mm (0 ins).
Corrected nominal distance H3 = H2 = 145.5 mm
(5.728 ins).
S = 145.9 + 1.90 -- 145.5 = 2.30 mm (S = 5.744
+ .074 -- 5.728 = .090 ins).
8. Remove the tools 380000249 and 50004; take
out the bearing external rings, the test shim and
two differential supports.
???.??.???.?? -- ?? -- ????
TAPER--ROLLER BEARINGS FOR PINION

SHAFT
1
1. Install the external bearing race together with the
previously calculated adjuster shim (S) and the
pinion complete with range gears.
2. Tighten the bearing adjustment nut (1) while

turning the pinion shaft to allow the bearings to
bed in until rolling torque of 1.5--2.0 Nm (13 -- 18
ins lbs) is obtained.
25799
74
3. Engage low range gears. With a cord wrapped

around the slow speed gear (low range) trans- 1
mission on the pinion, make sure that the gear-
box shafts are not turning (idle). The specified
rolling torque corresponding to a force measured
by the spring scale (1) should be 17.6--23.5 N (4
-- 5.2 lbs).
25919
75
4. After obtaining the recommended torque, bend

the securing plate (1) onto adjuster nut to lock the
nut in place.
TRE0516A
76
???.??.???.?? -- ?? -- ????
DIFFERENTIAL BEARINGS AND BACK-

LASH OF RING AND PINION TEETH
WARNING
WARNING
Always use appropriate tools to align the holes. NE-
VER USE YOUR FINGERS OR HANDS.
1. With pinion installed, install differential with ring

gear.
Install LH support (1) and tighten ring nut (2) to
ensure minimum ring gear to pinion backlash of
1 mm (.04 ins) approximately.
27300
77
2. Install RH support and tighten to 49 Nm (36 ft-
lbs).
Install and tighten RH ring nut while turning the 1
ring gear to seat the bearings. Tighten ring nut
until pinion ring gear assembly rolling torque is
9.8 -- 14.7 Nm (7.23 -- 10.85 ft-lbs). Torque can
be measured using spring scale and a cord
wrapped around differential carrier flange. Spe-
cified rolling torque is equivalent to a spring scale
force of 95 -- 147 N (22 -- 33 lbs).
TRE0517A
78
3. Use a dial gauge (1) to check the backlash (G)
of the ring and pinion (three measurements at
120° and average of the readings). Compare the
1
average of the three values with the normal pre-
scribed clearance: 0.18--0.23 mm, mean 0.21
mm (.007 -- .009, average .008 ins).
Note -- Differences among the three readings should

not exceed 0.05 mm (.002 ins).
TRE0518A
79
???.??.???.?? -- ?? -- ????
4. To compensate for excessive backlash, note that

the average ratio of normal backlash to equiva-
lent ring gear axial displacement is 1:1.4. Conse-
quently, axial displacement (Z) will be:
Z = (G--0.21) x 1.4
(Z = [G--.008]) x 1.4
where :
G = Ring gear backlash as previously measured.
NOTE: If Z < 0 then take the ring gear away from
the pinion and if Z > 0 or if Z = 0 then place the
ring gear closer to the pinion.
5. Unscrew the RH ring nut (1) using tool 50027 (2),

and tighten LH ring nut equivalently until recom-
mending backlash is achieved. 2
1
28118
80
6. 60° ring nut rotation, equivalent to one side of

ring nut hexagon and corresponds to a ring gear
axial displacement of .33 mm (.013 ins).
To calculate ring gear axial displacement (Z)
from degree rotation of the ring nut (A) use the
following formula:
Z in mm = A / 180 (Z in ins = A / 4615.3)
Note -- One complete turn of ring nut corresponds to

2 mm (.078 ins) ring gear axial movement. 60° turn
of ring nut, equivalent to one side of ring nut hexagon,
TRE0519A
corresponds to a ring gear axial displacement of .33
mm (.013 ins). 81
With backlash and rolling torque adjustment

completed, install the ring nut lock rings (38) fig.
6 with lock ring tab aligned with notch on differen-
tial support.
???.??.???.?? -- ?? -- ????
DIFFERENTIAL PLANETARY AND SIDE

GEAR BACKLASH
With the dismantled differential on the bench, pro-

ceed as follows :
WARNING
All parts of differential must be cleaned so that oil
residue will not effect the accuracy of the adjustment.
1. Mount the side gears (2 and 5) without rings (1

and 6) on the differential box. Insert the planetary 1 2 3 4
gears (3 and 8) complete with their respective 5
clearance rings and with the pin (7); tighten the
retaining bolt (4) by a few turns in order to pre- 6
vent the pin from falling out.
8
25920
82
2. Move the LH side gear to bring it in complete con-
tact with the planetary gear, then push it up
against the differential box. Use a dial gauge to
measure the side gear movement. Make two
measurements in diametrically opposit positions
and take the arithmetic mean of the two values H1
as H1.
24597
83
3. Do the same operations on the RH side gear.
H2
24598
84
???.??.???.?? -- ?? -- ????
4. Axial movement of each side gear (2 and 5) with-

out shims is given as : 1 2 3 4 5
Gs or Gd = H1
where : 6
Gs = axial movement of LH side gear;
Gd = axial movement of RH side gear;
H1 = distances measured on LH or RH side gear. 7
Normal clearance between the sides of the side gear 8
and differential pinion teeth is 0.15 mm (.006 ins) for
TD60 and TD70 models. The value is 0.18 mm (.007 25920
ins) for TD80, TD90 and TD95 models.
85
Bear in mind that the average ratio between the nor-
mal clearance of differential pinion--side gear and the
equivalent axial movement of the side gears is 1:1.7.
The axial movement of the side gears corresponding
to the normal prescribed clearance between the
teeth is :
0.15 (.006 ins) x1.7 = 0.25 mm (.010 ins) for TD60
and TD70 models;
0.18 (.007 ins) x1.7 = 0.30 mm (.012 ins) for TD80,
TD90 and TD95 models.
Thickness of the spacer rings (1 and 6) to be inserted
on the differential box are :
Ss = Gs -- 0.25 mm (.010 ins)
(for LH side gear of TD60 and TD70 models)
Sd = Gd -- 0.25 mm (.010 ins)
(for RH side gear of TD60 and TD70 models)
Ss = Gs -- 0.30 mm (.012 ins)
(for LH side gear of TD80, TD90 and
TD95 models)
Sd = Gd -- 0.30 mm (.012 ins)
(for RH side gear of TD80, TD90 and
TD95 models)
Available shims are 1.5 (.059 ins) and 1.6 mm (.062
ins) to use for the side gear as shown on page 1.
Install the shims at the closest thickness for the LH
and RH side gears according to calculations).
???.??.???.?? -- ?? -- ????
TRE0554A
86
Longitudinal and Cross Sectional Views of Bevel Gear Pair and Differential Unit
a. TD60 and TD70 models 12. Side gear shim
b. TD80, TD90 and TD95 models 13. Side gear shim
c. Longitudinal section for all models 14. Differential box
C1. Ring gear retaining screw 15. Bevel pinion shaft
C2. Differential support retaining screw 16. PTO shaft
S. Bevel pinion positioning shim 17. PTO control sleeve
1. Differential support 18. Fork
2. Differential support 19. Differential lock shaft
3. Taper roller bearing 20. Range gear retaining ring
4. Taper roller bearing 21. Bevel pinion securing plate
5. Differential lock sleeve 22. Differential bearing ring nut
6. Ring gear 33. Reverse driven gear
7. Side gear 34. Driven gear for slow speed gears
8. Side gear 35. Engagement sleeve for slow and fast speed
9. Differential pinion gears
10. Differential pinion shaft 36. Transmission driven shaft ring
11. Differential pinion shaft retaining screw 37. Retaining half--ring
???.??.???.?? -- ?? -- ????
FINAL DRIVE REMOVAL
WARNING
WARNING
Always use appropriate tools to align the holes.
CAUTION
Raise and handle all heavy components using a
suitable lift.
Ensure that units or parts are supported by suitable
slings or hooks. Ensure that there is no one in the
vicinity of the load to be lifted
Remove the final drive as follows :
1. Drain oil from rear transmission and final drive

housings.
2. Position a support stand under transmission

housing and remove ROPS frame, wheels,
fenders and platform.
3. Take out capscrews (C5) Fig.1, Page 4 and
remove final drive assembly as shown at Fig.87.
TRE3011A
87
Disassembly (Cover)
Remove the final drive as follows :

4. Take off capscrews (C1) Fig. 5, Page 7 and
remove final drive cover (3) Fig. 5 with driven
gear (8) Fig. 5.
???.??.???.?? -- ?? -- ????
Driven gear retaining nut removal

B
Remove the gear retaining :

5. Tighten two M16 x 1,5 screws (C5) Fig. 88, into
two of the wheel disc holes on hub and clamp
wheel shaft in vice Fig. 88;
6. Unscrew nut (C5, Fig. 5, page 7) as shown in
Fig. 88 with a suitable spanner (B).
TRE3012A C5
88
7. Withdraw driven gear (8). Fig. 5, page 7 from
wheel shaft (2) using puller as shown in Fig. 89
TRE3013A
89
Wheel shaft removal (installation) (Fig. 90)
(Arrow indicates shaft removal direction) 4 2 21 7
3
8. Knock out wheel shaft (2) by beating with lead
hammer in the direction shown by arrow in Fig.
90.
9. Use puller to withdraw outer ring (7) from cover
(3);
10. Finally, withdraw the bearing (4) from cover,
having first removed retaining circlip (21).
TRE3014A
90
DISASSEMBLY (housing) (Fig. -- 91)
11. Remove the bearing (5) from the housing (10)
Fig. 91, with a suitable puller; 10
12. Remove retaining ring (17) Fig. 91, and withdraw 5
axle shaft (9) Fig. 91, together with bearing (6)
Fig. 91, in the direction shown by arrow. 6
9
7
TRE3015A 17
91
???.??.???.?? -- ?? -- ????
13. Remove the roller bearing internal ring (7)

Fig.91, page 38, from the axle shaft, using puller
seperator as shown in Fig.92, and the ball
bearing (7) Fig. 5, page 7, from the axle shaft
(9) Fig. 91, having first removed the lockring;
D
14. Check and replace damaged and worn parts;
15. Check lip seals (11--12) Fig. 5, page 7, and 7
replace if necessary; position as shown in Fig. 5.
TRE3016A
92
ASSEMBLY
Carry out the above operations in the reverse order,
bearing in mind the following:
1. Place the roller bearing (7) Fig. 90, outer ring in
its seat in the final drive cover with mark on the
outside;
2. Install the other bearings, using appropriate

installers;
3. Fit the half shaft and wheel shaft, taking care not
to damage the seals (11--12) Fig. 5;
4. Fit the roller bearing internal ring (7) Fig.91, page

38, on the half shaft (9) Fig. 91 having heated it
in the oil to 80--90 °C (176--194°F);
5. Tighten the gear locknut (C5) Fig. 5 page 7,

using wrench (B) Fig. 88 page 38, previously
used for disassembly.
6. Tighten all the nuts and screws to the torque

values given on page 3.
7. Clean and grease the surfaces in contact

between the housing (10) Fig. 5 page 7 and the
cover (3) Fig. 5 page 7, inserting a new seal (20)
Fig. 5 page 7;
8. Throughly clean and grease the surfaces (X)

Fig.38 page 18, applying jointing compound.
???.??.???.?? -- ?? -- ????
???.??.???.?? -- ?? -- ????
SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 1
SECTION 31 -- POWER TAKE--OFF
Chapter 1 -- Mechanical Power take--off
CONTENTS

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal -- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
31 101 Bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
31 000 -- MAIN SPECIFICATION -- TORQUE SETTINGS -- TOOLS -- SECTIONAL DRAWINGS --

DESCRIPTION AND OPERATION -- TROUBLESHOOTING
MECHANICAL POWER TAKE--OFF
TD60 and TD70 TD80, TD90 and

TD95
540 rev/min PTO
1) Independent of tractor travel
speed
Type (Independent and ground speed PTO) . . . . . . . . . . . . . or:
2) Synchronized with gearbox
Engagement and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical by means of hand

levers located on RH and LH side of
driver’s seat (see page 9 and 10)
Direction of rotation (viewed from rear of tractor) . . . . . . . . . clockwise
Engine speed with PTO shaft rotating at 540 rev/min . . . . . rev/min 2200
PTO speed with engine at maximum power (2500 rev/min) rev/min 614
Ground speed PTO. Rear wheel speed with PTO shaft wheel
rotating at 540 rev/min speed
(30 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 8.2 8.9
(4WD 40 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 6.73 7.25
Diameter of PTO shaft at position of bearings . . . . . . . . . . . mm 49.938 -- 50.000
Diameter of PTO shaft at splined end . . . . . . . . . . . . . . . . . . 13/8 in. (6--spline)
??????????? -- 05 -- 2002
2 SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

(continued)
TD95
2--speed 540/750 rev/min PTO (option -- all models)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . as for single--speed PTO
Engagement and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . as for single--speed PTO
Direction of rotation (viewed from rear of tractor) . . . . . . . . . as for single--speed PTO
Speed selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of hand lever located to
rear RH side of driver’s seat
PTO speed with engine at maximum power speed (2500
rev/min:
-- for 540 rev/min PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 614
rotating at 540 rev/min speed see 540 rev/min PTO
(30 and 40 km/h versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min
(40 km/h 4WD version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 8.59 9.36
Diameter of driven shaft at grooved terminal . . . . . . . . . . . . 13/8 in. (6--spline)

2--speed 540/1000 rev/min PTO (option -- all models)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . as for single--speed PTO
Engagement and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . as for single--speed PTO
Direction of rotation (viewed from rear of tractor) . . . . . . . . . as for single--speed PTO
Speed selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of hand lever located on
rear RH side of driver’s seat
Engine speed with PTO shaft rotating at 1000 rev/min . . . . rev/min 2380
PTO speed with engine at maximum power
(2500 rev/min):
-- for 1000 rev/min PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 1050
??????????? -- 05 -- 2002

(continued)
TD95
rotating at 540/750 rev/min speed as for single--speed PTO
(30 and 40 km/h versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min
(40 km/h 4WD version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rev/min 11.5 12.4
Diameter of PTO shaft at splined end:

-- 540 rev/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/8 in. (6--spline)
-- 750 rev/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/8 in. (6--spline)
-- 1000 rev/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/8 in. (21--spline)
External diameter of driven gear support bushings . . . . . . . mm 49.925 -- 49.950
Internal diameter of driven gears . . . . . . . . . . . . . . . . . . . . . . mm 50.050 -- 50.089
Clearance between driven gears . . . . . . . . . . . . . . . . . . . . . . mm 0.100 -- 0.164
Diameter of driven shaft at front and centre bushings . . . . . mm 39.166 -- 39.191
Diameter of driven shaft at rear bushing . . . . . . . . . . . . . . . . mm 34.984 -- 35.000
Internal diameter of front and centre bushing . . . . . . . . . . . . mm 39.200 -- 39.239
Internal diameter of rear bushing . . . . . . . . . . . . . . . . . . . . . . mm 35.009 -- 35.048
Clearance between shaft and front and centre bushings . . mm 0.009 -- 0.073
Clearance between shaft and rear bushing . . . . . . . . . . . . . . mm 0.009 -- 0.064
TOOLS
Important -- The operations described in this section 291517 Hook for lifting PTO
must be performed solely with the ESSENTIAL tools
marked below with (X).
To work in complete safety and to ensure optimal
technical results with a minimum of time and effort, 293812 Guide pins for PTO unit
they must however be supplemented with the
specific tools recommended below and with those to
be specially constructed by you and for which the 291928 Installer for PTO driving shaft
construction diagrams are given in this manual. bearings
??????????? -- 05 -- 2002
TORQUE SETTINGS
C1 -- 221 Nm C2 -- 25 Nm C3 -- 162 Nm
C4 -- 294 Nm
Single--speed 540 rev/min PTO 2--speed 540/750 rev/min PTO
26276
TORQUE SETTINGS
Torque setting
PART TO BE TORQUED Thread
Nm kgm
Bearing support securing screws (2-- and 3--speed PTO) . . . . . . . . M 12 x 1.25 98 10
PTO box securing screws (C1, fig. 1) . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 221 22.5
PTO guard securing screws (C2, fig. 1) . . . . . . . . . . . . . . . . . . . . . . M 8 x 1.25 25 2.6
Self--locking nuts for securing splined shaft
(C3, fig. 1 for 2--speed PTO) or M 12 x 1.25 162 16.5
Driven gear shaft lock nut:

(C4, fig. 1) for single-- or 2--speed PTO . . . . . . . . . . . . . . . . . . . . . . M 32 x 1.5 294 30
??????????? -- 05 -- 2002
1 2
28 3
4
27
5
26
6
25
24
7
23
22
21
8
20
19 9
18
X X
10
17
16
11
15
14 13 12
a -- single--speed 540 rev/min PTO b - 2-- speed 540/750 rev/min PTO

26278
Sectional diagrams of single-- and 2--speed PTO

a. Sectional diagram of single--speed PTO. 13. Rear transmission support.
b. Sectional diagram of 2--speed PTO. 14. Driven gear.
1. 540 rev/min PTO cover. 15, 27, 28, 16 and 5. Snap rings.
2. 540/750 rev/min PTO cover. 17. PTO guard retaining screws.
3. PTO unit fixing screw. 18. 540 rev/min PTO driven shaft
4. Drive shaft bearings. 19. Driven gear support bushings.
6. Self--locking nut to secure splined shaft. 20. Driven shaft lock nut.
7. 540 rev/min splined shaft. 21. Fixed gear.
8. 750 rev/min splined shaft. 22. Coupling sleeve.
9. Seal 23. Driven gear for 750 rev/min speed.
10. Driven shaft bearings. 24. Driven gear for 540 rev/min speed.
11. Cover locating pin. 25. Double drive gear.
12. Rear transmission casing. 26. Drive gear.
NOTE: When installing use sealing compound of the type shown on page 1 section 00 on surface X as shown above.
??????????? -- 05 -- 2002
4
27
5
6
25
24
7
23
22
21
8
20
19 9
X
10
11
2--speed 540/1000 rev/min PTO

13 12
26278
Sectional diagram of single-- and 2--speed PTO

2. 540/1000 rev/min PTO cover. 12. Rear transmission casing.
3. PTO unit retaining screw. 13. Rear transmission support.
4. Drive shaft bearings. 19. Driven gear support bushings.
5. Snap ring. 20. Driven shaft lock nut.
6. Self--locking nut to secure splined shaft. 21. Fixed gear.
7. 540 rev/min splined shaft. 22. Coupling sleeve.
8. 1000 rev/min splined shaft. 23. Driven gear for 1000 rev/min speed.
9. Seal. 24. Driven gear for 540 rev/min speed.
10. Driven shaft bearings. 25. Double drive gear.
11. Cover locating pin. 27. Snap ring.
NOTE: When installing use sealing compound of the type shown on page 1 section 00 on surface X as shown above.
??????????? -- 05 -- 2002
TRE0308A
Sectional diagram of single-- and 2--speed PTO

17. PTO speed selector lever. 20. Rear cover.
18. Roll pin. 21. Fork.
19. Shaft. 22. O--ring.
??????????? -- 05 -- 2002
2
10
3
1
9
TRE0990A
Section views -- 540 -- 1000 rev/min PTO North American version (available on request), not
synchronised with gearbox, with speed selection by replacement of splined output shaft.
1. Splined 1 3/8” output shaft (6 splines) for 540 rpm
PTO, or 1 3/8” output shaft (21 splines) for 1000
6. Return spring.
rpm PTO.
2. Driven shaft. 7. Return rod.
3. Snap ring securing part (1). 8. Speed selector lever support.
4. Speed selector rod. 9. Speed selector lever.
5. Speed selector sleeve control fork. 10. Speed selector sleeve.
??????????? -- 05 -- 2002
DESCRIPTION AND OPERATION OF

MECHANICAL PTO
The PTO, located at the rear of the tractor, transfers

power to the implement being transported or towed.
It can be controlled either directly from the engine 1 2
clutch or from the gearbox clutch. The PTO is shown
with the safety cap (1) and the guard (2) in position.
The safety cap must be removed to couple up an
implement to the PTO shaft.
The PTO with mechanical engagement/disengage-

ment is available in three versions:
— single--speed PTO, 540 rev/min (standard)

26280
6
— two--speed PTO, 540/750 rev/min (option)
— two--speed PTO, 540/1000 rev/min (option).
Independent PTO
Proceed as follows:
— with the PTO clutch disengaged, i.e. with the
control lever (1) fig. 7, rearward at position A;
1
— move the PTO selector lever (1) fig. 8, to position
B so as to engage the PTO sleeve (3) fig. 9, with
the toothed coupling of the shaft (2) which is
driven by the engine;
A
— engage the PTO by slowly moving the lever (1)
fig. 7, forward to position D.
D
TRE0106A
When engaged, the PTO shaft rotates and the PTO
warning lamp on the instrument panel lights up. 7
In these conditions the operation of the PTO is

completely independent of the travel of the tractor, so:
— the tractor can be stopped without stopping the

PTO;
— the PTO can be stopped without stopping the
C
tractor (by disengaging the PTO clutch).
To disengage the PTO move the PTO clutch control E
lever (1) fig. 7, rearward to position A then move the
speed selector (1) fig. 8, to the central position E. B
1
TRE0043A
8
??????????? -- 05 -- 2002
Ground speed PTO
Proceed as follows:
— with the PTO clutch control lever (1) fig. 7, at
position D;
— fully depress the gearbox/engine clutch pedal;
— wait briefly, then move the PTO speed selector
(1) fig. 8, forward to position C and release the
gearbox/engine clutch pedal;
In these conditions the PTO coupling sleeve (3) fig. 9,
is turned directly by the toothed coupling of gear (1) in
the gearbox.
When the tractor is stationary the PTO shaft does not
turn. When changing from forward to reverse gear,
the direction of rotation of the PTO shaft reverses.
NOTE: When the PTO is not being used, move the

lever (1) fig. 8, to position E (the neutral position of
the PTO engagement sleeve (3) fig. 9).
26281
PTO speed selector lever (2) fig. 10
To change PTO speed, proceed as follows: 2
— lift the spring--loaded collar (1) upwards;

— move the lever (2) forward to position (3) to select 1
750 or 1000 rev/min PTO speed. 3
This activates the external control lever (17) fig. 4
by means of a tie--rod. The external control lever in
turn rotates the internal fork device (21) and
selects the PTO speed by means of the coupling
sleeves TRE0089A
10
TROUBLESHOOTING FOR MECHANICAL PTO
Faults Possible causes Remedies
Slipping with loss of speed of PTO Wear of clutch disc or of engine Check the data given in the
output shaft. flywheel pressure plate. appropriate pages of section 18,
Poor adjustment of PTO clutch replace the worn parts and adjust the
control lever. clutch control lever.
Difficulty in selecting PTO speed External control stiff. Check the control lever.
by means of lever (2) fig. 10.
??????????? -- 05 -- 2002
540/750 MECHANICAL PTO

Removal -- Refitting (Op. 31 112 20)
WARNING
Lift and handle all heavy parts using lifting tackle of
sufficient capacity.
Make sure that the units or parts are supported by
suitable harnesses and hooks. Check that no one is
in the vicinity of the load to be lifted.
1. Disconnect the negative cable from the battery.
2. Remove the top link (1) of the three--point

linkage. 1
24952
11
3. Remove the tow hook (1), if fitted.
1
24953
12
4. Remove the tow bar (1), if fitted.
1
24954
13
??????????? -- 05 -- 2002
5. Remove the six tow hook support fixing

screws (1). 1
24955
14
6. Drain out the transmission/gearbox oil and
collect it in a suitable container.
24956
15
7. Remove the PTO speed selector control lever
(1).
TRE0002A
16
8. Remove the screws (2) that fasten the retaining
bracket (1) for the PTO speed selector control.
1
2
TRE0002B
17
??????????? -- 05 -- 2002
9. Remove the two upper screws (1) which fasten

the PTO unit to the transmission. 1
24957
18
10. Insert the two guide pins 293812 (1) and remove
the two lower screws (2) which fasten the PTO 1
unit to the transmission.
2
24958
19
11. Engage the lever (1) fig. 8, in position (C), ground
speed PTO, so that the sleeve (3) fig. 9, rests on 1
the shaft (2) during the removal operation.
Withdraw the PTO unit by a few centimetres and
detach using the hook with lifting chain 291517 (1).
To reinstall proceed as follows:
— Clean the mating surfaces between the trans-
mission and PTO cover and apply sealing com-
pound as shown in figure 21.
— Raise the PTO unit and position it directly behind
the transmission casing. Slide the PTO cover
onto the guide pins 293812, for ease of assem-
bly. 24961
— Remove the hook with chain (1) fig. 20, and
fasten the PTO unit using the two lower screws. 20
— Remove the two guide pins 293812 and install
the two upper screws.
— Reinstall the bracket (1) fig. 17, that retains the
PTO speed selector control lever.
— Refit the tow bar support.
— Refit the tow bar, the tow hook and the three--
point linkage top link.
— Screw in and tighten the oil drain plug and fill the
transmission/gearbox with oil.
— Reconnect the negative battery cable.
26282
21
??????????? -- 05 -- 2002
MECHANICAL PTO (540/750 rpm PTO)

Bench overhaul (Op. 31 112 45 -- 31 112 48)
WARNING
another.
12. Place the PTO unit in the vice on the work

bench (1). 1
24962
22
13. Use a punch to straighten the corrugations (1) on
the ring nut that retains the driven shaft
components.
1
24963
23
14. Remove the ring nut (1) from the driven shaft.
1
24964
24
??????????? -- 05 -- 2002
15. Remove the four PTO unit internal support fixing

screws (1). 1
24965
25
16. Remove the pin (1) securing the fork rod.
TRE0153A
26
17. Withdraw the rod (1) from the rear cover.
1
24967
27
18. Partially withdraw the PTO output shaft (1) and
remove the internal support (3) together with the 1 2
drive shaft (2), the driven gears (4), the sleeve
and the engagement/disengagement/neutral
control fork of the 540/750 PTO. Also, retain the
thrust washer from the gear (24) fig 2 or 3, for
reuse during reassembly.
3
24968
28
??????????? -- 05 -- 2002
19. Remove the rear bearing thrust washer (1) and

remove the secondary shaft (2) complete with 1 2
PTO output shaft.
24969
29
20. Remove the retaining snap ring, the bearing (1)

and the seal (if it needs replacing) from the rear 1
cover.
24970
30
To reinstall, Refer to fig. 2b and proceed as follows:

