MF 2430 2435 2440 Inglese.1

MF 2430 - 2435 - 2440
TRAINING MANUAL
P/N 3681774M1 - EDITION 01-2006
MASSEY FERGUSON
INTRODUCTION
This manual refers to the MF 2430 - 2435 - 2440 tractor manufactured by ............ It is divided into sections
identified by numbers with three/four figures. The pages of each section are numbered separately.
- The subjects described are listed in the general index and appear in more detail in the specific index of the sec-
tion in question.
- The date of the relative edition/update is printed at the bottom of each page.
- Pages where future updates are made will have the same printed number but the new date of issue.
These pages will be supplied by a reprint of the duly updated index.
- The information in this manual was up to date on the date printed on the page. Since ........... constantly
updates its range of products, some of the information could no longer be up to date following modifications
made for technical or commercial reasons, or to adapt the machines to the laws in force in the various countries
of use.
Consult our Dealers and Assistance Centres if discrepancies are found.
LIABILITY
........... declines all liability for incorrect servicing operations, use of spurious spare parts and tampering with parts
of the product.
The person in charge of the personnel is responsible for ensuring that the safety regulations described in the manual
are applied. This person must be qualified to carry out the operations required, be familiar and strictly comply with
the prescriptions in this manual and the general safety regulations applicable. Failure to comply with the safety reg-
ulations may lead to persons being injured and damage to machine components.
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PURPOSE OF THE MANUAL
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This manual is mainly dedicated to workshop staff.

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This manual contains all the necessary technical information concerning the machine, allowing the servicing techni-
cians to work in safety and guarantee that the product remains perfectly efficient throughout its working life. How-
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ever, it is not a substitute for thorough professional training.

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To correctly carry out the servicing activities, it is assumed that the place of work conforms to the current standards
governing safety and hygiene.
This manual contains all the information required to correctly carry out modifications, tune ups, repairs and over-
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hauls.
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Read this manual carefully before proceeding with any work. Correct repairs are guaranteed and the operators safe-
guarded from accidents by compliance with the instructions supplied and by using the right tools.
COPYRIGHT
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This publication may neither be fully nor partly duplicated in any form without the prior authorisation of ...........
The illustrations and descriptions in this publication are purely indicative.
The Manufacturer reserves the right, at any moment, to make any modifications to the machines considered neces-
sary for improvement purposes or for manufacturing and marketing requirements, without being obliged to give
prior notice.
...........
VIA G. MATTEOTTI, 7 - 42042 FABBRICO (RE) - ITALY
PRINTED MATERIAL S/N 3681774M1 EDITION 01-2006
WRITTEN BY SST s.r.l. - TORINO
ii P/N 3681774M1 Edition 01-2006

TABLE OF CONTENTS
Section N° Edition
1 GENERAL INFORMATION
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 01-2006
2 ENGINE
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 01-2006
3 CLUTCH
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 01-2006
4 GEARBOX
Speedfive and Powerfive mechanical gearbox . . . . . . . . . . . . . . . . . . 400 01-2006
5 TRANSMISSION
Rear axle and side final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 01-2006
Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510 01-2006
6 POWER TAKE-OFF
Power take-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600 01-2006
7 HYDRAULIC SYSTEMS
Hydraulic systems - Rear power lift. . . . . . . . . . . . . . . . . . . . . . . . . . 700 01-2006
8 STEERING
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 01-2006
9 BRAKES
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 01-2006
10 ELECTRICAL SYSTEMS
Electrical system - Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 01-2006
Electrical system - Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010 01-2006
Electrical system – Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . 1020 01-2006
Electrical system – Recharging system . . . . . . . . . . . . . . . . . . . . . . . 1030 01-2006
Electrical system - Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040 01-2006
Electrical system – Electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . 1050 01-2006
11 CAB
Cab and A/C system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100 01-2006
P/N 3681774M1 Edition 01-2006 iii

iv P/N 3681774M1 Edition 01-2006
SECTION 100
GENERAL INFORMATION
SECTION 100 - GENERAL INFORMATION
TABLE OF CONTENTS
Description Page
SAFETY NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-3

Personal risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-3
Avoid accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-3
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-3
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-5
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-5
Electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-5
Hydraulic circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-5
Wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-6
Unhitching and re-hitching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-6
GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 100-7

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 100-7
Adjuster shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 100-7
Spinning shaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 100-7
O-ring toroid seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 100-7
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 100-7
Spring pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 100-7
Notes about spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 100-8
SPECIFIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 100-8
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-9
Meaning and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-9
DANGER SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-11

Positions of the danger decals - WEO markets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-11
SEALING AND FIXING SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-16
LUBRICANTS AND FUELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-17
CONVENTIONAL UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-18

Units of measurement (international system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-18
Conversion values for Imperial measurement system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-18
STANDARD DRIVING TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-19

Screws with metric threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-19
Nuts with metric threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-20
100-2 P/N 3681774M1 Edition 01-2006

SAFETY NOTES
Personal risk
This warning symbol draws your attention to mes-
sages that are important for your safety.
Read the safety notes carefully and comply with the
recommended precautions to avoid potential dan-
gers and safeguard your health and personal
safety.
This symbol appears in the text along with the fol-
lowing key words:
WARNING - To warn of unsuitable repair opera-
tions with potential consequences that could affect
the repair technician’s safety.
DANGER - To indicate warnings that specifically
2LA0663
denote potential dangers for the operator’s safety
or for other directly or indirectly involved persons. 1
Avoid accidents
The majority of accidents that occur in workshops are caused by failure to comply with some simple and fun-
damental rule of caution and safety. Therefore IN MOST CASES THEY CAN BE AVOIDED: all that’s needed is
to foresee the possible causes and consequently act with due care and caution.
However well a machine is designed and built, it is never possible to absolutely exclude all hazardous
situations.
A careful and prudent mechanic is the best guarantee against accidents.
Strict compliance with even only one elementary safety rule would be sufficient to avoid many serious acci-
dents.
DANGER. Never carry out any cleaning, lubricating or servicing operations whilst the engine is running.
General rules
- Carefully comply with the prescribed maintenance and repair procedures.
- Do not wear rings, watches, jewellery, unfastened or hanging garments, such as ties, torn clothing,
scarves, unbuttoned jackets or with open zip-fasteners that could become caught in moving parts. You
are advised to wear approved safety garments, such as: non-slip footwear, gloves, safety goggles, hel-
mets, etc.
- Never carry out repair work on the machine whilst someone is sitting in the driver’s seat, unless this per-
son is an authorized operator who is helping with the operations in progress.
- Only operate the machine and use the relative implements when you are sitting in the driver’s seat.
- Do not carry out any work on the machine when the engine is running, unless this is specifically pre-
scribed.
- Stop the engine and make sure that the pressure has been relieved from the hydraulic circuits before
removing any caps, covers, valves, etc.
- All servicing work must be carried out with the utmost care and attention.
- Ladders and platforms used in workshops or in the field must comply with the current safety regulations.
- Disconnect the batteries and label all the controls to warn others that work is being carried out. Block
the machine and all implements that must be raised.
- Do not check or fill fuel tanks, batteries, or use ignition fluid when smoking or near naked flames as
these liquids are inflammable.
- The brakes are disengaged when released by hand for servicing work: in these cases, the machine must
be kept under control by means of chocks or similar.
P/N 3681774M1 Edition 01-2006 100-3

- The fuel pump nozzle must always remain in contact with the filler. Keep it there until you finish filling so
as to prevent sparks from being created through an accumulation of static electricity.
- Only use the prescribed hitching points when towing. Make the connections with care: make sure that
the provided pins and/or latches are firmly fixed in place before beginning to tow. Keep well away from
tow bars, ropes or chains that are pulling a load.
- If possible, use a trailer or truck with a lowered loading platform when transferring a faulty machine.
- When a machine must be loaded on to or unloaded from the transport vehicle, choose flat ground able
to provide a solid bearing surface for the wheels of the trailer or truck. Fasten the machine to the truck
or trailer platform firmly and block the wheels as required by the haulage contractor.
- Only use auxiliary power sources with grounding circuits able to prevent electric shocks from electric
heaters, battery chargers and similar equipment.
- Use hoists and similar equipment with an adequate carrying capacity if heavy parts must be lifted or
transported.
- Pay particular attention to bystanders.
- Never pour petrol or diesel fuel into wide and shallow open vessels.
- Never use petrol, diesel fuel or other inflammable fluids as detergents: use the non-flammable and non-
toxic solvents available in the shops.
- Protect your eyes by wearing goggles with side guards when using compressed air to clean parts.
- Limit the pressure to 2.1 bars at most, in compliance with the local or national laws in force.
- Do not run the engine in a closed room without adequate ventilation.
- Do not smoke, use naked flames or create sparks in the vicinity when refuelling or handling easily
inflammable materials.
- Do not use flames as a means of lighting when repairing the machine or searching for "leaks".
- Move with the greatest care when working under, on or near the machine. Wear approved safety gar-
ments such as helmets, goggles and safety footwear.
- When the engine must be running in order to make the inspections, ask for help from an operator who
must remain in the driver’s seat and keep the mechanic under visual control at all times.
- If servicing is required away from the workshop, park the machine on flat ground and block it. If work on
slopes is unavoidable, block the machine and move it to a horizontal surface as soon as this can be done
within a certain safety margin.
- Do not use crushed or bent chains or ropes when lifting or towing are required. Always wear suitably
thick gloves to handle them.
- Chains must be firmly fixed in place: make sure that the fastening is sufficiently strong to bear the load
in question. Have all bystanders move well clear of the connection, chains or ropes used for lifting or
towing.
- The area where the servicing operations are carried out must always be kept CLEAN and DRY. Puddles or
water or oil stains must be cleaned up immediately.
- Do not form heaps of rags soaked in grease or oil: they could catch fire very easily. Always put them in a
closed metal container.
Check, regulate and lock the driver’s seat before starting the machine or implements. Make sure that
there are no bystanders within the range of action of the machine or implements.
- Do not carry objects that could drop unseen into the internal mechanisms of the machine, in your pock-
ets.
- Wear goggles with side guards, helmets, special safety footwear and gloves when you could be struck by
metal objects and similar, thrown up during the servicing work.
- Use the necessary safety protections when welding operations are carried out: dark glasses, helmets,
dungarees, special gloves and footwear. Dark glasses should also be worn by the people not actually
doing the work but who are in the vicinity when welding is being carried out. NEVER LOOK AT THE
WELDING ARC WITHOUT ADEQUATE EYE PROTECTION.
- Metal ropes become frayed with wear: always protect yourself in an adequate way when handling them
(wear gloves, goggles, etc.).
100-4 P/N 3681774M1 Edition 01-2006

- Handle all parts with the utmost care. Keep your hands and fingers well away from gaps, wheelwork and
similar. Always use approved personal protection devices such as safety goggles, gloves and safety foot-
wear.
Before you get on to the tractor, it is essential for you to have read and strictly
complied with the instructions in the operation and maintenance manual.
Starting
- Do not allow the engine to run in a closed room without adequate ventilation systems able to dispose of
the exhaust gas.
- Never put your head, body, limbs, feet, hands or fingers near spinning fans or belts.
Engine
- Before removing the radiator plug completely, turn it very slowly to relieve the pressure in the circuit.
Coolant fluid must only be topped up with the engine at a standstill or idling, if hot.
- Do not refuel whilst the engine is running, particularly if it is hot. This could lead to the risk of a fire out-
break if fuel were to be spilt.
- Do not attempt to check or adjust the tension of the fan belts with the engine running.
Do not regulate the fuel injection pump whilst the machine is on the move.
- Never lubricate the machine when the engine is running.
Electrical systems
- If auxiliary batteries must be used, remember that the cables must be connected in the prescribed way
at both ends: (+) with (+) and (-) with (-). Do not short-circuit the terminals. THE GAS ISSUED BY BAT-
TERIES IS HIGHLY INFLAMMABLE. Always leave the battery compartment uncovered when recharging,
to ensure a more efficient ventilation. Never ever check the battery charge using the "jumpers" obtained
by placing metal objects on the terminals. Prevent sparks or flames in the battery area. Do not smoke as
this could cause explosions.
- Before proceeding with any work, make sure that there are no fuel or electricity leaks: repair these leaks
before proceeding.
- Do not recharge batteries in closed places: make sure that there is adequate ventilation to prevent acci-
dental explosions from occurring due to an accumulation of the gas issued when recharging.
- Always disconnect the batteries before working on the electrical system.
Hydraulic circuits
- Fluid leaking from a very small hole can be almost invisible yet have sufficient force to penetrate under
the skin. Use a piece of cardboard or wood if you must check for such leaks. NEVER CHECK FOR LEAKS
WITH THE HANDS: immediately seek medical help if fluid penetrates under the skin. Serious infections
or dermatitis may occur if you fail to receive prompt medical treatment.
- Use the right tools to check the pressure in the circuits.
P/N 3681774M1 Edition 01-2006 100-5

Wheels and tyres

- Make sure that the tyres are correctly inflated to the pressure indicated by the manufacturer.
Periodically check the rims and tyres to make sure that they are not damaged.
- Keep to the side of the tyre when correcting the inflation pressure.
- Only check the pressure with the machine unloaded and the tyres cold, to prevent incorrect measure-
ments and overpressures. Do not reuse repaired wheel parts as badly made welds, brazing or heating
could have weakened them and cause breakage.
- Never cut or weld a rim with a tyre mounted and inflated.
- Block the machine at the front and rear on all wheels before demounting these latter. After you have
jacked up the machine, prevent it from dropping by placing supports underneath, in compliance with the
current laws in force.
- Deflate the tyres before removing any objects jammed between the treads.
- Never inflate the tyres with inflammable gas. This could lead to explosions and injure bystanders.
Unhitching and re-hitching

- Lift and handle all heavy parts with lifting equipment of an adequate capacity. Make sure that the parts
are supported by appropriate harness and hooks. Use the lifting eyelets provided. Take care of bystand-
ers near the load being lifted.
- Handle all parts with the utmost care. Do not put your hands or fingers between one part and the next.
Wear approved safety garments such as goggles, gloves and safety footwear.
- Do not twist metal ropes or chains. Always wear safety gloves when handling cables or chains.
100-6 P/N 3681774M1 Edition 01-2006

GENERAL INSTRUCTIONS
IMPORTANT WARNING
All the maintenance operations and repairs described in this manual must be carried out by the
........... assistance network only, in strict compliance with the indications given and using spe-
cial tools if necessary.
Anyone who carries out the described operations without strictly complying with the instruc-
tions becomes personally responsible for any consequent damage.
Battery
Before proceeding with any work, disconnect and insulate the negative battery cable unless other instruc-
tions are given for the specific operation required (for example: an operation where the engine must be run-
ning). After the operation has been terminated, detach this cable in order to finish the work.
Adjuster shims
Whenever adjustments are made, select the adjuster shims by measuring them one by one with a
micrometre and then adding the values gauged: do not trust in the erroneous measurement of the complete
pack or in the nominal value given for each ring.
Spinning shaft seals

Comply with the following instructions to correctly mount the spinning shaft seals:
- before they are mounted, allow the seals to soak for at least half an hour in a bath of the same type of
oil as that they will be sealing;
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- thoroughly clean the shaft and make sure that its operating surfaces are not damaged;
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- position the sealing lip towards the fluid. If the lip is the hydrodynamic type, the direction in which the
scoring points (considering the direction in which the shaft spins) must tend to make the fluid flow
towards the internal part of the seal;
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- spread a film of lubricant (oil is preferable to grease) on the sealing lip and fill the gap between the seal-
ing lip and dust guard lip of double-lipped seals with grease;
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- fit the seal into its housing by pressing or use a punch with a flat contact surface. Never hit the seal with
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a hammer or mallet;
- when a seal is mounted, make sure that it is inserted perpendicular to its housing. After mounting, make
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sure that it touches the supporting ridge (if applicable);

- to prevent the seal lip from being damaged by the shaft, fit an adequate guard whilst the two parts are
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being assembled.
O-ring toroid seals

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Lubricate the o-ring seals before they are fitted into their housings to prevent them from rolling around
themselves and becoming twisted as they are mounted, something that would compromise their sealing
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ability.
Bearings
It is advisable to proceed in the following way when mounting bearings:
- heat them to 80 − 90 °C before fitting them on to their respective shafts;
- cool them before externally fitting them into their housings.
Spring pins
When mounting split tube spring pins, make sure that their notches point in the direction of the force exer-
cised on the pin itself.
Spiral spring pins do not need to be set in any direction when mounted
P/N 3681774M1 Edition 01-2006 100-7

Notes about spare parts

Only use genuine ........... spare parts as only these are able to guarantee the same quality, life and safety as
the original components mounted on your machine.
Only genuine ........... spare parts can provide this guarantee.
Give the following information when ordering spare parts:
- tractor model (commercial denomination) and chassis number;
- engine type and number;
- order number of the required part, which can be found in the "Spare Parts Catalogue", according to
which the orders are fulfilled.
SPECIFIC EQUIPMENT
The equipment that ........... proposes and illustrates in this manual is:
- explicitly researched and designed for work on ........... tractors;
- necessary for reliable repairs;
- carefully made and thoroughly tested to provide efficient and long-lasting tools.
Repairers should also remember that using the right equipment means:
- working in technically optimum conditions;
- obtaining the best result;
- saving time and effort;
- working in greater safety.
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100-8 P/N 3681774M1 Edition 01-2006

SYMBOLS
Meaning and use

Certain symbols are used in this manual to underline and draw the reader’s attention to certain particular
aspects of the description, or to indicate the type of operation being illustrated.
The meanings of the various symbols used are described in the table below.
SYMBOL MEANING NOTES
Indicates a danger with the risk of even mortal

Warning: accident for the user.
! personal risk Pay the utmost attention to the texts indicated
with this symbol.
Indicates a danger with the risk of damage to the

Warning: environmental hazard natural environment. Pay the utmost attention to
the texts indicated with this symbol.
Warns that the machine or some other personal

Caution
property of the user could be damaged.
Indicates a warning, a note about key functions or

Note
some other useful information.
This indication means that there is a considerable

risk of damage to a part, e.g. when the wrong tool
! Prevent damage to material
is used or an assembly made by means of an
incorrect procedure.
Special tool/ A special tool or specific equipment must be used

specific equipment for the operations.
A visual inspection must be made. The user must

Visual observation read a measurement value, check an indication,
etc...
The operator must listen to a noise made when

Listen the machine operates. The inspection serves to
identify abnormal noise.
Symbol associated with a value: use a torque

Tighten and torque wrench to suit the value given and measure the
dwell angle at that torque value.
Symbol associated with two values: use a torque

Torquing with angle wrench to suit the value given and measure the
dwell angle at that torque value.
Operation carried out in order to obtain precise

Adjustment/Regulation
values (pressure, preload, relative distance, etc.).
Operation carried out in order to measure required

Measuring/Gauging to restore optimum functional conditions in the
correct way.
P/N 3681774M1 Edition 01-2006 100-9

SYMBOL MEANING NOTES
Lubrication (oiling, greasing, etc...) of a part/

Lubrication
device.
Sealant required in order to couple two parts

Sealing/Gluing
together.
Positioning Coupling with relative position references.
Indicates that only ........... spare parts must be

........... Spares.
used.
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100-10 P/N 3681774M1 Edition 01-2006

DANGER SIGNS
If a tractor part bearing a decal with a safety note (yellow colour) is replaced, it is ESSENTIAL to affix the
same decal to the spare part.
A complete list of all the places where decals are applied is given below.
Positions of the danger decals - WEO markets
1 2 3 4 5 6
17
16
15 14 12 13 11 10 9
4LA0129
Positions of the danger decals

Complete set of danger decals N. 3559 552 M95
P/N 3681774M1 Edition 01-2006 100-11

REF. CODE POSITION DESCRIPTION SYMBOL
WARNING: Danger of entangle-

On the left and ment. Keep your hands well clear of
right sides of the the fan blades when the engine is
1 3559 556 M1
radiator or mani- running.
fold. Always keep the guards and screens
mounted.
WARNING: Danger of entangle-

ment. Keep your hands well clear of
On both sides of spinning parts. Take care not to
2 3559 559 M1
the radiator. become entangled in the belts or pul-
leys whilst the engine is running. Keep
the guards in place.
WARNING: Risk of damage to the

brake circuit.
Near the brake Carefully read the danger warnings
3 3647 157 M1 circuit oil reser- and the instructions shown in the
voir. operation and maintenance manual
before starting maintenance opera-
tions.
WARNING: Electric shock.

Always disconnect the negative bat-
On the starter
4 3559 555 M1 tery terminal before removing the
motor.
cover of the solenoid and before serv-
icing the electrical system.
DANGER: Danger of being crushed.

DO NOT start the engine by shorting
across the terminals of the starter
On the starter
5 3648 152 M1 motor. This operation will place your
motor.
life in danger.
Only start the engine when you are
sitting in the driving seat.
100-12 P/N 3681774M1 Edition 01-2006

DANGER: Danger of being crushed.

Near handbrake When stopping the tractor, always
6 3647 643 M1
lever. apply the parking handbrake before
getting off.
DANGER: Danger of collisions and

On the right rear severe accidents. Stand by the side of
mudguard, with a tractor when using the external
7 3647 299 M1
electronic power power lift controls. DO NOT STAND
lift only. between the tractor and the tool: you
could be hit.
DANGER: Danger of entanglement.

Keep well away from spinning shafts.
On the inside of Take care NOT to remain caught up
8 3559 553 M1 the rear mud- by the PTO driveline.
guard. Keep all the guards mounted on the
transmission shafts of the tractor or
implements.
DANGER: Danger of collisions and

On the left rear severe accidents. Stand by the side of
mudguard, with a tractor when using the external
9 3647 463 M1
electronic power power lift controls.
lift only. DO NOT STAND between the tractor
and the tool: you could be hit.
P/N 3681774M1 Edition 01-2006 100-13

Inside cab on top

for tractors with- WARNING: Danger of being
out second pas- crushed. DO NOT allow anyone to sit
10 3647 032 M1 senger seat and on the mudguards or on any other
for tractors with part of the tractor or towed imple-
frame on left ments.
mudguard
Tractors with seat

belts. On the pil-
WARNING: Danger of being
lar inside the cab
crushed.
11 3648 447 M1 or on the left
Always wear the seat belt when the
mudguard for
safety frame is in the vertical position.
tractors with
safety frame.
DANGER: The tractor could overturn

Inside the cab on
and crush your chest. Hold firmly on
top or on the left
to the steering wheel if the tractor is
12 3559 557 M1 mudguard for
overturning.
tractors with
DO NOT leave your seat or jump off
safety frame.
the tractor.
Inside the cab on

WARNING: Pay attention.
top or on the left
Consult the operation and mainte-
13 3559 558 M1 mudguard for
nance manual for information about
tractors with
safety and how to use the tractor.
safety frame.
100-14 P/N 3681774M1 Edition 01-2006

DANGER: Jets of hot steam or hot

On engine cooling water. Protect the face. The radiator
14 3559 554 M1 circuit expansion will be under pressure when the
vessel. engine is hot. Remove the plug with
caution when the engine is cold.
WARNING: Very hot surfaces. The

On both sides of hands and fingers could be scorched.
15 3647 275 M1 the radiator or Keep away from hot parts. Observe a
intake manifold. safety distance. Keep protections fit-
ted when the engine is running.
Position near the DANGER: Beware of lifted loads.

16 3664 188 M1 front power lift Keep at a safe distance to prevent
(where fitted). being hit or crushed.
WARNING: Danger of electric shock.

Positioned near Always disconnect the negative bat-
17 3647 158 M1 the battery sup- tery terminal before removing the
port. battery or before servicing the electri-
cal system.
P/N 3681774M1 Edition 01-2006 100-15

SEALING AND FIXING SEALANTS
Apply the sealants given in the table to the surfaces to couple.

Prepare the surfaces in the following way before applying the sealants:
- remove any deposits with a metal brush;
- thoroughly degrease the surfaces with one of the following detergents: trichloroethylene, wash oil or
water and soda.
DENOMINATION TYPE USE
Weak locking and sealing of screws,

Weak locking Loctite 222
adjuster screws.
Threaded couplings
locking and sealing
Medium-strong locking and sealing of

Medium-strong thread locking Loctite 242
threaded parts in general.
Highly resistant fixing, locking and sealing of

Strong thread locking Loctite 270
stud bolts, nuts, screws.
Capillary locking and sealing of already

Penetrating thread locking Loctite 290
mounted parts. Microporosity sealing.
Locker Loctite 601 Highly resistant fixing of coupling surfaces.

Smooth couplings
Medium-strong resistance fixing of bushes,

Fixer Loctite 641 bearings, etc. Demounting possible using
normal tools.
Highly resistant fast fixing of cylindrical

Super-locker Loctite 638
parts. Dynamic work.
Fast fixing of cylindrical parts highly resist-

High-temperature locker Loctite 648
ant to heat.
Sealing of threaded unions on hydraulic or

Hydraulic
Hydraulic-hermetic Loctite 542

fittings
pneumatic pipes up to ¾" in diameter
Pipe-hermetic Loctite 572 Sealing of threaded unions in general.
Sealing of flat surfaces.

of surfaces
Thick flat-hermetic Loctite 510

Manual application.
Sealing
Sealing of precise flat surfaces. Applied by

Flat-hermetic Loctite 573
hand or by screen-print systems.
Hermetic plastic - spray type Perkins Hylo- Sealing of cylinder head surfaces.
Engine
mar power
Hermetic - paste type part Sealing of sump, cover surfaces.
100-16 P/N 3681774M1 Edition 01-2006

LUBRICANTS AND FUELS
Quantity dm3
(litres)
Assembly to be Ambient
Specifications AGROLUBE
filled temperature
2430
2435
2440
 LOWER THAN 0 °C 
API CE/SG
CCMC D4 FROM 0 °C TO 27 °C 
MB 227.0
Engine with filter 7.5 7.5 7.5
 HIGHER THAN 27 °C KRONOS 30
API CE/CF-4/SG
ALL
ACEA E2-B2-A2 KRONOS 15W40
TEMPERATURES
MB 228.1
Synch reverse shuttle

API GL 4 ALL
gearbox, steering and 35 35 35 SINCROS/B
MF 1135 TEMPERATURES
hydraulic circuit (1)
Powershuttle gearbox,
MF CSM- ALL
steering and hydraulic 35 35 35 SINCROS/C
MF 1135-1141 TEMPERATURES
circuit (2)
API GL 5 ALL
Rear final drives (each) 4 4 4 KRIPTOS 80W-90
MIL-2105 D TEMPERATURES
API GL 4 ALL
Front axle differential box 3.5 5.0 5.0 SINCROS/B
MF 1135 TEMPERATURES
API GL 5 ALL
Front final drives (each) 1.5 1.5 1.5 KRIPTOS 80W-90
MIL-2105 D TEMPERATURES
ALL
Braking circuit 0.9 0.9 0.9  XERONS RED (3)
TEMPERATURES
ALL G.M.P. GREASE

Greasing points    
TEMPERATURES EP
AGROLUBE MANTOS antifreeze in the following proportions according to

temperature:
Cooling
10 10 10 Ambient temperature Degrees °C -8° -15° -25° -35°
circuit
Antifreeze percentage % 20 30 40 50
ISO 8217 DMA,

Fuel tank 90 90 90 Decanted and filtered diesel fuel SB2869 A1 or A2
(cetane N.: 45 min)
(1) Use LANDINI M2 C 86 C, M-F 1135 compliant oils. LANDINI specifications require use of additives and anti-noise properties. The
use of different types of oil, or mixing other types of oil into the oil supplied with the tractor can lead to increased noise.
(2) Powershuttle transmission with electrohydraulic reverse shuttle uses ONLY AGROLUBE SINCROS / C oil.
(3) LANDINI S/ENG/I 102 compliant brake circuit mineral based oil.
P/N 3681774M1 Edition 01-2006 100-17

CONVENTIONAL UNITS OF MEASUREMENT
Units of measurement (international system)
Force in (Newtons) Conversion: 1N = 0.1019 kg

1 kg = 9.81 N
Power in kW (kilowatts) Conversion: 1 kW = 1.36 HP Other units:
1 kW = 1.34 HP HP (Horsepower)
1 CV = 0.736 kW HP (Horsepower)
1 HP = 0.986 HP
1 HP = 0.746 kW
1 HP = 1.014 HP
Torque in Nm Conversion: 1 Nm = 0.1019 kgm
(Newton meter) 1 kgm = 9.81 Nm
1 kgm = 10 Nm *
Specific consumption in g/kWh Conversion: 1 g/kWh = 0.736 g/HPh Other units:
(grams per kilowatt-hour) 1 g/HPh = 1.36 g/kWh g/CVh (grams per horsepower hour)
Pressure in kPa Conversion: 1 kg/cm2 = 1 Atm Other units:
(kilopascal) kg/cm2 (kilogram/square centimetre)
1 kg/cm2 = 98.1 kPa
Atm (Technical atmosphere)
1 kg/cm2 = 0.981 bar
psi (Pounds per square inch)
1 kg/cm2 = 1 bar *
1 kg/cm2 = 14.22 psi
1 bar = 100 kPa
1 bar = 1.02 kg/cm2
1 bar = 14.51 psi
1 psi = 6.9 kPa
1 psi = 0.069 bar
1 psi = 0.0703 kg/cm2
1 kPa = 0.145 psi
1 kPa = 0.0102 kg/cm2
1 kPa = 0.01 bar
* For the sake of simplicity, the Nm and bar units are converted according to ratios 10:1 and 1:1.
Conversion values for Imperial measurement system
0.1 mm = 3.937 mils

1 mm = 0.039 inch
1m = 3.281 ft
1 km = 0.621 miles
1 cm3 = 0.061 cu.in
1l = 1.759 pts (0.88 imp. qts)
1 bar = 14.5038 psi
1g = 0.035 oz. (0.564 dr)
1 kg = 2.205 lbs
1t = 1.102 short ton (0.9842 long ton)
0° C = 32° F
(In the case of temperature differences 1 °C = 1.8 °F)
100-18 P/N 3681774M1 Edition 01-2006

STANDARD DRIVING TORQUE VALUES
Screws with metric threads

Maximum driving torque values for metric threads in kgm.
Diameter Class 8.8 screw Class 10.9 screw Class 12.9 screw
x pitch
dxp Cadmium Cadmium Cadmium
Normal Galvanized Normal Galvanized Normal Galvanized
(mm) plated plated plated
3x5 0.153 0.137 0.122 0.193 0.173 0.15 0.234 0.21 0.187
4x0.7 0.316 0.284 0.252 0.438 0.394 0.35 0.53 0.477 0.424
5x0.8 0.612 0.55 0.49 0.87 0.78 0.69 1.03 0.93 0.82
6x1 1.06 0.95 0.85 1.48 1.33 1.18 1.78 1.60 1.42
8x1.25 2.51 2.25 2.00 3.54 3.18 2.83 4.24 3.02 3.39
8x1 2.65 2.38 2.12 3.73 3.35 2.98 4.47 4.03 3.57
10x1.5 5.11 4.60 4.08 7.19 6.47 5.75 8.63 7.76 6.90
10x1.25 5.34 4.81 4.27 7.51 6.75 6.00 9.02 8.11 7.21
12x1.75 8.65 7.78 6.02 12.14 10.92 9.71 14.59 13.13 11.67
12x1.25 9.24 8.32 7.39 12.95 11.66 10.36 15.61 14.05 12.48
14x2 13.77 12.39 11.01 19.38 17.44 15.50 23.26 20.93 18.60
14x1.5 14.59 13.13 11.67 20.61 18.55 16.48 24.69 22.20 19.75
16x2 20.91 18.82 16.72 29.38 26.44 23.50 35.30 31.77 28.24
16x1.5 21.83 19.65 17.46 30.81 27.73 24.64 36.93 33.24 29.54
18x2.5 28.87 25.98 23.09 40.61 36.55 32.48 48.77 43.69 39.00
18x1.5 31.42 28.28 25.13 44.28 39.85 35.42 53.06 47.75 42.44
20x2.5 40.81 36.73 32.64 57.34 51.61 45.87 68.77 61.89 56.00
20x2.5 40.81 36.73 32.64 57.34 51.61 45.87 68.77 61.89 56.00
20x1.5 43.97 39.58 35.17 61.93 55.74 49.54 74.28 66.25 59.42
22x2.5 54.23 48.85 43.42 76.32 68.69 61.05 91.53 82.37 73.22
22x1.5 58.26 54.43 46.60 81.93 73.74 65.54 98.36 88.53 78.68
24x3 70.51 63.45 56.40 99.08 89.17 79.26 119.33 107.44 95.50
24x2 74.53 67.13 59.67 105.10 94.59 84.08 125.51 112.95 100.40
27x3 100.36 92.75 82.44 144.89 130.40 115.91 173.46 156.12 138.76
27x2 109.18 98.26 87.34 153.06 137.75 122.44 183.67 165.30 140.97
30x3.5 130.79 125.81 111.03 198.93 177.24 157.54 235.71 212.14 183.60
30x2 151.02 135.91 120.81 212.24 191.02 169.79 254.08 228.67 203.26
P/N 3681774M1 Edition 01-2006 100-19

Nuts with metric threads

Maximum driving torque values for metric threads in kgm.
Diameter Standard nuts Lowered nuts Diameter Standard nuts Lowered nuts
x pitch galvanised galvanised x pitch galvanised galvanised
dxp dxp
(mm) MAT. 5S MAT. 8G MAT. 5S MAT. 8G (mm) MAT. 5S MAT. 8G MAT. 5S MAT. 8G
5x0.8 0.55 - 0.35 - 18x2.5 27.00 39.00 17.00 24.50
6x1 0.95 1.30 0.60 0.80 18x1.5 30.50 42.50 19.00 26.50
8x1.25 2.30 3.20 1.40 2.00 20x2.5 30.50 54.00 19.00 34.00
8x1 2.50 3.50 1.60 2.20 20x1.5 42.50 60.00 26.00 37.50
10x1.5 4.60 6.40 2.90 4.00 22x2.5 51.00 72.00 32.00 45.00
10x1.25 4.90 6.80 3.10 4.20 22x1.5 57.00 80.00 36.00 50.00
12x1.75 8.00 11.00 5.00 6.90 24x3 66.00 93.00 41.00 58.00
12x1.25 8.80 12.50 5.50 7.80 24x2 72.00 100.00 45.00 63.00
14x2 12.50 18.00 7.80 11.00 77x3 98.00 140.00 61.00 88.00
14x1.5 14.00 19.50 8.80 12.00 27x3 105.00 150.00 66.00 94.00
16x2 19.50 27.50 12.00 17.00 30x3.5 135.00 185.00 85.00 116.00
16x1.5 21.00 29.50 13.00 18.50 30x2 145.00 205.00 91.00 128.00
100-20 P/N 3681774M1 Edition 01-2006

SECTION 200
ENGINE
SECTION 200 - ENGINE
TABLE OF CONTENTS
Description Page
GENERAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-3
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-8
SECTIONS . . . . . . . .. . .. .. . .. .. . .. . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 200-10

Injection pump .. . .. .. . .. .. . .. . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 200-10
Injector . . . . . .. . .. .. . .. .. . .. . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 200-11
Turbocharger . .. . .. .. . .. .. . .. . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 200-11
DIAGRAMS AND CIRCUITS . . . . . . .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . . 200-12

Engine lubrication . . . . . . . . .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . . 200-12
Engine fuel feed . . . . . . . . . .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . . 200-13
Engine cooling . . . . . . . . . . .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . . 200-14
Engine intake and exhaust . .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . .. .. . .. .. . .. . . 200-15
ENGINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-16
COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-24

Compression degree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-24
Measuring procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-24
ADJUSTMENTS AND TESTS . . . . . . . . .. . .. .. . .. .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . .. 200-26

Valve play adjustment . . . . . . . . .. . .. .. . .. .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . .. 200-26
How to check the belt tension . . .. . .. .. . .. .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . .. 200-26
Injection pressure test . . . . . . . .. . .. .. . .. .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . .. 200-27
Jet inspection . . . . . . . . . . . . . . .. . .. .. . .. .. . .. . .. . . . . . . . . . . . . . . . . . . . . . . . .. 200-28
INJECTION PUMP TUNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-29
200-2 P/N 3681774M1 Edition 01-2006

GENERAL FEATURES
GENERAL FEATURES MF 2430
Engine
- Version/Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804C-33T
- Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERKINS
- Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diesel, four-stroke
- Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . turbocharger
- Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . direct
- Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 in line
- Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm) 94
- Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm) 120
- Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . (cm3) 3331
- Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
- Compression ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19:1
- Power ISO 3046/1 . . . . . . . . . . . . . . . . . . . . . . . . . . (HP/KW) 69/51
- Maximum power rate . . . . . . . . . . . . . . . . . . . . . . . . . . (rpm) 2500
- Maximum torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Nm) 217
- Maximum torque rate . . . . . . . . . . . . . . . . . . . . . . . . . .(RPM) 1600
- Idling rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(RPM) 1000
- Rotation direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anticlockwise (viewed from flywheel)
- Recommended diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . ISO 8217 DMA,

BS 2869 A1 or A2
(cetane N.: 45 min)
- Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forced lubrication with trochoid pump
- Capacity of lubricating oil reservoir. . . . . . . . . . . . . . . . (litres) 10
- Recommended lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . See section 100
- Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant/Radiator
- Capacity of cooling fluid reservoir. . . . . . . . . . . . . . . . . (litres) 5.5
- Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 vane fan
- Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal mechanical type

(all speeds)
- Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical
P/N 3681774M1 Edition 01-2006 200-3

Engine
- Version/Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804C-33T
- Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERKINS
- Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diesel, four-stroke
- Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . turbocharger
- Number of cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 in line
- Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm) 94
- Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm) 120
- Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . (cm3) 3331
- Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
- Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19:1
- Power ISO 3046/1 . . . . . . . . . . . . . . . . . . . . . . . . . . (HP/KW) 75/56
- Maximum torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Nm) 236
- Maximum torque rate. . . . . . . . . . . . . . . . . . . . . . . . . . (RPM) 1600
- Idling rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (RPM) 1000
- Rotation direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anticlockwise (viewed from flywheel)

BS 2869 A1 or A2
(cetane N.: 45 min)
- Lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forced lubrication with trochoid pump
- Capacity of lubricating oil reservoir . . . . . . . . . . . . . . . . (litres) 10
- Recommended lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . See section 100
- Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant/Radiator
- Capacity of cooling fluid reservoir . . . . . . . . . . . . . . . . . (litres) 5.5
- Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal mechanical type

(all speeds)
200-4 P/N 3681774M1 Edition 01-2006

Engine
- Version/Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804C-33T
- Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERKINS
- Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . diesel, four-stroke
- Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . turbocharger
- Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 in line
- Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm) 94
- Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm) 120
- Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . (cm3) 3331
- Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
- Compression ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19:1
- Power ISO 3046/1 . . . . . . . . . . . . . . . . . . . . . . . . . . (HP/KW) 81.5/60
- Maximum torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Nm) 251
- Maximum torque rate . . . . . . . . . . . . . . . . . . . . . . . . . .(RPM) 1600
- Idling rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(RPM) 1000
- Rotation direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anticlockwise (viewed from flywheel)

BS 2869 A1 or A2
(cetane N.: 45 min)
- Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forced lubrication with trochoid pump
- Capacity of lubricating oil reservoir. . . . . . . . . . . . . . . . (litres) 10
- Recommended lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . See section 100
- Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant/Radiator
- Capacity of cooling fluid reservoir. . . . . . . . . . . . . . . . . (litres) 5.5
- Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal mechanical type

(all speeds)
P/N 3681774M1 Edition 01-2006 200-5

GENERAL FEATURES MF 2430 MF 2435 MF 2440
LS
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With overhead valves controlled by

tappets
Suction valves
- number per cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
- diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm) 46
Exhaust valves:
- number per cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
- diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm) 37
Gap between valves and tappets with engine cold:
- intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm) 0.15-0.25
- exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm) 0.15-0.25
For further technical data about the timing system . . . . . . . . . . . .
Fuel system
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged
Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry filter with two elements removable for

maintenance
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perkins
Fuel cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper filter on injection pump delivery
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cam driven
Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perkins
Speed governor, at all rates, built into the pump. . . . . . . . . . . . . . Perkins
Automatic variable advance, built into the pump. . . . . . . . . . . . . . Perkins
Cold starting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostarter
For further technical data about the fuel system
- Fixed advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5°
- Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Perkins
- Pressure setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (bar) 181 - 191
200-6 P/N 3681774M1 Edition 01-2006

(Continued)
GENERAL FEATURES MF 2430 MF 2435 MF 2440
Lubrication
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . forced, by means of pump
Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gauze filter

(on pump intake)
cartridge filter
(on engine delivery)
Oil pressure at 1500 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . (bar) 3÷5
Recommended oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See section 100
Cooling
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . water, with forced circulation by

centrifugal pump operated by the gears of
the timing system
Capacity of cooling fluid reservoir. . . . . . . . . . . . . . . . . . . . . . . (l) 5.5
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vane fan
Fan diameter and number of blades . . . . . . . . . . . . . . . . . . . (mm) 7
Recommended fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See section 100
P/N 3681774M1 Edition 01-2006 200-7

ENGINE VIEWS
5LA0333
1
Engine view left side
1. Injector 10. Oil regulating valve

2. Glow plug 11. Oil drain cap
3. Intake manifold 12. Oil sump
4. Breather 13. Pressure sensor
5. Exhaust cap 14. Injection pump
6. Flywheel guard 15. Oil filler cap
7. Flywheel 16. Fan
8. Oil dipstick 17. Coolant pump
9. Oil filter
200-8 P/N 3681774M1 Edition 01-2006

5LA0334
2
Engine view right side
1. Valve cover 7. Turbocharger lubrication tube

2. Thermostat 8. Turbocharger lubrication exhaust tube
3. Alternator 9. Exhaust manifold
4. Poly-V belt 10. Shutdown valve
5. Pulley 11. Turbocharger
6. Starter motor 12. Upper oil filler cap
P/N 3681774M1 Edition 01-2006 200-9

SECTIONS
Injection pump
5LA0336
3
1. Control lever 7. Upper body
2. Centrifuge masses 8. Sleeve
3. Adjustment screws 9. Pumping piston
4. Control shaft 10. Cam
5. Adjuster lever 11. Spring
6. Stop solenoid 12. Delivery valve
1. Propeller shaft
2. Gear
3. Sleeve
4. Stop solenoid
5. Delivery valve
6. Spring
7. Cam
5LA0337
200-10 P/N 3681774M1 Edition 01-2006

Injector
1. Fuel delivery
2. Fuel return
3. Injector body
4. Pressure spring
5. Sealing needle
6. Nozzle
5LA0338
Turbocharger
1. Intake manifold
2. Compressor body
3. Compressor impeller
4. Bearing
5. Lubrication oil inlet
6. Bearing
7. Turbine body
8. Turbine impeller
9. Exhaust manifold
10. Lubrication oil drain
11. Exhaust gas inlet
5LA0342
P/N 3681774M1 Edition 01-2006 200-11

DIAGRAMS AND CIRCUITS
Engine lubrication
5LA0339
7
Engine lubrication circuit diagram
1. Piston lubrication pipe 8. Crankshaft

2. Rocker arm 9. Oil pump
3. Camshaft 10. Oil filter
4. Main delivery pipe 11. Oil sump
5. Oil radiator 12. Exhaust valve
6. Intermediate wheel 13. Turbocharger lubrication pipe
7. Adjustment valve 14. Turbocharger
200-12 P/N 3681774M1 Edition 01-2006

Engine fuel feed
5LA0335
8
Engine fuel feed diagram
1. Injectors 5. Fuel delivery pipe

2. High pressure pipe 6. Return pipe to tank
3. Return line 7. Fuel filter
4. Injection pump 8. Fuel tank
P/N 3681774M1 Edition 01-2006 200-13

Engine cooling
5LA0340
9
Engine cooling circuit diagram
1. Radiator 5. Coolant pump

2. Thermostat 6. Coolant pipes
3. Head 7. Oil radiator
4. Bypass
200-14 P/N 3681774M1 Edition 01-2006

Engine intake and exhaust
5LA0341
10
Engine intake and exhaust diagram
1. Turbocharger 3. Intake
2. Exhaust gas
P/N 3681774M1 Edition 01-2006 200-15

ENGINE TROUBLESHOOTING
Faults Possible causes Remedies
The engine fails to start 1. Battery slightly low. Check, recharge the battery and
replace it if necessary.
2. Connections to battery termi- Clean, inspect, tighten the nuts

nals corroded or slack. and, if necessary, replace any
excessively corroded terminals and
nuts.
3. Circuit open. Close the circuit.
4. Intake/exhaust valve play Adjust valve play.

incorrect.
5. Intake/exhaust valve seized. Replace.
6. Piston rings seized or broken. Replace piston ring.
7. Cylinder and piston rings worn. Lap and use larger size parts.
8. Big end pins and bearings Repair or replace.

seized.
9. Foreign body in combustion Demount and repair the chamber.

chamber. Remove the foreign body.
10. Intake/exhaust valve timing Adjust the valve play and check the
incorrect. timing of the intake/exhaust valves.
11. Incorrect timing of injection Correctly time the injection pump

pump on engine. on engine.
12. Impurities or water accumu- Detach the pipes, the injection

lated in the fuel pipes. pump and thoroughly clean them. If
necessary, clean and dry the fuel
tank.
13. No fuel in tank Fill tank.
14. No fuel supplied to injection Check and, if necessary, replace the

pump fuel pump.
15. Air in the fuel circuit. Check the pipes, unions, fuel pump,
filters and injection pump for air.
Lastly, bleed the circuit.
16. Starter motor damaged. Repair or replace the starter motor.
17. Faulty thermostarter. Check or replace the thermostarter.
200-16 P/N 3681774M1 Edition 01-2006

The engine starts but then 1. Idling rate too low. Adjust idling rate.
stops
2. Irregular fuel supply to injec- Check the flow rates on the test
tion pump bench.

tank.
4. Fuel filters clogged Replace integral filter cartridges.
5. Abnormal play between valves Adjust play between valves and

and rocker arms. rocker arms.
6. Valves seized, burnt or cracked. Replace the valves.
7. Air in the fuel circuit. Check the pipes, unions, fuel pump,
filters and injection pump for air.
Lastly, bleed the circuit.
8. Injection pump controls dam- Replace the damaged parts.

aged.
9. Damaged cylinder head seal. Replace the seal.
10. Piston ring seized or broken. Replace piston ring.
12. Big end pin and bearings Repair or replace.

seized.
13. Incorrect alignment of piston Correct gap alignment.

ring gap.
The engine overheats. 1. Centrifugal pump of engine Overhaul the pump and replace it if
cooling circuit inefficient. necessary.
2. Thermostat inefficient. Replace the thermostat.
3. Radiator partially inefficient. Remove any scaling by washing.

