Manual Service New Holland TC54 TC56 AL59

REPAIR MANUAL
NEW HOLLAND
TC54
TC56
AL59
Print No. 604.64.961.00

1st Edition
Your success - Our specialty Printed in Belgium English 06/03
NEW HOLLAND IS A BRAND OF CNH.

CNH: A WORLD-LEADING MANUFACTURER OF TRACTORS, COMBINES AND BALERS.
COMBINES
TC54 -- TC56 -- AL59
REPAIR MANUAL
SECTIONS
GENERAL INFORMATION
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
FRONT MECHANICAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
BRAKES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
CAB CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
PRODUCT FEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
THRESHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
GRAIN STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
PLATFORM, CAB, BODYWORK AND DECALS . . . . . . . . . . . . . . . . . . . . . . . 90
S E R V I C E
INDEX 1
TABLE OF CONTENTS
GENERAL INFORMATION
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rotating shaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
O--ring seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sealing compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cotter pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Protecting the electronic/electrical systems during charging or welding . 4
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Start--up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wheels and Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal and Re--fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Units of measure -- conversion chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Minimum hardware tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Explanation of machine serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
604.64.961.00 - 04 - 2003
2 INDEX
SECTION 10 -- ENGINE
Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cylinder head screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
System bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine overhaul -- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Injection pump timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Engine disassembly and overhaul:
coupled cylinder head, valves and other parts . . . . . . . . . . . . . . . . . . . . . . . 33
Engine front cover and timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Rear cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Oil pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Camshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Connecting rod bushing replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Cylinder block overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Engine compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
CHAPTER 2 -- COOLANT FILTER

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 21 -- TRANSMISSION
CHAPTER 1 -- TC TRANSMISSION
Mechanically--operated transmission, 4 gears . . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatically--operated transmission, 4 gears . . . . . . . . . . . . . . . . . . . . . 18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Clutch adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Ground speed variator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
604.64.961.00 - 04 - 2003
INDEX 3
CHAPTER 2 -- AL TRANSMISSION
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Preliminary remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Transmission housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SECTION 25 -- FRONT MECHANICAL DRIVE

CHAPTER 1 -- TC
Final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHAPTER 2 -- AL
Final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Single stage final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 29 -- HYDROSTATIC TRANSMISSION

CHAPTER 1 -- HYDRAULIC SYSTEM (TC)
Hydrostatic system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydrostatic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pump replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Motor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
System filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Charge pump intake pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Input shaft replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pump replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Motor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
System filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil and filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Charge pump intake pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Input shaft replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
604.64.961.00 - 04 - 2003
4 INDEX
CHAPTER 2 -- HYDRAULIC SYSTEM (AL)

Pump drive pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 33 -- BRAKES & CONTROLS

CHAPTER 1 -- TC
Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Brake pedal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake master cylinder operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Left circuit bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bleed of the fitting between the two brake master cylinders . . . . . . . . . . . 6
Right circuit bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parking brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Brake bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Left circuit bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bleed of the fitting between the two brake master cylinders . . . . . . . . . . . 6
Right circuit bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parking brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CHAPTER 2 -- AL
Service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Brake disc disassembly and replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacement of brake parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brake bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Replacement of brake parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Parking brake disc -- disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
604.64.961.00 - 04 - 2003
INDEX 5
SECTION 35 -- HYDRAULIC SYSTEMS

CHAPTER 1 -- TC
Hydraulic system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic valve functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hydraulic adjustment valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Steering valve removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydropneumatic accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Valve stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Adjustment valve repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hydraulic cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
CHAPTER 2 -- AL 59, LEVELLING AND PRESSURE CONTROL

Location of the hydraulic system main components . . . . . . . . . . . . . . . . . . 2
Power steering and hydraulic system line diagram . . . . . . . . . . . . . . . . . . . 5
Location of the levelling hydraulic system main components . . . . . . . . . . 7
Location of the hydraulic system main components . . . . . . . . . . . . . . . . . . 8
Height compensation line diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Header side compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Header pressure limiting valve stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Oil flow divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Levelling control double pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pump identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydraulic cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cross levelling cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Longitudinal levelling cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Header cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Header side compensation cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Driving wheel control cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
604.64.961.00 - 04 - 2003
6 INDEX
SECTION 41 -- STEERING
CHAPTER 1 -- TC
Steering wheel spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Spindle disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Spindle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering wheel toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fixed steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHAPTER 2 -- AL
Steering wheel spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Spindle disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Spindle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering wheel toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 50 -- CAB CLIMATE CONTROL

CHAPTER 1 -- CLIMATE CONTROL SYSTEM
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A/C system utilization according to the law prescriptions . . . . . . . . . . . . . . 3
Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A/C system circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Compressor clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Drying bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Circuit parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Low pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
High pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Drier filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CHAPTER 2 -- COMPRESSOR
Compressor clutch replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clutch installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
604.64.961.00 - 04 - 2003
INDEX 7
SECTION 55 -- ELECTRICAL SYSTEM

CHAPTER 1 -- GENERAL INFORMATION
Diagram info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ground speed calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CHAPTER 2 -- WIRING DIAGRAMS
Electrical diagrams -- Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
List of symbols and where to find them . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
SECTION 60 -- PRODUCT FEEDING

CHAPTER 1 -- STRAW ELEVATOR
Straw elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Straw elevator chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Lower shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Upper shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 66 -- THRESHING
CHAPTER 1 -- DRUM AND CONCAVE
Operating parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Concave types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Concave adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Concave replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dust sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Threshing drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drum variator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drum replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Threshing function adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Threshing drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Concave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Dust sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Stone trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
604.64.961.00 - 04 - 2003
8 INDEX
SECTION 72 -- SEPARATION
Beater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Beater shaft, bearing and drive belt replacement . . . . . . . . . . . . . . . . . . . . 4
Straw walker and straw walker shaft replacement . . . . . . . . . . . . . . . . . . . . 6
Straw walker adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SECTION 74 -- CLEANING
CHAPTER 1
Fan variator replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Deflector and cleaning fan adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Grain pan and cleaning shoe removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Upper and lower cleaning shoe removal and installation . . . . . . . . . . . . . . 6
Eccentric shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Upper and lower cleaning shoe removal --
Installation with sieve levelling cleaning system . . . . . . . . . . . . . . . . . . . . . . 15
Sieve levelling cleaning system upper sieve adjustment . . . . . . . . . . . . . . 17
Cleaning function adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Grain pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cleaning shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Self--levelling cleaning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Adjustable sieve types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 80 -- GRAIN STORAGE

CHAPTER 1 -- CROP TRANSPORT
Lower augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Grain tank filling auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tailing distribution auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unloading auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 90 -- CAB, PLATFORM, BODYWORK AND DECALS

CHAPTER 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Broken windscreen removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
604.64.961.00 - 04 - 2003
GENERAL INFORMATION 1
GENERAL INFORMATION
CONTENTS
Description Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rotating shaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
O--ring seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sealing compounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cotter pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Protecting the electronic/electrical systems during charging or welding . . . . . . . . . . . . . 4
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Start--up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wheels and Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal and Re--fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Units of measure -- conversion chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Minimum hardware tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Explanation of machine serial numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
604.64.961.00 - 04 - 2003
2 GENERAL INFORMATION
INTRODUCTION
This manual is subdivided in sections marked by two--digit numbers, with independent page numbering within
each section. When one section is formed by more chapters, each new chapter starts from page 1.
The paragraphs and information dealt with can be easily found out in the index, at the page of the relevant sec-
tion, or in the table of contents at the beginning of the manual.
At the bottom of each page there is the manual print number and the relevant publication/up--dating date.
The pages of further up--dating shall have the same print number, followed by a two digit number (for example:
1st Up--dating 604.64.961.01; 2nd Up--dating 604.64.961.02; etc.) and the relevant publication date. These pages
shall be completed by the new print of the index, duly revised.
The information in this manual is up--dated at the date of the publication. As NEW HOLLAND continuously im-
proves its product range, some information could be not up--dated due to modifications of technical or commer-
cial type, as well as for suiting the law regulations of the different countries.
In case of disagreement, refer to NEW HOLLAND Sales and Service networks.
IMPORTANT INFORMATION
All repair and maintenance works listed in this manual must be carried out only by staff belonging to the NEW
HOLLAND Service network, strictly complying with the instructions given.
Anyone who carries out the above operations without complying with the prescriptions shall be responsible for
the subsequent damages.
The manufacturer and all the organizations of its distribution chain, including -- without limitation -- national, re-
gional or local dealers, reject any responsibility for damage due to anomalous behaviour of parts and / or compo-
nents not approved by the manufacturer himself, including those used for servicing and/or repair of the product
manufactured or marketed by the Manufacturer. In any case, no warranty is given or attributed on the product
manufacturers as for the product manufactured or marketed in case of damages due to an anomalous behaviour
of parts and / or components not approved by the Manufacturer.
No reproduction, though partial, of text and illustrations allowed
604.64.961.00 - 04 - 2003
GENERAL INSTRUCTIONS
SHIMMING O--RING SEALS

Shims must be set during each new adjustment. Lubricate the O--ring seals before inserting them in
Measure the shims individually using a micrometer the seats; this will prevent them from overturning or
and sum the measured values. The measurement of twisting, which would jeopardise sealing efficiency.
the complete pack is not reliable.
SEALING COMPOUNDS
Apply one of the following sealing compounds on the
mating surfaces marked with an X: RTV SILMATE,
RHODORSIL CAF 1 or LOCTITE PLASTIC
ROTATING SHAFT SEALS GASKET.
For correct rotating shaft seal installation, proceed as Before applying the sealing compound, prepare the
follows: surfaces as follows:
-- remove any incrustations using a metal brush;
-- before assembly, allow the seal to soak in the oil
-- thoroughly de--grease the surfaces using one of
it will be sealing for at least thirty minutes;
the following cleaning agents: trichlorethylene or
-- thoroughly clean the shaft and check that the a water and soda solution.
working surface on the shaft is not damaged;
COTTER PINS
-- position the sealing lip front part facing the fluid;
with hydrodynamic seals, take into consideration When fitting split cotter pins, ensure that the pin notch
the shaft rotation direction and position the is positioned in the direction of the force acting on the
grooves so that they will deviate the fluid towards pin.
the inner side of the seal; Spiral cotter pins do not require special assembly
positioning.
-- coat the sealing lip with a thin layer of lubricant
(use oil rather than grease) and fill the gap be-
tween the sealing lip and the dust lip on double lip
seals with grease;
-- insert the seal in its seat and press down using a
flat punch, do not tap the seal with a hammer or
mallet;
-- whilst inserting the seal, check that it is perpen-
dicular to the seat. Once settled, make sure the
seal touches the thrust element;
-- to prevent damaging the seal lip on the shaft,
position a protective guard around the shaft or the
axle during installation operations.
604.64.961.00 - 04 - 2003
PROTECTING THE IMPORTANT: if welding must be performed on the

ELECTRONIC/ELECTRICAL SYSTEM unit, either the combine or the header (if it is at-
DURING CHARGING OR WELDING tached), the battery ground cable must be discon-
nected from the combine battery. The electronic
monitoring system and charging system will be dam-
1. Before connecting a battery charger, switch the aged if this is not done.
battery off through the suitable switch.
Check that the battery charger is correctly con-
nected.
CAUTION
2. Never let the engine run when the generator and Batteries contain sulphuric acid. In case of contact
the battery are disconnected. with skin, flush the affected area with water for at least
3. Disconnect the battery using the battery switch if five minutes. Seek medical attention immediately.
Avoid contact with the skin, eyes or clothing. Wear
any electric welding work is to be carried out on
eye protection when working near batteries.
the combine.
Secure the negative (--) terminal of the welding
apparatus as close as possible to the part to be
welded.
• If welding in close proximity to a computer

module, then the module should be removed
from the combine.
• Never allow welding cables to lay on, near or
across any electrical wiring or electronic com-
ponent while welding is in progress.
4. The positive (+) lead of the batteries is live at all
times. To prevent damage, first of all move apart
the battery ground cable (--).
5. Ensure the batteries are connected properly, i.e.
negative (--) lead to the negative (--) terminal and
positive (+) lead to the positive (+) terminal.
604.64.961.00 - 04 - 2003
SPARE PARTS
Only use original NEW HOLLAND spare parts bearing the logo shown below.
Only genuine spare parts guarantee the same quality, -- accurately built and rigorously tested so as to
duration and safety as original parts, as they are the offer efficient and long--lasting operation.
same parts that are assembled during standard pro- By using these tools, Repair Personnel will benefit
duction. from:
Only NEW HOLLAND genuine spare parts can offer
this guarantee. -- operating in optimal technical conditions;
When ordering spare parts, always provide the fol- -- obtaining the best result;
lowing information: -- saving time and effort;
-- machine model (commercial name) and serial
-- working in safe conditions.
number
-- part number of the ordered part, which can be
found in the ”Microfiches” or the ”Spare Parts
Catalogue”, used for order processing. NOTE: Welding limit values indicated for certain
parts should be considered to be recommended, but
not binding. The terms ”front”, ”rear”, ”right--hand”
TOOLS and ”left--hand” (when referred to different parts) are
determined with the operator sitting in his seat, facing
The tools that NEW HOLLAND suggests and illus-
in the direction of travel of the machine during oper-
trated in this manual have been:
ation.
-- specially researched and designed for use with
NEW HOLLAND machines;
-- essential for reliable repair operations;
604.64.961.00 - 04 - 2003
Safety regulations
WARNING AND DANGER SYMBOLS
This warning symbol points out important personal safety messages.

Carefully read the following safety regulations and observe advised precautions in
order to avoid potential hazards and safeguard your health and safety.
In this manual the symbol is accompanied by the following key--words:
WARNING -- Warnings concerning unsuitable repair operations that may jeopardise
the safety of Repair personnel.
DANGER -- Specific warnings concerning potential hazards for operators’ safety or
for other persons directly or indirectly involved.
ACCIDENT PREVENTION • Do not carry out repair operations with someone

Most accidents or injuries that occur in workshops are sitting in the driver’s seat, unless the person is a
the result of non--observance of simple and funda- trained technician who is assisting with the oper-
mental safety regulations. For this reason, IN MOST ation in question.
CASES THESE ACCIDENTS CAN BE AVOIDED by • Do not operate the machine or use any of the im-
foreseeing possible causes and consequently acting plements from different positions, other than the
with the necessary caution and care. driver’s seat.
Accidents may occur with all types of machine, re- • Do not carry out operations on the machine with
gardless of how well the machine in question was de- the engine running, unless specifically indicated.
signed and built. • Stop the engine and check that the hydraulic cir-
A careful and judicious service technician is the best cuits are pressure--free before removing caps,
guarantee against accidents. covers, valves, etc.
Precise observance of the most basic safety rules is • All repair and maintenance operations must be
normally sufficient to avoid many serious accidents. carried out using extreme care and attention.
DANGER • Service steps and platforms used in the work-
Never carry out any cleaning, lubrication or mainten- shop or elsewhere should be built according to
ance operations when the combine engine is running. standard accident prevention regulations.
• Any parts to be raised must be locked in position.
SAFETY RULES • Brakes are inoperative when manually released
General guidelines for repair or maintenance purposes. Use wedges
• Carefully follow specified repair and maintenance or similar devices to control the machine in these
procedures. conditions.
• Do not wear rings, wrist--watches, jewellery, un-
buttoned or loose articles of clothing such as:
ties, torn clothing, scarves, open jackets or shirts
with open zips that may remain entangled in mov-
ing parts. It is advised to wear approved safety
clothing, e.g.: non--slip footwear, gloves, safety
goggles, helmets, etc.
604.64.961.00 - 04 - 2003
• Only use specified towing points for towing the • When carrying out checks with the engine run-
machine. Connect parts carefully. Make sure that ning, request the assistance of an operator in the
all pins and/or locks are secured in position be- driver’s seat. The operator must maintain visual
fore applying traction. Do not stand next to bars, contact with the service technician at all times.
metal ropes or tensioned tow chains. • If operating outside the workshop, position the
• When loading or unloading the machine from the machine on a flat surface and lock in position. If
trailer (or other means of transportation), select operating on hillsides is required, first of all lock
a flat area capable of sustaining the trailer or truck the machine. If working on a slope, lock the ma-
wheels. Firmly secure the machine to the truck or chine in position. Move to a flat area as soon as
trailer and lock the wheels in the position used by safely possible.
the carrier. • Damaged or bent chains or metal ropes are unre-
• Electric heaters, battery--chargers and similar liable. Do not use them for lifting or towing. Al-
equipment must only be powered by auxiliary ways use suitable protective gloves when handl-
power supplies with efficient ground insulation to ing chains or cables.
avoid electrical shock hazards. • Chains should always be safely secured. Make
• Always use suitable hoisting or lifting devices sure that the hitch--up point is capable of sustain-
when raising or moving heavy parts. ing the load in question. Keep the area near the
hitch--up point, chains or cables free of all by-
• Take extra care if bystanders are present. standers.
• Never use gasoline, diesel oil or other inflam- • Maintenance and repair operations must be car-
mable liquids as cleaning agents. Use non--in- ried out in a CLEAN and DRY area. Eliminate any
flammable, non toxic commercially available sol- water or oil spillage immediately.
vents. • Do not create piles of oil or grease--soaked rags
• Wear safety goggles with side guards when as they represent a serious fire hazard. Always
cleaning parts with compressed air. store rags in a closed metal container.
• Reduce the air pressure according to the local re- Before engaging the machine, make sure that
gulations in force. there are no persons within the machine or imple-
• Do not run the combine engine in confined ment range of action.
spaces without suitable ventilation. • Empty your pockets of all objects that may fall
accidentally unobserved into the machine inner
• Never use naked flames for lighting when work-
compartments.
ing on the machine or checking for leaks.
• In the presence of protruding metal parts, use
• All movements must be carried out carefully protective goggles or goggles with side guards,
when working under, on or near the machine. helmets, special footwear and gloves.
Wear protective equipment: helmets, goggles
• When welding, use protective safety devices:
and special footwear.
tinted safety goggles, helmets, special overalls,
gloves and footwear. All persons present in the
area where welding is taking place must wear
tinted goggles. NEVER LOOK DIRECTLY AT
THE WELDING ARC WITHOUT SUITABLE EYE
PROTECTION.
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• Metal cables tend to fray with repeated use. Al- • Stand away from (at the side of) the tyre when
ways use suitable protective devices (gloves, checking inflation pressure.
goggles, etc.).
• Do not use parts of recovered wheels as incorrect
• Handle all parts carefully. Do not put your hands welding, brazing or heating may weaken and
or fingers between moving parts. Wear suitable eventually cause damage to the wheel.
safety clothing -- safety goggles, gloves and
shoes. • Never cut or weld a rim mounted with an inflated
tyre.
Start--up • To remove the wheels, lock all wheels. After hav-
• Never run the combine engine in confined spaces ing raised the machine, position supports under-
that are not equipped with adequate ventilation neath, according to regulations in force.
for exhaust gas extraction. • Deflate the tyre before removing any objects that
• Never place the head, body, limbs, feet, hands or may be jammed in the tyre tread.
fingers near rotating and moving parts. • Never inflate tyres using inflammable gasses, as
this may result in explosions and injury to by-
Hydraulics standers.
• A liquid leaking from a tiny hole may be almost in-
visible but, at the same time, be powerful enough
to penetrate the skin. To search for possible Removal and Re--fitting
leaks, NEVER USE YOUR HANDS, rather a
cardboard or a wooden stick. If any liquid pen- • Lift and handle all heavy parts using suitable ho-
etrates skin tissue, call for medical aid immedi- isting equipment. Make sure that parts are sus-
ately. Failure to treat this condition with correct tained by appropriate hooks and slings. Use the
medical procedure may result in serious infection hoisting eyebolts for lifting operations. Extra care
or dermatosis. should be taken if persons are present near the
load to be lifted.
• In order to check the pressure in the system use
suitable instruments. • Handle all parts carefully. Do not put your hands
or fingers between parts. Wear suitable safety
Wheels and Tyres clothing -- safety goggles, gloves and shoes.
• Make sure that the tyres are correctly inflated at • Avoid twisting chains or metal cables. Always
the pressure specified by the manufacturer. wear safety gloves when handling metal ropes or
Periodically check the rims and tyres for damage. chains.
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UNITS OF MEASURE -- CONVERSION CHART
Linear
1 mm -- 3/76” = 0.03937 in 1 Inch = 25.4 mm

1 km = 0.6214 miles 1 Mile = 1.6093 km
1m = 3.281 ft 1 Foot = 0.3048 m
Area
1 ha = 2.471 acre 1 acre = 0.4047 ha
Volume
1 litre = 0.0063 barrel 1 barrel = 158.987 litre

1 litre = 0.028 US bushel 1 US bushel = 35.2391 litre
1 litre = 0.2642 US gal 1 US gal = 3.7853 litre
1 litre = 1.057 US quart 1 US quart = 0.9464 litre
1 mm3 = 0.061 in3 1 in3 = 16387 mm3
Weight
1 kg = 2.204 pound 1 pound = 0.4536 kg
Tightening torque
1 Nm = 0.7376 lbf.ft 1 lbf ft = 1.3558 Nm
Capacity
1 kW = 1.358 hp 1 hp = 0.746 kW
Pressure
1 bar = 14.505 lbf/in2(psi) 1 lbf/in2(psi) = 0.06894 bar

1 kPa = 0.145 lbf/in2(psi) 1 lbf/in2(psi) = 6.894 kPa
1 pa = 10 --5 bar 1 bar = 100 kPa
Temperature
1 _C = ((1.8 x _C) + 32)_F 1 _F = (0.56 x (_C -- 32))_C
604.64.961.00 - 04 - 2003
MINIMUM HARDWARE TIGHTENING TORQUES
IN NEWTON-METRES -- Nm (FOOT POUNDS -- LBF. FT)

FOR NORMAL ASSEMBLY APPLICATIONS
METRIC HARDWARE AND LOCKNUTS
CLASS 5.8 CLASS 8.8 CLASS 10.9 LOCKNUT

NOMINAL CL.8
SIZE UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED W/CL8.8
W/ZnCr W/ZnCr W/ZnCr BOLT
M4 1.7 (15*) 2.2 (19*) 2.6 (23*) 3.4 (30*) 3.7 (33*) 4.8 (42*) 1.8 (16*)
M6 5.8 (51*) 7.6 (67*) 8.9 (79*) 12 (102*) 13 (115*) 17 (150*) 6.3 (56*)
M8 14 (124*) 18 (159*) 22 (195*) 28 (248*) 31 (274*) 40 (354*) 15 (133*)
M10 28 (21) 36 (27) 43 (32) 56 (41) 61 (45) 79 (58) 30 (22)
M12 49 (36) 63 (46) 75 (55) 97 (72) 107 (79) 138 (102) 53 (39)
M16 121 (89) 158 (117) 186 (137) 240 (177) 266 (196) 344 (254) 131 (97)
M20 237 (175) 307 (226) 375 (277) 485 (358) 519 (383) 671 (495) 265 (195)
M24 411 (303) 531 (392) 648 (478) 839 (619) 897 (662) 1160 (855) 458 (338)
NOTE: torque values shown with * are inch pounds.