— Mount the seal (9) (if removed in step 20), the
rear bearing and the retaining snap ring (5) on
the rear cover.
— Refit the thrust washer on the driven shaft.
— Refit the driven shaft gear (23), the fixed gear
(21), the sleeve (22), the fork and the fork
support rod.
— Insert the gear (24) onto the driven shaft, mount
the internal support (13) complete with drive
shaft (25). Fasten the support (13) using the four
screws, tightening them to the torque setting
specified on page 4.
— Mount the thrust washer on gear (24) and install
the bearing on the internal support (13) of the
driven shaft.
— Fasten the rod that supports the PTO speed se-
lector control fork pin as removed in step 16.
— Tighten the driven shaft locking ring nut to the
torque specified on page 4, then, using a suit-
able punch, corrugate the edge in order to pre-
vent it from loosening.
??????????? -- 05 -- 2002
MECHANICAL PTO (540/1000 rpm PTO) (Inter-

changeable PTO Shaft) (NASO Version)
Bench overhaul (Op. 31--114)
WARNING
another.
21. Place the PTO unit in the vice on the work

bench (1). 1
24962
31
22. Remove the bolts (1) and take off the cover (2).
1
2
TRE1000A
32
23. Remove the spacer (1).
TRE1001A
33
??????????? -- 05 -- 2002
24. Remove the two socket head screws (1) and

take off the PTO engagement mechanism (2)
completely. 2
TRE1002A
34
25. Withdraw two rods (1) from the cover.
C1: Shaft securing nut tightening torque: 26 kgm
(255Nm)
C2: Cover retaining bolts tightening torque: 10 kgm 1
(98 Nm)
C1
C2
TRE1003A
35
26. Remove the nut (1) securing the shaft and take
off the 4 bolts (2).
TRE1004A
36
27. Remove the socket head screw bolt (1) on the
side of the cover.
1
TRE1005A
37
??????????? -- 05 -- 2002
28. Remove the cover (1).
TRE1006A
38
29. Remove the washer (1) and take off the gear (2).
2
1
TRE1007A
39
30. Remove the rod (1), spring (2), fork (3) and the
synchroniser (4). 4 3
1
TRE1008A
40
31. Remove the driven gear (1).
1
TRE1009A
41
??????????? -- 05 -- 2002
TRE1010A
42
33. Remove the drive shaft(1).
1
TRE1011A
43
34. Remove both bearings (1) and (2) .
2
TRE1012A
44
35. Remove the shaft (1) and the plate (2).
1 2
TRE1013A
45
??????????? -- 05 -- 2002
To reinstall, reverse the removal procedure and refer

to fig. 5 and proceed as follows:
— Mount the shaft (1) and the plate (2) on the rear
cover (fig. 45).
— Refit the two bearings (1 and 2) (fig. 44).
— Refit the drive shaft (1) (fig. 43)
— Install the circlip (1) securing the bearing (fig. 42)
— Insert the gear (1) (fig. 41).
— Install the rod (1), spring (2), fork (3) and the syn-
chroniser (4) (fig. 40).
— Install the washer (1) and the gear (2) (fig. 39)
— Install the cover (1) fig. 38.
— Install the socket head screw (1) on the side of
the cover (fig. 37)
— Install the nut (1) securing the shaft and refit the
4 bolts (2) fig. 36. Tighten the nut (1) to 26 kgm
(255 Nm) and bolts (2) to 10 kgm (255 Nm).
— Install the two rods (1) fig. 35.
— Refit the PTO engagement mechanism (1) and

install the socket head screws securing the
mechanism fig. 34.
— Install 1000 rpm PTO shaft with related circlip.
1
NOTE: The adjustment procedure should be done
ONLY with the 1000 rpm PTO shaft is installed.
— Using a screwdriver (1) and a spanner (2) adjust

the distance X to “0 mm” fig. 46.
X
— Install the spacer (1) fig. 33. 2
TRE1014A
— Install the cover (2) fig. 32 and tighten the bolts
46
(1).
— Use suitable hooks to assemble the unit to the
tractor fig. 31.
??????????? -- 05 -- 2002
??????????? -- 05 -- 2002
SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1 1
SECTION 33 -- BRAKING SYSTEM

Chapter 1 -- Braking system
CONTENTS

Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description and operation--Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
33 202 Removal--Refitting -- Overhauling service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal--Refitting of front brake master cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

MAIN SPECIFICATION
Type:
-- service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with oil bath discs acting on

differential half--shafts
-- parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with oil bath discs acting on
differential half--shafts
with oil bath discs acting on the
bevel pinion shaft by means of a
gear ( Optional )
Control:
-- service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical, with independent

pedals (connected by means of a
pin)
-- parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical, by means of a hand

lever
Disc material for service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . organic agglomerate
Disc material for parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . steel

Mobile sector material for parking brake . . . . . . . . . . . . . . . . . . . . . sintered
or
organic agglomerate
Disc thickness:
-- service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4
Number of discs per service brake:

-- TD60 and TD70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
-- TD80, TD90 and TD95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(see over)
603.54.331.00 -- 12 -- 1996
2 SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1
MAIN SPECIFICATION
(cont.)
Thickness of friction discs for parking brake:
-- outer friction discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 3.1 -- 3.4
-- intermediate friction discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 4.2 -- 4.5
Adjusting the control pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see page 19
TORQUE SETTINGS
Torque setting
PARTS TO BE TORQUED Thread
Nm kgm
Nuts securing final drive box to transmission box

(C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 10
Bolts for securing shaft for parking brake driven shaft (C2) . . . . .
M 10 x 1.25 64 6.5
Guide dowels for parking brake friction discs (C3) . . . . . . . . . . . . . M 12 x 1.25 24 2.5
Bolts for securing parking brake support to transmission box (C4) M 12 x 1.25 98 10
C2 -- 64 Nm
C3 -- 24 Nm
C4 -- 98 Nm
TRE0300A
C1 -- 98 Nm
1
603.54.331.00 -- 12 -- 1996
19 12
13
18
17
16
15 14 C
26288
TRE0301A
2
Sectional drawing of service and parking brakes
a. TD60 and TD70 models. 10. Boot cover plate.
b. TD80, TD90 and TD95 models. 11. Boot.
c Parking brake drawing 12 Driven gear.
1. Brake link. 13 Driven gear pin.
2. Pin. 14 Parking brake friction discs.
3. Ball. 15 Parking brake steel discs.
4. Brake actuator. 16 Parking brake internal control lever.
5. Brake discs. 17 Parking brake support.
6. Back--up discs 18 Snap ring.
7. Actuator pull--off spring. 19 Thrust bearing.
8. Differential support.
9. Axle shaft.
N.B. -- When mounting apply sealing compound to surfaces X as shown on page 1 section 00.
603.54.331.00 -- 12 -- 1996
3
4
Lm T
Pd
4 8 c
6
Ps 5
M 9
12
1 3
a
4 d
3
3
7 b
12975
3
View of service and controls
a. R.H. brake pedal in rest position and L.H. brake ap- 1. Brake links.
plied. 3. Actuator ball.
b. Brakes in rest position. 4. Brake actuator.
c. Brakes applied. 5. Brakes discs.
d. Brakes in rest position. 6. Back--up discs.
Lm. Parking brake hand lever. 7. Actuator return spring.
M. Brake pedal return springs. 8. Differential support.
Pd. R.H. brake pedal. 9. Axle shaft.
T. Parking brake link. 12. Final drive housing.
603.54.331.00 -- 12 -- 1996
SERVICE BRAKE eration is similar when the R.H. ( Rd ) pedal is de-

pressed.
Refer to the illustrations on page 4. The service PARKING BRAKE
brakes are mechanically operated, oil immersed
Refer to the drawing on page 2 as shown in detail (c).
discs. When the L.H. brake pedal ( fig. a ) is de-
The parking brake is mechanical. It operates on the
pressed, links move as indicated by the arrows,
rear bevel pinion shaft by means of an idler gear and
causing the actuator discs to turn. Balls (3) in tapered
is controlled by a lever located on the LH side of the
seats force the discs apart as shown in detail (c).
operator.
These simultaneous actions compress the brake When the parking brake control lever is applied, the
discs against the differential support (8) and back--up flexible rod acts on the external support lever and
discs. Immediately upon releasing the pedal, the presses the friction discs against the three brake
spring (7) pulls the actuator (4) back to the rest posi- discs splined onto the idler gear, hence stopping the
tion ( fig. b and detail d ) thus releasing the discs. Op- tractor.
EQUIPMENT
List of special tools necessary for the various opera-
Warning -- The operations described in this section tions described in this section.
must be performed only with the ESSENTIAL equip-
ment marked with (X). X 293847 Driver for boot installation.
To operate safely and achieve best results however, 291517 Lifting hook.
while saving time and effort, essential equipment
must be used in conjunction with the special tools
recommended below, and tools which you must
make yourself and for which you will find the design
in this manual.
603.54.331.00 -- 12 -- 1996
BRAKE TROUBLESHOOTING
Braking ineffectual. 1. Friction material on brake Replace the brake discs.

discs worn.
Unbalanced braking. 1. Incorrect tyre pressure. Inflate the tyres to the correct pres-
sure.
2. Friction material on one of the Replace the discs.
brake discs worn.
Braking noisy. 1. Friction material on brake Replace the discs.

discs worn.
1. Brake discs worn. Replace the brake discs.

Parking
g brake does not lock.
1. Brake discs seized on brake Release and replace damaged parts.

Brakes locked on when the park- discs.
ing brake is disengaged.
603.54.331.00 -- 12 -- 1996
RIGHT HAND OR LEFT HAND BRAKE

Removal--Refitting (Op. 33 202 60)
DANGER
Lift and handle all heavy parts using lifting equipment
of adequate capacity.
Make sure that the units or parts are supported by
appropriate harnesses and hooks. Make sure that
there is no one in the vicinity of the load to be lifted.
Proceed as follows to remove the lateral final drive

box.
1. Disconnect the negative battery cable (1).

1
2. Block the front wheels using chocks.
25621
4
3. Remove the vertical rod (1) and the LH stabiliser
strut (2).
1
26253
5
4. Raise the rear section of the tractor and place a
stand beneath the tow bar support.
25647
603.54.331.00 -- 12 -- 1996
5. Undo the retaining bolts and remove the rear LH

wheel.
25646
7
6. Remove the plug (1) and drain the oil from the
rear transmission--gearbox casing.
1
25622
8
7. Fit lifting hooks (1) 291517 onto the lateral final
drive box. Connect a hydraulic lift to the hooks,
undo the retaining bolts and remove the LH later-
al final drive box from the transmission box.
TRE0188A
9
8. Remove the cotter pin (1). Withdraw the linkage
(2) from link.
1
TRE0214A
10
603.54.331.00 -- 12 -- 1996
11. Back off link (1) from spring side and remove the
complete brake unit. 1
TRE0215A
11
9. Check actuator and brake discs for wear.
WARNING
10. Refit the lateral final drive box to the rear trans-
mission box as follows:
— Refer to the illustrations on page 3 for the correct TRE0303A
orientation of the various components.
12
— Before refitting the lateral final drive box to the
rear transmission box, thoroughly clean and de-
grease the mating surfaces and apply a strip of
sealing compound of diameter about 2 mm as
shown in the illustration on page 10.
— Apply the torque settings listed on page 2.
— Using tool 293847 as shown, to position the boot
(11) correctly on the brake link (1). ( See fig. 12
)
— Fit the brake disc and spacers.
— Using hooks (tool 291517) and a hydraulic lift,
refit the lateral final drive complete with axle
shaft and rear reflector.
— Fit the LH wheel.
— Fit the stabiliser strut and the vertical rod.
— Remove the stands.
— Screw in the oil drain plug and refill.
— Connect the negative battery cable.
603.54.331.00 -- 12 -- 1996
TRE0304A
13
Diagram for application of sealing compound when fitting braking assembly and lateral final drives
to transmission box.
The types of sealing compound to be used are specified on page 1 sect. 00.
603.54.331.00 -- 12 -- 1996
ADJUSTMENTS
HEIGHT OF SERVICE BRAKE PEDALS
1. With the brake pedals connected to their respec-

tive forks and the pedal connecting pin removed,
check that the pedal adjustment.
2. Check that pedal free travel is the same for both

pedals and does not exceed 80 mm (3.14 ins).
TRE3875A
14
3. If adjustment is required, move brake hand lever
downwards. Slacken the lock nuts (A) and tight-
en or slacken the sleeves (B) until the required A
free travel is 45 mm (1.77 ins). Lastly tighten the
lock nuts (A).
B
TRE0229A
15
603.54.331.00 -- 12 -- 1996
HAND BRAKE CONTROL

Adjusting travel (Op. 33 110 08)
The travel of the parking brake control lever must be

adjusted whenever work is carried out on the unit and
when the lever is not on the third notch of the gear
sector when the brake is engaged.
Proceed as follows.
1. Slacken the lock nut (1).

2. Tighten or slacken the adjusting screw (2) until 2
the control lever is locked on the third notch.
3. Tighten the lock nut (1).
TRE0217A
16
603.54.331.00 -- 12 -- 1996
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1 1
SECTION 35 -- HYDRAULIC SYSTEM
Chapter 1 -- Rear mechanical hydraulic lift
CONTENTS

Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
35 114 Removal -- Refitting -- Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

MAIN SPECIFICATION OF REAR MECHANICAL HYDRAULIC LIFT
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . position or draft control with a

combination of the two
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . two independent levers
LIFT--O--MATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . provides fast lifting/lowering
operations using pushbuttons,
without using the position or draft
control levers
Single--acting cylinder:
-- rated diameter and stroke:
TD60, TD70, TD80, TD90 Models . . . . . . . . . . . . . . . . . . . . . . . mm 100x128
TD95 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 100x128
-- capacity:
TD60, TD70, TD80, TD90 Models . . . . . . . . . . . . . . . . . . . . . . . cm3 1005
TD95 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3 1005
Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 186 -- 191 (190 -- 195 kg/cm2)
Cylinder safety valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 210 -- 215 (214 -- 219 kg/cm2)
Lift piston diameter:
-- TD60, TD70, TD80, TD90 Models . . . . . . . . . . . . . . . . . . . . . . . mm 99.980 -- 100.000
-- TD95 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 99. 980--100.000
Internal diameter of cylinder liner:
-- TD95 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 100.036-- 100.071
Clearance between piston and liner . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.036 -- 0.091
??.??.???.?? -- ?? -- ????
2 SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
MAIN SPECIFICATION OF REAR MECHANICAL HYDRAULIC LIFT

(continued)
Diameter of lift arm shaft (11, fig. 3) at position of bushings:

-- right--hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 54.970 -- 55.000
-- left--hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 62.670 -- 62.700
Internal diameter of bushings fitted on lift body:
-- right--hand side (8, fig. 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 55.100 -- 55.184(1)
-- left--hand side (12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 62.800 -- 62.884(1)
Clearance between lift arm shaft and bushings . . . . . . . . . . . . . . . mm 0.100 -- 0.214
Interference between bushings and their seats . . . . . . . . . . . . . . . mm 0.065 -- 0.185
Axial clearance of shaft complete with lift arms . . . . . . . . . . . . . . . mm 0.2 -- 1.4
External diameter of draft control idler shaft . . . . . . . . . . . . . . . . . . mm 21.967 -- 22.000
Internal diameter of seats in support . . . . . . . . . . . . . . . . . . . . . . . . mm 22.020 -- 22.072
Clearance between idler shaft and its seat . . . . . . . . . . . . . . . . . . . mm 0.020 -- 0.105
Diameter of position control idler shaft . . . . . . . . . . . . . . . . . . . . . . . mm 13.973 -- 14.000
Internal diameter of position control idler shaft . . . . . . . . . . . . . . . . mm 14.016 -- 14.059
Clearance between draft control idler shaft and position control
idler shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.016 -- 0.086
Clearance between control valve block pin (8, fig. 4) and its seat
on the control valve block body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.008 -- 0.012(2)
Clearance between lift control valve (10) and its seat on the con-
trol valve block body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.008 -- 0.012(2)
Control valve block pin return spring (5, fig. 4):

-- free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 50.5
-- spring length under load of 31.7 -- 35 N (3.23 -- 3.57 kg) . . . . mm 34
Control valve return spring (9, fig. 4)
-- free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 44
-- spring length under load of 103 -- 114.7 N (10.5 -- 11.7 kg) mm 29
??.??.???.?? -- ?? -- ????
MAIN SPECIFICATION OF IMPLEMENT HITCHING DEVICE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . three--point linkage

Category:
-- All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Draft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of lower arms with flex
bar
Maximum liftable load with centre of gravity 610 mm from the
lower arm link ends: with arms horizontal (with top link connected
to hole on upper support):
-- TD60, TD70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg 2260
-- TD80, TD90 and TD95 Models . . . . . . . . . . . . . . . . . . . . . . . . . . kg 2700
Maximum liftable load: with arms horizontal (with top link connec-
ted to upper support pin):
-- TD60, TD70 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg 3000
-- TD80, TD90 and TD95 Models . . . . . . . . . . . . . . . . . . . . . . . . . . kg 3565
Flex bar diameter:
-- TD95 model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 24. 867--24. 900
Axial clearance of flex bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 1.2 -- 4.1
MAIN SPECIFICATION OF HYDRAULIC PUMP C31 (All models)
Filter
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mounted on pump body, suction
side
Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear type with oil suction from
transmission casing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . behind timing gear cover
Model A31
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOSCH
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driven by timing gears
Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . Counter Clockwise
Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . 1:0931
Maximum speed of rotation (with engine at maximum power) . . . . . rpm 2328
Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (l/min) 44
Bench output at 1450 rpm and pressure of
172 bar ( 175 kg/cm2):
-- for new or reconditioned pump . . . . . . . . . . . . . . . . . . . dm3/min (l/min) 19
-- for worn pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (l/min) 13.3
-- test oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C° 55 ÷ 65
-- test oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 20
??.??.???.?? -- ?? -- ????
MAIN SPECIFICATION OF HYDRAULIC PUMP (All models)

(continued)
Driven and driving gear shaft diameter . . . . . . . . . . . . . . . . . . . . . . mm 17.400 -- 17.418

Internal diameter of seats in supports . . . . . . . . . . . . . . . . . . . . . . . mm 17.450 -- 17.470
Clearance between gear shafts and their seats . . . . . . . . . . . . . . . mm 0.032 -- 0.070
-- maximum clearance due to wear . . . . . . . . . . . . . . . . . . . . . . . . mm 0.1
Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . . . . . mm 0.020 -- 0.064
Maximum wear on pump body, suction side, at position of gears mm 0.1
Width of gears (5, fig. 104) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 24.000 -- 24.015
Width of supports (4 and 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 24.490 -- 24.510
Width of pump body (3) for gear seats and supports . . . . . . . . . . mm 73.135 -- 73.160
Axial clearance of gears complete with supports in pump body
(recondition if necessary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.100 -- 0.180
LIFT HYDRAULIC PUMP (OPTIONAL) DATA DWG. 47129337 (*)
Filter
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . fixed to the pump housing on
suction side
Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear type with oil suction from
transmission casing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flanged on the rear left--hand
side of the engine
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch--Rexroth
Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of the engine gears
Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . left
Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 1.080
Maximum speed of pump rotation (with engine at maximum
power equivalent to 2500 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm 2700
Rated output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/turn 0.01950
Corresponding rated output for new pump . . . . . . . . . . dm3/min (l/min) 48
Corresponding rated output for pump with 300 hours
of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (l/min) 43
Bench output at 1500 rpm and a pressure of 2175 psi (150 bar):
-- for new pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (l/min) 24.8
-- for pump with 300 hours of work . . . . . . . . . . . . . . . dm3/min (l/min) 22.3
-- test oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °F 131 to 149
(°C) (55 to 65)
-- test oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CST
??.??.???.?? -- ?? -- ????
TORQUE SETTINGS
Torque setting
Thread
Nm kgm
Lift
Capscrew, lift to rear transmission case (C1, Fig.1) . . . . . . . . . . . . . M 12 x 1.25 98 10
Capscrew, control valve body to lift (C3, Fig.28) . . . . . . . . . . . . . . . . . M 8 x 1.25 26 2,7
Capscrew, lift arm plates (C2, Fig.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . M 14 x 1.5 147 15
Plug, max. arm raising adjustment (3, Fig.28) . . . . . . . . . . . . . . . . . . M 12 x 1.25 103 10,5
Nut, position control shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 59 6
Nuts for lever quadrant bracket securing stud bolts (2, Fig.32) . . . . M8x1.25 25 2.6
Lift cylinder securing bolts: M14x1,5 211 21,5
M16x1.5 260 26.5
Securing bolts for top link attachment bracket . . . . . . . . . . . . . . . . . . M14x1.5 147 15
Inner lift arm securing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 61 6.2
Capscrew, suction connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 12 x 1.25 98 10
Capscrew, delivery connection on lift control valve . . . . . . . . . . . . . . M 10 x 1.25 59 6
Capscrew, lift pump (Fig.86) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M6x1 8 0,8
Nut, pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1.25 41 4.2
Capscrew, flexion bar support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 221 22,5
Capscrew, chain support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 221 22,5
Capscrew, check link support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 221 22,5
Nut, tow bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 18 x 1.5 343 35
Control valves
Nut, control valve links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 20 2
Connection, outlet to fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 20 2
Plug, relief bar spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- 20 2
??.??.???.?? -- ?? -- ????
TOOLS
HYDRAULIC LIFT EQUIPMENT X 293838 Punch for fitting needle bearings to

upper/lower draft control levers and
to draft control link rod.
Warning -- The operations described in this section X 291862 Wrench for cylinder safety valve set-
cannot be carried out without the ESSENTIAL tools ting ring nut.
marked below with (X).
However, to ensure greater safety and obtain the X 291863 Wrench for lift pressure relief valve
best results while saving time and effort, we recom- setting ring nut.
mend that these essential tools are used in conjunc-
tion with the specific tools listed below as well as cer- 290284 Hand pump for valve calibration.
tain tools which are to be made following the
construction drawings given in this manual.
X 290828 Union for cylinder safety valve cal-
ibration.
X 293843 Ring for fitting piston with lift seals X 290824 Union for lift pressure relief valve
(TD60 and TD70 models). calibration.
X 291483 Ring for fitting piston with lift seals

(TD80, TD90 and TD95 models). X 293870 Wrench for locknut on end stop ad-
justing scew.
X 293842 Punch for fitting lift arm shaft seal.
X 293845 Draft control setting tool.
X 293839 Punch for fitting needle bearings on
control valve block control lever X 293846 Position and draft control setting
bushing. tool.
??.??.???.?? -- ?? -- ????
TRE0700A
Sectional drawing of lift

C1 Lift capscrews 8. L.H.Bushing.
C2. Thrust plate capscrews. 10. Thrust washers.
G = 0,2 to 1,4 mm. Shaft end float. 11. Top link support.
1. Inner arm. 12. Piston rod pin.
2. Cross shaft. 13. Travel limit adjusting screw.
3. Link arm. 14. Travel limit adjusting screw locknut.
4. Arm thrust plates. 15. Travel limit control rod.
5. R.H.Seal. 16. Control valve link pin.
6. L.H.Seal. 18. Draft control inner lever pivot.
7. R.H.Bushing. 19. .Set screw
??.??.???.?? -- ?? -- ????
TRE0701A
2
Sectional drawing of hydraulic lift control valve block
a. Detail of O--ring and back--up ring
1. Spool valve. 14. Ring.
2. Spool valve seat. 15. Cylinder safety valve.
3. Plug. 16. Response control valve.
4. Spool return spring. 17. Arm lowering speed control valve.
5. Valve plunger. 18. Ball.
6. Plunger spring. 19. Response control valve adjusting pin.
7. Plug. 20. Delivery connection.
8. Piston seat. 21. Check valve spring.
9. Piston. 22. Check valve.
10. Spring cup. 23. Check valve seat.
11. Draft sensitivity adjustment valve spring. 30. .Retaining ring.
12. Draft sensitivity adjustment valve. 31. .Roll pin.
13. Plug. 32. .Back--up ring.
33. .O--ring.
NOTE -- Install O--ring 33 and back--up ring 32 as shown in detail (a) using protection device 293858 and by
heating ring 32 in oil at 50 °C.
Take care to install ring 32 with flat surface facing upwards and concave surface facing O--ring 33. Take
necessary precautions not to damage them.
??.??.???.?? -- ?? -- ????

The mechanical lift can operate with controlled posi- Draft control is actuated by the flex bar positioned in
tion or draft control and with a combination of the two. the special box mounted under the rear transmis-
The lift is controlled by two levers located on the op- sion.
erator’s right. It also features the Lift--O--Matic device
which raises and lowers the implement without the The lower lift arms and corresponding control rods
need to use the position and draft control levers. are connected to the flex bar.
Static oil
Oil in suction
Tractor brake circuit oil (brakes off)
Pressurised oil
Exhaust oil flow
5
1
9
8
7
26428
6
3
HYDRAULIC LIFT CIRCUIT
1. Delivery line to control valve (3). 6. Lift control valve.
2. Trailer brake control valve. 7. Suction line.
3. Auxiliary control valves. 8. Oil filter.
4. Auxiliary control valve lines. 9. Hydraulic pump.
5. Trailer brake control valve line.
??.??.???.?? -- ?? -- ????
22 T
T1
9 1
T3
V
T2
5 6
P 8
Pressurised oil
Oil in suction, delivery or return
Static oil
TRE0702A
ARM LIFT PHASE
F. Filter. 5. Plunger.
P. Hydraulic pump. 6. Plunger spring.
T. Lift arm piston. 8. Piston seat.
V. Reliefvalve. 9. Piston.
1. Valve spool. 22. Check valve.
When the operator uses the position control lever lo- Oil flow to piston (9) is cut off and plunger (5) is forced
cated on his right to raise the arms, the movement to the left by spring (6), thus closing the exhaust port.
shown by the arrows is transmitted by internal link- Pressure oil opens check valve (22) and operates
age to the control valve block pin (1). piston (T) to raise the arms.
??.??.???.?? -- ?? -- ????
18 17 22
15
12
1
V 5
9
P 6
Pressurised oil
Static oil TRE0703A
NEUTRAL PHASE
F. Filter. 9. Piston.
P. Hydraulic pump. 12. Draft sensitivity valve.
V. Relief valve. 15. Cylinder safety valve.
1. Valve spool. 17. Arm lowering speed control valve.
5. Plunger. 18. Ball.
6. Plunger spring. 22. Check valve.
With spool (1) in the neutral position, oil is delivered plunger (5) to the right. This opens the exhaust port
through the response adjusting valve (12) to piston and directs oil flow to the tank in the rear transmission
(9), which overcomes spring reaction (6) and moves housing rather than to the cylinder.
??.??.???.?? -- ?? -- ????
17 T
F1
4 1
12
V 9 5
P
Pressurised oil
Static oil
TRE0704A
ARM LOWERING PHASE

F. Filter. 5. Plunger.
P. Hydraulic pump. 9. Plunger spring.
T. Lift arm piston. 12. Draft sensitivity valve.
V. Relief valve. 17. Arm lowering speed control valve.
1. Valve spool. F1. .Spool port
4. Spool return spring.
When the operator lowers the position control lever Through spool port (F1) and draft sensitivity valve
on his right, the return spring (4) pulls spool (1) to the (12) oil flows to piston (9), which holds plunger (5) in
right. Cylinder oil is exhausted under piston pressure the position shown, thus allowing pump delivery to be
(T) through lowering speed adjustment valve (17) exhausted past plunger (5).
and the port uncovered by spool.
??.??.???.?? -- ?? -- ????
HYDRAULIC LIFT DIAGNOSTICS
The lift does not raise. 1. Oil filter clogged. Replace filter.
2. Control valve jammed in dis- Release control valve.

charge position.
3. Hydraulic pump defective. Overhaul or replace pump.
The lift operates jerkily. 1. Oil filter clogged. Replace filter.
2. Air has got into the pump suc- Check that the couplings are airtight
tion line. and the seals are effective.
The lift raises too slowly. 1. Oil filter clogged. Replace filter.
2. Oil leaking past piston seals or Replace all defective seals.

seals on discharge fitting to
cylinder, with consequent loss
of pressure.
3. Hydraulic pump defective. Overhaul or replace pump.
The lift operates too quickly. 1. Foreign matter between the Take off the valve, remove the foreign
ball and its seat on the dis- matter and inspect the oil filter.
charge control valve.
2. Discharge control valve ball Replace discharge control valve.

seal defective.
3. Discharge control valve piston Take off the valve and free the piston.
jammed.
The lift operates too slowly. 1. Discharge ports on the dis- Take off the valve, unblock the holes
charge control valve blocked. and inspect the oil filter.
2. Discharge control valve piston Take off the valve and free the piston.
jammed.
??.??.???.?? -- ?? -- ????
HYDRAULIC LIFT DIAGNOSTICS

(continued)
The lift is unable to keep the load 1. Defective seal on check valve. Take off, check, clean and if neces-
raised (with the engine running, sary replace the parts concerned.
the load moves up and down
rhythmically; with the engine 2. Oil leaking past the seals on Replace seals.
turned off, the load lowers). the control valve block pin
seat.
3. Control valve block pin seal Take off and clean the seal and re-
defective. place the control valve block pin and
its seat if defective.
4. Oil leaking past the lift piston Replace the seals.

seal or the seals on the cylin-
der oil discharge fitting.
5. Defective seal or cylinder safety Replace the valve.

valve set to very low value.
The pressure relief valve cuts in 1. Lift arm travel set incorrectly. Set correctly.
when the lift arms reach their com-
pletely raised position.
Lift has poor lifting capacity. 1. Pressure relief valve set incor- Replace the valve.
rectly.
2. Cylinder safety valve set incor- Replace the valve.

rectly.
3. Poor pump efficiency (gener- Overhaul or replace the pump.

ally accompanied by a consid-
erable increase in lift time).
??.??.???.?? -- ?? -- ????
REMOVAL -- REFITTING -- OVERHAUL OF REAR MECHANICAL HYDRAULIC LIFT ASSEMBLY