Check and repair any leaks from the
tubes.
4. Scaling in the places where Thoroughly wash.

coolant passes in the cylinder
head and crankcase.
5. The belt that controls the cen- Check and adjust the belt tension.
trifugal pump and fan is too
slack.
6. Cooling fluid (quantity insuffi- Top up the level in the expansion

cient). tank using the recommended fluid.
(Continued)
P/N 3681774M1 Edition 01-2006 200-17

7. Incorrect engine timing. Check and correctly time the

engine.
8. Injection pump with incorrect Adjust the injection pump on the

setting. test bench in compliance with the
setting table.
9. Air filter clogged. Clean the unit and replace the filter
element if necessary.
10. Cylinder liners cracked Replace.
11. Damaged cylinder head seal. Replace the seal.
12. Spring rings jammed or dam- Replace the spring rings.

aged.
Coolant temperature too low. 1. The radiator’s cooling capacity Replace the thermostat.
is excessive owing to incorrect
operation of the thermostat.
Low engine power and irregu- 1. Incorrect timing of injection Correctly time the injection pump
lar operation. pump on engine. on engine.
2. Damaged automatic variable Overhaul the injection pump and

advance in injection pump. adjust it on the test bench in com-
pliance with the setting table.
3. Worn timing system pin. Overhaul the injection pump and

adjust it on the test bench in com-
4. Irregular fuel supply to injec- Overhaul the injection pump and

tion pump adjust it on the test bench in com-
5. Speed governor, at all rates, Overhaul the injection pump and

damaged. adjust it on the test bench in com-
6. Injectors partially clogged or Clean, overhaul and correctly cali-

damaged. brate the injectors.

tank.
8. Fuel pump damaged. Replace fuel pump.
10. Length of rod between acceler- Adjust rod length.

ator and injection pump badly
regulated.
(Continued)
200-18 P/N 3681774M1 Edition 01-2006

11. Injection pump with maximum Adjust the maximum screw.

screw badly adjusted.
12. Drop in engine compression due Replace the damaged parts or over-
to: haul the engine if necessary.
- jammed spring rings;
- worn cylinder liners;
- worn or badly adjusted valves.
13. Big end bearing and main bear- Measure or replace.

ing worn.
14. Reduced cooling effect from Defective thermostat (check/

radiator. replace). Adjust fan belt tension.
15. Insufficient cooling fluid. Check to make sure that no water

leaks from the cooling system and
clean it.
16. Wrong fan belt tension. Adjust fan belt tension.
17. Thermostat worn. Check/replace.
Abnormal knocking in engine. 1. Injectors partially clogged or Clean, overhaul and correctly cali-
damaged. brate the injectors.
2. Impurities in the fuel pipes. Clean the pipes and replace any
that are excessively dented. Clean
the injection pump if necessary.
3. Incorrect timing of injection Correctly time the injection pump

pump on engine. on engine.
4. The engine shaft knocks owing Grind the drive shaft pins; fit larger
to excessive play on one or bearings and bearing rings.
more main or big end bearings,
or too much play in the sup-
ports.
5. Drive shaft unbalanced. Check shaft alignment and balanc-

ing. Replace the shaft if necessary.
6. Flywheel fixing bolts slackened. Replace the slackened bolts and

tighten all bolts to the prescribed
torque value.
7. Axes of connecting rods not Straighten the connecting rods,

parallel. check the parallelism of the axes
and, if necessary, replace the con-
necting rods themselves.
8. Piston knocking due to abnor- Ream the cylinder liners and fit
mal wear. larger pistons.
(Continued)
P/N 3681774M1 Edition 01-2006 200-19

9. Noisy piston pins owing to Fit a larger piston pin, true the pis-
excessive play in the piston ton bosses and big end bushes.
bosses and big end pin. Bushes Replace the bushes.
free in the big end housing.
10. Ticking due to noisy timing sys- Make sure that there are no broken
tem. springs, that the play between
stems and guides, tappets and
housings is not excessive. Adjust
the play between the valves and
rocker arms.
Abnormal smoke from the 1. Maximum flow rate of injection Adjust the injection pump on the
engine: black or dark grey pump too high. test bench in compliance with the
smoke. setting table.
2. The injection pump is delayed Correctly time the injection pump

too much or the automatic vari- on the engine or check the auto-
able advance is damaged. matic variable advance.
3. Too much injection pump Correctly time the injection pump

advance. on engine.
4. Injectors partially and/or totally Clean, overhaul and correctly cali-

clogged or with incorrect set- brate the injectors; replace them if
ting. necessary.
6. Drop in engine compression due Replace the damaged parts or over-

to: haul the engine if necessary.
- jammed spring rings;
- worn cylinder liners;
- worn or badly adjusted valves.
7. Injection pipes damaged. Check the condition of the pipes

and replace them if necessary.
8. Diesel fuel with the wrong Use suitable diesel fuel.

specifications.
9. Engine used at high tempera- Use a higher powered engine.

tures and altitudes.
10. Exhaust pipe clogged. Clean pipe.
Grey smoke tending towards a 1. The injection pump is delayed Correctly time the injection pump
whitish, grey-blue or blue col- too much or the automatic vari- on the engine or check the auto-
our. able advance is damaged. matic variable advance.
2. Injectors clogged or defective. Clean, overhaul and correctly cali-

brate the injectors; replace them if
necessary.
3. Oil oozes from the piston rings Replace the damaged parts or over-
owing to jammed rings or worn haul the engine if necessary.
liners.
(Continued)
200-20 P/N 3681774M1 Edition 01-2006

4. Too much injection pump Correctly time the injection pump

advance. on engine.
5. Oil oozes through the intake Overhaul the cylinder head.

valve guide owing to worn
valve stems or guides.
6. The engine fails to reach oper- Replace the thermostat.

ating temperature (thermostat
damaged).
7. Spring rings incorrectly Mount correctly.

mounted/positioned.
8. Intake/exhaust valve timing Adjust valve play and timing.

incorrect.
9. Diesel fuel with the wrong Use suitable diesel fuel.

specifications.
10. Water in the fuelling circuit. Check and repair.
The engine fails to stop. 1. Stopping electromagnet dam- Replace the electromagnet.
aged.
2. Speed governor, at all rates, Overhaul the injection pump and

damaged. adjust it on the test bench in com-
Oscillation, instability in the

rotation rate.
1. Piston rings seized or broken. Replace the spring rings.
- when idling

seized.
3. Big end bearings and main Measure or replace.

bearings worn.
4. Injection pump regulator dam- Repair or replace.

aged.
5. Water in the fuelling circuit. Clean and repair.
- when operating 1. Intake/exhaust valves seized. Replace.

seized.

bearings worn.

aged.
5. Water in the fuelling circuit. Clean and repair.

(Continued)
P/N 3681774M1 Edition 01-2006 200-21

Excessive vibration in engine. 1. Intake/exhaust valves jammed. Replace.
2. Spring rings jammed or dam- Replace.

aged.
3. Big end pin and bearings Repair or replace.

jammed.

bearings worn.
5. Big end fixing bolts slackened. Tighten to the prescribed torque

value.

aged.
7. Too much injection pump Check and adjust.

advance.
Excessive fuel consumption. 1. Loss of compression from valve Lap valve housing.
housing.
2. Radiator cools too much. Thermostat defective.
3. Excessive delay on injection Check and adjust.

pump
Excessive consumption of 1. Piston rings seized or broken. Replace.

lubricating oil.
3. Incorrect alignment of piston Correct gap alignment.

ring gap.
4. Inverted assembly of piston Mount correctly.

rings
5. Impurities in combustion cham- Demount and remove the impuri-

ber. ties.
6. Intake/exhaust valve guide Measure or replace.

worn.
7. Lubricating oil with wrong spec- Use suitable lubricating oil.

ifications.
8. Leaks from lubricating oil pipes. Repair/replace.
Water in the lubricating oil. 1. Damaged cylinder head hous- Replace.

ing seal.
2. Cylinder liners cracked Replace.
Fuel in the lubricating oil. 1. Intake/exhaust valves seized. Replace.
2. Piston rings seized or broken. Replace.
(Continued)
200-22 P/N 3681774M1 Edition 01-2006

Lubricating oil pressure too 1. Big end bearings and main Measure/replace.
low. bearings worn.
2. Big end bolts slackened. Tighten bolt.
3. Cylinder liner cracked Replace.
4. Lubricating oil with wrong spec- Use suitable lubricating oil.

ifications.
5. Leaks from lubricating circuit Repair/replace.

pipes.
6. Lubricating oil filter clogged. Replace.
7. Worn pressure monitoring Clean, adjust or replace.

valve.
8. Insufficient oil capacity. Top up to maximum oil level.
Temperature increase at 1. Intake/exhaust valve play Adjust valve play.

exhaust. incorrect.
2. Loss of compression from valve Lap valve housing.

housings.
3. Spring rings seized or broken. Replace piston ring.
4. Reduced cooling effect from Check/replace thermostat.

radiator. Check/adjust fan belt slip.
5. Insufficient cooling fluid. Check for leaks from the system/

repair.
6. Fan belt tension incorrect. Adjust tension.

(Continued)
P/N 3681774M1 Edition 01-2006 200-23

COMPRESSION TEST
If the engine performances are insuffi-

cient, check the compression value of
each cylinder besides the injection appa-
ratus (overhaul the atomizers and injec-
tion pump).
WARNING
! Do not use matches, cigarette lighters or
torches as a light source on the machine
since it contains inflammable fluids.
Compression degree
The compression degree is a value that indicates
the quantity of air taken in and the condition of the
retaining parts of the cylinder (spring rings and
valves).
The compression value in the cylinders ensures that
the cylinders themselves operate correctly in the
condition where the same amount of fuel is
injected per cylinder per phase.
Insufficient compression not only lowers the engine
performance but also prevents the fuel from burn-
ing completely as there is not enough air to achieve
a perfect combustion.
In this case, the engine will no longer operate effi-
ciently and will consume too much fuel. This leads
to smoke at the exhaust and a reduction in the
exhaust orifices.
Since the compression degree also depends on
the engine temperature (there are lower com-
pression values with a cold engine, higher ones
with a hot engine), the compression value must
only be measured when the engine has reached its
operating temperature.
Measuring procedure
1. Bring the engine to operating temperature.
2. Turn off the engine.
3. Turn the regulator knob to the STOP position to
prevent fuel from flowing to the injectors.
4. Remove the injector that corresponds to the
cylinder being examined.
5. Allow the internal combustion engine to turn
over a few times by means of the starter motor
in order to expel any carbon residues.
6. Mount the dummy injector in place of the one

demounted previously, fitting a copper washer
in between.
200-24 P/N 3681774M1 Edition 01-2006

7. Connect the compression tester with an

adapter and pressure gauge (1) to the tested
cylinder and take the measurements by allow-
ing the internal combustion engine to run by
means of the starter motor until the pressure
gauge reading becomes stable.
5LA0348
11
8. Test the compression in the remaining cylinders
by repeating the previously described opera-
tions 4-5-6-7.
Compare the measured values with the ones in
the table below:
Compression pressure at 250 RPM. (kg/cm2) Difference in the compression pressure

Model
Normal Limit off the various cylinders (kg/cm2)
MF 2430 29 ± 1 24.5 ± 1 2−3
MF 2435 29 ± 1 24.5 ± 1 2−3
MF 2440 29 ± 1 24.5 ± 1 2−3
Also consider that every 100 metres above sea

level corresponds to a decrease of approximately
1%.
Although the aim is to always obtain the

highest compression values, the important
thing is to make sure that the compression in
the cylinders is uniform as this allows the
engine to operate in a regular way.
It is advisable to check a second time if considerable

drops in the compression in a cylinder are noted.
Before measuring, pour normal engine oil (about a
spoonful) through the injector hole, into the cylin-
der.
Allow the engine to run so that the oil spreads over
the walls of the cylinder, then repeat the test and
compare the two test values obtained.
If higher values are recorded during the second
test, this means that the piston rings could be worn
and/or the cylinder liners could be ovalized or dam-
aged.
If the values are not higher than the previous ones,
the fault will be due to the valves.
Only a slight improvement in the compression will
indicate that both the valves and piston rings are in
order.
Whatever the case, also consult "Troubleshooting"
on page 16.
P/N 3681774M1 Edition 01-2006 200-25

ADJUSTMENTS AND TESTS
Valve play adjustment

1. Check the valve play when the engine is cold.
2. Move the piston to top dead centre (TDC) in
the cylinder where the measurements are
being taken.
3. Using a spanner (2), slacken off the lock nut
and then the adjuster screw, using a screw-
driver (1). Make sure that the valve cap is cor-
rectly positioned and free from dirt deposits.
5LA0343
12
4. Insert a thickness gauge (3, Fig. 12) with a
clearance (G) of:
0.15 − 0.25 mm
between the rocker arm and cap of the intake/

exhaust valve.
Tighten the adjuster screw (1) until the rocker
arm pad touches the thickness gauge and fix
with the lock nut (2).
2LA0060
13
How to check the belt tension

1. Press with your hand in the direction of the
arrow the middle of the belt (1) between the
alternator (2) and the coolant pump (3). If the
deflection (F) is:
F = 5 − 10 mm
the belt tension is correct.

2. If the deflection does not correspond to specifi-
cations, adjust the tension by changing the
position of the alternator (2).
Loosen the screw (4) and move the alternator
and fasten it appropriately. 5LA0350
Repeat the test as shown in step 1. Tighten 14

screws (4) and (5) if it is successful.
200-26 P/N 3681774M1 Edition 01-2006

Injection pressure test
Carefully remove the carbon deposits from

the injector before proceeding with the
inspections.
1. Connect the injector (1) to the high pressure

hose of the injector test instrument (2).
2. Slowly operate the lever of the instrument (2)
and note down the value indicated by the pres-
sure gauge when the injector (1) starts to
spray.
The correct injection pressure should be:
181 - 191 bars 2LA0064
15
3. If the measured pressure is lower than speci-
fied, remove and carefully clean each compo-
nent of the injector. Repeat the test.
P/N 3681774M1 Edition 01-2006 200-27

Jet inspection
Operate the lever (3) of the injector test instrument
(2) four − six times, depending on the prescribed
injection pressure. Check the jets at the same time.
- Check that the jet is neither continuous nor
fragmented.
- Make sure that the jet of fuel around the
median line of the injector is tapered in shape
and that the delivery angle is about 150°.
2LA0066
16
Refer to the figure on the right in order to
define the shape of the jet:
• normal jet: see fig. 17;
• anomalous jet: see fig. 18.
- Place a sheet of white paper 30 cm under the
atomizer and make sure that the jet forms a
perfect circle.
- After injection, make sure that no fuel drips
from the injector.
- Make sure that there are no fuel leaks from the
injection hole if the pressure is slightly lower
than the prescribed value. 2LA0067
17
2LA0068
18
200-28 P/N 3681774M1 Edition 01-2006

INJECTION PUMP TUNING
1. Turn the crankshaft so that the suction valve of

cylinder 4 is open and the exhaust valve is
nearly closed.
2. Check reference alignment as shown in the fig-

ure.
5LA0345
19
3. With the pump fitted and the fastening screws
loose, remove the closing cap (1) on the pump
cover.
5LA0346
20
4. Fit a dial gauge as shown in the figure. Turn
the flywheel back slowly to take the piston to
BDC at beginning of delivery (the dial gauge
will stop descending).
5LA0349
21
P/N 3681774M1 Edition 01-2006 200-29

5. Reset the dial gauge and turn the flywheel

slowly to take the reference index to position
as shown in the figure.
5LA0347
22
6. Check on the dial gauge that the stroke of the
cylinder piston is 0.5 mm.
7. Otherwise, turn the pump to obtain the

required stroke.
When these conditions occur, fasten the pump
and tighten the respective fastening screws.
5LA0344
23
200-30 P/N 3681774M1 Edition 01-2006

SECTION 300
CLUTCH
SECTION 300 - CLUTCH
TABLE OF CONTENTS
Description Page
GENERAL SPECIFICATIONS OF THE LX (OX) 12” CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-3
GENERAL SPECIFICATIONS OF THE HI-LO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-3
DESCRIPTION AND OPERATION OF THE CLUTCH AND HI-LO SYSTEM . . . . . . . . . . . . . . . . . . . . . . 300-4

Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-4
HI-LO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-4
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-6
SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-7
CLUTCH HOUSING SEALANT APPLICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-10
CLUTCH ASSEMBLY TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-11
CLUTCH REMOVAL-REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-12

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-12
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-13
CLUTCH HOUSING - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-14

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-17
CLUTCH HOUSING WITH HI-LO - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-19

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-24
Reverse shuttle float adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-29
300-2 P/N 3681774M1 Edition 01-2006

GENERAL SPECIFICATIONS OF THE LX (OX) 12” CLUTCH
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . single plate, dry

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical, pedal operated
Engaging and disengaging mechanism . . . . . . . . . . . . . . . . . . . . . . . diaphragm spring
Type of coating on the clutch driven plate . . . . . . . . . . . . . . . . . . . . cerametallic
GENERAL SPECIFICATIONS OF THE HI-LO SYSTEM
HI-LO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . speed reducer
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . planetary gear reduction set

with wet multiple plate hydraulic
clutch
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . electrohydraulic, operated by

button on gear lever
P/N 3681774M1 Edition 01-2006 300-3

DESCRIPTION AND OPERATION OF THE CLUTCH AND HI-LO SYSTEM
Clutch
The clutch assembly transmits motion from the loaded by the diagram spring, presses the friction
engine to the driveline. It is engaged and released plate against the flywheel.
by means of the control pedal arranged on the left The friction plate is released when the clutch pedal
of the steering wheel on the cab floor. A dry single is pressed and the motion is interrupted.
plate clutch is fitted. Motion is transmitted by the
engine to the gearbox when the pressure plate,
HI-LO
The HI-LO assembly transmits the motion from the In such conditions, the input shaft (14) transmits
clutch to the driveline. Two ratios can be selected: motion to the hub (7), to the plates and the inter-
slow or fast. mediate plates (6), to the cover (1) and to the
A planetary reducer gear is found inside the unit for whole planetary gear set.
reducing the ratio by 20% and doubling the The difference between the number of teeth of the
number for each gear shift. double satellites (8) and the planetary gears (10
The unit is operated by means of a button on the and 11) causes a mechanical block which forces the
gear lever which controls the pressurised oil open- output shaft (9) to turn with the whole assembly
ing and closing solenoid valve inside the pipe (13). and the input shaft (14) at a 1:1 (or high) ratio.
To engage high ratios press the button controlling To engage low ratio, press the button controlling
the solenoid valve which sends oil at 17 bars to the the solenoid valve again which sends oil at 17 bars
piston chambers (3 and 12). to the piston chambers (3 and 12).
The piston (12) operated in this way makes the The clutch plates (6) are released and the plate (2)
clutch plates and intermediate plates integral (6) is blocked by the biased of the Belleville spring (5)
forming a single body with the disc holder hub (7) on the pressure plate (4).
fitted on the input shaft (14). The cover ring (1) allows the motion from the input
shaft (14) to be transferred from the planetary gear
The piston (3) acts on the thrust plate (4) overcom-
set (11) to the output shaft (10) via the satellites
ing the bias of the Belleville spring (5) and releas-
(8), thus causing a 20% reduction of the output
ing the plate (2) which prevents the rotation of the
shaft turns (9).
cover (1) on which it is fitted.
STANDARD TRANSMISSION
ENGINE + CLUTCH = 100 % ENGINE RPM
POWERFIVE (HI-LO) TRANSMISSION
100 % ENGINE RPM

ENGINE CLUTCH POWERFIVE
+ + =
(HI-LO)
80 % ENGINE RPM
5LA0183
300-4 P/N 3681774M1 Edition 01-2006

1
3 2
3 3 4 5 6 7 8 9
14 13 12 11 10
5LA0184
2
HI-LO longitudinal section
P/N 3681774M1 Edition 01-2006 300-5

CONTROLS
2
1
5LA0182
3
Clutch and HI-LO controls
1. Clutch control pedal 2. HI-LO control button
300-6 P/N 3681774M1 Edition 01-2006

SECTIONS
1 2 3
4
6
ø 304,8 (12")
10
5LA0172
4
Clutch longitudinal section
1. Flywheel 6. Diaphragm spring

2. Fixing screw 7. Hub
3. Friction plate 8. Flexible coupling springs
4. Pressure plate 9. Centring pin
5. Clutch cover
P/N 3681774M1 Edition 01-2006 300-7

5LA0159
5
Clutch housing longitudinal section
1. Clutch housing 9. Clutch fork control shaft

2. Friction plate 10. Clutch control fork
3. Pressure plate 11. Secondary shaft lubrication tube
4. Clutch cover 12. Clutch collar support
5. Flexible coupling springs 13. Input shaft
6. Diaphragm spring 14. Thrust bearing
7. Clutch control collar 15. Flywheel
8. Clutch fork fastening screw
300-8 P/N 3681774M1 Edition 01-2006

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24
25
26
27
5LA0126
36 35 34 33 32 31 30 29 28
6
HI-LO clutch housing longitudinal section
1. PTO shaft 19. Plate holder hub
2. Input shaft 20. Double satellite
3. Flexible coupling springs 21. Satellite holder housing
4. Thrust bearing 22. Satellite pin
5. Flywheel 23. Output shaft
6. Clutch housing 24. Secondary shaft lubrication tube
7. Friction plate 25. Output planetary
8. Pressure plate 26. Input planetary
9. Diaphragm spring 27. Multiple plate clutch piston
10. Clutch cover 28. DT upper shaft
11. Clutch control collar 29. Clutch plate
12. Clutch collar support 30. DT upper shaft gear
13. Clutch control fork 31. DT lower shaft gear
14. Single plate clutch piston 32. Multiple plate clutch cover
15. Pressure plate 33. Oil pipe
16. Spring flange 34. HI-LO cover
17. Belleville spring 35. Supporting flange
18. Clutch plates 36. DT lower shaft
P/N 3681774M1 Edition 01-2006 300-9

CLUTCH HOUSING SEALANT APPLICATION DIAGRAM
4LA0163
7
The types of sealant to apply are indicated in section 100.
300-10 P/N 3681774M1 Edition 01-2006

CLUTCH ASSEMBLY TROUBLESHOOTING
The clutch slips 1. Pressure plate and flywheel Compare with the values given in the
wear. indicated pages. Replace excessively
worn parts and adjust the levers and
clutch controls.
2. Stretched or damaged dia- Replace the diagram spring.

gram spring
3. Oil or grease on plate friction Replace the plate. Eliminate the cause
material. that led to the presence of lubricant in
the clutch housing and thoroughly
clean the friction surfaces.
The clutch jerks. 1. External controls hardened. Check the hinging and lubricate.
2. Deformed clutch plate. Replace the plate and adjust the

clutch lever.
3. Oil or grease on plate friction Replace the plate. Eliminate the cause
surfaces. that led to the presence of lubricant in
the clutch housing and thoroughly
clean the friction surfaces.
The clutch fails to disengage and 1. Deformed clutch plate. Replace the plate.
slips.
2. External controls seized. Check, replace the faulty parts and

lubricate.
3. Badly adjusted controls. Adjust the controls.
Clutch noisy when engaged and/or 1. Worn thrust bearings. Replace the bearing.
disengaged.
2. Clutch plate with damaged Replace the plate.

flexible coupling springs.
Clutch pedal too hard to operate. 1. External controls hardened. Check the hinging and lubricate.
2. Hardened pedal hinging. Check the hinging and lubricate.
P/N 3681774M1 Edition 01-2006 300-11

CLUTCH REMOVAL-REFITTING
Removal
WARNING
! Lift and handle all heavy parts with lifting
equipment of an adequate capacity.
Make sure that the units or parts are sup-
ported by appropriately sized harness and
hooks. Make sure that there are no
bystanders near the load being lifted.
WARNING
! Handle all parts with great care. Do not
put your hands or fingers between one
part and the next. Wear approved safety
garments such as goggles, gloves and
safety footwear.
Proceed as follows:
1. Remove the engine.
(See section 200).
5LA0166
8
2. Loosen the screws (1) fastening the clutch to
the flywheel (2).
Remove the complete clutch assembly.
5LA0185
300-12 P/N 3681774M1 Edition 01-2006

Refitting
WARNING
safety footwear.
Refit the clutch housing bearing the following rec-

ommendations in mind:
- For orientation of parts, refer to the illustration

on page 7
- Apply the tightening torques listed on page

100.
- Carefully clean all parts and inspect them.
- Replace all damaged or worn components.
- Check the flywheel surface and grind it if

needed. Remove no more than 1 mm of mate-
rial.
- Arrange the clutch assembly using tool (1) 02

FRI GL to centre it on the flywheel (2).
Fit the clutch cover (3) with diagram spring (4)
and tighten the screws.
5LA0167
10
P/N 3681774M1 Edition 01-2006 300-13

CLUTCH HOUSING - OVERHAUL
Disassembly
WARNING
safety footwear.

(See section 200).
2. Loosen the fastening screw (1), remove the
shaft (2) and the clutch fork (3).
Remove the collar (4) and thrust bearing (5).
Remove the PTO shaft (6).
5LA0087
11
3. Remove the clutch housing from the gearbox
housing (see section 400).
4. Remove the lubrication tube (1) of the gearbox
primary and secondary shaft.
5LA0168
12
300-14 P/N 3681774M1 Edition 01-2006

5. Remove the support (1) from the clutch collar

and cover the o-ring (2).
5LA0169
13
6. Remove the snap ring (1) that holds the input
shaft (2).
5LA0170
14
7. Remove from the front of the clutch housing
the input shaft (1) with reverse shuttle (2).
5LA0171
15
8. Remove the snap rings (2) and (3) from the
input shaft (1).
5LA0186
16
P/N 3681774M1 Edition 01-2006 300-15

9. Remove the synchroniser unit (1) from the

reverse shuttle and the gear (2).
5LA0173
17
10. Remove from the inner part of the input shaft 5LA0187
(1) the snap ring (2), the o-ring (3) and the 18
roller bearing (4).
5LA0174
19
300-16 P/N 3681774M1 Edition 01-2006

Assembly
WARNING
safety footwear.
Comply with the following recommendations when

refitting the clutch housing:

on page 8.
- Before remounting the housings, supports and

covers, thoroughly clean and degrease the cou-
pling surfaces and apply a strip of sealant about
2 mm in diameter as indicated in the figure on
page 10.

100.
- Replace all o-rings.
- Check rolling tracks of all bearings for anoma-

lies while rolling.
- Lubricate with grease the bearing and o-ring

seats.
- Check with a jet of air for obstructions of the

! channels and lubrication oil passage holes.
- Check synchroniser X height.
X = 1.25 mm (minimum)
5LA0116
20
P/N 3681774M1 Edition 01-2006 300-17

Proceed as follows:
1. Reassemble and refit the input shaft on the
clutch housing.
2. Fit the clutch collar support (1) with lubrication
hole orientated as shown by the arrow.
Tighten the fastening screws at the specified
torque of:
19 - 24 Nm
5LA0179
21
3. Fit the reverse shuttle synchronisation assem- 5LA0180
bly making sure snap rings (1) and (2) are cor- 22
rectly positioned because they are different.
5LA0181
23
300-18 P/N 3681774M1 Edition 01-2006

4. Fit the synchroniser ring (1) and calculate the

thickness of the shim which limits the reverse
shuttle float.
(See procedure on page 29).
5LA0188
24
CLUTCH HOUSING WITH HI-LO - OVERHAUL
Disassembly
WARNING
safety footwear.

(See section 200).
2. Remove the shaft and the clutch fork.
Remove the collar and the thrust bearing. 2
Remove the PTO shaft.
Loosen the screws (1) fastening the HI-LO
assembly (2).
5LA0083
25
3. Remove the HI-LO assembly (4) from the
clutch housing (5) keeping the shaft (1) con- 5
nected to the collar support (2).
For this operation, fit tool (3) 137 PNT GL on
the shaft (1) making it attach to the collar sup-
port (2) and fasten the screw.
4 2 3 1
4LA0146
26
P/N 3681774M1 Edition 01-2006 300-19

4. Remove the clutch housing from the gearbox

housing.
(See section 400).
5. Fasten the HI-LO assembly on the work bench

and remove the satellite holder housing (1) and
the output planetary gear (2).
4LA0147
27
6. Remove the complete clutch plate assembly
(1).
4LA0148
28
7. Remove the input shaft (1) with the plate
holder hub (2).
4LA0149
29
300-20 P/N 3681774M1 Edition 01-2006

8. Remove the clutch cover (1).
4LA0150
30
9. Remove the clutch piston (1) from the clutch
cover (2).
4LA0151
31
10. Remove the flange (1) and remove the Bel-
leville spring (2).
4LA0152
32
11. Remove the thrust plate (1), clutch single plate
(2) and the clutch piston (3).
4LA0153
33
P/N 3681774M1 Edition 01-2006 300-21

12. Remove the support collar (1) and use a press

to remove the support (2) from the HI-LO
cover.
4LA0154
34
13. Remove from the inside of the clutch housing,
the snap ring (1) from the output shaft (2).
2
5LA0006
35
14. Remove the complete reverse shutter assem-
bly.
5LA0007
36
15. Remove the snap ring (1) holding the synchro-
niser stop (2).
1
5LA0010
37
300-22 P/N 3681774M1 Edition 01-2006

16. Remove the synchroniser unit (1) from the

reverse shuttle and the gear (2).
5LA0011
38
17. Extract the roller bearing (2) from the output
shaft (1).
2
5LA0013
39
P/N 3681774M1 Edition 01-2006 300-23

Assembly
WARNING
safety footwear.

refitting the clutch housing:

on page 9.
- Before remounting the housings, supports and

covers, thoroughly clean and degrease the cou-
page 10.

100.

lies while rolling.

seats.

X = 1.25 mm (minimum)
5LA0116
40
300-24 P/N 3681774M1 Edition 01-2006

Proceed as follows:
1. Reassembly and refit the output shaft (2) from

the clutch housing and fasten it with the snap
ring (1).
2
5LA0006
41
2. Fit the reverse shuttle synchronisation assem- 5LA0180
bly making sure snap rings (1) and (2) are cor- 42
rectly positioned because they are different.
5LA0181
43
P/N 3681774M1 Edition 01-2006 300-25

3. Fit the synchroniser ring (1) and calculate the

thickness of the shim which limits the reverse
shuttle float
5LA0188
44
4. Fit on the support (1) of the HI-LO cover the
bearing (2) and the o-rings (3) and (4). 1
4 3 2
1
4LA0161
45
Respect the position and dimensions of
the o-rings and bearings as shown in the
figure. Fit the bearing (2), then the
smooth ring (3) and then the corrugated
ring (4).
4LA0160
46
5. With the help a press, fit the support (1) on the
HI-LO cover (2).
Orient the cover support so that the three
holes on the same correspond to those of
the cover.
4LA0162
47
300-26 P/N 3681774M1 Edition 01-2006

6. Fit and fasten the collar support.
7. Position the internal HI-LO components:
- clutch command piston
- clutch single plate

Check the friction material thickness of
the clutch plate.
- pressure plate
- Belleville spring
- Belleville spring flange
- clutch cover
- clutch piston.
8. Fit the input shaft (1) with the plate holder hub
(2).
4LA0149
48
9. Fit the complete clutch plate and input plane-
tary assembly.
5LA0189
49
P/N 3681774M1 Edition 01-2006 300-27

Check for absence of scratching, signs of

heavy overheating and distortion of the
steel plates.
Check the friction material thickness of

the clutch plates.
4LA0157
50
10. Reassemble the satellite holder housing.
4LA0155
51
11. Fit the satellites (1) and insert the pins (2) with
the lubrication hole oriented as shown in the
figure.
1
4LA0158
52
12. Before fitting the last satellite (1), position the 120°
output planetary (2) making sure that the ref-
erence on the satellite are present and con-
verge towards the centre.
After positioning the third satellite, check that
all three signs are correctly oriented. Other-
wise, repeat the assembly procedure.
120°
The timing error of a tooth will cause nois- 1

iness of the assembly. Incorrect timing of
two teeth, on the other hand, will cause
mechanical jamming of the device. 2
4LA0159
53
300-28 P/N 3681774M1 Edition 01-2006

13. Position the satellite holder housing, assemble

and fasten the complete HI-LO assembly in the
clutch housing.
14. Complete the inner details for operating the
clutch.
15. Refit the engine.
(See section 200).
Reverse shuttle float adjustment
WARNING
safety footwear.
Make sure that, once mounted, the

! reverse shuttle has a float of 0.3- 0.6 mm
to ensure that it operates correctly.
Proceed as follows:
1. Measure with a thickness micrometer distance

A between the synchroniser ring surface (1) 5LA0112
and the coupling plane and the clutch housing 54
(2).
Take 3 measurements at 120° and calculate
the arithmetical average of the three readings.
5LA0111
55
P/N 3681774M1 Edition 01-2006 300-29

2. Measure with a thickness micrometer distance

B between the primary shaft plane (1) and the 5LA0113
coupling plane and the clutch housing (2). 56
Take 3 measurements at 120° and calculate
the arithmetical average of the three readings.
5LA0115
57
3. The shim Sp to be arranged between the
reverse shuttle synchroniser ring (1) and the
gearbox primary shaft (2) is:
Sp = B - A - 0.45
where:
B = measured dimension
A= measured dimension
0.45 = average operating float
Round off to the lower figure.
The following shims Sp are available as spare 5LA0190

parts: 58
2.25 mm
2.50 mm
2.75 mm
3.00 mm
3.25 mm
300-30 P/N 3681774M1 Edition 01-2006

SECTION 400
SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX
SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX
TABLE OF CONTENTS
Description Page
MAIN SPECIFICATIONS OF THE SPEEDFIVE GEARBOX AND FINAL DRIVE . . . . . . . . . . . . . . . . . . . . 400-3
MAIN SPECIFICATIONS OF REVERSE SHUTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-3
MAIN SPECIFICATIONS OF SUPER FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-3
DESCRIPTION AND OPERATION OF THE SPEEDFIVE GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-4

Gearbox and reverse shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-4
Super final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-4
MAIN SPECIFICATIONS OF POWERFIVE GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-6
MAIN SPECIFICATIONS OF REVERSE SHUTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-6
MAIN SPECIFICATIONS OF SUPER FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-6
DESCRIPTION AND OPERATION OF THE POWERFIVE GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . 400-7

Gearbox and reverse shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-7
Super final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-7
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-8
SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-9
PERSPECTIVE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-10
GEARBOX HOUSING SEALANT APPLICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-12
GEARBOX, RANGE REDUCTION AND REVERSE SHUTTLE

AND REVERSE SHUTTLE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-13
SUPER FINAL DRIVE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-13
GEARBOX
REMOVAL-REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-14
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-18
GEARBOX HOUSING - OVERHAUL . . . . . . . . . . . . .. .. .... .. .. . . . . . .... .. .. . . . .. ..... 400-19

Disassembly . . . . . . . . . . . . . . . . . . . . . . . .. .. .... .. .. . . . . . .... .. .. . . . .. ..... 400-19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .... .. .. . . . . . .... .. .. . . . .. ..... 400-25
Four gear pack float adjustment . . . . . . . . .. .. .... .. .. . . . . . .... .. .. . . . .. ..... 400-31
4th gear synchronisation float adjustment . . .. .. .... .. .. . . . . . .... .. .. . . . .. ..... 400-33
GEAR LEVER SUPPORT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-35

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-35
400-2 P/N 3681774M1 Edition 01-2006

MAIN SPECIFICATIONS OF THE SPEEDFIVE GEARBOX AND FINAL DRIVE
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with 5 ratios, infinitely meshed

gears and synchronizers for all
speeds
Type of gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with helical toothing
Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cascade type with 3 speed

ranges for a total 15 speeds.
Type of gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with straight toothing
Gearbox and final drive controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . independent, with lever

installed on the operator’s right
MAIN SPECIFICATIONS OF REVERSE SHUTTLE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical with straight teeth,

installed between the main
clutch and gearbox.
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of dedicated lever on

the left of the steering wheel
MAIN SPECIFICATIONS OF SUPER FINAL DRIVE
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cascade with straight teeth,

installed between the gearbox
and bevel gear pair.
Obtains 30 forward and 30
reverse speeds
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of dedicated lever on

the operator’s left
P/N 3681774M1 Edition 01-2006 400-3

DESCRIPTION AND OPERATION OF THE SPEEDFIVE GEARBOX
Gearbox and reverse shuttle

The gearbox is equipped with helical toothed infi- The reverse shuttle is controlled by a specific lever
nitely meshed gears controlled by three synchro- arranged on the left of the steering wheel.
mesh units. It provides 5 speeds. The reverse shuttle consists of a straight toothed
The range reduction unit is the cascade type with gear. The reverse shuttle is engaged by means of a
infinitely meshed straight toothed gears. synchro-mesh.
The final drive offers three speed ranges: slow, The reverse shuttle is fitted inside the gearbox
normal and fast. housing between the clutch and gearbox.
The reverse shuttle is a mechanical device provid- The assembly is lubricated by the oil in the gearbox
ing 15 forward gears and 15 reverse gears. housing.
Super final drive

The super final drive is a mechanical device provid- the operator’s left.
ing 30 forward gears and 30 reverse gears. The super final drive can be used in low and normal
The super final drive is installed upstream of the ranges only.
gearbox and is controlled by a dedicated lever to
STANDARD GEARBOX
15 FORWARD GEARS
REVERSE SHUTTLE + 5 GEARS TIMES 3 RANGES =
15 REVERSE GEARS
GEARBOX WITH SUPER FINAL
30 FORWARD GEARS
SUPER
REVERSE SHUTTLE + 5 GEARS TIMES 3 + =
FINAL DRIVE
30 REVERSE GEARS
5LA0074
1
Speedfive gearbox configuration
400-4 P/N 3681774M1 Edition 01-2006

Working speed
Fast range
Standard gearbox
Normal range
Engine
rpm
Slow range
Basic gearbox: speed km/h (15 forward gears and 15 reverse gears)
Normal range
Super final drive
Slow range
Optional super final drive (10 ultra slow gears)

5LA0077
2
Speedfive basic gearbox with mechanical reverse shuttle 30 AV + 30 RM with 420/70-28 tyres
P/N 3681774M1 Edition 01-2006 400-5

MAIN SPECIFICATIONS OF POWERFIVE GEARBOX
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with 5 ratios, infinitely meshed

gears and synchronizers for all
speeds
Type of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with helical toothing
HI-LO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch fitted in front of gearbox
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . wet multiple plate, electrohy-

draulic controlled
Final drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cascade type with 3 speed

ranges for a total 30 speeds.
Type of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with straight toothing
Gearbox and final drive controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . independent, with lever and

button installed on the opera-
tor’s right
MAIN SPECIFICATIONS OF REVERSE SHUTTLE
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mechanical with straight teeth,

installed between the main
clutch and gearbox.
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of dedicated lever on

the left of the steering wheel
MAIN SPECIFICATIONS OF SUPER FINAL DRIVE
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cascade with straight teeth,

installed between the gearbox
and bevel gear pair.
Obtains 60 forward and 60
reverse speeds
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of dedicated lever on

the operator’s left
400-6 P/N 3681774M1 Edition 01-2006

DESCRIPTION AND OPERATION OF THE POWERFIVE GEARBOX
Gearbox and reverse shuttle

The gearbox is equipped with helical toothed infi- The final drive offers three speed ranges: slow,
nitely meshed gears controlled by three synchro- normal and fast.
mesh units. It provides 5 speeds. The reverse shuttle is a mechanical device provid-
The Powerfive module is a HI-LO electrohydraulic ing 30 forward gears and 30 reverse gears.
device consisting of a electro-hydraulically control- The reverse shuttle is controlled by a specific lever
led wet multiple plate clutch fitted in front of the arranged on the left of the steering wheel.
gearbox.
The reverse shuttle consists of a straight toothed
The Powerfive can engage a 20% step-down for gear. The reverse shuttle is engaged by means of a
each forward and reverse gear of the gearbox with- synchro-mesh.
out using the clutch.
The reverse shuttle is fitted inside the gearbox
Engagement is controlled by a solenoid valve oper- housing between the HI-LO and gearbox.
ated by the button on the gear lever.
The assembly is lubricated by the oil in the gearbox
The range reduction unit is the cascade type with housing.
infinitely meshed straight toothed gears.
Super final drive

The super final drive is a mechanical device provid- operator’s left.
ing 60 forward gears and 60 reverse gears. The super final drive can be used in low and normal
The super final drive is installed prior to the gear- ranges only.
box and is controlled by a dedicated lever to the
STANDARD GEARBOX
30 FORWARD GEARS
POWERFIVE
+ REVERSE SHUTTLE + 5 GEARS TIMES 3 RANGES =
HI-LO
30 REVERSE GEARS
GEARBOX WITH SUPER FINAL
60 FORWARD GEARS
POWERFIVE SUPER
+ REVERSE + 5 GEARS TIMES 3 + =
HI-LO FINAL DRIVE
60 REVERSE GEARS
5LA0075
3
Powerfive gearbox configuration
P/N 3681774M1 Edition 01-2006 400-7

CONTROLS
1 3
5LA0076
4
Gearbox controls
1. Reverse shuttle lever 4. Range selection lever