IDENTIFICATION
HEX CAP SCREW AND CARRIAGE BOLTS
CLASSES 5.6 AND UP
MANUFACTURER’S IDENTIFICATION
PROPERTY CLASS
HEX NUTS AND LOCKNUTS

CLASSES 05 AND UP
MANUFACTURER’S IDENTIFICATION
PROPERTY CLASS CLOCK MARKING
604.64.961.00 - 04 - 2003
IN NEWTON-METERS -- Nm (FOOT POUNDS -- LBF. FT)

FOR NORMAL ASSEMBLY APPLICATIONS
INCH HARDWARE AND LOCKNUTS
SAE GRADE 2 SAE GRADE 5 SAE GRADE 8 LOCKNUTS
NOMINAL UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED GR.B GR.C NOMINAL
SIZE or W/ZnCr or W/ZnCr or W/ZnCr w/GR5 w/GR8 SIZE
PLATED PLATED PLATED BOLT BOLT
SILVER GOLD SILVER GOLD SILVER GOLD
1/4 6.2 (55*) 8.1 (72*) 9.7 (86*) 13 (112*) 14 (121*) 18 (157*) 6.9 (61*) 9.8 (86*) 1/4
5/16 13 (115*) 17 (149*) 20 (178*) 26 (229*) 28 (250*) 37 (324* ) 14 (125* ) 20 (176*) 5/16
3/8 23 (17) 30 ( 22) 35 (26) 46 (34) 50 (37) 65 (48) 26 (19) 35 (26) 3/8
7/16 37( 27) 47 (35) 57 (42) 73 (54) 80 (59) 104 (77) 41 (30) 57 (42) 7/16
1/2 57 (42) 73 (54) 87 (64) 113 (83) 123 (91) 159 (117) 61 (45) 88 (64) 1/2
9/16 81 (60) 104 (77) 125 (92) 163 (120) 176 (130) 229 (169) 88 (65) 125 (92) 9/16
5/8 112 (83) 145 (107) 174 (128) 224 (165) 244 (180 ) 316 (233) 122 (90) 172 (127) 5/8
3/4 198 (146) 256 (189) 306 (226) 397 (293) 432 (319) 560 (413) 217 (160) 306 (226) 3/4
7/8 193 (142) 248 (183) 495 (365) 641 (473) 698 (515) 904 (667) 350 (258) 494 (364) 7/8
1 289 ((213) 373 (275) 742 (547) 960 ( 708) 1048 (773) 1356 (1000) 523 (386) 739 (545) 1
NOTE: torque values shown with * are inch pounds.

IDENTIFICATION
CAP SCREWS AND CARRIAGE BOLTS
SAE GRADE 2 SAE GRADE 5 SAE GRADE 8
REGULAR NUTS SAE GRADE 5 SAE GRADE 8

HEX NUTS HEX NUTS
LOCKNUTS
GRADE A NO MARK
GRADE B LETTER B
GRADE C LETTER C
GRADE IDENTIFICATION
GRADE IDENTIFICATION GRADE IDENTIFICATION
GRADE A NO MARKS
GRADE A NO NOTCHES
GRADE B THREE MARKS
GRADE B ONE CIRCUMFERENTIAL NOTCH
GRADE C SIX MARKS
GRADE C TWO CIRCUMFERENTIAL NOTCHES
MARKS NEED NOT BE LOCATED
AT CORNERS
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EXPLANATION OF MACHINE SERIAL NUMBERS
Example : n° 809262001
809262001: The first two digits identify the model
within a product line:
TC54 = 79
TC56 = 80
AL59 = 84
809262001: The third digit indicates the product line.

809262001: These 3 digits indicate the batch in
which the machine was made.
809262001: Product line number (1) and batch toge-

ther form the series number (9262).
809262001: The last 3 digits are a sequential

number for each model within a batch.
Summarizing we can say that this machine is the first

TC56 of serie 9262.
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SPEED (high idle)

Combine left side
1
Rpm
1 Beater 875
2 Lower auger layshaft 1759
3 Motor + hydraulic pump 2100
4 Straw spreader 275
5 Straw chopper 2465 or 3500
6 Returns elevator 368
7 Grain elevator 368
8 Eccentric shaft 320
9 Straw elevator 376
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Combine right side
Rpm
1 Engine layshaft 2600 -- 2636 (1)
2 Engine cooling fan Refer to your TC Oper-
ator’s manual
3 Alternator --
4 Grain tank bottom auger 575
5 Drum variator 430 -- 1070
6 Eccentric shaft 320
7 Fan variator 350--1000
8 Beater 875
9 Rotary separator 400--760
10 Walkers 220
(1) Only machines with 5 straw walkers and hydrostatic transmission
604.64.961.00 - 04 - 2003
SECTION 10 -- ENGINE -- CHAPTER 1 1
Chapter 1
Page
Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Cylinder head screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
System bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine overhaul -- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Injection pump timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Engine disassembly and overhaul:
coupled cylinder head, valves and other parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Engine front cover and timing gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Rear cover plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Oil pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Camshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Connecting rod bushing replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Cylinder block overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Engine compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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2 SECTION 10 -- ENGINE -- CHAPTER 1
IMPORTANT INFORMATION
Cylinder head screws (fig. 1)
1
When the cylinder head must be refitted after a repair,
the greased screws must be tightening according to
the below table (fig. 1) at the intervals of
156--190--210 Nm. During standard service, no
further tightening is required.
Valve clearance
Engine cold:
intake: 0.36 -- 0.46 mm
exhaust: 0.43 -- 0.53 mm
Ignition sequence:
6--cylinder engine: 1--5--3--6--2--4
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Injectors:
1. Opening pressure:
300 bar in starting position
2. Sealing: send a pressure by about 158 bar on the
injector and measure the time interval for the
pressure decrease from 152 to 103 bar. The max.
time interval should be 5 seconds.
3. Nozzle opening pressure
Inflate the injector tester and check the pressure
where the needle valve lifts and the fuel is
sprayed by the nozzle.
4. Spray type
Pump the tester quickly and check the spray
coming out from the five holes. The distance be- 2
tween two sprays should be the same. The spray
must be well spread and generate a 80--mm dia. Thermostat
cup at 10 mm from the injector.
5. Nozzle support loss
Number: 2
Wipe the nozzle tip dry and apply a pressure 10
Opening temperature: 79 -- 83_C
bar below the opening pressure. Keep this pres-
sure for 6 seconds, then wipe the nozzle tip with Fully open: 93 -- 96_C
a piece of blotting paper. The combustible oil Injection Pump
stain diameter should not exceed 13 mm. Removal
6. Installation 1. Remove dirt from the injection pump and from all
New cork dust washers and copper seal washers. the linked parts.
Fasten each injector with the two fastening 2. Disassemble and take out all the fuel lines (A)
screws and tighten at the torque of 20--24 Nm. from the injection pump (fig. 2) and plug the open-
Tighten the drain pipe at the torque of 7--14 Nm. ings to prevent any dirt inlet.
Tighten the high--pressure fuel lines at the torque
3. Disassembly the restriction cable in point B and
of 22--27 Nm.
the fuel stop solenoid cable in point C (fig. 2).
604.64.961.00 - 04 - 2003
4. If the pump needs no inner setting, before disas-

sembly note down the pump setting with respect
to the notch corresponding to 0 degrees at the
end of the engine front plate (D) (fig. 3). Mark the
plate with a centering punch, so that it can be di-
rected with the line (E) etched on the pump
flange.
5. Remove the engine adjustment guard (F) (fig. 4).

Take out the injection pump drive shaft drive gear
locking nut.
6. Check that the V--groove of the gear spline is in
the upper position.
7. Make a puller referring to figure 5. Fasten the

puller to the drive train with three screws 5/16” --
UNFx2” and an intermediate screw M12x50, then
remove the gear from the shaft.
8. Remove the gear from the engine only after re-
moving the engine front guard.
604.64.961.00 - 04 - 2003
9. Take out the fixing screws (G) of the pump (fig. 2). 5. Assemble the pump drive gear aligning it with the
Take out the pump from the engine cover plate. Woodruff key on the pump drive shaft.
Close all the openings with covers, to prevent any 6. Fit the safety washer and the fastening screw of
dirt inlet. the pump drive shaft and tighten to 79 Nm.
7. Fit a new control guard seal and fasten the control
Installation guard (F) (fig. 4) to the engine front plate; tighten
the fastening screws to 25 Nm.
1. Assembly a new pump on the O--ring of the en- 8. Fasten the fuel lines to the injection pump and
gine front plate, next to the pump fastening tighten to the torque of 27 Nm.
flange. 9. Assemble the fuel line (B) and the stop cock (C)
2. Fit the three screws (G) (fig. 2), fastening the in- on the injection pump (fig. 2).
jection pump to the engine front plate.
3. If the pump is adjusted inside, looking at the pump Venting the system
from the back, rotate the pump to the right by half
a notch with respect to the notch corresponding
1. Turn the ignition key to ON and press the reset
to zero degrees, at the engine front plate rear
push button.
end.
2. The electric pump supplies fuel to the filter and
4. If the pump is not adjusted inside, align the cut
the main pump.
line on the flange of the pump (E) (fig. 3) with the
centering punch previously fitted in the engine 3. Open a breather next to the filter.
front plate rear end. Tighten the fastening screws 4. After bleeding air, tighten the breather.
to 27 Nm.
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Filter change
OIL FILTER -- replace at each oil change.

Proceed as follows:
1. disassemble the threaded filter (4) on the ma-
chine left side.
2. Full up the new filter with oil and apply a film of oil
to the seal ring.
3. Screw on the new filter by hand. DO NOT USE
TOOLS for tightening!
4. Refill with clean engine oil. See paragraph ”Oil
change”.
5. Start the engine and search for possible leaks. 6
FILTER MAINTENANCE -- Air bleed system from the
engine housing
PRE--FILTER
(TC56H)
Clean this filter every 600 operating hours. Clean fol-
lowing the instructions below:
1. loosen the clamps 1 of the hose and remove the
filter 2.
2. Wash out the filter with kerosene and dry with
compressed air. Make sure there are no residues
of the washing fluid inside the filter.
3. Install the filter and tighten the hose clamps.
7
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FILTER -- ENGINE HOUSING AIR BLEED

(TC56H)
Replace the filter (3) every 600 operating hours or if
the sight glass shows a red pin.
Change the filter following the instructions below:
1. remove the filter housing;
2. take out the filter cartridge;
3. remove all oil residues;
4. fit the new filter cartridge;
5. assembly the filter housing again.
FILTER -- ENGINE HOUSING AIR BLEED
(TC54H and TC56M)
9
Replace the filter (1) every 600 operating hours.
1. Loosen the stops on the housing cover and re-
move the plug.
2. Remove the filter cartridge and all oil residues.
3. Fit the new filter cartridge and close the housing.
10
604.64.961.00 - 04 - 2003
SPECIFICATIONS
DESCRIPTION TC54 TC56 TC56+
Mechanical Hydrostatic Mechanical Hydrostatic Hydrostatic

drive drive drive drive drive
Type 675T/WN 675T/WP 675TA/YA 675TA/VJ
Gross power (ISO TR1436) 99 kW 125 kW 136 kW 168 kW
Governor Mechanical
Rated speed 2100 rpm
Low idle speed 1300 rpm
High idle speed 2205 rpm
Injection pump DP203 (rotary) ”A” in line ”P” in line
Displacement 7500 cc
Bore 112 mm
Stroke 127 mm
Water pump speed 2815 rpm
Ventilator speed 1762 rpm 2188 rpm 1601 rpm
Air compressor speed -- 2677 rpm
Crankcase capacity 23 litres
(with filter)
Battery 2 x 12 V -- 92 Ah
Starter motor 12 V -- 3.6 kW
Alternator type 100 A (12V) 135 A (12V)
Alternator speed 5794 rpm
Rotary screen speed 443 rpm 436 rpm
AC compressor speed 3173 rpm
Fuel tank 300 litres 400 litres
DESCRIPTION TC54 TC56 TC56+
Mechanical Hydrostatic Mechanical Hydrostatic Hydrostatic

drive drive drive drive drive
Type -- 675TA/HJ 675TA/CD --
Gross power (ISO TR14396) -- 125 kW 150 kW --
Governor Mechanical
Rated speed 2100 rpm
Low idle speed 1300 rpm
High idle speed 2205 rpm
Injection pump -- Rotary ”P” in line --
Displacement -- 7500 cc
Bore -- 112 mm
Stroke -- 127 mm
Water pump speed -- 2815 rpm 3859 rpm --
Ventilator speed -- 1762 rpm 1601 rpm --
Air compressor speed -- -- -- 2677 rpm --
Crankcase capacity -- 23 litres --
(with filter)
Battery -- 2 x 12 V -- 92 Ah --
Starter motor -- 12 V -- 3.6 kW --
Alternator type -- 100 A (12V) 135 A (12V) --
Alternator speed -- 5794 5426 rpm --
Rotary screen speed -- 443 rpm 436 rpm --
AC compressor speed -- 3173 rpm --
Fuel tank -- 300 litres --
604.64.961.00 - 04 - 2003
CYLINDER BLOCK
Cylinder bore taper 0.025 mm Repair limit
0.127 mm Wear limit
Cylinder bore out--of--round 0.030 mm Repair limit
0.127 mm Wear limit
Cylinder bore diameters 111.778--111.803 mm
Rear oil seal bore diameter 140.77--140.87 mm
Block and head surface flatness 0.08 mm in any 152 mm
0.03 mm in any 25.40 mm
CYLINDER HEAD
Valve guide bore diameter 9.469--9.495 mm
Block and head surface flatness 0.03 mm in any 25.40 mm or
0.127 mm as total limit
EXHAUST VALVES
Face angle 44515’--44530’ relative to the valve head
Stem diameter Standard: 9.401--9.421 mm

Oversize: 0.38
0 38 mm
9.781--9.802 mm
Head diameter 42.88--43.13 mm
Stem to guide clearance 0.048--0.094 mm
Lash clearance (cold) 0.43--0.53 mm
INTAKE VALVES
Face angle 29515’--29530’ relative to the valve head
Stem diameter Standard: 9.426--9.446 mm

Oversize: 0.381 mm
9.807--9.827 mm
Head diameter 47.37--47.63 mm
Stem to guide clearance 0.023--0.069 mm
Lash clearance (cold) 0.36--0.46 mm
VALVE SPRINGS
Number per valve 1
Free length 60.70 mm
Length under load of 27.7--31.3 kg 48.26 mm
Length under load of 61--69 kg 35.69 mm
CAMSHAFT LOBE LIFT

Intake 8.36 mm
Exhaust 8.36 mm
INSTALLED VALVE RECESSION

Intake 0.86--1.32 mm
Exhaust 1.17--1.65 mm
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VALVE INSERT
Exhaust valve insert Intake valve seat insert
Insert Oversize Counterbore diameter in Counterbore diameter in
cylinder head cylinder head
0.254 mm 44.17--44.20 mm 50.01--50.04 mm
0.508 mm 44.42--44.45 mm 50.27--50.29 mm
0.762 mm 44.68--44.70 mm 50.52--50.55 mm
VALVE SEATS
Exhaust valve seat angle 45500’ -- 45530’
Intake valve seat angle 30500’ -- 30530’
Interference between valve side angle and valve seat angle 0530’ -- 1515’
Valve insert concentricity 0,051 mm max. indicator
reading
Housing width: exhaust valve 1.8--2.3 mm
intake valve 1.9--2.5 mm
CAMSHAFT IDLER GEAR
Number of fingers 47
End play 0.076--0.35 mm
Bushing inside diameter 50.813--50.838 mm
Adapter outer diameter 50.762--50.775 mm
Backlash with crankshaft gear 0.10--0.36 mm
Backlash with camshaft ring gear 0.10--0.36 mm
Backlash with fuel injection pump 0.10--0.48 mm
CAMSHAFT RING GEAR
Timing gear backlash with idler 0.10--0.36 mm
ROCKER ARM SHAFT
Shaft diameter 25.40--25.43 mm
Shaft support internal diameter 25.45--25.20 mm
ROCKER ARM
Internal diameter 25.48--25.50 mm
TAPPETS
Clearance to bore 0.015--0.058 mm
Tappet diameter 25.113--25.131 mm
Tappet bore diameter 25.146--25.171 mm
CAMSHAFT
Bearing journal diameter 60.642--60.668 mm
Bearing clearance 0.076--0.178 mm
End play 0.051--0.18 mm
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CONNECTING ROD
Small end bushing (internal diameter) 44.460 -- 44.467 mm
Big end bearing clearance 0.038--0.104 mm
Bushing to piston pin clearance 0.013--0.025 mm
Lateral flotation 0.13--0.33 mm
Max. twist 0.30 mm
Max. bend 0.10 mm
PISTON PIN
Outer diameter 44.442--44.447 mm
PISTONS
Skirt--to--cylinder clearance 0.152--0.182 mm New or unrun engine
0.152--0.194 mm For run--in engines
Taper (out of round) 0.063--0.127 mm
Grading diameter (at right angles to piston pin) 111.64--111.74 mm with 0.0127--mm in-
creases
Piston pin clearance 0.0127--0.0254 mm at 21_C
Piston crown to block face, 0.005--0.015 mm
PISTON RINGS
Engines with mechanically controlled fuel injection pump
Upper compression ring Keystone tapered sides with letter ”O” at

the top
Second compression ring Parallel side outer pitch
Front side--ring groove clearance 0.06--0.105 mm
Piston groove width 2.435--2.455 mm
Oil control ring 1 off, directly above the piston pin
Type Grooved, with expansion
Side clearance--ring groove 0.030--0.070 mm
Engines with electronically controlled fuel injection pump

Upper compression ring Keystone tapered sides with letter ”O” at
the top
Second compression ring Keystone tapered sides with letter ”O” at
the top
Oil control 1 off, directly above the piston pin
Type Grooved, with expansion
Side clearance--ring groove 0.051--0.101 mm
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CRANKSHAFT
Main journal diameter -- Blue 85.631--85.644 mm
-- Red 85.644--85.656 mm
Main journal length
(except thrust, rear or intermediate) 36.96--37.21 mm
Main journal wear limits 0.127 mm max.
Crankpin fillet radius 0.25 mm
Thrust bearing journal length 37.06--37.11 mm
Intermediate bearing journal length 36.96--37.21 mm
Rear bearing journal length 37.97--38.48 mm
Crankpin journal length 42.62--42.72 mm
Crankpin diameter -- Blue 69.840--69.850 mm
-- Red 69.850--69.860 mm
End play 0.10--0.36 mm
Crankpin out--of--round 0.005 mm Total indicator reading
Taper surface parallel to centre line of crankpin 0.005 mm
Crankshaft rear oil seal journal diameter 122.12--122.28 mm
Crankshaft pulley diameter 51.788--51.808 mm
Crankshaft timing gear diameter 52.131--52.146 mm
Crankshaft flange clearance 0.038 mm max.
CRANKSHAFT DRIVE GEAR