REAR HYDRAULIC LIFT ASSEMBLY
DANGER
equipment with sufficient hoisting capacity.
Check that the assemblies or parts are held firmly
and supported by suitable slings and hooks. Make
sure nobody is standing near to the load.
To remove the hydraulic lift assembly from the rear

transmission casing, proceed as follows.
1. Disconnect the negative cable (1) from the
battery.
TRE0035A
1
2. Remove the top link (1).
1
TRE0112A
2
3. Undo the bolts (1) and use a chain and hoist to
remove the pick--up hitch hook (2) from the PTO 2
box.
1
TRE0113A
3
??.??.???.?? -- ?? -- ????
4. Remove the split pins and withdraw the shafts

(1). Remove the lift rods (2) and the lateral
stabiliser struts (3).
1
2
TRE0114A
4
5. Remove auxiliary control valve pipes (2) from
their support (1).
TRE0140A
5
6. Undo the two bolts (1) that secure the seven--
pole socket (2) and remove the socket.
1
2
TRE0122A
6
7. Undo the bolts (1) and remove the support (2).
1
2
TRE0115A
7
??.??.???.?? -- ?? -- ????
8. Remove the pipes on the lift (1) and the control

valve body (2). 1
TRE0138A
8
9. Unscrew the bolts (1) that secure the hydraulic
lift assembly to the transmission casing.
1
25556
9
10. Fit tool 292607 (1) on the lift and tighten the four
bolts (2).
1 2
25558
10
11. Fit tool 291259 (1) onto tool 292607 (2). Attach
the hoist to tool 291259, raise the hydraulic lift by
1 2
a few centimetres and pull it backwards, tilting it
so that it clears the breather pipe (3) without
damaging it.
25559
11
??.??.???.?? -- ?? -- ????
12. Refit the hydraulic lift assembly to the transmis-

sion casing as follows.
WARNING
Before refitting the hydraulic lift assembly to the

rear transmission casing, clean and degrease
the mating surfaces thoroughly and apply a strip
of sealing compound of about 2 mm diameter as
shown in fig. 12.
Apply the torque settings listed on page 5.
Use tools 291359 and 292607 to fit the hydraulic

lift assembly to the transmission casing and
tighten the bolts securely. 26295
Insert the electric leads into their clips on the lift 12

body.
Fit the lift control pipe. Diagram showing application of sealing com-
pound when fitting the hydraulic lift assembly to
transmission casing.
Fit the trailer brake control pipe (if fitted) and the
oil filler pipe. The types of sealing compounds to be applied are
specified on page 1, section 00.
Connect the Lift--o--Matic control rod.
Connect the lift control levers to their linkages.
Fit the top link attachment bracket and the quick--

fitting support plate for auxiliary control valves.
Fit the seven--pole socket, the earth leads, the

quick--fittings and the trailer brake control pipe to
their corresponding support brackets.
Fit the RH lift rod adjustment unit.
Fit the ground lift control lever.
Fit the lift rods and the lateral stabiliser struts.
Fit the pick--up hitch hook and the top link.
Connect the negative cable to the battery.
??.??.???.?? -- ?? -- ????
REAR HYDRAULIC LIFT ASSEMBLY

Disassembly--Assembly
(Op. 35 110 17 -- 35 110 40 -- 35 110 42 -- 35 110 46)
1
DANGER
Handle all parts with the utmost care.
Do not place your hands or fingers between one part
and another. Wear the prescribed safety clothing,
including glasses, gloves and protective footwear.
To disassemble the hydraulic lift, proceed as follows. TRE0143A
13
1. Position the hydraulic lift on a stand (1) fig. 13 ,
that will allow the assembly to be rotated. 2 1
2. Unscrew the securing bolts (1) and remove the
control valve block (2) fig. 14.
TRE3209A
14
3. Unscrew the two cylinder securing bolts posi-
tioned outside the cylinder body. Turn the lift
assembly and unscrew the lateral bolt (3).
1 2
4. Undo the bolts (1) that secures the internal
linkage (2) to the lift cylinder.
25626
15
5. Remove the cylinder (1) complete with piston.
1
25627
16
??.??.???.?? -- ?? -- ????
6. Remove the retaining pin from the internal draft

lever, unscrew the nut (1), then remove the unit
complete with internal linkages and the LIFT--
O--MATIC control lever.
TRE3260A
17
7. Take off the snap ring and remove the internal
position control lever (1).
1
TRE3261A
18
8. Unscrew the nuts (1) and remove the spring and
fixing bracket (2).Take off position and draft
2
control levers.
1
TRE3262A
19
9. Slacken the eccentric pin (2) retaining bolt (1),
withdraw the eccentric pin and remove the
internal linkage. 1
10. Unscrew the bolt (3), remove the washer (4), 2
withdraw the lift arm (5) and remove the thrust
washer. Repeat on the other lift arm. 3
4
5
25631
20
??.??.???.?? -- ?? -- ????
11. Remove the crimping on the internal arm locking

bolt (1) and unscrew the bolt. Withdraw the shaft
(2) and remove the seals (3).
1 2
3
25632
21
12. Use compressed air to remove the piston (2)
from its cylinder (1). 2
1
26297
22
13. Use striker tool 293838 (1) to replace the
bearings in the internal draft control lever (2). 2
1
14. Use striker tool 293839 to replace the control
valve block control lever bearings.
15. Fit the hydraulic lift as follows.
WARNING
26298
23
16. Insert the piston (1) into its cylinder (3), using
tool 293843 (2) for the TD60 and TD70 models
1 2
or tool 291483 (2) for the TD80, TD90 and TD95
models.
25634
24
??.??.???.?? -- ?? -- ????
17. Fit the lift arm shaft (2) and the internal arm (1)
inside the lift box, matching up the reference
marks, as shown. Tighten the securing bolt.
26299
25
18. To avoid damaging the internal seal lips, use a
flexible brass sheet (1) of size 200 x 90 mm and 1
thickness 0.05 -- 0.1 mm. Roll the sheet up and
insert the seal inside. Position the unit on the
spline and push the seal manually into its seat.
Then remove the sheet.
2
26300
26
19. Use striker tool 293842 (1) to complete the fitting
of the seals into the their seats on the lift arm
1
shaft.
26326
27
20. Fit the lift arms (1) on the shaft, matching up the
reference marks, as shown. Secure them by
tightening the bolts.
25633
28
??.??.???.?? -- ?? -- ????
21. Fit the internal linkages and the corresponding

eccentric pin. Fasten the eccentric pin by
tightening the securing bolts.
22. Fit the control levers complete with friction discs,
snap rings and stud bolts.
23. Fit the spring and use the bracket to secure the
lever unit.
24. Fit the internal position control lever.
25. Fit the internal linkages and the Lift--o--Matic
control lever.
26. Fit the cylinder complete with piston and secure
it.
27. Fit the internal linkages and fasten them to the
cylinder.
28. Clean the mating surfaces thoroughly and apply
a 2 mm diameter strip of sealing compound to the
lift box, as shown in fig. 29.
The types of sealing compound to be used are
shown on page 1, section 00.
Fit the hydraulic control valve block on the lift box TRE0705A
and secure it using the screws.
Make the following adjustments. 29
NOTE -- The adjustments must be made in the order

specified.
??.??.???.?? -- ?? -- ????
ADJUSTING THE LIFT

The following adjustments refer to a lift assembly
without hydraulic control valve block and mounted on
a rotary stand.
These adjustments must be made in the order speci-
fied.
The LIFT--O--MATIC device must be kept turned off
until otherwise specified.
Adjusting position control

Proceed as follows:
1
1. Move the external position control lever (1) fully
forward, against the spacer for the stud bolt
securing the spring retaining bracket as shown
by arrow A. Move the external draft control lever
(2) fully rearward against the spacer as shown by A
arrow B. B
2. Turn the lift arm control shaft until the internal
arm is in contact with the lift body.
2
TRE3263A
30
3. Use tool 293870 (1) figure 31, to slacken the lock
nut (4) figure 32. Loosen the end stop adjusting
1
screw (5) until it is no longer in contact with the
control valve block control lever (3).
TRE0706A
31
1 2 3 4
5
F1
L1
TRE3262A
32
??.??.???.?? -- ?? -- ????
4. Fit tool 293846 (4) fig 33, to the lift body. The tool
has a plunger operating in a tube, the outer end 1 2 3
of which has two reference surfaces (1) and (5).
5. Using two spanners (2) and (3), unscrew the
lock nut (1) fig. 32 and tighten or loosen the
adjustable push rod (2) fig. 32, so that the end of
the plunger (5) fig 33, is flush with the outer 6
register surface (6) of the tool.
NOTE -- This corresponds to a distance (L1 fig. 32)
of 82.0 -- 82.1 mm between the end of the lever (3) 5
fig. 32 and the front surface of the lift body when a 4
force (F 1 fig. 32) of 4 -- 4.5 da N (kg) is applied to
25639
the end of the lever.
33
6. Tighten the lock nut (1) fig. 32.

7. Move the external position control lever (1) fully 1
rearwards against the stud bolt spacer as shown
with arrow A. Both draft and position levers must
be at lowered position. Turn the lift arm control
shaft so that the piston is fully forward and check
that the plunger (5) fig. 33 is flush with or slightly
inside the inner reference surface (1) of the tool A
(4).
NOTE -- This corresponds to a distance (L1) fig. 32,

of greater than 86.5 mm between the end of the TRE3263A
lever (3) and the front surface of the lift body when
34
a force (F 1) of 4 -- 4.5 da N (kg) is applied to the end
of the lever.
Adjusting the maximum height of the lift arms

Proceed as follows.
1
8. With tool 293846 (4) fig. 33 fitted on the lift body,
move the external draft control lever (2) fully
rearward, against the spacer as shown by arrow
B. Move the external position control lever (1)
fully forward against the spacer as shown by A
arrow A.
B
9. Turn the lift arm control shaft until the internal
arm touches the lift body.
TRE3263A 2
35
??.??.???.?? -- ?? -- ????
10. Connect the fitting (5) of tool (2) to the workshop

compressed air system. Feed air into the
1
cylinder barrel to make the piston perform its
complete lifting stroke and use the air pressure
to keep it in this position.
11. Using tool 293870 (1), tighten the screw (5) fig. 5
32, until the end of the plunger (4) is flush with the
inner reference surface (3) of the tool (2) or up to
0.5 mm further in. 4
2
3
TRE0707A
36
NOTE -- This corresponds to a distance (L1) of
85--85.5 mm between the end of the lever (3) and the 1 2 3 4
front surface of the lift body.
5
12. Tighten the lock nut (4) to a torque of 15 Nm (1.5 F1
kgm).
L1
TRE3262A
37
Adjusting draft control
Proceed as follows: 1 2
13. Remove the end section of the draft control rod
(3) and mount it on the rod (5) of tool 293845 (1).
Fasten it using lock nut (4). 5 L3
14. Place the tool 293845 (1) complete with its rod
(5) and the end section of the draft control rod (3) 4
on a surface plate. Using a micrometer depth
gauge (2), measure the distance (L3) between 3
the upper surface of the rod and the micrometer
gauge bearing surface on the tool (be sure to 25645
tighten rod (3) onto rod (5) so that the surface of
rod (5) is a few mm lower than the micrometer 38
bearing surface on the tool).
15. With tool 293846 (2) fig. 36 mounted on the lift 1
body and disconnected from the compressed air
system, move the position control lever (1) fig. 39
and the draft control lever (2) fully back against
the spacer.
16. Move the eccentric pin (1) fig. 44, connected to

the internal draft control lever, to the horizontal A
B
position with the eccentric cam pointed towards
the rear of the lift assembly.
2
TRE3263A
39
??.??.???.?? -- ?? -- ????
17. Fit tool 293845 (1) to the lift body and fasten it
to the two holes in the box as shown in figure 40.
1
25642
40
18. Turn the screw (2) fig. 40 on the internal draft
control lever (3) fig. 40 until the end of the plunger
(1) fig. 41 is flush with the inner reference surface 2
(3) of tool 293846 (2). 1
3
TRE0708A
41
19. Turn the eccentric pin (1) slightly to withdraw the
end of the plunger of tool 293846 as far as
possible.
20. Again turn the screw (2) fig. 40 to adjust the 2 3 1

internal draft control lever (3) until the end of the
plunger fig. 42 is flush with the inner reference
surface (3) of the tool 293846.
21. Finally turn the eccentric pin (1) fig. 42 until the
end of the plunger is flush with the outer register
surface (2) of the tool 293846.
TRE0709A
42
22. Insert rod of tool 293845 (1) into the internal draft
control lever seat (2).
1 L2
23. With the end of the plunger of tool 293846 flush
with the outer reference surface (2) fig. 42, set
the adjustable linkage (3) fig. 43 and use a 2
micrometer depth gauge to measure the dis-
tance (L2) between the upper surface of the rod 3
and the micrometer gauge bearing surface on
the tool 293845 (1).
26348
43
??.??.???.?? -- ?? -- ????
24. The distance (L2, page 27) must be:

L2 = L3 +L4
where:
L3 = distance measured with tool 293845
mounted on a surface plate:
L4 = 22.9 -- 23.1 mm. Operating distance be-
tween the lift box bearing surface on the trans-
mission casing and the rod resting surface on the
lever (3, fig. 43).
NOTE -- This corresponds to a distance (L1, fig. 32)

of 82.0 -- 82.1 mm between the end of the lever and
the front surface of the lift body, measured with a
force (F1) of 4 -- 4.5 da N (kg) applied to the end of
the lever.
2 3 1
WARNING -- Always make sure that when the plung-
er of tool 293846 is flush with the outer reference sur-
face (2) the the distance (L2, fig.43 ) is:
L2 = L3 +L4
where:
L3 = distance measured with the tool 293845
mounted on the reference surface;
TRE0710A
L4 = 22.9 -- 23.1 mm. Operating distance between
the lift box bearing surface on the transmission cas- 44
ing and the rod bearing surface on the lever (3) fig.
43.
If these conditions are not met, adjust the eccentric
pin (1) and the knurled screw (2) fig. 43 of tool
293845 until they are.
1
25. Fit the threaded dowel (3) and tighten the screw
(1) without bending over the safety washer (2). 3 2
26. Remove the tools 293846 and 293845 and fit the
hydraulic control valve block on the lift body.
26350
45
Proceed to mount the lift assembly onto the tractor
as follows.
1
WARNING -- First position tool 293845 (1) on a sur-
face plate and use a micrometer depth gauge (2) to
2
measure the distance (L5) between the surface plate
and the point where the micrometer gauge rests on
the tool.
Make a note of the measured distance (L5). L5
26352
46
??.??.???.?? -- ?? -- ????
27. Fit the draft measuring device complete with

transmission lever (3) and draft control lever (2),
but without the flex bar, onto the rear transmis-
sion casing. L6 L7
28. Rest the transmission lever (3) on the draft 1
measuring device box and fit tool 293845.
Fasten it to two holes on the box so that the draft
control rod (2) fits exactly inside the tool hole as
shown in figure 48
29. Using a micrometer depth gauge (2) fig.48,
measure the distance (L8) fig.48, between the 2
top end of the rod (3) fig.48 and the micrometer
gauge resting surface on the tool.
NOTE -- The distance (L6) the top end of rod (2) pro- 3
trudes with respect to the transmission casing (with
flex bar removed) is given by:
L6 = L5 -- L8 26353
where:
47
L5 and L8 = distance measured with tool 293845
fitted on the surface plate (L5) fig. 46 or on the trans-
mission casing (L8) fig. 48.
30. Fit the flex bar and measure the new distance 1
(L9) between the top end of the rod (3) and the
micrometer gauge resting surface on the tool.
2
NOTE -- The distance (L7) fig. 47, that the top end of L8/L9
the rod (2) fig. 47, protrudes with respect to the trans-
mission casing (with flex bar fitted) is given by:
L7 = L5 -- L9 3
where:
L5 and L9 = distance measured with tool 293845
mounted on surface plate (L5) fig. 46 or on the trans- 26354
mission casing (L9).
48
31. Check that the distance (L7) is at least 5 mm

greater than the distance (L6).
32. Slacken the lock nut (1) fig. 47 and adjust the
length of the draft control rod until it protrudes by
a new distance (L7 = 18.3 -- 18.5 mm).
33. This distance (L7) can be calculated by subtrac-
tion using tool 293845:
L10 = L5 -- L7
where:
L7 = 18.3 -- 18.5 mm. Distance the end of the rod
(2) fig. 47, protrudes with respect to the transmis-
sion casing during operation.
L5 = distance measured with tool 293845
mounted on the surface plate.
L10 = distance to be measured with the microme-
ter gauge on tool 293845.
34. Tighten the lock nut (1) fig. 47, and mount the lift
on the tractor.
??.??.???.?? -- ?? -- ????
ADJUSTING LINKAGES (Op. 35 110 08)

Adjusting draft control linkage
Test conditions: 1
engine running at medium speed;
L2
allow the oil in the system to reach a temperature
of 30 -- 40 °C.
Then proceed as follows:
1. Move the draft control lever (1) to a distance (L2)
of 184 -- 186 mm from the beginning of the slot
and check that at this position the arms start to
rise.
TRE3265A
2. If they do not, adjust the eccentric pin (1) fig. 44,
to restore this distance. 49
3. Fasten the eccentric pin using the securing bolt.

Adjusting LIFT--O--MATIC device 1
Proceed as follows:
4. Start engine and run at half throttle.
5. Move the position control lever (1) and the draft

control lever (2) fully forward in the sector. 2
TRE3402A
50
6. Adjust Lift--O--MaticTM control lever support
position on lift lever support through screws (1) 2
so that, when pushbutton (2) is pressed, lift arms
start to move when pushbutton is still short of its
full stroke by a distance (L) Fig.52 of 7 to 10 mm
(0.2756 -- 0.3937).
1
TRE3401A
51
TRE3268A
52
??.??.???.?? -- ?? -- ????
LIFT PRESSURE RELIEF VALVE

Removing--Refitting (Op. 35 114 30)
Auxiliary control valve blocks. The lift pressure relief

valve (1) is located as shown in fig.53)
If defective, remove and change the valve. 1
TRE0139A
53
LIFT PRESSURE RELIEF VALVE

Calibration (Op. 35 114 32) 1
Proceed as follows.
1. Run the engine until the oil reaches a tempera-
ture of about 50°C.
2. Insert the fitting 293449 (1) in a quick--fit female

half--coupling and connect it to the 0 -- 250
kg/cm2 scale pressure gauge supplied with kit
292870.
3. Activate the half--coupling control valve block TRE0142A

lever until the pressure relief valve cuts in.
54
4. With the engine running at medium speed the
pressure gauge must show a pressure of about
186 -- 191 bar (190 -- 195 kg/cm2). If the valve
setting does not correspond to the prescribed
value, it is best to change it immediately.
However, if necessary, it can be adjusted by
turning the threaded cap using wrench 291863.
Tighten to increase the valve setting value or
slacken to reduce the value.
??.??.???.?? -- ?? -- ????
NOTE -- The pressure relief valve setting can be

bench tested as follows: 1 2 3
5. Fit the pressure relief valve (1) on the valve union
290824 (2) and connect the union to the hand
pump 290284 (3).
6. Operate the hand pump (3) and check that the
pressure relief valve opens at a pressure of about
186 -- 191 bar (190 -- 195 kg/cm2).
Warning -- During assembly, the pressure relief valve
is calibrated using oil flow and the check using hand
pump 290284 is to be considered only approximate.
It is therefore advisable to check the pressure relief
valve setting with the valve fitted on the tractor as de-
scribed above.
25720
55
??.??.???.?? -- ?? -- ????
LIFT CONTROL VALVE BLOCK, DETACHED

Disassembly--Assembly (Op. 35 114 14)
Proceed as follows.
WARNING
Handle all parts with the utmost care.
Do not place your hands or fingers between one part
1. Before removing the control valve, first remove

the pipes connected to the valve body..
TRE03506A
56
2. Before disassembly, thoroughly clean the
surfaces of the control valve block. Lock the
control valve block in a vice.
3. Unscrew the cap (1) and remove the spring (2)

and the control valve (3).
1 2 3
25707
57
??.??.???.?? -- ?? -- ????
4. Take off the cylinder safety valve (4) and remove

the arm lowering speed adjustment valve (3), the
spring (2) and the pin (1).
1 2 3 4
25709
58
5. Remove the check valve union (1), spring (2)
and ball (3).
1 2 3
25711
59
6. Take off the control valve block pin (1) and
remove the seat (3) and the spring (2). 1 2 3
25713
60
??.??.???.?? -- ?? -- ????
7. Check the wear of the seals on the control valve

block pin seat. If damaged, replace them using 1
protection device 293984 (1), following the
instructions given on page 8.
8. Check the efficiency of the control valve block

pin as follows.
25714
61
9. Fit the control valve block pin (2) complete with
seat (3) on the tool 293982 (1).
1 2 3
25715
62
10. Fit the control valve block pin spring (1) and the
cap (2) of tool 293982. Tighten the cap as far as
it will go and check that the control valve block
1 2
pin slides in its seat.
25716
63
11. Fit tool 293982 (2) on the hand pump 290284
(3), supplied with HYDROSYSTEM 68 oil.
Connect a dial gauge (1) and secure it with its
1
screw.
2
25717
64
??.??.???.?? -- ?? -- ????
12. Operate the hand pump and at the same time

tighten screw (1) on the tool until oil stops flowing
out through the control valve block pin seat
outlet.
13. Now zero the dial gauge.

14. Tighten the screw (1) on the tool further to move
the control valve block pin by 1.8 -- 2 mm, using
1
the dial gauge to read this distance.
25718
65
15. Operate the hand pump until the oil in the system
is at an initial pressure of 245 bar -- 250 kg/cm2.
Using the pressure gauge, check that it takes
more than six seconds for the pressure to fall
from 196 bar -- 200 kg/cm2 to 98 bar -- 100
kg/cm2. If it takes less than this, replace the
control valve block pin. Bear in mind that this part
is supplied together with its seat.
25719
66
??.??.???.?? -- ?? -- ????
16. Fit the cylinder safety valve (1) on the valve

union 290828 (2) and connect it to the hand
pump 290284 (3).
1 2 3
17. Operate the hand pump (3) and check that the
cylinder safety valve opens at a pressure of 210
-- 215 bar (214 -- 219 kg/cm2). If the valve setting
does not correspond to the specified value, it is
best to replace the valve straight away. If
necessary, however, it can be adjusted by
turning the threaded cap using spanner 291862.
Tighten to increase the valve setting value, or
slacken to decrease the value.
18. Fit the hydraulic control valve block as follows:
WARNING
Refer to the illustrations on page 8 for the orien-
tation of the various components:
Apply the torque settings listed on page 5.
Fit the complete control valve block pin.
Fit the check valve.
Fit the cylinder safety valve.
Fit the control valve.
Fit the complete pressure control valve.
Fit the cover on the control valve block.
25720
67
??.??.???.?? -- ?? -- ????
24622
68
Hydraulic lift control pump components
1. Front cover. 11. Driving shaft seal.

2. Cover seals. 12. Snap ring.
3. Pump body. 13. Safety washer.
4. Gear support. 14. Nut.
5. Driven and driving gear shafts. 15. Bolt.
6. Gear support. 16. Washer.
7. Bushing. 17. Key.
8. Control side cover. 18. Bushing.
9. Driving shaft seal. 19. Safety washer.
10. Spacer. 20. Nut.
HYDRAULIC LIFT CONTROL OIL PUMP
Removal -- refitting with pump removed 4. Mark parts 3, 4, 5 and 6 to enable them to be
(Op. 35 0101 10) remounted in the same position if they are in
good condition.
Proceed as follows: 5. Remove the supports (4 and 6) and the gears (5)
from the rear cover (8) and the pump body (3).
1. Remove the cover fastening nuts (20), then the 6. Remove the seals (2) and the anti--extrusion
bolts (15) and the safety washers. rings.
Once the parts are removed, proceed as follows:
2. Remove the nut (14) that fastens the sleeve to the 7. Check that the gear contact surfaces are flat and
pump driving shaft and the safety washer. perpendicular to their supports. Insert a thin layer
of carbon black. Small rough spots can be
3. Remove the front cover (8), the snap ring (12) removed using extremely fine and well lubricated
and the seals (9 and 11). abrasive paper.
??.??.???.?? -- ?? -- ????
8. Check that the axial play of the gear--support unit

in the pump body is 0.090 -- 0.160 mm. The
distance (2) must be 0.090 -- 0.160 mm smaller
than the distance (1).
If necessary, true the flat surfaces involved using lu-
bricated abrasive paper to remove extremely small
quantities of material. Ensure that axial play is still
within the limits of 0.090 -- 0.160 mm.
2
9. Clean all constituent parts thoroughly.
10. Replace the seals (2, 9 and 11).
11. Lubricate the parts with the same oil as the
system. Refit the pump, referring to fig. 68 and
proceed as follows:
12. refit, performing operations 6 to 1 in reverse
order;
25227
always ensure maximum cleanliness to prevent
69
foreign matter from entering, as this could dam-
age the pump;
fit together previously marked parts (3), (4), (5)
and (6) fig.68; see procedure on page 38 to refit
them in their original position;
mount the gear supports (4) and (6) fig. 68, in the
pump body. Mount them with the fittings on the
external circumference matched up with the dis-
charge pipes and the front faces with lubrication
millings in contact with the gears;
fit the plastic anti--extrusion rings on the seals (2)
fig. 68:
mount the seals (9) and (11) fig. 68, on the control
side cover (8), complete with spacer (10). Mount
them so that the cavity is between the seal lips
on the opposite side from this spacer. Finally fill
the cavity with AMBRA GR 9 grease.
??.??.???.?? -- ?? -- ????
NOTES
??.??.???.?? -- ?? -- ????
Chapter 2 -- Open centre system auxiliary control valves
CONTENTS
35 000 Main data -- Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see chapter 1
35 204 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
35 000 -- MAIN DATA -- TORQUE DATA -- TOOLS -- SECTIONAL VIEWS

-- DESCRIPTION AND OPERATION
MAIN DATA
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . full--flow filter, with paper

cartridge, (common to the
hydraulic lift circuit)
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear pump (common to the
hydraulic lift circuit, see chapter 1)
Auxiliary control valves
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . valve stack (up to a maximum of
3 valves) attached to the rear of
the centre housing
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hand lever
Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 186--191 (190--195 kg/cm2)
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . convertible for operation of single--
or double--acting cylinders,
convertible for operation of single--
and double--acting cylinders and
with automatic detent release, for
operation of double--acting
cylinders with float control and
automatic detent release
TOOLS
WARNING: The operations described in this section List of specific tools required for the various
must only be carried out using the ESSENTIAL tools operations described in this section.
marked below with an (X).
For greater safety and to obtain the best results while 292870 Universal pressure testing kit.
saving both time and effort, we recommend that
these essential tools are used in conjunction with the
specific tools listed below, and with certain tools
which are to be made following the constructional
drawings in this manual.
???.??.??.?? -- ?? -- ????
TRE0711A
Auxiliary control valves -- Section views

a. Auxiliary control valve configured for operation 11. Spool return spring.
of single/double--acting cylinder. 12. Spring cup.
b. Auxiliary control valve configured for operation 13. Seal.
of double--acting cylinder with automatic detent 14. Seal.
release. 15. Control lever
16. Control lever support.
17. Tapered needle.
NOTE: Section view of auxiliary control valve 18. Seal.
configured for operation of double--acting cylinder 19. Spring.
with float and automatic detent release was shown 20. Detent balls.
at page 3 . 21. Detent ball support.
22. Seal.
23. Internal plunger.
1. Cover. 24. Spring.
2. Distance piece. 25. Cover.
3. Spool. 26. Detent release pressure adjuster screw.
4. Check valve. 27. Spool return spring.
5. Housing. 28. Spring cup.
6. Seal. 29. Seal.
7. Seal 30. Seal.
8. Single/double--acting operation switching valve. 31. Detent notch body.
9. Single/double--acting operation adjusting spool 32. Detent screw locknut.
10. Valve body. 33. Circlip.
???.??.??.?? -- ?? -- ????