2. Gear lever 5. Super final drive lever
3. Powerfive engagement button
400-8 P/N 3681774M1 Edition 01-2006

SECTIONS
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
33 32 31 30 29 28 27 26 25 24 23 22 21 20
5LA00xx
5
Gearbox longitudinal section
1. Reverse shuttle gear 17. Adjuster ring
2. Reverse shuttle synchroniser assembly 18. Super final drive micro switch
3. Adjuster shim 19. Upper shaft
4. Primary shaft 20. Super final drive micro switch
5. Snap ring 21. Super final drive micro switch
6. Ball bearing 22. Super final drive double gear
7. 1st gear 23. Roller bearing
8. 1st and 2nd gear synchronisation assembly 24. 3rd and 4th double gear
25. Secondary shaft
9. 2nd gear
10. Bushing 26. 1rd and 2th double gear
27. DT propeller shaft
11. 3rd gear
28. Roller bearing
12. 3rd and 4th gear synchronisation assembly 29. Stop plate
13. Snap ring
14. Adjuster shim 30. 5th gear
15. 4th gear 31. 5th gear synchroniser
16. Ball bearing 32. Ring nut
33. Lubrication pipe
P/N 3681774M1 Edition 01-2006 400-9

PERSPECTIVE VIEWS
5LA0076
Reverse shuttle unit Super final drive micro switch
Primary shaft Secondary shaft
1st and 2nd gear assembly DT propeller shaft
3rd and 4th gear assembly 5th gear assembly
Super final drive micro switch Lubrication pipe
6
Gearbox perspective view
400-10 P/N 3681774M1 Edition 01-2006

5LA0078
7
Gearbox lever and fork perspective view
1. Reverse shuttle fork 4. 3rd and 4th gear fork

2. Gear lever
5. 1st and 2rd gear fork
3. Super final drive fork
6. 5th gear fork
P/N 3681774M1 Edition 01-2006 400-11

GEARBOX HOUSING SEALANT APPLICATION DIAGRAM
5LA0079
8
400-12 P/N 3681774M1 Edition 01-2006

GEARBOX, RANGE REDUCTION AND REVERSE SHUTTLE

AND REVERSE SHUTTLE TROUBLESHOOTING
The gearbox, final drive or reverse 1. Transmission rods and levers Adjust correctly.
shuttle disengage spontaneously. incorrectly adjusted.
2. Faulty control rod retention Replace the springs.
springs.
3. Faulty synchro-mesh engaging Remove the gearbox-transmission
teeth or engaging sleeves. housing and replace the synchro-
mesh units or engaging sleeves.
4. Incomplete engagement travel. Eliminate the causes and adjust for
complete travel.
The gearbox, final drive or reverse 1. Transmission rods and levers Adjust correctly.
shuttle are difficult to engage. incorrectly adjusted.
2. Transmission rods and levers Check the hinging and lubricate.
hardened and/or seized.
3. The central clutch drags. See sect. 300.
4. Faulty synchro-mesh units or Remove the gearbox-transmission

engaging sleeves. housing and replace the synchro-
mesh units or engaging sleeves.
5. The internal controls do not Overhaul the controls.
slide smoothly: rods, forks and
sleeves.
The gearbox, final drive or reverse 1. Some internal component is Remove the gearbox-transmission
shuttle operate in a noisy way. worn or defective. housing and replace the faulty
parts.
SUPER FINAL DRIVE TROUBLESHOOTING

Spontaneous super final drive 1. External rods and levers incor- Adjust correctly.
engagement. rectly adjusted.
2. Incomplete engagement travel. Eliminate the causes and adjust for
complete travel.
Difficult super final drive engage- 1. External rods and levers incor- Adjust correctly.
ment. rectly adjusted.
2. External rods and levers hard- Check the hinging and lubricate.
ened and/or seized.
3. The central clutch drags. See sect. 300.
4. The internal controls do not Overhaul the controls.

slide smoothly: rods, forks and
sleeves.
Super final drive noise. 1. Some internal component is Remove the gearbox housing and
worn or defective. replace the faulty parts.
P/N 3681774M1 Edition 01-2006 400-13

GEARBOX
REMOVAL-REFITTING
Removal
DANGER
hooks.
Make sure that there are no bystanders
near the load being lifted.
WARNING
safety footwear.
Proceed as follows:
1. Remove the cab (see section 1100).
2. Remove the engine (see section 200).
3. Loosen the filler caps and drain the gearbox oil.
Old oil must be disposed of in compliance

with the current laws.
4. Remove all plastic clips fastening the gearbox

wiring harnesses.
5. Disconnect from the solenoid valve unit (1), the

hydraulic circuit relief pipes and the electrical
circuit wiring harnesses.
5LA0081
9
6. Disconnect the gearbox lubrication contoured
tube.
7. Disconnect the oil return pipe from the radiator
to the solenoid valve block.
400-14 P/N 3681774M1 Edition 01-2006

8. Disconnect the electrical connector (1) on the

reverse safety switch.
5LA0082
10
9. Disconnect the rubber joint sleeve (1) from the
two hydraulic circuit suction half tubes.
5LA0080
1
11
10. Disconnect the high pressure hydraulic circuit
delivery pipe (1).
1
5LA0088
12
11. Fasten the front axle with two wooden wedges
to prevent the engine rocking.
12. Appropriately support the engine, the transmis-
sion and the gearbox.
Loosen the screws fastening the clutch housing
to the engine and separate the two assemblies
being careful to maintain the alignment and
parallelism of the junction planes.
13. Hitch the clutch housing using appropriate lift-
ing equipment and maintain alignment.
P/N 3681774M1 Edition 01-2006 400-15

14. Remove the upper gearbox housing cover.
5LA0084
13
15. Remove the reverse shuttle engagement levers
(1) and (2).
5LA0085
14
16. Take out the rod (1) and recover the reverse
shuttle fork (2).
5LA0086
15
17. SPEEDFIVE GEARBOX
- Loosen the fastening screw (1), remove the
shaft (2) and the clutch fork (3).
- Remove the collar (4) and thrust bearing (5).
- Remove the PTO shaft (6).
5LA0087
16
400-16 P/N 3681774M1 Edition 01-2006

17. POWERFIVE GEARBOX

- Remove the shaft and the clutch fork.
- Remove the collar and the thrust bearing.
- Remove the PTO shaft.
- Loosen the screws (1) fastening the HI-LO
assembly (2). 2
5LA0083
17
- Remove the HI-LO assembly (4) from the
clutch housing (5) keeping the shaft (1) con- 5
nected to the collar support (2). For this oper-
ation, fit tool (3) 137 PNT GL on the shaft (1)
making it attach to the collar support (2) and
fasten the screw.
4 2 3 1
4LA0146
18
18. Remove the clutch housing (1) from the gear-
box housing (2) keeping correct alignment.
5LA0089
19
19. Remove the gearbox housing from the differen-
tial housing (see section 500).
P/N 3681774M1 Edition 01-2006 400-17

Refitting
refitting the gearbox housing:
WARNING
safety footwear.
- For orientation of parts, refer to the illustra-

tion on pages 9, 10 and 11.
- Before refitting the housings, supports and
covers, thoroughly clean and degrease the
coupling surfaces and apply a strip of sealant
about 2 mm in diameter as indicated in the
figure on page 12.
- Refit the differential housing (see section
500).
- Refit the clutch housing favouring the trans-
mission shaft coupling. Tighten the fastening
screws at the specified torque of:
98 - 120 Nm
- Powerfive gearbox
Fit the HI-LO assembly inside the clutch
housing.
- Position and fit the PTO shaft, the collar and
thrust bearing, the fork and clutch actuating
shaft.
- Fit the reverse shuttle rod and fork.
- Fit the reverse shuttle engagement levers.
- Fit the gearbox housing cover.
- Connect all hydraulic pipes and electrical con-
nections.
- Restore lubricant oil levels.
- Refit the engine (see section 200).
- Refit the cab (see section 1100).
400-18 P/N 3681774M1 Edition 01-2006

GEARBOX HOUSING - OVERHAUL
Disassembly
WARNING
safety footwear.
Proceed as follows:
1. Fasten the gearbox housing to the working
stand.
5LA0095
20
2. Remove the lubrication tube (1) from the pri-
mary shaft gears.
5LA0090
21
3. Remove the gear control lever support (1).
5LA0091
22
P/N 3681774M1 Edition 01-2006 400-19

4. Remove the super final drive rod and fork.
5. Remove the super final drive gear (1).
5LA0092
23
6. Remove the support guard (1) with super final
drive double gear (2).
5LA0093
24
7. Remove the rod (1), the fork (2) and the
engagement block (3) of the 1st and 2nd gear.
Remove the same components of the 3rd and
4th gear.
Recover the rod springs and balls.
5LA0094
25
400-20 P/N 3681774M1 Edition 01-2006

8. Extract the 4th gear (1) and bearing. Use a

plastic hammer for assistance.
1
4LA0168
26
9. Remove the snap ring (1) to extract the bear-
ing (2) from the 4th gear (2).
2
3
4LA0169
27
10. Use a specific extractor to remove the bearing.
5LA0000
28
11. Loosen the nut ring (1) and remove the stop
plate (2) of the 5th gear synchroniser.
5LA0100
29
P/N 3681774M1 Edition 01-2006 400-21

12. Extract the stop pin (1) from the engagement

block (2) of the 5th gear.
2
1
5LA0003
30
13. Extract the stop pin (1) from the fork (2),
remove the rod (3) and recover the spring and
the stop ball.
14. Remove the synchroniser and 5th gear, bear-
1
ings and slewing bearing.
2
5LA0002
31
15. Remove the snap ring (1) of the primary shaft.
(Also see detail 1 fig. 33). 1
5LA0001
32
5LA0097
33
400-22 P/N 3681774M1 Edition 01-2006

16. Remove the snap ring (1) of the primary shaft

journal bearing.
(Also see detail 2 fig. 33).
A pair of snub tipped pliers may be used for
this operation as shown in figure 35.
5LA0098
34
5LA0099
35
17. Remove from the front the primary shaft (1)
being careful to withhold all the gears and syn-
chroniser assemblies (2) of the four gears.
5LA0101
36
18. Loosen the fastening screws (1) and remove
the stop plate (2) of the secondary shaft bear- 2
ing (3).
1
3
5LA0004
37
P/N 3681774M1 Edition 01-2006 400-23

19. Remove the front part of the secondary shaft

(1) with two double gears (2).
5LA0102
38
20. Extract the reverse shuttle double gear (2)
shaft (1) with the bearing (3).
2 3
1
5LA0096
39
For this operation, fasten the tool (1) 16 CMB
GL to the double gear support.
The rear bearing must remain inserted in the
housing on the gearbox housing.
5LA0103
40
400-24 P/N 3681774M1 Edition 01-2006

Assembly
WARNING
safety footwear.

refitting the gearbox:
tion on pages 9, 10 and 11.
figure on page 12.
100.
- Check rolling tracks of all bearings for anom-

alies while rolling.

seats.

X = 1 mm (minimum)
5LA0116
41
P/N 3681774M1 Edition 01-2006 400-25

Proceed as follows:
1. Fit the reverse shuttle double gear (2) shaft (1)
with the bearing.
2 3
1
5LA0096
42
2. Fit the secondary shaft (1) and the two double
gears (2) with respective support tapered bear-
ings.
5LA0102
43
3. Fit and fasten the bearing stop plate (1) of the
secondary shaft (2). 1
The secondary shaft tapered bearing preload is
determined by blocking the plate.
2
5LA0104
44
4. To proceed with the assembly operation:
a.Calculate thickness of the shim (1) limiting
the four gear pack (2) float.
b.Calculate thickness of the shim (3) limiting
the 4th gear synchroniser (4) float.
5LA0117
45
400-26 P/N 3681774M1 Edition 01-2006

5. Position the gears and four gear synchronisers

(1) and insert the primary shaft from the top
(2).
5LA0106
46
6. Fit from the front the snap ring (1) of the pri-
mary shaft.
(Also see detail 2 in fig. 48).
5LA0098
47
5LA0097
48
7. Position the shim (1) limiting the four gear
pack (2) float.
(For selecting the shim, see procedure on page
31)
5LA0119
49
P/N 3681774M1 Edition 01-2006 400-27

8. Fit from the rear the snap ring (1) of the pri-
mary shaft. 1
(Also see detail 1 in fig. 48).
5LA0001
50
th
9. Fit bearing (2) and snap ring (3) on 4 gear
(1).
2
1
5LA0114
51
th
10. Assemble 4 gear (1) with shim (2) and syn-
chroniser ring (3).
(For selecting the shim, see procedure on page
33)
5LA00
52
th
11. Position the 4 gear (1) complete.
5LA0168
53
400-28 P/N 3681774M1 Edition 01-2006

12. Fit the super final drive assembly.
13. Fit the following in the order given on the sec-

ondary shaft:
a. slewing bearing (1)
b. bushing (2)
c. thrust bearing (3)
d. slewing bearing (4)
e. 5th gear (5)
f. thrust bearing (6)
g. synchroniser assembly (7)
h. stop plate (8)
i. nut ring (9). 5LA0118
54
Tighten the nut ring at the specified torque of
150 - 170 Nm.
14. Fit the 5th gear rod, the fork and pawl.
15. Fit all internal components for engaging the

four gears.
Pay attention to the pawl (1) between the rods
(2) and (3).
5LA0120
55
16. Fit the balls, the springs and the rod stop caps.
17. Fit the support guard with super final drive
double gear.
Tighten the screws at the specified torque of:
45 - 52 Nm
18. Position the two screws fastening the gearbox
to the clutch housing.
Respect the given assembly sequence oth-
erwise it will be impossible to position the
screws after fitting the super final drive
gear.
19. Fit the super final drive gear.
P/N 3681774M1 Edition 01-2006 400-29

20. Fit the rod, the fork and all the super final drive
engagement components.
5LA0121
56
After assembly, check that the gear and

super final drive engage smoothly without
slipping.
Otherwise, replace the rods and forks.
400-30 P/N 3681774M1 Edition 01-2006

Four gear pack float adjustment
WARNING
safety footwear.
Make sure that, once mounted, the 4 gear

! pack has a float of 0 - 0.1 mm to ensure
that it operates correctly.
Proceed as follows:
1. Pre-fit the gears and 4 gear synchronisation

assemblies on the primary shaft.
2. Fit on the primary shaft the snap ring (1) with-
out the shim (2).
5LA0124
57
5LA0105
58
3. Measure the space L between the snap ring (1)
and the hub (2) of the 3rd and 4th gear syn-
chroniser with a dial gauge.
5LA0125
59
P/N 3681774M1 Edition 01-2006 400-31

4. The shim Sp1 to be arranged between the syn-

chroniser and snap ring results from:
Sp1 = L - 0.1
where
L = measured dimension
0.1 = operating float
The following shims Sp 1 are available as spare
parts:
2.985 mm
3.100 mm
3.200 mm
3.250 mm
3.300 mm
3.400 mm
3.500 mm
3.550 mm
400-32 P/N 3681774M1 Edition 01-2006

4th gear synchronisation float adjustment
WARNING
safety footwear.
Make sure that the 4th gear synchroniser

! once fitted has a float of 0.35 - 0.45 mm
to ensure that it operates correctly.
Proceed as follows:
1. Measure with a micrometer dimension C

between the surface A of the gearbox and the
surface B on the 4th gear synchroniser.
5LA0108
60
2. Measure with a micrometric thickness gauge
the distance D from the 4a gear.
5LA0109
61
P/N 3681774M1 Edition 01-2006 400-33

3. The shim Sp2 to be arranged between the syn-

chroniser ring (1) and the 4th gear (2) is:
Sp2 = C - D - 0.45
where
C = measured dimension
D = measured dimension
0.45 = operating float
The following shims Sp 2 are available as spare
parts:
5LA0122
1.75 mm
2.00 mm 62
2.25 mm
2.50 mm
2.75 mm
3.00 mm
3.25 mm
400-34 P/N 3681774M1 Edition 01-2006

GEAR LEVER SUPPORT HOUSING
Disassembly
WARNING
safety footwear.
Proceed as follows:
1. Remove the cover (1).
3. Loosen the screw (3).
4. Remove the fork (4).
5. Remove the snap ring (5) holding the support
(6).
6. Remove the snap ring (7), remove the shaft (9)
and remove the springs and respective rings
and bearing rings from inside the box (10).
5LA0123
63
P/N 3681774M1 Edition 01-2006 400-35

400-36 P/N 3681774M1 Edition 01-2006

SECTION 500
REAR AXLE AND SIDE FINAL DRIVES
SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES
TABLE OF CONTENTS
Description Page
MAIN SPECIFICATIONS OF THE STANDARD BEVEL GEAR PAIR AND DIFFERENTIAL . . . . . . . . . . . . 500-3
MAIN SPECIFICATIONS OF STANDARD SIDE FINAL DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-3
MAIN SPECIFICATIONS OF GT BEVEL GEAR PAIR AND DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . 500-3
MAIN SPECIFICATIONS OF GT SIDE FINAL DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-3
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-4
BEVEL GEAR PAIR AND DIFFERENTIAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-4
SIDE FINAL DRIVES TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-4
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-5
PERSPECTIVE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-10
DIFFERENTIAL HOUSING SEALANT APPLICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-12
STANDARD SIDE FINAL DRIVE HOUSING SEALANT APPLICATION DIAGRAM . . . . . . . . . . . . . . . . 500-13
GT SIDE FINAL DRIVE HOUSING SEALANT APPLICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . 500-14
REAR DIFFERENTIAL HOUSING

REMOVAL-REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-15
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-19
REAR DIFFERENTIAL HOUSING - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-20

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-28
Pinion position adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-31
Pinion taper bearing preload adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-34
Differential support tapered bearing preload adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 500-35
Pinion and ring teeth clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-37
STANDARD SIDE FINAL DRIVE - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-39

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-39
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-40
Axle shaft taper bearing preload adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-41
Wheel hub taper bearing preload adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-43
GS SIDE FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-45

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-45
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-46
500-2 P/N 3681774M1 Edition 01-2006

MAIN SPECIFICATIONS OF THE STANDARD BEVEL GEAR PAIR AND DIFFERENTIAL
Bevel gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With helical toothing
Bevel gear pair gear ratio. . . . . . . . . . . . . . . . . . . . . . . . . 9/38
Clearance between bevel pair teeth . . . . . . . . . . . . . . . . . (mm) 0.18 - 0.34
Type of differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with two satellite gears
Mechanical control of diff lock . . . . . . . . . . . . . . . . . . . . . Electrohydraulic with mechanical

engagement
MAIN SPECIFICATIONS OF STANDARD SIDE FINAL DRIVES
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With straight toothing
Gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/62
MAIN SPECIFICATIONS OF GT BEVEL GEAR PAIR AND DIFFERENTIAL
Bevel gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With helical toothing
Bevel gear pair gear ratio. . . . . . . . . . . . . . . . . . . . . . . . . 9/41
Clearance between bevel pair teeth . . . . . . . . . . . . . . . . . (mm) 0.18 - 0.34
Type of differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with two satellite gears
Mechanical control of diff lock . . . . . . . . . . . . . . . . . . . . . Electrohydraulic with mechanical

engagement
MAIN SPECIFICATIONS OF GT SIDE FINAL DRIVES
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With straight toothing
Gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51/10
P/N 3681774M1 Edition 01-2006 500-3

DESCRIPTION AND OPERATION
The rear transmission transmits drive from the toothing and are controlled by the bevel gear pair
gearbox to the side final drives, by means of the output axle shaft, the same that control the main
bevel gear pair. The bevel gear pair is the type with brakes.
helical toothing and is supported by taper roller 4WD is engaged by the spring-on device which
bearings. engages automatically also when the engine is
The differential has two satellite gears and is pro- stopped.
vided with a mechanically engaged, electro-hydrau- The spring-on coupling is a mechanical, electrically
lically engaged lock. released device.
The side final drives are the type with straight
BEVEL GEAR PAIR AND DIFFERENTIAL TROUBLESHOOTING
Noisy transmission when the 1. Satellite and planetary Detach the rear transmission hous-
tractor is on the move, even gears incorrectly adjusted ing, replace the worn parts and
with the gears in neutral (not or worn. correctly adjust the differential
due to the side final drives). gears.
2. Excessive play in the groove Remove the rear transmission

where the axle shafts are housing and replace the damaged
shrunk on to the crown parts.
wheels.
Noisy transmission when the 1. Some internal component is Detach the rear transmission hous-
tractor is on load and without faulty or defective. ing, replace the worn parts and
load. correctly adjust the differential
gear play.
Noisy transmission with over- 2. Insufficient coupling play Remove the rear transmission
heating. between the pinion teeth housing and correctly adjust the
and bevel gear pair. bearings that support the ring
bevel gear.
SIDE FINAL DRIVES TROUBLESHOOTING
Noisy side final drives when the 1. Some internal component is Remove the side final drive housing
tractor is on the move, even faulty or defective. and replace the damaged parts.
with the gears in neutral.
2. Excessive play in the groove Remove the side final drive housing
where the wheel axle shafts and replace the damaged parts.
are shrunk on to the side
final drives.
500-4 P/N 3681774M1 Edition 01-2006

CONTROLS
1
5LA0127
1
Rear differential controls
1. Differential lock switch 2. 4WD selection switch
P/N 3681774M1 Edition 01-2006 500-5

SECTIONS
1
1 2 3 4 5 6 7 8 9 10 11 12
40
39
38
37
36
35
34
33
32
31
30
29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13
5LA0126
2
Rear differential longitudinal section
1. Upper shaft 21. Ball bearing

2. Ball bearing 22. Thrust bearing washer
3. Fast range gear 23. Reduction gear
4. Engagement hub 24. DT gear
5. Snap ring 25. DT shaft (rear)
6. Normal range shaft 26. Oil duct
7. Ball bearing 27. DT engagement sleeve
8. Snap ring 28. Spring
9. PTO shaft sleeve 29. Plate
10. PTO shaft 30. Snap ring
11. PTO upper shaft 31. Spacer
12. PTO hydraulic clutch 32. Snap ring
13. PTO output shaft 33. Ball bearing
14. PTO gear (1000) 34. Sleeve
15. PTO gear (540) 35. DT shaft (front)
16. Proportional PTO gear 36. Fast range gear
17. Proportional PTO shaft 37. Ring nut
18. Pinion 38. Taper bearing
19. Taper bearing 39. Snap ring
20. Bushing 40. Spacer
500-6 P/N 3681774M1 Edition 01-2006

5LA0128
3
Rear differential transversal section
1. Differential lock rod 10. Planetary gear

2. Spring 11. Satellite gear
3. Differential lock fork 12. Satellite pin
4. Differential lock hydraulic actuator 13. Slewing bearing
5. Supporting flange 14. Differential housing
6. Adjuster shim 15. Taper bearing
7. Axle shaft 16. Axle shaft
8. Taper bearing 17. Adjuster shim
9. Slewing bearing 18. Supporting flange
P/N 3681774M1 Edition 01-2006 500-7

5LA0130
4
Standard side final drive section
1. Wheel hub 10. Side final drive body

2. O-ring 11. Axle shaft
3. Wheel hub tapered bearing 12. Brake assembly
4. Drive axle tapered bearing 13. Ring gear
5. Spacer 14. Snap ring
6. Reducer cover 15. Adjuster shim
7. Drive axle tapered bearing 16. Wheel hub tapered bearing
8. Adjuster shim 17. Fixing screw
9. Retention ring 18. Retention ring
500-8 P/N 3681774M1 Edition 01-2006

5LA0131
5
GT side final drive sections
1. Axle shaft 9. Taper bearing

2. Brake assembly 10. Retention ring
3. Retention ring 11. Wheel hub
4. Snap ring 12. Taper bearing
5. Radial roller bearing 13. Gear
6. Inner guard 14. Nut
7. External guard fastening screws 15. Inner guard fastening screws
8. External guard
P/N 3681774M1 Edition 01-2006 500-9

PERSPECTIVE VIEWS
1
Range selector Proportional PTO shaft
PTO shaft DT engagement unit (Spring-on)
Pinion DT axle
Ring gear Range assembly
5LA0129
6
Rear transmission assembly perspective view
500-10 P/N 3681774M1 Edition 01-2006

Axle shaft
Differential assembly
Reduction gear
Wheel hub
5LA0133
7
GT side final drive perspective view
P/N 3681774M1 Edition 01-2006 500-11

DIFFERENTIAL HOUSING SEALANT APPLICATION DIAGRAM
5LA0132
8
500-12 P/N 3681774M1 Edition 01-2006

STANDARD SIDE FINAL DRIVE HOUSING SEALANT APPLICATION DIAGRAM
4LA0166
9
P/N 3681774M1 Edition 01-2006 500-13

GT SIDE FINAL DRIVE HOUSING SEALANT APPLICATION DIAGRAM
4LA0167
10
500-14 P/N 3681774M1 Edition 01-2006

REAR DIFFERENTIAL HOUSING

REMOVAL-REFITTING
Removal
DANGER
hooks.
Make sure that there are no bystanders
near the load being lifted.
WARNING
safety footwear.
Proceed as follows:
1. Remove the cab (see section 1100).
2. Loosen the filler caps and drain the transmis-
sion oil.
Old oil must be disposed of in compliance

with the current laws.
3. Remove all plastic clips fastening the gearbox

wiring harnesses.
4. Disconnect the hydraulic pipes and the power
lift electrical connections.
5. Disconnect the rear current socket electrical
connection.
6. Disconnect the oil suction tube (1) from the
gearbox.
5LA0136
1
11
P/N 3681774M1 Edition 01-2006 500-15

7. Disconnect:
- the speed sensor electrical connector (1); 5
- the right brake linkage (2);
- the spring-on device oil supply tube (3);
- the brake cylinder oil supply tube (4);
4 1
- the differential lock cylinder oil supply tube
(5).
2
5LA0135
3
12
8. Disconnect the supply tube (1) from the PTO
clutch and brake (2).
2
5LA0138
13
9. Disconnect:
- the hydraulic tube (1); 1
- the brake cylinder oil supply tube (2);
- the left brake linkage (3);
- the gearbox oil return tube (4);
2
- the high pressure hydraulic circuit delivery 5
pipe (5).
3
4
5LA0134
14
10. Remove the upper gearbox cover (1) and the
lower differential housing cover (2).
2
5LA0137
15
500-16 P/N 3681774M1 Edition 01-2006

11. Loosen two lower and upper screws between

gearbox and differential housing.
5LA0062
16
12. Engage the permanently meshed super final
drive gear (1).
5LA0139
17
13. Fasten the front axle with two wooden wedges
to prevent the engine rocking.
14. Appropriately support the differential housing
and the front transmission.
Loosen the external screws fastening and sepa-
rate the two assemblies being careful to main-
tain the alignment and parallelism of the
junction planes.
Remove the PTO shaft from the back of
the transmission to facilitate separation of
the two assemblies.
15. Standard side final drives

- Ensure the side final drives (1) to an appro- 2 1
priate lifting device.
- Loosen the fastening screws to the differen-
tial housing.
- Loosen the differential housing side final drive
(2).
4LA0136
18
P/N 3681774M1 Edition 01-2006 500-17

15. GT side final drives

- Ensure the external guard (1) of the side final
drive to an appropriate lifting device.
- Loosen the fastening screws to the inner
guard (2).
- Remove the outer component of the side final
drive.
5LA0060
19
- Ensure the lifting tool (1) 100 RID GL to the
inner guard (2).
- Loosen the inner and outer screws for fasten-
ing the inner components to the differential
housing and removing it keeping it well
aligned to facilitate sliding of brake discs on
the axle shaft.
5LA0059
20
500-18 P/N 3681774M1 Edition 01-2006

Refitting
refitting the differential housing:
WARNING
safety footwear.

tion on pages 6 and 7.
figure on page 12.
- Refit the differential housing favouring the
transmission shaft coupling. Tighten the fas-
tening screws at the specified torque of:
98 - 120 Nm
- Fit the differential housing lower cover.
- Fit the gearbox upper cover.
- Fit the side final drives.
- Connect the brake linkages.
- Connect the oil supply tubes of the brake cyl-
inders.
- Connect the spring-on device oil supply tube.
- Connect the differential lock cylinder oil sup-
ply tube.
- Connect the PTO clutch and brake oil supply
tubes.
- Connect all hydraulic pipes between differen-
tial and gearbox.
- Connect all electrical connections.
- Restore lubricant oil levels.
- Refit the cab (see section 1100).
P/N 3681774M1 Edition 01-2006 500-19

REAR DIFFERENTIAL HOUSING - OVERHAUL
Disassembly
WARNING
safety footwear.
Proceed as follows:
1. Fasten the differential housing to the working
stand.
2. Remove the spring (1) and the brake external

lever (2). Hold the lever (3) pulled and remove
the pressure plate (4).
5LA0058
21
3. Remove the range lever support and the
hydraulic power lift.
4. Remove the spring pins, remove the rods (1)

and recover the engagement blocks (2).
5LA0056
22
500-20 P/N 3681774M1 Edition 01-2006

5. Loosen the fixing screws (1) and remove the

plate (2).
5LA0055
23
6. With the help of a lever, remove the shaft (1)
from the slow /R range.
5LA0053
24
Remember that the double gear (1) is not
easy to remove because it is obstructed
by the fast range shaft.
5LA0054
25
7. With the help of a lever, move the upper shaft
(1) slightly forward to allow access to the snap
ring.
5LA0140
26
P/N 3681774M1 Edition 01-2006 500-21

8. Remove the snap ring (1) from its seat.
5LA0052
27
9. Remove the upper shaft (1) and recover the
fast range gear (2) and engagement hub (3).
5LA0051
28
10. Recover the slow range/R double gear (1).
5LA0050
29
11. Remove the differential lock actuator (1).
5LA0049
30
500-22 P/N 3681774M1 Edition 01-2006

Be careful when removing the differential

! lock spring.
Use protective gloves to hold the spring
compressed with your hand.
12. Remove the rod (1) and recover the fork (2)
and the spring (3) from inside the differential
housing.
5LA00048
31
13. Refit on the PTO clutch cover.
5LA00047
32
14. Remove the clutch assembly (1) and remove
the PTO shaft (2).
5LA0046
33
P/N 3681774M1 Edition 01-2006 500-23

15. Remove the snap ring (1) from the normal

range shaft (2).
5LA0045
34
16. Remove the normal range shaft (1) from inside
the differential housing using the tool (2) 33
DIF GL as shown in the figure.
5LA0044
35
17. Loosen the upper PTO shaft (2) nut ring (1).
5LA0041
36
18. Remove the upper PTO shaft (1).
5LA0040
37
500-24 P/N 3681774M1 Edition 01-2006

19. Remove the differential support (2) flange (1).

Appropriately mark the left and right
flange to reposition it again correctly.
5LA0032
38
20. Remove the complete differential assembly (1).
5LA0031
39
21. Position the differential assembly and disas-
semble as follows:
- remove the spring pin (1) holding the satellite
holder pin (2);
- remove the body from the differential (3);
- extract the two satellites (4) and the respec-
tive slewing bearing (5);
- extract the two planetary gears (6) and the
respective slewing bearings (7).
5LA0027
40
22. Loosen the tapered pinion lock nut.
5LA0030
41
P/N 3681774M1 Edition 01-2006 500-25

23. Remove the tapered bearing (1). Remove the

snap ring (2) fitted on the tapered pinion shaft
(3).
5LA0029
42
24. Loosen the bevel pinion (1) from the differen-
tial housing with the respective gears and
spacers.
5LA0141
43
25. Lever inside the differential housing to move
the spring-on device forward.
5LA0142
44
26. Remove the complete assembly (1) and
recover the DT gear (2) and the slewing bear-
ing (3).
5LA0143
45
500-26 P/N 3681774M1 Edition 01-2006

Be very careful when removing the spring-

! on device contrast spring because it is
highly compressed and withheld in posi-
tion only by the snap ring.
Use appropriate safety devices.
27. Remove the snap ring (1) and remove the

spacer (2).
5LA0144
46
28. Fit the assembly on the tool (1) 164 DT GL to
compress the spring (2) and remove the snap
ring (3).
5LA0145
47
P/N 3681774M1 Edition 01-2006 500-27

Assembly
WARNING
safety footwear.

refitting the differential:
tion on pages 6 and 7.
figure on page 12.
100.


seats.

Proceed as follows:
1. Adjust the position of the pinion (1).
2. Adjust the preload of the two pinion taper
bearings (2).
3. Adjust the preload of the differential support
tapered bearings (3).
4. Adjust pinion and ring (4) teeth clearance.
5LA0146
48
500-28 P/N 3681774M1 Edition 01-2006

5. Reassemble and refit the spring-on unit.

Use the tool 164 DT GL already used for dis-
assembly to compress the contrast spring.
6. Fit the bevel pinion and respective gears and
bearings.
7. Reassemble the differential assembly fastening

inside the body (3) the two satellite gears (6)
with the respective slewing bearings (7), the
two satellite gears (4) with the respective slew-
ing bearings (5) fastening the pin (2) with a
spring pin (1).
5LA0027
49
8. Position the differential assembly inside the
housing.
9. Fit the differential support flange and tighten
the fastening screws at a specified torque of:
48 - 52 Nm
Respect the flange assembly position fol-
lowing the marking made during disas-
sembly.
Make sure that the clearance between the

! pinion and ring teeth is from 0.18 to 0.30
mm with a maximum admitted variation of
0.1 mm.
5LA0018
50
10. Fasten and block the upper PTO shaft.
P/N 3681774M1 Edition 01-2006 500-29

11. Fasten and block the normal range shaft (1)

using tool (2) 37 DIF GL.
5LA0017
51
12. Position the PTO shaft and the clutch assembly.
13. Fit the PTO clutch cover.
14. Fit the differential lock fork (1), the rod (2) and
the spring (3).
Adjust the screw (4) to centre the fork (1) in
the engagement sleeve (5).
Check that the engagement pins of the sleeve
have a minimum clearance with respect to the
planetary gear surface.
5LA0016
52
15. Fit the differential lock actuator.
16. Position the slow range/R double gear.
17. Fit and fasten the upper shaft with fast speed
gear and engagement hub.
18. Fit and fasten the slow range/R shaft.
19. Fit all range engagement internal components.
20. Position and fasten the power lift and range
lever support.
21. Fit all brake components.
500-30 P/N 3681774M1 Edition 01-2006

Pinion position adjustment
WARNING
safety footwear.
This adjustment procedure is required

! whenever the rear pinion tapered bearing
(1), bevel pair or differential housing is
replaced.
Make sure that after being fitted the pin-

! ion is positioned with respect to the ring
at a minimum dimension of B = 120 mm
to ensure the correct operation of the
bevel pair.
Dimension B may vary according to the
correction shown on the pinion. 5LA0147
53
Proceed as follows:
1. Fit the rear tapered bearing (1) on the tool (2)
45 DIF GL.
5LA0024
54
2. Measure dimension C with a micrometer thick-
ness gauge.
This is the distance between the tapered bear-
ing abutment on the guard and the bevel pin-
ion supporting surface.
5LA0148
55
P/N 3681774M1 Edition 01-2006 500-31

3. Observe the value A printed on the differential

housing.
5LA0026
56
4. Observe the value D printed on the bevel pin-
ion.
5LA0025
57
5. The shim Sp to be arranged between outer
bearing ring and differential casing abutment
is:
Sp = A - [(B + D) + C]
if D is positive
or
Sp = A - [(B - D) + C]
if D is negative
5LA0149
58
where:
A =Value printed on the differential housing

B = Nominal dimension
C = Measured dimension
D = Value printed on the bevel pinion
500-32 P/N 3681774M1 Edition 01-2006

Example 1:
A =133.80 mm. Value printed on the differen-
tial housing
B = 120 mm. Nominal dimension
C = 11.5 mm. Dimension measured
D = +0.15 mm. Value printed on the bevel pin-
ion
Sp = 133.8 - [(120 + 0.15) + 11.5] = 2.15 mm
Example 2:
A =133.3 mm. Value printed on the differential
housing
B = 120 mm. Nominal dimension
C = 11.8 mm. Dimension measured
D = -0.12 mm. Value printed on the bevel pin-
ion
Sp = 133.3 - [(120 -0.12) +11.8] = 1.62 mm
6. Insert the calculated shim Sp, fit the tapered
bearings, the pinoin and the lock nut.
P/N 3681774M1 Edition 01-2006 500-33

Pinion taper bearing preload adjustment
WARNING
safety footwear.
Make sure that the rolling torque of the

! bevel pinion after fitting is 3-4 Nm to
ensure correct operation of the bevel pair.
Proceed as follows:
1. Preliminarily tighten the bevel pinion lock nut.
5LA0030
59
2. Use a plastic hammer to settle the pinion on
the bearings.
3. Tighten the lock nut to obtain a rolling torque
of the pinion of 3 - 4 Nm.
5LA0023
60
the bearings again.
5. Measure the rolling torque again and when the
correct value is reached, rivet the edge of the
nut into the pinion shaft grooves.
500-34 P/N 3681774M1 Edition 01-2006

Differential support tapered bearing preload

adjustment
WARNING
safety footwear.
Make sure that the differential tapered

! bearings have after fitting a preload of 0-
0.1 mm to ensure correct operation of the
differential.
Proceed as follows:
1. Fit the bevel ring on the differential body and
tighten the screws at a specified torque of:
110 - 120 Nm
2. Fit the two dummy bearings (1) 35 DIF GL on

the differential body (2).
5LA0022
61
3. Position the differential inside the box blocking
it with the supporting flanges.
Respect the flange assembly position fol-
lowing the marking made during disas-
sembly.
P/N 3681774M1 Edition 01-2006 500-35

4. Using a lever, shift the differential assembly

against the support B.
Measure with a thickness gauge the space X
between the dummy bearing and the abutment
on the differential body.
Make sure that the dummy bearing is perfectly
in contact with the support B. Repeat the
measurement three times and calculate the
arithmetical average of the three readings.
5LA0021
62
5. The total shim St to be inserted considering
the preload of 0.1 mm is:
St = X + 0.1
where:
X = measured dimension
0.1 = functional preload
The total shim St must be split between
the left and right supporting flange as
shown in the following procedure “Pinion
and ring teeth clearance adjustment”.
500-36 P/N 3681774M1 Edition 01-2006

Pinion and ring teeth clearance adjustment
WARNING
safety footwear.