MAIN BEARING
Liner length (except thrust liner) 27.94--28.19 mm
Liner length (thrust liner) 39.91--39.96 mm
Vertical assembled bearing clearance 0.055--0.117 mm
CRANKPIN BEARINGS
Line length 31.5--31.75 mm
Vertical assembled bearing clearance 0.038--0.104 mm
Bearing clearance -- Service limit 0.127 mm
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CRANKSHAFT RE--GRINDING
When re--grinding a crankshaft the main and crankpin journal diameters should be reduced the same amount
as the undersize bearings used, and the following dimensions apply. The rear end of the crankshaft should be
located on the 60_ chamfer of the pilot bearing bore.
UNDERSIZE BEARING AVAILABLE

CRANKPIN DIAMETERS
0.051 mm 85.580--85.593 mm
0.254 mm 85.390--85.402 mm
0.508 mm 85.136--85.148 mm
0.762 mm 84.882--84.894 mm
1.016 mm 84.628--84.640 mm
UNDERSIZE BEARING AVAILABLE

CRANKPIN JOURNAL DIAMETERS
0.051 mm 69.789--69.799 mm
0.254 mm 69.956--69.606 mm
0.508 mm 69.342--69.352 mm
0.762 mm 69.088--69.098 mm
1.016 mm 68.834--68.844 mm
FLYWHEEL
Runout of the clutch side
(between outer edge and mounting bolt holes) 0.127 mm
Ring gear runout 0.63 mm
OIL PUMP
Delivery 91 l/min. at 2100 engine rpm and 1.38
bar
Rotor clearance 0.025--0.15 mm
Rotor to pump housing clearance 0.15--0.28 mm
Rotor end play 0.025--0.089 mm
Pump gear to camshaft gear backlash 0.40--0.56 mm
OIL PRESSURE
Minimum at low idle speed 0.83 bar at standard operating tempera-
ture
Minimum at engine rated speed 2.41 bar at standard operating tempera-
ture
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OIL FILTER SUPPORT

Relief valve, operating pressure 3.8--4.1 bar
Flow rate 68.1--75.7 l/min.
ENGINE OILS AND CHANGE INTERVALS

Refer to Operator’s Manual
Model litres
6 CYL 23.0
GREASE AND SEALANTS

Code Number Name
A NEW HOLLAND Grease
NLG/2
B ESF--M1C43--A Grease--silicone with light consistency
C 82995768 Sealant--Anaerobic Low strength (Loctiter 565)
D and J 82995776 Sealant--Silicone
E and F 82995774 Sealant--Polyester Urethane
G 82995773 Sealant--Anaerobic (Loctiter 565)
K 82995772 Thread and Stud Lock(Loctiter 565)
L 82995771 Flexible Gasket Sealant
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THERMOSTAT
Opening temperature 79--83_C
Fully open 93--96_C
RADIATOR CAP
Opening pressure 1.0 bar
WATER PUMP
Type Centrifugal
Transmission Poly V--belt,
with 8 ribs
FAN BELT
Belt tension kept by automatic idler
COOLING SYSTEM CAPACITIES

See Operator’s Manual
COOLING FLUID
Content: mixture -- water 50%, NEW HOLLAND 50% Antifreeze
(NEW HOLLAND antifreeze specifications)
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TIGHTENING TORQUES Nm
Main bearing bolts 81 + 90_
Connecting rod bolts 149
Cylinder head bolts (with engine cold) 55--95+90_
Cylinder head through rocker shaft bolts As above +45_
Intake manifold--to--cylinder head 35
Exhaust manifold--to--cylinder head 61
Exhaust pipe--to--flange 31
Flywheel to crankshaft 197
Oil pan drain plug 41
Valve rocker cover bolts 24
Crankshaft pulley to crankshaft 224
Self--locking screw -- valve rocker arm 24
Injector fastening bolts 23
Cover bolts (oil drilling protection) 31
Oil pump to block 23
Water pump to cylinder block 35
Water pump cover--to--pump 27
Oil pan to cylinder block 44
Injection line nuts 27
Unload tube pivoting bushing connection bolts 6
Injection pump--to--front cover 24
Camshaft idler drive gear--to--block 237
Front cover--to--cylinder block 24
Thermostat housing bolts 24
Camshaft gear bolt 69
Camshaft rear gear plate bolts 47
Oil filter adaptor bolts 42
Oil filter mounting bolt insert 34
Starting motor--to--rear adaptor plate 31
Injection pump--to--gear nut 92
Oil pressure switch assembly 31
Turbocharger--to--exhaust manifold nut 44
Fan blade to viscous unit 27
Viscous unit to pulley 54
Crankshaft rear oil seal retainer 20
Belt tensioner pulley bolt 54
Temperature sender 20
Tensioner to water pump bolt 54
Tensioner pulley blt 54
Pump connector to block 27
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The following general nut and bolt installation torque

requirements (lubricated) apply to any operation not
previously listed.
INCH SERIES Nm
1/ -- 20 11
4
1/ -- 28 11
4
5/ --18 19
16
5/ --24 23
16
3/ -- 16 31
4
3/ -- 24 45
4
7/ --14 65
16
7/ --20 75
16
1/ -- 13 88
2
1/ -- 20 102
2
9/ --18 122
16
5/ --18 187
6
CYLINDER BLOCK PLUGS
1/ -- 27 NPT 11
4
1/ -- 18 NPT 29.8
4
3/ -- 18 NPT 38
4
3/ -- 14 NPT 27
4
SPECIAL TOOLS
605
10 mm
11
Fuel Injection Pump Drive Gear Puller
(Local manufacture or Special Tool No. 38 0000 323)
1. Bolt 5/16--UNFx51 mm with integral washer (3 bolts required)
2. Bolt 3/4x16--UNCx251 mm
3. Three holes 9.5--mm dia. on 56.87 mm--dia.
equally spaced material of 10 mm plate HRLC P&O Steel
(Prior Tool Numbers, where applicable, shown in brackets)
604.64.961.00 - 04 - 2003
Description Tool number

code
Engine sling hook, 38 0000 216
(use with brackets 50075 and 50076)
Engine revolving stand 38 0000 301
Engine overhaul brackets kit 38 0000 313
Cylinder pressure test kit 295039 e
38 0000 303
Lube pressure check kit 292870
Piston ring pliers 38 0000 324
Piston install band 38 0000 325
Crankshaft rear seal installer 38 0000 332
Crankshaft front seal installer 297670
Crankshaft front seal puller 297637/1
Valve guide set reamers 38 0000 319
Valve spring compressor 38 0000 302
Water pump impeller seal installer 295007
Injector -- hand pump tester 290284
Injector -- cleaning kit 38 0000 254
Injector -- splitting block 38 0000 308
Injector -- Splitting socket kit 38 0000 309
Injection pump drive gear puller 38 0000 322
Adjustable bridge puller 38 0000 329
Shaft protector 297107
Step plate adaptors --
Bushing kit --
Con rod bush -- remove/install tool 134--00002
Camshaft bearing installer 38 0000 331
Handle (for camshaft bearing installer) 291896
Crankshaft Timing Pin 38 0000 172
Fuel Injection Pump Timing Pin 38 0000 318
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FAULT FINDING
IMPORTANT: Whenever effecting a repair, the cause

of the fault must be identified and corrected to avoid
repeated failures.
The following table lists problems and their possible
causes with recommended remedial action.
PROBLEM POSSIBLE CAUSES CORRECTION
Engine does not develop 1. Clogged air cleaner 1. Clean or renew element
full power
2. Fuel line obstructed 2. Clean
3. Faulty injectors 3. Clean and reset
4. Incorrect valve clearance 4. Check and reset
adjustment
5. Burnt, worn or sticking valves 5. Replace valves with new or
oversized, and/or machine the
valve guide bores
6. Blown head gasket 6. Check head flatness and fit new
gasket
7. Incorrect fuel delivery 7. Check injectors and pump
8. Low cylinder compression 8. Renew piston rings or
re--bore/re--sleeve as necessary
Oil pressure warning 1. Bulb burnt out 1. Renew bulb
light fails to operate
2. Warning Light pressure switch 2. Renew pressure switch
faulty
3. Warning light circuit faulty 3. Check and renew wiring
Excessive exhaust 1. Oil leak on compressor or turbine 1. Overhaul the turbocharger
smoke side of turbocharger, where fitted
2. Exhaust leak on exhaust manifold 2. Fit new gasket
side of turbocharger, where fitted
3. Air cleaner dirty or restricted 3. Clean
4. Excessive fuel delivery 4. Overhaul injection pump and
injectors
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Engine knocks 1. Diluted or thin oil 1. Check crankshaft bearings for
damage, change as required.
Drain and refill with specified oil
and renew filter. Ascertain cause
of dilution
2. Insufficient oil supply 2. Check oil level and top up as
necessary. Overhaul or renew
pump as necessary. Check oil
filter is not clogged
3. Low oil pressure 3. Overhaul pump or relief valve as
necessary
4. Excessive crankshaft end play 4. Install new thrust bearing liner
5. Excessive flywheel or ring gear 5. Shim flywheel or fit new ring gear
run--out
6. Excessive connecting rod or main 6. Install new bearing inserts and/or
bearing clearance re--grind crankshaft
7. Bent or twisted connecting rods 7. Renew connecting rods
8. Crankshaft journals out-- 8. Re--grind crankshaft and fit
of--round undersized bearing inserts
9. Excessive piston--to--cylinder 9. Re--bore/re--sleeve block and fit
bore clearance new pistons
10. Excessive piston ring clearance 10. Fit new pistons and rings
11. Broken rings 11. Fit new rings, check bore and
pistons for damage
12. Excessive piston pin clearance 12. Fit new piston or pin
13. Piston pin retainer loose or 13. Install new retainer, and check
missing bore/pistons for damage
14. Excessive camshaft play 14. Install new thrust plate
15. Imperfections on timing gear 15. Renew timing gear
teeth
16. Excessive timing gear backlash 16. Check and adjust backlash
/renew timing gear
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Engine overheats 1. Hose connection leaking or 1. Tighten hose connection, renew
collapsed hose if damaged
2. Radiator cap defective or not 2. Renew radiator cap
sealing
3. Radiator leakage 3. Repair/renew radiator
4. Improper fan belt adjustment 4. Re--adjust fan belt
5. Radiator fins restricted 5. Clean with compressed air
6. Faulty thermostat 6. Renew thermostat
7. Internal engine leakage 7. Check for source of leakage,
renew gasket or defective parts
8. Water pump faulty 8. Overhaul water pump
9. Exhaust gas leakage into cooling 9. Renew cylinder head gasket,
system check head for damage or
distortion
10. Coolant aeration 10. Tighten all connections and
check coolant level is correct.
Ensure cylinder head gasket has
not blown
11. Cylinder head gasket improperly 11. Renew cylinder head gasket
installed
12. Hot spots due to rust and scale 12. Reverse flush entire cooling
or clogged water jackets system
13. Obstruction to radiator air flow 13. Remove the obstruction
14. Extended engine idling 14. Do not allow engine to idle for
long periods
15. Oil cooler tube blocked 15. Clean
16. Radiator core tubes blocked 16. Check free flow
Water temperature gauge 1. Faulty temperature sender 1. Renew sender switch
fails to reach normal op-
op
erating temperature 2. Incorrect or faulty thermostat 2. Renew thermostat
3. Faulty water temperature gauge 3. Renew temperature gauge
604.64.961.00 - 04 - 2003

Low oil pressure 1. Engine oil level low 1. Top up, as necessary
2. Wrong grade of oil 2. Drain and refill with correct grade
of oil
3. Blocked oil pump sump screen 3. Clean pump screen
4. Oil pressure relief valve faulty 4. Fit new relief valve
5. Oil pump worn 5. Renew oil pump
6. Excessive oil pump rotor and 6. Overhaul pump
shaft assembly clearance
7. Excessive main or connecting rod 7. Install new bearing inserts and /
bearing clearance or re--grind crankshaft if
necessary
Excessive oil consump- 1. Engine oil level too high 1. Reduce oil level
tion
2. External oil leaks 2. Replace the seals, if required.
Check mating surfaces for
damage or distortion
3. Worn valves, valve guides or 3. Replace
bores
4. Cylinder head gasket leaking 4. Renew gasket.Check head for
damage or distortion
5. Oil leaking through the pistons 5. Renew rings and/or rebore/
and rings re--sleeve block as necessary
6. Oil cooler leak 6. Repair/renew oil cooler assembly
Engine tends to keep fir- 1. Air cleaner dirty or restricted 1. Clean or renew element
ing after fuel is shut off
2. Oil leak on compressor side of 2. Overhaul the turbocharger
turbocharger, where fitted
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DESCRIPTION AND OPERATION
12
The 7.5 litre engine is a 6--cylinder turbocharged and CYLINDER BLOCK ASSEMBLY
aftercooled, having a bore of 111.8 mm and a stroke The cylinder block is an alloy cast iron with deep cylin-
of 127 mm, which generates a displacement of 7.5 der skirts and water jackets for cooling the cylinders.
litres. The cylinder bores are machined integral with the cyl-
The engine uses a mechanical or electronically con- inder block, during the manufacturing process.
trolled in--line injection pump depending on model Cylinders are in line and vertical and numbered 1 to
and has been designed to meet current emission re- 6 from the front to the rear of the engine. They can be
gulations and must only be serviced by an authorised bored oversize for the fitment of sleeves, which are
service agent. For a detailed Description and Oper- available in service.
ation of the fuel system reference must be made to
the Fuel System Chapter in this Section of the man- The oil pan is the reservoir for the engine oil lubrica-
ual. tion system and a cast iron front cover on the front of
the engine covers the timing gear assembly.
All engines feature cross flow cylinder heads, with the
inlet and exhaust manifolds on opposite sides of the
cylinder head. The fuel and air combustion process
takes place in the specially designed bowl in the
crown of the pistons.
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CYLINDER HEAD ASSEMBLY

The cylinder head incorporates an inlet and exhaust
valve per cylinder with the valve rocker arm shaft as-
sembly bolted to the cylinder block through the cylin-
der head. Cylinder head retaining bolts are evenly
spaced with a six--point pattern around each cylinder,
this ensures an even clamping load across the cylin-
der head area.
The intake and exhaust manifolds are bolted to the
head, the intake manifold is mounted on the right
hand side of the engine, with the diesel injectors
mounted outside the rocker cover. The exhaust mani-
fold is mounted on the left hand side of the engine.
Water outlet connections and thermostats are at- 13
tached to the front of the cylinder block.
Valve guides are integral in the cylinder head, and
valves with oversized stems are available in service.
Special replaceable sintered iron valve seats are
pressed into each valve port during manufacture and
oversized valve seats are also available in service.
All valves are fitted with positive valve rotators and
valve stem oil seals. Valve clearance is maintained by
adjustment of the self--locking adjusting screw,
mounted in each of the rocker arms.
CAMSHAFT ASSEMBLY
The camshaft runs in 5 replaceable bearings. The
camshaft drive gear is in mesh with and driven by the
camshaft idler gear, which is driven by the crankshaft
timing gear.
Camshaft end thrust is controlled by a thrust plate
bolted to the block, and located between the cam-
shaft gear and the front camshaft journal.
A helical gear is mounted on the rear of the camshaft
and drives the engine oil lubrication pump mounted
in front of the flywheel.
396--E--16 TI
14
CRANKSHAFT ASSEMBLY
The crankshaft is supported in the cylinder block by
7 main bearings.
The crankshaft is manufactured from steel with ma-
chine--finished crank webs.
End thrust is controlled by a thrust bearing incorpo-
rated in the centre main bearing of the crankshaft.
An external damper is fitted to the crankshaft pulley
to ensure smooth running operation. Front and rear
crankshaft oil sealing is effected by cassette type
seals that are designed for long and durable service
life.
15
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CONNECTING RODS
Connecting rods ‘‘Teepee” (wedge) shaped at the
small end have been designed to reduce the recipro-
cating weight at the piston end. The connecting rods
are of a heavy beam construction and are assembled
as a matched set to each engine.
They are retained in position by the connecting rod
big end cap and secured by two bolts per rod. The
small end of the connecting rod is fitted with a re-
placeable bronze bushing, through which the free
floating piston pin is fitted. The steel pin is being held
in place within the piston by two snap rings.
16
PISTONS
Pistons are constructed of an aluminium silicon alloy
with an iron insert for the top ring. The combustion
chamber is recessed into the piston crown.
Each piston has two compression rings and one oil
control ring, to reduce friction and increase positive
sealing. All rings are located above the piston pin.
A Engines with electronically--controlled injec-
tion pump
B Engines with mechanically--controlled injec-
tion pump
MANIFOLDS 17
The cross flow design aluminium intake and cast iron
exhaust manifolds are on opposite sides of the cylin-
der head. This is designed to maintain balanced heat
distribution within the cylinder head. The configur-
ation of the manifolds also ensures minimum heat
transfer to the intake manifold.
A grid heater is fitted to the intake manifold to assist
in cold starting of the engine when coolant water tem-
perature is below 30_C.
TIMING GEARS
18
The crankshaft timing gear is heated and press--fitted
4 1
on the front of the crankshaft, to a high degree of accu-
racy during manufacturing. This enables precise tim-
ing being maintained during the life of the engine. The
crankshaft gear (2) drives the idler gear (3), which is
attached to the front of the cylinder block. The idler . ..
gear then drives the camshaft gear (1) and the injec-
tion pump gear (4).
The camshaft gear is bolted to the front of the cam- ..
shaft and is keyed to maintain position of the gear on
the camshaft. 2
3
P396--E--36
19
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LUBRICATION SYSTEM
20
Engine lubrication system
The engine lubrication, fig. 20, is maintained by a

rotor type oil pump mounted in the rear of the engine
block, in front of the flywheel on the left hand side of
the engine.
TA6010058
21
The oil pump is driven from the rear of the camshaft
and draws oil from the engine oil pan through a tube
and screen assembly.
22
604.64.961.00 - 04 - 2003
A spring loaded relief valve is integral with the dummy

oil filter head mounted on the left hand side of the en-
gine block and prevents over--pressurisation of the
system.
396--E--18 TI
23
The spin--on type oil filter is mounted at the rear of the

engine.
24
Oil flows from the filter to the main oil gallery, which
runs the length of the cylinder block and also inter-
sects the camshaft follower chamber.
The main gallery supplies oil to the crankshaft main
bearings, connecting rods and both big and small
ends. The underside of the pistons and pins is lubri-
cated by oil pressure jets mounted adjacent to each
main journal housing.
The camshaft drive gear bushing is pressure--lubri-
cated through a drilled passage from the front main
bearing. The gear has small oil passages machined
on both sides, allowing excess oil to escape.
396--E--26 T
25
An intermittent flow of oil is directed to the valve
rocker arm shaft assembly via a drilled passage in the 1
cylinder block. This is located vertically above cam-
shaft bushing (1) and aligns to a hole in the cylinder
head. The rotation of the camshaft allows a controlled
intermediate flow of lubrication.
396--E--16 TI
26
604.64.961.00 - 04 - 2003
Timing gears are lubricated by splashed oil from the

cam follower chamber and the camshaft drive gear
bushing is pressure--lubricated.
P396--E--36
27
The turbocharger is supplied with oil from the oil filter

support housing (1), mounted on the left side of the
engine.
28
The fuel injection pump is pressure--lubricated from
a port (1) on the right side of the engine block.
The fuel pump is either electronically--controlled
using an electronic control unit
29
or
mechanically--controlled, depending on model.
30
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ENGINE OVERHAUL -- INTRODUCTION
In the following procedures and illustrations the en- refer to the ”Engine Fault Codes” chapter in the sec-
gine is shown removed from the vehicle; however, tion of the electrical system of the manual.
there are certain operations that can be performed
with the engine installed. Operations or repairs that can be performed
Where it is necessary to remove the engine, use a with the engine still in the vehicle.
suitable hoist or overhead gantry and standard engin- 1. Front timing cover, pump drive gear and idler
eering procedures. Removal of the engine is de- gear. Removal of engine is required in order to re-
scribed in Chapter 3, Section 10 of this manual. move and replace the camshaft timing gear.
Dismantle the engine following conventional tech- 2. Front pulley and damper assembly.
niques and by referring to the appropriate overhaul
3. Cylinder head and associated inlet and exhaust
sections of this chapter. Always refer to the specifica-
components.
tion section as necessary.
4. Fuel injection pump removal and timing.
NOTE: All gaskets, seals and ‘O’ rings must be re-
placed during re--assembly. Where new sealant is to 5. Water pump, thermostat and associated compo-
be applied refer to ‘‘Engine Specifications”. nents.
For concerns relating to the fuel system refer to the 6. Oil pump relief valve.
fuel system Chapter in this manual. On engines fitted 7. Turbocharger.
with the electronically--controlled fuel injection pump,
604.64.961.00 - 04 - 2003
INJECTION PUMP TIMING CHECK
If a fuel related concern is identified check the injec-

tion pump timing before proceeding with any other
disassembly.
1. Remove engine drive belts.
31
2. Remove injection pump timing cover.
32
3. Using a 29 mm socket rotate crankshaft to top
dead centre (TDC) with number 1 cylinder firing.
33
4. When engine is at TDC the threaded hole in the
injection pump drive flange aligns with the pump
timing plate.
34
604.64.961.00 - 04 - 2003
5. To ensure the crankshaft is accurately positioned

at TDC remove the crankshaft timing plug (1),
from the side of the engine block.
IMPORTANT: DO NOT TOUCH the bushing (2) of
the timing pin. This bushing has been precision--set
during its original positioning. If the bushing is moved,
the pump timing CANNOT be accurately set.
35
6. Insert the crankshaft timing pin 38 0000 172 into
the side of the block.
36
7. If required, gently turn the crankshaft to engage
the rounded end of the timing pin in the slot of the
crankshaft. This is not visible and must be per-
formed by ”feel”.
37
8. When the timing pin is located in the slot of the
crankshaft the pin is fully seated.
Do not attempt to rotate the crankshaft when tim-
ing pin is fully inserted as damage will occur.
38
604.64.961.00 - 04 - 2003
9. Check that the injection pump go/no--go timing

pin tool No. 38 0000 318 will screw into the pump
hub.
IMPORTANT: The engine must never be rotated
while the timing pin is installed.
10. If the pin engages in the pump timing plate (inset,
figure 40) when the crankshaft is at the TDC, the
pump timing is correct.
39
11. If pump timing is incorrect and timing pin can not
be screwed into pump, remove pump timing gear,
install rigid timing pin no. 38 0000 318 into pump
and refit timing gear.
40
NOTE: This injection pump timing check assumes
that the crankshaft and camshaft timing gears were
correctly positioned during engine assembly. To
check the position of these timing gears it is necess-
ary to remove the engine front cover.
604.64.961.00 - 04 - 2003
ENGINE DISASSEMBLY AND