The auxiliary control valves serve to control hydraulic 3. Neutral -- When the lever is released from the
loads external to the tractor. lifting and lowering positions it will automatically
Up to a maximum of three auxiliary control valves may return to neutral position.
be mounted at the rear of the centre housing.
The auxiliary control valves are operated by hand le- 4. Float -- Push the lever forward beyond the
vers located to the right of the driving position. “lowering” position to select “float position”. In this
position the only force exerted on the implement
Each control lever will have three or four positions will be that created by its own weight, thus allowing
depending on the type of control valve it operates. the implement to follow the profile of the terrain.
1. Lifting -- Pull lever back to lift the implement.
2. Lowering -- Push the lever forward to lower the The operation of the hydraulic control valves is
implement. described in the following pages.
OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR OPERATION OF A DOUBLE--ACTING

CYLINDER WITH AUTOMATIC DETENT RELEASE AND FLOAT POSITION
TRE0750A
Section view
2. Spool.
23. Internal plunger. NOTE: Some parts releated with automatic detent
24. Spring. release are not shown in this view. Automatic detent
25. Cover. release working principle of valve shown in Fig. 2 is
26. Detent balls. same as the valve shown at Fig. 9 & Fig. 10.
27. Spool return spring.
28. Spring cup.
32. Float mode selection groove.
FLOAT CONTROL OPERATION

To select float control operation, push the control le- to both ports. In this condition, the only force acting
ver (located right hand side of the operator) fully for- on the attached implement is that created by its own
ward. The control valve spool (2) will move and det- weight and the hydraulic lift may be operated. Auto-
ent balls (26) will engage in the grooves (32) where matic detent release does not occur during float con-
they will be held in position by the support and the trol as there is no pressure inside the auxiliary control
spring (24). In this position the spool directs the oil at valve.
A and B ports to exhaust lines T. No pressure applied
???.??.??.?? -- ?? -- ????
OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR OPERATION A DOUBLE-- ACTING CYL-
INDER AUTOMATIC DETENT RELEASE AND FLOAT POSITION
TRE0750B
LIFTING
When the spool (2) moves to left, the detent balls (26) exhaust line (T) by way of line (A), intercepting the
engage the groove (33), where they are held in place supply of oil to the hydraulic lift control valve. Automatic
by the support (28) and spring (24). The movement of detent release working principle is explained at Page.
the spool (2) connects: the pressure line (P) with the 6.
line (B), and also the upper cylinder chamber with the
TRE0750C
LOWERING
When the spool (2) moves to right, the detent balls line (B), while the upper chamber is connected with
engage in the groove (34) where they are held in the pressure line (P) by way of line (A). On
position by the support (28) and the spring (24). In completion of the lowering operation, the detent will
this condition the oil contained in the lower chamber be automatically released as explained at Page 6.
of the cylinder can flow to the exhaust (T) by way of
???.??.??.?? -- ?? -- ????
OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR OPERATION OF A DOUBLE--ACTING

CYLINDER (FIGS. 5 & 6) AND SINGLE --ACTING CYLINDER (FIGS. 7 & 8)
1. LIFTING -- On pulling back the control lever, (located

right hand side of the operator) the control valve spool
(2) moves to connect: pressure line (P) with the lower
chamber of the cylinder by way of line (A), and also
exhaust line (T) by way of line (B), intercepting the
supply of oil to the lift control valve. Keep the lever
pulled back, to extend the cylinder to its full stroke. On
releasing the lever it will automatically return to neutral
position, under the action of the return spring, and the
entire flow from the pump will be conveyed to the lift
control valve by way of line (P).
TRE0712A
5
2. LOWERING -- To lower the implement, push the
control lever (located right hand side of the operator)
forward. The control valve spool (2) will move to the
position indicated in fig. 6, thus allowing the oil in the
lower cylinder chamber to flow to the exhaust (T)
through line (A), while the upper chamber is
connected to the pressure line (P) through line (B) .
3. LIFTING -- On pulling the control lever back, the

control valve spool (2) fig. 7 moves to connect the
cylinder with the pressure line (P) by way of line (A).
TRE0713A
Line (C), for the control of single--acting cylinders, is
used in this stage as it is permanently connected to the 6
exhaust (T) by the open position of the switching valve
(1).
4. LOWERING -- On pushing the control lever forward,

the spool (2) will move to the position indicated in fig.
8. The oil contained in the cylinder, pressurised by the
weight of the lifted implement, will flow to the exhaust
(T) by way of line (A), while the entire flow from the
pump is also conveyed to the exhaust (T) through the
line (B).
TRE0714A
Pressurised oil
Suction, delivery or exhaust oil
Static oil
NOTE: To operate a double--acting cylinder, tighten

screw (1) fully home. To operate a single--acting TRE0715A
cylinder, fully undo screw (1).
8
???.??.??.?? -- ?? -- ????
OPERATING STAGES OF AUXILIARY CONTROL VALVE OPERATING A DOUBLE--ACTING CYLINDER

WITH AUTOMATIC DETENT RELEASE
TRE0716A
LIFTING
On pulling back the control lever, the spool (2) moves through port (V), it overcomes the resistance of the
and the detent balls (26) engage the groove, where spring of the needle valve (23). Inside chamber (D), the
they are held in place by the support (28) and spring oil pressure increases and, acting on the detent ball
(24). The movement of the spool (2) connects: the support (28), it overcomes the resistance of the spring,
pressure line (P) with the line (B), and also the upper thus moving the support (28). In this condition the two
cylinder chamber with the exhaust line (T) by way of detent balls (26) drop onto the support, releasing the
line (A), intercepting the supply of oil to the hydraulic lift spool (2) which, under the action of spring (6) returns
control valve. to neutral position. Consequently the entire flow from
On completion of the lifting movement, the oil pressure the pump is conveyed to the lift control valve through
increases to 170--175 bar (173--178 kg/cm2). Acting lines (P).
TRE0717A
10
LOWERING
To lower the implement, push the control lever by way of line (B), while the upper chamber is
forward. The control valve spool (2) moves and the connected with the pressure line (P) by way of line
detent balls engage in the central groove where they (A). On completion of the lowering operation, the
are held in position by the support (28) and the spring detent will be automatically released in the manner
(24). In this condition the oil contained in the lower described previously.
chamber of the cylinder can flow to the exhaust (T)
???.??.??.?? -- ?? -- ????
AUXILIARY CONTROL VALVES (REMOVED FROM TRACTOR)

Disassembly -- Assembly (Op. 35 204 46)
of valves removed from tractor
3
6
7
8
1
2 7
4
TRE1100A
11
Convertible single/double--acting auxiliary control WARNING

valve.
Do not insert fingers or hands between one part and
Disassemble the auxiliary control valve into its another.
component parts referring to the sectional views (fig. Wear suitable safety clothing, i.e., safety goggles,
1) and the following instructions: gloves and shoes.
1. Remove cover (3) and O--rings (7). WARNING

2. Remove the control lever support (4) and take out Always use suitable tools to align holes. NEVER USE
YOUR FINGERS OR HANDS.
the seal (7).
3. Withdraw the spool (8).
4. Remove plug (6) and extract the single/double
acting switching valve (5).
5. Remove relief valve block (1) and check valve (2)
6. Remove the valve housing (9)
7. Check the condition of the seals before re--
assembly.
???.??.??.?? -- ?? -- ????
Convertible single/double--acting auxiliary control valve with float control and detent release.
WARNING
Do not insert fingers or hands between one part and
another.
Wear suitable safety clothing, i.e., safety goggles,
gloves and shoes.
WARNING
Always use suitable tools to align holes. NEVER USE
YOUR FINGERS OR HANDS.
6
3
5
7
9
8
7
8
1
2
TRE1101A 4
12
2. Check valve
3. Kick--out (detent) and float control assembly
4. Control lever support
5. Single double acting converting valve
6. Oil return valve
7. Spool O--ring kit
8. Kick--out control assembly.
Disassemble the auxiliary control valve into its

component parts referring to the sectional views (fig.
1) and the following instructions:
???.??.??.?? -- ?? -- ????
WARNING
During the overhaul and disassembly--assembly of 1
the units, put special protective devices between the
bits of the vice, for preventing any damage to the
valve components.
1. Remove Allen screws (1) Fig.14.
TRE1102A
14
2. Remove both covers (1) Fig.15
TRE1103A
15
3. Remove both spacers (1) Fig.16
1
TRE1104A
16
4. Remove the circlip (1) and take the cover (2)
Fig.17 of the valve (Float & detent release) 2
1
TRE1105A
17
???.??.??.?? -- ?? -- ????
5. Withdraw the spool assembly (1) Fig.18.

1
TRE1106A
18
6. Complete spool assembly (Float & detent re-
lease) is shown at Fig.19.
TRE1107A
19
7. Remove circlip (1) and take off the washer (2)
Fig. 20. Disassamble the unit to all its compo-
nents.
2
TRE1108A
20
8. Disassambled unit (Float & detent release) is
shown at Fig.21.
TRE1109A
21
???.??.??.?? -- ?? -- ????
9. Remove circlip (1) Fig.22.
TRE1110A
22
10. Take off the cover (1) Fig. 23.
1
TRE1111A
23
11. Remove the spool assembly (Detent release) (1)
Fig.24. 1
TRE1112A
24
12. Remove the nut (1) Fig.25 fixing the assembly.
1
TRE1113A
25
???.??.??.?? -- ?? -- ????
13. Remove the spring and the detent body (1)

Fig.26. 1
TRE1114A
26
14. Remove the nut fixing the detent body (1) Fig.27
TRE1115A
27
15. Complete spool assembly (Detent Release) is
shown at Fig.28.
TRE1116A
28
16. Remove oil return valve (1) Fig.29.
TRE1117A
29
???.??.??.?? -- ?? -- ????
17. Take off oil return valve (1) Fig.30
TRE1118A
30
18. Remove relief valve (1) Fig.31.
TRE1119A
31
19. Withdraw relief valve (1) Fig.32.
The relief valve can be checked when the engine is 1

running. When the relief valve is tested as explained
Section 35 Chapter 1 Page 54 the pressure gauge
must show a pressure of 186--191 bar (190--195kg/
cm2).
If the valve does not correspond to the prescribed
value, it is best to change it immediately.
TRE1120A
32
20. Slacken, single--double acting converting valve
(1) Fig.33.
TRE1121A
33
???.??.??.?? -- ?? -- ????
21. Remove, single--double acting converting valve

(1) Fig.34.
TRE1122A
34
22. Take off the ball of, single--double acting convert-
ing valve (1) Fig.35.
1
TRE1123A
35
23. Slacken the allen screws (1) fixing the cover the
cover (2) Fig.36.
TRE1124A
36
24. Withdraw the cover (1) and the spacer (2) Fig.37.
25. Check the condition of all seals before reas- 1
sembly.
2
TRE1125A
37
???.??.??.?? -- ?? -- ????
Double--acting auxiliary control valve with float

control and automatic detent release.
Disassemble the auxiliary control valve into its
component parts referring to the sectional views (fig. 1)
3. Withdraw the spool (10).
and the following instructions:
4. Remove the valve housing and extract the check
1. Unscrew the retaining screws and remove the
valve and spring.
cover (11) and the distance piece.
2. Unscrew the retaining screws and remove the 5. Check the condition of the seals before re--
control lever support (12) and related seal. assembly.
SPOOL BINDING TEST
N 2 2 T
0 0
M 1 1
A
D
T
A B A B
TRE0719A
38
Control valve spool binding test (fig. 38). tion) the flow goes through the valve from inlet to
Install the auxiliary control valve assembly and the test outlet (tank line) (P) to (T). Now regulate the
apparatus as indicated in the diagrams (fig. 38 ) and re- maximum pressure of the VS (main relief valve)
ferring to the following instructions: valve inside bank A (in the schematic). This
pressure is the maximum pressure that can be
— The test is carried out with mineral oil in obtained with the type of valve and spring used.
accordance with DIN 32 norm. Flow rate is the Now move each single spool in each section.
nominal for the valve (for VDM07 it is 50 l/min). With the ports closed, the pressure will rise until
Connect line P (pump line) to the inlet port of the the relief valve opens. In this situation check if
valve and close the working ports A and B of spools move to the neutral (central) position
each section (see schematic) with plugs. without sticking, under the action of springs and
Start the test, increasing the flow coming from flow forces only. The relief valve D, in line before
the pump until nominal flow plus 25% is reached the directional valve, has to substitute the VS in
(in the case of VDM07 it is 75 l/min). With the A in case of problems or in case of directional
control lever in the neutral position (mid--posi- valve without VS.
???.??.??.?? -- ?? -- ????
SPOOL LEAKAGE TEST
2 2 T
N
0 0
M 1 1
D A
C C
B B
C C
TRE0720A
39
Valve leakage test seconds). From this stroke, calculate the volume of
oil per minute through that section of the cylinder.
After the binding test (with hot oil and valve), This check has to be carried out for each section
measure the leakage rate for each section. It is (each spool).
important to do this with the system hot. Connect After this check, with the pump disconnected, move
working ports A and B of each section to the cylinders the spool to its working position: now test the check
(one for each section). Alongside each cylinder lay a valve (VU:Check Valve) of the distributor. This valve
ruler to measure the stroke. closes the connection from P to T (N), also the
Supply oil to the cylinder, moving the spool to the connection P with A or P when B is open (spool in
working position (oil flowing from A or B) until it working position). If the check valve is working
reaches the end of its stroke and the main relief valve correctly, the normal flow rate will be seen (the same
opens. Now that the oil column is pressurised from value observed with spool in the neutral position). If
the working section to the cylinder allow the lever to it is see that one or more sections operates more
return to the neutral position (called 0). The spool than in a previous check, it means that check valve
closes A and B ports. Now check the position of the is not working properly (does not close completely).
cylinder observing the ruler beside it. As the cylinder
moves, check the stroke in a fixed time (say 60
???.??.??.?? -- ?? -- ????
ADJUSTMENT OF THE AUTOMATIC DETENT RELEASE PRESSURE
After servicing the detent regulating valve or if the will fluctuate and the handle return to the neutral
control levers and spool are returning to neutral pre- position. Note the gauge reading immediately
maturely, the detent regulating valve should be prior to the needle fluctuation. The reading
should be within the specified value (1741--1886
tested as follows: lbf/in2) 120 bar+10 bar --0 bar.
NOTE: Detent release pressure is ONLY adjustable

on one spool in the valve that is NOT fitted with float.
The spools fitted with kick out and float have no
visible means of adjustment. -- If the reading is not to specification adjust the
detent pressure as follows:
-- Install inlet hose of flowmeter (1) into lift coupler . . . . . Remove the circlip (33) and the cover (25),
of valve to be tested. (Fig.1. Page.2) of the valve .
. . . . . Loosen locknut (32) on detent regulating ad-

-- Install return hose from flowmeter into lift coupler juster screw (26).
of the same valve on tractor.
. . . . . Turn detent regulating valve adjusting screw
(26) to change pressure setting.
-- Ensure load valve on flow meter is fully open;
-- Start tractor and set engine speed to 1700

rev/min;
-- Pull lever of remote control valve to be tested,

fully rearwards, to extend position.
-- Adjust load valve (2) on flowmeter until pressure 1

is 80 bar (1161lbf/in2) and run until hydraulic oil
is at an operating temperature of 65_C ± 5_C.
2
TRE1126A
40
-- With lever of remote control valve to be tested in
the cylinder extend position slowly close the
flowmeter load valve while observing the
flowmeter pressure gauge.
-- The pressure should steadily rise until the detent

regulating valve opens, at which point the needle
???.??.??.?? -- ?? -- ????
NOTES
???.??.??.?? -- ?? -- ????
Chapter 3-- Trailer brake auxiliary control valve
CONTENTS
35 000 Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Trailer brake remote control valve linkage adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Section view of auxiliary control valve for trailer

braking
1. Flow control valve.

2. Piston.
3. Check valve.
4. Relief valve.
TRE0721A

The trailer brake valve is mounted on the rear control valves and the hydraulic lift.
transmission casing forward of the hydraulic lift. It is The hydraulic operation of these valves is described on
supplied by the same pump as the lift circuit. pages 3 & 4.
The trailer brake valve has priority over the auxiliary
???.??.???.?? -- ?? -- ????
TRAILER BRAKE AUXILIARY CONTROL VALVE
Static oil
Oil in suction
Tractor brake circuit oil (brakes off)
Pressurised oil
Exhaust oil flow
5
1
9
8
7
26428
6
2
Diagram of the hydraulic trailer brake circuit
1. Delivery line to control valve (3). 6. Lift control valve.

2. Trailer brake control valve. 7. Suction line.
3. Auxiliary control valves. 8. Oil filter.
4. Auxiliary control valve lines. 9. Hydraulic pump.
5. Trailer brake control valve line.
???.??.??.?? -- ?? -- ????
TRAILER BRAKES OFF -- When tractor brakes are

inactive, pressure limiter (4) and piston (2) take up 11 1 9
the positions shown in fig 3.
Pf P1 10
Oil from hydraulic pump (8, fig 3) is directed to fitting
N 4
(P1) through diaphragm (11) and restriction (9) which F
causes a pressure drop to move flow control valve
(1) to the right.
Most of the oil flows through connection (N) to the re- R

mote control valves. The remaining output is drained 2
into the hydraulic lift through port (10), piston (2) and
connection (R).
TRE0722A
3
Trailer brakes off
Pressurised oil N. To auxiliary control valves.
P1. From hydraulic pump to lift circuit.
R. To lift return line.
Static oil
START OF BRAKING -- When tractor brake pedal

(Pf) is applied, fork (F) moves pressure relief valve 3 11 12
1 9
(4) and piston (2) to the left, which discontinues com-
munication between oil drain fitting (R) and both trail-
er brake connection (B) and port (10). P1
10
N 4
F
Pf
The oil inside the flow control valve (1) is maintained
at a uniform pressure and so the valve element,
B
under the action of the spring, shifts to the left to
assume the position indicated in fig.4.
R
13
2
Part of the oil from the hydraulic pump in port (P1)
flows to the auxiliary control valves through port (N).
while the remaining part arrives at the trailer braking
element via the diaphragm (11), line (12), check
TRE0723A
valve (3) and port (B).
4
As the pressure of the oil in the trailer brake work port Start of braking
(B) increases, it acts on the active surface (13) of
the spool (2), opposing the effect of control fork (F) B. To trailer brake
on relief valve (4) N. To auxiliary control valves.
R. To return line in the lift.
???.??.???.?? -- ?? -- ????
BRAKING -- Continued brake pedal application

causes an increase in oil pressure at trailer brake
connection (B) which, acting on effective area (13) of 11 12
3 1
piston (2), moves the latter to the right threby over- 9
coming the opposition of relief valve springs (8).
P1 10
N 8 4
Pf F
13 R
When the trailer brake circuit oil pressure is equal to 2
spring (8) pressure, piston (2) stabilises as shown in fig
5 and establishes communication between oil from
pump and lift drain through connection (P1), diaphragm
TRE0724A
(11), restriction (9), port (10) and connection (R).
5
Braking
B. To trailer brake
R. To return line in the lift.
Diaphragm (11) and restriction (9) cause a pressure

drop in flow control valve (1) which moves rightward to
close port (12) and consequently, check valve (3).
Pressurised oil
Further pressure on the tractor brake pedals (Pf) Static oil
causes a leftward movement of relief valve (4) and
piston (2), with a consequent increase in trailer brake
circuit oil pressure as the sequence described in
paragraph b START OF BRAKING at page 3.is re-
peated.
Upon releasing brake pedals, system returns to the

conditions shown in fig 3 at page 3.
???.??.??.?? -- ?? -- ????
TRE0725A
6
Trailer brake remote control valve linkage adjustment
C. Wrench flats on link (6) G = 0,3--0,5mm. Clearance between fork (7) and piston (10) M Pressure gauge
with 0 to 250 kg/cm2 scale of kit 293300 V . Trailer brake control valve 1-- Connection 293799 of kit 293300
2-- Connection 291323 of kit 293300 3-- Delivery line to trailer brake 4-- Cup 5-- Lock nut 6--
Link 7-- Fork 8-- Brake pedals 10-- Trailer brake control valve piston
???.??.???.?? -- ?? -- ????
TRAILER BRAKE REMOTE CONTROL VALVE LINKAGE ADJUSTMENT

Proceed as follows: 8. Run engine at around 2000 rpm.
1. Adjust the brake pedal (8) free travel as indicated 9. Check that pressure gauge (M) reading is zero
before. when brake pedals (8) are not applied.
2. Adjust parking brake lever (9) as indicated before. 10. Depress brake pedals until pedal free travel is
3. Fully tighten cup (4), slacken lock nut (5) and ad- taken up and check on pressure gauge (M) that
just lenght of link (6), using wrench flats (C) to ob- pressure is 100 bar (102 kg/cm2)
tain a clearance (G) of 0,3 to 0,5 mm between 11. Repeat this operation at least three times, check-
fork (7) and piston (10). ing that system pressure reading drops to zero
4. Tighten loc nut (5). when pedals (8) are released.
5. Disconnect trailer brake oil delivery line (3) from 12. Apply parking brake (9) a few times without de-
brake control valve body (V). pressing brake pedals and check that pressure
6. Connect pressure (M) with 0 to 250 kg/cm2 scale reading on pressure gauge (M) remains at zero.
of kit 293300 to control valve body, using connec-
tions 293799 (1) and 291323 (2) (Both connec-
tions belong to kit 293300)
7. Start engine and bring oil temperature to 50 --
60°C.
???.??.??.?? -- ?? -- ????
SECTION 41 -- STEERING -- CHAPTER 1 1
SECTION 41 -- STEERING
Chapter 1
CONTENTS
41 000 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
41 204 Hydrostatic steering control valve -- Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydrostatic steering control valve -- Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . 14
Hydrostatic steering control valve -- Bench testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
41 206 Hydrostatic steering oil pump -- Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
41 216 Steering cylinder -- Removal--Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
PRINCIPAL DATA
HYDROSTATIC STEERING
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . independent hydrostatic control,

Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . feed by hydraulic pump
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . metal cartridge, built
into oil reservoir
Control valve
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DANFOSS OR ORSTA
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rotary valve controlled directly
from the steering column; the
steering continues to function
even if the pump is
non--functional
Outfit code:
-- DANFOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OSPC 100
-- ORSTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LAG--B 100--LVP16--2
Pressure relief valve setting (22) fig. 2

-- 2WD models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 bar (125 kg/cm2)
-- 4WD models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 bar (127 kg/cm2)
???
2 SECTION 41 -- STEERING -- CHAPTER 1
MAIN SPECIFICATIONS OF HYDRAULIC PUMP C25
Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear type with oil suction from
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . transmission casing
behind timing gear cover
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C 25
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FIAT
Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driven by timing gears
Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . . . . . . clockwise
Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,931:1
Maximum speed of rotation (with engine at maximum power) . rev/min 2328
Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/min 26.4
Bench output at 1450 rev/min and pressure of

153 bar (156 kg/cm2):
-- for new or reconditioned pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/min 15.3
-- for worn pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/min 10.7
-- test oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C° 55 -- 65
-- test oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 20
Diameter of driven and driving gear shafts . . . . . . . . . . . . . . . . . . . . mm 17.400 -- 17.418
Internal diameter of seats in supports . . . . . . . . . . . . . . . . . . . . . . . . mm 17.450 -- 17.475
Clearance between gear shafts and their seats . . . . . . . . . . . . . . . . mm 0.032 -- 0.075
-- maximum clearance due to wear . . . . . . . . . . . . . . . . . . . . . . . . . . . mm 0.1
Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . . . . . . mm 0.020 -- 0.064
Maximum wear on pump body, suction side, at position of gears . mm 0.1
Power Cylinder
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double acting, located behind
front axle
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEBER or SIMA or ERBER
Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 mm (1.89 in)
Piston rod diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 mm (0.866 in)
Maximum piston stroke
WEBER or ERBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 ( 8.464 in)
SIMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 mm (8.425 in)
Maximum piston stroke
WEBER or ERBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 mm (7.874 in)
SIMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 mm (7.638 in )
???
TORQUE SETTINGS
Torque setting
PART Thread
Nm kgm
Bolt fixing hydrostatic steering to tractor . . . . . . . . . . . . . . . . . . . . . . . . . 3/8”--16 UNC 44 4,5
Bolt fixing cover to hydrostatic steering housing (13, fig. 2) . . . . . . . . . M8x1 34 3,5
M 8 x 1* 29 3
Hydrostatic steering control pump fixing bolt . . . . . . . . . . . . . . . . . . . . . M6x1 8 0,8
Nut for bolt fixing cover to pump housing (20, fig. 1) . . . . . . . . . . . . . . . M 10 x 1,25 39 4
Nut for securing thrust sleeve to pump drive shaft (14, fig. 1)) . . . . . . 7/16 in
--20UNF--2B 28 2,8
Nut, power cylinder pivot pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 18 x 1.5 294 30
Nut, power cylinder piston rod to steering arm . . . . . . . . . . . . . . . . . . . . M 14 x 1.5 147 15
Nut, piston to rod

--WEBER cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 83 8.5
--SIMA cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 98 10
--ERBER cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 98 10
Capscrew, contol valve support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1.5 147 15
Capscrew, LVP safety valve block to body . . . . . . . . . . . . . . . . . . . . . . . -- 64 6.5
* ORSTA
???
1
Hydrostatic steering -- Oil pump components
1. Front cover 11. Driving shaft seal

2. Cover seals 12. Snap ring
3. Pump body 13. Lock washer
4. Gear support 14. Nut
5. Driven and driving gear shafts 15. Bolt
6. Gear support 16. Washer
7. Bushing 17. Key
8. Control side cover 18. Bushing.
9. Driving shaft seal 19. Safety washer
10. Spacer 20. Nut.
???
24725
Hydrostatic steering -- Control valve components 2
1. Dust seal
2. Reflux valve balls 12. Rotor control shaft -- sleeve trim pin
3. Reflux valve pins 13. Cover fixing screws
4. Control valve body, rotary valve and rotary 14. Check valve seat screw
valve seat sleeve 15. Washers
5. Check valve ball 16. Cover
6. Threaded plug of check valve 17. O--rings
7. O--ring seal 18. Rotor and fixed ring for rotor
8. Support ring for O--ring (7) 19. Thrust washer
9. Thrust bearing components 20. O--ring
10. Retaining ring for springs (11) 21. Rotor control shaft
11. Springs for returning sleeve to neutral position 22. Pressure relief valve complete with spring
???
26 M S
27
D1
TRE0431A
3
General hydraulic diagram
H Control cylinders 26 Oil in intake line
D1 Hydrostatic steering control valve 27 Oil in delivery line from pump
E Filter
T Oil tank M Oil
P Pump S Oil at lubrication pressure
???
OPERATION direct mechanical connection between the column

and the steered wheels.
The oil taken in by the rear axle is pushed into the Neutral position
pump through a filter, pressurized by the rotating When the steering wheel is stationary, the leaf
gears and expelled from the delivery side of the springs in the steering motor push the spool and the
pump to the steering motor. Once in the steering sleeve in, and keep them in the neutral position. This
motor, the pressurized oil is directed to the steering ensures that no further oil is supplied to the steering
cylinder when the steering wheel is turned. cylinder. The sleeve also blocks the oil inside the
cylinder, keeping the wheels in a set position, fig. 4.
Inside the steering motor, there is a measuring
device which controls the volume of oil supplied to Oil in intake line
the cylinder so that it is proportional to the angular
movement of the steering wheel. The metering valve Oil in delivery line from pump
together with the intake valves also allows MANUAL Oil at static rest
operation of the steering, without pressurized oil
being emitted by the pump. Oil returning to reservoir
The system is totally hydrostatic and as such, has no
a
1
13
12
5
11
10
6
TRE0432A 9 7
8
4
Diagram of hydrostatic steering operation
a 2WD models 7. Pump

1. Equalization valve 8. Filter
2. Steering cylinder 9. Return line to reservoir
3. Metering valve 10. Pressure relief valve
4. Check valve 11. Control valve external rotor
5. Non--return valve 12. Control valve internal rotor
6. Resonance damper 13. Anti--cavitation valves
???
Steering to the right (fig. 5) Steering to the right manually