! pinion and ring teeth is after assembly
0.18 - 0.34 mm to ensure the correct
operation of the bevel gear.
Proceed as follows:
1. Position a dial gauge on the differential housing
to measure the clearance between the pinion
and ring teeth.
5LA0018
63
2. A correct average clearance should be between
0.18 mm and 0.34 mm, thus an average 0.26
mm will be considered for the successive calcu-
lations.
3. Make the differential assembly slide between
the two supporting flanges until the dial gauge
detects a clearance between the teeth of 0.26
mm.
Take three measurements at 120° and calcu-
late the arithmetical average of the three read-
ings.
4. Measure with a thickness gauge the space X1
between the supporting flange A and the
dummy bearing (1).
Take three measurements at 120° and calcu-
late the arithmetical average of the three read-
ings.
5LA0150
64
P/N 3681774M1 Edition 01-2006 500-37

5. Given the value X1 and the total shim St previ-

ously detected (see procedure on page 35), the
space X2 between the supporting flange B and
the dummy bearing (2) is:
X2 = S t - X 1
where:
St = measured dimension
X1 = measured dimension
The values X1and X2 correspond to the

shim values Sp1 and Sp2 if the fitted
dummy bearings have the same thickness
as real tapered bearings to be fitted.
Differences will therefore be checked.
6. Measure with a micrometric thickness gauge,

the thickness V1 of the real tapered bearing (1)
and the thickness Z1 of the dummy bearing
(2).
Calculate the difference of thickness ∆S1.
Repeat the same procedure for the other bear-
ings.
∆S1 = V1 - Z1
∆S2 = V2 - Z2
5LA0019
65
7. The right Sp1 and left Sp2 shims to be inserted
inside the bearings are:
Sp1 = X1 ± ∆S1
Sp2 = X2 ± ∆S2
where:
∆S1 = calculated thickness difference
∆S2 = calculated thickness difference
Round off to the lower figure within 0.05 mm. 5LA0157
66
500-38 P/N 3681774M1 Edition 01-2006

Example:
St = 3.6 mm. Dimension measured with the
procedure “Differential support tapered
bearing preload adjustment”
X1 = 1.6 mm. Dimension measured
∆S1 = 0.15 mm. Calculated value
∆S2 = -0.10 mm. Calculated value
X2 = 3.6 - 1.6 = 2.0 mm
Sp1 = 1.6 + 0.15 = 1.75 mm
Sp2 = 2.0 -0.1 = 1.9 mm
STANDARD SIDE FINAL DRIVE - OVERHAUL
Disassembly
WARNING
safety footwear.
Proceed as follows with the side final drive removed

from the differential housing:
1. Fasten to the wheel hub (1) the lifting tool (2)
131 RID GL. 2
2. Loosen the fasten screws of the cover (3), 1
remove the entire group including the tapered
bearing (4) and the axle shaft (5) from the side 3
final drive body (6).
6 5
4LA0137
67
3. Remove the snap ring (1).
4. Using a press, remove the wheel hub (2) from
the cover (3) recovering the gear (4) and the 1 2
bearing (5).
3
5
4LA0138
68
P/N 3681774M1 Edition 01-2006 500-39

Assembly
WARNING
safety footwear.

refitting the side final drive:
tion on page 8.
figure on page 13.
100.


seats.
Proceed as follows:
1. Adjust the preload of the two axle shaft taper
bearings (1).
2. Adjust the preload of the two wheel hub taper
bearings (2).
5LA0151
69
3. Fit the cover assembly and fasten the screws.
500-40 P/N 3681774M1 Edition 01-2006

4. Fit on the wheel hub (1) the tool (2) 131 RID
GL and check that the rolling torque is:
15 - 35 Nm
1
2
4LA0142
70
Axle shaft taper bearing preload adjustment
WARNING
safety footwear.
Make sure that the drive axle taper bear-

! ings after fitting have a preload of 0 - 0.05
mm to ensure correct operation of the
final drive.
Proceed as follows:
1. Measure with a micrometer thickness gauge
the distance A1 between the reducer resting
surface and the axle shaft taper bearing seat.
4LA0139
71
P/N 3681774M1 Edition 01-2006 500-41

2. Measure with a micrometer thickness gauge or

dial gauge the distance B1 between the cover
resting surface and the axle shaft taper bearing
seat.
5LA0153
72
To easily determine the distance B1 make
use of the tool (1) 130 RID GL which
holds in position the outer ring of the axle
shaft tapered bearing.
4LA0140
73
3. The shim S1 to be arranged between the taper
bearing outer ring (1) and the resting plane on
the side final drive body (2) is:
S1 = (A1 - B1) + P
where:
A1 = measured dimension
B1 = measured dimension
P = 0.05 mm. Functional preload

5LA0154
74
500-42 P/N 3681774M1 Edition 01-2006

Wheel hub taper bearing preload adjustment
WARNING
safety footwear.
Make sure that the wheel hub bearings

! after fitting have a preload of 0 - 0.15 mm
to ensure correct operation of the final
drive.
Proceed as follows:
1. Measure with a micrometer thickness gauge
the distance A2 between the reducer resting
surface and the wheel hub taper bearing seat.
5LA0152
75
2. Measure with a micrometer thickness gauge or
dial gauge the distance B2 between the cover
resting surface and the wheel hub taper bear-
ing seat.
5LA0155
76
P/N 3681774M1 Edition 01-2006 500-43

To easily determine the distance B2 make

use of the tool (1) 130 RID GL which
holds in position the outer ring of the
wheel hub bearing.
4LA0140
77
3. The shim S2 to be arranged between the taper
bearing outer ring (1) and the resting plane on
the side final drive body (2) is:
S2 = (A2 - B2) + P
where:
A2 = measured dimension
B2 = measured dimension
P = 0.15 mm. Functional preload

5LA0156
78
500-44 P/N 3681774M1 Edition 01-2006

GS SIDE FINAL DRIVE
Disassembly
WARNING
safety footwear.
Proceed as follows with the inner and outer side

final drives separated and removed from the differ-
ential housing:
1. Loosen the lock nut (1) and remove the gear
(2).
2. Remove the taper bearing (3) and remove the
wheel hub (4) from the outer final drive (5).
5LA0065
79
3. Remove the o-ring (2) from the inner final drive
(1).
4. Remove the snap ring (3) from the radial bear-
ing (4) and remove the inner axle shift (5).
To remove the radial bearing from its seat,
use tool 103 RID GL for 10 teeth axle
shafts and tool 104 RID GL for 11 teeth
axle shafts.
5LA0066
80
P/N 3681774M1 Edition 01-2006 500-45

Assembly
WARNING
safety footwear.

tion on page 9.
figure on page 14.
100.


seats.
Proceed as follows:
1. Insert the wheel hub with the tapered bearing
in the outer final drive body.
2. Fit the gear (1) and preliminary fasten the lock
nut (2).
3. Tighten the nut to reach a rolling torque of:
6 - 8 Nm
5LA0067
81
500-46 P/N 3681774M1 Edition 01-2006

4. Fit the radial bearing on the inner axle shaft.
To fit the radial bearing in its seat on the

axle shaft, use tool 103 RID GL for 10
teeth axle shafts and tool 104 RID GL for
11 teeth axle shafts.
5LA0068
82
5. Insert the o-ring (1), the spacer (2) on the axle
shaft (3).
6. Fit the axle shaft and inner final drive.
7. Assemble the inner final drive to the outer final
drive.
5LA0069
83
P/N 3681774M1 Edition 01-2006 500-47

500-48 P/N 3681774M1 Edition 01-2006

SECTION 510
FRONT AXLE
SECTION 510 - FRONT AXLE
TABLE OF CONTENTS
Description Page
MAIN SPECIFICATIONS OF FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-3

Axle 710/515 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-3
Axle 716/513 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-3
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-4
SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-5
DIFFERENTIAL ASSEMBLY - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-7

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-10
Pinion position adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-11
Pinion taper bearing preload adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-13
Pinion and crown teeth clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-14
FINAL DRIVE - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-16

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-16
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-18
510-2 P/N 3681774M1 Edition 01-2006

MAIN SPECIFICATIONS OF FRONT AXLE
Axle 710/515
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spheroid cast iron construction, pivoting,

with central mount
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrolock
Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle epicyclical
DT engagement/disengagement . . . . . . . . . . . . . . . . . . . Mechanical, electro-hydraulically disen-

gaged
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . By switch on the operator's right.
Bevel torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/51
Bevel pair ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 3.923
Final drive ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 4.6
Total ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 18.046
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil bath
Axle 716/513
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spheroid cast iron construction, pivoting,

with central mount
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrolock
Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle epicyclical
DT engagement/disengagement . . . . . . . . . . . . . . . . . . . Mechanical, electro-hydraulically disen-

gaged
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . By switch on the operator's right.
Bevel torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/53
Bevel pair ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 4.076
Final drive ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 4.6
Total ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 : 18.753
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil bath
P/N 3681774M1 Edition 01-2006 510-3

The front axle for 4WD models consists of a sphe- borne by two supports fixed to the chassis.
roid cast iron central body which incorporates the The spring-on front drive engagement unit is a
lockable differential assembly and a final drive. mechanically engaged and electro-hydraulically
The drive torque is transmitted by the differential to released device controlled by a switch arranged on
the final drives through the axle shafts, each of the driver's right.
which is braked by oil bath wet plates. 4WD is always engaged when the tractor stops to
The axle can swing around horizontally as it is ensure perfect braking.
CONTROLS
1
5LA0127
1
1. Differential lock switch 2. 4WD selection switch
510-4 P/N 3681774M1 Edition 01-2006

SECTIONS
5LA0286
2
Central final drive section
1. Left axle shaft 23. Slewing bearing
2. Screw 24. O-ring
3. Brake housing cover 25. Piston
4. Ring nut 26. O-ring
5. Piston 27. Union
6. Brake housing 28. Cap
7. Taper bearing 29. Spring
8. Satellite pin 30. Snap ring
9. Screw 31. Brake hub
10. Ring nut 32. Bevel pinion ring
11. Lock housing 33. Bevel pinion
12. O-ring 34. O-ring
13. O-ring 35. Taper bearing
14. Piston 36. Shim
15. Brake disc 37. Taper bearing
16. Counter disc 38. Bevel ring gear
17. Hydrolock housing 39. Differential mount
18. Spring guide 40. Snap ring
19. O-ring 41. Brake hub
20. Thrust slewing bearing 42. Axial guard
21. Right axle shaft 43. Planetary gear
22. Snap ring
P/N 3681774M1 Edition 01-2006 510-5

5LA0287
3
Final drive section
1. Ring gear 12. Circlip

2. Pin stop roller 13. Satellite holder cover
3. Circlip 14. Ring nut
4. Screw 15. Planetary gear
5. Ring 16. Circlip
6. Hub o-ring 17. Washer
7. Axle shaft o-ring 18. Spacer
8. Upper pin cover 19. Satellite gear
9. Fork 20. Shimming ring
10. Tapered bearings for wheel hub 21. Satellite pin
11. Flange 22. Roller bearing
510-6 P/N 3681774M1 Edition 01-2006

DIFFERENTIAL ASSEMBLY - OVERHAUL
Disassembly
WARNING
safety footwear.
Proceed as follows:
1. Loosen the differential mount fastening screws,
remove the complete assembly (1) using tool
(2) 75 DTI GL and bushing 75a DT GL.
5LA0288
4
2. Fasten the vice assembly and remove the dif-
ferential lock oil supply tube (1).
5LA0289
5
3. Remove the hydrolock housing (1) with the dif-
ferential lock engagement sleeve (2) and the
brake discs (3) from the piston holder housing
(4).
5LA0290
P/N 3681774M1 Edition 01-2006 510-7

4. Remove the brake housing cover (1) with the

brake discs (2-3) from the brake housing (4).
5LA0291
7
5. Using tool 82 DT GL, remove the ring nut (1)
and the one of the other mount.
5LA0292
8
6. Remove the two housings (1 and 2) with the
differential unit.
5LA0293
9
7. Remove the bevel pinion ring nut (1).
5LA0294
10
510-8 P/N 3681774M1 Edition 01-2006

8. Remove the pinion (1) from the seat with the

tapered bearing outer ring (2) and shim (3).
5LA0314
11
9. After removing the screws (1), remove the ring
bevel gear (2) and disassemble the differential.
5LA0315
12
10. Extract piston (1) from the housing (2) by
introducing air.
5LA0316
13
P/N 3681774M1 Edition 01-2006 510-9

Assembly
WARNING
safety footwear.

refitting the front differential:
on page 5.
100.

lies while rolling.

seats.

Proceed as follows:
1. Assemble by reversing the remove sequence
and adjust as follows:
- Adjust the pinion position (1).
- Adjust the preload of the two pinion taper
bearings (2).
- Adjust pinion and ring teeth clearance (3).
5LA0295
14
510-10 P/N 3681774M1 Edition 01-2006

Pinion position adjustment
WARNING
safety footwear.
This adjustment procedure is required

! whenever the rear pinion tapered bearing,
bevel pair or differential housing is
replaced.
Make sure that after being fitted the pin-

! ion is positioned with respect to the crown
at a minimum dimension of B = 90 mm to
ensure the correct operation of the bevel
pair.
Dimension B may vary according to the
correction shown on the pinion.
Proceed as follows:
1. Measure dimension A with a micrometer thick-
ness gauge.
This is the distance between the tapered bear-
ing abutment on the differential mount (1) and
the bevel pinion supporting surface (2).
5LA0296
15
2. Observe the value D printed on the bevel pin-
ion.
5LA0025
16
P/N 3681774M1 Edition 01-2006 510-11

3. The shim Sp to be arranged between outer

bearing ring and differential mount is:
Sp = 78 + [A - (B + D)]
if D is positive
or
Sp = 78 + [A - (B - D)]
if D is negative
5LA0295
17
where:
78 = Nominal value
A = Measured dimension
B = Nominal distance
D = Value printed on the bevel pinion
Example 1: Example 2:
78 =Nominal value 78 =Nominal value
A = 14.1 mm. Dimension shown on the differ- A = 13.9 mm. Dimension shown on the differ-
ential mount ential mount
B = 90 mm. Nominal dimension B = 90 mm. Nominal dimension
D = +0.15 mm. Value printed on the bevel D = -0.12 mm. Value printed on the bevel pin-
pinion ion
Sp = 78 + [14.1 - (90 + 0.15)] = 1.95 mm Sp = 78 - [13.9 - (90 - 0.12)] = 2.10 mm
Round off to the lower figure. Round off to the lower figure.
4. Insert the calculated shim Sp, fit the tapered

bearings (2), the pinion (3) and the lock nut.
5LA0297
18
510-12 P/N 3681774M1 Edition 01-2006

Pinion taper bearing preload adjustment
WARNING
safety footwear.
Make sure that the rolling torque of the

! bevel pinion after fitting is 1.4 - 1.8 Nm to
ensure correct operation of the bevel pair.
Proceed as follows:
1. Fit the bearing (1), the o-ring (2) and the ring
nut (3).
Preliminarily tighten the bevel pinion lock nut.
5LA0298
19
the bearings.
3. Tighten the ring nut to reach a pinion rolling
torque of:
1.4 - 1.8 Nm
5LA0299
20
the bearings again.
5. Measure the rolling torque again and when the
correct value is reached, rivet the edge of the
ring nut into the pinion shaft grooves.
P/N 3681774M1 Edition 01-2006 510-13

Pinion and crown teeth clearance adjustment
WARNING
safety footwear.

! pinion and crown teeth is after assembly
0.10 - 0.25 mm to ensure the correct
operation of the bevel gear.
Proceed as follows:
1. Apply sealant to the mount (1) as shown in the
figure.
5LA0300
21
2. Fit on the mount (1) housings (2) and (3).
Tighten the fastening screws at the specified
torque of:
100 - 120 Nm
5LA0301
22
510-14 P/N 3681774M1 Edition 01-2006

3. Fit the ring nuts (1) and (2) and fasten to elim-
inate the differential float.
5LA0302
23
4. Position a dial gauge on the mount to measure
the clearance between the pinion and ring
teeth.
Push the differential assembly against the ring
nut. Either fasten or loosen the ring nut to
obtain a clearance between pinion and ring
teeth from 0.10 to 0.25 mm.
3LA0303
24
5. Turn the ring nut in the opposite direction to
eliminate differential assembly float and ensure
to the pinion a rolling torque of:
1.8 - 2.2 Nm
6. After assembly, check that the clearance
between pinion teeth and ring is:
0.10 - 0.25 mm
and that the differential rolling torque is:
2.5 - 3.5 Nm
7. After reaching the specified values, rivet the

nut ring edges into the specific grooves.
P/N 3681774M1 Edition 01-2006 510-15

FINAL DRIVE - OVERHAUL
Disassembly
WARNING
safety footwear.
Proceed as follows:
1. Drain oil from the side final drive.
2. Remove the screws (1) and remove the cover
(2) with satellite holder housing levering on the
two millings on the ring (3).
5LA0304
25
3. Remove the circlip (1) and remove the plane-
tary gear set (2).
5LA0305
26
4. With the help of the tool, remove the nut ring
(1) after removing the edge rivetted on the
fork (2).
5LA0306
27
510-16 P/N 3681774M1 Edition 01-2006

5. Remove the crown (1) with the help of a lever.
5LA0307
28
6. Remove the ring (1).
5LA0308
29
7. Remove the three circlips (1) using a 8 MA
screw, remove the three pins (2) with stop roll-
ers from the cover (3).
5LA0309
30
8. Remove from the central hole the three satel-
lites (1), the slewing bearings (2) and the
respective roller bearings (3).
5LA0310
31
P/N 3681774M1 Edition 01-2006 510-17

Assembly
WARNING
safety footwear.

on page 6.
100.

lies while rolling.

seats.
Proceed as follows:
1. Assemble by reversing the disassembly order.
2. Fit and tighten the nut ring (1) at the specified

torque of:
360 - 400 Nm
5LA0311
32
510-18 P/N 3681774M1 Edition 01-2006

3. Fit the cover (1) and tighten the fastening

screws (2) at the specified torque of:
75 - 80 Nm
The front axle toe-in adjustable through the

steering track rod (3) must be:
0 ± 4 mm
measured on a diameter of 800 mm
5LA0312
33
P/N 3681774M1 Edition 01-2006 510-19

510-20 P/N 3681774M1 Edition 01-2006

SECTION 600
POWER TAKE-OFF
SECTION 600 - POWER TAKE-OFF
TABLE OF CONTENTS
Description Page
MAIN SPECIFICATIONS OF REAR POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-3
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-4
SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-5
POWER TAKE-OFF COVER SEALANT APPLICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-6
POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-7

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-12
600-2 P/N 3681774M1 Edition 01-2006

MAIN SPECIFICATIONS OF REAR POWER TAKE-OFF
Type (with two functions). . . . . . . . . . . . . . . . . . . . . . 1) independent in relation to the

tractor’s ground speed
or:
2) synchronised with the
gearbox
Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . electrohydraulic with hydraulic,

electro-hydraulically controlled
clutch
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . by switch on the operator's right.
Speed selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . by means of a lever position on

the operator's left
Spinning direction (tractor viewed from the rear) . . . . . clockwise
Engine rate with PTO at 540 rpm . . . . . . . . . . . . . . . .

(rpm) 2363
Engine rate with PTO at 540E rpm . . . . . . . . . . . . . . .

(rpm) 1697
Diameter of the driven shaft on output spline shaft . . . 13/8” (6 spines)
Rotation rate with 540E rpm PTO synchronized with the

gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (rpm/ 10.769 (STD)
wheel 12.119 (GT)
turn)
P/N 3681774M1 Edition 01-2006 600-3

The power take-off (PTO) is characterised by the The PTO engages gradually and progressively.
two-shaft transmission and a multiple plate wet When disengaged, an electrohydraulic device stops
hydraulic clutch. PTO shaft rotation.
The hydraulic clutch is located on the rear end of The PTO has two basic speeds:
the differential box and receives oil from the low - 540-540 ECO rpm
pressure circuit. The oil before reaching the clutch
- 540-1000 rpm
crosses a hydraulic damper which modulates pres-
sure to ensure a constantly gradual engagement. A PTO proportional to advancement is available for
special applications.
The switch on the console on the operator's right
along with the two levers on the left can be used to The speed is selected by means of PTO selection
operate all PTO functions. levers:
The engagement switch must be pressed and - PTO speed selection lever
turned for reasons of safety to prevent involuntary - PTO selection lever independent or proportional
engagement. to tractor advancement.
CONTROLS
1
3 2
5LA0200
1
Rear PTO controls
1. PTO engagement switch 3. Proportional force PTO selection lever

2. PTO speed selection lever
600-4 P/N 3681774M1 Edition 01-2006

SECTIONS
1 2
7 6 5 4 3
5LA0199
2
PTO longitudinal section
1. PTO upper shaft 5. PTO gear (540)

2. PTO hydraulic clutch 6. Proportional PTO gear
3. PTO output shaft 7. Proportional PTO shaft
4. PTO gear (1000)
P/N 3681774M1 Edition 01-2006 600-5

POWER TAKE-OFF COVER SEALANT APPLICATION DIAGRAM
4LA0165
3
600-6 P/N 3681774M1 Edition 01-2006

POWER TAKE-OFF
Disassembly
WARNING
safety footwear.
Proceed as follows:
1. Remove the power lift assembly.
5LA0201
4
2. Remove the PTO clutch cover.
The brake pressure plate and three pistons will
remain inside the cover.
5LA0202
5
3. Remove the clutch assembly (1) and the shaft
(2).
5LA0046
P/N 3681774M1 Edition 01-2006 600-7

4. Loosen and remove the nut ring (1).
5LA0191
7
5. Remove the upper PTO shaft (1).
5LA0192
8
6. Extract the dual speed selection fork (2) spring
pin (1). 2
1
5LA0193
9
7. Remove the dual speed selection control (1).
5LA0194
10
600-8 P/N 3681774M1 Edition 01-2006

8. Remove the proportional PTO gear (2) snap

ring (1).
2
1
5LA0195
11
9. Using tool (1) 94 PTO GL extract the PTO out-
put shaft (2).
5LA0204
12
1
5LA0196
13
11. Remove the proportional PTO shaft bearing (2)
snap ring (1).
1 2
5LA0197
14
P/N 3681774M1 Edition 01-2006 600-9

12. Remove the differential housing lower cover

and using a lever shift the proportional PTO
shaft from its seat.
13. Remove the proportional PTO shaft (1) from

the opposite side of the differential housing.
5LA0198
15
14. Position on the PTO clutch assembly on the
working surface.
15. Remove the snap ring (1) and remove the shaft
(2). 3
Remove the brake steel plate (3).
1
5LA0205
16
16. Remove the snap ring (1) and the steel plate
(2). 4 2
Remove the sintered plate (3) and the steel
plates (4). 3 1
5LA0203
17
600-10 P/N 3681774M1 Edition 01-2006

17. Using tool (1) 95 PTO GL remove the snap

ring (2) and the spring (3).
5LA0208
18
18. Extract the piston (2) from the bell (1), using
compressed air if needed. 1
5LA0207
19
P/N 3681774M1 Edition 01-2006 600-11

Assembly
WARNING
safety footwear.

refitting the differential:
on page 5.
- Before refitting the housings, supports and cov-
ers, thoroughly clean and degrease the cou-
page 6.
100.

lies while rolling.

seats.

Proceed as follows:
1. Fit the piston inside the clutch bell.
600-12 P/N 3681774M1 Edition 01-2006

2. Using tool (1) 95 PTO GL, refit the spring (2)

and the snap ring (3).
5LA0206
20
3. Insert in the bell the clutch plates and fasten
with the snap ring (1).
Firstly insert a steel plate in contact with the
piston and then a sintered plate and a steel
plate.
5LA0209
21
4. Fit the brake steel plate and the input shaft fas-
tening with the snap ring.
5. Position the proportional PTO shaft fastening it
with the snap ring.
6. Fit the PTO output shaft and respective gear
fastening it with a snap ring.
7. Position and fasten the shaft and the dual
speed selection fork.
8. Fit the upper PTO shaft and fasten it with the
respective snap ring.
Tighten the nut ring to obtain a specified
torque of:
215 - 250 Nm
9. Fit the clutch assembly and cover.
10. Fit the power lift assembly.
P/N 3681774M1 Edition 01-2006 600-13

600-14 P/N 3681774M1 Edition 01-2006

SECTION 700
HYDRAULIC CIRCUITS – REAR POWER LIFT
SECTION 700 - HYDRAULIC CIRCUITS – REAR POWER LIFT
TABLE OF CONTENTS
Description Page
MAIN TECHNICAL SPECIFICATIONS OF HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-5
HYDRAULIC CIRCUIT GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-8

Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-8
LOW FLOW RATE CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-10
HIGH DELIVERY CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-12
STEERING CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-14
HYDRAULIC PUMP DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-16
HYDRAULIC UNIT WITH THREE SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-17
HYDRAULIC UNIT WITH FOUR SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-18
HYDRAULIC UNIT WITH FOUR SOLENOID VALVES FOR FAST RUN . . . . . . . . . . . . . . . . . . . . . . . 700-19
HYDRAULIC UNIT WITH FIVE SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-20
DIFFERENTIAL LOCK FEEDING CIRCUIT DESCRIPTION

(FRONT/REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-21
PTO AND PTO BRAKE FEEDING CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-22
HI-LO HYDRAULIC FEEDING CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-23
SPRING-ON FEEDING CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-24
TRAILER BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-25

Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-25
TRAILER BRAKE VALVE (ITALIAN VERSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-27

Step with trailer hitched and brake pedals released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-27
Step with trailer hitched and brake pedals applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-28
Step with parking brake applied and brake pedals released . . . . . . . . . . . . . . . . . . . . . . . . 700-29
Release pressure inspection and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-30
TRAILER BRAKE VALVE (EXPORT VERSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-34

Step with trailer hitched and brake pedals released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-34
Step with trailer hitched and brake pedals applied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-35
SUPPLEMENTARY DISTRIBUTOR DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 700-38
HYDRAULIC-MECHANICAL POWER LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-39

Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-39
PERSPECTIVE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-40
700-2 P/N 3681774M1 Edition 01-2006

Power lift troubleshooting . . . . . . . . . . . . . . . . . . . . . ........................... 700-42

Power lift sealant application diagram . . . . . . . . . . . . . ........................... 700-44
Controlled position operation . . . . . . . . . . . . . . . . . . . ........................... 700-45
Controlled draft operation . . . . . . . . . . . . . . . . . . . . . ........................... 700-46
Mixed position and draft operation (Intermix) . . . . . . . ........................... 700-48
Floating operation . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................... 700-48
Hydraulic distributor - Neutral step . . . . . . . . . . . . . . . ........................... 700-49
Hydraulic distributor - Delivery step . . . . . . . . . . . . . . ........................... 700-50
Hydraulic distributor - Exhaust step . . . . . . . . . . . . . . ........................... 700-51
HYDRAULIC-MECHANICAL POWER LIFT OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-52

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-52
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-55
HYDRAULIC-MECHANICAL POWER LIFT OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-56

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-56
HYDRAULIC DISTRIBUTOR - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-60

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-60
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-62
Hydraulic inspections and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-63
Anti-shock valve inspection and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-64
Discharge valve leakage inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-66
Check valve leakage inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-67
Maximum valve inspection and calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-68
Delivery pipe leakage inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-70
On-tractor power lift adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-72
Sensitivity adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-72
Position control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-73
Draft control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-74
P/N 3681774M1 Edition 01-2006 700-3

700-4 P/N 3681774M1 Edition 01-2006

MAIN TECHNICAL SPECIFICATIONS OF HYDRAULIC SYSTEMS
Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . double gear
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BX/DX
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A510-F45-280
Engine/pump rpm ratio . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1
Maximum operating pressure . . . . . . . . . . . . . . . . . . . . . . (bar) 180 +5
Max. flow rate at 2500 engine rpm (high pressure). . . . . . . (l/ 55

rpm)
Max. flow rate at 2500 engine rpm (low pressure) . . . . . . . (l/ 27.5
rpm)
Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . front right-hand side of engine
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve system gears
Hydraulic/transmission oil quantity . . . . . . . . . . . . . . . . . . (l) 35
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfluid AS/B/C
Filters
Type (on the intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . washable metallic simple car-

tridge
Type (delivery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . replacement paper simple car-

tridge
P/N 3681774M1 Edition 01-2006 700-5

Steering
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydrostatic distribution
Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BX/DX/OX
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orbitrol OSPC 80
Nominal cylinder 4 R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . (cm3/g) 80
Valve calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (bar) 150 +5
Anti-shock valve calibration . . . . . . . . . . . . . . . . . . . . . . . (bar) 200 +5
Steering cylinder type . . . . . . . . . . . . . . . . . . . . . . . . . . . . double acting balanced
Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...........
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm) 35 x 57 x 204/2

E
Steering wheel turns . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
AR
Steering wheel diameter . . . . . . . . . . . . . . . . . . . . . . . . . (mm) 360

N
R
Hydraulic unit
IO
Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SX
G
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . electrohydraulic
AG
Low pressure valve calibration . . . . . . . . . . . . . . . . . . . . . (bar) 19
Cooling circuit valve calibration . . . . . . . . . . . . . . . . . . . . . (bar) 7

A
D
Forced lubrication valve calibration . . . . . . . . . . . . . . . . . . (bar) 5
700-6 P/N 3681774M1 Edition 01-2006

Supplementary distributors
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HYX
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . standard-simple/double acting/

floating with automatic kick-out
release
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . with open centre and push-pull

quick couplings
Calibration valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (bar) 180 +5
Maximum flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (l/ 55

rpm)
Maximum quantity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Connection to the circuit . . . . . . . . . . . . . . . . . . . . . . . . . in series
Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rear
Hydraulic-mechanical power lift
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MIX
Operating modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . position/intermix draft control/

floating
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . open-centre type
Standard cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . simple acting
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm) Ø 90x116
Supplementary cylinders . . . . . . . . . . . . . . . . . . . . . . . . . two simple acting
Valve calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (bar) 180 +5
Anti-shock valve calibration . . . . . . . . . . . . . . . . . . . . . . . (bar) 200 +5
P/N 3681774M1 Edition 01-2006 700-7

HYDRAULIC CIRCUIT GENERAL DESCRIPTION
The hydraulic circuit consists of two separate cir- The two pump stages, with different sections, have
cuits fed by a two-stage gear pump (2A/2B) con- different pressures and two separate conduits for
nected to the engine distribution from which it high and low flow rates.
takes rotation motion. The diagram below shows the assemblies fed by
The two pump stages have a common feed. Oil is the hydraulic system, the low flow rate closed cen-
taken in through a 40 micron filter (1) arranged tre circuit (2A) and the open centre high flow rate
inside the gearbox casing which acts as hydraulic circuit (2B).
oil reservoir.
Hydraulic circuit
1
11- -FILTER
FILTROON SUCTION
SULL'ASPIRAZIONE
2A
2A-- LOW
POMPAFLOW RATE PUMP
A BASSA PORTATA 22 --DOUBLE GEAR PUMP 2B
2B--HIGH
POMPAFLOW ADRATE
ALTAPUMP
PORTATA
POMPA DOPPIA AD FITTED
MAXIMUM FLOW RATE
PORTATA MASSIMA AT
AL MAX ON RH SIDE OFMONTATA
ENGINE MAXIMUM FLOW RATE
PORTATA MASSIMA AT
AL MAX
INGRANAGGI
MAX. ENGINE
N. GIRI MOTORERPM MAX. ENGINE
N. GIRI MOTORERPM 35 l/min.
SUL LATO DX DEL MOTORE
27,5l/min
27.5 l / min 0,55
55 I / min
l/min
3 - DELIVERY FILTER
3 - FILTRO IN MANDATA
SUPPLIED HYDRAULIC
CIRCUITI IDRAULICI CIRCUITS
ALIMENTATI
SUPPLIED HYDRAULIC
CIRCUITI IDRAULICI CIRCUITS
ALIMENTATI
9 - TRAILER BRAKE VALVE

9 - VALVOLA FRENO A RIMORCHIO
4 - HYDROSTATIC STEERING CIRCUIT
4 - CIRCUITO STERZO IDROSTATICO
Max. working pressure 150± 5 bar
pressione max. di lavoro 150 ± 5 bar 1010- DISTRIBUTORI
-SUPPLEMENTARY DISTRIBUTORSMAX.3
SUPPLEMENTARI MAX. 3
MAXIMUM WORKING PRESSURE 180± 5
PRESSIONE MAX. DI LAVORO 180 ± 50 bar
bar Make HYDROCONTROL SE/DE convert-
55
- -CILINDRO
STEERING CYLINDER
STERZO Marca
ible, standard available convertibili SE/DE,
HYDROCONTROL"
with automatic
disponibili standardrelease and floating posi-
tion.
66
- -CENTRALINA
HYDRAULICIDRAULICA
UNIT (low (Circuito
pressureBassa
circuit)
Pressione) Con sgancio automatico con posizione
flottante
A A- FRIZIONE
- FAST-RUN HYDRAULIC
IDRAULICA CLUTCH
FAST-RUN
B B- FRIZIONE
- DUAL DRIVE HYDRAULIC
IDRAULICA CLUTCH
DOPPIA TRAZIONE 1111- DISTRIBUTORE
-POWER LIFT DISTRIBUTOR
DEL SOLLEVATORE
Max. working pressure 180 ± 5 bar
C C- BLOCCAGGIO
- DIFFERENTIAL LOCK (FRONT(ANT.
DIFFERENZIALE C1 - C1
REAR C2) C2)
- POST. Pressione max; di lavoro 180 ± 50 bar
D D- P.d.F.
- HYDRAULIC PTO
IDRAULICA
E E- FRENELLO
- HYDRAULIC BRAKE
P.d.F. PTO
IDRAULICO 1212- CILINDRO
-POWER LIFT CYLINDER
DI SOLLEVAMENTO
F F- VALVOLA
- PTO CLUTCH MODULATING
MODULAZIONE VALVEP.D.F.
FRIZIONE
GG- HYDRAULIC
- HYDRAULIC HI-LO
HI-LO 1313- CILINDRO
- LH OUTER CYLINDER
ESTERNO SX
77
- -CIRCUITO
OIL COOLING CIRCUIT
DI RAFFREDDAMENTO DELL'OLIO 1414- CILINDRO
-LH OUTERESTERNO
CYLINDERDX
R R- VALVOLA
- COOLING CIRCUITDIVALVE
CIRCUITO 7 bar
RAFFREDDAMENTO 7 bar
1515- DISTRIBUTORE
-RH LEVELLING IDRAULICO
HYDRAULIC DISTRIBUTOR
88
- -VALVOLA
GEARBOXPERLUBRICATION VALVEDEL
LUBRIFICAZIONE (5 bar)
CAMBIO (5 BAR) (OPTIONAL)
DI LIVELLAMENTO DX
8A8A -GEARBOX LUBRICATION
- LUBRIFICAZIONE DEL CAMBIO (A RICHIESTA)
8B -HI-LO LUBRICATION
8B - LUBRIFICAZIONE HI-LO
700-8 P/N 3681774M1 Edition 01-2006

5LA0211
1
General hydraulic circuit
P/N 3681774M1 Edition 01-2006 700-9

LOW FLOW RATE CIRCUIT DESCRIPTION
The transmission oil is take in by the inner pump - - PTO clutch (E);
stage (2A) and conveyed to the Orbitrol unit (4) - - DTi engagement clutch (B);
according to high priority after crossing the filter
- - STr engagement clutch (A);
(3).
- - hydraulic Hi-Lo (G).
The Orbitrol thus supplied can either use the oil to
feed the steering cylinder (5), controlled by the Each unit can be activated by separate electrohy-
maximum valve (150 bars), or direct it towards the draulic commands positioned inside the cab, either
exhaust, i.e. the hydraulic unit feeding line (6). The individually or in combination.
unit (6) is always supplied also when the Orbitrol is The oil discharged by the units may return directly
empty by the pump, by unused oil or oil in excess. to the gearbox casing through a specific tube.
A closed centre circuit is formed inside the hydrau- The oil released by the calibration valve (19 bars) is
lic unit (6) when pressure is kept constantly at 19.3 let into a controlled cooling circuit by a 7 bars valve
bars and controlled by the calibration valve. and after the radiator (7) it is conveyed to the
The circuit pressurised in this way ensures the cor- transmission lubrication circuit (8a-8b-8c) control-
rect pressure for activating the following units as led by the 5 bars calibrated valve.
needed: The 18.7 and 5 bar calibration valves are located
- - front and rear differential lock (C1-C2); inside the hydraulic unit (6).
- - intermediate PTO clutch (D);
700-10 P/N 3681774M1 Edition 01-2006

5LA0212
2
Low flow rate circuit
P/N 3681774M1 Edition 01-2006 700-11

HIGH DELIVERY CIRCUIT DESCRIPTION «
The pump (2B) after taking in appropriately filtered mentary distributors where the maximum valve cal-
oil from the transmission, sends it in absolute prior- ibrated at 180 bars is located. The supplementary
ity to the trailer brake valve (9) and then to the distributor can use all the oil flow from the pump
supplementary distributors (10) and to the hydrau- for external units connected to it, in absolute prior-
lic power lift (11). ity with respect to the hydraulic power lift.
The trailer brake valve, which incorporates a maxi- The supplementary distributors outlet supplies the
mum valve calibrated at 130 bars, uses a very small hydraulic lift via the distributor which incorporates a
part of the oil for the braking actions. The unused maximum valve calibrated at 180 bars and a safety
part is conveyed to the inlet plate of the supple- valve calibrated at 200 bars.
700-12 P/N 3681774M1 Edition 01-2006

5LA0213
3
High flow rate circuit
P/N 3681774M1 Edition 01-2006 700-13

STEERING CIRCUIT DESCRIPTION
The low flow rate circuit consists of a first high The steering system fitted on the MF tractor series
pressure section for operating the hydraulic steer- is hydrostatic: there is no mechanical connection
ing. between the steering wheel and the steering cylin-
The oil from the pump low flow rate stage (2a) der.
crosses the filter (3) and feeds the Orbitrol steering Each minimum turn of the steering wheel corre-
distributor (4) to then power the respective steer- sponds to an equivalent turn of the wheels.
ing cylinder (5). If the engine breaks down or the hydraulic pump
The oil discharged by the Orbitrol feeds the hydrau- fails to operate, the Orbitrol acts like a hand pump
lic unit (6) and through a low pressure circuit is operated by the steering wheel which allows steer-
directed to the various units. ing.
700-14 P/N 3681774M1 Edition 01-2006

5LA0214
4
Steering circuit
P/N 3681774M1 Edition 01-2006 700-15

HYDRAULIC PUMP DESCRIPTION AND OPERATION
The hydraulic gear pump consists of a single block (27.5 l/rpm), while the delivery 2B feeds the high
with two different stages, two suction channels and flow rate circuit (55 l/rpm).
two separate delivery channels at different flow Being connected directly to the engine, the pump is
rates. activated whenever the engine is running, taking in
The suction holes are made in the rear part of the the filtered oil from the transmission and conveying
pump and the delivery holes are found in the front. it on both the low flow rate circuit and the high rate
The delivery hole 2A feeds the low pressure circuit circuit at the same time.
1
5LA0215
5
Hydraulic pump
1. Double body pump 5. Pump shaft

2A. Low flow rate stage 6. Coupling flange
2B. High flow rate stage 7. Suction holes
3. O-ring 8. Low pressure delivery hole
4. Pump drive gear 9. High pressure delivery hole
700-16 P/N 3681774M1 Edition 01-2006

HYDRAULIC UNIT WITH THREE SOLENOID VALVES

1
VIEW FROM C
1 SPRING ON
2 REAR PTO
3 REAR PTO BRAKE
4 DIFF LOCK
1 2 3 4
P
L1
19,3 BAR
PS
L2
M 7 BAR 5 BAR
R in
T T2
T1
R out
5LA0216
P/N 3681774M1 Edition 01-2006 700-17

HYDRAULIC UNIT WITH FOUR SOLENOID VALVES

1
VIEW FROM B
1 SPRING ON
2 REAR PTO
3 REAR PTO BRAKE
4 DIFF LOCK
5 SPEED SHIFT
2 3 4 5 1
P
L1
19.3 BAR
PS
L2
M 7 BAR 5 BAR
R in
T T2
T1
R out
5LA0217
700-18 P/N 3681774M1 Edition 01-2006

HYDRAULIC UNIT WITH FOUR SOLENOID VALVES FOR FAST RUN

1
B
B
VIEW FROM B
1
21 BE-SPEED
32 DT
43 REAR PTO
54 REAR PTO BRAKE
65 DIFF LOCK
3 4 5 1 2
3 4 6 5 1 2
P
P
L1
19,3 BAR L1
PS
19,3 BAR
PS L2
L2
M 7 BAR 5 BAR
M 7 BAR 5 BAR R in
T2 R in
T T1
T T2
T1
R out
R out
5LA0218
P/N 3681774M1 Edition 01-2006 700-19

HYDRAULIC UNIT WITH FIVE SOLENOID VALVES

1
VIEW FROM B
1 BE-SPEED
2 DT
3 REAR PTO
4 REAR PTO BRAKE
5 DIFF LOCK
6 SPEED SHIFT
3 4 6 5 1 2
P
L1
19,3 BAR
PS
L2
M 7 BAR 5 BAR
R in
T T2
T1
R out
5LA0219
700-20 P/N 3681774M1 Edition 01-2006

DIFFERENTIAL LOCK FEEDING CIRCUIT DESCRIPTION

(FRONT/REAR)
The front and rear differential is locked by shifting lock.

two mechanical engagements operated by a piston The differential is released when by means of the
fed by pressurised oil at 18 bars. brake pedals (5) the solenoid valve (BLc) is de-
This occurs when the driver presses the control energised, closing the oil feed and opening commu-
button (1) and energises the concerned solenoid nication with exhaust.
valve (BLc) fitted on the unit (2). The inner springs recall two block mechanisms in
Energising makes the solenoid valve open the home position deactivating the action on the two
simultaneous oil feed to the rear (3) and front (4) respective differentials.
1
5LA0220
10
P/N 3681774M1 Edition 01-2006 700-21

PTO AND PTO BRAKE FEEDING CIRCUIT DESCRIPTION
The PTO is engaged when the pressurised oil at 18 via the same solenoid valve (PTO/FRn) but via a
bars feeds the hydraulic piston making integral the different outlet hole (FRn) and different piping,
plates and inter plates of the wet hydraulic clutch alternative to the clutch feed (PTO).
(1) thus transmission motion from the engine to When not energised (i.e. then the PTO clutch is not
the rear tractor PTO shaft (2). powered), the solenoid valve (PTO/FRn) feeds oil to
When the PTO / FRn solenoid valve is energised, the three PTO brake pistons.
the oil from the unit (6) via the tube (5) crosses the Therefore the solenoid valve (PTO/FRn) when ener-
regulating valve (4), comes into communication gised operates the PTO clutch and releases the PTO
with the accumulator (3) and engages the PTO. brake, while when it is not energised feeds the PTO
The PTO clutch is disengaged when the solenoid brake pistons and releases the PTO clutch.
valve is de-energised by the control knob. The accumulator (3) consists of a hollow cylinder
A brake system consisting of a plate and three (8), a piston (9), a spring (10) and a cover (11)
hydraulic actuators is provided to eliminate the pos- with a stop ring (12). The hole (13) is connected to
sible rotation of the PTO shaft due to dragging of the PTO feeding pipe and lets oil into the cylinder
the wet plates. into contact with the piston (9) exerting pressure
The actuators are fed at the same 18 bars pressure accumulation.
5LA0221
11
700-22 P/N 3681774M1 Edition 01-2006

HI-LO HYDRAULIC FEEDING CIRCUIT DESCRIPTION
The electrohydraulic Hi-Lo command allows a 20% the hydraulic clutch and releases the brake allowing
speed reduction by pressing a button located on direct motion take-off.
the gear lever. De-energising the solenoid valve takes the oil pres-
When the solenoid valve (A) is energised, oil is sup- sure to 0 bars allowing the operation of the plane-
plied to the Hi-Lo unit (B) causing the engagement tary gear reducer: this reduces the speed by 20%
of high gear ranges because the oil pressure locks and provides low gear ranges.
1
5LA0222
12
P/N 3681774M1 Edition 01-2006 700-23

SPRING-ON FEEDING CIRCUIT DESCRIPTION
A spring-on DT release system is provided as an 4WD is always engaged when the tractor engine is
alternative to the DT with hydraulic clutch. stopped to ensure perfect braking.
The spring-on is a mechanical engagement device De-energising the solenoid valve (A) allows oil at a
for the four drive wheels with hydraulically control- pressure of 18 bars to disengage 4WD by axially
led release. shifting the sleeve (11) from position (X) to position
(Y).
1
5LA0223
13
700-24 P/N 3681774M1 Edition 01-2006

TRAILER BRAKE VALVE
Description and operation

The trailer brake valve (1) is fitted on the back of
the tractor and feeds the trailer via the oil union 3 2
(2).
The oil reaching the valve has absolute priority with
respect to the high flow rate circuit.
The oil not used by the trailer brake is sent to the
1
supplementary distributors (2).
5LA0224
14
The trailer brake is activated at the same time as
the tractor brakes and when the dashboard indica-
tor (1) lights up. 1
5LA0225
15
The tractor may be equipped with two types of
valves:
1. Trailer valve (Italian version)
2. Trailer valve (export version)
The trailer valve (Italian version) presents with
respect to the export version a supplementary
device in the lower part with a tie-rod connected to
the parking brake.
This is because Italian legislation requires trailers to
be equipped with a self-braking device. This must
ensure application of the trailer brakes when dis-
connected from the tractor. Furthermore, this brak-
ing mechanism must come into action when the
tractor stops and the parking brake is applied. Con-
sequently, to tow the trailer, a flow of oil must be
maintained on the trailer brake mechanism at a
constant pressure in the 10-15 bars range to keep
the mechanical brakes released.
P/N 3681774M1 Edition 01-2006 700-25

Proceed as follows in presence of the Italian ver-

sion trailer valve for correct and safe removal and
refitting of the flexible brake tube of the trailer
from/to the union (2, fig. 14) on the back of the
tractor.
WARNING
! This operation is extremely important and
must be performed always before and
after the trailer is unhitched from the trac-
tor because this ensures the immediate
intervention of the automatic safety brak-
ing system equipping the trailer braking
system by law.
The trailer-tractor connection tube removal-refitting

operation can be performed with either the engine
stopped or running:
- with engine stopped: there is no problem for
engaging and disengaging because there is no
oil pressure in the circuit.
- with engine running: always apply the hand-
brake because this will ensure that there is no
pressure in the brake circuit.
700-26 P/N 3681774M1 Edition 01-2006

TRAILER BRAKE VALVE (ITALIAN VERSION)
Step with trailer hitched and brake pedals released

The oil from the pump crosses pipe “P” to groove This is ensured by the position assumed by the
“C” proceeding on one side of the channel “R” to main piston “Q”.
reach and in this way feed, through chamber “H”, Spring “G1”, acting on the latter, maintains a con-
the trailer and release the self-braking device. stant pressure around 10-15 bars needed to
The same oil from the pump crosses groove “C” deactivate the trailer brake.
and is also put into communication with the pipe
“N” to feed the power lift.
1
E1 E2 P N T
K2 C G Q G2 K
G1
W
A B
H
K1 Y
O
M
G3
L R F D S
5LA0226
16
A. Trailer brake connection quick connection K1. Piston stroke adjustment shims (Q)
B. Distributor activation piston K2. 140 bar pressure adjustment shims
C. Pump-power lift connection groove L. Trailer brake feeding command piston
D. Chamber M. Parking brake connection tie-rod
E1. Pressure switch N. Power lift feeding
E2. Pressure switch O. Return piston
F. Chamber P. Pump feed
G. 140 bar pressure hold spring Q. Main piston
G1. 10-15 bar pressure hold spring R. Trailer brake feeding channel
G2. Sleeve return spring (W) S. Brake tie-rid inner channel
G3. Piston spring (L) T. Discharge channel
H. Trailer brake outlet chamber W. Sleeve
K. 10-15 bar pressure adjustment shims Y. Tractor brake feed
P/N 3681774M1 Edition 01-2006 700-27

Step with trailer hitched and brake pedals applied

The oil from the brake pedal shifts the piston “B” bars. Having obtained the braking action, the
which thus compresses the spring “G” and shifts increased pressure shifts the piston “O” which
the main piston “Q”. This movement conveys the returns the main piston “Q” to neutral position reo-
pressurised oil entirely into the channel “R” and pening the passage to the channel “N” for feeding
then, through the groove “F”, to chamber “H”, thus the power lift.
feeding the trailer brake at a pressure of max. 140
1
E1 E2 P N T
K2 C G Q G2 K
G1
W
A B
H
K1 Y
O
M
G3
L R F D S
5LA0227
17
700-28 P/N 3681774M1 Edition 01-2006

Step with parking brake applied and brake pedals

released
By activating the parking brake via the tie-rod “M”, matic trailer braking device is released in this way.
communication is effected between the exhaust “T” The oil from the pump, in addition to being con-
and the chamber “S” inside the tie-rod; being the veyed into chamber “D”, feeds the hydraulic power
latter connected to the chamber “H” which feeds lift via the pipe “N” put into communication by
the trailer, has practically no pressure. The auto- groove “C”.
1
E1 E2 P N T
K2 C G Q G2 K
G1
W
A B
H
K1 Y
O
M
G3
L R F D S
5LA0228
18
P/N 3681774M1 Edition 01-2006 700-29