OVERHAUL:
COUPLED CYLINDER HEAD, VALVES AND

OTHER PARTS
Cylinder Head Removal

NOTE: The cylinder head can be removed with the
engine installed in the combine.
1. Drain the engine coolant by placing a suitable
container (3), below the coolant drain hose (2).
41
2. Coolant can be drained from the engine by the
drain valve (1) opening, located at the front bot-
tom of the radiator, on the engine side, facing the
machine running direction.
3. Remove all necessary hardware and compo-

nents in order to gain access to the cylinder head.
Refer to chapter 12--3 ”Remove and install, 7.5 l
engine” for further information.
4. Remove the fan belt.
42
604.64.961.00 - 04 - 2003
5. Clean the area surrounding the fuel injectors. Dis-

connect and remove injection lines (1) and leak--
off lines (2) from the fuel injectors and injection 1
pump. Cap all exposed openings.
2
43
6. Remove injectors from the cylinder head.
44
7. Remove the turbocharger assembly, ensuring all
openings are capped to prevent dirt inlet.
45
8. Remove the thermostat (1) and the water
pump (2).
46
604.64.961.00 - 04 - 2003
9. Remove the rocker cover and gasket.
47
10. Loosen the rocker shaft retaining bolts (which
also serve as head bolts) evenly and alternately
and remove the rocker shaft assembly.
48
NOTE: Leave bolts in the rocker shaft supports dur-
ing removal, as they retain the support on the shaft.
11. Remove pushrods in turn and place them in a
numbered rack to maintain the same position for
reassembly.
49
12. Remove remaining cylinder head bolts by work-
ing progressively from each end of the cylinder
head towards the centre.
13. Carefully lift the cylinder head assembly away
from the engine block.
50
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Cylinder Head Removal

1
1. Using a valve spring compressor, tool No. 38 0000
302 (1), remove the retainer locks (2) and place
them in a numbered rack.
2. Clean the cylinder head, and remove carbon de-
posits from around the valve heads.
TA6010011
51
52
Intake and exhaust valves
1. Retainers 7. Spring
2. Spring Retainer 8. Gasket
3. Gasket 9. Spring Rotator
4. Spring 10. Spring Rotator
5. Intake valve 11. Retainers
6. Exhaust valve
604.64.961.00 - 04 - 2003
Inspection and Repair, Cylinder Head

1. Replace cylinder head core plugs if discoloured
(rusty), or leaking. Before fitting new plugs re-
move all old sealant from the cylinder head. Apply
sealant (G) (see ”SPECIFICATIONS”), to the
new plug mating faces, and drive the new plugs
into location.
The core plugs fitted to the cylinder head are:--
6 off, in the top, and 1 off, in the rear of the cylinder
head.
5 off, in the intake face.
2. Scrape all gasket surfaces clean, wash cylinder TA6010008
head in a suitable solvent and clean valve guide
53
bores.
NOTE: Ensure injector washers have been removed
prior to cleaning.
3. Inspect cylinder head for nicks and burrs on mat-
ing face. Remove using a suitable abrasive and
ensure faces are clean after repair.
4. Using a straight edge and feeler gauges, check
that the flatness of the cylinder head in all direc-
tions does not exceed 0.03 mm in any 25.4 mm,
or 0.127 mm, overall limit. 2 3 4 5 6 6 7 8
5. If the cylinder head has been resurfaced, deter-
mine that all head bolt faces will seat by placing
the cylinder head without gasket on the cylinder
block and installing bolts hand--tight.
TA6010012
54
6. Ensure rocker shaft supports are fitted with long
bolts. Using a feeler gauge, check clearance be-
tween underside of bolt heads and cylinder head
or rocker shaft support.
7. If a 0.25--mm feeler gauge can be inserted under
the bolt head the bolt has bottomed. Therefore,
the cylinder block thread must be increased using
a 9/16--13 UNC--2A thread tap. Identify each
head bolt to ensure they are reinstalled in the bolt
holes they were checked in.
55
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Valve inserts
Counterbore in cylinder head
Insert oversize
Exhaust valve insert Intake valve seat insert
0.25 mm 44.17--44.20 mm 50.01--50.04 mm
0.58 mm 44.42--44.45 mm 50.27--50.29 mm
0.76 mm 44.68--44.70 mm 50.52--50.55 mm
NOTE: Refacing the valve seat should always be co--

ordinated with refacing of the valve to ensure a com-
pression--tight fit.
1. Examine the valve seat inserts and reface if
pitted, renew if loose or damaged.
2. To install new valve inserts, the cylinder head
must be counter--bored, as described in the
above chart. The new inserts must be chilled in
dry ice prior to installation.
Valve seat specifications, fig. 56.
1. Valve seat angle
3
Intake 30.0_--30.30_ 1
Exhaust 45.0_--45.30_
2. Valve seat width
Intake 1.9--2.4 mm
Exhaust 1.8--2.3 mm
3. Valve Head Face to Cylinder Head Face Depth
Intake 0.89--1.29 mm
Exhaust 1.2--1.6 mm
NOTE: In production, sometimes, valve inserts are 2
fitted with diameter oversized by 0.25 mm and 0.5
mm. Cylinder heads with oversized inserts are TA6010013
stamped so10/os, so20/os, on the exhaust manifold 56
side in line with the valve seat concerned.
3. Check the width of the valve seat inserts, and as
required reface by grinding to dimensions de-
tailed above.
4. Measure the concentricity of valve seats, using a
dial gauge; measure concentricity of seat to the
valve guide bore.
Total indicator reading should not exceed 0.051
mm, fig. 57.
57
604.64.961.00 - 04 - 2003
5. Use a seat cutter to correct any seat eccentricity,

or clean up of pits and grooves. Ensure after any
rework that seat width is within specified limits.
6. Rotate a new or refaced valve in the seat using
engineering blue, ensure all the blue is trans-
ferred to the valve head protrusion. If any blue re-
mains below or around the seat raise or lower the
seat accordingly, fig. 58, proceeding as follows.
7. Lower the valve seat (1), fig. 58, and remove
some material from the seat upper part. To this
purpose, use a 30_ grinding wheel for exhaust
valves and a 15_ grinding wheel for intake valves.
8. Lift the valve seat (2) fig. 58, by removing some TA6010016
material from the bottom of the seat. To this pur- 58
pose, use a 60_ grinding wheel for exhaust valves
and a 45_ grinding wheel for intake valves.
Critical valve points, fig. 59:
1. Valve Land Edge
2. Valve Head
3. Valve Face Angle
4. Valve Face
5. Valve Stem
6. Valve Tip
Valve Guides
1. Using a telescopic gauge and micrometer,
measure the valve guide bore clearance, and en-
sure it does not exceed 0.114 mm on the intake
valve stem and 0.140 mm on the exhaust valve 59
stem, fig. 60.
NOTE: Production cylinder heads may have one or
more machined, oversized valve guide bores, or
valves installed, (0.38 mm). These cylinder heads
show the initials 15 or V015OS printed on the exhaust
manifold of the cylinder head next to the concerned
one.
2. Using reamer set, 38 0000 319, ream out the
valve stem guide, with three reamer and pilot
combinations as follows:
when going from a standard valve stem to an
oversized one, always use reamers in sequence
0.38 mm oversized reamer and 0.076 mm over-
sized pilot. TA6010018
60
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Valve Springs
1. Checked on a flat surface squareness, should not
exceed 1.52 mm between the square and spring
at the top edge, fig. 61.
Length of valve springs should be checked on
both free length and loaded length.
Free length = 60.7 mm
Installed length = 47--49.6 mm
Loaded length = 48.26 mm using a weight of
28--31 kg
Loaded length = 35.69 mm using a weight of
61--69 kg.
Ensure the valve spring retainer locks are in good 61
condition, and replace if worn or damaged.
Rocker Shaft Inspection and Reassembly
1 2 3
1. Separate rocker shaft assembly by removing the
cylinder head bolts (3) and withdraw the sup-
ports (2), springs (1), rockers (4) and spacers (6).
2. Clean all components using an approved clean-
ing solution and make sure all oil passages are
clear.
3. Inspect rocker arm adjusting screws, and push
rod ends of the rocker arm, including the ball end
of the screws for nicks, damage or excessive
wear.
4. Inspect the inside diameter of the rocker arm for 6 5 4
damage or wear. If any of these characteristics TA6010010
are not to specification, replace with new parts. 62
5. Check the ends of the push rods for damage or
wear. If not to specification or push rods were
found not to be straight during dismantling, install
new rods.
NOTE: Do not attempt to straighten bent push rods,
replace with new.
6. Check the rocker shaft for signs of wear or dam-
age on internal and external diameters, respect-
ively.
7. Re--assemble the rocker shaft components onto
the shaft ensuring the shaft identification
groove (1) is positioned forwards and upwards.
This ensures oil grooves and holes face down-
wards. 63
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Cylinder Head Re--assembly

1. Insert the valves into the guide bores from which
they were removed and lap with a suitable paste.
Ensure all traces of paste is removed after lap-
ping.
NOTE: Lubricate all components with clean engine
oil on re-assembly.
2. Use a spring compressor to reassemble the
valves, valve springs, retainers, rotators and
collets, and install new valve stem gaskets.
TA6010011
64
3. Install new gasket and lower cylinder head into
place while ensuring the gasket remains in posi-
tion.
4. Loosely position all cylinder head bolts except
those which retain the rocker shaft assembly.
NOTE: Cylinder head bolts may only be removed and
refitted four times, after which they must be replaced
with new parts.
65
5. Install rocker push rods in cylinder head and lo-
cate rocker shaft assembly onto cylinder head
using the longer cylinder head bolts.
66
6. Tighten the cylinder head bolts in sequence, pro-
gressively, in the following stages, fig. 67.
NOTE: Lightly lubricate the bolts prior to assembly,
and tighten to the torque specification, with the en-
gine cold.
67
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Stage 1, all bolts, 55 Nm.
68
Stage 2, all bolts, 95 Nm.
69
Stage 3, all bolts, a further 90_ using a torque angle
gauge, fig. 70.
70
Stage 4, rocker shaft securing bolts only, tighten
a further 45_, fig. 72, using a torque angle gauge. Se-
24 16 8 2 10 18 26
quentially, (2), (8), (10), (16), (18), (24), (26).
71
604.64.961.00 - 04 - 2003
Stage 4, rocker shaft bolts.
45_
72
7. Adjust valve clearance setting with each piston in
turn, at TDC, and rockers free to move, fig. 73.
Intake valve clearance,
0.36--0.46 mm
Exhaust valve clearance,
0.43--0.53 mm
NOTE: Valve clearance is to be set only when the en-
gine is cold.
8. Install the injectors with new seat washers, cork
seals, and torque to 23 Nm, fig. 74.
73
9. Install the injector lines and torque to 24 Nm. In-
stall the leak--off line with new washers, and
torque the leak--off banjo bolts to 6 Nm.
NOTE: Hold the leak--off plastic line when tightening
to prevent the pipes from pivoting, during torque up.
10. Exhaust manifold bolts are to be refitted and tigh-
tened to a torque of 38 Nm.
11. Intake manifold bolts are to be refitted and tigh-
tened to a torque of 38 Nm.
74
12. Using new gaskets install intake and exhaust
manifolds. Initially install all bolts finger--tight en-
suring the gaskets are aligned with the intake and
exhaust ports.
13. Tighten the bolts to a torque of 61 Nm working from
the central bolts outwards.
14. Re--tighten the bolts to a torque of 61 Nm.
NOTE: When the manifold bolts are torqued, the
gaskets may show signs of distortion between the in-
take and exhaust ports. This is normal for this type of
gaskets and is the reason for the retorquing pro-
cedure.
75
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ENGINE FRONT COVER AND TIMING

GEARS
Timing Gears Checking and Removal
IMPORTANT: If the injection pump timing has been
checked, ensure the timing pins 38 0000 318 and 38
0000 172 have been removed before proceeding.
Refer to ”Injection Pump Timing Check”, earlier in this
chapter.
TA6010027
76
1. Using a puller, 38 0000 329 and a shaft guard
297107, remove the crankshaft damper.
2. Remove the front cover plate.
3. When the engine timing has been checked (as
described in ”Injection Pump Timing Check”
earlier in this chapter) the timing marks (dots) on
the crankshaft and camshaft timing gears align.
77
1. Camshaft gear
4 1
2. Crankshaft timing gear
3. Camshaft idler gear
4. Injection pump drive gear
NOTE: The crankshaft timing gear (2) should not be .
removed. The gear is heat shrunk on to the crank- ..
shaft and aligned to the crankshaft No. 1 pin, to
0.10--mm clearance. If the gear is damaged, a new
crankshaft is required. ..
3 2
P396--E--36
78
4. Before removing the timing gears perform the fol-
lowing checks:
use a dial indicator or feeler gauge, fig. 79, to
measure the backlash between each set of bear-
ings.
Rotate the gears and check the backlash at four
equal points on the gears. Renew if the backlash
exceeds the following values:
Crankshaft to camshaft idler gear 0.1--0.36 mm
Camshaft to camshaft idler gear 0.1--0.36 mm
Fuel injection pump to camshaft idler gear
0.10--0.48 mm TA6010029
79
604.64.961.00 - 04 - 2003
5. Check camshaft gear end float as follows:

pry the camshaft gear using a lever, away from
thrust plate. Using a dial indicator or feeler gauge,
check the clearance.
P396--E--28 TI
80
If clearance is outside 0.05--1.8 mm limit, fit a new
camshaft thrust plate, item 1, fig. 81.
NOTE: The camshaft gear is interference--fit with the 1
camshaft and removal requires a three legged puller.
It is recommended that this gear is only removed
when necessary and during a total engine rebuild.
This will enable both the gear and camshaft to be re-
moved from the front of the engine.
396--E--45 TI
81
6. Check idler gear end float using similar procedure
described for the camshaft gear. If outside limits
of 0.073--0.35 mm, fit a new idler gear wear
plate (1).
82
7. To remove the fuel pump drive gear remove the
4 retaining bolts.
..
1
..
P396--E--36 TI
83
604.64.961.00 - 04 - 2003
8. If required the timing gear rear cover plate may

now be removed. Remove the six retaining bolts
and carefully pry the cover from the engine block.
When replacing the cover tighten retaining bolts
to a torque of 24 Nm.
84
Inspection and repair of gears
1. Wash the gears using a suitable solvent, and
examine gear teeth for wear, burrs, or scratches.
Minor marks can be removed using a fine abras-
ive, thoroughly clean before re--assembly.
2. Ensure the camshaft idler gear adaptor is free
from obstruction and bushing is not damaged.
Camshaft key and key--way should be checked
for damage and repaired as required.
TI
85
Installation
1. Position piston no. 1 at TDC and install timing pin
38 0000 172.
86
2. Ensure the timing marks on the pump are aligned
and screw the rigid timing pin 38 0000 318
through the pump flange and timing plate.
87
604.64.961.00 - 04 - 2003
3. If the pump has been removed during engine

overhaul, refit pump onto engine.
88
4. Install timing gears ensuring the timing marks on
the crankshaft, idler and camshaft gears align.
5. Fit the pump drive gear and remove pump timing
pin.
6. Torque bolts as follows.
Camshaft gear 69 Nm ..
Idler gear 204--279 Nm
Pump drive gear 38 Nm. ..
P396--E--36 TI
89
7. Remove crankshaft timing pin and install plug.
90
8. Position gasket on the front cover plate.
9. Install the front cover, ensuring alignment with
dowel pins. Tighten the retaining bolts in the 1--4
sequence shown to a torque of 34--41 Nm.
10. Install the oil pan as described on the following
page.
11. Install new front crankshaft oil seal as described
in ”Front Crankshaft Cassette Oil Seal Replace-
ment” later in this chapter.
91
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OIL PAN
Removal
1. Remove engine as described in the engine re-
moval chapter in this section of the manual.
2. Drain engine oil through oil pan drain plug and re-
move the dipstick.
3. Remove oil pan bolts and lower pan to the
ground.
Checking and adjusting

1. Clean gasket material from sump face, clean 92
sump in a suitable solvent, inspect sump for
cracks, damaged threads or damaged sump
face.
Reassemble
1. Installation is the reverse of removal but with the
following requirements.
2. Ensure block face is clean and free of gasket ma-
terial.
+0.15
NOTE: Before installing the oilpan ensurethat therear
- 0.22
oil seal carrier (2) is correctly aligned with the block (1),
i.e. less than 0.15--mm protruded or 0.22--mm re-
cessed.
93
3. Apply gasket sealant 82995770 (Loctiter 518) to
the areas shown and install a new gasket on the
oil pan.
94
4. Position the oil pan and install a bolt finger--tight
at each corner. Install remaining bolts and torque
to 44 Nm.
604.64.961.00 - 04 - 2003
FLYWHEEL
Removal
1. To gain access to the flywheel remove the engine.
2. Prior to removing flywheel use a dial indicator to
measure flywheel run--out. The maximum total
indicator reading should be 0.127 mm. If not to
specification, check crankshaft--to--flywheel
seating.
TA6010053
95
3. Support flywheel, remove retaining bolts and
separate flywheel from crankshaft.
96
Checking and adjusting
1. Inspect the flywheel ring gear, and if damaged
renew in the following manner:
2. cut old ring gear free from the flywheel.
3. Clean the mating surfaces of the new ring gear
and flywheel.
4. Use temperature indicating crayons to mark the
side face of the ring gear in six equal places, mark
with a 204_C (400_F) crayon at a point 13 mm
below the root of the teeth, and mark with a
212_C (450_F) crayon at a point just below root
of the teeth.
5. Use an oxy--acetylene torch with a tip size no.2
97
maximum, and direct the flame against the inter-
nal face of the gear.
6. Quickly place the hot gear on the flywheel, with
flat face against the shoulder on the flywheel. The
gear--to--flywheel runout should be checked
using a dial gauge and should not exceed a total
indicator reading of 0.63 mm.
Installation
1. Clean the crankshaft rear flange and mating sur-
face of the flywheel. Install the flywheel, torquing
the bolts to 197 Nm (145 ft. lb.)
604.64.961.00 - 04 - 2003
REAR COVER PLATE