When you turn the steering wheel clockwise, the
springs (11) fig. 2 deform, allowing the valve (12) fig. If there is a fault or loss of oil pressure at the hydro-
4 to rotate in relation to the sleeve (11). static steering pump, steering can also be performed
manually.
In this state, the following takes place:
-- de--synchronisation of the internal ducts with When you turn the steering wheel clockwise, the ro-
parts (11) and (12) fig. 4, which were aligned in the tor inside the hydrostatic steering control valve (3)
neutral phase, resulting in interruption of the flow fig. 4 performs the function of a hand pump, sending
of oil to the outlet. oil to the control cylinder rod side (2), thus allowing
-- alignment with the same number of internal ducts the wheels to be steered to the right manually.
connected moment by moment with the rotor
compartments at intake from the pump (7) fig. 4 Steering to the left manually
and in the delivery line to the steering cylinders
When you turn the steering wheel anticlockwise, you
(2), thus allowing the wheels to be steered to the
act upon the rotor inside the hydrostatic steering con-
right.
trol valve which, by operating as a hand pump as pre-
Steering to the left viously described, sends oil to the control cylinder
piston side, thus allowing the wheels to be steered to
When you turn the steering wheel anticlockwise, the the left manually.
grooves inside parts (11) and (12) fig. 4 and the deliv-
ery lines to the steering cylinders are reversed, thus
allowing the wheels to be steered to the left.
25162
5
Diagram showing operation of the hydrostatic steering
a 2WD models Oil in delivery line from pump
A Steering to the right
B Steering to the left Oil in delivery line to hydraulic cylinder
Oil in intake line Oil returning to reservoir

???
HYDROSTATIC STEERING FAULT DIAGNOSIS
Refer to fig. 2 for component identification
Problem Possible causes Corrective action

Oil leaking from hydrostatic steer- 13. O--ring seal defective (7). Renew the seal and the stop ring
ing unit: using special tool 293955.
a. Control side.
b. Cover side.
14. Screws (13) not sufficiently Tighten the screws to the prescribed
tight. torque (24--36 Nm, 2.5--3.7 kgm).
15. Sealing washers (15) or O-- Renew the washers and seals.
rings (17) defective.
Steering wheel excessively stiff 1. Hydraulic pump inefficient. Repair the pump.
2. Check valve (5) held open by Eliminate foreign bodies and clean
foreign bodies or open due to the filter; put a new ball into the seat
absence of ball. (if missing).
3. Pressure relief valve (22) Reset the valve.
incorrectly set.
4. Pressure relief valve (22) Eliminate foreign bodies and clean
jammed or held open by for- the filter.
eign bodies.
5. Steering column has become Eliminate the causes.
stiff on its bushing due to
rusting, seizing, etc.
Excessive play of steering wheel 1. Excessive play between the Renew the worn parts.
steering column and the
coupling with the rotary valve
(4).
2. Excessive play in the coupling Renew the worn parts.
between shaft (21) and trim
pin (12).
3. Excessive play in the splined Renew the worn parts.
coupling between the shaft
(21) and the rotor (18).
4. Combination of excessive Renew the most worn parts.
play as described above.
5. Leaf springs (11) broken or Renew the springs.
fatigued.
The steering wheel turns normally, 1. Inadequate seal of control Renew the seal.
but steering is: cylinder.
a. Slow. 2. Cylinder rod broken. Renew the damaged part.
b. No steering. 3. Rotor control shaft (21) or pin Renew the damaged part.
(12) broken.
With the engine stopped, the 1. Excessive wear between rotor Renew the worn parts.
steering wheel can be turned with- and fixed ring (18).
out turning the wheels.
2. Check valve damaged. Renew the control valve.
(continued)
???
HYDROSTATIC STEERING FAULT DIAGNOSIS
Refer to fig. 2 for component identification
(continuation)
Problem Possible causes Corrective action
Steering wheel jolts, steering 1. Incorrect synchronization of Synchronize correctly.

uncontrollable, wheels steering in hydrostatic steering. Correct the connections.
the opposite direction to the 2. Hoses to cylinder reversed.
desired direction.
The wheels do not maintain the 1. Hydraulic cylinder piston seal Renew the seal.
desired alignment and continual worn.
correction with the steering wheel 2. Reflux valve (2) damaged or Eliminate the foreign bodies and
is necessary. held open by foreign bodies. clean the filter or renew the control
valve.
3. Mechanical wear of control
valve. Renew the control valve.
Neutral phase of hydrostatic 1. Leaf springs (11) for returning Renew the pack of leaf springs.
steering unobtainable. During sleeve (4) to neutral position
manual control, operation is broken or fatigued.
normal. When stopping manual 2. Sleeve and rotary valve (4) Eliminate the foreign bodies and
control, the steering wheel moves blocked in delivery position by clean the filter.
on its own or remains stationary, foreign bodies.
but steering continues slowly in
3. Crushing of sleeve (4) on Check the setting of the pressure
the direction first turned
rotary valve due to excessive relief valve (22).
(motoring), so the steering wheel
pressure.
must be continually corrected.
Front wheel vibration (shimmy). 1. Air pockets in the hydraulic Bleed the air and eliminate the causes
cylinder. of possible infiltration.
2. Wear of mechanical joints of Renew the worn parts.
steering tie rods.
3. Reflux valve (2) damaged or Remove the foreign bodies and clean
held open by foreign bodies. the filter or renew the control valve.
Difficulty in steering in general, or 1. Insufficient pressure. Check the hydraulic pump and the
in one direction. setting of the pressure relief valve
(22).
2. Excessive leakage inside the Renew the control valve.
control valve.
List of special tools necessary for the various

TOOLS operations described in this section.
WARNING: The operations described in this section

must be performed only with the ESSENTIAL X 293390 Hyd. steering rotor retaining lever.
equipment marked with (X). X 291182 Steering wheel extractor.
To operate safely and achieve best results, while
saving time and effort, essential equipment must be X 292870 Universal pressure checking kit.
used in conjunction with the special tools X 293388 Tool for fitting hydrostatic steering
recommended below, and tools which you must toroidal seal.
make yourself and for which you will find the design 293389 Plug for fitting hydrostatic steering
in this manual. rotary valve return springs.
???
HYDROSTATIC STEERING CONTROL VALVE

1
WARNING
Wear the recommended safety clothing such as
goggles, gloves and safety boots.
To remove the hydrostatic steering control valve,

proceed as follows:
1. Disconnect the negative cable (1) from the
battery. 25621
2. Drain the oil from the steering system.
6
3. To access the engine the hood must be
opened.
TRE0033A
4. Disconnect the oil pipes from the hydrostatic

steering control valve unit (1).
TRE0434A
8
5. Remove the steering wheel (1) retaining nut and
remove the steering wheel and hand throtltle
lever.
25758
???
6. Remove the four securing screws (1) from the 1 1

instrument panel (2).
1 1
TRE2146A
10
7. Disconnect the electrical leads (1) from the rear 2
of the instrument panel. Unscrew the tachometer
cable (2). Remove the instrument panel.
TRE2146A
1
TRE0851B
11
8. Unscrew the bolts(1) securing the bonnet to the
support frame on right hand side.
TRE2136A
12

support frame on left hand side.
TRE2137A
13
???
10. Remove the screws (1) securing the rear hood

to the support frame.
1
TRE3057A
14
11. Unscrew the keyhole bracket(1), turn indicator

bracket (2) and light control switch (3). Remove 4
the screws (4) fastening the rear hood.
1
2
3
TRE3056A
15
12. Remove the hydrostatic steering unit support

bolts and take of the hydrostatic steering unit.
TRE0028A
16
???
-- To refit the control valve, proceed as follows:

--
-- Refit the hydrostatic steering unit
-- Refit the complete rear hood.
-- Secure the rear hood with the screws previously
removed.
-- Reconnect the electrical leads and reconnect
the the tachometer cable.
-- Re--install the four screws securing the
instrument panel.
-- Re--install thehand throttle and steering wheel.
Secure the wheel with the central retaining nut.
-- Reconnect the oil pipes to the hydrostatic
steering control valve unit.
-- Fill the the steering system with oil.
-- Reconnect the negative cable to the battery and
close the hood.

Disassembly--Assembly with the control valve
removed (Op. 41 204 34 )
To disassemble the hydrostatic steering control
valve, proceed as follows:
1. Remove the control valve cover retaining bolts.
24701
17
???
2. Remove the cover by sliding to one side.
24702
18
3. Remove the rotor fixed ring, the rotor and the
inner spacer.
4. Remove the two O--ring seals on the rotor fixed

ring.
24703
19
5. Extract the rotor drive shaft
24704
20
6. Extract the thrust washer.
24705
21
???
7. Remove the threaded plug on the non--return

valve seat.
24706
22
8. Extract the O--ring seal from the control valve
body.
24707
23
9. Position the control valve body and the rotor
drive shaft so that the sleeve--control shaft trim
pin is in a horizontal position.
10. Push the rotary valve inwards, so that the valve,
the valve seat sleeve and the thrust bearing can
be extracted from the control valve body.
24709
24
11. Extract the thrust bearing from the rotary valve,
complete with the two external rings. Remove
the spring retaining ring from the valve seat
sleeve.
24710
25
???
12. Extract the valve--sleeve trim pin.
24711
26
WARNING: On assembly, two reference marks

(arrowed) were made on the rotary valve and the
sleeve, corresponding to the neutral position main-
tained by the springs. Before removing the springs,
check that the marks are clearly visible. If not clear,
make new reference marks.
24712
27
13. Extract the rotary valve from the valve seat sleeve.
24713
28
14. Remove the neutral position springs, extracting
them from their seats.
24714
29
???
15. Remove the dust seal and the O--ring seal from
their seats in the control valve body.
20428
30
16. Using a 6 mm Allen wrench, remove the
threaded plugs from the two cylinder safety
valves and extract the seals.
20429
31
17. Using a 6 mm Allen wrench, remove the setting
adjuster screws from the cylinder safety valves.
See also fig. 33.
18. Turn the control valve body over and extract the
balls, the springs and the spring guides from the
two cylinder safety valves.
20432
32
Cylinder safety valves components (order of disas-
sembly--assembly).
1 2 3 4 5
1. Cylinder safety valve ball.
2. Pressure spring.
3. Setting adjuster screw.
4. Seal.
5. Plug.
25790
33
???
19. Using a 6 mm Allen wrench, remove the

threaded plug on the pressure relief valve and
extract the seal.
20434
34
20. Remove the pressure relief valve adjuster screw.
21. Turn the control valve body over and complete

disassembly by extracting the spring and the
pressure relief valve piston.
20436
35
Pressure relief valve components (order of

assembly).
1 2 3 4 5
2. Pressure spring.
4. Seal.
5. Plug.
27099
36
???
22. Thoroughly clean all control valve component

parts.
23. Replace the washers and seals.
24. Carefully check all mechanical parts, replacing

components that show signs of wear.
25. Before re--fitting, lubricate the components with

hydraulic oil.
26. Re--fit the rotary valve on the sleeve, checking

that the reference marks indicated in the drawing
coincide.
24726
37
27. Use tool 293389 to insert the flat and curved
springs (12) fig. 2.
Diagram for fitting springs (12) fig. 2 neutral position
for OSPC 80 ON--150N 1058 hydrostatic steering ).
24728
38
28. After inserting the springs in the seat, align and
centre (as shown in the drawing).
24729
39
???
29. Fit the neutral position spring retaining ring on

the valve seat sleeve, remembering that the ring
must rotate freely without being impeded by the
springs.
24730
40
30. Insert the sleeve--rotor drive shaft trim pin.
24731
41
31. Fit the thrust bearing, following the order
indicated in fig. 43.
24732
42
1. Bearing external ring.
1
2. Thrust bearing.
2
3. Bearing internal ring with bevel facing contact
surface of part (5). 3
4. Rotary valve. 4
5. Rotary valve seat sleeve. 5
24733
43
???
32. Position the control valve body so that the

housing seat on the rotary valve sleeve is
positioned horizontally, then insert the guide
bushing (1) of tool 293388.
1
24734
44
33. Lubricate the support ring (1) and O--ring seal (2)
with hydraulic oil and fit them on the head (3) of
the tool 293388, as shown in the drawing.
2
1
Support head for support and seal rings (part

of tool 293388)
24735
45
34. Insert the complete drift in the guide bushing

previously installed.
24736
46
???
35. Holding the external bushing in position man-

ually, press fully down, whilst simultaneously
rotating the drift, in order to facilitate the entry of
the O--ring seal in the control valve body seat.
24737
47
36. Extract the components of tool 293388 ( external
bushing and drift).
NOTE: The support head of the support and seal

rings remains on the control valve body (see fig. 45).
48
37. Insert the parts that were previously fitted in
operations 26 -- 31 on the control valve body.
Hold the sleeve--to--rotor drive shaft trim pin in a
horizontal position, to prevent it from slipping out
and jamming in the slots inside the control valve
body.
24739
49
38. Press the rotary valve so as to bring the thrust
bearing into contact with the control valve body.
This operation simultaneously expels the head
(1) of tool 293338, inserting the rings (1) and (2)
fig 45 into the seat of the control valve body (see
operation 33).
25795
50
???
39. Rotate the control valve body and insert the

non--return valve ball into the seat indicated by
the arrow.
24741
51
40. Screw the threaded plug into the non--return
valve seat until the upper surface is below the
coupling surface of the control valve body.
24742
52
41. Lubricate the O--ring seal and insert into the seat
on the control valve body.
24746
53
42. Fit the thrust washer, so that the holes coincide
with the holes in the control valve body.
24747
54
???
43. Make a reference mark on the upper part of the

teeth (1), in line with the seat (2), to indicate the
exact position of the valve--to--sleeve trim pin.
24748
55
44. Fit the rotor drive shaft into the control valve
body. Insert tool 293390 for retaining and
centring the rotor drive shaft, between the rotor
drive shaft and the thrust washer. Rotate the
shaft so as to facilitate coupling between the seat
(2) fig. 55 and the trim pin installed in the sleeve.
24749
56
45. To refit the rotor, proceed as follows:
a) each time the hydrostatic steering is disas-

sembled, turn the rotor over so as to limit wear to
the splined coupling;
b) in the drawing below, the rotor shaft has been

removed in order to show the phasing between the
rotor, rotor drive shaft and the trim pin;
c) fit the rotor on the drive shaft, remembering that

phasing is obtained by aligning the teeth (1), on the
trim pin axis plane (shown in fig. 55) with the centre
line of one of the recesses between the lobes of the
rotor.
24750
57
???
46. Lubricate the two O--ring seals (1) with hydraulic

oil and insert them in the rotor fixed ring seat. Fix
in position by aligning the retaining holes (2) with
those on the thrust washer.
24751
58
47. Fit the cover, aligning the retaining holes with
those on the rotor fixed ring.
24753
59
48. Remove retaining tool 293390 and fit the special
screw and washer in the non--return valve seat,
shown in the drawing.
24754
60
49. Fit the other six cover retaining bolts with the
washers and tighten in diagonal sequence to the
torque setting value shown in the table on page
3.
24755
61
???
50. Turn over the control valve body and insert the
pressure relief valve piston in the seat, as
indicated in the drawing. See fig. 36 for
component assembly order.
24756
62
51. Insert the pressure relief valve spring.
24757
63
52. Using an 8 mm Allen wrench, insert the pressure
relief valve setting screw.
NOTE: Setting should be carried out on the

workbench or on the tractor to the values shown in
the table on page 1.
24758
64
53. Tighten the plug (2), with the associated seal,
using an 8 mm Allen wrench. Tighten to the
1
prescribed torque value 40 -- 60 Nm (4.1 -- 6.1
kgm), after having carried out the setting on the
workbench or on the tractor.
54. Insert the balls (1) into the two cylinder safety
2
valve seats, indicated by the arrows. See fig. 66
component assembly order.
25789
65
???
Cylinder safety valves components (order of

assembly)
1 2 3 4 5
1. Cylinder safety valve ball.
2. Pressure spring.
4. Seal.
5. Plug.
25790
66
55. Insert the springs (2, fig. 69) in the cylinder
safety valve seats.
56. Using a 6 mm Allen wrench, tighten the two
cylinder safety valve setting adjuster bolts (3,
fig. 69).
NOTE: Setting should be carried out on the wor-

kbench or on the tractor to the values shown in the
table on page 1.
20475
67
57. Tighten the two plugs (5, fig. 69) and the
relative seals (4) using a 6 mm Allen wrench.
Once setting is completed, tighten to the
prescribed torque value of 30 Nm (3 kgm).
20429
68
58. When the unit has been assembled, insert the
dust seal in the seat in the control valve body.
24764
69
???

Bench testing (Op. 41 204 38 )
Test conditions.
Oil type . . . . . . . . . . . . . . . . . . . IDRAULICAR AP51
Oil viscosity . . . . . . . . . . . . . . . . . . . . . . . SAE 20 W
Oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . 60_C
Hydraulic pump capacity . . . . . . . . . . . . . dm3/min
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (litres/min.) 12
Speed of electric motor . . . . . . . . . . . . . . . rpm 1450
2
1
24912
Installation diagram of equipment for testing the rotary valve, 68

seals and for setting the pressure relief valve.
1. Splined control shaft 4. Restriction
2. Torque wrench 5. Pressure adjustment handwheel
3. Delivery line
A -- CHECKING ROTARY VALVE WEAR
1. Make the connections shown in fig. 68 and
complete the circuit as in fig. 69. Using the
splined control shaft (1), hold the steering control
valve in steering position (right or left).
2. Using the handwheel (5), increase the circuit
pressure to as near as possible the pressure
relief valve cracking pressure (page 1) without
the valve actually opening.
3. Using a torque wrench (2), apply a torque of
approx. 34 Nm (3.5 kg) to the control shaft (1),
and check that the rotary valve takes more than
10 seconds to complete one full rotation. If it
takes less than 10 seconds, change the rotary
valve (4, fig. 2) and the sleeve .
???
B -- CHECKING RETURN TO NEUTRAL POSITION

In the same test conditions as A, check that the valve
automatically returns to neutral position when the 1
control shaft (1) is released after each simulated
steering movement.
C -- CHECKING SEAL EFFICIENCY
7
In the same test conditions as A, hold the valve in
steering position with the control shaft (1) for about
three minutes and check the seals for leaks. 6 2
D -- SETTING THE PRESSURE RELIEF VALVE
1. Make the connections as shown in figure (68)
and complete the circuit as in figure (69).
2. Using the control shaft (1), simulate a steering
cycle (to right or left) so as to interrupt the oil flow
to the outlet.
3. Gradually increase the pressure in the circuit by
turning the handwheel (5) fig. 68, and check on
the pressure gauge that the pressure relief valve
(22, fig. 2) cuts in at the pressure shown on page 5
1. If not, increase or reduce the pressure relief
valve setting by tightening or slackening the ad-
juster screw.
3
4
24911
69
1. Splined control shaft -- 2. Plug G 1/2” -- 3. To
throttle -- 4. Outlet -- 5. Three--way coupling G 1/2” --
6. From delivery line -- 7. Outlet coupling G 1/2”
CHECKING THE HYDROSTATIC STEERING

PRESSURE RELIEF VALVE WITH STEERING
CONTROL VALVE INSTALLED ON TRACTOR.
Proceed as follows: 3
4 5
1. Start the engine and run until the oil temperature 1 2
reaches approx. 50oC.
2. Switch off the engine and unscrew the oil delivery
pipe union (4) on the hydraulic cylinder (5).
3. Fit union (2) in place of union (4), and connect the
pressure gauge (1) with a 0 -- 150 kg/cm3 scale
by way of union (3).
4. Start the engine again, bring the speed up to
medium rpm, and apply full--steering lock to
bring the hydraulic cylinder to the stroke--end 24915
position. 70
In this condition, the pressure relief valve (22, fig. 2)
should open and the pressure gauge should indicate 1. Pressure gauge (supplied in kit 292870) -- 2.
the value given on page 1. Union 293874 (supplied in kit 292870) to be fitted
5. If the pressure gauge reading deviates signifi- in place of original union -- 3. Union 291318
cantly from the prescribed value, adjust the valve (supplied in kit 292870) -- 4. Hydraulic cylinder oil
opening pressure by way of the adjuster screw. feed pipe -- 5. Hydraulic cylinder.
???
Hydrostatic steering oil pump components 71
Hydrostatic steering oil pump components
1. Front cover 11.Driving shaft seal.

2. Cover seals 12. Snap ring
3. Pump body 13. Safety washer
4. Gear support 14. Nut
5. Driven and driving gear shafts 15. Bolt
6. Gear support 16. Washer
7. Bushing 17. Key
8. Control side cover 18. Bushing
9. Driving shaft seal 19. Safety washer
10. Spacer 20. Nut
Proceed as follows:
1. Remove the cover fastening nuts (20), then the
bolts (15) and the safety washers.
2. Remove the nut (14) that fastens the sleeve to the
pump driving shaft and the safety washer.
3. Remove the front cover (8), the snap ring (12)
and the seals ( 9 and 11 ).
4. Mark parts 3, 4, 5 and 6 to enable them to be re-
mounted in the same position if they are in good
condition.
???
5. Remove the supports (4 and 6) and the gears

(5) from the rear cover (8) and the pump body (3).
6. Remove the seals (2) and the anti--extrusion
rings.Once the parts are removed, proceed as fol-
lows:
7. Check that the gear contact surfaces are flat
and perpendicular to their supports. Interpose a
thin layer of carbon black. Small rough spots can
be removed using extremely fine and adequately
lubricated abrasive paper.
8. Check that the axial play of the gear--support
unit in the pump body is 0.100 -- 0.180 mm. The
distance (Fig 72, 2) must be 0.100 -- 0.180 mm
smaller than the distance (Fig 72, 1).If necessary,
true the flat surfaces involved using lubricated 2
abrasive paper to remove extremely small quanti-
ties of material
9. Clean all constituent parts thoroughly.
10. Replace the seals (2, 9 and 11).
11. Lubricate the parts with the same oil as the sys-
tem Refit the pump, referring to fig. 71 and pro-
ceeding as follows:
12. refit, performing operations 6 to 1 in reverse or- 25227
der;-- always ensure the maximum cleanliness to
prevent foreign matter from entering, as this 72
could damage the pump;-- fit together previous-
ly marked parts (3, 4, 5 and 6, fig. 71); see op.
page 45 to refit them in their original position;--
mount the gear supports (4 and 6 fig. 71) in the
pump body; orient them with the fittings on the
exter nal circumference matched up with the dis-
charge pipes and the front faces with lubrica-
tion millings in . . . . . . . contact with the gears;--
fit the plastic anti--extrusion rings on the seals (2,
fig. 71);-- mount the seals (9 and 11, fig. 71) on
the control side cover (8) complete with
spacer (10); orient them so that the cavity is
between the seal lips on the opposite side
from this spacer; lastly fill this cavity with GR 75
MD grease.Install the pump on the tractor. Fill the
suction pipe and the pump housing with AMBRA
MULTI F oil in order to facilitate priming and pre-
vent the risk of seizure during initial operation.
???
FRONT AXLE STEERING CYLINDER (Two wheel

drive axle)(Op. 41 216 20)
Removal--Refitting
WARNING
To remove the front axle steering cylinder, proceed

as follows:
24768
1. Remove the exhaust pipe, lift the hood and
disconnect the negative cable from the battery. 73
2. Unscrew the unions securing the oil delivery and
return hoses (1) to the cylinder (2).
3. Remove the nut securing the cylinder rod ball
end to the steering arm (1).
24858
74
4. Using a suitable puller (1), separate the cylinder
rod ball end from the steering arm.
24859
75
5. Remove the pin securing the steering cylinder
(1) to the axle and remove the cylinder.
6. To refit the steering cylinder, follow the removal
procedure in reverse order.
24860
76
???
FRONT AXLE STEERING CYLINDER (Four

wheel drive axle)
Removal--Refitting 1
WARNING
To remove the front axle steering cylinder, proceed

as follows:
24863
2. Unscrew the unions securing the delivery and
return hoses to the steering cylinder. 77
3. Remove the snap ring (1) and remove the

cylinder rod articulation pin (2) connected to 2
the stub axle housing.
24861
78
4. Remove the retaining screw and extract the pin
(1) securing the steering cylinder to the axle.
Remove the steering cylinder. 1
NOTE: Should you want to remove both steering

cylinders complete with supply pipes, omit step 3
described above and carry out steps 2 and 4 for the
other cylinder too.
24862
79
5. Remove the two actuator cylinders complete
with supply pipes.
24864
80
???
SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1 1
SECTION 44 -- FRONT AXLE AND WHEELS

Chapter 1 -- Front axle and wheels
CONTENTS
44 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
44 101 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
44 101 Axle Wheel Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
44 101 Stub Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
???????????- 05--2002
2 SECTION 44 -- FRONT AXLE AND WHEELS -- CHAPTER 1
SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . inverted U--section, tele-

scopic
and oscillating at center
Wheel angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2°, corresponding to 15 mm
( 590 ins)
(.590
for 16 in. wheels
Toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (ins) 0 -- 5 (0 -- .196)
Stub axle articulation
Diameter of stub axle pin (7, page 7) at bushing . . . . . . . . . . . . . . mm (ins) 37.961 -- 38.000
(1.494 -- 1.496)
Bore of installed bushings (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (ins) 38.050 -- 38.140
(1.498 -- 1.501) (*)
Clearance between stub axle pin and relative bushings . . . . . . . . mm (ins) 0.050 -- 0.179
(.001 -- .007)
Axle articulation
Diameter of axle articulation pin (1, page 7) . . . . . . . . . . . . . . . . . . mm (ins) 37.961 -- 38.000

(1.494 -- 1.496)
Bore of installed bushings (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (ins) 38.050 -- 38.140
(1.498 -- 1.501) (*)
Clearance between stub axle pin and bushing . . . . . . . . . . . . . . . . mm (ins) 0.050 -- 0.179
(.001 -- .007)
(*) Value to be obtained without refacing.
??????????? - 05--2002
(cont.)
Alternative track settings mm (ins)

Model Standard wheel tracks
Tires
mm (ins) A B C D E F
TD60 7 50--16 in.

7.50--16 in 1500 (59) 1400 1500 1600 1700 1800 1900
TD70
(55) (59) (63) (67) (70.86) (74.8)
TD80
TD90 1410 1510 1610 1710 1810 1910
TD95 7.50--18 in. 1510 (59.5)
( )
(55.5) (59.5) (63.38) (67.32) (71.25) (75.19)
DIAGRAM OF 2WD FRONT WHEEL TRACKS
23928
???????????- 05--2002
26155
Sections of stub axle, articulation pin and front axle

6. Axle articulation pin 9. Cap
7. Axle articulation bushing 10. Bronze thrust ring
8. Steering transverse tie rod 11. Seal
9. Stub axle control lever 12. Wheel hub
10. Axle sup- 13. Steel thrust washer
port 14. Grub screw for cap (11) and thrust washer (12)
11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bushing 15. Taper roller bearing for wheel
12. Stub axle 16. Bearing cover for greasing and adjustment
pin 17. Cylinder fulcrum pin (18)
13. Support 18. Power steering cylinder installation position
ring grub screw (13)
??????????? - 05--2002
TIGHTENING TORQUES
C1 -- 49 Nm C2 -- 314 Nm (231.5 ft-lbs)

(36 ft-lbs)
C6 -- 186 -- 206 Nm
(137 -- 152 ft-lbs)
C5 -- 186 -- 206 Nm
(137 -- 152 ft-lbs)
C3 -- (*)
C4 -- 186 -- 257,7 Nm
(137 -- 190 ft-lbs)
26157
Front axle
C1 Axle articulation pin bolt C5 Nut for stub axle pin control lever
C2 Nut securing disc to wheel hub C6 Nut securing cylinder to fulcrum pin
C3 Bearing adjuster nut
C4 Axle end nut
* See operations 26. and 27., page 16.
???????????- 05--2002
Torque setting
PART Thread
Nm ft-lbs
Front axle
Bolt securing axle to engine (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 18 x 1,5 353 260
Bolt securing axle articulation pin (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 10 x 1,25 49 36
Nut for axle end fixing screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 16 x 1,5 211 155.5
Nut securing LH and RH levers on the stub axles (4) . . . . . . . . . . . . . . M 16 x 1,5 294 217
Nut securing ball end for transverse steering tie rod . . . . . . . . . . . . . . . M 14 x 1,5 118 87
Nut securing transverse steering tie rod . . . . . . . . . . . . . . . . . . . . . . . . . M 20 x 1 176 130
Bolt securing front wheel to hub (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M 18 x 1,5 314 231.5
SPECIAL TOOLS
List of special tools necessary for the various opera-

WARNING: The operations described in this section tions described in this section.
must be performed only with the ESSENTIAL equip-
ment marked with (X).
X 290793 Adaptor (M12x1.25) for axle articu-
To operate safely and achieve best results, while lation pin (use with slide hammer
saving time and effort, essential equipment must be 292927)
used in conjunction with the special tools recom-
mended below and tools which you must make your-
self and for which you will find the design in this 293890 Device for checking toe--in.
manual.
292400 Wheel lifting hook.
TROUBLESHOOTING
Problem Possible cause Corrective action
Abnormal wear of tires. 1. Incorrect tire pressure. Inflate the tires to the correct pres-
sure, referring to the pressures recom-
mended in the Use and Maintenance
handbook, and more especially, to the
pressures recommended by the
manufacturer of the tires fitted.
2. Incorrect toe--in of front Correct the toe--in.
wheels.
Poor stability of tractor. 1. Incorrect tire pressure. Inflate the tires correctly as detailed
above.
??????????? - 05--2002
OVERHAUL
FRONT AXLE
Removal
DANGER
Lift and handle all heavy parts with lifting equipment
of suitable capacity. Make certain that the units or
parts are supported by appropriate slings and
hooks. Ensure that there are no persons in the vi-
cinity of the load to be lifted.
To remove the complete axle from the tractor,
proceed as follows:
1. Disconnect the negative cable from the battery
and isolate it; chock the rear wheels.
2. Lift the front of the tractor.
24765
4
3. Place a stand (1) beneath the engine sump,
inserting a block of wood between the engine
sump and stand.
1
24766
5
4. Remove the front wheel bolts (1).
24767
6
???????????- 05--2002
5. Disconnect the hoses (1) of the power steering

cylinder (2).
1 2
24768
6. Remove the axle articulation pin securing bolt

(1).
24769
8
7. Secure the axle by means of a sling (1).
24770
9
8. Take out the axle articulation pin (1) using slide
hammer 292927, equipped with adaptor 290793
and extension.
24771
10
??????????? - 05--2002
9. Remove the complete axle (1).