Release pressure inspection and adjustment
Adjust as follows if the pressure measured

using a pressure gauge applied to the
trailer brake connector is not included in
the range from 10 to15 bars.
WARNING
! Wait for the pressure in the hydraulic cir-
cuit to drop to zero before starting.
WARNING
! Sprays of hot pressurised fluid may cause
severe lesions and burns.
Use the appropriate safety devices.
1. Remove the tractor valve by disconnecting all

the tubes. Protect all the holes to avoid letting
in dirt and dust.
2. Remove the piston cover (1).
5LA0229
19
3. Extract the complete piston (1) from the valve
body.
During this operation, keep the piston in

horizontal position to prevent components
from falling into the valve.
5LA0230
20
700-30 P/N 3681774M1 Edition 01-2006

4. Remove the slewing bearing (1), the spring (2)

and the spring (3) from the piston (4).
Add or remove the shims (5) considering that a
variation of 1 mm will vary the pressure by
approximately 1.5 bars with the engine at 900 -
1000 rpm.
5LA0231
21
5. Refit the valve by reversing the removal
sequence.
6. Connect the pressure gauge to the trailer brake
connection again and check that the working
pressure is 10 -15 bars. Repeat the operations
above if it is not.
Adjust as follows if the braking pressure

measured using a pressure gauge applied
to the trailer brake connector is not 140
bars.
WARNING
WARNING
1. Remove the tractor valve by disconnecting all

the tubes. Protect all the holes to avoid letting
in dirt and dust.
P/N 3681774M1 Edition 01-2006 700-31

2. Remove the piston cover (1).
5LA0229
22
3. Extract the complete piston (1) from the valve
body.
During this operation, keep the piston in

horizontal position to prevent components
from falling into the valve.
5LA0230
23
4. Remove the slewing bearing (1), the spring (2)
and the spring (3) from the piston (4).
5LA0232
24
700-32 P/N 3681774M1 Edition 01-2006

5. Fit the piston (1) on the tool (2) 171 IDR GL

to compress the inner spring (1, fig. 26) and
facilitate cap disassembly (2, fig. 26).
5LA0233
25
6. Loosen the cap (1), extract the spring (1) and
add or remove the shims (3) considering that a
approximately 10 bars with the engine at 900 -
1000 rpm.
5LA0234
26
sequence.
pressure is 140 bars. Repeat the operations
above if it is not.
P/N 3681774M1 Edition 01-2006 700-33

TRAILER BRAKE VALVE (EXPORT VERSION)
Step with trailer hitched and brake pedals released

The oil is sent from the pump through pipe “P” and in communication with discharge “T” via groove “R”
via groove “C” it proceeds via pipe “N”, thus feeding and the chamber of spring “G”.
the hydraulic power lift. During this step, no braking device is applied to the
There is no pressure in the oil in chamber “H” being trailer.
1
C P N T
Q
G
A B
H
O Y
R J
5LA0235
27
A. Trailer brake connection quick connection O. Return piston
B. Distributor activation piston P. From pump
C. Pump-power lift connection groove Q. Distributor main piston
G. 140 bar pressure hold spring R. Trailer brake feeding groove
H. Trailer brake outlet T. To exhaust
J. Cap Y. From tractor brakes
N. To power lift
700-34 P/N 3681774M1 Edition 01-2006

Step with trailer hitched and brake pedals applied

Oil from the brake pedals shifts piston “B” which to a maximum pressure of 140 bars.
thus shifts the spring compression “G” and shifts Having obtained the braking action, the increased
the main piston “Q”. pressure shifts the piston “O” which returns the
This movement allows the oil from the pump to be main piston “Q” to neutral position reopening in
entirely conveyed via pipe “P” to groove “R” to this way the passage to the channel “N” for feeding
reach chamber “H” thus feeding the trailer brake up the hydraulic power lift.
1
P N T
C Q
G
A B
H
Y
O
5LA0236
28
A. Trailer brake connection quick connection O. Return piston
B. Distributor activation piston P. From pump
C. Pump-power lift connection groove Q. Distributor main piston
G. 140 bar pressure hold spring R. Trailer brake feeding groove
H. Trailer brake outlet T. To exhaust
N. To power lift Y. From tractor brakes
P/N 3681774M1 Edition 01-2006 700-35

Adjust as follows if the braking pressure

measured using a pressure gauge applied
to the trailer brake connector is not 140
bars.
WARNING
WARNING
1. Wash the valve carefully and leave it fitted on

the tractor.
2. Loosen and remove the quick coupling (1).
5LA0237
29
3. Extract from the valve body the sleeve (1) and
the piston (2).
5LA0238
30
700-36 P/N 3681774M1 Edition 01-2006

4. Fit the piston (1) on the tool (2) 171 IDR GL

to compress the inner spring (1, fig. 26) and
facilitate cap disassembly (2, fig. 26).
5LA0233
31
5. Loosen the cap (1), extract the spring (1) and
add or remove the shims (3) considering that a
approximately 10 bars with the engine at 900 -
1000 rpm.
5LA0234
32
sequence.
pressure is 140 bars. Repeat the operations
above if it is not.
P/N 3681774M1 Edition 01-2006 700-37

SUPPLEMENTARY DISTRIBUTOR DESCRIPTION AND OPERATION
The supplementary distributors are fitted on the The distributors are powered simultaneously: acti-
central rear side of the tractor, fastened to the vation of either one or the other blocks the feed of
hydraulic power lift body and used to control the oil to the next distributors and to the power lift thus
outer jacks. preventing contemporary operation. An optional
They are combined with the hydraulic power lift cir- flow baffle may be fitted on the inlet body (E) to
cuit and use the same transmission oil from an divert the flow to the first distributor conveying the
open centre circuit. remaining oil flow from the pump to a second dis-
tributor or to the hydraulic power lift.
The supplementary distributor control levers are
arranged on the console on the right of the driver’s The following distributor versions are provided:
seat. The rods of the distributors themselves are - standard simple and double acting distributor
operated by means of a flexible cable. - automatic release simple and double acting dis-
This consist of an inlet body (E) where oil is sent by tributor
the pump (P) in priority via the 180 bar calibration - floating position simple and double acting dis-
valve (V), from one or more elements (up to a max- tributor
imum of three) and the outlet body (U) from which
- hydraulic motor distributor
departs the hydraulic power lift feeding pipe (S).
1
E U
V
180 b
P S
A1
A2
A3
B1
B2
B3
5LA0239
33
700-38 P/N 3681774M1 Edition 01-2006

HYDRAULIC-MECHANICAL POWER LIFT
Description and operation

The tractor hydraulic-mechanical power lift is con- - controlled draft operation
nected by appropriate tie-rods to the external - mixed position and draft operation
implements which are raised and lowered.
- floating operation
It consists of a lifting body, one or more double act-
The hydraulic distributor governs three different
ing cylinders and two external levers which control
steps:
a hydraulic distributor.
- delivery or lifting step
A special Load Sensing distributor ensures
smooth movements and controls without jerks - neutral step
when moving upwards. - discharge or lowering step.
The power lift has four operating modes: A descent speed regulator provides full control by
- controlled position operation the operator and hydraulically blocks the system
during transportation.
1
5LA0240
34
1. Pivoting support 7. Draft control lever
2. Power lift unit 8. Controlled position lever fitted on power lift
3. Power lift arm 9. Control draft rod
4. Arm holder shaft P. P - Controlled position lever on control selector
5. Command distributor S. S - Draft control lever
6. Cylinder
P/N 3681774M1 Edition 01-2006 700-39

PERSPECTIVE VIEWS
1
5LA0241
35
Hydraulic-mechanical power lift
1. Pivoting support 7. Draft control lever

2. Power lift unit 8. Controlled position lever
3. Power lift arms 9. Controlled draft tie-rod
4. Arm holder shaft 10. Inner lever unit
5. Command distributor 11. Cylinder
6. Cylinder 12. Arm control wheel
700-40 P/N 3681774M1 Edition 01-2006

5LA0242
36
Hydraulic valve system
1. Rubber guard 18. Dowel

2. Nut 19. Supporting shim
3. Dowel 20. Anti-shock valve spring
4. Screw 21. Anti-shock valve ball
5. Calibration valve ball 22. Complete discharge valve
6. Spring guide plate 23. Discharge valve
7. Calibration valve spring 24. Discharge valve spring
8. Spring guide 25. Cap
9. Regulator piston 26. Choking spring with hole
10. Regulator piston spring 27. Valve system casing
11. Spring holder cap 28. Check valve
12. Supporting shim 29. Check valve spring
13. Retainer plate 30. Valve seat
14. Screw 31. Block valve and descent control
15. Control rod 32. Roller
16. Control rod spring 33. Valve body and control assembly
17. Nut 34. Upper lid
P/N 3681774M1 Edition 01-2006 700-41

Power lift troubleshooting
The power lift does not keep 1. Faulty check valve tightness Remove, check, clean and if
the load raised (with the engine required replace the concerned
running the height swings parts.
rhythmically; when the engine
is stopped the load is lowered).
2. Oil leakage through the dis- Replace the seals.

tributor pin seat seals.
3. Faulty distributor pin tight- Remove and check tightness.

ness. Replace the distributor pin and
respective seat if faulty.
4. Oil leakage through lifting Replace the seals.

piston seal or through cylin-
der oil delivery union seals.
5. Fault sealing or very low Replace the valve.

calibration of cylinder safety
valve.
The overpressure valve trips 1. Incorrect setting of lifting Adjust correctly.

when the lifting arms are raised arm stroke.
to the maximum.
Low lifting capacity. 1. Incorrectly calibrated over- Replace the valve.

pressure valve.
2. Incorrectly calibrated cylin- Replace the valve.

der safety valve.
3. Poor pump performance Overhaul or replace the pump.

(generally accompanied by
long lifting time).
The power lift does not raise. 1. Obstructed oil filter. Replace the filter.
2. Control valve jammed in the Release the control valve.

discharge position.
3. Faulty hydraulic pump. Overhaul or replace the pump.
700-42 P/N 3681774M1 Edition 01-2006

The power lift jerks. 1. Obstructed oil filter. Replace the filter.
2. Air infiltration along the Check tightness of unions and effi-

pump suction pipe. ciency of seals.
The power lift raises too slowly. 1. Obstructed oil filter. Replace the filter.
2. Oil leaks through the seals, Replace the faulty seals.

with consequent drop in
pressure: piston or cylinder
deliver union seals.
3. Faulty hydraulic pump. Overhaul or replace the pump.
The power lift moves down too 1. Incorrect arm descent Adjust correctly.
slowly. speed setting.
The power lift moves down too 1. Incorrect arm descent Adjust correctly.
fast. speed setting.
P/N 3681774M1 Edition 01-2006 700-43

Power lift sealant application diagram
5LA0243
37
700-44 P/N 3681774M1 Edition 01-2006

Controlled position operation

Position the draft control lever (S) against the stop During the lifting movement of the arms, the crank
in the bottom of the sector: the roller (12) sliding (9) and pin (7), turning anticlockwise via the
on the rocker arm (13) and the draft cam (11) shackle (8), turn the position cam (5) clockwise.
moves away. The rocker arm (6) can turn anticlockwise when the
In this way, the draft levers do not effect controlled roller (4) meets the slanted surface of the cam (5).
position operation. This via the shock absorber (15) turns anticlock-
The arms are raised by moving the position control wise the transmission lever (16-1), pushed by the
lever (P) upwards. The linkages work as follows. spring of the distributor rod (18) which shifts to
neutral position (n), thus stopping the arm move-
The crank (3) integral with the shaft (2) turns anti-
ment. When moving the arms down, the linkages
clockwise making the roller (4) slide on the position
move in the opposite direction. The arm position,
cam (5). This causes the rocker arm clockwise rota-
both moving up and down, corresponds to a certain
tion (13) via the shock absorber (15) transmits an
position of the position control lever (P) on the sec-
anticlockwise rotation to the transmission lever (16
tor.
and 1), taking the distributor rod (18) to delivery
position (c) with consequent lifting of the arms.
1
5LA0244
38
P/N 3681774M1 Edition 01-2006 700-45

Controlled draft operation

By positioning the position control lever (P) against turns anticlockwise and by means of the tie-rod (5)
the stop on the bottom of the selector, the crank (3, makes the roller (10) slide on the rocker arm (11).
fig. 38) reaches its extreme anticlockwise rotation The roller (10), when it encounters the slanted sur-
position. face of the draft cam (9) allows the anticlockwise
In this position, the roller (4, fig. 38) moves fully rotation of the rocker (11) which with the shock
down from the slanted surface of the position cam absorber (14) turns the transmission lever (15-1)
(5, fig. 38) allowing the anticlockwise rotation of anticlockwise, thus leaving the distributor rod (16)
the rocker arm (6, fig. 38) and the clockwise rota- free to move to neutral position (n).
tion of the transmission lever (15-1), pushed by the Continuing to move the lever (S) down to discharge
spring of the rod (16) which is in small discharge position (s) makes the arm lower.
position (s).
Indeed, in the initial part of the downward stroke,
In this way, the position levers do not effect con- the draft control lever (S) does not manifest the
trolled draft operation. corresponding arm lowering.
By positioning the control lever (S) against the stop The traction effort on the third point (6) stresses
on the top of the sector, the draft shaft (3) is the tie-rod (7) in the direction indicated by the
turned clockwise. arrow (RP) making the crank (8) turn clockwise and
The crank (4) integral with the shaft (3) reaches its the draft cam (9) fastened on to the same pin.
extreme rotation position and via the tie-rod (5) When the slanted surface of the draft cam (9)
shifts the roller (10) which reacts on the draft cam encounters the draft cam (9), the anticlockwise
(9) turning clockwise the rocker arm (11) which, via rotation of the rocker (11) is obtained. This along
the shock absorber (14) turns the transmission with the shock absorber (14) turns the transmission
lever anticlockwise (15-1), thus taking the distribu- lever (15-1) anticlockwise, thus leaving the distrib-
tor rod (16) to loading position (c) with consequent utor rod (16) in neutral position (n) and stopping
lifting of the arms. the arm movement.
The arms stop only when the piston comes into With the increased traction effort, the draft cam (9)
contact with the end-of-stroke pin (13). moves the roller (10), thus increasing the move-
This, by means of the tie-rod (12) turns the lever ment above.
clockwise (15-1), compressing the shock absorber The distributor rod (16) moves from neutral posi-
spring (14) and thus leaving the rod (16) free to tion (n) to loading position (c), consequently raising
shift from natural position (n) where it is pushed the arms.
out by the spring.
When the traction effort decreases, the rod (16)
Shifting the control lever (S) down the linkages returns either to neutral or lowered position by
causes the following: reversing the linkage movement with respect to
The crank (4), integral with the draft shaft (3), that shown.
700-46 P/N 3681774M1 Edition 01-2006

5LA0245
39
P/N 3681774M1 Edition 01-2006 700-47

Mixed position and draft operation (Intermix)

Proceed as follows to use the power lift in this con- 38) prevent the rod (16) from going to the lowered
dition: position (s) and therefore the arms cannot be low-
Rest the position control lever (P) on the stop on ered also when the traction effort on the third point
the bottom of the sector to obtain maximum work- (6) tends to decrease, thus stressing the tie-rod (7)
ing depth. in the direction of the arrow (RN).
Determine the minimum depth required by means This condition does not prevent the power lift from
of the draft control lever lifting it from zero posi- working in controlled draft mode if in the presence
tion, so that the roller (10) reacting with the draft of harder soil the traction effort on the third point
cam (9) takes to lifting position (c) the distributor (6) tends to increase, stressing the tie-rod (7) in
stem (1) and determines a further upward shift of the direction of the arrow (RP).
the lifting arms. Therefore, the mixed position and draft control lim-
Due to the position previously established with the its downward depth variations characteristic of con-
control lever in position (P), the rocker arm (11), trolled draft use, thus ensuring the required
the roller (4, fig. 38) and the position cam (5, fig. maximum working depth.
Floating operation
In floating position, the lifting arms are free to a) Take the lever (P) to control position in the bot-
move up or down following the unevenness of the tom of its sector against the lower stop.
soil on which the implement rests. b) Take the draft control lever (S) downwards in its
Proceed as follows to use the power lift with this sector to obtain floating operation and allowing
function: the implement to float on the soil profile.
5LA0245
40
700-48 P/N 3681774M1 Edition 01-2006

Hydraulic distributor - Neutral step

During this step, the control distributor keeps the casing.
oil contained in the cylinder under pressure, allow- The oil contained in the chamber cylinder (26)
ing the oil from the pump to flow freely to the remains pressurised because it is withheld by the
transmission casing. During this step, the control check valve (24), by the relief valve (6) and by the
rod (19) is in such a position to connect the cham- safety valve (14) which are connected to the cylin-
ber (16) directly to the exhaust via the hole (18). der from the annular conduit (11) and therefore
The oil from the pump thus moves the regulator supports the load applied to the lifting arms. The
piston (10) downwards, feeds the chamber (9), anti-shock safety valve (14) protects the cylinder
opens the holes (17) entering inside the annular from overpressure.
conduit (22) and then proceeds to the transmission
1
Static pressure oil

Oil from pump
Discharged oil (pressure 0 bars)
5LA0246
41
P/N 3681774M1 Edition 01-2006 700-49

Hydraulic distributor - Delivery step

During this step, the control distributor sends pres- (19).
surised oil to the cylinder and consequently lifts the The regulator piston (3) governs the oil flow from
arms; the control rod (11) connects chamber (8) to the cylinder because the chambers (8) and (4) are
the oil from the pump via the annular conduit (6) subjected to the difference of pressure created by
and the holes (1) and (2). the passage of oil through the fixed choking (15)
In this way, the chambers (8) and (4) are influ- and the variable chocking created by the control
enced by the same pressure and the regulator pis- rod (11) according to its upward shift by effect of
ton (3) closes the exhaust holes (9) pushing the power lift internal linkages. The flow in excess
upwards the return spring. is relieved at the lifting pressure through holes (9)
Pressurised oil thus goes to the cylinder passing thus regulating the maximum lifting speed and
through the annular conduit (6) entering the hole allow slow lifting arm departure and arrival.
(1) through the fixed chocking (15) and the variable During this step, the maximum lifting pressure is
chocking created by the control rod (11) with the controlled by the calibration valve (13) which is
hole (2), opens the check valve (17) enters the connected to the annular conduit (6) via the holes
annular conduit (5) and feeds the cylinder chamber (1) and (2).
1
Pressurised oil
5LA0247
42
700-50 P/N 3681774M1 Edition 01-2006

Hydraulic distributor - Exhaust step

During this step, the control distributor makes (15) to the annular conduit (14) crosses from the
exhaust flow away along with the oil from the descent speed control valve (1) and via the hole (3)
pump and the oil from the cylinder with consequent enters into the discharge valve chamber (4) going
lowering of the lifting arms. to the exhaust from the hole (6) causing the lower-
The control rod (12) is in such a position to connect ing of the lifting arms.
the chamber (9) directly to the exhaust via the hole During this step, the descent speed of the imple-
(11). ment may be adjusted with the manual lever (2),
The oil from the pump, as during the neutral step, fastening to decrease the descent speed.
shifts the regulator piston (5) downwards and dis- For safe transfer on roads and preventing accident
charges the oil from the holes (10). operation of the power lift control levers, secure
At the same time, the oil from the chamber cylinder the lever (2) fully against the valve (1) in its seat.
Oil from pump

5LA0248
43
P/N 3681774M1 Edition 01-2006 700-51


OVERHAUL
Disassembly
WARNING
safety footwear.
1. Position the power lift on a work bench.

2. Loosen the fastening screws and remove the
cylinder (1).
5LA0249
44
3. Loosen the fastening screws and remove the
complete hydraulic distributor (1).
5LA0250
45
4. Disconnect the draft transmission tie-rod (1) by
loosening the screw (2) and the lock nut (6).
Arrange the pivoting support (5) by removing
the hinge pin (4) after removing the snap ring
(3).
Loosen the screws (8) and remove the reaction
spring (7) with its cover.
5LA0251
46
700-52 P/N 3681774M1 Edition 01-2006

5. Remove the snap rings (1) and (2) from the

respective inner linkage support pins.
Loosen and arrange the two hexagonal support
pins (3) and (4), after removing a second snap
ring on the pin (4) against the rocker arm (5).
Remove the lever unit with the rocker (5), the
stop pin (6), the linkage (7), the transmission
lever (8), the spring guide pin and the shim
with screw (9) for operating the hydraulic dis-
tributor.
5LA0252
47
6. Loosen the threaded dowels (1) and (2) then
remove the cam (3) and the position connect-
ing rod (4) with the transmission shackle (5),
hinged onto the pin (6);
5LA0253
48
7. Remove the draft cam fastening spring pin (1)

and remove it from the pin (2).
Arrange the draft crank (3) with the linkage (4) 5LA0254
and the guiding shackles (5).
49
Remove the snap ring (6) then remove the pin
(2) with the draft transmission linkage.
5LA0255
50
P/N 3681774M1 Edition 01-2006 700-53

8. Loosen the two fastening screws (1) of the

control lever supports (2) and (3) and remove
all with the two position (4) and draft (5) shafts
positioned one against the other then separate
them.
5LA0256
51
9. Remove the two snap rings (1) holding the lift-
ing arms (2), remove them making a reference
mark for correct refitting on the shaft (3).
Loosen the threaded retainer dowel (4), then
remove the shaft (3) from the left of the power
lift body: this will drag the left o-ring (5).
Remove and arrange the push arm (6) along
with the respective connecting rod.
5LA0257
52
700-54 P/N 3681774M1 Edition 01-2006

Adjustments
1. Check the perfect state of all removed compo-
nents, as well as the perfect mobility of all link-
ages, stops, and pins.
2. Check adjustment of spring guide pin (1). The

position must be:
Y = 59.5 mm
Check distance between screw head (2) and
the valve cap (3). The position must be:
X = 15 - 15.5 mm
5LA0258
53
3. For correct assembly of the reaction spring (1)
follow the indications below:
- The spring pusher (2) must not overcome
the spring but be fastened so that the
spring can turn on its axis without float.
- Dimension (L) forming the cover (3) fitted
on the power lift body must be the same as
the dimension measured on the spring
pack. If this does not occur, replace the
washer (4) with a suitable shim.
5LA0259
54
4. Replace all the shaft support bushings for arm
holders (3) as well as the o-rings (5), copper
seals, snap rings (1) and spring pins.
5LA0257
55
5. Carefully wash and clean the power lift body
and all internal components to be refitted on
the power lift body itself.
P/N 3681774M1 Edition 01-2006 700-55


OVERHAUL
Assembly
WARNING
safety footwear.

refitting the power lift:
on pages 39 and 40.
- Before refitting the housings, supports and cov-
ers, thoroughly clean and degrease the cou-
page 44.
100.

lies while rolling.

seats.

700-56 P/N 3681774M1 Edition 01-2006

Proceed as follows:
1. Arrange the lifting shaft (1) in its seat on the
power lift body, insert the push arm (2) and
correctly align the hole with the fastening
dowel seat (3), fasten and tighten the dowel.
Fit in the respective seats the two o-rings (4) of
the power lift shaft using tool 119a SOL-GL.
Insert the lifting arms (5) into the coupling on
the shaft (1) aligning them with the reference
made during disassembly when fitting the two
retainer snap rings.
Lubricate the mobile parts, hinged and
removed, to obtain perfect mobility and sliding 5LA0260
of the linkage. 56
2. Temporarily position on a bench with the help

of appropriate supports the entire linkage and
the power lift components. Arrange them as far
as possible in their real working position for
better visibility and familiarity.
5LA0261
57
3. Place on the power lift body, the first control
linkage components (controlled draft) arrang-
ing them in their real and correct position.
5LA0262
58
P/N 3681774M1 Edition 01-2006 700-57

4. Arrange on the power lift body. Then refit and 5LA0263
connect the draft cam (1) pins. 59
5LA0264
60
5. Perform the same procedure on the controlled 5LA0265
position linkages and then arrange on the 61

power lift in definitive position.
5LA0266
62
700-58 P/N 3681774M1 Edition 01-2006

6. Present the complete rocker arm linkage

assembly (1) with the tie-rods, levers and
hydraulic distributor actuator pins, correctly
arranged and then arrange on the cover mak-
ing sure that the adjustable valve cap (2) is in
its circular seat on the power lift body. At the 5LA0267
same time, arrange the lower arm of the rocker 63

(1) underneath with the contact rollers
arranged on the position connecting rod cam
(3), not forgetting to position the snap ring in
contact with the rocker (1).
Arrange the hydraulic distributor (4) in its seat
on the power lift body and fasten it with the
respective screws.
5LA0268
64
Check that the linkage movements are

correct after each operation and that
there are no improper interferences.
Arrange all the snap rings, the pins and
threaded dowels. Tighten the various fas-
tening screws.
7. Position the cylinder with the respective piston

(2) and new o-ring (3). Tighten fastening
screws at 120 Nm.
5LA0269
65
P/N 3681774M1 Edition 01-2006 700-59

HYDRAULIC DISTRIBUTOR - OVERHAUL
Disassembly
WARNING
safety footwear.
Proceed as follows:
1. Loosen the fastening nuts and loosen the two
adjustment dowels (1) and (2) of the calibra-
tion valve and anti-shock valve respectively, to
decrease the push of the respective springs
outwards. Remove the retainer plate (3) by
loosening the three fastening screws (4) with
the control rod (5) and respective recall spring.
5LA0270
66
2. Loosen from its seat the cap (1), the spring (2)
and the regulator piston (or servo valve) (3).
5LA0272
67
3. Remove from its seat the calibration valve com-
ponents, i.e. the spring guide (1), the spring
(2), the spring plate (3) and the ball (4).
Remove from its seat the anti-shock valve com-
ponents, i.e. the lower and upper plate (5), the
spring (6) and the ball valve (7).
5LA0274
68
700-60 P/N 3681774M1 Edition 01-2006

4. Turn the hydraulic distributor upside-down and

straight, remove the rubber protection (1),
loosen the fastening screws (2) and put the
cover down (3).
Extract the valve adjustment body (4), then the
lock valve (5), the roller (6), the valve seat (7), 5LA0275
the spring (8) and the retainer valve (9). 69
5LA0276
70
5. Remove the discharge valve group with plug
(1), sleeve (2), rod (3) and spring (4).
5LA0277
71
P/N 3681774M1 Edition 01-2006 700-61

Assembly
WARNING
safety footwear.

refitting the distributor:
on page 41.
100.

lies while rolling.

seats.

Proceed as follows:
1. With all components perfectly clean and lubri-
cated, refit by fastening the distributor body in
a vice and reversing the removal sequence.
2. Be very careful to correctly connect the dis-

charge valve (1) into its body (2) with the
transversal drainage hole (3) facing the inside
of the distributor.
5LA0278
72
700-62 P/N 3681774M1 Edition 01-2006

3. Make sure that all components are correctly

positioned, that the control rod (1) and regula- 5LA0271
tor piston (3) in particular are perfectly free 73
and slide in their respective seats for the entire
stroke.
5LA0273
74
Hydraulic inspections and adjustments

The distributor hydraulic control puts the assembly
into the various operating conditions of the power
lift. These tests allow the valves to be calibrated, to
make sure that there are no leaks and to establish
beforehand whether the assembly operates within
the limits for which it was designed and built.
The following tests can be carried out:
- Anti-shock valve inspection and adjustment
- Discharge valve leakage inspection
- Check valve leakage inspection
- Maximum valve inspection and calibration
- Delivery pipe leakage inspection
Use transmission oil at a temperature of approxi-
mately 50°C corresponding to a density of 3-3.5
Enghel degrees when performing the off-vehicle
hydraulic checks and inspections. Use a high pres-
sure pump (e.g. an injector test hand pump) and
specific tool 120 IDR GL which simulates the
power lift distributor.
P/N 3681774M1 Edition 01-2006 700-63

Anti-shock valve inspection and adjustment

1. Position and fasten the distributor assembly (2) the discharge outlet of the discharge valve (8).
inside the tool (1) 120 IDR GL. 4. Operate the pump to open the anti-shock valve
2. Connect the high pressure pump pipe (3) to (9).
the upper fitting (4) of the tool. This opening must occur at 200 bars.
3. Connect between the foot of the tool (1) 120 If this fails to occur, adjust the valve by means
IDR GL and the distributor rod (5), tool (6) 121 of the adjustment screw of the spring (10).
IDR GL or screw and nut which performs the Tighten the adjustment screw to increase the
same functions. setting value, slacken it off to decrease the
Loosen the screw to push the distributor rod value.
inwards to take the distributor to discharge step 5. After calibrating the valve, hold the pressure in
and neutral step. To identify the discharge valve the circuit at a value of approximately 120 bars
start of closure point, operate the hand pump for 2 or 3 minutes.
until oil stops flowing out from the discharge No oil must leak from the anti-shock valve. If
pipe (7). this does not occur, lap the seat with fine
Extend the tool by 1 mm to confer a covering of emery to ensure a perfect hold.
1
5LA0279
75
700-64 P/N 3681774M1 Edition 01-2006

5LA0281
76
P/N 3681774M1 Edition 01-2006 700-65

Discharge valve leakage inspection

1. Keep the pump (3) connected to the same The maximum admitted leakage between the
union (4) and keep tool (6) 121 IDR GL fitted piston (8) and its seat (11) is 4 cm3 in 1
in the same position as the previous test. minute at a pressure of 100 bars and with oil at
2. Operate the hand pump to take the pressure in approximately 50°C.
the circuit to 100 bars. In these conditions, the If this value is exceeded, remove the valve and
pressure must be maintained or drop very replace the o-rings. Then repeat the test and if
slowly. The presence of leakage is manifested the leakage remains, replace the discharge
by oil being let out through the pipe (7). valve (8) and its seat (11).
5LA0279
77
700-66 P/N 3681774M1 Edition 01-2006

5LA0281
78
Check valve leakage inspection

Another cause of leakage may be the check valve
(12). To facilitate location and to define the entity
of the leakage, remove the maximum valve (13)
which is in direct communication with the check
valve delivery pipe (12). Oil cannot be let out from
the respective pipe directly in this way.
If this occurs, lap the seat with fine emery to recre-
ate tightness.
Do not attempt to recreate the seats by

hitting the balls or the valves because this
would only cause stretching and possible
oil leakage.
P/N 3681774M1 Edition 01-2006 700-67

Maximum valve inspection and calibration

This test must be performed with tool (1) 120 IDR condition to take the distributor to delivery
GL. Move the pump delivery pipe (2) to the lower step.
union (3) and fasten the closing plug on the union 3. Operate the pump and make the maximum
(4) used for the previous test. valve (13) open. This opening must occur at
1. Fit the previously removed maximum valve 180 bars.
(13) on the distributor. If you need to adjust the valve, turn the adjust-
2. Extend the tool (5) 121 IDR GL turning it by ment screw (14) to increase the pressure and
one turn and a half with respect to the previous loosen it to decrease it.
5LA0280
79
700-68 P/N 3681774M1 Edition 01-2006

5LA0281
80
P/N 3681774M1 Edition 01-2006 700-69

Delivery pipe leakage inspection

1. Keeping the distributor in the previous condi- 3. Check tightness of the regulator piston (15).
tions, operate the pump and take the pressure The maximum admitted leakage is 15 cm3 in 1
in the circuit to 120 bars. minute. If oil leaks from pipe (7), this is due to
2. Check tightness of the valve (13): there must the play between the upper part (6) of the rod
be no oil leakage. If this does not occur, lap (7) and the distributor body. It will not be due
with fine emery the seat to provide perfect to the discharge valve (8) as this has already
tightness again. been checked. The maximum leakage is 10
cm3 in 1 minute.
1
5LA0280
81
700-70 P/N 3681774M1 Edition 01-2006

5LA0281
82
P/N 3681774M1 Edition 01-2006 700-71

On-tractor power lift adjustments

The on-tractor power lift adjustments must be per-
formed after removing the assembly for overhaul-
ing or to test correct operation. Before adjusting,
make sure that the two control levers (position and
draft) are perfectly coupled on the sector with the
two levers fitted on the power lift (1 and 2), to
ensure reaching end of stroke position of the power
lift and on the control sector. Take note of any dif-
ferences.
The adjustments must be made with the engine
running and oil at a temperature of 50°- 60°C
Access the distributor though the opening under
the driver’s seat. 5LA0282
Perform the following adjustments: 83

- Sensitivity adjustment
- Position control adjustment
- Draft control adjustment
Sensitivity adjustment
The purpose of this adjustment is to confer maxi-
mum sensitivity to the power lift by correctly posi-
tioning the discharge valve.
Proceed as follows:
1. Apply to the power lift arms a minimum weight
of 100 kg.
2. Start the engine and run it at 1000-1500 rpm.
3. Take the lifting arms to approximately half
stroke with the controlled position lever.
4. Loosen the nut (1) and loosen the discharge

valve adjustment screw (2) to seek its opening
point. This will be denoted by the appearance
of a rhythmic swing from the lift links.
Slowly fasten the screw (2) until the rhythmic
swinging of the arms ends: the discharge valve
is closed in this position.
Fasten the screw (2) by another one fourth of a
turn to cover the valve by approximately 0.3
mm.
The valve is now in maximum sensitivity condi-
tion.
Fasten the nut (1). 5LA0283
84
700-72 P/N 3681774M1 Edition 01-2006

Position control adjustment

The purpose of the controlled position adjustment with the help of a wrench, turn the position
is to ensure the intervention of the arm stroke control shaft anticlockwise (3) until the arms
stops by the linkage system using the hydraulic stop moving up because the inner hydraulic
stop of the cylinder piston for safety functions. stroke trips. Since in controlled position, the
Proceed as follows: maximum upward angular range of the arms
must not trip the hydraulic stop a certain safety
1. Apply to the power lift arms a minimum weight
margin must be left.
of 100 kg.
5. Therefore, turn the shaft (G) anticlockwise to
2. Loosen the screw (1) making the lever (2) inte-
lower the arms by 20-30 mm.
gral with the position control shaft (3).
6. After the operation, make the transmission
3. Fully raise the position control lever (P) to the
lever (2) held against the stop (5) integral with
stop (4) so that the transmission lever (2) goes
the shaft (3) tightening the screw (1). To check
against the stop (5). The draft control lever (S)
operation, move the lifting arms up and down a
must remain down in zero position (lever 6
few times, checking that in maximum raised
against stop 7).
position they always stop in the same point.
4. Maintaining levers (P) and (S) in this position,
1
5LA0284
85
P/N 3681774M1 Edition 01-2006 700-73

Draft control adjustment

The purpose of the controlled draft adjustment is to 15-20 mm. If the measurement is larger than
ensure that the power lift arms raise a little before 15-20 mm, (3.5-4.5 mm between lever (4) and
the end of the draft lever reaches end of stroke on stop F), shorten the linkage (6) fastening the
the control sector when the pivoting support is adjustment plate (7). Make it longer otherwise.
pulled to maximum rear position (negative draft).
Proceed as follows:
Before changing the linkage length (6),
1. Take the pivoting support to fully retracted stop the engine, block the screw (8) and
position (maximum negative draft) using tool the lock nut (9).
(1) 127 IDR GL or a long lever.
2. Start the engine and take it to approximately
1000 rpm. 5. After adjusting, check that the dimension of
15-20 mm remains unchanged when the arms
3. Take the controlled position lever (P) all down
start raising. Otherwise, change the linkage
against the stop (2) and slowly raise the draft
adjustment (6).
control lever (S) to the stop (3) on the sector.
Stop the lever movement as soon as the arms
lift. Note: Controlled draft movements are
4. Check with a gauge the distance between the stopped by the internal safety stop.
lever and the stop (3): the correct dimension is
5LA0285
86
700-74 P/N 3681774M1 Edition 01-2006

SECTION 800
STEERING SYSTEM
SECTION 800 - STEERING SYSTEM
TABLE OF CONTENTS
Description Page
MAIN SPECIFICATIONS OF THE HYDROSTATIC STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800-3
STEERING CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800-4
SECTIONS AND PROSPECTIVE VIEWS . . . . . . . . . . . . . . . . . ..... ... . . . . . . . . . . . . . . . . . . . . 800-6

Operation - neutral position . . . . . . . . . . . . . . . . . . . . ..... ... . . . . . . . . . . . . . . . . . . . . 800-9
Operation - steering position . . . . . . . . . . . . . . . . . . . ..... ... . . . . . . . . . . . . . . . . . . . 800-10
Manual steering operation (engine stationary) . . . . . . . ..... ... . . . . . . . . . . . . . . . . . . . 800-11
ORBITROL - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800-12

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800-12
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800-14
800-2 P/N 3681774M1 Edition 01-2006

MAIN SPECIFICATIONS OF THE HYDROSTATIC STEERING
System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic distributor controlled by the

steering wheel
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orbitrol OSPC 80
Pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . . geared
Pump flow rate . . . . . . . . . . . . . . . . . . . . . . . . l/ 27.5 (at maximum engine speed)

rpm
Maximum operating pressure . . . . . . . . . . . . . . . (bar) 150 ± 5
Steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . double acting, balanced
Cylinder dimensions. . . . . . . . . . . . . . . . . . . . . . mm 35 x 57 x204/2
Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . Telescopic, adjustable height and slant
Steering wheel diameter . . . . . . . . . . . . . . . . . . mm 360
Steering wheel turns . . . . . . . . . . . . . . . . . . . . . 2 (right)

1.75 (left)
Minimum turning radius . . . . . . . . . . . . . . . . . . . (m) 2.91 (with brakes)

3.67 (without brakes)
P/N 3681774M1 Edition 01-2006 800-3

STEERING CIRCUIT DESCRIPTION
The low flow rate circuit consists of a first high The steering system fitted on the MF tractor series
pressure section for operating the hydraulic steer- is hydrostatic: there is no mechanical connection
ing. between the steering wheel and the steering cylin-
The oil from the pump low flow rate stage (2a) der.
crosses the filter (3) and feeds the Orbitrol steering Each minimum turn of the steering wheel corre-
distributor (4) to then power the respective steer- sponds to an equivalent turn of the wheels.
ing cylinder (5). If the engine breaks down or the hydraulic pump
The oil discharged by the Orbitrol feeds the hydrau- fails to operate, the Orbitrol acts like a hand pump
lic unit (6) and through a low pressure circuit is operated by the steering wheel which allows the
directed to the various units. turn to be made.
800-4 P/N 3681774M1 Edition 01-2006

5LA0214
1
Steering circuit
P/N 3681774M1 Edition 01-2006 800-5

SECTIONS AND PROSPECTIVE VIEWS

1
5LA0313
2
ORBITROL distributor section
800-6 P/N 3681774M1 Edition 01-2006

1. Check valve 16. Ring

2. One-way valve 17. Washer
3. Stator 18. Anti-shock valve
4. Rotor 19. Roller bearing
5. Screw 20. Washer
6. Spacer 21. O-ring
7. Screw 22. Ring
8. Seal 23. Centring springs
9. Closing plate 24. O-ring
10. O-ring 25. "Orbitrol" distributor
11. O-ring 26. Pin
12. Distributor plate 27. Sleeve
13. O-ring 28. Anti-cavitation valve
14. Connection shaft 29. Safety valve
15. Drum
P/N 3681774M1 Edition 01-2006 800-7

5LA0317
3
ORBITROL distributor prospective view
1. Check valve 16. Ring
2. One-way valve 17. Washer
3. Stator 18. Anti-shock valve
4. Rotor 19. Roller bearing
5. Screw 20. Washer
6. Spacer 21. O-ring
7. Screw 22. Ring
8. Seal 23. Centring springs
9. Closing plate 24. O-ring
10. O-ring 25. "Orbitrol" distributor
11. O-ring 26. Pin
12. Distributor plate 27. Sleeve
13. O-ring 28. Anti-cavitation valve
14. Connection shaft 29. Safety valve
15. Drum
800-8 P/N 3681774M1 Edition 01-2006

Operation - neutral position

In this position, the drum (1) is centred with distributor.
respect to the sleeve (2) by the springs. The anti-shock valves (3) protect the circuit
Pipes P1-L-R are not supplied. between the steering cylinder and the distributor
The oil from the pipe P passes directly to the pipe T from shocks on the wheels.
to feed the hydraulic unit. The circuit is of the open The anti-cavitation valves (4) let the oil discharged
centre type. from the anti-shock valves (3) to cross from the
Two anti-shock valves (3) and two anti-cavitation right pipe to the left pipe and vice versa, according
valves (4) are placed in the holes L and R of the to the shift of the piston in the steering cylinder.
1
5LA0318
A. Steering cylinder P1. Feed to metering device

B. Steering column position R. Feed to right union of steering cylinder
L. Feed to left union of steering cylinder T. Discharge to hydraulic unit
P. Low flow rate feed from hydraulic pump
P/N 3681774M1 Edition 01-2006 800-9

Operation - steering position

Turning the steering wheel (to the right or to the left) therefore proportional to the rotation angle of the
causes an angular rotation of the drum (1) with steering wheel. The drum (1) allows according to
respect to the sleeve (2). The flow from the pump is whether steering to the left or right to send oil from
conveyed to the metering device, namely the stator the metering device - stator (4) and rotor (3) - to the
(4) and the rotor (3). The rotor (3) turns and sends hole L or R.
back to the cylinder a quantity of oil proportional to The sleeve (2) ensures during the rotation the syn-
the rotation angle. The rotation of the rotor (3) is chronous communication of the metering device
equal to that of the steering wheel. cavities with the circuit form the pump on one side
Example: Supposing that the steering wheel is and the circuit to the cylinder A on the other.
turned by an angle of 5°. This causes an angular A check valve (5) is fastened into the distributor feed
rotation of the drum (1) of 5° with respect to the hole. This is a one-way valve which prevents exces-
sleeve (2). The rotor (3) is turned until it is fed. sive pressures exerted on the wheels to be transmit-
It in turn drives the connection shaft and the sleeve ted to the pump when the wheels are steered. If the
(2). When these have turned by 5°, the drum (1) and pressure in the steering circuit is too high, the safety
the sleeve (2) are centred on the springs again. The valve (6) located on the distributor is stressed and
rotor ceases to be powered and is blocked. The same the pressure in excess is directed towards the pipe T.
principle applies to wider angles. The amount of oil
discharged by the power steering to the cylinder A is
1
5LA0319
5
800-10 P/N 3681774M1 Edition 01-2006

Manual steering operation (engine stationary)

The rotor (2) is not hydraulically driven when the manual pump.
pump is not conveying oil and when the available The return oil from the cylinder A crosses the check
pressure is too low. There is no power assistance in valve (3) and supplies the metering device.
this case.
The pressure generated is proportional to the
Turning the steering wheel will compress the cen- torque exerted on the steering wheel. In this case,
tring springs. This cancels the angular float the effort on the steering wheel is high.
between the pin and the sleeve and the rotor is
driven mechanically. The distributor now works as a
1
5LA0320

P/N 3681774M1 Edition 01-2006 800-11

ORBITROL - OVERHAUL
Disassembly
WARNING
safety footwear.
Proceed as follows:
1. Remove the distributor from the tractor.
2. Fasten the distributor to the vice.
Close the vice so to avoid damage.
3. Loosen the screws (1) and (5) and mark their
respective position.
4. Remove the closing plate (9), the o-ring (10),
the stator (3) and the o-ring (11).
5. Remove the spacer (6), the rotor (4), the dis-
tributor plate (12) and the o-ring (13).
6. Extract the spline shaft (14).
7. Remove the threaded bushing and recover the
check valve ball (2).
8. Extract the two spring pins and two balls from
the anti-cavitation valves (28) of the distribu-
tor.
9. Extract by pushing the sleeve unit (27) and
drum (15), checking that the pin (26) is
directed on the horizontal axis.
10. Remove the washers (17) and (20), the roller
bearing (19) and the bushing (16) from the
sleeve/drum assembly. Remove the pin (26)
and the centring springs (23) by pushing on
one of the ends. Separate the sleeve (27) from
the drum (15).
11. Remove the safety valve plug (29). With a 8
mm Allen wrench, remove the threaded bush-
ing and remove the seal, the spring and the
valve (the recessed seat cannot be removed).
12. Loosen the two anti-shock valves (18) and
remove the seals. With a 6 mm Allen wrench,
remove the threaded bushing and remove the
springs, the balls and the seats (the recessed
seats cannot be removed).
13. Extract the o-ring (24), the bushing (22) and
the o-ring (21).
14. Remove the check valve (1).
800-12 P/N 3681774M1 Edition 01-2006

5LA0313
P/N 3681774M1 Edition 01-2006 800-13

Assembly
WARNING
safety footwear.

refitting the Orbitrol distributor:
on pages 6 and 7.
100.

lies while rolling.

seats.