Removal 1
1. To gain access to the engine oil pump, camshaft 11 9
gear or end of crankshaft remove the oil pan and 2 5
flywheel as previously described. 3
2. Remove the 12 attaching bolts, and gently pry off
cover plate (1). 4
3. Clean off all sealant, remove crankshaft oil seal,
and check for damage or distortion around the 6 1
8
sealing faces.
10 12
P396--E--54 TI
98
Installation
1. Install new gasket and rear plate, tightening the 1
retaining bolts (2) and (3) finger--tight, fig. 98.
2. Apply a thick film of new engine oil on a new oil
seal and position the rear seal over the end of the
crankshaft. Locate tool no. 38 0000 332 (1),
fig. 99, on the end of the crankshaft using the
three attaching bolts. Tighten evenly, and square-
ly, until the seal is fully seated.
As an alternative, the rear crankshaft oil seal can be
installed using the following installation tool.
TA6010054
99
3. Apply a thick film of clean engine oil to the rear
seal retainer, seal and journal. A new seal should 1
be mounted on the crankshaft, then bolt tool 38
0000 332 (1) fig. 100, to the crankshaft end and
install the new seal squarely.
4. Secure centre stock of tool to crankshaft flange
with two screws. Assemble cylinder end plate to
centre stock and secure with nut and washer as
shown in fig. 100. Tighten the nut until outer di-
ameter of tool abuts retainer. Tool must not be
over tightened as stress and distortion could be
imposed on the retainer.
TA6010055
100
5. Remove the tool after assembly.
NOTE: The first seal replacement should be pushed
into retainer with plain end of tool and subsequent
seals with stepped end of tool which will reposition
seal 1.52 mm further in.
TA6010056
101
604.64.961.00 - 04 - 2003
6. Place a straight edge along the rear of the engine

block above the seal carrier. Ensure the edge of
the carrier is aligned to the block to within
0.15--mm, protruded or 0.22--mm recessed. If not
within specifications, orientate the carrier around
the slotted bolts (2 and 3), fig. 98. Hand tighten +0.15
this bolt followed by the remaining bolts and en- - 0.22
sure the carrier is still correctly aligned. Fully
tighten the twelve bolts, in sequence to 11--14 Nm
and then 16--23 Nm, fig. 98.
102
7. Place a dial gauge on the end of the crankshaft
and ensure seal runout is within 0.51 mm of the
total indicator reading.
8. Refit the oil pan.
TA6010056
103
OIL PUMP
Removal
NOTE: The oil pump can only be removed with the
engine split from the transmission and the flywheel,
back plate, engine oil pan and oil pump tube re-
moved.
1. Prior to pump removal check pump gear to cam-
shaft gear backlash does not exceed, 0.40--0.56
mm.
TA6010057
104
2. Loosen and remove the camshaft gear, to expose
the oil pump, detach the 3 pump mounting bolts,
and withdraw the pump from the block.
TA6010058
105
604.64.961.00 - 04 - 2003
Disassembly
1. Loosen and remove the pump face plate to body
bolts (4). Disassemble the pump and discard the
O--rings.
Checking and repairing

TA6010059
106
1. Wash all parts in a suitable solvent and inspect in-
side of pump plate and body, for excessive wear
or damage. If visually okay, check in the following
manner.
2. Invert pump plate/rotor assembly, and place
outer rotor over inner rotor. Placing a ruler across
top of both, slide a feeler gauge, between ruler
and inner rotor and measure clearance which
must be 0.025--0.089 mm, fig. 107.
TA6010060
107
3. Place outer rotor in pump body and check clear-
ance, by inserting a feeler gauge between the
rotor and body. Check clearance does not exceed
a maximum of 0.55 mm. If exceeded, a new pump
is required.
NOTE: If not to specifications, replace the oil pump,
as reduced pump pressure through wear could result
in reduced engine life.
Assembly
TA6010061
108
1. Clean and coat parts in new engine oil. Place 1
outer rotor in pump body, and ensure free rota-
tion. Insert inner rotor, and pump plate assembly,
into the body and ensure that shaft is fully seated
into bushing.
2. Assemble the front plate to the body and torque
the retaining bolts to 23.0--28.4 Nm.
NOTE: After tightening, ensure the drive gear rotates
freely by hand, at least 5 revolutions, if not ”disas-
semble” and repeat the procedure.
2
TA6010059
109
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3. Fit a new O--ring (1), fig. 109, to the outlet tube,

lubricate and insert the pump into the block,
tightening the bolts to a torque of 23.0--28.4 Nm.
4. Fit a new O--ring (2), fig. 109, into the suction
port. Lubricate and insert tube/screen assembly
(2) into pump (1), through bottom of engine. Fit a
new gasket (4) and torque the attaching bolts (3),
fig. 111, to the torque of 27--34 Nm.
TA6010058
110
NOTE: Plug (5) fig. 111 is factory installed for an
easier machining and should not be removed during
the life of the engine. 1
5. Refit gears as previously described along with the
rear plate and flywheel.
5
2
4
3
TA6010062
111
OIL PRESSURE RELIEF VALVE
Removal
1. Remove the plug (3), the spring (2) and the valve
(1). To ensure correct operation of the pressure 3
relief valve, check spring length:
free length = 52.8 mm
compressed length = 37.0 mm using a weight of
15.6 kg.
2. Clean assembly in a suitable solvent and ensure
all ports are free of dirt. 3
3. Check the parts for damage, wear and replace as
necessary. Failure to do so could result in prema-
ture wear to the engine, due to oil bypassing the 1
filter and returning back to the system.
396--E--18 2 TI
Installation
1. Lubricate the pressure relief valve (1) and 112
spring (2), and insert into housing, ensuring free
movement.
Fit a new O--ring to plug (3) and torque to 55 Nm.
604.64.961.00 - 04 - 2003
CAMSHAFT
1
Removal
NOTE: The camshaft bearings and tappets can only
be serviced with engine removed from the vehicle.
1. Remove the engine front cover and cylinder
head.
2. Check the camshaft end play, see timing gears
section and remove gear; install a new thrust
plate prior to re--assembly, if required.
3. After removal of the flywheel and rear cover, re- TA6010057
move the camshaft oil pump drive gear (1). 113
4. Invert the engine on the stand, if camshaft bear-
ings are to be replaced, and remove the oil pan.
5. Carefully withdraw the camshaft from the front of
engine.
6. Lift out the tappets and place in a numbered rack
for reassembly.
396--E--16 TI
114
1. Inspect the camshaft journals and lobes, for dam-
age, pitting or heat discoloration. If any of these
conditions exist install a new camshaft.
2. Inspect the oil pump drive gear on camshaft for
broken or worn teeth, and mating gear on oil
pump. If any wear or damage is apparent fit new
gears.
3. Check each tappet for wear or damage; check di-
ameters and, if not to specifications, renew,
25.113--25.131 mm.
4. Measure the diameter and out--of--round condi-
396--E--23 TI
tion of bearing journals; if limits are exceeded, fit
a new camshaft, 60.642--60.668 mm. 115
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CAMSHAFT BEARINGS
1. Inspect the camshaft bearings for wear or dam-

age. Measure the clearance between the internal
diameter of bearing and outside diameter of re-
spective journal, 0.074--0.178 mm.
2. If specification is exceeded, install new bearings
using remover/replacer tool No. 38 0000 331 and
handle, Tool No. 291896.
3. To remove, position tool against bearing to be re-
moved and attach handle, driving bearing from
bore.
TA6010071
4. To install, align oil holes of new bearing with holes 116
in block, and drive bearing into bore using tools
as described.
NOTE: A positive alignment check can only be made
with crankshaft removed when a 4.6 mm rod can be
passed down the oil passage from the crankshaft
main bearing. Bearing is correctly positioned when
end of rod passes through oil hole in the bearing.
Installation
1. Apply petroleum jelly to each tappet foot and coat
tappet body with oil. Install tappets in bores from
which they were removed.
396--E--23 TI
117
2. Oil camshaft journals and apply petroleum jelly to
the cam lobes.
3. Install camshaft through front of engine.
396--E--16 TI
118
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4. Align the camshaft gear timing mark. Recheck

end play.
..
..
P396--E--36 TI
119
5. Install camshaft pump drive gear at rear of en-
gine. Tighten bolt to torque of 57--77 Nm.
120
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PISTONS
Removal
NOTE: The pistons, crankshaft and cylinder block
can only be serviced with the engine removed from
the vehicle.
1. Remove the oil pan.
2. With cylinder head removed, clean off any ridge
from the top of the cylinder bores, with a ridge re-
mover, to enable removal of the pistons; this is
essential if old pistons are to be re--used, as fail-
ure to do so could result in ring land damage.
121
3. With the piston at the bottom of the stroke remove
the end cap bolts, cap and liner.
TA6010033
122
4. Using the handle end of a hammer push the pis-
ton assembly out through the top of the block, and
remove the bearing liner from the connecting rod,
fig. 122.
NOTE: Bearing caps and liners must be kept with
their respective connecting rods.
5. Turn the crankshaft again and repeat the process
for the remaining pistons.
123
1. Remove piston pin snap rings from each side of
piston and remove pin. Using an expander, tool
no. 38 0000 324, remove the piston rings.
2. Ensure each piston and rod assembly remains
matched together for re--assembly into the cylin-
der block.
TA6010034
124
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125
Piston Assembly
1. Con rod 7. Piston ring (oil control)
2. Pistons 8. Bolt
3. Piston pin 9. Bearing cap
4. Lock 10. Bearing liner
5. Piston ring (compression) 11. Bearing liner
6. Piston ring (compression) 12. Bushing
3. Clean the piston and connecting rod assembly in Measure the outside diameter of the piston pin, and
a suitable solvent and inspect for damage to ring inside diameter of the connecting rod bushing, to the
lands, skirts or pin bosses. following values:
4. Check connecting rod components for damage,
and place in an alignment fixture to check for dis- Piston pin outside diameter
tortion; ensure that any distortion is within specifi- 44.442--44.447 mm
cation as follows.
Max. twist 0.30 mm Connecting rod bushing internal diameter
Max. bend 0.10 mm 44.460--44.467 mm
5. Check piston pin bushing for damage or wear in
the following manner.
604.64.961.00 - 04 - 2003
CONNECTING ROD BUSH

REPLACEMENT
1. If connecting rod bushes are not to specification
replace the old bushes using using the following
procedure.
2. Place the connecting rod securely in a bench
press. Manufacture from suitable bar stock a
press tool with the end face ground at an angle,
to suit the connecting rod bush side face. Position
the tool on the bush, and gently drive the bush
from its position. It is recommended to manufac-
ture a guide to assist alignment of the bar stock
during this operation.
3. A new bush can then be fitted in a similar manner,
by using a suitable piece of bar stock, with an end
face machined flat to suit the standard parallel
bush. Use a guide as described, and gently drive
the new bush into the connecting rod.
NOTE: Ensure the split in the small end bush is at
right angle to centre line of connecting rod.
6010035
126
4. After installation, grind the side faces of the new
bush to match the side faces of the connecting
rod. Ensure all sharp edges are removed and
loose chippings are cleaned from the connecting
rod before re--assembly into the engine.
5. With a new bushing fitted, drill a hole through the
top of the connecting rod using a 4.6--mm bit. Drill
the hole for oil passage, fig. 127.
TA6010036
127
6. Use an expanding reamer to obtain correct bush-
ing to piston pin clearance referring to specifica-
tion section. Remove burrs and chippings, before
refitting.
7. On re--assembly of piston lubricate all of the com-
ponents with engine oil. Assemble the connecting
rod and piston with the letter or grade mark on the
piston aligned to the pip (1), fig. 128, on the con-
necting rod. Install the piston pin and retainers.
TA6010045
128
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CYLINDER BLOCK OVERHAUL
T A6010038
3 2 1
129
Cylinder block core plug and sensor ports, front and left hand side
3 1
4 5
T A6010039
2
130
Cylinder block core plug and sensor ports, rear and right hand side
1. Cylinder block plugs and senders, require chang- Plug (4), drive into block. Use sealant G.
ing if leaking or rusty. Clean the old sealant off the Fig. 130 refers to the rear and right side of the block.
block, and fit new plugs with sealant.
Pipe plug (1), tightening torque 8--14 Nm.
Fig. 129 refers to the front and left side of the cylinder Use sealant, E.
block.
NOTE: New part mating faces and threads should be Use sealant, E.
coated in sealant, refer to ”Specifications”. Assemble
in the following manner. Plug (3), drive into block.
Use sealant, G.
Plug (1), tightening torque 8--14 Nm.
Use sealant, E. Plug (4), tightening torque 54--81 Nm. Use sealant, E.
Plug (2), tightening torque 27--47 Nm. Oil ports (5) replace with new if damaged, apply en-
Use sealant, E. gine oil only on re--assembly. Do not use sealant.
Use sealant, E.
604.64.961.00 - 04 - 2003
CYLINDER BORE
1. Check the cylinder bore for scuffing or rings
around the ring travel area. Irregularities can be
felt by running a finger over the surface. To check
out--of--roundness, wear or taper, use a tele-
scopic gauge, fig. 131.
Measure lengthwise (A) to (B) and (C) to (D) and
compare dimensions. Variances between the read-
ings will indicate ‘‘taper”.
Measure crosswise (C) to (D) and compare length di-
mensions from (A) to (B). Variances indicate out--of--
round.
TA6010040
131
Specifications C
NOTE: ”Repair Limit” refers to the tolerance allowed
after a repair has been performed, i.e. the repair must A
be within the repair limit. The ”Wear Limit” is the toler-
ance prior to repair.
Taper of cylinder bore,
repair limit -- 0.025 mm
wear limit -- 0.127 mm
Cylinder bore out of round,
repair limit -- 0.03 mm (0.0015 in) B
wear limit-- 0.127 mm (0.005 in)
Cylinder bore diameter, D
TA6010041
111.778--111.803 mm
132
1. Where only minor imperfections exist and bores
are to specification, hone the bores prior to instal-
ling new piston rings. Provided piston to bore
clearance does not exceed 0.250 mm.
2. Sleeving of the cylinder bores becomes expedi-
ent when:
minor imperfections to the bores are outside of
the specification.
Oil consumption is high.
Replacing sleeves, installed in service.
Cylinder bore is damaged beyond re--boring li-
mits.
NOTE: Oversize pistons are available in specific
markets only. In markets where these are available
the bore should be bored or honed to fit the next over-
sized piston.
Oversize pistons available:
0.51 mm
1.00 mm
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SLEEVING -- BORING AND HONING 0.005

0.06
455
0.040
3. Measure the outside diameter (1) of the sleeve in
several places and average the dimension.
Counter--bore the cylinder block (see step 2)
using the average dimension to obtain a press--fit 8.31
between bore and sleeve. Interference of sleeve

8.46 8.06
to the cylinder bore must be 0.025--0.076 mm.
4. Counter--bore to a depth of 204.7 mm from the
block face, surface finish of the bore is not to ex- 0.38
0.40
ceed (80 micron). Leave a step at the bottom of
the bore minimum of 9.60--10.16 mm, allowing for 4.454/4.456
run out of chamfers.

1
5. Bore through diameter, to the diameter of TA6010042
114.3--116.0 mm. 133

6. Clean the cylinder bores and thoroughly dry.
7. Grease the sleeve with a general purpose grease
and press the sleeve home to the lip in the bore.
The top of the sleeve should protrude through the
top of the block, 0.127--1.0 mm.
8. Bore the sleeve to 110.00--111.76 mm.
9. Skim the block face and top of sleeves, to achieve
the specified flatness of
0.08 mm (0.003 in) in any 152 mm (6 in)
0.03 mm (0.001 in) in any 25.4 mm (1 in).
A chamfer in the internal diameter at the top of the
sleeve to 45_ x 0.5 mm (0.020 in) should be main-
tained, to prevent piston damage on re--assem-
bly.
10. Break the sharp edge at the bottom of the sleeve
prior to honing.
11. Hone the cylinder bore to grade B,
111.790--111.803 mm
NOTE: Surface finish should feature an average
value from 20--30 micron, cross hatched at 355 -- 555.
Maximum taper,
0.025 mm on bottom of the bore.
Maximum out--of--round,
0.038 mm
604.64.961.00 - 04 - 2003
Assembly
NOTE: Pistons that are replaced must be of the same
type than the removed and have the same identifica-
tion letters and numbers, as embossed on the piston
crown.
1. Upon re--assembly with the piston at TDC, en-
sure the piston to block height is correct using a
dial gauge, fig. 134.
0.13--0.38 mm
TA6010043
134
2. Check the piston--to--bore clearance in the follow-
ing manner.
A. Measure the cylinder bore diameter at point A,
82.6 mm from the top of the block. A
B. Measure the diameter of the piston at point B,
25.4 mm from the crown of the piston.
C. Subtract piston diameter from the bore diam-
eter and the resultant figure for a new, unused en-
gine should be:
B
0.152--0.178 mm.
TA6010044
135
After an engine has run and settled down, the
maximum bore--to--piston clearance allowed is
0.250 mm.
Where pistons are only available as standard,
new pistons should always be fitted if the clear-
ance exceeds specification.
D. If clearance is ”greater” try a similar new pis-
ton, if limit is still exceeded, it will be necessary to
rebore and resleeve.
E. If the clearance is ”less”, hone bore to obtain
desired clearance.
3. Lubricate all of the components with engine oil TA6010045
and assemble the connecting rod and piston, with
the letter or grade mark on the piston, aligned to 136
the pip (1) on the connecting rod. Install the piston
pin and retainers.
604.64.961.00 - 04 - 2003
4. Check the piston ring gap width, using a feeler

gauge, in a vertical position at the top, middle and
bottom of the bore, fig. 137.
Ring gap specifications (new rings and bore):
top compression ring
0.29--0.53 mm
Second compression ring

0.49--0.63 mm
Oil control ring

0.29--0.58 mm
TA6010046
137
5. Using a new piston ring, check with a feeler
gauge, measure the gap between the ring and
groove.
Engines with mechanically--controlled fuel injec-
tion pump:
second compression ring
0.06--0.105 mm,
Oil control ring
0.030--0.070 mm
Engines with electronically--controlled fuel injec-
tion pump:
oil control ring
0.051--0.101 mm
6010048
6. Install the piston rings, but note the following:
138
7. Always ensure to use the correct expander, tool
no. 38 0000 324, to remove or install rings,
fig. 138.
6010047
139
8. Install top and second compression rings with the
word TOP towards the top of the piston. Ensure
the ring gaps are staggered a minimum of 120_
from each other on the diameter, and with no gap
on the thrust side of the piston.
A Engines with electronically--controlled injec-
tion pump
B Engines with mechanically--controlled injec-
tion pump
NOTE: Before installing new pistons and rings into a
used cylinder bore, remove the high polish from the
cylinder walls by honing as previously described.
140
604.64.961.00 - 04 - 2003
INSTALLING PISTON ASSEMBLY INTO

BLOCK
1. Select the correct bearing liners as in the follow-
ing crankshaft section and install the rod and cap;
ensure the liner tang locates in the slots of the rod
and cap.
2. Turn the crankshaft to position no. 1 crankpin at
the bottom of the stroke and lubricate all parts
with new engine oil.
3. Locate piston into bore ensuring the dot on the
connecting rod and arrow or grade letter on the
pistons face the front of the engine.
141
4. Using ring compressor, tool no. 38 0000 325, and
a soft drive slide pistons into bores.
6010050
142
5. Ensure the connecting rod bearing liner seats on
the crankpin with the bearing cap fitted to the con-
necting rod as a matched assembly. Fit new bolts
lubricated with oil, and tighten to a torque value
of 149 Nm.
6. Using feeler gauges, check the side clearance of
each connecting rod to crankshaft, fig. 143,
0.13--0.33 mm and continue for remaining as-
semblies.
7. Refit the oil pump tube/screen and oil pan as
previously described, refill engine oil and coolant
and run the engine checking for leaks.
TA6010051
143
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CRANKSHAFT
Removal
1. Remove the engine, flywheel and oil pan as previ-
ously described.
2. Remove the connecting rod caps, main bearing
caps and liners, and identify to facilitate re--as-
sembly.
396--E--13 TI
144
3. Carefully remove crankshaft from cylinder block.
6010065
145
NOTE: Current production engines may have a
crankshaft with main or crankpin journals ground 0.25
mm undersize. These are identified with the letters
010 MUS and/or 010 PUS respectively, letters being
stamped on one of the crankshaft counter balance
weights.
1. Thoroughly clean bearings, journals and caps, in-
spect for wear, scores, or damage: replace as re-
quired.
NOTE: It is recommended that all the main bearings
should be replaced if it is found necessary to replace
any set of main bearings.
146
2. If crankshaft timing gear teeth are worn or dam-
aged it will be necessary to replace the complete
crankshaft assembly inner part.
147
604.64.961.00 - 04 - 2003
3. Wash the crankshaft and drilled passages in a

suitable solvent. Dress minor imperfections using
an oil stone, but for severely marked journals ma-
chine to the next undersize bearing size.
4. Measure diameter of each journal, fig. 148, in
four places, to determine out--of--round, taper or
wear. B
Dimension (A), compared with (B), corresponds A D
to vertical out--of--round. C
Dimension (C), compared with (D), corresponds
to horizontal out--of--round.
Comparing the dimensions (A) and (B) with (C)
and (D), you get the journal out--of--round. TA6010067
5. If the journal exceeds specified limits refer to the 148
chapter ”Specifications” and refinish journal to
the next undersized bearing.
6. Examine the rear oil seal journal for score marks,
remove minor imperfections with fine emery
cloth, and if severely damaged renew the crank-
shaft.
Installation
1. Check the crankshaft bearing clearance using a
plastic gauge as follows.
2. Position a piece of correct sized plastic gauge
across the full width of the bearing cap, approxi-
mately 6.35 mm off--centre, fig. 149.
TA6010068
149
3. Install the cap and tighten bolts to 149 Nm.
4. Remove the cap and use the scale to check the
width of the flattened plastic gauge, fig. 149.
5. Widest point of gauge establishes the minimum
clearance.
6. Narrowest point of gauge establishes maximum
clearance. The difference between the two read-
ings is the taper.
NOTE: Normally main bearing journals wear evenly
and will not be out--of--round, but if a bearing which is
to specification is fitted to an out--of round journal, en-
sure liner suits maximum diameter of journal.
6010069
150
604.64.961.00 - 04 - 2003
7. If the combinations of bearings do not produce

specified clearance, refinish crankshaft and fit
appropriate size service bearings.
IMPORTANT: Engines may be assembled with bear-
ings of different material, but bearings of the same
material must be used on the same journal.
8. Make sure the bearing sleeve are clean and align
the oil cavities with the relevant oil grooves. The
bearing tangs must align with the block grooves.
396--E--26 TI
151
9. Coat liners with oil and install crankshaft.
6010065
152
10. Install a thrust bearing cap with flange--type bear-
ing first, installing remaining bearing caps to their
original location and tightening finger--tight.
396--E--9 TI
153
11. Tighten the main bearing caps in two stages:
Stage 1, tighten all bolts to a torque of 81 Nm. 81