1
24772
11
Installation
1. To install the complete axle, follow the disassem-
bly procedure in reverse order. Install the axle ar-
ticulation pin (1) using a bronze punch.
2. Install the bolt connecting the axle articulation
pin.
24769
12
3. Reconnect the hoses (1) of the power steering
cylinder (2).
1 2
24768
13
AXLE WHEEL HUB
Removal
WARNING
The wheel hubs can be removed with the axle

installed on the tractor. Proceed as follows for each
wheel.
1. Disconnect the negative cable of the battery and
isolate it; chock the rear wheels.
???????????- 05--2002
24765
14

sump and stand.
1
24766
15
4. Remove the front wheel bolts.
24767
16
5. Remove the wheel hub bearing cover (1).
1
24775
17
??????????? - 05--2002
6. Remove the grease nipple as shown in figure.
TRE4001A
18
7. Remove the split pin (1) securing the wheel hub
bearing adjuster nut.
TRE4002A
19
8. Using a socket wrench, unscrew the wheel hub
bearing adjuster nut.
24777
20
9. Remove the wheel hub bearing adjuster nut (1).
1
TRE4003A
21
???????????- 05--2002
10. Remove the wheel hub bearing washer (1).

1
TRE4004A
22
11. Remove the wheel hub (2) and take out the
bearings (1 and 3).
1 2 3
24778
23
12. Remove the bearing (1).
1
TRE4005A
24
13. Remove black (Twin lip) wheel bearing seal (1).
1
TRE4006A
25
??????????? - 05--2002
14. Remove white back up ring (1).

1
TRE4007A
26
15. Replace worn bearings and seals, using suitable
extractors and punches.
24780
27
???????????- 05--2002
AXLE WHEEL HUB

Refitting:
16. Place a hydraulic jack beneath the stub axle and

unscrew the bolt (1) fixing the control lever (2) to
the stub axle pin.
24782B
28
17. Withdraw the control lever (1) from the stub axle
pin (2).
24783B
29
18. Lower the hydraulic jack and remove the stub
axle (1).
1
24784
30
19. Put the stub axle on a suitable vice and install
white back up ring (1).
1
TRE4008A
31
??????????? - 05--2002
20. Install black (Twin lip) wheel bearing seal (1).

1
TRE4008A
32
21. Install both black (Twin lip) wheel bearing seal
and white back up ring together with a suitable
installer and a hammer.
TRE4008A
33
22. Install bearing with a suitable installer and a
hammer.
TRE4008A
34
23. The wear sleeve (1) for the seal must be installed
in the hub with a high strength bearing fit adhe-
sive compound (loctite) to ensure the secure 1
retention in the hub.
The hub and the wear sleeve must be throughly

clean and dry. Apply high strength bearing fit com-
pound. Press in the wear sleeve, using a suitable
press.
After installing the wear sleeve, the compound must
be allowed to cure for a minimum of three hours prior
to assembling the bearings and seals in the hub.
TRE4008A
35
???????????- 05--2002
24. Pack the wheel hub with AMBRA GR9 grease.
25. Refit the wheel hub (2) complete with bearings (1

1 2 3
and 3).
24778
36
26. Install a new nut and, using a torque wrench,
tighten the nut to a torque of 196 Nm (20 kgm),
turning the wheel hub (1) simultaneously in order
to settle the bearings. 1
27. Loosen the nut slightly and tighten it again to a
torque of 24 -- 29 Nm (2.5 -- 3 kgm) while continu-
ing to turn the wheel hub.
Note -- the nut must be changed each time the wheel
hub is fitted.
28. Check the rolling torque R, bearing in mind that:

R ≤ 0.8 kgm 24779
37
29. Install the split pin (1) securing the wheel hub
bearing adjuster nut and bend it over the nut to
prevent turning the nut.
24776
38
30. Install the grease nipple as shown in figure.
TRE4001A
39
??????????? - 05--2002
31. Install the wheel hub bearing cover (1).
1
24775
40
STUB AXLE
Removal
WARNING
The stub axles can be removed with the axle

installed on the tractor. Proceed as follows for each
wheel.
1. Disconnect the negative cable of the battery and
isolate it; chock the rear wheels.
24765
41
sump and stand.
1
24766
42
???????????- 05--2002
4. Remove the front wheel bolts (1).
24767
43
5. Place a hydraulic jack beneath the stub axle and

unscrew the bolt (1) connecting the control lever
(2) to the stub axle pin.
24782
44
6. Withdraw the control lever (1) from the stub axle
pin (2).
24783
45
7. Lower the hydraulic jack and remove the stub
axle (1).
1
24784
46
??????????? - 05--2002
8. Unscrew the axle end securing bolts (1).
24785
47
9. Remove the axle end (1).
24786
48
10. Clamp the end of the axle in a vice and using a
slide hammer, take out the stub axle pin articula-
tion bushing (1).
24787
49
Installation
1. To install the stub axle, follow the disassembly
procedure in reverse order, using a suitable
hammer to install the new bushings on the axle
ends.
24788
50
???????????- 05--2002
2. Install the axle end (1).
24786
51
3. At the base of the stub axle install the cap (9, fig. 1),
then the levelling rings (1), inserting them on the
stop grub screws (8 and 14, as shown in figure 1).
24789
52
4. Install the stub axle on the axle end.

5. Position the control lever (1) on the stub axle pin
(2) and tighten the securing screw.
24783
53
??????????? - 05--2002
ADJUSTMENTS
TOE--IN
A
Check the alignment of the front wheels, bearing in
mind that for driving in a straight line, the wheels must
be at an angle of 2° to the vertical. This corresponds
to a difference of approximately 15 mm (.59 ins) for 16
in. wheels, between the top edge of the rim (A) and A+X
bottom edge (A + X).
When driving in a straight line, the wheels must be
parallel to the longitudinal axis of the tractor or have B2
a maximum of 5 mm (.196 ins) toe--in at the front,
measured between the wheel--rims.
To check the toe--in, proceed as follows:
1. Inflate the front tires to a pressure of 2.5 bar B1

(36 psi).
8821
2. Position the steering wheel in the middle of its
travel, with one spoke along the longitudinal axis 54
of the tractor.
3. Check that the wheels are parallel with the

longitudinal axis of the tractor.
4. With the tractor parked on a flat, level surface,
measure the distance (B1) between the front of
the wheel rims, at hub height. Make a chalk mark
on the rims where the measurement has taken
place. Move the tractor forward to rotate both
wheels exactly 180o and check the
measurements again at the chalk marks B2 (now
positioned at the rear of the wheels). This will
eliminate wheel rim run--out errors.
5. Correct the toe--in, if necessary, by adjustment

of the end of the transverse steering tie--rod.
???????????- 05--2002
??????????? - 05--2002
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 1
SECTION 55 -- ELECTRICAL SYSTEM
Chapter 1 -- Instrument Cluster
CONTENTS

Instrument Cluster Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Analog Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warning and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuel Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tachometer and Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine Coolant Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
INSTRUMENT CLUSTER DESCRIPTION
ANALOGUE INSTRUMENT PANEL
1 1
4 3 2
TRE2146A
The analogue instrument panel consists of four display sections:
1) Warning and Indicator Lights;
2) Fuel Level Gauge;
3) Tachometer and Hourmeter;
4) Engine Coolant Temperature Gauge.

Warning and Indicator Lights
2
10
1
3 4 5 6 7 8 9
11 12 13
TRE0621A
Condition Indicator
1. Left direction indicator ON Flashing (green)

2. Side lights ON Fixed (green)
3. Main beam headlights ON Fixed (blue)
4. Water in fuel warning Fixed (red)
5. Air filter blocked warning Fixed (amber)
6. Engine oil pressure low warning Fixed (amber)
7. Battery charge low warning Fixed (red)
8. Brake fluid level low warning Fixed (red
9. Hand brake ON Fixed (red)
10. Rght direction indicator ON Flashing (green)
11. First trailer direction indicator* Flashing (green)
12. Second trailer direction indicator* Flashing (green)
13. Power take--off ON Fixed (amber)
* Not available on North America models.

Fuel Level Gauge
This instrument shows the level of fuel in the tank.
When the tank is full, the needle moves completely

to the right.
When the fuel level falls less than 1/4 tank, the
needle moves into the red area.
TRE2146D
Tachometer and Hourmeter
Engine speed indicator displays rev/min with a six

digit hourmeter. The digits on black background
signify hours of work done and the digits on red
background (far right) represent tenths of an hour.
The green sector identifies engine speed at which

optimum power take--off performance is achieved
on the standard 540 rpm PTO.
TRE2146B
4
Engine Coolant Temperature Gauge
-- Green area = normal temperature.
-- White area = temperature low.
-- Red area = engine overheating.
TRE2146C
5
Chapter 2 -- Components
CONTENTS

Electrical Components Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Instrument Console Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Lights Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rear Hood Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Transmitters and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ELECTRICAL COMPONENTS DESCRIPTION
TRE2051A
INSTRUMENT CONSOLE CONTROLS
1. Hazard warning light switch
Push switch to operate hazard warning lights.The 1
lever operates external lights, horn and the 2
direction indicators.
2. Hand throttle lever:
-- Pushed fully forward; max. engine speed
-- Pulled fully backward; min. engine speed. 3 4
3. Direction indicator lamp control switch.
Explained at page 2--9 Operator’s Manual 6
4. Lights switch.
Explained at page 2--9 Operator’s Manual 5
5. Starter switch.
1
Explained at page 2--11 Operator’s Manual
6. Thermostarter button.
This is used to start the engine in particularly cold
weather.
For further details, see page 2--20 Opera-
The multi--function stalk controls the lights, horn,
turn indicators and headlight flasher and is also 2
used to switch from dipped to main beam front
headlights.
Direction indicators 1
To indicate a right turn, move the switch (1) fig.2

right to position B.
To indicate a left turn, move the switch to position A B

A.
TRE2051A
REAR HOOD CONTROLS

Starter Switch (1)
To operate the four functions of the switch, turn the

key through the following positions:
A
A. No power to circuits (key can be removed). En- P B
C
gine stopped: automatic activation of fuel injec-
tion cut--off.
B. Engine pre--start setting. Operation of panel
lights and instruments. Power supplied to vari-
ous circuits.
TRE2130A
C. Starting the engine: when released, the key re-
turns automatically to position (B). 3
P. Parking lights on, instrument panel lighted (key

removable).
TRANSMITTERS AND SWITCHES

Description
A. MAIN FUSE BOX

The tractors fuses relays are housed under a
plastic cover.
B. BATTERY
The tractors are fitted with maintenance--free
batteries. Keep the top part clean and dry. Check
that the level of electrolyte reaches the top mark
and never falls below the lower mark.
C. ALTERNATOR
This provides a square wave signal and re-
charges the battery. It also provides power re-
quired by electric devices.
D. TRANSMISSION CLUTCH PEDAL SWITCH

This switch is activated when the transmission
clutch pedal is depressed.
E. AIR CLEANER CLOGGED SENSOR

This is activated when the vacuum in the air oper-
ating system exceeds a pre--set value. It lights up
the warning light.
F. FUEL SEDIMENTER
Activated when water goes into the fuel filter.
G. ENGINE OIL PRESSURE SWITCH

This is activated as soon as oil pressure in the
engine drops less than 0.68 bar. It lights up the
warning light. This switch is usually closed.
H. FUEL TANK LEVEL TRANSMITTER

A signal from the transmitter potentiometer de-
fines the level of fuel in the tank. The level is
shown by the gauge.
I. ENGINE COOLANT TEMPERATURE

The temperature transmitter resistance varies in
proportion to the coolant temperature, generat-
ing a modulated voltage signal picked up by the
gauge.
J. BRAKE LIGHT SWITCHES

These are activated when the brakes are on.
L. PARKING BRAKE SWITCH

This is activated when the parking brakes are on.
M. OPERATOR SEAT TRANSMITTER

A transmitter in the seat detects when an opera-
tor is seated.
Locations
26608
6
26608
7
26608
8
Chapter 3 -- Starting System
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Starting System Test on Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power Absorption in Starter Motor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Resistance in Ignition System Circuit (Voltage Drop) . . . . . . . . . . . . . . . . . . . . . . . . 6
Battery Positive Cable Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Starter Motor Ground Lead Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Battery Ground Cable Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
55 201 50 Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
55 201 54 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Starter Motor Tests and Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Armature Shaft End-Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Starter Motor Test Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Field Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bearing Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Driving Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIFICATIONS
CHARACTERISTICS TD60 TD70 TD80 TD90 TD95

Starter motor BOSCH
Power (kW) 2.5 3.5
Maximum current drain with- 60 A 160
out load (Amp) at 11.6 V at 11.5 V
and 8600 rev/min and 8000 rev/min
Minimum brush length
-- 7.0 (.275)
mm (ins)
Minimum switch diameter
42 (1.65) 42.5 (1.67)
mm (ins)
Maximum armature shaft
0.5 -- 0.8 (.019) 0.4 (.015)
end play mm (ins)
TIGHTENING TORQUES
Nm Ft-lbs.
Starter motor and engine block fastening bolts 34 25

Box on starter motor/earth (ground) cable side 16 12
Solenoid valve wire nuts 7 5
Box nuts on starter motor side 10 7
Solenoid valve fastening bolts 5 3.6
The starting system installed depends on the type of ion engage the flywheel ring gear. The moment the
gearbox fitted on the tractor. All systems consist of pinion touches the ring gear, the plunger closes a se-
an ignition key switch, heavy--duty wiring, a starter ries of contacts and powers all four field windings di-
motor with solenoid, a start--up relay and a clutch rectly from the battery, thus giving full power to the
pedal switch. These are the basic circuit components starter motor.
used on versions with mechanical gearbox. More so-
phisticated systems include other components, At this stage, one end of the pull--in coil is connected
which ensure the engine can be started only under to the positive battery pole through the starter switch,
the proper conditions. while the other end in connected to the positive pole
through the solenoid valve contacts. The pull--in coil
There are four types of gearbox: with range reduction is thus bypassed, without absorbing power, and the
gear (synchro command), with range reduction gear hold--in coil alone keeps the plunger in position.
and inverter (shuttle command). The starting circuit
is illustrated in figure 1. The starter motor includes a series of contacts and
a two--part solenoid plunger which completely closes
There are two available types of starter motors: 2.5 the contacts even if the pinion teeth are not perfectly
kW or 3.5 kW rating. They both have four poles, four in line with the ring gear. When this happens, a clutch
brushes with integrated solenoid and positive mesh spring compresses the pinion, forcing it to connect
engagement control. completely as soon as the starter motor starts
turning.
The solenoid consists of two coils connected in paral-
lel. The low resistance pull--in coil is earthed When the key ignition switch is released, power is
(grounded) via the engine, while the high resistance taken from both the solenoid and the motor. The so-
hold--in coil is earthed (grounded) via the solenoid lenoid return spring, acting on the flexible joint mech-
body. anism, frees the driving pinion from the gear and
opens the solenoid valve contacts again.
When the ignition switch is closed, with the clutch
pedal depressed and gear in neutral (except in the A roller type clutch is incorporated to the driving pin-
case of mechanical gearboxes), the coils are ener- ion group. This prevents the pinion from overspeed-
gised and the plunger is magnetically drawn inside ing if it stays engaged with the flywheel ring gear after
the solenoid. This movement, transmitted by means the engine has been started.
of an flexible joint mechanism, makes the driving pin-
17 19
2,5 N/R
1,5 P/Y
18
6
2,5W/R
11
10
50
-- 2,5 N/U 15A 2,0 N/U
+ 30 5 2,0 Y/W 2,0 P/Y
10 N 40A 15A
12
D+ B+ 13
3 N/P 3,0 B
0.5 N/Y
6N
29
2,5 W/Y 2,5 W/R
6,0 N
30 2
6,0 Y/W
15/54 2,5 N/U
50 2,5 W/Y 2,5 W/Y 5 5 2,5 W/Y
28
2,5 W/R 9 9 2,5 W/R

0,5 N/Y
16 1
1
START--UP CIRCUIT DIAGRAM
1 -- Instrument panel 11 -- Starter motor 19 -- Engine shut--off solenoid
2 -- Starter switch 12 -- Alternator 28 -- Main harness-- Chassis
5 -- Main fuse 13 -- Over Voltage circuit breaker harness connection con-
6 -- Fuse box 17 -- Thermostarter nector 12 way
10 -- Battery 18 -- Thermostarter switch 29 -- Starter inhibitor switch
26628 26629
TRE0069A
Fuse Panel 2 Starter Motor 3

OVERHAUL
STARTING SYSTEM TEST ON TRACTOR

To easily and quickly trouble--shoot the starting sys-
tem problems and reach conclusive results, it is
recommended that you use a battery/starting tester
(high discharge multimeter) with incorporated
0--20V voltmeter and 0--500 A ammeter.
When using testing devices, follow test procedures

recommended by the manufacturer. If you do not
have access to testing devices, carry out the follow-
ing test using a normal 0--20V voltmeter and a
0--500 Amp ammeter in order to check correct start-
er motor functioning without removing it from the
engine.
Before carrying out the test:
• check the battery is fully charged;
• check that no wires in the starting system are

broken or frayed and that there are no loose
connections;
• check the engine is not seized.
Power Absorption In Starter Motor Circuit

1. Disconnect earth (ground) (negative) battery
cable (3).
5 1
2. Disconnect positive battery cable from starter
solenoid. Connect the positive ammeter point
(1) to the positive battery terminal clamp and
the negative point to the solenoid input termi-
nal. 4
3. Reconnect earth (ground) (negative) cable to
negative battery terminal clamp (3).
4. Connect the positive voltmeter point (2) to the
positive battery terminal clamp and the nega-
tive to the negative battery terminal clamp. 3 2
26630
4
5. Disconnect the wire from the injection pump
shut--off solenoid.
6. Run the engine and note voltmeter and amme-
ter readings. Voltage must be constantly about
12V and absorption in the range of 250--300 A.
• If absorption corresponds to the readings
above, then the starter motor (4) fig. 4, is
working correctly. If voltage drops during
the test, follow “Resistance in starting
system circuit” procedure (see relative
paragraph).
• If absorption is higher than the readings
above, check the circuit as follows. If the
starting system circuits are in good
condition, then the starter motor is
malfunctioning and must be removed for
further examination.
• If absorption is lower than the readings
above, the starter motor is malfunctioning
and must be removed for further
examination.
Resistance In Ignition System Circuit

(Voltage Drop)
If there is a higher than necessary power absorp-
tion, check the circuit to find the cause of the volt-
age drop occurring within circuit components.
IMPORTANT: Disconnect the injection pump sole-

noid fuel closing wire. 2 1
Battery Positive Cable Check V

positive battery terminal clamp (2).
3
2. Connect the negative voltmeter point to starter
motor solenoid terminal (3).
3. Run the engine and check the readings on the
voltmeter. If voltage is higher than 0.2 V., check
and tighten wire connections. Check voltage
26631
again and if it is still high install a new battery
cable. 5
Starter Motor Ground Lead Check
2 1
starter motor casing (2).
2. Connect the negative voltmeter point to the en-
gine block (3).
earth (ground) connections between the starter
motor flange and the rear engine cover.
26632
3
6
Battery Ground Cable Check 1
2
engine block (2). V
2. Connect the negative voltmeter point to the
negative battery terminal clamp (3).
and tighten the earth (ground) cable connec-
tions. Check the voltage again and if it is still
higher, then install a new earth (ground) cable.
3
26633
7
Op. 55 201 50
2 3
STARTER MOTOR
Removal
1. Disconnect negative battery cable. 6
2. Unscrew the nut and bolt (1) and remove the
protection cover (2) from starter motor (3).
3. Unscrew the nut and remove power clamp (5) 1
and emergency switch clamp (4). 4
4. Remove the starter motor securing bolts (6)
and remove the starter motor. 26634
5
8
Installation
To install the starter motor, reverse the order of
removal.
26635
9
Starter Motor Components
1. Solenoid 7. Field windings and casing
2. Solenoid bolts 8. Brush holder
3. Bolt and stud group
9. Brush plate
4. Control side support
5. Lever 10. Armature
6. Reducer 11. Clutch
Op. 55 201 54
Disassembly
Refer to figure 3. 3. Remove the three screws from the front casing
and remove the solenoid. Note that the plunger
1. Place the starter motor in a vice with protected will remain connected to the control lever.
jaws.
4. Remove solenoid plunger from the control lever
2. Disconnect the biggest braided wire which runs by holding and lifting it at the front in order to un-
from the field winding casing to the solenoid. clip it from the lever.
5. Remove the two nuts from the rear casing and Assembly
the two screws which fasten the rear cover and
1. To assemble the starter motor, reverse the re-
brush plate to the casing. Remove clamp C and
moval procedure.
armature shaft end play spacers, leaving the
brush gear on the commutator. Remove the thin
Before reconnecting, test the armature shaft end
metal washer on the commutator side of the ar-
play and test the starter motor without load.
mature.
6. At this stage of the procedure, check the brushes STARTER MOTOR TESTS AND
and commutator. Check that the brushes are not
INSPECTIONS
sticking and, if necessary, clean the brushes and
their respective channels with a rag and solvent. Armature Shaft End-Play
Check the brushes are not worn. If they are worn
1. Place the starter motor in a vice with protected
and minimum length is less than that shown in
jaws and connect a dial gauge to the flange on
the technical information table, it will be neces-
the control side of the casing. Position the dial
sary to change the starter motor.
gauge pointer on the end of the armature shaft.
NOTE: The brushes are not serviced separately.
2. Push the armature forward and reset the gauge
They are welded to their support and will not be
to zero. Push the armature back as far as it will
changed for the whole operating life of the starter
go and note the gauge reading.
motor.
3. Readings must fall within the limits specified in
7. Remove the motor casing from the armature and the technical information table. If the value is
the control side bracket. higher, check that armature and brush plate are
not worn. Change the worn components, as nec-
8. Remove the control lever knuckle pin from the essary, and check end play again.
control side of the casing.
9. Remove the retaining ring which holds the con-
trol group and the inner plate from the armature
shaft, by first removing the pressure collar per-
pendicularly from the retaining ring support by
means of an appropriately sized tube. Then lever
the retaining ring from the groove.
10. Remove armature and control group.
Starter Motor Test Without Load
(Refer to Figure 10) 6 7
NOTE: A fully charged battery and a battery/start-

ing tester (high discharge multitester) with carbon 1
battery (variable load resistance) are needed to
carry out this test.
5
2
1. Place the starter motor in a vice with protected
jaws.
2. Connect negative battery cable (4) to the start-
er motor flange. 3
4
3. Bridge the solenoid contacts (6) with a short 26636
wire (7). 10
positive battery terminal clamp and the nega-
tive voltmeter point to the negative battery ter-
minal clamp. Connect the ammeter positive
point (1) to the positive battery clamp (4) and
the negative point to the battery or to the starter
motor terminal clamp.
5. Place a manual tachometer (5) on the end of
the armature shaft. Check maximum power ab-
sorption. This value is specific for each starter
motor and must be included in the range of val-
ues in the TECHNICAL INFORMATION table.
Regulate carbon battery voltage (2) and arma-
ture speed according to the information in the
technical information table.
6. If the starter motor does not work according to
the technical information specification, check if
there are earthed (grounded) field windings, if
the armature is scuffed or scraped or if the shaft
is misshapen or otherwise damaged.
Armature
(Refer to Figure 11)
1. The commutator surface must be clean and 1
not burnt. If burning needs to be removed, use
fine sandpaper and not abrasive fabric (emery
cloth). Finally, clean the commutator with a rag
and solvent.
2. If the commutator needs refacing, check it is
not smaller than the minimum value specified
in the TECHNICAL INFORMATION table. Af-
ter refacing, the commutator must be polished
with sandpaper and cleaned with a rag and
solvent.
26637
NOTE: Do not cut the armature metal when mak-
ing insulation slots. 11
3. Armature insulation can be checked by con-
necting an ohmmeter (1) between commutator
segments and armature shaft. This reading
should show infinity, in other words there
should be no continuity.
4. To test there are no short circuits, use an ap-
propriate testing device. The only alternative is
to try changing the armature.
5. If the armature circumference has obviously
been in contact with pole pieces, the pole bear-
ings are probably worn. First check the pole
pieces are fixed and that the armature spins
well in a lathe. If necessary, change the arma-
ture bearing.
Field Windings
1. To test field winding insulation, connect an
ohmmeter to each of the coil brushes in turn
and to a clean and unpainted area of the casing.
There should be no readings, that is, there
should be no continuity.
2. To test coil continuity, connect an ohmmeter to
each of the coil brushes in turn and to the main
power clamp (biggest braided wire). The read-
ing should be 1 Ω.
3. If there is a failure in the field windings, then it
will be necessary to change the whole box and 1
26638
field winding system.
12
Bearing Bushings
1. Check if the bushing on the brush plate and in
the box on the pinion side are worn. Assemble
the armature shaft and note play. Change the
bushing if there is too much play. Check the
field poles to see if there are any signs of scrap-
ing against the casing. This can also be caused
by a worn bushing.
Driving Pinion
1. Check the roller clutch operation. The pinion
must spin clockwise only. If the pinion is either
seized or spins in both directions, or if the pin-
ion teeth are damaged, assemble a new con-
trol group.
2. If there is clear evidence of damage to the
pinion teeth, check the flywheel ring gear, as
described in section 10, Engines.
Chapter 4 -- Charging System
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tests and Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Alternator Wire Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging Current and Regulated Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Charging Circuit Voltage Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Alternator Maximum Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Alternator Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS
ALTERNATOR
CHARACTERISTICS MODELS
Polarity Neg Neg Neg Neg Neg
Nominal voltage (V) 14 14 14 14 14
Max rotation speed (rpm) 15000 15000 15000 15000 15000
Maximum output (A) 65 65 65 65 85
Regulator controlled 13.6 -- 14.4 13.6 -- 14.4 13.6 -- 14.4 13.6 -- 14.4
voltage (V)
Rotor field winding 2.9 2.9 2.9 2.9
resistance (Ω)
Stator field winding 0.2 0.2 0.2 0.2
resistance (Ω)
New brush length (mm) 20 20 20 20
Minimum brush 5 5 5 5
length (mm)
Brush spring force (N) 1.3 -- 2.7 1.3 -- 2.7 1.3 -- 2.7 1.3 -- 2.7
Maximum power at 540W 540W 540W 540W 540W
2500 erpm
TIGHTENING TORQUES
Nm Ft.-Lb.
Alternator fastening bolts 6 5
Pulley fastening nut 70 52
Rectifier fastening screws 4.0 3
Brush box and regulator screws 2.7 2
Terminal nuts 2.7 2
The TD60, TD70, TD80 and TD90 alternator is a