Proceed as follows:
1. Remove the check valve (1, fig. 7).
2. Fit the o-ring (24, fig. 7).
3. Fit the o-ring (21) and the ring (22) on the tool
(115 IDR GL).
4. Position the complete tool in the distributor
body (5) and push the tool until the o-rings are
fitted in their seats.
5LA0321
800-14 P/N 3681774M1 Edition 01-2006

5. Arrange the balls and springs in the anti-shock

valve seats (18, fig. 7). Fasten the threaded
bushings, arrange the seals and tighten the
plugs.
6. Arrange the valve and the spring in the dis-
charge valve (29, fig. 7) and fasten the
threaded bushing. Arrange the seal and fasten
the plug at a torque of 40 - 60 Nm.
7. Insert the drum (5, fig. 7) in the sleeve (27, fig.
7).
8. Introduce the tool 113 IDR GL for fitting the 5LA0322
centring springs (23) through the slot. Fasten 9

the springs on the tool as shown and arrange
the pin (26, fig. 7).
5LA0323
10
9. Position the bushing (16, fig. 7) on the sleeve
and drum assembly using the chamfering to
facilitate assembly in the distributor.
10. Arrange the washers (17 and 20, fig. 7), with
the washer chamfering (17, fig. 7) oriented
towards the centring springs (23, fig. 7) placing
the roller bearing in between (19, fig. 7).
11. Fit the sleeve and drum assembly in the distrib-
utor applying a slight oscillating movement.
Make sure that the pin (26, fig. 7) is held hori-
zontally.
12. Arrange the two balls and the two spring pins
in the suction valve seat (28, fig. 7).
13. Arrange the ball in the check valve seat (2, fig.
7) and fasten the threaded bushing.
P/N 3681774M1 Edition 01-2006 800-15

14. Extract the connection spline shaft (14, fig. 7).

15. Arrange the o-ring (3, fig. 7) and the distribu-
tor plate (12, fig. 7).
16. Fit the rotor (4) so that the two C cavities are
in line with the spline shaft axis (14). Refit the
spacer 6, fig. 7).
5LA0324
11
17. Arrange the o-rings (10, fig. 7) and (11, fig. 7)
on the stator (3, fig. 7).
18. Avoid moving the rotor (4, fig. 7) and refit the
stator (3, fig. 7). Then move the stator so that
its fastening holes correspond to that of the
distributor.
The rotor (4) and the slot C must be in the

position shown.
5LA0325
12
19. Refit the closing plate (9, fig. 7).
20. Refit the screw (5, fig. 7) in the position
marked during disassembly and the screws (7,
fig. 7) with seals (8, fig. 7). Tighten crossingly
at a torque of
30-35 Nm.
21. Use an appropriate pad to check settings and

operation of the distributor.
22. Refit the distributor on the tractor.
800-16 P/N 3681774M1 Edition 01-2006

SECTION 900
BRAKES
SECTION 900 - BRAKES
TABLE OF CONTENTS
Description Page
MAIN SPECIFICATIONS OF BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900-3
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900-5
SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900-6
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . . . . 900-8
Rear brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . . . . 900-8
Front brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . . . . 900-9
Parking brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. .. . . . . . 900-10
900-2 P/N 3681774M1 Edition 01-2006

MAIN SPECIFICATIONS OF BRAKES
Rear brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . wet multiple disc fitted on rear

differential axle shafts
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBS hydraulic (simultaneous

braking with front brakes) oper-
ated by two pedals positioned
on the driver’s right.
Nr. of friction plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 (4 per side)
Friction material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . resin-graphite
Front brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . wet multiple disc fitted on rear

differential axle shafts
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBS hydraulic (simultaneous

braking with rear brakes) oper-
ated by two pedals positioned
on the driver’s right.
Nr. of friction plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 (2 per side)
Friction material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . resin-graphite
Parking brake
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand lever and independent

linkages acting directly on serv-
ice brakes
Trailer brake (optional)
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . hydraulic
P/N 3681774M1 Edition 01-2006 900-3

The tractor braking system is characterised by an The control valve ensures braking on the four
“IBS” (Integral Braking System) featuring a hydro- wheels when the pedals are coupled by means of a
static control circuit and front and rear wet discs. bolt and on the rear wheels only when only one
Braking is governed by a control valve which deter- pedal is pressed or when the pedals are not bolted
mines the operation of either only the rear brakes together.
or the front and rear brakes at the same time.
1
5LA0326
1
1. Brake cylinders 4. Rear disk brakes
2. Check valve 5. Hydraulic trailer brake (optional)
3. Front disk brakes
900-4 P/N 3681774M1 Edition 01-2006

CONTROLS
1
5LA0327
2
Brake controls
1. Left brake control pedal 3. Coupling bolt

2. Right brake control pedal 4. Parking brake control lever
P/N 3681774M1 Edition 01-2006 900-5

SECTIONS
1
5LA0328
3
Rear differential - rear brakes cross-section
1. Differential lock rod 11. Satellite gear

2. Spring 12. Satellite pin
3. Differential lock fork 13. Slewing bearing
4. Differential lock hydraulic actuator 14. Differential housing
5. Supporting flange 15. Taper bearing
6. Adjuster shim 16. AXLE SHAFT
7. AXLE SHAFT 17. Adjuster shim
8. Taper bearing 18. Supporting flange
9. Slewing bearing 19. BRAKE ASSEMBLY
10. Planetary gear
900-6 P/N 3681774M1 Edition 01-2006

5LA0286
4
Front differential - front brakes cross-section
1. LEFT AXLE SHAFT 23. Slewing bearing
2. Screw 24. O-ring
3. BRAKE CASING COVER 25. Piston
4. Ring nut 26. O-ring
5. Piston 27. Union
6. Brake housing 28. Cap
7. Taper bearing 29. Spring
8. Satellite pin 30. Snap ring
9. Screw 31. BRAKE HUB
10. Ring nut 32. Bevel pinion ring
11. LOCK CASING 33. Bevel pinion
12. O-ring 34. O-RING
13. O-ring 35. TAPERED BEARING
14. PISTON 36. Shim
15. DISC BRAKE 37. Taper bearing
16. COUNTER DISC 38. Bevel ring gear
17. HYDROLOCK CASING 39. Differential mount
18. Spring guide 40. Snap ring
19. O-ring 41. Brake hub
20. Thrust slewing bearing 42. Axial guard
21. RIGHT AXLE SHAFT 43. Planetary gear
22. Snap ring
P/N 3681774M1 Edition 01-2006 900-7

ADJUSTMENTS
Rear brake adjustment
WARNING
safety footwear.
This adjustment is required whenever the

! control panel free stroke is excessive and
the pedals are near end of stroke.
Make sure that the control pedal free

! stroke is approximately 35 mm.
Proceed as follows:
Make sure that there is no air in the

hydraulic brake circuit. Otherwise, bleed
the circuit as shown in the general service
procedure section.
Air is normally present when the pedal
feels spongy.
1. Lift the rear wheels with a jack.

2. Make sure that the parking brake is not
engaged.
3. Make the two brake pedals independent by lift-
ing the coupling bolt.
4. Loosen the lock nut (1).

Fasten the nut (2) slowly until the wheel can-
not be turned by hand anymore.
5LA0329
900-8 P/N 3681774M1 Edition 01-2006

5. Mark a reference line on the nut (2) and on the

control lever (3).
5LA0329
6
6. Loosen the adjustment nut (2) by one turn and
1/6th and until the wheel can be turned again
by hand.
Fasten the lock nut.
5LA0330
7
7. Check that the pedal free stroke is approxi-
mately 35 mm. Otherwise, repeat the adjust-
ment procedure.
5LA0331
8
8. Repeat the same operations on the other side,
making sure that the brake pedal free stroke is
identical and that they work simultaneously.
Front brake adjustment
No periodical adjustment is needed

because these brakes are self-adjusting.
P/N 3681774M1 Edition 01-2006 900-9

Parking brake adjustment
WARNING
safety footwear.
Make sure that the parking brake lever is

! operated after two notches felt on the
button on the lever itself.
Proceed as follows:
Adjust the brakes as shown in the proce-

dure on page 8.
1. Adjust the lever idle stroke by means of the

adjustment nut (1) until the brake is applied at
the second notch of the stroke.
5LA0332
900-10 P/N 3681774M1 Edition 01-2006

SECTION 1000
ELECTRICAL SYSTEM - INSTRUMENTS
SECTION 1000 - ELECTRICAL SYSTEM - INSTRUMENTS
TABLE OF CONTENTS
Description Page
INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000-3
Warning light identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000-4
Indicators and external connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000-5
RPM meter and hour counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000-7
Fuel level gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000-7
Engine coolant temperature indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000-7
TRANSMITTERS, SENSORS AND SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000-8
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000-12
Instrument replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000-12
1000-2 P/N 3681774M1 Edition 01-2006

INSTRUMENTS
1 2 3
15
10 20
STOP
P ! 5 25
!
rpm
! x 100
4
0 30 ECO
1 2
FRONT
N
A
B
Km/ha
MPH
9 8 7 6 5
4LA0006
1
The instrument is positioned on the dashboard. It consists of nine display sections, plus two side selection
and programming buttons.
1. On/off and warning lights 9. Engine coolant temperature instrument

2. RPM meter and hour counter A-B.Programming/setting buttons for the following func-
3. On/off and warning lights tions:
4. Fuel level gauge - Clock
5. Right turn indicator warning light - Odometer
- PTO speed
6. PTO speed digital display
- Hour counter reset
7. Tractor speed digital display - Worked area
8. Left turn indicator warning light
P/N 3681774M1 Edition 01-2006 1000-3

Warning light identification
1 13
2 14
3 15
7 19
15
4 8 10 20 20
16
STOP
P !
9 5 25
!
rpm
5 ! x 100
17
0 30 ECO
11 1 2
21
FRONT
N
6 18
Km/ha
MPH
28 10 12 31 25 27 26 23 30 29 24 22
4LA0011
The position of indicator lights on the panel and their functions are described in the following list:
FUNCTION INDICATOR COLOUR

1. ALTERNATOR red
2. ENGINE OIL PRESSURE red
3. HANDBRAKE red
4. SUPER FINAL DRIVE yellow
5. DRIVING BEAM HEADLIGHTS blue
6. SIDE LIGHTS green
7. TRAILER BRAKE OIL PRESSURE red
8. ENGINE ALARM yellow
9. DIFFERENTIAL LOCKS yellow
10. TRAILER FIRST TURN INDICATOR green
11. 4WD ENGAGED yellow
12. TRAILER SECOND TURN INDICATOR green
13. OBSTRUCTED AIR CLEANER red
14. HYDRAULIC CIRCUIT VACUUM METER red
15. TRANSMISSION OIL FILTER red
16. PTO OVERSPEED (NAO MARKET) yellow
17. SYNCHRONISED PTO yellow
18. FRONT PTO yellow
19. BRAKE OIL PRESSURE red
1000-4 P/N 3681774M1 Edition 01-2006

FUNCTION INDICATOR COLOUR

20. GLOW PLUGS yellow
21. ECO PTO yellow
22. MID/BY SPEED PTO yellow
23. REAR PTO (INDEPENDENT PTO) yellow
24. FAST PTO / WHEEL SLIP yellow
25. FORWARD DIRECTION green
26. REVERSE DIRECTION green
27. BRAKES red
28. COOLANT TEMPERATURE red
29. FUEL RESERVE yellow
30. RH DIRECTION green
31. LH DIRECTION green
Indicators and external connections

Refer to the following table to identify the indicators on the panel:
FUNCTION CONNECTOR A PIN N.

BATTERY 1
HANDBRAKE 2
ENGINE OIL PRESSURE 3
BRAKE OIL PRESSURE 4
Not connected 5
HYDRAULIC CIRCUIT VACUUM METER 6
OBSTRUCTED AIR CLEANER 7
KEY (IGNITION) 8
TRANSMISSION OIL FILTER 9
4WD ENGAGED 10
DIFFERENTIAL LOCKS 11
SUPER FINAL DRIVE 12
MID/BY SPEED PTO 13
GROUND 14
SYNCHRONISED PTO 15
REAR PTO (INDEPENDENT PTO) 16
FRONT PTO 17
ECO PTO 18
TRAILER BRAKE OIL PRESSURE 19
ENABLE SLIP CONTROL 20
DRIVING BEAM HEADLIGHTS 21
SIDE LIGHTS 22
LH DIRECTION 23
RH DIRECTION 24
TRAILER FIRST TURN INDICATOR 25
TRAILER SECOND TURN INDICATOR 26
P/N 3681774M1 Edition 01-2006 1000-5

FUNCTION CONNECTOR B PIN N.

ENGINE RPM 1
REAR PTO RPM 2
SPEED 3
CAN_SHIELD 4
CAN_H 5
CAN_L 6
BATTERY 7
RADAR 8
BUZZER 9
ALTERNATOR (D+) 10
K LINE (SERIAL) 11
REVERSE DIRECTION 12
KEY (IGNITION) 13
FUEL RESERVE 14
SLOW PTO 15
FAST PTO 16
GLOW PLUGS 17
FORWARD DIRECTION 18
GROUND 19
Not connected 20
COOLANT TEMPERATURE 21
FUEL LEVEL 22
Not connected 23
Not connected 24
Not connected 25
Not connected 26
1000-6 P/N 3681774M1 Edition 01-2006

RPM meter and hour counter

Engine RPM is shown on an analogue gauge on
which, as RPM increases, a pointer moves around a 15
graduated scale. The indication must be multiplied 10 20
one hundred. The LCD inside the instrument pro-
STOP
vides the following indications:
5 25
- clock function rpm
x 100
- hour counter function (resettable)

- worked area function 0 30
- engaged gears function.
N
4LA0041
Fuel level gauge

Indicates the level of the fuel in the tank.
The pointer moves fully towards the right when the
tank is full (green zone).
When the fuel tank is less than ¼ full, the pointer
moves to the yellow zone and the indicator (1)
lights up to indicate fuel reserve conditions.
4LA0042
Engine coolant temperature indicator

- Blue zone = low temperature (engine cold)
- Green zone = temperature OK
- Red zone = engine excessively overheated.
In this latter case, the engine must be allowed to
idle (without being stopped). Check the cooling
system if the indication persists.
Indicator light (1) on the instrument comes on 1
when the temperature reaches 105−110°C.
4LA0043
P/N 3681774M1 Edition 01-2006 1000-7

TRANSMITTERS, SENSORS AND SOLENOID VALVES
A B
4LA0035
1000-8 P/N 3681774M1 Edition 01-2006

4LA0038
P/N 3681774M1 Edition 01-2006 1000-9

M
N
O
P
4LA0039
1000-10 P/N 3681774M1 Edition 01-2006

A. ENGINE COOLANT TEMPERATURE SENSOR (for starter)

Detects the maximum engine coolant temperature limit.
B. ENGINE COOLANT TEMPERATURE SENSOR (for instrument panel)

The resistance of the temperature transmitter varies in proportion to the temperature of the coolant,
generating a modulated voltage that is measured by the instrument.
C. ALTERNATOR
Transmits a square wave signal, recharges the battery and makes up for the power draw depending
on the amount required by the users.
D. ENGINE OIL PRESSURE SENSOR.

Operates as soon as the pressure of the engine oil drops below a certain value, after which the indi-
cator light on the instrument comes on.
E HYDRAULIC OIL PUMP OBSTRUCTION PRESSURE SWITCH

Detects the pressure difference in the hydraulic circuit and lights up the indicator on the instrument
panel if an obstruction is found.
F BRAKE FLUID LEVEL SENSOR

Detects the level of brake fluid in the tank inside the dashboard (right-hand side) and lights up the
respective indicators on the instrument panel.
G FUEL PUMP
This is fastened to the fuel filter and is connected in parallel to the injection pump and the starter.
H GEARBOX OIL VACUUM METER

Detects the pressure difference in the gearbox oil circuit and lights up the respective indicator if the
pressure is low.
I 4WD SOLENOID VALVE

Controls hydraulic operation of 4WD and is connected to the respective switch on the right mud-
guard.
L BY SPEED SOLENOID VALVE

Controls the by speed system hydraulic circuit.
M REAR PTO SOLENOID VALVE AND PTO BRAKE

Controls the rear PTO hydraulic circuit and is connected to the respective control switch on the right
mudguard.
N AIR CLEANER VACUUM METER

Comes into action when the vacuum in the air suction system exceeds a predetermined value and
lights up the indicator on the instrument panel.
O FUEL LEVEL TRANSMITTER

The signal issued by the transmitter determines the fuel level indicated on the instrument and turns
on the warning light when the fuel is in reserve.
P DIFFERENTIAL LOCK SOLENOID VALVE

Controls the differential lock circuit by means of the respective button on the right mudguard.
Q SPEED SHIFT SOLENOID VALVE

Controls operation of the gear shift hydraulic circuit and is connected to the control button on the
gear lever.
P/N 3681774M1 Edition 01-2006 1000-11

MAINTENANCE
Instrument replacement
Proceed as follows to replace the instrument:
1. Use a screwdriver as a lever in order to remove 10
15
20
the instrument from its housing. P ! 5

STOP
25
!
rpm
! x 100
0 30 ECO
1 2
FRONT
Km/ha
MPH
4LA0058
9
2. Remove the instrument from its housing and
disconnect the connectors (1) and (2).
3. Fit a new instrument and reconnect the two
connectors, considering that they are not inter- 1 2
changeable despite the same number of pins
and the same shape. Indeed, connector (1) has
five inner references (keys) while connector (2)
has three.
4LA0013
10
1000-12 P/N 3681774M1 Edition 01-2006

SECTION 1010
ELECTRICAL SYSTEM - COMPONENTS
SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS
TABLE OF CONTENTS
Description Page
CONTROL PANEL WITH ANALOGUE/DIGITAL INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-3
HAZARD LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-4
ROTATING LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-4
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-4
LIGHT STALK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. ..... 1010-5

Turn indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. ..... 1010-5
Driving beam blinking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. ..... 1010-5
Side and tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. ..... 1010-6
Driving/dipped beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. ..... 1010-6
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. ..... 1010-6
WORKING LIGHT SWITCH (VERSION WITHOUT CAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-6
RIGHT SIDE COMMANDS (VERSION WITHOUT ELECTRONIC POWER LIFT) . . . . . . . . . . . . . . . . . 1010-7

Differential lock button (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-7
4WD and by speed switch (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-8
PTO switch (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-8
Speed shift button (2, fig. 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-8
RIGHT SIDE COMMANDS (VERSION WITH ELECTRONIC POWER LIFT) . . . . . . . . . . . . . . . . . . . . . 1010-9

Differential lock button (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-9
4WD and by speed switch (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-9
PTO switch (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-10
Electronic power lift control panel (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-10
External controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-11
CONTROLS ON THE RIGHT CAB PILLAR . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ..... ........ 1010-12

A/C knob (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ..... ........ 1010-12
Fan knob (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ..... ........ 1010-12
A/C button (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ..... ........ 1010-13
Front working light switch (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ..... ........ 1010-13
Washer switch (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ..... ........ 1010-13
Rear working light switch (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. ..... ........ 1010-13
CAB COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-14
ISO/NAO REAR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-15

1. ISO version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-15
2. NAO version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-15
Reverse light (Japan only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-15
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-16
Headlight bulbs. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-16
Front side light and turn indicator bulbs. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-17
Tail light, brake light and rear turn indicator bulbs. Replacement . . . . . . . . . . . . . . . . . . . 1010-17
Cab working light bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-18
Rear working light bulb (version without cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-18
Rotating light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-19
BULB SPECIFICATIONS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-19
1010-2 P/N 3681774M1 Edition 01-2006

CONTROL PANEL WITH ANALOGUE/DIGITAL INSTRUMENT
2
6
5
4
4LA0005
1
1. Central analogue/digital instrument 4. Ignition switch
2. Hazard light switch 5. Light switch
3. Rotating light switch 6. Working light switch (version without cab only)
P/N 3681774M1 Edition 01-2006 1010-3

HAZARD LIGHT SWITCH
Press the switch (2, fig. 1) to turn on the hazard

lights. After the button has been pressed, the
switch will blink along with the turn indicators.
ROTATING LIGHT SWITCH
Press the switch (3, fig. 1) to operate the rotating

light. 1
4LA0000
IGNITION SWITCH
Turn the key to the following positions to obtain the

three ignition switch functions (4, fig. 1):
- position A = no circuit powered (the key can be
removed). The engine stops.
- position B = presetting position for engine igni-
tion. The indicator lights and monitoring instru-
ments light up. Various users are powered.
- position C = the thermo starter warms up so
that the engine can start in cold climates.
- position D = cranks the engine: the key returns
automatically to position (B) when released.
2LA0710
1010-4 P/N 3681774M1 Edition 01-2006

LIGHT STALK
The light stalk (1, fig. 4) is arranged near the steer-

ing column and operates: turn indicators, headlight
blinks, side/taillight, dipped beam and driving
headlight selection, horn.
Turn indicators
To signal that you are about to turn to the left, pull
the light switch lever (1) back to position (C).
To signal that you are about to turn to the right,
push the lever forwards to position (D).
2LA0485
Driving beam blinking function

With the lights off or with the driving beams on,
push the lever up to position (A, fig. 4) to blink the
driving beams. The lever will automatically return
to its original position when released.
P/N 3681774M1 Edition 01-2006 1010-5

Side and tail lights

Turn knob (3) taking pointer (2) to symbol (1). The
side and tail lights and the control panel will light
up.
2LA0486
Driving/dipped beams
Move the pointer (2) of the knob (1) to symbol (3)
to turn on the dipped beams or down to position
(B, fig. 4) for the fixed driving beams.
Horn
Press the button at the end of the lever (1, fig. 4)
to operate the horn.
2LA0487
WORKING LIGHT SWITCH (VERSION

WITHOUT CAB)
To operate the rear working light (1), press the

switch (6, fig. 1) on the left of the control panel.
4LA0007
1010-6 P/N 3681774M1 Edition 01-2006

RIGHT SIDE COMMANDS (VERSION WITHOUT ELECTRONIC POWER LIFT)
1 2 3 4
4LA0004
8
The following controls and components are located on the right mudguard:
1. Differential lock button 3. PTO switch
2. 4WD and by speed switch 4. Cigar lighter
Differential lock button (1)

Press button (1) to lock the differential.
Locking is confirmed by the indicator light (9, fig. 2)
described in section 1000.
Depress one or both of the brake pedals to unlock
the differential.
To obtain the best result, the diff lock

should be engaged before the wheels
begin to slip. Do not engage the lock while
a wheel is actually slipping.
P/N 3681774M1 Edition 01-2006 1010-7

4WD and by speed switch (2)

This control engages 4WD and switch position of
the by speed function controlled by the lever (1,
fig. 6).
PTO switch (3)

The switch (3, fig. 8) is used to switch the PTO on
and off.
- on = switch turned towards the cab window
- off = switch turned N position
PTO engagement is managed by an electromag-
netic clutch. The respective indicator lights up on
the instrument panel when engaged.
Speed shift button (2, fig. 9)

Press the button (2), positioned on the gearbox
lever (1), to engage the speed shift system (for 1
shift down by half a gear).
The button controls via a toggle relay and relay
switch the solenoid valve of the hydraulic system
related to the system.
4LA0051
2
9
1010-8 P/N 3681774M1 Edition 01-2006

RIGHT SIDE COMMANDS (VERSION WITH ELECTRONIC POWER LIFT)
3
5
2
5 4
6 3
5
STO
P 7 2
1
4
8
9
3
2
1 2 3 4
5LA0364
10
1. Differential lock button 3. PTO switch
2. 4WD and by speed switch 4. Electronic power lift control panel
Differential lock button (1)

Press button (1) to lock the differential.
Locking is confirmed by the indicator light (9, fig. 2)
described in section 1000.
Depress one or both of the brake pedals to unlock
the differential.
To obtain the best result, the diff lock

should be engaged before the wheels
begin to slip. Do not engage the lock while
a wheel is actually slipping.
4WD and by speed switch (2)

This control engages 4WD and switch position of
the by speed function controlled by the lever (1,
fig. 6).
P/N 3681774M1 Edition 01-2006 1010-9

PTO switch (3)

The switch (3, fig. 8) is used to switch the PTO on PTO engagement is managed by an electromag-
and off. netic clutch. The respective indicator lights up on
- on = switch turned towards the cab window the instrument panel when engaged.
- off = switch turned N position
Electronic power lift control panel (4)

This is located on the right mudguard and controls
the entire system.
1 2 3 4 5 6
C
B
A
10 9 8 7
4LA0131
11
1. Three position up/down switch: 5. Lifting indicator
A. Down - Working position. Working position is 6. Function selector:
obtained according to the setting of controls (6 and Position control, turned anticlockwise
8) Draft control, turned clockwise
B. Stop - No power lift arm movements are allowed Intermediate positions: draft and position control
in this position combination (INTERMIX)
C. Up - Transport: the maximum lift position is 7. Lowering indicator
determined by the limiter (4) 8. Implement working depth/height control
2. Descent speed selector: 0 - Down
0 - No descent. Padlock - Turned anticlockwise 10 - Max. height from ground
3. Electronic power lift “Check Control” self-diagnostic 9. “Shock Absorber” button and indicator in transport
indicator position
4. Maximum height limiter: 10. Quick dig button
Minimum height, turned anticlockwise
Maximum height, turned clockwise
1010-10 P/N 3681774M1 Edition 01-2006

External controls
The power lift can be controlled by two outer but-
tons positioned respectively on two rear sides of
the tractor, by the side of the rear lights:
1. Arm up button
2. Arm down button
4LA0132
12
The entire electronic power lift system is controlled
by an electronic unit wired into the right mudguard.
See section 1050, page 48 for a specific description
of this unit.
P/N 3681774M1 Edition 01-2006 1010-11

CONTROLS ON THE RIGHT CAB PILLAR
The following controls are fitted on the right cab

pillar:
1. A/C knob
2. Fan knob
3. A/C button 1
4. Front working light switch
5. Washer switch
6. Rear working light switch 2 3
2
4LA0008
13
A/C knob (1)

Turn the knob anticlockwise (to the blue zone) for
maximum cooling. Turn the knob clockwise for
maximum heating.
Fan knob (2)

The fan works with the ignition key in position B
(see fig. 3) and has four working positions:
0. Stop
1. Low speed
2. Medium speed
3. High speed
1010-12 P/N 3681774M1 Edition 01-2006

A/C button (3)

This controls the A/C compressor (1) and is ena-
bled when the engine is running.
4LA0021
14
Front working light switch (4)

This switches on the front working lights on the cab
roof.
Washer switch (5)

This control has a neutral central position and two
unstable side positions: press leftwards to operate 1
the windscreen washer pump. Press rightwards to
operate the rear window washer.
Press the switch (1) located directly on the front
windscreen to operate the windscreen wiper motor.
4LA0019
15
Press the switch (1) located directly on the front
window to operate the rear window wiper motor.
1
4LA0020
16
Rear working light switch (6)

This switches on the rear working lights on the cab
roof.
P/N 3681774M1 Edition 01-2006 1010-13

CAB COMPONENTS
1 2 3
4LA0015
17
The following components are arranged under the cab roof:
1. Ceiling light 3. Right speaker
2. Left radio speaker
1010-14 P/N 3681774M1 Edition 01-2006

ISO/NAO REAR LIGHTS
The rear light clusters differ in terms of functions

and components according to version type. Two
versions are available:
1. ISO version
- light cluster with brake light and tail light func-
tion (2) (red lens), turn indicators (1) (yellow 2
lens);
- a light cluster (3) with supplementary brake
light and tail light (red lens).
1 3
4LA0009
18
2. NAO version
- a light cluster (1) with turn indicator functions
(yellow lens)
- a light cluster (2) with supplementary tail light
and turn indicators (red lens).
1 2
4LA0012
19
Reverse light (Japan only)

A reverse light is provided for the Japanese market.
The light is white and combined with a buzzer for
indicating tractor movements.
P/N 3681774M1 Edition 01-2006 1010-15

MAINTENANCE
Headlight bulbs. Replacement
CAUTION
Handle halogen bulbs by the metal part
only. The light intensity of the bulb would
be impaired if it were touched by the fin-
gers and it would not last so long.
If your fingers accidentally touch the
bulbs, clean them with a cloth soaked in
cleaning spirits and allow them to dry.
Proceed in the following way to replace the burnt-

out bulbs:
- pull the red knob (1) on the engine (right hand
side) and then lift the engine bonnet;
1
4LA0026
20
- detach the connection (3) on the headlight (1);
- remove the rubber guard (2);
- release the spring that holds the light fitting in
place and turn in an anticlockwise direction
remove the bulb. 3
Replace the halogen lamp with a new one with the 2
same rating (55÷60 W).
4LA0025
21
1010-16 P/N 3681774M1 Edition 01-2006

Front side light and turn indicator bulbs.

Replacement
Remove the transparent cover (3), and replace the
faulty lamp with a new one with the same rating:
- turn indicator bulb (1) (21W): press the bulb
inwards, turn it in the anti-clockwise direction
and remove it;
- turn indicator bulb (2) (21W): pull the bulb out-
wards and replace it.
The orange lens must be fitted back point-

ing upwards.
2LA0495
22
Tail light, brake light and rear turn indicator bulbs.

Replacement
Remove the transparent cover (1), press the burnt-
out bulb inwards, turn it in the anti-clockwise direc-
tion and remove it. Replace it with another of an
equal power rating:
- turn indicator bulb (21W):
- double-filament brake lights and side lights 1
21W/5W.
The orange lens must be fitted back point-

ing downwards.
4LA0057
23
CAUTION
Handle halogen bulbs by the metal part
only. The light intensity of the bulb would
be impaired if it were touched by the fin-
gers and it would not last so long.
If your fingers accidentally touch the
bulbs, clean them with a cloth soaked in
cleaning spirits and allow them to dry.
P/N 3681774M1 Edition 01-2006 1010-17

Cab working light bulbs

Proceed as follows to replace the working light
bulbs:
- turn the headlight (1) to reach the rear part
(wire inlet side);
- turn the bulb holder connection unit (2) and
extract it from the headlight; 1
- Remove the halogen bulb and replace the
burnt-out bulb with another of an equal power
rating (55 W).
2
4LA0018
24
Rear working light bulb (version without cab)

Proceed in the following way to replace the bulb:
- loosen the four lens fastening screws (1);
1 1
4LA0016
25
- open the tab (1) and extract the bulb holder
(2); 1
- replace the burnt-out bulb with another of an
equal power rating (40 W).
2
4LA0017
26
1010-18 P/N 3681774M1 Edition 01-2006

Rotating light bulb

To replace the rotating light bulb, loosen the
orange lens, then extract the bulb (1) from the
holder and replace it with one of equal rating (55
1
W).
4LA0023
27
BULB SPECIFICATIONS OVERVIEW
TYPE OF TYPE OF
BULB FUNCTION POWER
ATTACHMENT BULB
DRIVING BEAM HEADLIGHTS 60 W H4 halogen
DIPPED BEAM HEADLIGHTS 55 W H4 halogen
NUMBER PLATE LIGHT 5W filament
TURN INDICATORS 21 W filament
SIDE/TAIL LIGHTS 5W filament
BRAKE LIGHTS 21 W filament
REVERSE LIGHT (Japan version) 21 W filament
ROTATING LIGHT 55 W H1 halogen
CAB CEILING LIGHT 10 W filament
WORKING LIGHTS (with cab) 55 W H3 halogen
WORKING LIGHT (version with cab) 40 W halogen
P/N 3681774M1 Edition 01-2006 1010-19

1010-20 P/N 3681774M1 Edition 01-2006

SECTION 1020
ELECTRICAL SYSTEM – IGNITION SYSTEM
SECTION 1020 - ELECTRICAL SYSTEM – IGNITION SYSTEM
TABLE OF CONTENTS
Description Page
TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020-3
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020-4
TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020-5
Ignition system test on the tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020-5
Power draw in the starter motor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020-5
Resistance in the ignition system circuit (voltage drop) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020-6
Positive battery cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020-6
Ground connection of the starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020-6
Battery ground cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020-7
STARTER MOTOR. REMOVAL - REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020-7
1020-2 P/N 3681774M1 Edition 01-2006

TECHNICAL SPECIFICATIONS
FEATURES TYPE OF STARTER MOTOR
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . PERKINS 32A66-11100,4318 - 12V
Power rating . . . . . . . . . . . . . . . . . . . . . . . . (kW) 2.2
Maximum power draw with no load (A) . . . . . . . . 60 at 11.7 V and 7000 RPM
Spinning direction (viewed from pinion side) . . . . clockwise
Minimum diameter of commutator . . . . . . . (mm) 45
Maximum armature shaft float . . . . . . . . . . (mm) 0.1 - 0.4
P/N 3681774M1 Edition 01-2006 1020-3

The type of ignition system depends on the type of motor.

gearbox mounted on the tractor. All systems At this point, one end of the power coil is con-
include a key-switch, starter motor with electro- nected to the battery positive by means of the igni-
magnet, switches for the gearbox, reduction gear tion switch while the other end is connected to the
on the PTO lever. These are components of the positive by means of the solenoid valve contacts.
basic circuit used with mechanical gearboxes. This allows the power coil to be bypassed without
The standard starter motor with a 2.2 kW nominal power being drawn and the retention coil keeps the
power rating is the type with four poles and four plunger of the electromagnet engaged on its own.
brushes, with built-in electromagnet and control The starter motor contains a single set of contacts
unit with positive meshing. and a plunger of the electromagnet in two parts,
The electromagnet contains two windings con- which completely close the contacts even when the
nected in parallel. One is the low resistance wind- pinion teeth are not perfectly aligned with those of
ing of the power coil, grounded by the engine, the ring gear. When this occurs, an engaging spring
while the other is the high resistance winding of the compresses and forces the pinion to fully mesh as
retention coil, grounded by the body of the electro- soon as the starter motor starts to turn.
magnet. When the key switch is released, power is shut off
When the key-switch makes contact, with the gear- both from the electromagnet and starter motor. By
box and reduction unit in neutral and the PTO lever acting through the positionable articulation, the
in the disengaged position, the coils of the electro- return spring of the electromagnet frees the control
magnet are energized and the plunger is magneti- pinion from its meshed condition and re-opens the
cally attracted inside the electromagnet. This contacts of the solenoid valve.
movement, which is transmitted by means of a The pinion unit includes a roller meshing device
positionable articulation, forces the control pinion that prevents the armature from turning too much
to mesh with the ring gear of the flywheel. The if the pinion remains meshed in the flywheel ring
moment in which the pinion touches the ring gear, gear after the engine has started.
the plunger of the electromagnet makes a series of
contacts to directly power all four coils from the
battery, thus supplying full power to the starter
1020-4 P/N 3681774M1 Edition 01-2006

TESTS
Ignition system test on the tractor

Use a battery/ignition tester (tester with a high dis-
charge rate) with a 0-200V voltmeter and 0-500 A
ammeter to quickly and easily identify faults in the
ignition system and obtain conclusive results.
Comply with the test procedures recommended by
the manufacturer when test equipment is used. If
test equipment is not available, use the following
test procedure with a normal 0-20 V voltmeter and
0-500 A ammeter to check that the starter motor
operates correctly without removing it from the
engine.
Prior to the test:
- Make sure that the battery is fully charged
- Make sure that none of the ignition system
wires is broken or frayed and that none of the
connections is slack.
- Make sure that the engine is not seized.
Power draw in the starter motor circuit

1. Disconnect the ground wire (negative) from
the battery (3).
2. Disconnect the positive battery wire from the
starter motor (4). Connect the positive prod of
an ammeter (1) to the positive battery terminal
and the negative prod to the power terminal.
3. Re-connect the ground wire (negative) to the
negative terminal of the battery (3).
4. Connect the positive prod of a voltmeter (2) to
the positive battery terminal and the negative
prod to the negative terminal of the battery.
5. Disconnect the wire from the closing solenoid 4LA0064
valve of the injection pump.
1
6. Allow the engine to operate and check the

readings on the voltmeter and ammeter. The
voltage must remain constantly at around 12 V
with a 250-300 A power draw.
• If the power draw corresponds to the tech-
nical value, this means that the starter
motor (4) operates correctly. If the voltage
drops during the test, comply with the pro-
cedure described in the "Resistance in the
ignition circuit" section.
P/N 3681774M1 Edition 01-2006 1020-5

• If the power draw is higher than the techni-

cal value, check the circuit as described
below. If the ignition circuit tests are satis-
factory, the starter motor is defective and
must be demounted in order to identify the
cause.
• If the power draw corresponds is less than
the technical value, this means that the
starter motor must be demounted in order
to identify the cause.
Resistance in the ignition system circuit (voltage

drop)
If the power draw is excessive, check the circuit to
find out what is causing the voltage drop between
the individual components of the circuit itself.
4LA0065
Positive battery cable

1. Connect the positive prod of the voltmeter (1)
to the positive terminal of the battery (2).
2. Connect the negative prod of the voltmeter to
the power terminal of the starter motor (3).
reading on the voltmeter. If the voltage
exceeds 0.2 Volts, check and tighten the cable
connections. Check the voltage again and
install a new cable if it is too high.
Ground connection of the starter motor

to the casing of the starter motor (2).
the engine block (3).
reading on the voltmeter. If it is higher than 0.2
V, check the ground connections between the
flange of the starter motor and the rear engine
cover.
4LA0066
1020-6 P/N 3681774M1 Edition 01-2006

Battery ground cable

to the engine block (2).
the negative terminal of the battery (3).
reading on the voltmeter. If the voltage
exceeds 0.2 Volts, check and tighten the
ground cable connections. Check the voltage
again and install a new ground cable if it is still
too high.
2LA0501
STARTER MOTOR. REMOVAL - REFITTING
1. Disconnect the negative wire from the battery.

2. Loosen the nut and remove the power terminal
(1).
3. Remove the two fixing bolts (3) of the starter
1
motor (2) and remove it.
4. Work through the removal operations in
reverse order to remount the starter motor.
3 2
4LA0045
P/N 3681774M1 Edition 01-2006 1020-7

1020-8 P/N 3681774M1 Edition 01-2006

SECTION 1030
ELECTRICAL SYSTEM – RECHARGING SYSTEM
SECTION 1030 - ELECTRICAL SYSTEM – RECHARGING SYSTEM
TABLE OF CONTENTS
Description Page

Description of the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1030-4
Alternator operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1030-5
TESTS AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . ..... .. .. ......... ......... 1030-6

Precautions to take during the operation . . . . . . . . . . . ..... .. .. ......... ......... 1030-6
Preliminary inspections . . . . . . . . . . . . . . . . . . . . . . . ..... .. .. ......... ......... 1030-7
Initial tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... .. .. ......... ......... 1030-8
Alternator connection test . . . . . . . . . . . . . . . . . . . . . ..... .. .. ......... ......... 1030-8
Charge current and regulated voltage tests . . . . . . . . . ..... .. .. ......... ......... 1030-9
Alternator component tests . . . . . . . . . . . . . . . . . . . . ..... .. .. ......... ......... 1030-9
ALTERNATOR. REMOVAL - REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1030-10
1030-2 P/N 3681774M1 Edition 01-2006

TYPE OF ALTERNATOR
FEATURES DENSO
32 A68-04700
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative ground
Spinning direction (viewed from pulley side). . . . . . . . . . . . . . . . . . . clockwise
Voltage rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (V) 14
Maximum rotation rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (RPM) 18,000
Maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (A) 90A
Voltage monitored by governor . . . . . . . . . . . . . . . . . . . . . . . . . (V) 14.2 - 14.8
Working temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (°C) -30 - 90
Voltage governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Built-in
P/N 3681774M1 Edition 01-2006 1030-3

Description of the alternator

All models are fitted with a Denso 90 A alternator,
with internal cooling fan. The stator winding is ven-
tilated by means of an air conveying diaphragm in 1
the support on the rectifier link side and with
peripheral openings around the support on the con-
trol side. The alternator is installed on the right-
hand side of the engine and is operated by a pulley
via a V-belt. The alternators are equipped with a
built-in governor.
90 A alternator
2
1. Battery power connection (terminal B+) 4LA0010
2. Alternator indicator and ignition switch connection. 1
1030-4 P/N 3681774M1 Edition 01-2006

1 2
B+
IG
IG
B P
PI
L
4
F IC 3
L
+
7
E
-
E
4LA0031
6 5
2
Alternator charging circuit
1. Alternator 5. Battery
2. Ignition switch 6. Electronic voltage governor circuit of the alternator
3. Alternator charge indicator light 7. RPM meter signal
4. Users
Alternator operation
A current passes from the battery through the field The direct current is then conveyed around the cir-
winding of the rotor when the ignition key is cuit again to increase the current that flows
turned. The circuit closes between the light that through the field winding of the rotor.
indicates the charge, terminal L of the alternator, This action leads to a continuous increase in the
the rotor field winding, the alternator governor and rotor’s magnetic field plus a rapid increase in cur-
ground. rent production.
At this point, the indicator light comes on and the The luminosity of the indicator light diminishes dur-
rotor is partially magnetized. ing the voltage increase generated on the output
Three-phase alternate current is generated when (which reflects on terminal L) and when the voltage
the engine starts and the partially magnetized rotor on terminal L is the same as that on the battery
turns inside the stator windings. A constant quan- side, the indicator light goes out.
tity of that current is converted into direct current The voltage continues to increase until it reaches
by the three field diodes built into the rectifier unit. the preset regulated voltage level.
P/N 3681774M1 Edition 01-2006 1030-5

The alternator will be unable to operate if the con-

trol belt breaks, thus the charge indicator will 1
remain on to warn of the fault.
4LA0027
3
Fan belt tensioner
1. Belt stretcher nut

2. Belt
TESTS AND TROUBLESHOOTING
Precautions to take during the operation
Take the following precautions to prevent

the components of the alternator charging
system from being damaged:
• NEVER EVER MAKE OR BREAK any
connection in the charging circuit,
including the battery, when the engine
is running.
• NEVER EVER SHORT-CIRCUIT the
positive terminal of the alternator to
check whether this latter is working.
• ALWAYS DISCONNECT the battery
cables when the battery is recharged
on the tractor with a battery charger.
• ALWAYS COMPLY WITH the correct
polarity when the battery is installed
or when an auxiliary battery is used to
start the engine.
• DO NOT SHORT-CIRCUIT the input
and output terminals of the voltage
governor when the alternator is oper-
ating.
1030-6 P/N 3681774M1 Edition 01-2006

Preliminary inspections
Before proceeding with the electrical tests, carefully
inspect the charging system and electrical system
in general.
Make sure that none of the conductors or connec-
tions are broken and check that they are all firmly
fastened.
1. Battery inspection
Check all the battery components with a den-
simeter. The battery must be charged to at
least 70% of its capacity and be efficient (see
section 1040, page 5).
2. Control belt inspection
Inspect the pulley and alternator belt to make
sure that they are clean, with no traces of oil or
grease and that they are in a good condition.
Periodically check the tension of the alternator belt.
If you think that the belt is not taut enough, check
the stretcher as indicated below, with reference to
fig. 3:
- loosen the alternator fixing nut (2) on the
stretcher bracket.
- using a lever, move the alternator along the
stretcher bracket until the correct belt (1) ten-
sion is obtained (10-11 mm), then re-tighten
the fixing nut (2).
The belt must be replaced if it is cracked

or needs adjusting too frequently.
3. Indicator light inspection

Turn the ignition key and make sure that the
indicator light comes fully on.
If the bulb is not burnt out, test the connec-
tions of the alternator winding as described in
the "INITIAL TESTS" chapter of this section.
If the indicator light is on, start the engine and
allow it to run at a higher rate than idling. The
indicator light must go out.
If it fails to go out, stop the engine and remove
the wire from terminal L. If the light now goes
out, it means that one of the alternator compo-
nents is defective.
P/N 3681774M1 Edition 01-2006 1030-7

Initial tests
The initial tests can be conducted without removing
any of the charging circuit components from the
tractor. They allow you to check:
- the condition of the alternator wire connections
- the alternator charge current and controlled
voltage
- the voltage drops in the charging circuit of the
alternator
- the maximum output of the alternator
- Test equipment required:
- 0 to 30 V voltmeter with mobile coil
- 0 to 1 V millivoltmeter
- 0 to 110 A ammeter with mobile coil
- 1.5 Ohm 110 A variable load resistance.
Alternator connection test

1. Disconnect the battery.
2. Disconnect the terminals (1) and (2) of the
1
alternator.
3. Re-connect the battery and turn the ignition
key to the ON position but without starting the
engine. Connect a voltmeter between each ter-
minal and ground. Battery voltage must be
L
P
present.
If there is no voltage, identify and repair a con- IG
tinuity fault in the external cable circuit. Refer
to the wiring diagram in figure 2.
2
4LA0036
4
4. Connect terminal L of the indicator light to
ground. The indicator light must come on.
5. Disconnect the battery and re-connect the pre-
viously disconnected connectors to the alterna-
tor.
If the indicator light fails to come on when

the wire is re-connected to the alternator,
this means that there is a fault in the
alternator’s governor circuit or in that of
the rotor. Make sure that terminal D+ is
clean and then test the alternator compo-
nents as described in this section.
1030-8 P/N 3681774M1 Edition 01-2006

Charge current and regulated voltage tests

Make sure that all the tractor’s electrical users are
off and that the ignition key is in the OFF position.
1
1. Disconnect negative battery terminal and ter-
minal (1) of the alternator.
2. Connect an ammeter between the detached
cable and alternator terminal (1).
L
3. Connect a voltmeter between terminal (1) of P
the alternator and ground.
4. Re-connect the battery. Start the engine and IG
accelerate to 2000 RPM. Check the voltmeter
and ammeter readings. 2
4LA0036
5
The voltmeter must give a higher value than the
battery voltage and, when the ammeter reading
drops below 10 A, the voltmeter reading must sta-
bilize between 13.6 V 14 V.
5. Slowly increase the current charge (lowering
the value of the resistance) until the ammeter
reading becomes 40 A.
6. Check the voltmeter reading, which must not
drop below 13.6 V.
A reading of less than 13.6 means that there is a
defective component in the alternator. Test the
alternator components as described in this chapter.
Alternator component tests

The component tests, which must only be carried
out if the INITIAL TESTS have identified a defective
component in the alternator, allow you to check:
- the governor;
- the no-break condition of the rotor field wind-
ings;
- the brushes, springs and contact rings of the
rotor.
The previously described component tests

can be conducted with the alternator
installed in the tractor. To test the other
components, the alternator must be
removed from the tractor.
P/N 3681774M1 Edition 01-2006 1030-9

ALTERNATOR. REMOVAL - REFITTING
Make sure that the ignition key is in the

OFF position before disconnecting the 1
alternator wires.
1. Raise the bonnet.