60
154
604.64.961.00 - 04 - 2003
Stage 2, using a torque angle gauge tighten all

bolts a further 90_, in a single stroke.
12. Check crankshaft end play with a dial indicator
gauge, pry crankshaft towards front of engine
and set dial indicator to zero. Pry crankshaft to-
wards rear of engine and note reading on dial; if
end play exceeds 0.10--0.20 mm fit a new thrust
bearing.
155
13. If the end play is less than specifications, check
thrust bearing for burrs, scratches or dirt, and re--
align thrust bearing as in operation 12.
14. Install rear crankshaft oil seal as previously de-
scribed in the rear cover plate removal operation.
NOTE: Do not pre-install seal into retainer. To ensure
seal concentricity, it must be assembled with rear
plate and installation tool when fitted to crankshaft.
A6010070
156
15. Install the camshaft idler gear ensuring the timing
marks are correctly aligned.
..
..
P396--E--36 TI
157
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FRONT CRANKSHAFT CASSETTE OIL

SEAL REPLACEMENT
Removal
1. Remove crankshaft pulley using tool no. 38 0000
329 or equivalent equipment.
TA6010027
158
2. Remove the fitting key (1).
159
3. Remove the shield (1) from the front of the seal
to expose the lip of the seal outer casing.
160
The seal (1) must be removed from the guard (2).
161
604.64.961.00 - 04 - 2003
4. Use seal puller tool number 297670 to extract the

seal from the engine front cover.
162
5. Position the puller over the end of the crankshaft
and remove the seal.
NOTE: Protect the end of the crankshaft using a suit-
able step plate to prevent any damage when turning
the extracting bolt.
163
6. After extracting the seal (2), remove wear sleeve
(1) and O--Ring (3).
NOTE: The wear sleeve is tight--fit on the seal and
may be removed when extracting the seal. If this oc-
curs, separate and retain the sleeve for use during in-
stallation of the new seal.
164
Installation
IMPORTANT: DO NOT apply any lubricant to the
seal, shield or wear sleeve during or after installation.
1. Clean all parts and install the O--ring (1).
165
604.64.961.00 - 04 - 2003
2. Remove the shield of the replacement seal with

care.
NOTE: It is important that shield is removed as this
will affect the correct positioning of the seal in the en-
gine front cover during the installation process.
166
The seal (1) must be removed from the shield (2).
167
3. Using fingers, push the inner section of seal for-
ward.
168
4. Set the seal on the installation tool 297637/1.
NOTE: The installation tool must be used for fitting
the seal. Failure to use the tool will result in incorrect
positioning of the seal and consequential leakage
after a few hours of operation.
Locate tool
169
604.64.961.00 - 04 - 2003
5. Locate tool onto end of crankshaft.
170
6. Tighten bolt to press seal into end cover.
IMPORTANT: Only tighten the bolt sufficiently to en-
sure face of tool touches face of end cover.
171
7. Install the shield (1) on the seal.
172
8. Clean and refit the wear sleeve (1) over crank-
shaft and into the seal. Use the seal installer to
push the wear sleeve into the centre of the seal.
NOTE: Only fit a new sleeve if the outer surface is

worn or damaged.
173
604.64.961.00 - 04 - 2003
9. Install the engagement key (1).
174
10. Install front crankshaft pulley using T--bar tool no.
38 0000 329 or equivalent equipment.
11. Check and top--up engine with oil as specified in
the Operator’s Manual.
175
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ENGINE COMPRESSION TEST TEST READINGS

1. All cylinder compressions should be uniformly
TEST PROCEDURE within 1.7 bar of each other.
1. Be sure battery performance meets specifica- 2. A reading of more than 1.7 bar below the other
tions. cylinders indicates leakage at the cylinder head
2. Warm up the engine by operating for a minimum gasket, piston rings or valves.
of half an hour at 1200 rpm. 3. A reading of more than 1.7 bar above the other
3. Stop the engine and remove the injector and seat cylinders indicates excessive carbon deposits on
washer from no. 1 cylinder. the piston and cylinder head.
4. Clean the injector bore and crank the engine to 4. A low even compression in two adjacent cylinders
blow out any loose carbon particles. indicates a cylinder head gasket leak. Check this
5. Install an engine compression test gauge, from item before condemning the rings or valves.
kit no. 38 0000 303 with fake injector 295039, into
the injector bore, using a new seat washer and TEST CONCLUSION
the injector mounting bolts. To determine whether the rings or the valves are at
6. Connect the gauge and hose to the adapter. fault, squirt the equivalent of a tablespoon of heavy
7. Crank the engine at 200 rpm with the electric fuel oil into the combustion chamber. Crank the engine to
shut--off wire disconnected to prevent engine distribute the oil and repeat the compression test.
start--up. The oil will temporarily seal any leakage through the
8. Observe the gauge reading and repeat the com- rings. If approximately the same reading is obtained,
pression test, steps 5--7, for each cylinder. the rings are satisfactory, but the valves are leaking.
If compression has increased over the original read-
ing, there is leakage through the rings.
During a compression test, if the pressure fails to
climb steadily and remains the same during the first
two successive strokes, but climbs higher on the
succeeding strokes, or fails to climb during the entire
test, suspect a sticking valve.
604.64.961.00 - 04 - 2003
604.64.961.00 - 04 - 2003
Chapter 2 -- Coolant filter

Page
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
604.64.961.00 - 04 - 2003
ASSEMBLY
COOLANT ROTARY FILTER ASSEMBLY AND ADJUSTMENT(fig. 1)

Pre--assembly
1. Write the numbers on the outer edge, as shown in the illustration of the page here next.
2. Figure I:
the disk (A) has a 0--mm opening. The opening no. 1 is located on the left of the latter.
Mark the radius between this point and point no. 1 on the outer edge.
Then, proceed as shown in the drawing.
Note: the drawing no. 1 shows the radius heads on the disc (A) directed upwards (circle in the drawing).
3. Figure II:
connect the no. 3 on the disc (A) in point 3 on the outer edge.
The radiuses must be correctly crossed (towards the back).
4. Figure III:
find out point 2 on the disc (B) by the 9--mm dia. opening on the disc (A).
Mark the radiuses according to figure III.
5. Mark the radiuses according to figure IV.
Wheel orientation
Tension the radiuses until getting a distance by 66 + 2 mm.
0
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ASSEMBLY DIAGRAM
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604.64.961.00 - 04 - 2003
SECTION 21 -- TRANSMISSION -- CHAPTER 1 1
Chapter 1 -- TC transmission
Page
Hydrostatically--operated transmission, 4 gears . . . . . . . . . . . . . . . . . . . . . 18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Clutch adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Ground speed variator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
604.64.961.00 - 04 - 2003
2 SECTION 21 -- TRANSMISSION -- CHAPTER 1
MECHANICALLY--OPERATED TRANSMISSION, 4 GEARS
Gearshifting diagram
Shaft A: differential half shafts and
brake housing
Shaft B: main shaft
Shaft C: layshaft
Shaft D: input shaft
Shifting diagram
First gear: 1--2--3--4 differential
Second gear: 1--2--5--6 differential
Third gear: 1--2--7--8 differential
Fourth gear: 1--2--9 differential
Reverse: 10--11 differential
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Removal
General remarks
5. Remove the clutch housing from the trans-
mission housing.
6. Remove the guard after the screws (A) (fig. 3).
Gearshifting fork (A) and shaft (B) removal

1. Take out the cotter pins (C) (fig. 4).
2. Push the gearshifting shafts (B) to the right
(fig. 4) and remove the gearshifting forks (A). Pay
attention not to make the balls and springs fall in-
side the transmission.
Input shaft removal (fig. 5)

1. Remove the shielding (B) (fig. 3).
2. Remove the safety bracket (A) (fig. 5) and, with
the gear (C), move the bracket to the left, against
the gear (B).
3. Press the special tool (E) (fig. 5) part no. 439120,
between the gear (C) and the gearbox housing,
on the shaft. Remove the side clearance by the
adjusting screws (F).
604.64.961.00 - 04 - 2003
4. Press the input shaft to the right and remove the

bearing (A) (fig. 6).
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Removal of the layshaft (D) (fig. 5)

1. Remove the five nuts (B) (fig. 7) and hit the bear-
ing housing (A) from inside, with a plastic hammer
(fig. 8) to remove it.
2. Assemble the special tool (B) (fig. 9), part.
no. 434443 then install the bearing housing (A)
overturned.
3. Press the layshaft to the right until the shaft left

side comes out of the left bearing.
4. Remove the bearing housing (A) (fig. 9) and the

special tool (B) (part no. 434443).
5. Remove the shaft and the gears (C) (fig. 9)
and (D). Then, remove the gear (E).
CAUTION
The gear (C) (fig. 9) is asymmetric.
NOTE: The layshaft can be removed without disas-

sembling the gearshifting shafts or the input shaft (D)
(fig. 5).
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Removal of the main shaft (F) (fig. 10)

1. Remove the guard boot (C) (fig. 7) on the right
side.
2. Remove the bearing housing (A) tightening the
two screws M12x70, (B) (fig. 10) in the bearing
housing.
10
3. By a special puller (B) (part no. 434463), take the

bearing (A) (fig. 11) out of the shaft, on the right
side.
11
4. Press the shaft to the left and remove the nut (32),
the washer (33) (fig. 13) and the bearing (A)
(fig. 12).
5. Remove the ring (27), the gear (28), the needle
bearing (29), the ring (30) and the safety
bracket (31) (fig. 13) through the opening on the
left side of the gearbox housing.
6. Remove the shaft and the gears from the gearbox
housing.
12
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13
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Removal of axle shafts from the differential and

the brake housing
1. Remove the safety bracket (A) (fig. 14) and the

ring (B).
2. Remove the guard (D) (fig. 14) with the two

screws M8x7 in the openings (C).
3. Remove the nuts (E) (fig. 14) and the pin (F), then
rotate the lever (G) backwards.
14
4. Remove the rubber guard (H) (fig. 14).
5. Remove the outer brake disc (A) (fig. 15), the

brake mechanism (B) and the inner brake
disc (C).
6. Remove the safety bracket (A) (fig. 16), the

shaft (C) and the nuts (B); remove the brake
housing (D).
7. Remove the differential from the gearbox hous-

ing.
NOTE: The differential can be removed without dis- 15

assembling the input shaft (D) (fig. 5), the main shaft
(F) (fig. 10) and the layshaft (A) (fig. 7).
Proceed as follows:
a) Remove both brake housings and axle

shafts.
b) Slide the front gearshifting shaft to the right,

to take it out of the gearbox housing.
c) Remove the differential from the gearbox

housing.
16
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ASSEMBLY
Axle shafts and brake housings
1. Fit a new gasket (F) (fig. 20) on the left and on the
right side.
2. Fit a new oil seal (A) (fig. 20) on the left and on the
right side, on the brake housing (G).
3. Assemble both brake housings, first on the left
and then on the right, then fasten using the
nuts (B) (fig. 17).
4. Install both axle shafts (B) (fig. 20) with the safety
bracket (C), the ring (D) and the safety
bracket (E).
5. Install the inner brake disc (C) (fig. 18), the brake
17
mechanism (B) and the outer brake disc (A).
6. Install the guard (E) (fig. 19), the rubber
guard (D), the brake levers (A), the pin (C) and
the nuts (B).
7. Install the special tool (H) (fig. 19) (part
no. 434639) with the ring (F) and the safety
bracket (G). Take the axle shaft out and install the
safety bracket (G).
18
19
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20
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Installation of the main shaft (F) (fig. 10)
Position the shaft (F) (fig. 10) vertically, with the right
side downwards, then install the following parts in se-
quence:
1. Sleeve (A), needle bearing (B), gear (C), drive
gear (D) and drive ring (E).
2. Sleeve (G), needle bearing (H) and gears (J).
21
3. Ring (A) (beveled side down), sleeve (B), needle

bearing (C) and gear (D).
22
4. Drive gear (F) (fig. 23 and 24), drive ring (E) and
safety ring (G).
23
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Fit the pre--assembled shaft in the gearbox housing

and assemble the following parts sequentially:
1. Safety ring (G), ring (A) (beveled side towards the
safety ring), needle bearing (B), gear (C) and ring
(D).
24
2. Left side
a) Press the shaft and the shaft bearing (A)
further into the gearbox housing.
b) Install the special tool (B)
(part no. 434450).
25
3. Right side
a) Bearing (A) with special tool (B) (part no.
434446).
b) Bearing housing (A) (fig. 27) with special
tool (B) (part no. 434417).
26
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NOTE: Remove the inner part of the special tool (B)

(fig. 27) as soon as the bearing housing is at a suffi-
cient height from the bearing.
Remove the special tool (B) (fig. 25) on the left side
and press the unit to the left (fig. 27). Assemble the
guard (C) (fig. 7) on the right side.
27
Press the shaft and the bearing to the right, assemble

the safety ring (A) and tighten the nut (B) at 15 daNm.
28
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Assembly of the countershaft D (fig. 7)
Assemble the following parts on the shaft, outside the

gearbox housing.
1. Bearing (A) on the right side (the small gear on
the right side belongs to the shaft).
2. Narrow ring (B).
3. Gear (C) (fig. 29) with the hub large part to the
left.
4. Large ring (D).
5. Gear (E) with the hub large side to the left.
29

and assemble the following parts.
1. Gear (A) with the hub large part to the right.
2. Fit the gasket with the bearing housing (C)
through the special tool (B) (part no. 434446).
Fasten the bearing housing with five nuts (B)
(fig. 7).
30
3. Fit the left bearing (A), leaving a minimum

longitudinal clearance between the gears.
31
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IMPORTANT: The filler opening of the bearing outer

ring must be positioned with an angle of ± 25_ in front
of the vertical axis (fig. 32).
32
Drive shaft or clutch shaft (D) assembly
1. Install the shaft (D) with the pre--assembled right

bearing in the gearbox housing, with two gears
(E) and two slip rings (F).
33
2. Assemble the right bearing (B) in the gearbox

housing, assemble the guard (C) and press the
shaft fully to the right.
34
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3. Assemble the gears (E) and the safety bracket

(F) in the correct position.
4. Assemble the left bearing against the left gear (E)
leaving a minimum clearance.
35
Assembly of gearshifting shafts and forks
1. Assemble the ball and the spring in the gearshift-

ing forks (A) by the special tool (B) (fig. 37) (part
no. 434416).
2. Press the gearshifting shafts (B) (fig. 36) in the
forks (A) (with notch upwards) and fasten the
latter by the pins (C), on their turn connected by
a metal wire.
36
Calculation of the number of washers to be
fitted on the shafts
ON THE INPUT SHAFT OR ON THE CLUTCH

SHAFT (fig. 5) AND ON THE LAYSHAFT (fig. 7)
The longitudinal clearance of these shafts must
range between 0.2 and 0.6 mm.
Calculation example for shaft D:
ON THE MAIN SHAFT (F) (fig. 10)
The longitudinal clearance of this shaft must range

between 0.5 and 0.8 mm.
To calculate the number of shims, proceed as above
described.
37
1. Depth of the bearing in gearbox housing: 2mm

2. Projecting part from the clutch housing: 1.2 mm
Difference: 8 mm
3. Seal thickness: 0.15 mm
Total:: 0.95 mm
Shims to be fitted: From 0.75 to 0.35 mm
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Assembly of the guard
Assemble the guard with the gasket on the gearbox

housing and adjust the pawl (G) as follows:
1. Position the gearshifting shaft in first or second
gear.
2. Tighten the adjusting screw (H) and loosen it by
one turn. Tighten the jam nut.
3. Position the gearshifting shaft in reverse.
4. Tighten the adjusting screw (J) and loosen it by
Fill the gearbox housing with 15 l of SAE 80 W--90
(API GL5) oil.
38
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HYDROSTATICALLY--OPERATED TRANSMISSION, 4 GEARS

Gearshifting diagram (fig. 39)
Shaft A: brake housing and differential
axle shafts
Shaft B: main shaft
Shaft C: layshaft
Shaft D: input shaft
39
Shifting diagram (fig. 40)

Second gear: 1--2--5--6 differential
Third gear: 1--2--7--8 differential
Fourth gear: 1--2--9 differential
40
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Removal
General remarks
1. Remove the hydrostatic motor with the gearbox
housing.
2. Take the guard out after removing the screws (A).
41
Gearshifting forks (A) and shafts (B) removal

1. Take out the cotter pins (C).
2. Push the gearshifting shafts (B) to the right
(fig. 43) and remove the gearshifting forks (A).
Pay attention not to make the balls and springs
fall inside the transmission.
NOTE: The reverse gearshifting fork spring is differ-
ent from the other springs.
42
Input shaft removal (fig. 44)

1. Remove the guard (B) (fig. 41).
2. Remove the slip ring (E) (fig. 43) and press the
shaft (D) by half of its length.
3. Press the input shaft (D) to the left (fig. 43).
43
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4. Remove the bearing (A) and press the slip

ring (E) and the gearshifting shaft (B) out of the
shaft (D) (fig. 44).
5. Remove the shaft (D) operating from the left side.
44
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Layshaft (D) removal
1. Remove the five nuts (B) and hit the bearing

housing (A) (fig. 46) with a plastic hammer to take
it out, acting from the inside.
CAUTION
The gear (C) (fig. 47) is asymmetric.
NOTE: The layshaft can be removed even without re-

moving the gearshifting shafts (B) (fig. 42) or the
input shaft (D) (fig. 44).
45
46
2. Assemble the special tool (B) (part no. 434443)

and assemble the bearing housing (A) over-
turned.
3. Press the layshaft to the right until the shaft left
side comes out of the left bearing.
4. Remove the bearing housing and the special tool
(B) (part no. 434443).
5. Remove the shaft and the gears (C) and (D).
Then, remove the gear (E).
47
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Removal of the main shaft (F)
1. Remove the guard boot (C) (fig. 45) on the right

side.
2. Remove the bearing housing (A) (fig. 48) tighten-
ing the two screws (B) M12x70 (fig. 10) in the
bearing housing.
48
3. By a special puller (B) (part no. 434463), take the

bearing (A) out of the shaft, on the right side.
49
4. Press the shaft to the left and remove the nut (32),
the washer (33) (fig. 51) and the bearing (A).
50
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5. Remove the ring (27), the gear (28), the needle

bearing (29), the ring (30) and the slip ring (31)
through the opening on the left gearbox housing.
6. Remove the shaft and the gears from the gearbox
housing.
51
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Removal of axle shafts from the differential and

from the brake housing
1. Remove the slip ring (A) (fig. 52) and the ring (B).
2. Remove the guard (D) with the two screws M8x7

in the openings (C).
3. Remove the nut (E) (fig. 52) and the pin (F), then
press the lever (G) backwards (fig. 54).
4. Remove the rubber guard (H) (fig. 52).