Bosch 65 A (TD95 use 85 A) alternator with exter-
nal cooling fan. Stator winding is ventilated with an
air conducting diaphragm in the support on the rec-
tifier bridge side and peripheral openings in the sup-
port on the control side. The alternator, installed on
the left side of the engine, is operated by a pulley
and a V-type driving belt. Alternators contain a
built--in regulator.
26639
1
Bosch Alternator
1. Battery Connection (B+ Terminal)
2. Terminal Protection Sheath
3. Alternator Charge Indicator Connection (D+ Terminal)
7
3
5
4
26640
Alternator Charging Circuit Diagram 2
1. Ignition Switch 5. Alternator Electronic Voltage Regulation Circuit

2. Alternator Charge Indicator Light 6. B+ : Battery Connection
3. Battery 7. D+ : Alternator Charge Indicator
4. Alternator
See figure 2. This action causes a constant increase in the rotor

magnetic field and a fast increase of current and volt-
When the ignition key is turned, a small current age output.
passes from the battery through the rotor field wind-
ing wiring. The circuit closes powering the charge As the generated voltage output (reflected by D+ ter-
warning light, the alternator D+ terminal, the rotor minal) increases, the warning light intensity de-
field winding, the alternator regulator and ground. creases and when the voltage at the D+ terminal
equals that on the battery side of the warning light,
At this stage, the warning light comes on and the ro- the light goes out.
tor is partially magnetised.
Voltage increases until it reaches the pre--set regu-
When the engine starts and the rotor, partially mag- lated voltage level.
netised, turns inside the stator windings and gener-
ates three--phase alternating current. A constant If the driving belt breaks, there will be no voltage ac-
quantity of this current is transformed into direct cur- cumulation in the alternator. The charge warning light
rent by three field diodes built into the rectifier. will stay on, thus indicating a fault.
The direct current is then reintroduced into the circuit

to increase current flow through the rotor field wind-
ing.
3
2
4
3
1 1
26641 26642
3 4
Fan Belt on Models Less Air-Conditioning Fan Belt on Models With Air-Conditioning
1. Alternator 1. Belt Tensioner

2. Belt Tensioner 2. Belt Tensioner Bolt
3. Belt Tensioner Bolt 3. Fan Belt
4. Fan Belt
TROUBLESHOOTING
PRECAUTIONS 1. CHECKING THE BATTERY

To avoid damaging alternator charging system com- Check all battery elements with a densimeter. The
ponents, take the following precautions: battery must be at least 70% charged and efficient.
• DO NOT MAKE OR INTERRUPT any charging 2. CHECKING THE DRIVING BELT

circuit connection, including the battery, while the
engine is running. Inspect the alternator driving belt and pulley, check-
ing that they are both clean, with no traces of oil or
• NEVER SHORT--CIRCUIT the alternator posi- lubricant and in good condition.
tive terminal to check if it is working.
Check the alternator driving belt tension regularly. If
• ALWAYS DISCONNECT battery cables when you suspect the belt is not tight, check the tensioner
recharging the battery in the tractor with a battery as follows:
charger.
• ALWAYS CHECK battery polarity when instal- Belt for versions without air conditioning (Fig. 3)
ling a battery or using a supplementary battery to
• loosen the nut (3) which secures the alternator to
start the engine.
the tensioner bracket (2).
• DO NOT SHORT--CIRCUIT regulator input/ out-
• with a lever, move the alternator (1) on the ten-
put terminals when the alternator is working.
sioner bracket (2) to reach correct belt tension
• CONNECT POSITIVE TO POSITIVE AND and tighten the securing nut (3) to 55 Nm.
NEGATIVE TO NEGATIVE.
Belt for versions with air conditioning (Fig. 4)
PRELIMINARY CHECKS
• loosen the belt tensioner securing nuts (3)
Before carrying out these electrical tests, carefully
inspect the charging system and the electrical sys- • hold the belt tensioner arm (2) and move it on the
tem in general. bracket to reach the correct belt tension, then
tighten the securing nuts (3) to 55 Nm.
Check continuity in all conductors and connections.
Check they are all clean and well fastened.
Correct deflection values, measured by applying the TESTS AND CHECKS

following loads to the middle of the belt: These preliminary tests can be carried out without
removing any components from the tractor charging
circuit. These tests check:
Version
without cab Version with • the alternator wire connections
or with cab cab and air
without air conditioning • alternator charging current and controlled volt-
conditioning age
Load (N) 78 -- 98 60 -- 75 • voltage drop in the alternator charging circuit

Deflection 10 -- 11 10 • maximum alternator output
(mm)
The following testing devices are required:
3. CHECKING THE WARNING LIGHT • 0--30V moving coil voltmeter
Turn the ignition key and check the light is completely • 0--1V millivoltmeter
lit.
• 0--110 A moving coil ammeter
If the warning light does not light completely, check
the light bulb. If the light bulb has not blown, carry out • 1.5 ohm, 110 A varying load resistance
the alternator wiring connection tests as described in
the paragraph “PRELIMINARY TESTS” in this sec- NOTE: Most testing devices on the market today
tion. combine several electrical test functions (multime-
ters). When using these devices, follow the manufac-
If the light is on, start the engine and run it above mini- turer’s instructions.
mum speed. The warning light should go out.
If the warning light does not go out, stop the engine

and disconnect the D+ terminal wire. If the warning
light goes out now, one of the alternator components
is malfunctioning. Carry out “ALTERNATOR COM-
PONENT TESTS” described in this section.
If the warning light stays on, check there is no short

circuit between D+ wire ending and warning light.
Alternator Wire Connections

See figure 5.
1. Disconnect the battery.
2. Disconnect B+ (2) and D+ (3) alternator
terminals.
3. Reconnect the battery and turn the ignition key
into position ON but without starting the engine.
Connect a voltmeter (4) between each terminal
and ground (1). There must be voltage at the
battery.
26643
If there is no voltage at the battery, check for a
continuity fault in the external wiring. See circuit 5
diagram in figure 2.
4. Connect D+ terminal, warning light wire (red)

and ground. The warning light should
illuminate.
5. Disconnect the battery and reconnect the
cables to the alternator at (2) and (3) fig. 5.
NOTE: If the warning light does not light up when
the wire is connected to the alternator, this means
that there is a fault either in the alternator regulator
circuit or in the rotor circuit. Check D+ terminal is
clean and then test the alternator components as
described in this section.
Charging Current and Regulated Voltage

See figure 6.
1. Check that all tractor electrical devices are
switched off and the ignition key is in the OFF
position.
2. Disconnect the negative battery terminal clamp
and the B+ negative alternator terminal.
3. Connect an ammeter (1) between the discon-
nected wire (red) (4) and the B+ alternator ter-
minal (3).
4. Connect a voltmeter (2) between the B+ alter- 26644
nator terminal (3) and ground. 6

5. Reconnect the battery. Start the engine and run
it at 2000 rev/min. Note the readings on the volt-
meter and the ammeter.
The voltmeter reading should be higher than the
battery voltage and when the ammeter reading falls
below 10 A, the voltmeter reading should stabilise
at 13.6 -- 14 V (Magneti Marelli alternator) or 13.6
-- 14.4 V (Bosch alternator).
If the voltmeter reading is higher than 14 V or 14.4
V, for Magneti Marelli or Bosch alternators
respectively, the alternator regulator must be
changed, as described in this section. (After
installing a new regulator, carry out tests 4 and 5).
If the voltmeter reading is less than 13.6 V, there is

either a faulty component in the alternator or a
failure due to excessive resistance in the external
charging system connections.
If the ammeter reads zero amps, then one of the

alternator components is malfunctioning. Turn the
engine off and carry out the alternator component
test, as described in this chapter.
Charging Circuit Voltage Drop
Insulated side voltage drop
See figure 7.
Check the ignition key is in OFF position.

1. Disconnect the negative battery cable and the
B+ alternator wire (1).
2. Connect a millivoltmeter (5) between the posi-
tive battery terminal clamp and D+ wire (3)
(positive side of the wire)
3. Connect an ammeter (2) between the B+ alter- 26645
nator terminal and the D+ wire (negative side of

7
the wire).
4. Reconnect the negative battery cable and con-
nect a varying load resistance (4) with cursor in
minimum current absorption position (maxi-
mum resistance) through the battery terminal
clamps.
5. Start the engine and increase speed to 2000
rev/min.
6. Decrease resistance charging load (decreas-
ing resistance) slowly until the ammeter reads
45 or 65 A. according to the type of alternator.
7. Note the reading on the millivoltmeter. This
must not be higher than 400 millivolts.
A reading higher than 400 millivolts indicates mal-
functioning due to excessive resistance in the
external circuits.
If the alternator does not output required power and

the millivoltmeter reading is less than 400 millivolts,
there is a malfunctioning component in the alterna-
tor. Carry out the alternator component tests, as
8. Stop the engine.

Ground side voltage drop test
See figure 8.
1. Check the ignition key is in OFF position.

2. The circuit is the same as that described in the
previous test, except that the millivoltmeter (4)
is now connected between the negative battery
terminal clamp and the alternator casing (nega-
tive side of casing).
NOTE: Check the varying load resistance (3) is in
minimum current absorption position (maximum
26646
resistance).
8
3. Start the engine and increase speed to 2000
rev/min.
4. Increase resistance current load (decreasing
resistance itself) slowly until the ammeter (2)
reads 45 or 65 A. according to the type of alter-
nator.
5. Note the reading on the voltmeter. This must
not be higher than 200 millivolts.
A reading higher than 200 millivolts indicates mal-

functioning due to excessive resistance in the ex-
ternal circuits.
If the alternator does not output required power and

the millivoltmeter reading is less than 200 millivolts,
there is a malfunctioning component in the alter-
nator. Carry out the alternator component tests as
6. Stop the engine.
Alternator Maximum Output

See figure 9.
1. Check the ignition key is in the OFF position.
2. Disconnect the negative battery cable and the
B+ alternator wire (4).
3. Connect an ammeter (5) between B+ alternator
terminal (4) and D+ wire (1) (negative side of
the wire).
4. Connect a voltmeter (4) between the B+ alter-
nator terminal (5) and ground.
26647
5. Reconnect the negative battery cable. Start the
engine and increase speed to 2000 rev/min. 9
6. Increase resistance current load (2) (decreas-
ing resistance) slowly until the ammeter reads
45 or 65 A., according to the type of alternator.
7. Note the reading on the voltmeter. This must
not be less than 13.6 V.
A reading lower than 13.6 V. shows there is a mal-
functioning component in the alternator. Carry out
the alternator component tests, as described in this
section.
Alternator Component Tests
These alternator tests must be carried out only if

the PRELIMINARY TESTS have shown a malfunc-
tioning alternator component. These tests check:
• the regulator,
• rotor field winding continuity,
• rotor brushes, springs and contact rings.
NOTE: The previously described component tests
can be carried out with the alternator installed in the
tractor. In order to carry out the other alternator
tests, it will be necessary to remove the alternator
from the tractor. Refer to the section “FUNC-
TIONAL TESTS” in this chapter.
OVERHAUL
ALTERNATOR
IMPORTANT: Before disconnecting the alternator
wires, check that the ignition key is in the OFF
position.
Removal
1. Disconnect the negative battery cable.
2. Disconnect B+ (1) and D+ (2) wires from the
alternator.
26648
3. Loosen and remove the nut and bolt (3) secur-
ing the alternator to the belt tensioner (4). 10
4. Move the alternator to reduce belt tension (5)

and remove it from the alternator pulley (6).
5. Unscrew and remove the nut and bolt (7).
Remove the alternator.
26649
11
1 2 3 4 5 6 7 8
10 9
26650
Alternator Components 12
1. Pulley retaining nut 6. Stator
2. Pulley 7. Rear support plate
3. Cooling fan 8. Rectifier bridge
4. Front support plate 9. Protection guard
5. Rotor 10. Electronic voltage regulator with built--in brushes
Disassembly
1. Firmly fix the alternator horizontally to an ap-
propriate holder with internal surfaces pro-
tected with soft material.
2. Remove the guard (1) after unscrewing the
nuts which fasten it to the alternator (Fig. 13)
3. Before dismantling the alternator completely,
carry out the following tests:
26651
13
Alternator Component Testing

Rotor and regulator field circuit test
The following testing devices are required:

• 12 volt battery
• multitester
• 2 watt test lamp.
See figure 14.

1. Disconnect all alternator wires.
26652
2. Connect a 12 V. battery and a 2.2 watt test lamp
(2) in series to D+ (1) and alternator casing 14
(negative side of the casing).
3. The test lamp should light up.
If the test lamp does not light up, then the rotor cir-
cuit is faulty. Check brushes, contact rings and rotor
field winding continuity.
If the test shows these components are satisfacto-

ry, then the regulator may be faulty.
Checking continuity of three stator windings
Position the points of an ohmmeter (regulated on Ω

Ω x1 scale) so that they touch the stator phase ends
(a -- b -- c) in the three possible ways shown in fig-
ures 15, 16 and 17. Each reading should show a
certain resistance value which should be the same
for all three readings.
If resistance shows infinity or zero, the measured

phase is either interrupted or short--circuited and
the stator needs to be changed.
26653
15
26654
16
26655
17
Checking the diodes
Disconnect the terminal wire connector (1) of the

excitation diodes from the positive brush pin (Fig.
18)
26656
18
Unweld stator winding terminals (2) from the recti-
fier bridge (Fig. 19).
26657
19
Excitation diodes test
Insert an ohmmeter point in the connector men-

tioned above (1) (Fig. 18). The second point must
be put in contact successively with each of the three
terminals (A--B--C): Repeat the three measure-
ments after reversing the instrument points (Fig.
20).
26658
20
Positive power diodes test
Put an ohmmeter point in contact with the positive

(X) alternator terminal and the other successively
with each of the three terminals (A--B--C) (Fig. 21).
Repeat the three measurements after reversing the

instrument point connections.
26659
21
Negative power diodes test
Put an ohmmeter point in contact with the negative

(Y) diodes plate and the other successively with
each of the three terminals (A--B--C) (Fig. 22).
Repeat the three measurements after reversing the

instrument point connections.
26660
22
In the three tests described above, the instrument
should show resistance at each terminal (A--B--C).
Reversing the instrument point connection, there
should be no resistance (Fig. 22). If there is resis-
tance in both cases, this means short--circuited
diodes. Otherwise, with a R=0 value (interrupted
diode), change the whole rectifier bridge.
Check on rotor winding resistance measured
between pins connected to brushes
Disconnect the excitation diode terminal wire con-

nector (1) from the pin connected to the positive
brush. Put both points of an ohmmeter (regulated
on Ω x 1 scale) in contact with the two voltage regu-
lator--brush holder pins. If resistance reading is dif-
ferent from the indicated value or if it shows infinity
(interrupted circuit), check and, if necessary,
change the rotor (Fig. 23).
26661
23
Op. 55 301 12
Rotor
1. Place a suitable Allen wrench in the hexagonal

hole in the alternator shaft to prevent the alter-
nator shaft from turning. With another wrench,
unscrew the fan and rotor pulley fastening nut.
Draw out the above mentioned parts, spacing
collars and alternator washers (Fig. 24).
26662
24
2. Disconnect the excitation diode terminal wire
connector (2) from the pin connected to the
positive brush. Unscrew and remove the
screws (3) securing the electronic voltage regu-
lator (4), complete with brushes, to the rear al-
ternator support. Unscrew nuts (5) and remove
the screws fastening the alternator main exter-
nal parts (Fig. 25).
26663
25
Electronic voltage regulator
a. Brushes
b. Pins
26664
26
Separate the parts (as illustrated) bearing in mind
that it is necessary to apply a considerable degree
of pressure on the rotor shaft to free the front sup-
port plate (6) and the rotor (7) (Fig. 27).
If you do not have a press, use a brass drift, to avoid

damaging the thread.
26665
27
Unscrew the screws (9) which fasten the rectifier
bridge (10) to the rear support plate (8) (Fig. 28).
The rectifier bridge must not be dismantled: the

spare part is supplied as a complete unit.
26666
28
Separate the rectifier bridge (10) from the rear sup-

port plate. Unweld the stator winding terminals (11)
(Fig. 29).
26667
29
Separate the stator (12) and the terminals (11) from
the rear support plate (8) (Fig. 30).
26668
30
Inductor coil insulation test
Put both ohmmeter points (fixed at Ω x 1 scale) in

contact respectively with a slip ring and the rotor
casing (see arrows). The instrument should show
infinity resistance. If this is not the case, change the
rotor (Fig. 31).
26669
31
Check rotor inductor resistance on slip rings
Put both ohmmeter points (fixed at Ω x 1 scale) in

contact respectively with the slip rings (see ar-
rows). The instrument should show a certain de-
gree of resistance (Fig. 32).
If the instrument reading is different from the pre-

scribed value or shows infinity (interrupted circuit),
change the rotor.
26670
32
Check the ball bearing moves freely, without sticking
or noise. Check the collectors have not been dam-
aged by the brushes. If this is the case, change the
whole rotor.
Assembly
To assemble, reverse the order of the operations
described.
Repair 4
1. Check the rotor and stator poles are not worn.
If this is the case, it means the ball bearings are
worn, the casings are not in line or the rotor 2
shaft is misshapen.
NOTE: Alternator ball bearings cannot be serviced
separately. When necessary, therefore, both must
be changed.
2. Unscrew the screws (1) securing plate (2) that 1

locks bearing (3). Remove it from the front sup- 3
port plate (4) (Fig. 33). Check if it is worn or 26671
damaged; if so, change it. Before installing the
ball bearing, check the front support plate 33
holder and clean it carefully.
3. Installation of bearing (5) on support plate side

is different from the one described above. A
new rotor complete with bearing must be
installed (Fig. 34).
26672
34
Installation
1. Install the alternator by reversing the removal
procedure.
During installation, remember to:

• Check the negative (ground) battery cable is dis-
connected from the battery while re--installing
the alternator.
• Adjust the alternator drive belt, as described pre-
viously in this chapter.
Chapter 5 -- Battery
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Relative Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dry-Charged Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
CHARACTERISTICS TYPE OF BATTERY

Voltage (V) 12
Cold start amperage (C.C.A) 800
Capacity (Ah) 120
Number of elements 6
Number of plates per element 21
Energy reserve (SAE) (min.) 210
Weight (kg) 35
Earth (ground) terminal Negative
TROUBLESHOOTING
Discrepancy 5. Crystals are formed when batteries are left flat.

High temperature and long periods with the bat-
1. Internal open circuit. tery flat increase this condition. If a battery is left
2. Internal short--circuit. at room temperature for a week it can rarely be
charged in the vehicle. Battery recharge requires
3. Battery electrolyte leakage. higher constant voltage. After three weeks the
4. Grid active material separation. battery will be permanently jeopardized and it will
be necessary to follow the procedure described
5. Accumulation of sulphate crystals too big to be for “very flat batteries”.
dispersed.
Fully charged batteries have longer a life. A lead--cal-
Probable Causes cium battery discharges 3% a month. This means
that in 16 months it will reach 50% charge. In the trac-
1. Component failure inside the elements. tor, inactive load is approximately 50 mA. To forecast
2. Excessive crystal growth which can pierce the discharge on a vehicle not in use add approximately
spacers and cause short circuits. 8 Ah a week to this value.
3. Excessive overload (bad charging system, high It is worth noting that if a battery is weak during en-
voltage fast charging, high operating tempera- gine start--up, it is best to let the battery rest for two
tures). minutes. This rest time increases as the temperature
decreases.
4. Battery electrolyte freezing.
A fully charged battery freezes at --65°C. A 50% When two batteries are installed, do not use an old
charged battery freezes between --17°C and battery with a new one. One battery will always stop
--27°C. A completely flat battery freezes between before the other one. If the battery has lasted as fore-
-- 3°C and --11°C. Excessively fast charging and casted, charge both batteries. If one has stopped be-
boiling caused by gas formation cause the sepa- fore the forecasted time due to a defect, then change
ration of active material from the grids. Separa- only the defective battery.
tion destroys the battery chemical function.
The 800cca battery used on TD models is a sealed Each element of the battery consists of positive and
maintenance-free type. The battery is installed negative plates, positioned alternatively, one next to
above the front axle support (Fig. 1). the other. Each positive plate is separated from the
adjacent negative plate by means of a porous insu-
NOTE: “Maintenance--free” means that the battery lating spacer. If one of the positive plates touches a
electrolyte, in normal conditions of use, does not negative plate in the element, the element will short--
leak. It could leak if the battery is loaded over 14.4 V. circuit and be irreversibly damaged. The positive
This, in fact, causes the water to boil due to gas plates are welded to a collecting bar and form a posi-
formed as the battery charges up completely. It can tive terminal. The negative plates are welded to a
be caused by a faulty charging system, by quick similar collecting bar and form a negative terminal.
charging or topping up.
Each positive plate consists of a lead grid with lead
The four main functions of a battery are: peroxide pasted to the grid holes. The negative
plates consist of a lead grid with lead sponge pasted
• to supply a source of electricity for starting, igni- to the grid holes.
tion and instrument lighting and functioning.
The plates are covered by an electrolyte which con-
• to control voltage in the electrical system. sists of diluted sulphuric acid solution.
• to supply electricity when the power required is The battery casing is made of polypropylene.
higher than that produced by the alternator.
• to support inactive loads from radio and micro-

processor memory.
OVERHAUL
BATTERY
Op. 55 301 40
Removal
1. Lift the engine hood.
2. Disconnect ground cable from tractor structure
and position it safely, away from the structure it-
self.
3. Loosen the bolts on both terminal clamps and
disconnect the positive and negative battery
cables. Ensure they do not touch the battery
itself.
4. Lift the battery from the tractor by the two han-
dles at each end of the battery.
24569
Installation
1
To install the battery, reverse the removal procedure,
with the following precautions:
• Check that the battery is clean, there are no signs

of electrolyte leak and the breather covers are
completely installed. Coat the terminals and
clamps with a petroleum jelly (such as Vaseline).
Do not use traditional lubricants as they can lead
to electrolytic corrosion.
• Check the battery compartment or support. The
clamps should be clean and there should be no
stones or other small objects, which could pierce
the battery casing.
• Check that terminal polarity is correct. Check ter-

minal clamp connections are not too tight.
• If a radio is installed, it will lose all saved data and
will need to be reprogrammed. Electronic panels
and microprocessors, for those models to which
they are fitted, will not lose their memory
function.
BATTERY MAINTENANCE Table 1

Relative Density Fully charged battery
The relative density of the battery electrolyte shows Temperature performance
the charge level of the battery. When the battery is
fully charged, the relative density of the electrolyte, 25.0°C 100%
at 25°C, is at least 1.280. --4.5°C 82%
--24.0°C 64%
Alternatively, approximate charge can be measured --27.5°C 58%
using a digital voltmeter (± 0.01 V) as follows: --31.0°C 50%
--34.5°C 40%
less than 10.5 V unusable battery* --37.5°C 33%
less than 11.8 V flat battery
less than 12.3 V half--charged battery Maximum battery life can be obtained by paying the
more than 12.6 V fully--charged battery right attention and by carrying out regular checks.
The energy capacity output must not be exceeded by
* See notes to paragraph “TESTS” for instructions on constant overload and charging requirements must
how to recuperate a slightly sulphurized battery. be respected.
Battery voltage must be registered on a flat battery
Precautions
considering the following:
IMPORTANT: Batteries contain sulphuric acid and
A) the battery must be flat for at least 4 hours generate a highly explosive hydrogen and oxygen
mix during charging.
B) if the vehicle has been used recently, or if the bat- • Do not use devices producing flames or sparks
tery has been charged recently, switch the headlights to inspect the electrolyte level.
on for 2 minutes.
• Do not remove battery caps without protecting
When a battery is flat, the sulphuric acid in the elec- your hands and your eyes.
trolyte combines chemically with the plates and this
decreases the relative density of the solution. During battery maintenance, follow the steps below:
1. Keep the electrolyte level 17 mm over the plates.
A battery densimeter will determine the relative den- If this is not respected, the acid concentration will
sity of the electrolyte in an element. A reduction in the vary, which could damage spacers and cause a
amount of sulphuric acid in the solution will show the deterioration in plate performance.
degree of charge of that element.
2. Use distilled or de--mineralized water only. Never
The lower the temperature at which the battery oper- use tap water or rain water or water from any oth-
ates, the more necessary it is to keep the battery fully er source.
charged. For example, a battery with a relative densi-
3. Keep the battery charged at least 75% to avoid
ty of 1.225 at 27°C (80°F) can start the engine at mild
plate sulphurization, performance loss and pos-
outside temperatures but might not do so at lower
sible freezing at low temperatures.
temperatures because of lower battery performance.
4. Avoid overcharging the battery. Excessive
Table 1 shows the effect of temperature on battery charge will generate high internal heat which will
performance. cause grid deterioration and water loss.
5. During quick recharge, check the battery tem-
perature does not exceed 50°C.
6. Do not add sulphuric acid to an element unless
some electrolyte has been spilt. Before filling,
check the solution has the correct relative densi-
ty. Slow recharge is the only way to recharge the
battery completely. You can use a high amper-
age battery charger to charge the battery with
high current intensity for short periods of time.
Use a slow charge to bring the battery to its full
capacity.
Dry-Charged Batteries 2. When using a fast or high ampere charge, follow

the manufacturer’s instructions carefully. High
Dry charged batteries must be prepared as followed:
charging amperage increases electrolyte tem-
1. Remove the breather caps from each battery perature and, if the battery charger is not
element. equipped with an automatic time or temperature
switch, it can cause the electrolyte temperature
2. Fill each element to the recommended level with to rise above 50°C. This can cause violent boiling
electrolyte at a relative density of 1.260. in the battery and damage internal components.
NOTE: The electrolyte consists of diluted sulphuric 3. Check electrolyte level in each element again
acid, preferably at a temperature of 21° -- 32°C. and, if necessary, top up with distilled water.
3. After filling, leave the battery to rest for 15 min- WARNING

utes. Check the electrolyte level and top up, if Explosive gas is formed when a battery is
necessary. charged. Do not smoke or use naked flames
4. Charge the battery for 4 hours at 5--8 A., check- when checking electrolyte level. Check that the
ing that all the elements are producing gas freely. battery charger is switched off, before connec-
tion and disconnection, to avoid sparks which
5. Replace the breather caps. could ignite the gas.
Charging Very Flat Batteries

Charging The Battery
To recharge a Pb--Ca maintenance--free battery we
Before charging a battery: recommend using a constant voltage battery char-
ger. For very flat batteries, charge for 48 hours, at 16
1. Clean the battery casing and element covers V., with current limitation (50 A. for 105 Ah and 66 A
carefully with ammonia diluted in warm water for 120 Ah).
and clean the terminals;
2. Check the electrolyte level and, if it is below the This method is self--regulating. High current is pro-
plate level, top up with distilled water to cover the vided at the beginning (when the battery voltage is
plates. very low). Current decreases progressively when the
battery is fully charged (and its voltage is high).
If only constant voltage battery chargers are avail-

Normal Charging (Top Up) able, we recommend using voltage levels and times
1. Charge the battery completely with a slow bat- shown in table 2. These figures refer to very flat bat-
tery charger at 3 to 6 amperes for the required teries. If the battery is only 50% discharged, use half
time. This can last 36 hours, or more, if the bat- the time shown (slow charging programme). For
tery is very flat. A severely sulphated battery may other conditions, reduce charging time proportion-
not charge. When the battery is completely ally. When feasible, use the slowest charging pro-
charged, the elements will produce gas freely gramme for increased battery life.
and the relative density will remain constant. Dis-
connect the battery charger after three consecu-
tive densimeter readings, recorded every hour,
showing that relative density has stabilised.
If violent boiling occurs during charging, due to gas Example 1:

formation or electrolyte leakage, or if the battery box Temperature below 30°C
is hot (50°C or higher), temporarily reduce or stop Battery electrolyte temperature 19°C
battery charging to avoid damaging the battery. Densimeter reading 1.270
Subtract 11.0 x 0.004
5.5
Table 2 Correct relative density = 1.262
120Ah
(800 cca)
Slow charging programs 30 hrs at 5A
15 hrs at 10A Example 2:
Temperature above 30°C
Fast charging programs 10 hrs at 18A Battery electrolyte temperature 40°C
(emergency use only) Densimeter reading 1.220
Add 10.0 x 0.004 0.007
5.5
Correct relative density = 1.227
Testing
Before carrying out battery tests, check the breath-
ers are not blocked, there is no rust, the breather
caps are not open and the casing is not cracked. 3. Use the following table to determine the charge
level.
Required testing equipment:
• Densimeter Correct Correct
Charge relative relative Average
• Battery starter tester (high amperage tester) battery
condition density at density at
• Thermometer 15°C 25°C voltage
• Battery charger 100% 1.295 1.287 12.66