2. Disconnect the terminal (1) and the connection
(2).
2
4LA0010
6
3. Loosen and remove the nut and bolt (1) that
fixes the alternator to the belt tensioner. 1
4. Move the alternator in order to slacken the belt
(2) thus removing it from the pulley.
5. Remove the nut (3) from the through bolt that
fixes the alternator to the engine. 2
4LA0037
3
7
1030-10 P/N 3681774M1 Edition 01-2006

SECTION 1040
ELECTRICAL SYSTEM - BATTERY
SECTION 1040 - ELECTRICAL SYSTEM - BATTERY
TABLE OF CONTENTS
Description Page
BATTERY REMOVAL - REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-4

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-4
Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-4
MAINTENANCE AND BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-5

Relative density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-6
Dry charged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-7
Battery charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-7
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-9
COMMON CAUSES OF BATTERY FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-12
1040-2 P/N 3681774M1 Edition 01-2006

FEATURES TYPE OF BATTERY
Voltage (V) 12
Cold starting current (C.C.A) 800
Capacity (Ah) 100
Number of elements 6
Weight (kg) ~ 20
Ground terminal Negative
The battery is the maintenance-free "sealed" type. The battery is made so that each element contains
It is installed as standard supply in all models and positive and negative plates arranged alternately,
is positioned behind the operator's seat. one alongside the other. Each positive plate is sepa-
rated from the negative plate by a separator with a
"Maintenance-free" means that the bat- porous and insulating casing. If one of the positive
tery does not lose water from the electro- plates comes into contact with the negative plates
lyte during normal charging conditions. in an element, this latter will short-circuit and be
The conditions that could lead to water subjected to irreparable damage. All the positive
leaks include charged prolonged beyond plates are welded to a collector bar and form a pos-
14.4 V where gassing occurs as the bat- itive terminal. All the negative plates are welded to
tery fully charges. This can be caused by a a similar collector bar and form a negative terminal.
defective charging system, by quick- Each positive plate consists of a lead grid with led
charging equipment, etc. peroxide plugged in the grid openings. The nega-
tive plates consist of a lead grid with spongy lead
The three main functions of the battery are: plugged in the grid openings.
- To provide a source of electric current for start- The plates are immersed in electrolyte formed by a
ing, ignition and the instruments. solution of diluted sulphuric acid.
- To monitor the voltage of the electrical system. The battery case is made of polypropylene.
- To supply electric current when the power
draws exceed the energy provided by the alter-
nator.
P/N 3681774M1 Edition 01-2006 1040-3

BATTERY REMOVAL - REFITTING
Removal
1. Raise the bonnet.
2. Loosen the bolts of both terminals and discon-
nect the negative (1) and positive cables (2) 1 2
from the battery. Make sure that they do not
touch the battery itself.
3. Loosen the battery fixing bolt (3) on the front
3
part.
4LA0022
Refitting
Work through the demounting procedure in reverse
order when remounting the battery, and take the
following precautions:
- Make sure that the battery is clean and that
there are no traces of spilt electrolyte on the
outside. Make sure that the vents are com-
pletely installed. Smear Vaseline or similar on
the terminals. Do not use conventional lubricat-
ing grease as this could cause electrolytic cor-
rosion.
- Make sure that the battery housing or supports
and the terminals are clean, with no stones or
small objects that could perforate the battery
case.
- Make sure that the polarity of the battery termi-
nals is correct and that the terminal connec-
tions are firmly fastened.
1040-4 P/N 3681774M1 Edition 01-2006

MAINTENANCE AND BATTERY INSPECTION
Relative density
The relative density of the battery acid indicates will indicate the charge degree of that element.
the charge status. When the battery is fully The lower the temperature at which the battery
charged, the relative density of the electrolyte is at must operate, the more the battery must be kept in
least 1.280 at 25°C. fully charged conditions. For example, a battery
Alternatively, the approximate charge status can be with a relative density of 1.225 at 27°C (80°F) will
measured with a digital voltmeter operate the starter motor at mild ambient tempera-
(± 0.01V) as follows: tures, but may not do this at low temperatures
Less than 10.5 V Unserviceable battery* owing to inferior battery efficiency.
Less than 11.8 V Battery discharged Table 1 illustrates the effect of the temperature on
Less than 12.3 V Battery half charged battery efficiency.
More than 12.6 V Battery fully charged Table 1
* Consult the notes in chapter "TESTS" for
instructions about how to recover a slightly sul- Efficiency of a
phated battery. Temperature
fully charged battery
The battery voltage must be measured with the
25.0°C 100%
battery discharged and:
-4.5°C 82%
A. After the battery has been discharged for at -24.0°C 64%
least 4 hours. -27.5°C 58%
B. Turn on the headlights for 2 minutes if the trac- -31.0°C 50%
tor has been used recently or if the battery has -34.5°C 40%
been charged recently. -37.5°C 33%
When a battery is discharged, the sulphuric acid in
the electrolyte combines chemically with the plates Maximum battery life can be obtained by paying
and this action causes the relative density of the the necessary attention and making periodical
solution to diminish. inspections. The capacity delivered must not be
A battery densimeter will determine the relative exceeded by constant and excessive overcharging
density of the electrolyte in an element and the and the charging requisites must be maintained.
quantity of unused sulphuric acid in the solution
P/N 3681774M1 Edition 01-2006 1040-5

Maintenance
DANGER
! Batteries contain sulphuric acid. When
they are charged they generate a highly
explosive mixture of hydrogen and oxygen
gas.
- Never use tools that produce flames or sparks

to check the level of the battery acid.
- Never remove the caps from the battery with-
out protecting your eyes and hands.
Take the following steps during battery mainte-
nance:
1. Keep the electrolyte at the recommended level,
i.e. 17 mm above the plates. Failing this, the
acid will reach a high concentration that could
damage the separators and impair the effi-
ciency of the plates.
2. Use only distilled or demineralised water. Do
not overfill and do not use tap water, rain water
or water from other sources to top up the bat-
tery acid.
3. Always keep the battery at least 75% charged,
otherwise the plates will become sulphated.
This will lead to a drop in efficiency with possi-
ble damage from freezing at low temperatures.
4. Do not overcharge the battery as this can lead
to excessive internal heat which damages the
plate grid and leads to water leaks.
5. During rapid charges, make sure that the tem-
perature of the battery does not exceed 50°C.
6. Do not add sulphuric acid to an element unless
the battery acid has been lost through leaking.
Before filling, make sure that the relative den-
sity of the solution is correct. Slow charging is
the only method to use if the battery is to be
fully charged. A high current battery charger
can be used to charge the battery quickly, but
this latter must subsequently be slowly charged
in order to ensure full charging.
1040-6 P/N 3681774M1 Edition 01-2006

Dry charged batteries

Dry charged batteries must be prepared for use in
the following way:
1. Remove the vent plugs from the battery ele-
ment.
2. Fill each element to the recommended level
using electrolyte with a 1.260 relative density.
The electrolyte must consist of diluted sul-

phuric acid at the preferable temperature
of 21°-32° C.
3. After it has been filled, allow the battery to rest

for 15 minutes, then check the level of the
electrolyte again and top up if necessary.
4. Charge the battery for 4 hours with a 5-8 A
current rating and make sure that all the ele-
ments freely develop gas.
5. Fit the vent plugs of the battery element back
in place.
Battery charging
Before charging a battery:
1. Thoroughly clean the battery case and the cov-
ers of the elements with diluted ammonia or
hot water, and clean the terminals.
2. Check the level of the electrolyte in each ele-
ment and, if it is below the plates, add distilled
water to bring it above plate level.
Normal charge
1. With a slow battery charger, use a 3 to 6 A cur-
rent for the time required to fully charge the
battery. This operation could last 36 hours or
more if the battery charge is very low. A seri-
ously sulphated battery may not charge. When
the battery is fully charged, the elements will
freely develop gas and the relative density will
remain constant. Disconnect the battery
charger after three consecutive readings of the
densimeter made each hour, that indicate that
the relative density has stopped rising.
2. High charging current raises the temperature
of the electrolyte and, unless the battery
charger has an automatic timing or tempera-
ture device, the temperature of the electrolyte
could exceed 50°C. This could lead to violent
gassing and damage the internal battery com-
ponents.
3. Check the level of the electrolyte in each ele-
ment again, and add distilled water if neces-
sary.
P/N 3681774M1 Edition 01-2006 1040-7

DANGER
! An explosive gas is produced when a bat-
tery is charged. Do not smoke or use
naked flames when checking the level of
the electrolyte and make sure that the
battery charger is off before connecting or
disconnecting, in order to prevent the for-
mation of sparks which could ignite the
gas.
Charging very discharged batteries

The best way to charge a maintenance-free Pb-Ca
battery is to use a constant voltage battery charger.
For very low batteries, it is advisable to charge for
48 hours at 16 Volts with current limitation (30A
per 60Ah).
This system is self-regulating: a high current is sup-
plied at the beginning (when the battery voltage is
very low), while an increasingly lower current is
then absorbed when the battery is fully charged
(and its voltage is high).
If only constant voltage battery chargers are availa-
ble, it is advisable to comply with the voltage levels
and time settings given in Table 2. The figures refer
to batteries with very low charges. If the battery is
only half discharged, allow half the time indicated
(slow charging methods). Proportionally reduce the
charging time for other conditions of discharge.
When possible, use the slower recharging method
to increase battery life.
Table 2
Type of battery
100Ah
Slow charging meth- 25 hours at 5A

ods 12.5 hours at 10A
Quick charging meth- 7 hours at 10A

ods (only for emergen-
cies)
If violent gassing or overflowing electrolyte occur

when the battery is being charged, or the battery
case becomes hot (50°C or more), reduce or stop
charging temporarily in order to prevent the battery
from being damaged.
1040-8 P/N 3681774M1 Edition 01-2006

Tests
Before beginning the tests, check the battery to
make sure that none of the vents are clogged, that
there is no rust, raise vent caps and that the case is
not cracked.
Equipment required for the tests:
- Densimeter
- Battery starter tester (high current discharge
tester)
- Thermometer
- Battery charger
Relative density: This test establishes the battery
charge status.
1. Take a reading with the float in the vertical
position.
2. Adjust the reading of the densimeter for the
temperature variations of the electrolyte by
subtracting 4 points (relative density 0.004) for
every 5.5°C below the temperature for which
the densimeter is calibrated, and by adding 4
points (relative density 0.004) for every 5.5°C
above this temperature.
The following examples have been calculated using
a densimeter with a 30°C setting.
Example 1:
Temperature less than 30°C
Electrolyte temperature 19°C
Densimeter reading 1.270
Subtract 11.0 x 0.004
5,5
Correct relative density = 1.262
Example 2:
Temperature more than 30°C
Electrolyte temperature 40°C
Densimeter reading 1.220
Add 10.0 x 0.004 0.007
5,5
Correct relative density = 1.227
3. Use the following table to establish the charg-
ing condition.
Charging Relative Relative Average

condition density density battery
correct correct voltage
at 15°C at 25°C
100% 1.295 1.287 12.66
75% 1.253 1.246 12.45
50% 1.217 1.210 12.30
25% 1.177 1.170 12.00
Discharged 1.137 1.130 11.84
The relative density should not vary more

than 0.025 points between the various
cells.
P/N 3681774M1 Edition 01-2006 1040-9

4. If the relative density is 1.280 or more, the bat-

tery is fully charged and in good operating con-
ditions.
5. If the correct relative density is less than 1.280,
charge the battery and check the charging sys-
tem to find out why the battery charge is low.
If distilled water has been added recently,

the battery must be recharged for a short
period of time, otherwise the densimeter
will be unable to give precise readings.
If the battery has been charged in static conditions,

the electrolyte that accumulates at the bottom of
the elements will be more dense. The battery must
be shaken every so often in order to mix the elec-
trolyte: this will improve the charge current and will
allow the densimeter to give more accurate read-
ings during the tests.
Efficiency test
The efficiency test allows you to ascertain whether
the capacity of the battery is sufficient to start the
engine. The voltage reading obtained is used to
identify the battery condition. Before conducting
the test, make sure that the level of the battery
acid is correct and that the open circuit voltage is
12,5V or more. The battery can be tested either on
or disconnected from the tractor.
1. Set the current control switch of the battery
starting tester (high current discharge tester)
to the "off" position and the voltage selector
switch to the nominal voltage of the battery or
slightly higher. Connect the positive conductors
of the tester to the positive battery terminal
and the negative conductors to the negative
battery terminal.
2. Turn the current control knob until the reading
on the ammeter is half the cold starting current
of the battery. Now read the voltage value.
• If the reading is 9.6 V or more after 15 sec-
onds, the battery has an acceptable deliv-
ered energy capacity and will promptly
accept a nominal charge.
• If the reading is below 9.6 V, the battery
must be considered unsatisfactory for use
and the charge must be tested as described
below.
CAUTION
Do not leave the current charge on the
battery for more than 15 seconds.
1040-10 P/N 3681774M1 Edition 01-2006

Test charging: only batteries that have not

passed the previous capacity test need to be sub- Relative density Rapid charge until:
jected to this test. 1.150 or less 60 minutes
1. Connect the positive conductors of the starter
tester to the positive battery terminal and the from 1.151 to 1.175 45 minutes
negative conductors to the negative battery
terminal. from 1.176 to 1.200 30 minutes
2. Connect the positive conductor of the battery
charger to the positive battery terminal and the from 1.200 to 1.225 15 minutes
negative conductor to the negative battery ter- (Slow charging only)
minal.
3. Turn the battery charger timer beyond the "3
minutes" charge indication and then to the "3
minutes" mark again.
4. Set the charge current as near to 40 A as possi-
ble.
5. Check the voltmeter reading after 3 minutes of
this quick charge.
• If the total voltage exceeds 15.5 V, the bat-
tery is unsatisfactory. It is probably sul-
phated or worn and must be replaced.
A slightly sulphated battery can be recov-

ered by using a battery charger of the
multiple type, with a 50 V higher open cir-
cuit voltage limit. In view of the high
resistance of a sulphated battery, a higher
voltage value must be selected initially in
order to overcome the sulphation resist-
ance. There may be no visible acceptance
of the charge at the beginning. A small
charge will appear after a few minutes,
followed by a fast increase in the amper-
age. The current must not exceed 14 A
and the temperature of the electrolyte
must not exceed 50 °C. When the current
has stabilized, restore the voltage until a
permanent 5 A has been reached. Con-
tinue with this current until the relative
density of the electrolyte stops rising at
about 1.275-1.280 at 20°C. This could
require 48 hours charging. Allow the bat-
tery to rest for 24 hours and then conduct
the previously described capacity test.
• If the total voltage is below 15.5 V, test the

relative density of each element and
recharge the battery according to the fol-
lowing scale:
P/N 3681774M1 Edition 01-2006 1040-11

COMMON CAUSES OF BATTERY FAULTS
1. Internal circuit open.

2. Internal short-circuit.
3. Leaking electrolyte.
4. Separation of active substances from the grids.
5. Accumulation of sulphate crystals too large to
disperse.
These faults normally have the following causes:
1. Faulty components inside the element.
2. Excessive development of crystals which could
perforate the separators and cause short-cir-
cuits.
3. Excessive overload (faulty operation of the
charging system, rapid charging and high volt-
age restoration techniques, operation at very
high temperatures).
4. Freezing electrolyte.
A fully charged battery does not freeze down to
-65°C. A 50% charged battery freezes between
-17°C and -27°C. A completely discharged elec-
trolyte freezes between -3°C and -11°C. An
excessively high fast charge and gassing also
cause the active substances to separate from
the grids. Separation destroys the chemical
function of the battery.
5. Crystals develop whenever batteries are left to
remain discharged. High temperatures and
lengthy discharge periods favour this condition.
It is unlikely that a battery can be recovered on
a vehicle after a week, at ambient temperature.
Recharging will require a higher constant volt-
age. After 3 weeks, the battery will have been
subjected to a permanent degradation and the
previously described procedure must be used
in order to charge a "very discharged" battery.
Batteries last a long time when they are fully
charged. Pb-Ca batteries discharge 3% per month.
This means that a battery takes 16 months for its
charge to become halved. The inactive charge is
about 50mA on tractors. To forecast discharging on
a static vehicle, add this value as though it corre-
sponded to about 8Ah per week.
It is worthwhile noting that if a battery begins to
fade during the starting phase, it is better to stop
for two minutes and allow it to recover. The colder
the temperature, the longer the battery will take to
recover.
1040-12 P/N 3681774M1 Edition 01-2006

SECTION 1050
ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS
SECTION 1050 - ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS
TABLE OF CONTENTS
Description Page
ELECTRICAL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-3
LOCATIONS OF FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-7

Main fuse box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-7
Main fuse box location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-7
FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-8
MAXI FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-9
MAIN FUSE BOX RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-9
REAR CAB PILLAR FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-10
CAB REAR PILLAR RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-11

Relays location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-11
TURN INDICATOR AND HAZARD LIGHTS BLINKERS – NAO ECU

(NORTH AMERICA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-12
POWER SOCKET - 7-PIN JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-12
COLOUR CODES OF THE ELECTRICAL WIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-13
IDENTIFICATION CODE OF THE WIRING DIAGRAMS AND CONNECTIONS . . . . . . . . . . . . . . . . . 1050-13
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-13
REAR PTO IGNITION, 4WD,

BY SPEED SYSTEM, IGNITION SWITCH RELAY CIRCUIT (DIAGRAM A) . . . . . . . . . . . . . . . . . . . . 1050-14
DRIVING BEAMS - DIPPED BEAM LIGHTS, HAZARD LIGHTS, DIFFERENTIAL LOCKING,

FUEL PUMP, INJECTION PUMP, STARTER CIRCUIT (DIAGRAM B) . . . . . . . . . . . . . . . . . . . . . . . . 1050-20
INSTRUMENT, SENSORS, RADIO, ROTATING BEAM, CAB LIGHT, AIR SEAT CIRCUIT
(DIAGRAM C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-26
WORKING LIGHTS, REVERSING LIGHT (JAPAN VERSION), SPEED SHIFT (DIAGRAM D) . . . . . . . . 1050-34
CLIMATE CONTROL, WINDSCREEN WIPER/WASHER, PASSENGER COMPARTMENT FAN,

CIGAR LIGHTER CIRCUIT (DIAGRAM E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-40
ELECTRONICALLY CONTROLLED HYDRAULIC POWER LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-46

Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-46
Electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-47
ECU connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-48
Control panel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-49
ELECTRONIC POWER LIFT CIRCUIT (DIAGRAM F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-50
1050-2 P/N 3681774M1 Edition 01-2006

ELECTRICAL SYSTEM COMPONENTS
1 SOUND SYSTEM
2 INSTRUMENT
3 ALTERNATOR
4 ELECTRONIC BLINKER
5 GLOW PLUGS
6 CIGAR LIGHTER
7 LH HEADLIGHT (DIPPED/DRIVING BEAM)
8 RH HEADLIGHT (DIPPED/DRIVING BEAM)
9 NUMBER PLATE LIGHT
10 CAB LIGHT
11 ROTATING LIGHT
12 REVERSE INDICATOR LIGHT (Japan only)
13 LH FRONT WORKING LIGHT
14 RH FRONT WORKING LIGHT
15 LH REAR WORKING LIGHT
16 RH REAR WORKING LIGHT
17 BRAKE PEDAL COUPLING WARNING LIGHT
18 HORN
19 ALARM BUZZER
20 REVERSE INDICATOR BUZZER (Japan only)
21 LH BRAKE INDICATOR
22 RH BRAKE INDICATOR
23 LH FRONT TURN INDICATOR
24 LH REAR TURN INDICATOR
25 RH FRONT TURN INDICATOR
26 RH REAR TURN INDICATOR
27 LH FRONT SIDE LIGHT
28 LH REAR SIDE LIGHT
29 RH FRONT SIDE LIGHT
30 RH REAR SIDE LIGHT
31 RH TURN INDICATOR (NAO OUTFIT)
32 LH TURN INDICATOR (NAO OUTFIT)
33 STARTER MOTOR
34 WINDSCREEN WIPER MOTOR
35 WINDSCREEN WASHER MOTOR
P/N 3681774M1 Edition 01-2006 1050-3

36 REAR WINDOW WASHER MOTOR

37 REAR WINDOW WIPER MOTOR
38 CONDITIONER COMPRESSOR
39 CAB FAN
40 CONDITIONER FAN ADJUSTMENT RESISTOR
41 VEHICLE SPEED SENSOR PULL-UP RESISTOR
42 CONDITIONER FAN ADJUSTMENT RESISTOR
43 SPEED SHIFT TOGGLE RELAY
44 IGNITION SWITCH
45 FRONT PTO BUTTON
46 4WD/BY SPEED SWITCH
47 FRONT LOADER SWITCH
48 HAZARD LIGHT SWITCH
49 LIGHT STALK
50 ROTATING LIGHT SWITCH
51 FRONT WORKING LIGHT SWITCH
52 REAR WORKING LIGHT SWITCH
53 FRONT/REAR WINDOW WASHER SWITCH
54 WINDSCREEN WIPER SWITCH
55 REAR WINDOW WIPER SWITCH
56 CONDITIONER SWITCH
57 CONDITIONER FAN SPEED SELECTOR
58 REAR PTO SWITCH
59 DIFFERENTIAL LOCK BUTTON
60 HORN BUTTON ON LIGHT STALK
61 SPEED SHIFT BUTTON
62 BRAKE OIL LEVEL SENSOR
63 FUEL LEVEL SENSOR
64 PRESSURE SWITCH
65 ENGINE OIL PRESSURE SWITCH
66 AIR CLEANER VACUUM METER
67 GEARBOX OIL VACUUM METER
68 14 BAR PRESSURE SWITCH
69 TRAILER BRAKE PRESSURE SWITCH
70 CONDITIONER PRESSURE SWITCH
71 SYNCHRONISED PTO MICRO SWITCH
1050-4 P/N 3681774M1 Edition 01-2006

72 REVERSE SHUTTLE/GEAR IMMOBILISER MICRO SWITCH

73 GEAR LEVEL BY SPEED OFF MICRO SWITCH
74 SUPER FINAL DRIVE MICRO SWITCH
75 SLOW PTO MICRO SWITCH (540)
76 FAST PTO MICRO SWITCH (540E - 1000)
77 HANDBRAKE MICRO SWITCH
78 REVERSE POSITION REVERSER LEVER MICRO SWITCH (hydraulic gearbox outfit)
79 FORWARD DIRECTION MICRO SWITCH
80 BY SPEED PROXIMITY SENSOR
81 BRAKE PEDAL COUPLING SENSOR
82 PTO SPEED SENSOR
83 TRACTOR SPEED SENSOR (for odometer)
84 TEMPERATURE SENSOR FOR STARTER
85 COOLANT TEMPERATURE SENSOR
86 CONDITIONER FROST THERMOSTAT
87 AUXILIARY SOCKET IN CAB
88 NAO OUTFIT CONNECTOR
89 FUEL PUMP
90 STARTER
91 INJECTION PUMP
92 REAR PTO/BRAKE SOLENOID VALVE
93 FRONT PTO SOLENOID VALVE
94 4WD SOLENOID VALVE
95 BY SPEED SOLENOID VALVE
96 FRONT LOADER SOLENOID VALVE
97 DIFFERENTIAL LOCK SOLENOID VALVE
98 SPEED SHIFT SOLENOID VALVE
99 ENGINE WIRING CONNECTION (34 PIN)
100 REAR WIRING CONNECTION (34 PIN)
101 LH REAR LIGHT CONNECTION (6 PIN)
102 RH REAR LIGHT CONNECTION (6 PIN)
103 7-PIN SOCKET
104 WORKING LIGHT (version without cab)
105 ELECTRONIC POWER LIFT CONNECTION (4 PIN)
106 PLATFORM WIRING CONNECTION (10 PIN)
107 PLATFORM WIRING CONNECTION (18 PIN)
P/N 3681774M1 Edition 01-2006 1050-5

108 CONDITIONER WIRING CONNECTION (6 PIN)

109 LEFT SPEAKER
110 RIGHT SPEAKER
111 CAB CONNECTION (6 PIN)
112 CAB CONNECTION (2 PIN)
113 REAR WORKING LIGHT SWITCH (version without cab)
114 ENGINE POWER CONNECTION (2 PIN)
115 AIR SEAT ADJUSTMENT MOTOR
116 ELECTRONIC POWER LIFT UNIT
117 ELECTRONIC POWER LIFT CONTROL PANEL
118 EXTERNAL BUTTON LEFT INTERMEDIATE CONNECTION FOR POWER LIFT
119 EXTERNAL BUTTON RIGHT INTERMEDIATE CONNECTION FOR POWER LIFT
120 POWER LIFT UP SOLENOID VALVE
121 POWER LIFT DOWN SOLENOID VALVE
122 POWER LIFT ARM POSITION SENSOR
123 POWER LIFT EFFORT SENSOR
124 POWER LIFT UP LEFT CONTROL BUTTON
125 POWER LIFT DOWN LEFT CONTROL BUTTON
126 POWER LIFT UP RIGHT CONTROL BUTTON
127 POWER LIFT DOWN RIGHT CONTROL BUTTON
1050-6 P/N 3681774M1 Edition 01-2006

LOCATIONS OF FUSES AND RELAYS
Main fuse box
CAUTION
When fuses are changed, make sure that
the new fuse has the same rating as the
old one. Even though they are inter-
changeable, use of different fuses would
seriously impair tractor operation.
Main fuse box location

The fuse box is located inside the dashboard on the
left side. To access the fuses, remove the cover 1
panel by loosening the screw (1).
4LA0063
1 2 3 4 5 6 7 8 9 10
10 9 8 7 6 5 4 3 2 1
11 12 13 14 15 16 17 18 19 20
20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7 8 9 10
30 29 28 27 26 25 24 23 22 21
31 32 33 34
20 19 18 17 16 15 14 13 12 11
85 87a 86
85 87a 86
85 87a 86
30
87
30
87
30
87
K1 K2 K3
3 2 1
85 87a 86
85 87a 86
85 87a 86
30
87
30
87
30
87
K4 K5 K6
6 5 4
85 87a 86
85 87a 86
85 87a 86
30
87
30
87
30
87
K12 K13 K8
8 13 12
85 87a 86
85 87a 86
85 87a 86
K10 K11 K7
30
87
30
87
30
87
7 11 10
14 9
86 86
K9 K14 87 87A 30 30 87
85 85
Front Rear
4LA0044
view view
2
The fuses and relays are arranged in the fuse box as shown in the above figure.
P/N 3681774M1 Edition 01-2006 1050-7

FUSES
Fuses CIRCUITS PROTECTED Amp.
F1 IGNITION SWITCH POWER RELAY FUSE 5
F2 REAR PTO FUSE 5
F3 FRONT PTO FUSE 5
F4 IMMOBILISER FUSE 5
F5 4WD/BY SPEED FUSE 7.5
F6 BRAKE PEDAL COUPLING SENSOR FUSE 5
F7 FRONT LOADER SOLENOID FUSE 5
F8 GLOW PLUG RELAY FUSE 5
F9 IGNITION FUSE 15
F10 ALTERNATOR FUSE 5
F11 D+ ALTERNATOR FUSE (FOR ELECTRONIC POWER LIFT) 5
F12 ELECTRONIC POWER LIFT IGNITION SWITCH FUSE 5
F13 STARTER/FUEL PUMP/INJECTION PUMP FUSE 7.5
F14 DIFFERENTIAL LOCK/BRAKE FUSE 15
F15 DIFFERENTIAL LOCK SOLENOID VALVE FUSE 5
F16 DIPPED BEAM FUSE 15
F17 DRIVING BEAM FUSE 15
F18 HAZARD LIGHT FUSE 10
F19 LIGHT STALK FUSE 15
F20 LH REAR INDICATOR FUSE 5
F21 RH REAR INDICATOR FUSE 5
F22 ROTATING HEADLIGHT FUSE 10
F23 CIGAR LIGHTER FUSE 25
F24 IGNITION SWITCH POWER FUSE INSTRUMENT - AUXILIARY SOCKET 5
F25 INSTRUMENT DIRECTOR POWER FUSE/BUZZER 5
F26 SPEED SHIFT SYSTEM FUSE 5
F27 REVERSE INDICATOR FUSE 7.5
F28 NAO UNIT FUSE 15
F29 CAB POWER FUSE 10
F30 AUXILIARY SOCKET FUSE 25
F31 WORKING LIGHT FUSE 7.5
F32 HORN FUSE 10
F33 30A AUXILIARY SOCKET FUSE 25
F34 AIR SEAT FUSE 15
1050-8 P/N 3681774M1 Edition 01-2006

MAXI FUSES
Glow plug maxi fuse 50

1
General power supply maxi fuse 50
Cab maxi fuse -
5LA0371
3
1. Maxi fuses
2. Electronic blinker
MAIN FUSE BOX RELAYS
K01 Ignition switch power relay

K04 Reverse indicator relay
K05 PTO immobiliser relay rear
K06 By speed system on relay
K07 By speed warning light relay
K08 Ignition relay
K09 Glow plug preheat relay
K10 Brake relay
K11 Differential lock self-retaining rely
K12 Dipped beam relay
K13 Driving beam relay
K14 Speed shift solenoid valve relay
P/N 3681774M1 Edition 01-2006 1050-9

REAR CAB PILLAR FUSE BOX
The fuse box (1) connects to all consumers in the

cab. It is located on the right rear pillar inside the 1
cab.
4LA0014
4
List of functions:
Fuses Protected circuits Amp.
21 Front windscreen wiper 20

23 22 21
22 Front working lights 15
23 Rear field lights 15
24 Conditioner solenoid valve 30
25 Conditioner pressure switch 7.5 26 25 24

and compressor
26 Cab light - rear window wiper 5

4LA0047
1050-10 P/N 3681774M1 Edition 01-2006

CAB REAR PILLAR RELAY
CAUTION
When the relay in the electrical system
must be changed, make sure that the new
relay is the same type as the old one.
Even though they are interchangeable,
use of different relays would seriously
impair tractor operation.
Relays location
The relay wiring is located inside the right cab pillar.
Remove the plastic cover to access the relays. The K17
relay arrangement is shown in Fig.6
K18
Relays: K15
K15 Reverse indicator control relay
(Japan only) K16
K16 Windscreen wiper/washer relay
K17 Conditioner fan relay K19
K18 Front working light relay K20
K19 Rear working light relay
K20 Conditioner compressor relay K21 4LA0003
K21 Conditioner fan relay
6
P/N 3681774M1 Edition 01-2006 1050-11

TURN INDICATOR AND HAZARD LIGHTS BLINKERS – NAO ECU

(NORTH AMERICA)
The turn indicator blinker (1) and NAO unit (North

America) are arranged inside the instrument panel.
4LA0050
POWER SOCKET - 7-PIN JOINT
These are located on the rear left of the tractor

(fig. 8)
1. 7-pin socket 1 2
2. Power socket
2LA0662
8
See fig. 9 (rear view) for position on the pins in the
socket.
2LA0703
1050-12 P/N 3681774M1 Edition 01-2006

COLOUR CODES OF THE ELECTRICAL WIRES
A Light blue M Brown
B White N Black
C Orange R Red
G Yellow S Pink
H Grey V Green
L BLUE Z Purple
Cross-section areas are 1 mm2 unless otherwise shown.

When two letters are shown, the first identifies the basic colour and the second the longitudinal stripes. An
asterisk appears in front of Kabelcar wire colours.
IDENTIFICATION CODE OF THE WIRING DIAGRAMS AND CONNECTIONS
0,5 - RN -
WIRE CROSS-SECTION
WIRE COLOUR
WIRING DIAGRAMS
DESCRIPTION DIAGRAM
Rear PTO ignition, 4WD, by speed system, ignition switch power relay circuit A
Driving beams - dipped beam lights, hazard lights, differential locking, fuel pump, injection B
pump, starter circuit
Instrument, sensors, radio, rotating beam, cab light, air seat circuit C
Working lights, reversing light (Japan version), speed shift circuit D
Climate control, windscreen wiper/washer, passenger compartment fan, cigar lighter circuit E
Electronic power lift circuit F
P/N 3681774M1 Edition 01-2006 1050-13

REAR PTO IGNITION, 4WD,

BY SPEED SYSTEM, IGNITION SWITCH RELAY CIRCUIT
(DIAGRAM A)
5 Glow plugs K6 By speed system on relay

17 Brake pedal coupling warning light K7 By speed warning light relay
33 Starter motor K8 Ignition relay
44 Ignition switch K9 Glow plug preheat relay
45 Front PTO button F1 Ignition switch power relay fuse
46 4WD/by speed switch F2 Rear PTO fuse
47 Front loader switch F3 Front PTO fuse
58 Rear PTO switch F4 Immobiliser fuse
71 Synchronised PTO micro switch F5 4WD/by speed fuse
72 Reverse shuttle/gear immobiliser micro F6 Brake pedal coupling sensor fuse
switch F7 Front loader solenoid valve fuse
73 Gear level by speed off micro switch
F8 Glow plug relay fuse
80 By speed proximity sensor F9 Ignition fuse
81 Brake pedal coupling sensor F10 Glow plug, alternator fuse
92 Rear PTO/brake solenoid valve
F35 Alternator ignition switch fuse
93 Front PTO solenoid valve FU1 General fuse
94 4WD solenoid valve G Glow warning light
95 By speed solenoid valve
K Synchro warning light
96 Front loader solenoid valve N By speed warning light
K1 Ignition switch power relay W PTO warning light
X1 IG alternator
K3 Ignition switch power relay Z Front PTO warning light
K5 PTO immobiliser relay
1050-14 P/N 3681774M1 Edition 01-2006

REAR PTO IGNITION, 4WD, BY SPEED SYSTEM, IGNITION SWITCH POWER RELAY CIRCUIT - Diagram A
FU1
80A
44
2 3 4
RN
F6 F7 F8 F9 F10
F1 F35 F2 F3 F4 F5
7,5A
5A
5A
5A
5A
5A
15A
50A
5A
5A
5A
RC
RN
N
R
L
K5 47
X1
+ SCH. E
K8 K9
92 K5 93 K8 94
G
80 73
CZ
K
81
72
W
K Z
GB
K6 95 K7
GB
V
GB
33
GB
GB
0
1 2
1 2
58 71 45 46 K6 K7 17 M
K1 K2 K3 K4 96 K9
5
4LA0052
P/N 3681774M1 Edition 01-2006 1050-15

5 50
1.5 L
1.5
L
33
N
10
4RN
16R
16R
4R
4R
4L
2.5L
1.5M
6M
1.5N
44
4R
10
1050-16 P/N 3681774M1 Edition 01-2006

AV
MS
4
3
3
B
2
B
1
145
4
B
4
*
3
2
2
B
1
B
CB
BG
47 1
46
1
MR
2
GN
BL
58
11
* Jumper valid for outfit without front PTO.
P/N 3681774M1 Edition 01-2006 1050-17

AR
72
S
M
2
1
71
2
ZN
1
GM
73
B
BR
CB
80
BR
B
3
LR
2
2
1
MV
81
MN
3
B
2
1
MV
12
1050-18 P/N 3681774M1 Edition 01-2006

92
1
2
1
LR 2
BL
2
93
AV
1
94
BG
BR
1
1
BR 2
2
95
2
1
LR
2
96 2
1
1
ZN
2
1
B
GN
13
P/N 3681774M1 Edition 01-2006 1050-19

DRIVING BEAMS - DIPPED BEAM LIGHTS, HAZARD LIGHTS, DIFFERENTIAL LOCKING,

FUEL PUMP, INJECTION PUMP, STARTER CIRCUIT
(Diagram B)
3 Alternator K1 Ignition switch power relay

4 Electronic blinker K10 Brake relay
7 LH headlight (dipped/driving beam) K11 Differential lock self-retaining rely
8 RH headlight (dipped/driving beam) K12 Dipped beam relay
9 Number plate light K13 Driving beam relay
21 LH brake light F11 D+ alternator fuse (for electronic power lift)
22 RH brake light F12 Electronic power lift ignition key fuse
23 LH front turn indicator F13 Starter / fuel pump / injection pump fuse
24 LH rear turn indicator F14 Differential lock / brakes fuse
25 RH front turn indicator F15 Differential lock solenoid valve fuse
26 RH rear turn indicator F16 Dipped beam fuse
27 LH front side light F17 Driving beam fuse
28 LH tail light F18 Hazard light fuse
29 RH front side light F19 Light stalk fuse
30 RH tail light F20 LH side light fuse
48 Hazard light switch F21 RH side light fuse
49 Light stalk FU2 General alternator fuse
59 Differential lock button H Differential lock warning light
64 Pressure switch M Alternator warning light
79 Forward direction micro switch X2 Ignition switch power
89 Fuel pump X3 Engine speed
90 Starter X4 Electronic power lift
91 Injection pump X5 7-pin socket
97 Diff lock solenoid valve
1050-20 P/N 3681774M1 Edition 01-2006

DRIVING BEAMS - DIPPED BEAM LIGHTS, HAZARD LIGHTS, DIFFERENTIAL LOCKING, FUEL PUMP, INJECTION PUMP, STARTER CIRCUIT (Diagram B)
R
F19
10A
M2
M1
K1
M
R
L
48 49
1 3 9
FU2 F12 F13 F14 F16 F17 3 2 2M 2M
VCS
100A
VON
VON
7,5A
15A
15A
15A
5A
1 1M 1M
11 2 5 17 18 6 3 5 4 2 7
CN
BN
HN
MN
HN
HR
RN
VN
VN
64 59 K10
3 B+
K12 K13 F18 F20 F21
5A
5A
10A
IG P
F15
HR
M
N
G
V
10A
X4
6 4
4
RN
1 2 5
H X5
BL
SV
X2 X3 K11
F11
5A
X4 X5
H
HL
M
79
X4 M
90 89 91 K10 K11 97 21 22 7 8 23 24 25 26 9 27 28 29 30 K13 K12
4LA0053
P/N 3681774M1 Edition 01-2006 1050-21

4
Pos.1 B
3
Pos.2 SV
5
4
6
HM
AN Pos.3
GR 1.5BN
Pos.4
1.5BN
Pos.5 BL
3 B+
Pos.6 HR
R
16
7 8
HN
HN
VN
VN
B
14
1050-22 P/N 3681774M1 Edition 01-2006

9 M
2
1 pos.3 - G
B
23 pos.2 - N
pos.1 - B
pos.3 - V
25 pos.2 - M
pos.1 - B pos. 1 1.5LN 10 3 2 1 8

pos. 2 HR
pos. 3 1.5R 9 6 5 4 7
pos. 4
pos. 5 1.5BN
pos. 6 G-DIODO
pos. 7 48
pos. 8 B
pos. 9 V-DIODO
pos.10 HG
15
P/N 3681774M1 Edition 01-2006 1050-23

MN
49
HN
1.5BN
RN
1.5R
1
4
7
1.5Z
10
VN
B
2
5
8
G
11
1.5M
3
6
9
G
V G
V 0.5G
V
0.5V RV R
GR 59
2
1
BR
64
R
1
M 89
B
2
2
1 CN
79
MV
2
RN
1
16
1050-24 P/N 3681774M1 Edition 01-2006

CN
CB
90 91
97
1
BR
2
1
2
B
17
P/N 3681774M1 Edition 01-2006 1050-25

INSTRUMENT, SENSORS, RADIO, ROTATING BEAM, CAB LIGHT, AIR SEAT CIRCUIT
(Diagram C)
2 Instrument 62 Brake oil level sensor

1 Glow plug warning light 63 Fuel level sensor
2 Alternator warning light
65 Engine oil pressure switch
3 4WD warning light
4 Differential lock warning light 66 Air cleaner vacuum meter
5 Driving beam warning light 67 Gearbox oil vacuum meter
6 Side/tail light warning light
68 14 bar pressure switch
7 LH turn indicator warning light
8 RH turn indicator warning light 69 Trailer brake pressure switch
9 Turn indicator 1st trailer warning light 74 Super final drive micro switch
10 Turn indicator 2nd trailer warning light
75 Slow PTO micro switch (540)
11 By speed warning light
12 Engine speed warning light 76 Fast PTO micro switch (540e - 1000)
13 Speed shift warning light 77 Handbrake micro switch
14 Reverse gear warning light 82 PTO speed sensor
15 Forward gear warning light
16 Front PTO warning light 83 Tractor speed sensor (for odometer)
17 Independent PTO warning light 85 Coolant temperature sensor
18 Synchronised PTO warning light 87 Auxiliary cab socket
10 Cab light 88 NAO outfit connector
11 Rotating light 115 Air seat motor
18 Horn K2 Ignition switch power relay
19 Alarm buzzer F22 Cab accessory /rotating light / horn fuse
31 RH turn indicator (NAO outfit) F23 Auxiliary socket, cigar light fuse
32 LH turn indicator (NAO outfit) F24 Ignition switch instrument power fuse
41 Vehicle speed sensor pull-up resistor F25 Direct instrument power fuse / buzzer
50 Rotating beam switch F36 Air seat power fuse
60 Horn button on light stalk FU3 General fuse
1050-26 P/N 3681774M1 Edition 01-2006