52
5. Remove the outer brake disc (A), the brake

mechanism (B) and the inner brake disc (C).
6. Remove the slip ring (A) (fig. 54), the shaft (C)
and the nuts (B), then remove the brake hous-
ing (D).

ing.
NOTE: The differential can be removed without first

disassembling the input shaft or the clutch
shaft (fig. 43), the main shaft (F) (fig. 48) and the lay-
shaft (A) (fig. 45).
53
Proceed as follows:
a) Remove both brake housings and axle

shafts.
b) Press the front gearshifting shaft to the right

to take it out of the gearbox housing.
c) Remove the differential from the gearbox

housing.
54
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Assembly
Axle shafts and brake housings
1. Fit a new gasket (F) (fig. 58) on the left and on the
right side.
2. Fit a new oil seal (A) (fig. 58) on the left and on the
right side, in the brake housing (G).
3. Assemble both brake housings, first on the left
and then on the right, using the nuts (B) (fig. 55).
4. Install both axle shafts (B) (fig. 58) with the safety
bracket (C), the ring (D) and the slip ring (E).
55
5. Install the inner brake disc (C), the brake mech-

anism (B) and the outer brake disc (A).
56
6. Install the guard (E), the rubber guard (D), the

brake levers (A), the pin (C) and the nuts (B).
7. Install the special tool (H) (part no. 434639) with
the ring (F) and the retaining ring (G). Take the
axle shaft out and install the slip ring (G).
57
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58
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Installation of the main shaft (F)

1. Position the shaft (F) vertically, with the right side
downwards, then install the following parts in se-
quence:
a) Sleeve (A), needle bearing (B), gear (C),
drive gear (D) and drive ring (E).
b) Sleeve (G), needle bearing (H), gear (I) and
intermediate ring (J) with the beveled side
upwards.
59
c) Ring (A) (beveled side downwards), sleeve

(B), needle bearing (C) and gear (D).
60
d) Drive gear (F) (fig. 61 and 62), drive ring (E)

and safety ring (G).
61
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2. Fit the pre--assembled shaft in the gearbox hous-

ing and assemble the following parts sequential-
ly:
a) Safety ring (G), ring (A) (beveled side
towards the safety ring), needle bearing (B),
gear (C) and ring (D).
62
b) Left side: press the shaft and the bearing (A)

on the shaft further into the gearbox housing.
c) Install the special tool (B) (part no. 434450).
63
64
604.64.961.00 - 04 - 2003
d) Right side: bearing (A) with special tool (B)

(part no. 434446), bearing housing (A)
(fig. 27 on page 13) with special tool (B) (part
no. 434417).
NOTE: Remove the inner part of the special tool (B)
(fig. 65) as soon as the bearing housing is at a suffi-
cient height from the bearing.
e) Remove the special tool (B) on the left side
and press the unit to the left (fig. 45).
Assemble the guard (C) (fig. 7) on the right
side.
65
f) Press the shaft and the bearing to the right,

assemble the slip ring (A) and tighten the nut
(B) at 15 daNm.
66
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Assembly of the countershaft (fig. 45)
Assemble the following parts on the shaft, outside the

gearbox housing.
1. Bearing (A) on the right side (the small gear on
the right side belongs to the shaft).
2. Narrow ring (B).
3. Gear (C) with the hub large part to the left.
4. Large ring (D).
5. Gear (E) with the hub large side to the left.
67

and assemble the following parts.
1. Gear (A) with the hub large part to the right.
2. Fit the gasket with the bearing housing (C) by the
special tool (B) (part no. 434446). Fasten the
bearing housing with five nuts (B) (fig. 45).
68
3. Fit the left bearing (A) leaving a minimum longi-

tudinal clearance between the gears.
69
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Input shaft (D) assembly
1. Install the shaft (D) (fig. 70) with the pre--as-

sembled left bearing (A) in the gearbox housing
and press the gears (E) with two slip rings (F) on
the shaft.
70
2. Assemble the right bearing (B) (fig. 71) in the

gearbox housing, then assemble the guard (C).
71
3. Fit the gears (E) (fig. 73) and the slip ring (F) in
the correct position.
4. Assemble the left bearing against the left gear (E)
leaving a minimum clearance (fig. 70). Make
sure the filling opening of the bearing outer ring
is at an angle of +25_ with respect to the vertical
axis.
72
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Assembly of gearshifting shafts and forks
1. Assemble the ball and the spring in the gearshift-

ing fork (A) by the special tool (B) (fig. 74) (part
no. 434416).
2. Press the gearshifting shafts (B) (fig. 73) in the
forks (A) (with the notch upwards) and fasten the
latter by the pins (C), on their turn connected by
a metal wire.
Calculation of the number of shims to be fitted
on the shafts
ON THE INPUT SHAFT OR ON THE CLUTCH

SHAFT AND ON THE LAYSHAFT
The longitudinal clearance of these shafts must
range between 0.2 and 0.6 mm. 73
Calculation example for shaft D:
1. depth of the bearing in
the gearbox housing: 2 mm
2. Clutch housing
projecting part:
1.2 mm
Difference: 0.8 mm
3. Seal thickness:
0.15 mm
Total: 0.95 mm
Shims to be fitted: from 0.75 to
0.35 mm
ON THE MAIN SHAFT (F)

The longitudinal clearance of this shaft must range
between 0.5 and 0.8 mm.
To calculate the number of shims, proceed as above 74
described.
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Assembly of the guard (fig. 75)
Assemble the guard with the gasket on the gearbox

housing and adjust the pawl (G) as follows:
1. Position the gearshifting shaft in third or fourth
gear.
2. Tighten the adjusting screw (H) and loosen it by
3. Position the gearshifting shaft in first or second
gear. Tighten the adjusting screw (J) and loosen
it by one turn. Tighten the jam nut.
Fill the gearbox housing with 15 l of SAE 80 W--90
(API GL5) oil.
75
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MECHANICALLY--OPERATED TRANSMISSION, 3 GEARS

Gearshifting diagram
Shaft A: brake housing and differential
axle shaft
Shaft B1: drive shaft
Shaft B2: main shaft
Shaft C: layshaft (gear block)
Shaft D: reverse shaft
76
Shifting diagram
Second gear: 1--2--5--6 differential (6 -- B2
by ring)
Third gear: 1--B2 by ring
Reverse: 1--2--7--8--9 differential
77
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REMOVAL
General remarks
1. Remove the clutch and the clutch housing from

the gearbox housing.
2. Remove the guard from the gearbox housing.
Gearshifting fork (A) and shaft (B) removal
1. Remove the metal wire locking the screws (C)

and take the screws out.
2. Press the slip ring (D) to the left.
3. Remove the sleeves (E) on the left side and press
the gearshifting shafts (B) to the right, one after
the other.
Pay attention not to lose the balls (A) (fig. 80), the
springs (B) and the sliding pin (A) (fig. 79) in the
pawl (F).
4. Remove the sleeves (G) on the right side.
78
79
80
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Input shaft removal
1. Remove the clutch housing.

2. Remove the shaft (A) (fig. 81) with the bearing (B)
and the spacer (C).
IMPORTANT: Use a brass punch.
3. To remove the bearing (B) (fig. 81), take out the
safety bracket (D).
81
4. Remove the slip ring (E) and the needle bearing

(F).
82
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Input shaft and main shaft removal
This shaft is coupled to the clutch shaft. To remove it,

first take the clutch shaft out.
1. Remove the guard boot (A) (fig. 83) on the right
side.
2. Remove the retaining ring (H) (fig. 85) on the
main shaft.
3. Remove the bearing housing (B) (fig. 84) with the
shaft (A) tightening the two screws (C) (M 12x70)
in the bearing housing, then removing the
ring (A), (fig. 85), the gear (B), the gear (C), the
needle bearing (D), the washer (E) and the
gear (F).
4. Remove the slip ring (G) (fig. 85), the sleeve (J),
the seal ring (K) and the B--shaped gasket (L) with 83
a special tool (A) (fig. 86) (part no. 356390).
5. Remove the slip ring (M) (fig. 85) from the bear-
ing housing, then take the housing and the bear-
ing out of the shaft (fig. 87).
84
85
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Reverse shaft removal

1. Press the axis (C) (fig. 88) to take it out of the
gearbox housing by the special tool (B) (part no.
434637). Use care not to lose the spacers (D).
The brake housing should not be removed.
2. Remove the gear (A) (fig. 88) from the axis (C),
then remove the gear and the spacers (D) from
the gearbox housing.
86
87
88
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3. Remove the slip ring (B) (fig. 89) from the

gear (A) and press the bearing (C) to take it out
of the gear.
89
Layshaft removal
1. Remove the slip ring (B) (fig. 90) on the right side.
2. Move the gear block (A) (fig. 90) in the direction
of the arrow and fit the special tool (B) (fig. 91)
(part no. 434440) between the bearing (C) and
the support (D).
3. Press the gear block (A) (fig. 90) to the left hitting
it through the oil level opening, to take it out of the
bearing (C).
4. Remove the bearing (C) (fig. 90), then take the
gear block (A) out of the gearbox housing.
5. Remove the bearing (E) (fig. 92) from the gear
block (A).
90
91
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Differential removal from the gearbox housing
1. Remove the brake housing guard (D) (fig. 93),

the brake disc (B), the brake mechanism (C) and
the brake housing (A), on the left and on the right
side.
92
93
2. Remove both shafts (A).
94
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3. Remove the round ring nut (A) (fig. 95) on the left
drive shaft.
4. Remove both adjustment pins (A) (fig. 96) on the
flange of the left wheel hub (B).
5. Take out the left drive shaft by the special tool (B)
(part no. 434428) through the gear (C) (fig. 95).
Position the drive shaft in the gearbox housing
and remove the gear (C) (fig. 95) from the trans-
mission housing.
95
96
6. Remove the left bearing housing (D) from the dif-

ferential (C), then remove the differential from the
left bearing housing (B).
ing.
97
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Removal of the gear from the differential axle

shaft (fig. 98)
In the following order, remove:

the round ring nut (A), the safety spring washer (B),
the ring (C), the gasket (D) and the bearing (E).
98
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Bearing and drive shaft removal
TC 54 model
1. Remove the adjustment pins (A) (fig. 96) from the
wheel hub (B).
2. Remove the round ring nut (A) (fig. 95) and take
out the drive shaft through the gear (C) by the
special tool (B) (part no. 434428). Remove the
shaft from the gearbox housing.
3. Remove the slip ring (A) (fig. 100).
4. Remove the bearing (B) (fig. 100) and the ring (J)
from the gearbox housing.
5. Remove the round ring nut (D) (fig. 100) and the
ring (E).
6. Remove the wheel hub (F) (fig. 100) from the 99
gearbox housing (I) and remove the bearing (E)
from the wheel hub (F).
7. Remove the gasket (H) (fig. 99) taking it out of the
bearing (G) (fig. 100).
100
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TC 56 -- 54 model (rice version)
The differences between this version and the stan-

dard one are the following:
-- An additional gasket (A) (fig. 101)
-- The hub is filled with one liter of oil rather than with
grease.
101
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ASSEMBLY
Assembly of the layshaft (gear block)
1. Assemble the left bearing on the layshaft (A).

Assemble the unit in the gearbox housing.
2. Assemble the right bearing with the special
tool (C) (part no. 434439) in the support (B).
102
IMPORTANT: The bearing filling opening must be in

one of the positions shown in fig. 103.
3. Assemble the slip ring (D) (fig. 102) in the sup-
port (B) and move the shaft to the left, against the
slip ring (D).
103
Assembly of the reverse shaft
1. Assemble the bearing (B) and the slip ring (C) in

the gear (A).
104
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2. Assemble the shaft (D) in the gearbox housing

and press the gear (A) on the shaft, with the slip
ring toward the shaft neck.
Fit the large ring (B) and the spacers (C) to get a
0.1+0.2 mm clearance.
3. Press the shaft in position and pay attention so
that the screw (E) (fig. 104) does not fall in the
area where the clutch assembly must be fitted.
105
106
Main shaft assembly (A) 5. Fit the pre--assembled shaft on the gearbox
housing and press the double gear (F) (fig. 106)
on the shaft; the notch on the shaft must be to the
1. Fit the bearing (P) (fig. 106) in the bearing hous-
left.
ing (Q) and press the unit on the main shaft (N).
6. Fit the washer (E) (fig. 106) with the beveled side
2. Assemble the slip ring (M) (fig. 106) on the
to the right, the gear (C) with the needle bear-
shaft (N). Fit the O--ring (L) and the sleeve (J)
ing (D), the gear (B) and the ring (A). Fit the slip
with the gasket (K).
ring (H).
3. Assemble the slip ring (G) (fig. 106) in the bearing
7. Fit the guard boot (A) (fig. 83) on the shaft right
housing (Q).
side.
4. Fit the inner ring of the needle bearing (S)
(fig. 106) and of the slip ring (R) on the left side.
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Assembly of the input shaft
1. Assemble the needle bearing (F), the slip ring (E),

the bearing (B), the slip ring (D) and the ring (C).
2. Fit the pre--assembled shaft (G) in the gearbox
housing and connect it to the main shaft.
107
108
Assembly of the pawl and of the gearshifting

shafts
1. Assemble the pawl (F) with the machines side to

the right, at a clearance of 52 mm between the
outer side of the gearbox housing (fig. 108) and
the center of ball housing of the pawl (F).
2. Fit both left--hand long sleeves (E) with the side
opening downward side. Fasten the washer (A)
and the nut (B) (fig. 110).
109
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3. Fit two sleeves (G) (fig. 109) on the right side and
fasten with the washer (C) (fig. 110) and the
nut (D).
4. Fit the spring (B) (fig. 108) and the ball (A) in the
pawl (F).
5. Press the rear gearshifting shaft (E) (fig. 109) in
the gearbox housing (with the notch for the slip
ring (F) on the shaft) and press the shaft further
into the sleeve through the gearshifting fork (G),
on the left side. Fit the slip ring in the correct posi-
tion.
6. Place the rear gearshifting shaft (E) (fig. 110) in
neutral position and assemble the pawl pin (I).
7. Assemble the ball and the spring in front of the
gearshifting shaft (J) (fig. 110), then assemble
the gearshifting shaft. 110
8. Fit the adjusting screws (C) (fig. 109) in the gear-
shifting forks (A) and fasten the screws with an in-
candescent metal wire.
Differential assembly (fig. 111)

Assemble in sequence:
1. right bearing housing (B)
2. gear (A) on the right drive shaft
3. differential (C) of the right bearing housing (B)
4. left bearing housing (D)
5. left gear (E) on the left drive shaft.
111
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Assembly of the axle shaft in the differential

and in the brake housing
1. In the following order, install on the axle shaft:

bearing (E) (fig. 112), seal (D), ring (C) (with the
hole beveled side towards the seal D), safety
washer (B) and round ring nut (A) (with the be-
veled side towards the safety ring B). Tighten the
nut (A) and fasten with the safety washer (B).
2. Place the pre--assembled shaft in the differential
and make sure that the bearing filling opening is
horizontal.
112
3. Fit the brake housing (A) (fig. 113), the brake

discs (B), the brake mechanism (C) and the
brake housing guard (D).
113
Clutch bearing assembly
The pin (B) should not project over 3 mm beyond the

fork (C).
114
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Drive shaft assembly (fig. 116)
1. Assemble the ring (R) on the shaft and make sure

the beveled side is facing outside.
2. Assemble the drive shaft (K) in the gearbox hous-
ing (I).
3. Assemble the needle bearing (B) and the seal (L)
in the ring (J), then fit this assembly in the gearbox
housing.
4. Assemble the slip ring (A).
5. Assemble the ring (M) on the drive shaft and
make sure the beveled side is towards the shifter
gear (P).
6. Press the drive shaft through the bearing (B) and
the drive gear (P), then assemble the safety
washer (S) and the round ring nut (N).
7. Assemble the ring (W), the seal (H) and the bear-
ing (G) in the wheel hub (F).
8. Assemble the wheel hub in the gearbox housing.
Assemble the bearing (E) with the filling openings
in horizontal position. The hub is fastened to the
gearbox housing with a round ring nut and a
safety sheet.
To adjust bearing load: tighten the round ring nut
to 100 Nm, loosen the nut and tighten it again at
a torque ranging from 200 to 40 Nm. Fasten the
nut with the safety sheet.
9. Assemble the flange (T) with two adjustment
pins (U) (flat side towards the wheel). Both ad-
justment pins are fastened on the wheel hub side
through two rivets.
10. Pull the round ring nut (N) in the gearbox housing
and fasten by the safety washer (S).
Fill the hub with ± 1.5 kg of multipurpose NLGI2
lubricant.
Rice version
The hub is filled with ± 1 l of oil rather than with grease.
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115
116
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CLUTCH
Transmission clutch removal and assembly
1. Depending on the drive wheel dimensions and on
the clutch access possibility, remove the left side
drive wheel (fig. 117).
2. Remove the guards to access the transmission
clutch.
3. Remove the belt of the eccentric shaft towards
the grain elevator auger. Remove the V--belt from
the pulley on the clutch input shaft.
117
Loosen the screw (A).

Loosen the screw (B), until the lower V--belt can
be removed from the clutch input shaft pulley.
118
4. Separate the lubricant line (D).

5. Remove the clutch housing (C) fastening support
and the screws (D).
6. Remove the screws (E) and take out the clutch
housing (two holes are available to separate the
two housing parts).
Assembly
Follow the reverse order.
119
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CLUTCH ADJUSTMENTS
TC 54
Diaphragm clutches do not need any adjustment.
TC 56 (fig. 120)
1. Clutch pedal height X = 54 mm
2. First of all remove the safety washers.
3. Adjust with the nuts (A) after replacing the stan-
dard clutch disc, with a 10--mm spacer.
50443
120
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Specifications
TC 54 TC 56
Type -- Fichtel & Sachs -- Fichtel & Sachs

-- Simple -- Simple
-- Diaphragm clutch -- Diaphragm clutch
Diameter 305 mm 305 mm
Average static sliding torque 47 daNm 50 daNm

Max. release pressure 2700 N 2890 N
Engagement pressure 8800--10200 N 9560--10650 N

Disc thickness 10 mm 10 mm
Spring colour -- blue
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121
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Clutch control adjustment (fig. 121)
1. Remove the pin (C) and adjust the height of the

pedal X = 205 + 5 mm with the adjustment
screw (D).
2. Take out the rod (E) and set the adjustment
fork (F) until the pin (C) can be freely fitted (0.8
mm clearance).
3. Remove the pin (G) and press the ball thrust
bearing against the diaphragm or the pins (de-
pending on the clutch type). Strongly press the
rod (E) in the clutch cylinder. Set the adjustment
fork (K) to get a clearance W = 19 ± 1 mm in
TC 52--TC 54 models and W = 27.5 ± 1 mm in
TC 56 model.
Bleed
Open the valve (L) until outflowing fluid shows no air
bubbles. After bleeding, fill the container to the max.
level notch. Possibly top--up with SAR J 1703a oil.
Total capacity = 0.5 liters.
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GROUND SPEED VARIATOR

Set--up
1. Adjust the variator between min. and max. level
(16.5 mm between variator drive pulleys).
2. Leave a straight edge against the outer side of the
variator drive pulleys (A).
Adjust the clearance X = 3 + 3 mm through the
rod (B) and the clearance Y = 10,5 + 3 mm
through the rod (C).
122
Belt tension
1. Adjust the variator at 1/4 of its max. stroke.
2. Measure the belt tension midway between upper
and lower belt.
3. The belt tension is correct when the belt deflects
20 mm when undergoing an effort from 140 to
210 Nm.
Adjustment
Loosen the intermediate screw (A) and adjust it by the
rod (B).
NOTE: After the adjustment, do not forget to tighten
the intermediate screw (A) again.
123
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Variator adjustment (fig. 124)
After tightening the screws, adjust the clearance X

between drive pulleys at 1 mm.
Proceed as follows:
1. Adjust the variator arm in its highest position (fully
extended cylinder).
Fasten the adjustment nut (A) to the rod (C) with
the nut (B).
Remove the fork (E) from the rod (C) with the
nut (D).
Adjust the variator by tightening or loosening the
rod (C) and the nut (A) or (B).
Fasten the fork (E) to the rod (C) with the nut (D).
2. Adjust the variator arm in its lowest position (fully
retracted cylinder).
Loosen the nut (B) to release the adjustment
nut (A). Release the variator by tightening or
loosening the adjustment nut (A).
Adjust the variator by tightening or loosening the
adjustment nut (A) in the rod (C).
Tighten the nut (B).
NOTE:
-- After any adjustment, move and check the
variator.
-- Do not tighten or loosen the adjustment
nut (A) if it does not touch the cylinder.
124
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Chapter 2 -- AL transmission
Page
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Preliminary remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Transmission assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Transmission housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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TRANSMISSION
REMOVAL
DANGER
Heavy parts must be handled and transported only
with lifting devices having a suitable capacity. The rel-
evant assemblies must be lifted with suitable slings
and hooks. While lifting, no one should stand in the
lifting device operating range.
1. Park the combine on level ground and block front

and rear wheels with suitable wedges.
2. Remove the left--hand side guards and the inner
reinforcements (1).
3. Remove the fastening clamp (2) of the hydro-

static line and the clamp (3).
4. Take the fastening screws (4) out of the hydro-
static motor.
DANGER
Handle all the parts with care. Never fit hands or
fingers between parts. Always wear suitable safety
clothing such as safety goggles, gloves and shoes.
5. Fasten sturdily the hydrostatic motor (5) and take

it out from its housing.
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6. Remove the pin (6) of the brake control linkage,

the gearshifting rod (7) and the gearshifting bear-
ing of the gearshifting lever. Remove the odo-
meter sensor cable.
7. Lift the transmission with the relevant lifting tool
no. 296115 with a hydraulic lifting device having
a capacity by at least 500 kg.
8. Take out the 4 front (9) and rear (10) fastening
screws of the transmission.
9. Lower the transmission. Press first on one side

and then on the other to release the telescoping
shafts.
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INSTALLATION
DANGER
Lift the transmission with the relevant lifting tool
no. 296115 with a hydraulic lifting device having a ca-
pacity by at least 500 kg. Align the holes with suitable
tools.
NEVER CARRY OUT THIS OPERATION DIRECT-
LY WITH YOUR HANDS!
1. Lift the transmission with the lifting device and

press it first on one side and then on the other, to
engage the telescoping shafts.
2. The telescoping shafts can be connected using
the larger V--groove as a reference. Proceed fol-
lowing the instructions.
3. Go on lifting with the suitable device until the
transmission threaded holes align.
4. Apply Loctiter 242 on the threads of the 4 fasten-

ing screws (9), tighten the screws to fasten the
transmission and tighten them to the torque of
210 Nm.
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5. Tighten the transmission rear screw (10) and

tighten to the torque of 331 Nm.
6. Assemble the remaining parts: the gearshifting
lever bearing (8), the gearshifting rod (7), the pin
(6) of the parking brake linkage and the odometer
sensor cable.
7. Make sure that the sleeve (11) of the hydrostatic

motor clutch and the main drive shaft are fitted.
10
8. Assemble the hydrostatic motor and fit the

screws (4).
9. Fit the fastening clamp (2) of the hydrostatic line
and the clamp (3).
11
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10. Fit the rear reinforcements (1), proceeding in the

following order:
• Tighten the rear screws (12) to the torque
of 343 Nm.
12
• Tighten the nut (13) up to the safety sheet (14).