75% 1.253 1.246 12.45
50% 1.217 1.210 12.30
Relative density: This test shows the charge level 25% 1.177 1.170 12.00
of a battery. Flat 1.137 1.130 11.84
1. With the float in a vertical position, note the read-

ing.
NOTE: Relative density should not vary more than
2. Regulate the densimeter reading for battery 0.025 points between cells.
electrolyte temperature variations subtracting 4
points (relative density 0.004) for every 5.5°C be- 4. If relative density is 1.280 or higher, the battery
low the temperature the densimeter is calibrated is fully charged and in good working condition.
at and adding 4 points (relative density 0.004) for 5. If the correct relative density is less than 1.280,
every 5.5°C above this temperature. charge the battery and check the charging sys-
The following examples have been calculated with a tem, to find the cause of low battery load.
densimeter calibrated at 30°C.
NOTE: If distilled water has recently been added, the
battery must be charged for a short period of time to
obtain precise densimeter readings.
If the battery has been loaded and kept still, the bat-
tery electrolyte will be thicker at the base of the ele-
ments. The battery must be shaken periodically to
mix the electrolyte. This will improve charging am-
perage and allow more precise densimeter readings
during tests.
Performance tests 4. Set the charging amperage as close as possible

to 40 A.
Performance tests help to understand if a battery can
adequately run the engine. Voltage readings show 5. After a 3 minute fast charge, read the voltmeter.
battery condition. Before carrying out the test, check
• If the total voltage is higher than 15.5 V., the
the battery electrolyte level is correct and the open
battery is not satisfactory. It is probably sul-
circuit voltage is 12.5V or more. The battery can be
phated or worn and must be changed.
tested in the tractor or removed.
1. Switch the battery start tester current control to NOTE: A slightly sulphated battery can be renewed
“off” (high amperage discharge tester). Calibrate using a multiple type battery charger, with upper
the voltage selection switch to the nominal bat- open circuit voltage limit of 50V. A sulphated battery
tery voltage or slightly higher. Connect the posi- has high resistance and for this reason it will be nec-
tive tester conductors to the positive battery ter- essary to set a high voltage at the beginning to over-
minal and the negative conductors to the come resistance. At the beginning there may be no
negative battery terminal. visible sign of charging. After some minutes of inac-
2. Turn the current control knob until the ammeter tivity, a low charge will show. This is followed by a fast
reading reaches half the cold start battery rise in amperage. Amperage must not exceed 14.0
amperage and note the voltage reading. A. and the battery electrolyte temperature must not
exceed 50°C. When amperage stabilizes, set the
• If the reading shows 9.6 V. or higher after 15 voltage until amperage corresponds to 5 A. Continue
seconds, the battery has adequate power this amperage until the relative density of the battery
output and can easily be charged following electrolyte stabilises (1.275 -- 1.280 at 20°C). This
the normal procedure. could take approximately 48 hours. Let the battery
• If the reading is lower than 9.6 V., battery is rest for 24 hours and then carry out the previously de-
not satisfactory for use and the charge must scribed performance test.
be tested as follows.
• If the total voltage is less than 15.5 V., check
WARNING the relative density of each element and
recharge the battery according to the follow-
Do not leave a high discharge tester on the bat- ing scale:
tery for more than 15 seconds.
Relative density Fast charge up to:
Test charging: This test is only for those batteries 1.150 or less 60 minutes
which have not passed the performance test above.
from 1.151 to 1.175 45 minutes
1. Connect the positive battery charger tester con-
ductors (high amperage discharge tester) to the 30 minutes
from 1.176 to 1.200
positive battery terminal and the negative con-
ductors to the negative battery terminal. from 1,200 to 1.225 15 minutes
2. Connect the positive battery charger conductor (slow charge only)
to the positive battery terminal and the negative
conductor to the negative battery terminal.
NOTE: When there are problems with a battery,
3. Turn the battery charger timer to more than a 3 check fan belt tension and the complete charging
minute charge and then back to a 3 minute system.
charge.
Chapter 6-- Electrical Circuits
CONTENTS

Electrical Diagram Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Wire Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fuse Box/Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Main Wiring Diagrams (Cab or ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Diagrams A, B, C and D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Diagram A (Main Harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Diagram B (Dash Harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Diagram C (Rear Harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Diagram D (Cab/Platform Harness) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Individual Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Start-up Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
High and Low Beam Headlights, Cornering and Parking Lights . . . . . . . . . . . . . . 18
Direction Indicators and Hazard Lights Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Work Lamp Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Operator’s Presence Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Analog Instrument Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Heating and Air-Conditioning System Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
ELECTRICAL DIAGRAM SYMBOLS
Speaker
Ignition Switch
Diode
Connection
Battery
Solenoid Valve
Fuse
Motor Thermostart
Lighting and Indicator Lamps Horn
Switch Relay
Variable Resistance
Switch Relay Lighter
Pressure Switch
Electrical Supply Socket
Indicator Switch
Control Switch
Dual Filament Lamps

26679
WIRE COLOR CODING
Wire Color Code Used in Diagrams

Black B
Green G
Pink K
Light Green LG
Tan LN
Brown N
Orange O
Purple P
Red R
Grey S
Turquoise TQ
Blue U
White W
Yellow Y
FUSES AND RELAYS MAIN BOX
11 10
BRAKE FLASHER
RELAY
4 3 2 1
15 A 7.5 A 15 A 10 A
8 7 6 5
10 A 10 A 15 A 7.5 A
9
10 A
13
Fuses PROTECTED CIRCUITS Amps.

1 Hazard warning light switch, turn signal 15
2 Thermostarter 15
3 Fuel sedimenting device, horn 7.5
4 Stop lights 15
5 Fuel shut--off solenoid 7.5
6 Main beam headlights 15
7 Dipped beam headlights 10
8 Rear worklight, left sidelights 10
9 Front worklight, right sidelights 10
10 Flasher --
11 Brake relay --
MAIN WIRING DIAGRAMS

DIAGRAMS
Legend
1 – Instrument Panel 17 – Thermostarter
1. High beam indicator
2. Park 18 – Thermostart Switch
3. Left signal
4. 2nd Trailer indicator
5. 1 st Trailer indicator
19 – Engine Shut--Off Solenoid
6. Ground
7. Fuel gauge 20 – Water temp. gauge sending unit
10. Engine water temp. gauge
11. Fuel filter 21 – Oil Pressure Indicator Sending Unit
12. Right turn indicator
13. Air filter restriction indicator 22 – Main Harness-- Headlamp Harness Connec-
15. Eng. Oil pressure indicator
16. Battery charge indicator
tion Connector 6 Way
18. Power
19. Park brake indicator 23 – Right Headlamp Connection Connectors, 3
Way
2 – Starter Switch
24 – Right Headlamp Connection Connectors, 3
3 – Beam, Park, Horn Switch Way
1. Parking lights
2. High beam. 25 – Right Headlamp
3. Power (Park and Headlamp)
4. Low beam
5. Power (Horn, High beam)
26 – Left Headlamp
6. Horn
27 – Horn
4 – Hazard Warning Switch
5 – Main Fuse 28 – Main Harness -- Chassis Harness Connection
connector 12 Way
6 – Fuse Box
7 – Signal Button 29 – Starter Inhibitor Switch
1. Right signal
2. Left signal 30 –
3. Power
31 –
8 – Brake Relay
9 – Flasher 32 –
10 – Battery 34 –
11 – Starter 35 –
12 – Alternator 36 –
13 – Over voltage circuit breaker 37 –

a. Ign. Relay – cab
14 – Air filter b. Ign. Relay – work lamps
c. Rear work l;amps relay
d. Front work lamps relay
15 – Fuel Gauge Sending Unit
16 – Fuel Send. Meter

38 – Fuse Box (cab) 48 – Washer

a. rear work lamps relay
b. front work lamp relay 50 – Clutch Pedal Switch
c. front & rear work lamp switches
d. empty
e. heater control switch
51 – Operator’s Presence Switch
f. Intirior lamps
g. Washer 52 – Operator’s Presence Control Module
h. Wiper
53 – PTO Switch
39 – Power Outlets
54 – A/C Compressor
40 – Switches
a. front work lamps 55 – Cornering Lights Switch
b. rear work lamps
c. washer switch
d. wiper switch 56 – Wiper Switch (Rear)
41 – Rear Work Lamps 57 – Cornering Lights
42 – Front Work Lamps 58 – Front Cab Flashers

a. right side
43 – Speakers b. left side
44 – Interior Lamps 59 – Wiper Switch (Front)
45 – Wiper 60 – Fuel Filter
46 – Radio 61 – Advance Solenoid
47 – Heater 62 – Solenoid Switch

50045263
Diagram “A” (Main Harness)

20045256
Diagram “A” (Main Harness) (continued)

20045257
Diagram “B” (Dash Harness)

20045258
Diagram “B” (Dash Harness) (continued)

20045259
Diagram “C” (Rear Harness)

20045253
Diagram “D” (Cab/Platform Harness)

20045254
Diagram “D” (Cab/Platform Harness) (continued)

INDIVIDUAL CIRCUITS
50045255
Start-Up Circuit
2 Starter switch
18 Thermostart switch
5 -- Fuse box
5a -- Fuse #13, 15A 27 -- Fuelshut-off solenoid
5b -- Fuse #5, 7.5A
28 -- Thermostart devise
8 -- Starter relay
31 -- Starter inhibitor unit
11 -- Battery
35 -- Maxi Fuse, 40A
12 -- Starter Motor
50 -- Clutch pedal switch
13 -- Alternator
53 -- PTO switch
14 -- Over Voltage protection devise
High and Low Beam Headlights, Cornering and Parking Lights
1 -- Instrument panel with headlamp high beam

indicator
2 -- Key switch
Ign. Switch continuity Chart
3 – Multi--function light switch
1 -- Parking lights +12V Pos. 58/57 57 30 15/54 50
4 – High beam +12V
5 – Keyed +12V supply PARK
7 – Low beam +12V
OFF
5 – Fuse box
a -- fuse # 1, 15A RUN
b – fuse # 2, 10A
c – fuse # 8, 20A START
d – fuse # 16, 40A
e – fuse # 3, 20A
6 – Low beam relay
7 – High beam relay
11 – Battery
21 – Left rear parking, turn signal & brake lights
25 – 7--Pin external socket
32 – Headlamps
34 – Right rear parking, turn signal & brake lights
55 – Cornering lights switch
57 – Cornering lights
50045260
High and Low Beam Headlights, Cornering and Parking Lights

Direction Indicators and Hazard Lights Circuit
1 -- Instrument panel
3 – Left turn indicator
12 – Right turn indicator
2 -- Key switch
3 – Multi--function light switch

2 – Right turn signal
3 – Left turn signal
5 – Keyed +12V supply
6 – Keyed +12V
8 -- Keyed +12V
5 – Fuse box
a -- fuse # 16, 40A
b – fuse # 7, 15A
c – fuse # 11, 20A
d – fuse # 6, 20A
e – fuse # 9, 15A
f – fuse # 3, 20A
10 – Electronic flasher unit

A1 -- +12V supply
A2 – Hazard flasher, right side
A4 – Hazard flasher, left side
A6 – Hazard switch indicator lamp
A8 -- +12V keyed power
B1 -- +12V supply
B2 – Input, right turn signal
B3 – Input, left turn signal
B4 – Input, hazard flasher switch
B6 – Left turn signal, output
B7 – Right turn signal, output
B8 -- Ground
11 – Battery
20 – Front turn signal lights

a – right
b – left
21 – Left rear parking and turn signal lights
34 – Right rear parking and turnsignal lights
35 – Maxi Fuse – 40A
58 – Cab flashers
50045264
Direction Indicators and Hazard Light Circuits

50045261
Work Lamp Circuit
37 -- Cab Relays 40 -- Switches

a -- Ign. relay a -- Front work lamps
b -- Ign. relay -- work lamps f -- Rear work lamp relay
c -- rear work lamps relay
d -- front work lamps relay 41 -- Rear work lamps
38 -- Cab Fuse Box
a -- Rear work lamp relay 42 -- Front work lamps
b -- Front work lamp relay
c -- Front and rear work lamp switches relay
Operator’s Presence Circuit
2 -- Key switch Ign. Switch continuity Chart
Pos. 58/57 57 30 15/54 50
PARK
OFF
RUN
5 – Fuse box START
a -- fuse # 9, 15A
b – fuse # 6, 20A
11 – Battery
29 – Park brake indicator switch
35 – Maxi Fuse – 40A
51 – Operator’s presence switch
52 – Operator’s presence control module

1 -- +12V power supply
2 – Park brake circuit
3 – Operator’s presence circuit
4 -- +12V power supply
5 – Ground
6 – Keyed +12V
7 – PTO circuit
8 – Not used
53 – PTO switch
50045262
Operator’s Presence Circuit

TRE0628A
Analogue Instrument Circuit
1 -- Left turn indicator 9.-- Brake oil level low

2 -- Cornering lights indicator
10 -- Parking brake
3 -- Headlamp main beam
4 -- Water in fuel
11 -- Right turn indicator
5 -- Air filter blocked
6 -- Unused 12 -- 1st. trailer turn signal*
7 -- Engine oil pressure 13 -- 2nd. trailer turn signal*

14 -- Unused
8 -- Battery charger
15 -- PTO rotational speed

* Not applicable to North America models
50045265
Heating and Air-Conditioning System Circuit
2 -- Starter switch 66 -- Main harness -- Switches harness connection

connectors, 4 ways
5 -- Fuse box
74 -- Main harness -- Driver cab harness
11 -- Battery connection connectors, 4 ways
12 -- Starter 3 -- Main harness -- Driver cab harness
35 -- Main fuse connection connectors, 2 ways
37 -- Relay box I -- Electrical fans
38 -- Fuse box II -- Air-conditioning -- thermostat
47 -- Heater III -- Air-conditioning pressure switch
56 -- Compressor IV -- Electric fan control switch
63 -- Main harness -- Switches harness connection V -- Air-conditioning control switch
connectors, 15 ways black VI -- Heating control
64 -- Main harness -- Switches harness connection VII -- Air-conditioning control switch connection
connectors, 8 ways
ELECTRICAL CIRCUIT DIAGRAM
1--Instrument panel
1-- High beam 14--Air filter
2-- Park 15--Fuel gauge sending unit
3-- Left signal

16--Fuel send. meter
4-- 2nd trailer 17--Thermostarter

16
1,0 P/W
0,5 P/W
17 5-- 1st trailer 18--Thermostarter switch
85 30
19 6-- Earth 19--Engine shut--off solenoid
8 87A
2,5 N/R
7-- Fuel gauge 20--Water temp. gauge sending unit
86 87
1,5 P/Y
1,0 R
0,5 U
1,0 B
10-- Engine water temp. gauge
18 21--Oil pressure indicator sending unit
11-- Fuel filter
1,0 G
22--Main harness-- head lamp harness connection connector 6 way
1,0 G/O
12--Right signal
23--Right headlamp connection connectors, 3 ways
13-- Air filter
15-- Oil pressure 24--Left headlamp connection connector, 3 ways
16-- Battery charge indicator 25--Right headlamp
18-- Power
26--Left headlamp
19-- Parking brake
11
27--Horn
2,5W/R
10 2-- Starter switch
50
--
3-- Beam--Park--Horn--Switch 28--Main harness--Chassis harness connection connector 12 way
+ 30 5 6
1-- Park 29--Starter inhibitor switch
10 N 40A 2,0 N 2,0 P
15A
2-- High beam
30--Chassis harness-- Right wing harness connection connector 4 way
2,5 N/U 2,0 N/U
15A 3-- Power (Park and headlamp)
31--Chassis harness--Left wing harness connection connector 4 way
6,0 N
6,0 N
2,0 Y/W 2.0 P/B 4-- Low beam
7,5A
2,0 Y/W 2.0 P/W 5-- Power (horn, high beam) 32--Beacon lamp switch
15A
6-- Horn
2,0 Y/W 2.0 P/Y 33--Beacon lamp
7,5A
4-- Hazard warning switch 34--Handbrake send unit
2,5 U/W 2,5 U/W
15A
5-- Main fuse
35--Stop light switch
2,0 U/R 2,0 U/R
10A 6-- Fuse box
36--Trailer socket
2,0 R 2,0 R
10A 7-- Signal button
0,56 R/W 37--Right rear signal, park, stop lamp
2,0 R/W 1-- Righ signal
10A 1,0 R/B
2-- Left signal 38-- Right front signal, park
3-- Power 39--Working lamp
12 8--Brake relay 40--Left rear signal, park, stop lamp
9-- Flasher 41--Left front signal, park

D+ B+ 13
3 N/P 3,0 B 10-- Battery
42--Plate socket 4 way
11-- Starter
6N
43--Plate lamp
0.5 N/Y
12-- Alternator
13-- Over voltage circuit breaker
1,5 LG/N
4 49A
0,5 B
31
1,5 G/W
0,5 R R
1,5 O
1,5 LG/N
49 C 49A 1,5 G/R
L
0,5 R
9
C3 C2 31 2,0 P
30
1B
49 15
0,5 LG/Y
0,5 LG/R
20 30
21
0,75 G/W
1,5 B 1,5 B 1,0 B
1 1
0,75 R 37
0.5 G/U
0.5 W/N
0,75 G/P 0,75 G/P 0,75 G/P
2 2
0,75 G/W 0,75 G/W 0,75 G/W
3 3
0,75 B
1,0 R 1,0 R 38
4 4 0,75 R
6,0 N
2 0,75 G/N
30 0,75 B
6,0 Y/W
2,0 N/U
39
2,0 R 15/54
57
31
29
2,0 U
2,0 U 58/57 2,5 W/Y 0,75 G/R
50
1,0 B 1,0 B 0,75 B
2,5 W/Y 2,5 W/R 1 1
0,75 R/B 40
0,75 G/P 0,75 G/P 0,75 G/P
2 2
0,75 G/R 0,75 G/R 0,75 G/R
3 3
0,75 B
0,75 R/B 0,75 R/B 0,75 R/B 41
4 4
2,0 R 1 1 1,0 R
7
1,0 R/B 2 2 1,0 R/B
1 1,0 G/W 1,5 G/R 3 3 0,75 G/R
1,0 G/R 1,5 G/W 0,75 G/W
2 4 4
1,5 LG/N 2,5 W/Y 5 5 2,5 W/Y
3
2,0 B 6 6 2,0 B
1,0 G 7 28 7 0,75 G
1,0 G/O 0,75 G/O 42
8 8
2,5 W/R 9 9 2,5 W/R
1,5 P 1,5 P 0,5 R/B 0,5 R/B
10 10 1 1
2,0 U
1 11 11 0,5 B 0,5 B 43
2,5 U/W 2 2
2 12 12
2,5 S 3 3 3 3
2,0 U/R 14
4
1,0 P/B
5 4 4
1,0 P/N 6
0.5 N/Y
0.5 R/K
0.5 G
0.5 W/N
0.5 B/S
0.5 G/W
0.5 U
20 19 18 17 16 15 14 13 12 11
1 7 6 5 4 2 1
10 9 8 3
15
0.5 G/B
0.5 G/U
0.5 LG/Y
0.5 LG/R
0.5 G/R
0.5 R/W
0.5 U/W
0.5 B
0,5 B
1,5 P
32
0.5 B
1,5 B
0,5 B
0,75 G/O
0,75 G
0,75 G/R
0,75 G/W
0,75 G/P
1,5 B
0,75 R/B
0,75 R
0,75 G/P
2,0 B 2,0 B
6.0 B 1 2 3 4 5 6
2,0 B
2,0 B
0.5 B
33 34
0,75 B
2.0 B
6.0 B
1.0 B 35 36
1.0 B
0.5 B
2,0 U/R
1,0 P/N
2,0 U/W
2,0 B
4 3 2 1
CABLE COLORS
22 FUSES
4 3 2 1
NH CODES COLOR
B BLACK
10A
2,0 B
Hazard warning,signal
2,0 U/R
1,0 P/N
2,0 U/W
G GREEN
15A Termostarter
K PINK
23
7,5A Fuel send. meter,headlamp, horn
1,0 U/R LG LIGHT GREEN
1 1
1,0 U/W 15A Stop lamp LN TAN
25 2 2
1,0 B
3 3 7,5A N
Solenoid BROWN
1,0 U/R 15A O ORANGE

1 1 Headlamp
1,0 U/W
2 2 P PURPLE
26 10A
1,0 B Headlamp
3 3
R RED
10A Left park,rear working lamp
24 S GREY
10A Right park,plate
TQ TURQUOISE
U BLUE
1,0 B W WHITE
27 1,0 P/N Y YELLOW
SYMBOLS
30
31 49A
R
57 15/54 L
58 50
30 A --
58/57 50
49 15 + 30 D+ B+
Starter switch Hazard warning unit Fuse Relay Battery Starter Alternator Circuit breaker Oil pres. sending unit
Air filter Water temp. send. unit Horn Signal lamp,headlamp Lamp Fuel gauge send. unit Engine shut--off solenoid
+ --
Thermostarter Hand brake send. unit Starter inhibitor switch Plug Switch Speaker
SECTION 90 -- CAB -- CHAPTER 1 1
SECTION 90 -- PLATFORM AND BODYWORK
Chapter 1 -- Platform and Bodywork
CONTENTS

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Footboard, Roll Bar and Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
????????????- 06--2002
2 SECTION 90 -- CAB -- CHAPTER 1
OVERHAUL
FOOTBOARD, ROLL BAR, BONNET

Disassembly
1
TRE0247A
2. Remove the bolts (1) securing the rear fenders to the 2

1
footboards (2) on both sides.
TRE1320A
3. Unscrew the bolts (1) securing the roll bar side

plate to the fender on both sides and take off side
lights (2).
1 2
2
TRE3885B
???????????? - 06--2002
4. Unscrew the bolts (1) securing the PTO clutch le-

ver assembly to the Roll Bar bracket.
1 1
TRE2131A
5. Remove the bolts (1) securing the shuttle lever

to the footboard and remove the bolts (2) fasten-
ing the 4WD engagement lever to the footboard.
1
TRE3073A
5
6. Remove the 4WD split pin(1) securing the pin (2) 2
and take off the pin (2).
TRE3013A
6
7. Remove clutch pedal spring (1).
TRE3918A
????????????- 06--2002
8. Unscrew the screws (1) securing the shuttle

lever arm bracket to the footboard.
TRE3094A
9. Unscrew the bolts (1) securing the footboard to

the gearbox on left hand side.
TRE3918A
9
10. Remove the bolt (1) securing the footboard to the
roll bar mounting bracket.
1
TRE3012A
10
11. Unscrew the bolts(1) securing the footboard to
gearbox on left hand side. Remove the bolts (2)
fastening the ladder to the footboard. 1
2
TRE3877A
11
???????????? - 06--2002
12. Remove the split pin (1) and the pin (2) of throttle
lever on right hand side.
1
TRE3016A
12
13. Remove brake pedal springs (1).

1
TRE3904A
13
14. Unscrew the Allen screw (1) and bolt (2) securing
the handbrake lever fastening bracket at right
hand side to remove the lever.
2
TRE3148A
14
15. Remove the screws (1) and take the remote
valve lever support completely.
TRE3007A
15
????????????- 06--2002
16. Remove the bolts (1) and take off the seat (2)
completely. 2
1
1
TRE3064A
16
17. Unscrew the bolts( 1) securing the hydraulic

tubes fastening bracket at right hand side.
1
TRE3877A
17
18. Unscrew the bolts (1) securing the footboard to
the gearbox on right hand side.
1
TRE3904A
18
19. Remove the bolt (1) securing the footboard to the
roll bar mounting bracket.
TRE3913A
19
???????????? - 06--2002
20. Unscrew the bolts(1) securing the footboard to

gearbox on right hand side. Remove the bolts (2)
fastening the ladder to the footboard.
TRE3875A
2
20
21. Unscrew the bolts(1) securing the roll bar to final

drive casings on right and left hand sides.
TRE3913A
21
support frame on right hand side.
TRE2136A
22
support frame on left hand side.
TRE2137A
23
????????????- 06--2002
24. Remove the screws (1) securing the rear hood

to the support frame.
1
TRE3057A
24
25. Unscrew the keyhole bracket(1), turn indicator

bracket (2) and light control switch (3). Remove 4
the screws (4) fastening the rear hood.
1
2
3
TRE3056A
25
26. Unscrew the bolts (1) securing the bonnet and
remove the lover (2) and upper (3) fixing bolts of
gas strut. Take off the bonnet.
3
1
1
TRE3127A
26
27. Remove the retaining bolts (1) on the control
panel and detach the electrical connector. Re-
move the rev counter and the control panel (2)
1 1
1 1
TRE2146A
2
27
???????????? - 06--2002
28. Remove the screws (1) securing the rear hood.

Take off the cover (2) and unscrew the nut under 2
the cover (2) to take off the steering wheel (3). 4
Take off the plastic cover (4) and take off the rear
hood (5).
3
5
TRE3131A
28
????????????- 06--2002
Assembly
1. Install the rear hood, and plastic cover. Install the
steering wheel.
2. Install the electrical connector and rev counter

and instrument cluster.
3. Install the bonnet with its gas strut.

4. Install the keyhole bracket, turn indicator bracket
and light control switch to the rear hood.
5. Install the Roll Bar.

6. Install left and right footboards.
7. Install the ladders to the footboards on both
sides.
8. Install the bolts securing the hydraulic tubes
fastening bracket at right hand side.
9. Install the operator’s seat.
10. Install the remote valve lever support and its
linkages on right hand side to the fender.
11. Install the handbrake lever.
12. Install brake pedal springs.
13. Install the throttle pedal lever.

14. Install the shuttle lever arm bracket on left hand
side.
15. Install the clutch pedal spring.
16. Install the FWD and Shuttle Levers.
17. Install the PTO clutch lever support.
???????????? - 06--2002

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TD60 – TD70 – TD80 – TD90 – TD95

STRADDLE MOUNT MODEL TRACTORS

TEXT AND ILLUSTRATIONS ARE THE PROPERTY

No part of the text or illustrations

NEW HOLLAND ????????. – ??????????????????????????????????

General Instructions and Health and Safety Chapter 1

Section Description Page

00 000 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Engine System Chapter 1

Section Description Page

10 000 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

18 000 General Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Mechanical Transmission (12x4) Chapter 1

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

Reverser (12x12) Chapter 2

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

Reverser and Creeper (20x12) Chapter 3

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

DRIVE LINES SECTION 23

Drive Lines Chapter 1

23 000 Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Front Axle Mechanical Transmission Chapter 1

25 000 Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

REAR AXLE AND TRANSMISSION SECTION 27

Rear Axle And Transmission Chapter 1

27 000 Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

POWER TAKE–OFF SECTION 31

Mechanical Power Take – Off Chapter 1

31 000 Main specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Braking System Chapter 1

31 000 Main specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

HYDRAULIC SYSTEM SECTION 35

Rear Mechanical Hydraulic Lift Chapter 1

35 000 Main specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Open Centre System Auxiliary Control Valves Chapter 2

35 000 Main data – Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Trailer Brake Auxiliary Control Valve Chapter 3

35 000 Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

41 000 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

FRONT AXLE AND WHEELS SECTION 44

Front Axle And Wheels Chapter 1

44 000 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

ELECTRICAL SYSTEM SECTION 55

55 418 Analogue instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Starting System Chapter 3

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

Charging System Chapter 4

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

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

Electrical Circuits Chapter 6

55 100 Fuses (all versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

BODYWORK AND DRIVER POSITION SECTION 90

Bodywork And Driver Position Chapter 1

ROTATING SHAFT SEALS

NOTES FOR SPARE PARTS

NOTES FOR EQUIPMENT

HOW TO MOVE THE TRACTOR WITH THE BATTERY REMOVED

PAY ATTENTION TO THIS SYMBOL

TO PREVENT ACCIDENTS if they are certified operators to assist in the

START UP HYDRAULIC SYSTEMS

◊ To remove the wheels, block both front and rear

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

GENERAL SPECIFICATION 3–cylinder 4–cylinder

Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . camshaft