INSTRUMENT, SENSORS, RADIO, ROTATING BEAM, CAB LIGHT, AIR SEAT CIRCUIT (Diagram C)
+30
FU3
60A
K2
RN
F 22 F 23
F 36 F 24 F 25
63
2 0A
15A
10A
5A
5A
R
15
82 87
31
2 3 4 5 6 7 8 9 10 11 12 13
19
+
HA2
1
-
1HG
HB
1BL
1SG
BR
HM
BG
MB
1SV
RN
VN
GR
1S
R
G
V
B10 B9 A8 A10 A11 A21 A22 A23 A24 A1 A25 A26 B22 A13 B14 B1 B20
B13 B7
B3 CN
B17
A14
B21 A3 A7 A9 A6 A12 A19 B15 B16 A4 A2 B2 A15 A16 A17 tbd tbd B19
50 60 2
1BL
BN
BN
BN
BN
BN
1HL
VB
ZB
ZB
ZB
GM
RV
AV
LG
B
GV
88
41
115 18 17 16 15 14
GR
1k2
GR
RV
+
85 65 66 67 68 74 69 75 76 62 77 82
- 83
10 11 18 31 32
4LA0054
P/N 3681774M1 Edition 01-2006 1050-27

1050-28 P/N 3681774M1 Edition 01-2006

pos. 1 0.5R pos.14 0.5B

pos. 2 0.5HB pos.15 0.5GM
pos. 3 0.5RV pos.16 BL
pos. 4 0.5BN pos.17 0.5AV
3 5
pos. 5 TAPPO pos.18 TAPPO 1 7
pos. 6 ZL pos.19 0.5MB 8 13
19
pos. 7 0.5LG pos.20 14
20 26
pos. 8 0.5RN pos.21 0.5VN 21 25
pos. 9 0.5ZB pos.22 HG
pos.10 0.5BG pos.23 0.5G A
pos.11 0.5BR pos.24 0.5V
pos.12 0.5MN pos.25 SV
pos.13 0.5MB pos.26 BL
2
pos. 1 0.5GR pos.14 SG

pos. 2 0.5HL pos.15 0.5CN
pos. 3 0.5CN pos.16 0.5BN
pos. 4 pos.17 0.5N
3 5
pos. 5 pos.18 MV 1 7
pos. 6 pos.19 0.5B 8 13
14 19
pos. 7 0.5R pos.20 26
20
pos. 8 pos.21 0.5VB 21 25
pos. 9 0.5HB pos.22 S
pos.10 0.5HM pos.23 B
pos.11 pos.24
pos.12 MB pos.25
pos.13 0.5RN pos.26
18
P/N 3681774M1 Edition 01-2006 1050-29

RV
GR
11
10
B B
19
CN
RN
B
18
Z
1.5
4
1.5
3
2
8
1
7
6
5
pos. 1 _ 10 3 2 1 8
pos. 2 R
pos. 3 RV 9 6 5 4 7
62 pos. 4 _
pos. 5 _
0.5BN
0.5B
pos. 6 _
50
pos. 7 B
pos. 8 HG
pos. 9 B
pos.10 _
19
1050-30 P/N 3681774M1 Edition 01-2006

S
B SG
RV
65
3 2 1
63
3 2 1
66
LG
B
B
ZL
68 67
ZB
20
P/N 3681774M1 Edition 01-2006 1050-31

69
2
1 2 1
2
74
B
MB
MN
B
BN
2
2
1
1
2
1
1
2
76
75 B
CN
B
21
1050-32 P/N 3681774M1 Edition 01-2006

77
HB
82
B
B
2
HL
2
1
1
83
RN
B
3
2
2
1 CN
1
VB
85
87
Pos1 2.5RN
2
Pos2 MR
1
Pos3 2.5B
22
P/N 3681774M1 Edition 01-2006 1050-33

WORKING LIGHTS, REVERSING LIGHT (JAPAN VERSION),

SPEED SHIFT
(DIAGRAM D)
12 Reverse indicator light (Japan only)

13 LH front working light
14 RH front working light
15 LH rear working light
16 RH rear working light
20 Reverse indicator buzzer (Japan only)
43 Speed shift toggle relay
51 Front working light switch
52 Rear working light switch
61 Speed shift button
78 Reverse shuttle lever switch (hydraulic gearbox version)
79 Forward direction micro switch
98 Speed shift solenoid valve
K14 Speed shift solenoid valve relay
K15 Reverse indicator control relay
K16 Windscreen wiper/washer relay
K18 Front working light relay
K19 Rear working light relay
F26 Speed shift fuse
F27 Reverse indicator and working light fuse
F28 Front working light fuse
F29 Rear working light fuse
F38 70 A general fuse
FU4 70 A general fuse
X Reverse warning light
Y Forward direction warning light
Z Speed shift warning light
1050-34 P/N 3681774M1 Edition 01-2006

WORKING LIGHTS, REVERSING LIGHT (JAPAN VERSION), SPEED SHIFT CIRCUIT (DIAGRAM D)
FU4 F 38
70A
70A
M
K3
N
F 26 F 27 F 28 F 29
7,5A
15A
15A
5A
HN
HN
61 K14 78 K15 79
X Y K18 K19
0 1 0 1
1 1
+ IN
43 51 52
OUT -
HG
HV
HG
HV
4 A.XS4
12 -
20
K14 98 K15 K18 K19 K16

13 14 15 16
4LA0055
P/N 3681774M1 Edition 01-2006 1050-35

12 HR B
B
13
B HN
HN
14 15
15
H B
B
B
HN 20
B
HR
16 HR
23
1050-36 P/N 3681774M1 Edition 01-2006

Pos.1 -
51 Pos.2 M
Pos.3 HL
Pos.4 -
3
6
Pos.5 -
2
5
Pos.6 -
Pos.7 B
1
4
Pos.8 HG
8
7
Pos.9 -
Pos.10 -
Pos.1 -
52 Pos.2 M
Pos.3 HM
Pos.4 -
6
Pos.5 -
5
Pos.6 -
Pos.7 B
4
Pos.8 HG
7
Pos.9 -
Pos.10 -
24
P/N 3681774M1 Edition 01-2006 1050-37

61 78
GN
GM
MB
2
RN
79
MV
2
RN
1
98
2
1
2
B
1
LG
25
1050-38 P/N 3681774M1 Edition 01-2006

RELE' K15 RELE' K16
Pos.30 4C Pos.30 BR
Pos.85 GM Pos.85 BN
MB MB
Pos.86 Pos.86
MB MB
Pos.87 6B Pos.87 VZ
Pos.87a Pos.87a
87a
87a
86
86
85
85
87 87
K15 K16
30 30
RELE' K18 RELE' K19
Pos.30 2.5HN Pos.30 2.5H

B B
Pos.85 Pos.85
B B
Pos.86 HM Pos.86 HL
HN H
Pos.87 Pos.87
HN H
Pos.87a Pos.87a
87a
87a
86
86
85
85
87 87
K18 K19
30 30
26
P/N 3681774M1 Edition 01-2006 1050-39

CLIMATE CONTROL, WINDSCREEN WIPER/WASHER, PASSENGER COMPARTMENT FAN,

CIGAR LIGHTER CIRCUIT
(Diagram E)
1 Sound system
6 Cigar lighter
34 Windscreen wiper motor
35 Windscreen washer motor
36 Rear window washer motor
37 Rear window wiper motor
38 Conditioner compressor
39 Cab fan
42 Conditioner fan adjustment resistor
53 Front/rear washer switch
54 Windscreen wiper switch
55 Rear window wiper switch
56 Conditioner switch
57 Conditioner fan speed selector
70 Conditioner pressure switch
86 Conditioner frost thermostat
K16 Wiper/washer
K17 Conditioner fan
K20 Conditioner compressor
K21 Conditioner fan
F30 Wiper/washer fuse
F31 Cigar lighter fuse
F32 Conditioner compressor and pressure switch fuse
F33 Conditioner fan fuse
1050-40 P/N 3681774M1 Edition 01-2006

CLIMATE CONTROL, WINDSCREEN WIPER/WASHER, PASSENGER COMPARTMENT FAN, CIGAR LIGHTER CIRCUIT (Diagram E)
SCH-A
42 57 56 86
M
F32 F33
7,5A
30A
K16 1 2 3 4 B L M H C 1 2 3 4 3C 4
M
F 30 F31
20A
5A
RL
RV
K20 K21
K17 K20 K21
4 7 8 8
1
0 2 0 1 0 1
1 2 1 1
1 70 M 39
8 7 7
53 54 55
M M M M
4 7
M
K17
8
35 36 34 37 6 38
4LA0056
P/N 3681774M1 Edition 01-2006 1050-41

7 1
3 5 3
1 5
8 2 7
4 6 4
2 6
8
Pos.1 G Pos.1 -
Pos.2 GN Pos.2 -
Pos.3 - Pos.3 -
Pos.4 - Pos.4 R
Pos.5 - Pos.5 -
Pos.6 - Pos.6 -
R
Pos.7 AN Pos.7
R
Pos.8 A Pos.8 B
M
1.5GV
1.5B
34
1.5B
1.5HR
27
1050-42 P/N 3681774M1 Edition 01-2006

VB
36
B 1.5B
1.5GR
35
37
38
1.5B
1.5GR
BR
28
P/N 3681774M1 Edition 01-2006 1050-43

1.5VN
2.5B
GM
1.5VN
2.5H
B
C B H
M
Pos.1 LR
53 Pos.2 1.5GR
Pos.3 VB
57
Pos.4 -
3
6
Pos.5 -
2
5
Pos.6 -
1
4
Pos.7 B
Pos.8 HG
8
7
Pos.9 -
Pos.10 -
VZ
56
1 2 3 4
70
BR
Pos.1 B
Pos.2 MN
Pos.3 1.5VN
Pos.4 MB
1 2 3 4
A
B
29
1050-44 P/N 3681774M1 Edition 01-2006

RELE' K16 RELE' K17
Pos.30 BR Pos.30 6A
Pos.85 BN Pos.85 B
MB MB
Pos.86 Pos.86
MB MB
Pos.87 VZ Pos.87 4M
Pos.87a Pos.87a
87a
87a
86
86
85
85
87 87
K16 K17
30 30
RELE' K20 RELE' K21
Pos.30 2.5R Pos.30 6A
Pos.85 B Pos.85 B
MB MB
Pos.86 Pos.86
MB MB
Pos.87 2.5RN Pos.87 4M
Pos.87a Pos.87a
87a
87a
86
86
85
85
87 87
K20 K21
30 30
30
P/N 3681774M1 Edition 01-2006 1050-45

ELECTRONICALLY CONTROLLED HYDRAULIC POWER LIFT
Main components
4LA0135
31
The power lift control system consists of five fundamental components:
A. Control panel located inside the cab on the right- D. Position sensor located on arm supporting shaft
hand side E. Draft sensor located at the third point support
B. ECU located inside the right-hand mudguard F. Electrohydraulic distributor fitted on gearbox cover
C. External buttons fitted on rear mudguards
1050-46 P/N 3681774M1 Edition 01-2006

Electronic control unit

The ECU (1) is the "brain" of the electronic power
lift control system.
The ECU compares the signals from the sensors
with those set by the operator on the control con-
sole. H
When the values transmitted by the sensors and
the console do to correspond, the ECU activates the 1 G
control block solenoid valves to raise or lower the
arms until the set values and the measured values
are the same.
A specific safety system has been installed to pre-
vent the electronic system from running after the
5LA0365
engine is stopped.
32
The ECU requires to power lines to work: the igni-
tion switch power and the alternator power.
The ECU will not run if either one of these two line
is missing. Consequently, when the engine is not
running, the electronically controlled power lift can-
not be operated in any way.
The ECU (1) is located inside the right-hand mud-
guard.
To remove it, remove the panel from the rear side
and loosen the fastening screws (G). Operate the
metallic tab (H) to disconnect the connector.
P/N 3681774M1 Edition 01-2006 1050-47

ECU connection
The 25-pin connection allows communication
between the ECU and the other electrical and elec-
tronic components of the power lift system.
25 14
13 1
4LA0133
33
The pins used are listed below:
PIN N. FUNCTION
1 Ground
2 Up solenoid valve
3 Potentiometer power
4 Adjustment - intermix
5 Alternator
6 Solenoid valve power
7 Not used
8 Up/down switches
9 Diagnostic LED
10 External control buttons
11 Oscillator LED
12 Control panel power
13 Sensor power
14 Down solenoid valve
15 Sensor ground
16 Working depth adjustment
17 Draft sensor
18 Draft sensor
19 Position sensor signal
20 External control buttons
21 Shock absorber (on-off)
22 Maximum height adjustment
23 Not used
24 Down speed adjustment
25 Battery power
1050-48 P/N 3681774M1 Edition 01-2006

Control panel connection

The 21-pin connector interfaces the ECU and the
controls on the panel.
The pins used are shown in the figure.
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15
16 17 18 19 20
21 22 23 24
4LA0134
34
P/N 3681774M1 Edition 01-2006 1050-49

ELECTRONIC POWER LIFT CIRCUIT

(DIAGRAM F)
105 Electronic power lift connection (pin 4)

116 Electronic power lift ECU
117 Electronic power lift control panel
118 Power lift external button left intermediate connection
119 Power lift external button right intermediate connection
120 Power lift up solenoid valve
121 Power lift down solenoid valve
122 Power lift arm position sensor
123 Power lift draft sensor
124 Power lift "up" left control button
125 Power lift "down" left control button
126 Power lift "up" right control button
127 Power lift "down" right control button
A Ignition switch power
B D+ alternator signal
C Ground
D Night light
1050-50 P/N 3681774M1 Edition 01-2006

ELECTRONIC POWER LIFT CIRCUIT (Diagram F)
10 Rx
117
116
21
1 B 06
14 H
390 330
2 LN
15 V R9 R10
3 LB
16 RV 470
R4 R2
4 G 08 R11
17 V
VG 16
5 H
17 560
18 GV
09
6 CN
07 12
19 GN
7
R5
20 G 12
8 L
21 BZ 13
R6
9 MN
560
22 VN 14
R8
10 BV
23
S1
11 Z
24 GH
12 A
25 RN D2
13 C 03
19
118
119
BV
G
L
15R/2W
02 x
R1
A 5
B 01
C
D M
R14
20
D 18
10
1 23 1 23
V C
1 3 1 3
120 121
123
122 124 126
4LA0130
125 127
P/N 3681774M1 Edition 01-2006 1050-51

105
HM
1.5B
4
4
3
3
RN
2
2
1
1
M
H
pos. 1 B pos.14
H
116 pos. 2
LN
pos.15 V
LN
pos. 3 BL pos.16 RV
pos. 4 G GV
pos.17
GV
1 14
pos. 5 HM
2
15 pos.18 GV
3
pos. 6 CN
16
4 17
5
18
pos.19 GN
6
19 pos. 7 - G
pos.20
7 20
9
21
pos. 8 L- G
22
10
23 pos.21 BZ
11
24 pos. 9 MN
12
13
25
B pos.22 VN
pos.10
B
pos.11 Z pos.23 -
pos.12 A pos.24 HG
pos.13 C pos.25 RN
35
1050-52 P/N 3681774M1 Edition 01-2006

pos. 1 B pos.12 MN
pos. 2 M pos.13 Z
pos. 3 LN pos.14
pos. 4 -
pos.15 -
pos. 5 -
pos.16 L
117 pos. 6 A
pos.17 VN
pos. 7 RV
1 2 3 4 pos.18 -
pos. 8 BL
5 6 7 8 9
10 11 12 13 14 15 pos. 9 G pos.19 H
16 17 18 19 20
21 22 23 24 pos.10 - pos.20 -
pos.11 - pos.21 HG
118 B
A
119 B
A
36
P/N 3681774M1 Edition 01-2006 1050-53

CN 120
H
2
1
CN 121
LN 2
1
122
C
3
GN
2
1
123
C
3
GV
2
1
37
1050-54 P/N 3681774M1 Edition 01-2006

124 A
4
3
5
2
6
1
7
A
A
4
3
5
2
6
1
7
125 G
A
4
3
5
2
6
1
7
126 B
A
A
4
3
5
2
6
1
7
127 G
38
P/N 3681774M1 Edition 01-2006 1050-55

1050-56 P/N 3681774M1 Edition 01-2006

SECTION 1100
CAB AND A/C SYSTEM
SECTION 1100 - CAB AND A/C SYSTEM
TABLE OF CONTENTS
Description Page
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-3
Main specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-3
External cab components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-4
Interior cab components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-4
INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-6
A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-8
INSTRUCTIONS FOR USING THE A/C SYSTEM .. . . . .. .... ..... .. .................... 1100-9
Starting . . . . . . . . . . ............. .. . . . .. .... ..... .. .................... 1100-9
Settings . . . . . . . . . . ............. .. . . . .. .... ..... .. .................... 1100-9
Stopping . . . . . . . . . ............. .. . . . .. .... ..... .. .................... 1100-9
A/C SYSTEM OPERATING PRINCIPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-10
A/C SYSTEM MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .... 1100-11

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .... 1100-12
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .... 1100-13
Drier filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .... 1100-13
Thermostatic expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .... 1100-14
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .... 1100-15
Thermostatic switch (frost sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .... 1100-16
SWITCHING THE A/C ON AND SETTING THE TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-17
A/C SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-18
WARNINGS FOR REPAIRING THE CAB A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-20
CAB A/C TROUBLESHOOTING OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-20
A/C SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-21
1100-2 P/N 3681774M1 Edition 01-2006

CAB
Main specifications
The cab of the wide, four pillar type, is approved simple, immediate operation.
and compliant to safety standards in the event of The steering wheel slant and height can be
roll-over. It is equipped with air conditioning sys- adjusted. Thanks to the adjustable seat, the posi-
tem. The windscreen and rear tailgate can be pivot tion can be adapted to the driver’s needs.
open to improve ventilation.
High pressurisation means that the vehicle can be
The roof is provided with a clear top to improve vis- used when working with plant protection products.
ibility of front loaders. Windows and doors are perfectly sealed.
Four working lights are arranged on the roof to Soundproofing is excellent thanks to the use of
complete the basic specifications. specific materials, high trimming standards and
The driving position offers a comfortable environ- quieter engines, with a noise level of 79 dBA.
ment for operations. All controls are arranged for
5LA0438
P/N 3681774M1 Edition 01-2006 1100-3

External cab components

1. Opening front window
2. Front working lights 1 2 3 4 6
3. Clear top and sun blinds
4. Rotating light 8
5. Adjustable rearview mirrors
6. Rear field lights
7. Opening rear window
8. Opening left and right side doors 5 7
5LA0351
Interior cab components

1. Front windscreen wiper
2. Front window locks
2 1 2
5LA0352
3
1. Cab air recirculation
2. Ventilation vents
3. Ceiling light
4. Rear window wiper 2
1
3
4
5LA0353
1100-4 P/N 3681774M1 Edition 01-2006

The driver’s seat is equipped with devices for

adjusting the suspension, the height and the dis-
tance referred to controls.
1. Longitudinal lock lever

2. Suspension adjustment knob
3. Height adjustment knob
The knob (4) is used to adjust the descent speed of

the mechanically controlled power lift.
5LA0354
5
The steering wheel height can be adjusted by loos-
ening the knob (1).
The steering wheel slant can be adjusted after
releasing the lever (2). 1
5LA0355
P/N 3681774M1 Edition 01-2006 1100-5

INSTRUMENTS AND CONTROLS

1
4 5
3 6
2 9
1 12
7 11
14
8
20
23
15
21
16
22
10 13 19 18 17
5LA0356
7
Front zone controls Right side controls
1. Light switch 16. Electronic power lift control panel

2. Reverse shuttle lever 17. Cigar lighter
3. Instrument panel 18. PTO selection switch
4. Steering wheel height adjustment 19. 4RM and Fast-Run/Fast-Run selection switch
5. Hazard lights and rotating light switch 20. Differential lock switch
6. Ignition switch 21. PTO speed selection lever
7. Clutch pedal 22. PTO engagement lever proportional to speed
8. Steering wheel slant adjustment 23. Super final drive engagement lever
9. Brake pedal
10. Accelerator control pedal
11. Gear lever
12. Speed - Shift engagement button
13. Range selection lever
14. Auxiliary distributor lever
15. Accelerator hand level
1100-6 P/N 3681774M1 Edition 01-2006

1. Temperature adjustment knob

2. Fan speed selection knob
3. A/C button
1
2
3
5LA0357
8
1. Headlight switch
2. Rear light switch
3. Windscreen and rear window wiper switch
1
2
3
5LA0358
P/N 3681774M1 Edition 01-2006 1100-7

A/C SYSTEM
solution of boric acid and water (one table-

WARNING spoon of acid in ¼ of water). Call a doctor
! ! immediately.
- Freezing caused by the refrigerant can be
treated by gradually warming up the injured
Refrigerant must be handled with care to avoid part with cool water and applying a greasy
injury to operators. Always wear gloves and eye- cream. Call a doctor.
wear.
- The A/C system contains a mixture of pressu-
Liquid refrigerant can freeze the skin causing rised oil and refrigerant: never loosen unions or
severe injury to eyes and even blindness in the work on pipes before discharging the system.
severest cases.
- Similarly, never loosen the compressor oil
Keep the refrigerant container away from sources inspection cap when the system is charged.
of heat because the pressure increase of refrigerant - Do not heat up the refrigerant container. Over
due to heat may make the container explode. 50°C the increase of pressure due to heating is
Refrigerant may form a poisonous gas in contact very rapid.
with naked flames and heated metallic surfaces. - Keep the A/C system away from sources of heat
The gas if inhaled may cause severe intoxication. to avoid possible explosions due to the increase
Observe the simple precautions below to prevent of gas pressure in the system piping.
accidents. Use only type-approved cylinders and other con-
The system must be discharged and charged in a tainers equipped with safety valves to transfer and
ventilated environment away from naked flames. store the refrigerant.
During the system discharging and charging opera- Never charge refrigerant containers over 80% of
tions, take the necessary precautions to protect their total capacity.
your face - and especially your eyes - from refriger- Do not modify the calibration of safety valves and
ant. control components.
Never connect a recovery/recycling and emptying/
Proceed as follows in the event of an accident: recharging station to power mains other than those
- If refrigerant gets splashed into your eyes, specified. Do not leave them powered between
wash immediately with a few drops of mineral usages.
water then continue to rinse your eyes with a
1100-8 P/N 3681774M1 Edition 01-2006

INSTRUCTIONS FOR USING THE A/C SYSTEM
Settings
CAUTION
For correct climate control inside the cab, open the
When the engine is stationary, the A/C will
recirculation vents while the A/C system is running
not work because the compressor is oper-
and keep the doors and the front and rear windows
ated by the engine.
closed.
For maximum cooling capacity, turn knob (1, fig. 8)
The conditioning system provides cool dehumidified anticlockwise all to the left.
air or warm dehumidified air.
Proceed as follows:
It is advisable to close the recirculation
Starting vents when working in dusty environ-
Starting the system at low temperatures may cause ments to increase cab pressure and pre-
damage to the compressor. Wait for the engine to vent infiltration of dust inside.
warm up and the cab to reach 20°C before starting
the A/C system. The dehumidifying action of the A/C system is pro-
vided at any internal temperature set by turning
CAUTION the knob (1, fig. 8).
Make sure that the A/C is off (3, fig. 8) To make the temperature inside the cab comforta-
before starting the engine. ble after standing for a long time in sun, it is a good
idea to get the tractor moving, switch on the A/C
With the engine running and the fan on, press (3, system and open the rear window for approxi-
fig. 8) to start the A/C system. mately one minute to let the overheated air out.
The window on the top of the drier filter will appear
clear and without bubbles after a few minutes of Stopping
operation. Always switch the A/C system off by turning the
Contact your dealer if this does not occur. knob (1, fig. 8), before stopping the engine. Then
turn the fan knob (2) to the stopped position.
P/N 3681774M1 Edition 01-2006 1100-9

A/C SYSTEM OPERATING PRINCIPLES
The A/C system is designed to create inside the cab No limits can be defined for air purity. It must be
the most comfortable environmental conditions for remembered that humans alter the composition of
the driver. air in the environments where they live, increasing
These conditions are essentially linked to four fac- the level of carbon dioxide and humidity, decreas-
tors: ing the percentage of oxygen, etc.
- temperature Such problems can be avoided by letting in small
amounts of air from the outside, particularly for
- humidity
farming tractors working in very dust environments
- speed (ploughing, hay making, etc.), in which case dry fil-
- purity of the air in the cab. ters are fitted on the external air vents.
It is not possible to define the optimal values of The application of A/C systems in tractors and
these quantities once and for all because they vary farming machines in general therefore neutralises
from person to person. However, it is possible to the negative effects on comfort caused by heat and
define the ranges within which most individuals feel humidity generated in the cab. The system works
most comfortable. on the temperature and humidity features of the air
As concerns temperature and humidity, a zone present or let into the cab to obtain cooling and
called the “wellbeing zone” can be defined in which humidity levels comfortable for the driver.
the temperature-humidity pair corresponds to com- The working principle of an A/C system is similar to
fortable conditions. that of a domestic refrigerator: to cool an environ-
The chart shows that humidity is comfortable in the ment down, heat must be subtracted from it by
range from 30% to 70% (under 30% the nose and means of a physical process (evaporation of a fluid)
throat tissues tend to dry while over 70% it is which absorbs heat from the surrounding environ-
formed an unpleasant feeling of humidity in various ment.
parts of the body). Temperature may vary from 18 The liquid used, called refrigerant fluid, is a product
to 28°C. characterised by a high refrigeration coefficient,
The air flow speed must not be excessive to pre- low toxicity and good mixability with lubricant oils.
vent annoyance. Values in the 0.07 - 0.25 m/s Appropriate lines connect the various components
range are normally acceptable. and hold pressure in the system where the refriger-
ant circulates.
Simplified wellbeing chart Relative humidity %

1. Unbearable cold feeling
2. Cold feeling
3. Wellbeing zone
4. Hot feeling
5. Unbearable hot feeling
5LA0359 Temperature °C
10
1100-10 P/N 3681774M1 Edition 01-2006

A/C SYSTEM MAIN COMPONENTS
The A/C system consists of essentially five ele- The fluid at the high pressure liquid state is purified
ments: by crossing the drier fluid (2) and goes to the
1. Compressor expansion valve (4) which intercepting by a bottle-
neck the flow of coolant lowers its temperature.
2. Condenser
Through the valve (4), a part of the coolant is
3. Drier filter
transformed into low temperature vapour and the
4. Thermostatic expansion valve mixture thus formed of low temperature and low
5. Evaporator. pressure liquid and vapour is let into the evaporator
To explain the operating cycle of the system, we (5).
will follow the course of the fluid from the compres- Here the fan causes a continuous circulation of air
sor (1). inside the cab on the evaporator fins (5), facilitating
The compressor takes in the refrigerant in cold the absorption of heat by the mixture which is com-
vapour state at a pressure of 0.2-2.5 bars and completely transformed into vapour.
presses it to a pressure of 10-22 bars. The process of evaporation of the refrigerant sub-
The fluid heated by compression to 60-120 °C is let tracts heat from the air with touches the evaporator
into the condenser serpentine (2) on the cab roof (5) and therefore cools it, thus lowering the tem-
always in vapour state. perature in the cab.
The current of air produced by the fan on the cab The flow of air on the cold surface of the evapora-
roof near the condenser (2) cools the thermal tor (5) also condenses part of the air, thus lowering
exchange fluid. the degree of humidity in the cab atmosphere.
By effect of cooling, the coolant vapour reaches the The low pressure mixture at evaporator outlet (5)
condensation point from 40 to 70 °C according to from 0 to 15°C is aspirated by the compressor (1)
the external temperature and turns liquid. again to start a new cycle.
1
5LA0360
11
Simplified graphic representation of the system
1. Compressor 4. Expansion valve and thermostatic sensor
2. Condenser 5. Evaporator.
3. Drier filter
P/N 3681774M1 Edition 01-2006 1100-11

Compressor
The compressor compresses and circulates the
refrigerant inside the system.
The R134a refrigerant is used by the compressor.
Important notes:
Never keep the compressor oil container open.
Make sure the container is always well closed to
prevent absorbing humidity that is harmful for the
system.
Never transfer the compressor oil from its container
to another.
Never add anything to refrigerant and to system oil.
All additional substances may contain elements
which are incompatible with the chemical base of
the refrigerant and may decay the features of the
fluid itself.
Never use engine oil or other types of oil to lubri-
cate the system and the compressor.
WARNING
! Relevant leakage of R134a will be accom-
E
panied by relevant leakage of compressor
AR
lubricant. Check the oil level in the com-

pressor in these cases.
Contact a ........... dealership workshop if
N
this type of problem occurs.

R
IO
G
AG
A
D
1100-12 P/N 3681774M1 Edition 01-2006

Condenser
The condenser transforms refrigerant fluid from
vapour to liquid.
Since this occurs by transfer of heat from the fluid
to the external environment air, the condenser
works in a similar way as the engine coolant radia-
tor.
It consists of a series of tubes inside which the
refrigerant fluid circuits and a finned pack which
pressed on the tubes covers them entirely with thin
aluminium sheets for surrendering heat to the
external environment.
The condenser radiator is installed under the cover
on the roof of the cab.
A fan installed on the condenser takes in the air
flow needed for heat exchange.
Drier filter
The drier filter is installed on the condenser on the
cab roof and is connected to the expansion valve
by a pipe. It has two fundamental purposes:
- It acts as a filtering element for liquid particles
(water) and solid particles which form in the
system.
- It acts as a reservoir-plenum for the coolant
during the various variable load stages.
Eliminating that water from the system is important
to prevent the creation of corrosion which could
deteriorate system components.
For this purpose, particular substances capable of
absorbing humidity are housed in the filter.
Also solid components such as sand, mechanical
particles originated from compressor wear, oxides,
tube particles can cause damage to the system and
are therefore withheld by appropriate filters.
P/N 3681774M1 Edition 01-2006 1100-13

Thermostatic expansion valve

This device reduces the pressure of the refrigerant
fluid at condenser outlet so that the fluid circulating
the evaporator can change state and thus subtract
heat from the air to be cooled.
The expansion valve has two fundamental tasks:
- metering: the calibrated hole (6) inside the
valve body creates a pressure difference of the
refrigerant fluid between inlet (4) (liquid state)
and outlet (7) (mixed liquid/vapour state); the
calibrated hole (6) also atomises the liquid to
vapour before evaporation;
- modulation: inside the valve body a thermo-
5LA0361
static sensor slides between the maximum
opening and maximum closing positions to 12
meter the fluid flow to the evaporator and Block expansion valve
obtain complete evaporation. 1. From the evaporator outlet union
If the thermostatic sensor (2) detects a tempera- 2. Thermostatic sensor
ture increase of the fluid at evaporator outlet, it 3. To the compressor suction union
increases refrigerant flow. 4. From the drier filter
5. Spring
A decrease in temperature or increase in compres-
6. Calibrated hole and ball
sor flow rate (due to increase of engine speed)
causes instead a decrease of refrigerant coolant 7. To the evaporator inlet union
flow rate in the evaporator.
The expansion valve is fitted on the inlet union (7) Replace the valve in the event of a failure.
of the evaporator and being part of the internal
refrigerant gas modulating system is fully auto-
matic and does not require particular maintenance.
Operation can be checked with the conditioning
system fully charged.
1100-14 P/N 3681774M1 Edition 01-2006

Evaporator
The refrigerating cycle is completed inside the
evaporator.
The refrigerant let out by the expansion valve is a
mixture of vapour and liquid at low temperature
and pressure.
Through the evaporator, it absorbs heat from the
environment to be treated, vaporises and having
developed the required refrigerating effect is taken
in by the compressor in vapour state.
The operation of the evaporator is controlled by the
expansion valve which controls exactly the quantity
of refrigerant needed to produce the required air
treatment.
The evaporator operation is exactly opposite to that
of the condenser, buts its basic structure is identi-
cal. The main dimensions and the configuration of
the internal hydraulic circuit change.
The evaporator is responsible also for a further
function: dehumidifying air.
Since the air that crosses the evaporator contains a
certain amount of humidity, the optimal degree of
wellbeing is not reached if this is not carefully con-
trolled and eliminated.
The elimination of some of the humidity, in the
form of condensation, is performed by the evapora-
tor fins as the air cools down.
The centrifuge fan takes in ambient air making it
cross the finned pack so to cool it, dehumidify it
and convey it back into the cab.
The casing forms the housing of the finned pack
and the fan is provided with a container for collect-
ing condensation which is then conveyed outside
by drain tubes.
P/N 3681774M1 Edition 01-2006 1100-15

Thermostatic switch (frost sensor)

The thermostatic switch or thermostat for short is a
safety device provided with a serpentine sensor
which, appropriately inserted on the evaporator
outlet pipe, constantly detects the temperature.
The sensor serpentine is indeed filled with a special
gas whose variation in volume depending on the
temperature of the evaporator allows, by acting on
a membrane connected to a complex mechanism,
the opening or closing of an electrical circuit con-
nected to the electromagnetic clutch of the com-
pressor which causes the latter to be switched on
or off.
The serpentine thermostatic sensor therefore
avoids that the evaporator in the presence of very
humid air freezes and obstructs the circulation of
air to the cab.
For this reason, it is very important following
replacements and maintenance to arrange the ser-
pentine thermostatic sensor back on the evaporator
outlet pipe.
Hold the two in contact with insulating tape so that
the system will work correctly.
Replace the serpentine thermostatic

switch in the event of faulty operation.
1100-16 P/N 3681774M1 Edition 01-2006

SWITCHING THE A/C ON AND SETTING THE TEMPERATURE
The cab A/C system works when the igni-

tion key is on.
When the engine is stationary, the A/C will
not work because the compressor is oper-
ated by the engine.
Make sure the A/C system is off before

starting the engine.
Always switch the fan on before the A/C
system.
The A/C system cannot work with the fan
off.
1. Set the fan knob (2) to the required speed.

2. Press button (3) to switch the A/C on.
3. Adjust the knob (1) to select the required tem- 1
perature and the fan speed.
2
3
5LA0357
13
The flow of air into the cab can be directed by
appropriately turning the vents (1).
Climate controlled air recirculation is obtained by
opening the rear ventilation vent (2).
1
5LA0362
14
P/N 3681774M1 Edition 01-2006 1100-17

A/C SYSTEM MAINTENANCE
Check efficiency and correct operation of the sys-

tem at the beginning of the usage season.
If the charged system has remained off for a long
time, the oil may have flowed from the compressor
to other parts of the system and must flow back.
For this purpose:
1. Start the engine and run it at 1500 rpm for
approximately 10 minutes.
2. Set the fan to the maximum speed and switch
the A/C on.
3. Check that the ratio between external tempera-
ture and temperature measured at the vents
inside the cab respects the values shown in the
table.
External air 20°C 27°C 28°C 35°C 36°C 43°C
Air at vent outlet (inside cab) 4 - 8°C 6 - 12°C 12 - 20°C
If the values are respected, it means that the A/C

E
system is working correctly. Simply inspect the fol-
AR
lowing main components:

1. COMPRESSOR: check fastenings, tension of
drive belt and oil level.
N
2. CONDENSER: check fastenings and finned sur-

R
faces which must not present excessive depos-

its. Straighten any bent fins.
IO
Check the EVAPORATOR (9) and CON-

DENSER (5) in the same way.
G
AG
3. DRIER FILTER: useful indication on system

operation can be understood by observing the
inspection glass of the filter as shown below.
A
Replace the drier filter after two repair inter-

D
ventions on the system.

4. EXPANSION VALVE The valve does not require
maintenance. Call ........... specialised person-
nel in the event of faulty operation.
If the temperature at vent outlet does not comply
with the data shown in the table, seek the trouble
causing system inefficiency as shown below.
1100-18 P/N 3681774M1 Edition 01-2006

5LA0363
15
A/C system schematics
1. Compressor 6. Drier filter
2. Suction tube (low pressure) 7. Warning light glass
3. Delivery tube (high pressure) 8. Expansion valve and thermostatic sensor
4. Hot air 9. Evaporator
5. Condenser 10. Dry, dehumidified air
P/N 3681774M1 Edition 01-2006 1100-19

WARNINGS FOR REPAIRING THE CAB A/C SYSTEM
WARNING
! Always run the recovery, recirculation and
recharging operation on the system when
replacing one or more system components
as shown on page 9
Important notes:
When disassembling system tubes, place plastic
caps on the extremities to prevent entrance of
humidity and dust which could damage the system.
When loosening fittings, always use two tools to
prevent abnormal twisting.
CAB A/C TROUBLESHOOTING OVERVIEW
Three main cases of faulty operation may occur: tem, as shown on the following pages.
- the system does not work at all Visual component inspection
- the system does not provide sufficient cooling These checks must be performed with the engine
action stationary and the heating and A/C system off.
- the compressor is not running smoothly. - Check cleanness of external cab air vents.
Given that insufficient cooling may be caused by - Look for visible leakage of refrigerant from sys-
problems external to the A/C system, generally a tem pipes and fittings.
mechanical and visual inspection is sufficient to - Check cleanness of engine radiators, condenser
verify system efficiency. and evaporator.
This information may be completed by an electrical - Check that the thermostatic sensor is in contact
test. with the evaporator outlet pipe with insulating
At this point, if you still have not identified the tape to ensure correct operation of the system.
fault, run a detailed troubleshooting procedure by Run a detailed troubleshooting procedure of
analysing pressures in the various parts of the sys- the A/C system as described below.
1100-20 P/N 3681774M1 Edition 01-2006

A/C SYSTEM TROUBLESHOOTING

1
THE SYSTEM DOES NOT WORK
1. Check the system fuses.
2. Check compressor belt tension.

3. Check if current reaches the
clutch coil.
4. Make sure that the ground con-
tact is efficient.
5. Check the control devices and the

systems, relays, wiring, thermo-
stat, etc.
6. Visually check conditions of all fit-
tings and pipes.
7. Check the distance (play)
between front plate and pulley of
the electromagnetic clutch.
P/N 3681774M1 Edition 01-2006 1100-21

A/C SYSTEM TROUBLESHOOTING (CONTINUED)

1
INSUFFICIENT
COOLING
HIGH EXHAUST PRESSURE AND/OR LOW EXHAUST PRESSURE AND/OR NORMAL EXHAUST PRESSURE AND/
HIGH SUCTION PRESSURE LOW SUCTION PRESSURE OR NORMAL SUCTION PRESSURE
N.B.: The low pressure gauges dur-

EXCESSIVE REFRIGERANT IN THE Insufficient refrigerant. This may be ing the test may point to the vac-
SYSTEM caused by minor leaks. uum zone or indicate normal values.
Drain refrigerant in excess. 1. Check for leaks and eliminate HUMIDITY IN THE SYSTEM
them. 1. Drain refrigerant from the sys-
2. Add refrigerant. tem.
2. Replace the drier filter.
3. Vent the system and recharge it.
CONDENSER
1. May be obstructed or not
receive sufficient flow of air.
Clean the finned surface of the con-
denser.
EXPANSION VALVE
Check the valve. Replace it if it does
not pass the test.
1100-22 P/N 3681774M1 Edition 01-2006


1
INSUFFICIENT
COOLING
HIGH EXHAUST PRESSURE AND/OR HIGH EXHAUST PRESSURE AND/OR NORMAL EXHAUST PRESSURE AND/
NORMAL SUCTION PRESSURE LOW SUCTION PRESSURE OR NORMAL-HIGH SUCTION
PRESSURE
Note: The high pressure gauge BOTTLENECK FROST SWITCH

reading will not be constant and Water or ice is formed downstream The compressor electromagnetic
should not decrease. of the bottleneck (on drier filter or clutch remains engaged with exter-
PRESENCE OF AIR IN THE SYSTEM on condenser outlet to expansion nal temperatures lower than 30°C.
valve). 1. Check the switch.
1. Recover and recycle system 2. Replace the frost switch if it is
refrigerant. 1. Remove the concerned compo-
nent, eliminate the bottleneck not working correctly being
2. Replace the drier filter. careful not to squeeze the ser-
3. Vent the system and recharge or replace the component.
pentine. Install it the same posi-
it. tion as before on the evaporator
outlet pipe.
P/N 3681774M1 Edition 01-2006 1100-23


1
COMPRESSOR AND ELECTRO-

MAGNETIC CLUTCH
UNUSUAL NOISE WHEN CLUTCH IS NO COOLING UNUSUAL NOISE WITH CLUTCH

ENGAGED RELEASED OR VIBRATION
1. Check all compressor fastening The compressor makes a noise or 1. Check electrical power.
elements. does not work at all. 2. Check the distance (play)
2. Check the engine components between front plate and pulley.
near the compressor.
3. Check if the electromagnetic
clutch works intermittently or
slips.
4. Check the clutch bearing. 1. Check compressor belt state,

5. Check pulley slipping of the correct tension and pulley
electromagnetic clutch. alignment.
6. Check compressor oil level. 2. Check the distance (play)
between front plate and pulley
of the electromagnetic clutch.
3. Check power voltage of clutch,
current draw, power wire and
grounding.
4. Check pulley slipping of the

electromagnetic clutch.
5. Check whether refrigerant level
is sufficient.
6. Check the compressor for leak-
age.
7. Check the system for leakage.
1100-24 P/N 3681774M1 Edition 01-2006

MF 2430 2435 2440 Inglese.1

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This manual is mainly dedicated to workshop staff.

ever, it is not a substitute for thorough professional training.

ii P/N 3681774M1 Edition 01-2006

P/N 3681774M1 Edition 01-2006 iii

SAFETY NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-3

GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 100-7

DANGER SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-11

SEALING AND FIXING SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-16

LUBRICANTS AND FUELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-17

CONVENTIONAL UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-18

STANDARD DRIVING TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-19

100-2 P/N 3681774M1 Edition 01-2006

P/N 3681774M1 Edition 01-2006 100-3

100-4 P/N 3681774M1 Edition 01-2006

P/N 3681774M1 Edition 01-2006 100-5

Wheels and tyres

Unhitching and re-hitching

100-6 P/N 3681774M1 Edition 01-2006

Spinning shaft seals

sure that it touches the supporting ridge (if applicable);

O-ring toroid seals

P/N 3681774M1 Edition 01-2006 100-7

Notes about spare parts

100-8 P/N 3681774M1 Edition 01-2006

Meaning and use

SYMBOL MEANING NOTES

Indicates a danger with the risk of even mortal

Indicates a danger with the risk of damage to the

Warns that the machine or some other personal

Indicates a warning, a note about key functions or

This indication means that there is a considerable

Special tool/ A special tool or specific equipment must be used

A visual inspection must be made. The user must

The operator must listen to a noise made when

Symbol associated with a value: use a torque

Symbol associated with two values: use a torque

Operation carried out in order to obtain precise

Operation carried out in order to measure required

P/N 3681774M1 Edition 01-2006 100-9

SYMBOL MEANING NOTES

Lubrication (oiling, greasing, etc...) of a part/

Sealant required in order to couple two parts

Positioning Coupling with relative position references.

Indicates that only ........... spare parts must be

100-10 P/N 3681774M1 Edition 01-2006

Positions of the danger decals - WEO markets

Positions of the danger decals

P/N 3681774M1 Edition 01-2006 100-11

REF. CODE POSITION DESCRIPTION SYMBOL

WARNING: Danger of entangle-

WARNING: Danger of entangle-

WARNING: Risk of damage to the

WARNING: Electric shock.

DANGER: Danger of being crushed.

100-12 P/N 3681774M1 Edition 01-2006

REF. CODE POSITION DESCRIPTION SYMBOL

DANGER: Danger of being crushed.

DANGER: Danger of collisions and

DANGER: Danger of entanglement.

DANGER: Danger of collisions and

P/N 3681774M1 Edition 01-2006 100-13

REF. CODE POSITION DESCRIPTION SYMBOL