• Tighten the front nut (15) to the torque of 700 Nm.
• Then, bend the edges of the safety sheet (14) so
that they lay on the surface of nuts (13) and (15).
• Install the left guards again.
13
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14
1. Input shaft (clearance from bearing neck to bearing neck: 0 -- 0.05 mm)
2. Layshaft (clearance from bearing neck to bearing neck: 0.3 -- 0.08 mm)
3. Main shaft (clearance from bearing neck to bearing neck: 0.05 -- 0.10 mm)
4. Bearing neck screws (tighten to 70 Nm)
5. Differential bearing
6. Differential bearing screws (tighten to 120 Nm)
7. Differential housing fastening screws (tighten to 120 Nm)
8. Clean and grease the connecting surfaces, then, just before assembly, apply Loctite Superfast 510.
NOTE:
-- The screws in the blank housings must be oiled.
-- Apply Loctiter 242 on the previously oiled screws.
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TRANSMISSION
PRELIMINARY REMARKS
Disassembly/removal procedure of parts (assembled transmission housing cover, factory installed)
INPUT SHAFT: Remove/install immediately

MAIN SHAFT: Remove/install immediately
COUNTERSHAFT: The removal is possible only after removing the auxiliary shaft.
The assembly is possible only before fitting the auxiliary shaft.
DIFFERENTIAL ASSEMBLY: The removal is possible only after removing the main shaft.
The assembly is possible only before fitting the main shaft.
To correct the shaft bearing end float, suitable shims

are available.
15
To correct the intermediate shaft gear end float, suit-

able shims are available.
16
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TRANSMISSION DISASSEMBLY
DANGER
To disassemble, proceed as follows:

1. Remove the transmission with the tool 296119 on
the transmission test bench 290090. Remove the
screws (1) and the transmission housing cover
(2).
2. Drain oil.
DANGER
During this operation, the use of rubber gloves is
compulsory.
Collect oil in a suitable container. Make sure there are
no oil leaks.
17
3. Remove the screws (3) and the bearing clutch (4)
of the hydrostatic motor.
18
4. Remove the screws (5), the cotter pins (6) and
the springs (7), then collect the balls under the
springs.
5. Remove the piston rods (8).
6. Remove the bracket (10) and the toothed fitting
(11).
19
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MAIN SHAFT (23) -- DISASSEMBLY

23
1. Take out the screws (12) and the flange (13).
20
2. Take out the sleeve (15) with a punch (16).
21
3. Remove the ring (17).
22
4. Remove the snap ring (18).
23
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24
25
7. Take out the main shaft (23) using a bronze
punch (24).
26
INPUT SHAFT (27) -- DISASSEMBLY
DANGER

2. Take out the shaft (27).
27
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3. Take out the bearing ring (28) with a punch (29).
28
COUNTERSHAFT (36) -- REMOVAL
36
29
30
DANGER
3. Take out the shaft (36) with a bronze punch, until

the sleeve (37) comes out from the other side.
31
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4. Take out the shaft (38) with the gears (see figure).
36
32
5. Take out the bearing (40) with the gear (41), using
the puller (42).
33
6. Take out the snap rings (43) and the shaft (38).
36
34
7. Take out the bearing (44) with the puller (42).
35
604.64.961.00 - 04 - 2003
8. Strongly support the differential.

9. Remove the screws (46) and press the bearing
(47) to take it out of the notches (48).
36
10. Remove the screws (49) and press the bearing
(50) to take it out of the notches (51).
37
11. Separate the differential from the bearing (53)
using a suitably sized punch (54) and take it out.
38
12. Remove the screws (55) and disassemble all
parts.
39
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DIFFERENTIAL BEARING -- DISASSEMBLY
DANGER
40
2. Disassemble the bearing (57) using the puller
(58).
41
42
4. Remove the sleeve (60) by the puller (61).
43
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DIFFERENTIAL
44
1. Half--housing 8. Half--housing
2. Spacing ring 10. Ring bevel gear
3. Cross pin 11. Screws M12x60 R 100
4. Intermediate gear 13. Screws M12x110 R 100
5. Tapered ring 14. Sleeve
7. Tapered pinion 15. Sleeve
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TRANSMISSION ASSEMBLY
DIFFERENTIAL
DANGER
To assemble, proceed as follows:

1. Carefully clean and degrease the half--housings.
2. Check the wear of the different components, es-
pecially tapered rings.
3. Fit the spacer ring (2) in the half--housing.
45
4. Oil the cross pin and fit the intermediate gears (4)
and the tapered rings (5).
46
5. Fit the tapered pinion (7) and the whole cross pin
(3) in the half--housing (1).
6. The tabs (6) of tapered rings (5) must lay on the
inner edge of the half--housing.
47
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7. Fit the whole cross pin (3) in cross direction vs.

the previously fitted one, following the same in-
structions.
48
8. Fit the remaining tapered pinion (7) on the inter-
mediate gear already fitted, then engage the suit-
able spacing rings (2).
49
9. Lay the half--housing (8) aligning the marks (9).
50
10. Fit the ring bevel gear (10) with the rectified side
towards the differential.
11. Apply medium thread--locking Loctiter 242 on the
threads of the four screws M12x60 R 100.
12. Fit the screws in the holes for the intermediate
gear pins (3) without tightening them in this step.
51
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13. Tighten the screws M12x110 R 100 (13) without

using Loctiter.
52
14. Tighten all screws in the sequence shown, even-
ly, to 120 Nm.
53
15. Press both sleeves (14 and 15) with a suitable
punch.
54
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INPUT SHAFT -- INSTALLATION
DANGER
To install, proceed as follows:

1. Remove the transmission with the tool 296119 on
the transmission test bench 290090.
2. First of all, install the sleeves on the shaft (1).
3. Assemble the inner ring of the ring metal gasket
(2) of the housing.
4. Tighten the input shaft (1) and fit the ring metal 55
gasket of the outer ring (3).
5. Pre--charge the ring metal gasket (3) of the outer
ring with a pressure of 2 bar.
6. Measure the end float and determine the corre-
sponding thickness considering that the allowed
end float between rings is 0 -- 0.05 mm; (for the
available shims, see page 8).
7. Install the corresponding shims (4). This shims
must be smooth and clean.
56
57
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8. Assemble the flange (5). Tighten the flange

screws at 70 Nm.
9. The shaft must rotate easily.
58
COUNTERSHAFT -- INSTALLATION
DANGER

1. Install the gears and the sleeves on the counter-
shaft (6) in the sequence shown.
59
2. Assemble the gear (7), the shaft with gears and
the ring metal gasket (8).
60
3. Apply a film of Loctiter 510 on the flange mating
surface (9) and position the flange on the gearbox
housing.
4. Apply medium thread--locking Loctiter 242 on the
threads of the screws (10) and tighten to 70 Nm.
61
604.64.961.00 - 04 - 2003
5. Pre--charge the ring metal gasket (11) with a

pressure of 2 bar.
6. Measure the end float and determine the corre-
sponding thickness considering that the allowed
end float between rings is 0,03 -- 0.08 mm; (for the
62
7. Install the corresponding shims. This shims must
be smooth and clean.
8. Assemble the flange (12). Tighten the flange
screws (13) at 70 Nm.
The shaft must rotate easily.
DIFFERENTIAL AND MAIN SHAFT --

INSTALLATION
63
DANGER

1. Assemble the differential.
2. Fit the differential (14) in the transmission hous-
ing.
64
3. Fit the special tool no. 51009 (for its dimensions,
see page 33) in the transmission housing, so that
the differential cannot fall down.
65
604.64.961.00 - 04 - 2003
4. Assemble the sleeve (15) on the shaft (16).

5. Assemble the remaining parts on the intermedi-
ate shaft (16), in the sequence shown.
6. A standard shim (17) is supplied, with dimen-
sions 4.4 mm.
66
7. Balance the clearance with a punch (18).
67
8. Fit the snap ring (19) and possibly remove the
clearance between snap ring and gears. Other-
wise, replace the standard shim (17) with a more
suitable one (for the available shims, see page 8).
68
9. Fit the gear on the driving shaft no. 296120.
10. Remove the snap ring (19), rotate the assembly
and transfer the gear block from the main shaft to
the drive tool, as shown.
69
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11. Fit the input shaft no. 296120 with the parts of the
main shaft so that the input shaft can be taken out
of the gearbox housing on the left side.
70
12. Fit the main shaft (16) with the previously fitted
sleeve (15), from the right side.
13. Slightly beat with a plastic hammer to fit it.
71
14. After fitting the shaft (16), the driving shaft no.
296120 comes out of the other side of the gear-
box housing and the gear can be taken out.
15. Manually press the input shaft, straight on,
through the housing.
72
16. Using a suitable punch (19), assemble the
gasket (17) on the flange (18). Do not forget to oil
the outer and the inner side of the gearbox hous-
ing.
73
604.64.961.00 - 04 - 2003
17. Assemble the ring metal gasket (20).

18. Lay a film of Loctiter 510 on the surface.
19. Assemble the flange (18) on the transmission.
20. Apply medium--thread locking Loctiter 242 on the
threads then fit the screws and tighten to the
torque of 70 Nm.
74
21. Fit the snap ring (19) on the opposite side.
75
22. Fit the gear (22).
76
23. Fit the snap ring (23).
77
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24. Fit the spacer ring (24) with the machined side in-
wards.
78
25. With a suitably sized punch (25) measure the
clearance of the spacer ring (24), then check with
a slide gauge if the end float in point (25) ranges
from 0.5 to 0.8 mm.
79
26. If the end float is lower than 0.5 mm, the lower
part (27) of the spacer ring (24) must be posi-
tioned deeper. If the end float is higher than 0.8
mm, the lower inner part (28) of the spacer ring
(24) must be positioned deeper. For this oper-
ation, suitable machine tools are required.
80
27. Assemble the sleeve and the corresponding ring
metal gasket (30).
28. Pre--charge the ring metal gasket (30) with a
pressure of 2 bar.
Measure the end float.
81
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29. To calculate the shims, you need to measure the

projection of the ring metal gasket (30) and the
depth of the flange (31). Consider that the al-
lowed end float (from 0,03 to 0.08 mm) (for the
30. Assemble the flange (31). Tighten the screws
to 70 Nm.
The shaft must rotate easily.
82
31. Lay a film of Loctiter 510 on the surface (32).
32. Then, assemble the supporting bearing (33) and
tighten the bearing screws to 70 Nm.
83
33. Assemble the piston rods (34) with the brackets
(35) and the toothed fittings (36).
34. Lock the transmission drive clutch (36) with the
spring keys (37).
35. Fit the balls (38) and the springs (39).
84
36. Arrange the special tool 51010 for positioning the
piston rods in neutral position (for the dimen-
sions, see page 33).
37. Fit the screws (40) and make sure the area
around the control rings (41) is evenly distributed.
38. Possibly the assembly can be adjusted by the
screws (40). These screws have tapered bits, so
that the brackets can be moved in axial direction
by slightly loosening one screw and tightening
another further on.
39. After the adjustment, tighten the self--locking
nuts (40).
85
604.64.961.00 - 04 - 2003
40. Lay some silicone Simate sealant (silicone

rubber produced by General Electric Co.) on the
seal ring (42), press it strongly in the center to
seal and fasten the piston rods.
86
DANGER
DIFFERENTIAL -- SIDE SUPPORTING BEARING

RIGHT SUPPORTING BEARING
1. With a suitable punch (46), assemble the gasket
(44) on the side support bearing (45). To this pur-
pose, oil both the outer and inner part of the hous-
ing.
87
2. Fit the snap ring (47) and the sleeve (48) with a
suitable punch (49).
88
3. Assemble the snap ring (50).
89
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4. Press the supporting ring (51) with a suitable

punch (52).
5. Assemble the snap ring (53).
90
LEFT SUPPORTING BEARING
1. Install the gasket (54) on the supporting bearing
(55) with a suitable punch (56). Oil both the outer
and inner part of the housing.
91
2. Fit the snap ring (57), the shim (58) and the
sleeve (59) with a suitable punch (60).
Fit the snap ring (61).
92
3. Fit the supporting bearing (55) with a suitable
punch (63).
4. Check that the shim (64) is positioned correctly
and install the snap ring (65).
93
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Fully fit the supporting bearing (67) and tighten
the screws (68) to 120 Nm.
94
Fully fit the supporting bearing (70) and tighten
the screws (71) to 120 Nm.
95
GEARBOX HOUSING COVER
DANGER
1. Oil the seals (72 and 73) both outside and inside,
then place them on the supporting bearing (74).
96
2. Fit the supporting bearing (74) and tighten the
screws (75).
97
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3. Assemble the gearshifting lever components as

shown.
4. Fit the lever (76).
5. Fit the pin (77).
98
7. Assemble the cover (81) by correctly fitting the
lever (78) in the toothed fittings (36).
8. Fit the screws (82) and tighten to the torque of 70
Nm.
9. The gears (76) must be correctly fitted and should
easily move when the lever is operated.
10. Fill the transmission with AMBRA HYPOIDE 90
oil (capacity 12 liters, part no. NH520A).
11. Check the filling oil through the plug (83).
12. Manually assemble the brake disc and the slide
gauge (see page 59).
99
TACHOMETER SENSOR
To adjust the tachometer sensor (84) correctly,
tighten it almost completely, then loosen it by half a
turn and by a further one sixth of turn.
This adjustment creates a clearance of 0.7--0.8 mm
between sensor and differential ring bevel gear.
100
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TRANSMISSION HOUSING COVER
101
33. Hydrostatic motor bearing 41. Drive ring
34. Gearshifting rod 42. Seal ring
35. Gear engagement bracket 75. Screw
38. Ball 76. Gear engagement lever
39. Spring 81. Transmission housing cover
40. Screw 82. Cover screw
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TOOLS
CAUTION: To get a safe operation, best

performance as well as to save time and effort, each
assembly must be fitted using the specified tools.
Assembly must be carried out correctly: for diagrams
and instructions, refer to this manual.
Differential support device: (device part no. 51009).

Material: FE OO.
102
To press and keep pressed the transmission gear-

shifting clutch springs, make this device out of FE OO
(for the device, see part no. 51010).
103
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604.64.961.00 - 04 - 2003
SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1 1
Chapter 1 -- TC
Page
Final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
604.64.961.00 - 04 - 2003
2 SECTION 25 -- FRONT MECHANICAL DRIVE -- CHAPTER 1
FINAL DRIVES
REMOVAL (fig. 1)
Input shaft
1. After draining oil, remove the guard (P), the three
screws (G), the washer (F), the shims (H) and the
guard of the housing upper part.
2. Make the input shaft (B) slide to take it out of the
housing, leaving the bearing (C) and the
gasket (D) on the shaft.
3. Remove the rings of the bearings (C) and (E) from
the housing.
4. Remove the gasket (D) from the input shaft.
Drive shaft
1. Remove the bearing guards (R) and (S) and the
shims (I).
2. Take the shaft out of the housing.
3. Remove the rings of the bearing from the housing
and take the bearings out of the shaft.
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ASSEMBLY (fig. 1)
Input shaft Drive shaft
1. Install both bearings on the shaft and oil them. 1. Fit the rings of the bearings (C) and (E) in the
housing.
2. Fit the pre--assembled shaft in the housing.
2. Grease the gasket (D) (multipurpose lubricant
3. Assemble the rings of the bearings (L) and (M). NLGI2) and assemble the gasket and the bear-
4. Fasten the bearing guard (R) with adhesive. ing (C) on the shaft (B).
5. Assemble a new gasket on the bearing guard (S) 3. Fit the gearbox in the housing.
and assemble the guard. 4. Press the shaft (B) in the housing till the gasket
is completely fitted in.
5. Lay the gearbox flat on the wheel flange.
6. Fit the slip ring (N), the bearing (E) and the
washer (F).
7. Press the bearing on the shaft tightening the
screws (G) to the torque of 90 Nm.
Longitudinal clearance adjustment Pre--load adjustment

1. Loosen the three screws (G) until getting a re-
1. Tighten the screws of the guard (S) to the torque
duced longitudinal clearance of the drive shaft.
of 34 Nm.
2. Loosen the screws. 2. Position a gauge next to the washer (F) and
tighten the three screws (G) in the same way, until
3. Tighten the screws again and, with a gauge, sim-
getting a longitudinal clearance equal to zero.
ultaneously check if the longitudinal clearance is
still 0.1 mm on the upper side of the shaft (K). 3. Remove the three screws (G) and the washer (F).
4. Measure the longitudinal clearance between 4. Measure distance X between the shaft end and
housing and bearing guard (S), then fit shims with the bearing edge.
the same thickness. Tighten the screws again to 5. Fit the shims corresponding to the measured
a torque of 34 Nm. Check the longitudinal clear- value, X -- 0.3 mm.
ance again: now it should range between 0.05 6. Fit the washer (F) and the screws (G), then
and 0.1 mm. If this is not the case, add or remove tighten the screws to the torque of 235 Nm.
shims.
7. Lay some adhesive on the guard (P) and as-
5. Apply adhesive between the bearing guard (S)
semble the guard. Assemble the housing guard
and the housing, as well as between the individ-
with a new gasket.
ual shims.
6. Tighten the screws of the bearing guard (S) to the 8. Fill the final drive housing with 5.5 l of SAE
torque of 34 Nm. 80W--90 oil (API--GL5).
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604.64.961.00 - 04 - 2003
Chapter 2 -- AL
Page
Final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Single stage final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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FINAL DRIVES -- REMOVAL
DANGER
1. Park the combine on even ground and block the

front and rear wheels with suitable wedges.
2. Lock the front axle on the side where the wheel
is to be removed, using a stand with capacity of
at least 8,000 kg.
3. Remove the wheel.
1
4. Remove the fastening screws (1) of brake caliper.
5. Remove the brake caliper. Fit a shim with suitable
thickness for the next fitting of the brake caliper
in the brake disc.
6. Fit the brake caliper in the housing (2). Pay atten-
tion not to bend the brake hose and interrupt the
flow.
7. Support final drives with a hydraulic lifting device

with capacity of 500 kg and the tool no. 296145.
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8. Remove the screws (3) and the relevant pins.

9. Collect the available shims.
10. Remove the final drives to take the telescoping

shaft (4) out.
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INSTALLATION
DANGER
Use a hydraulic lifting device with capacity of at least
500 kg and the tool no. 296145. Handle all the parts
with care. Never fit hands or fingers between parts.
Always wear suitable safety clothing such as safety
goggles, gloves and shoes.
1. Lift the final drives and place them in assembly

position, so that the telescoping shaft can be
fitted.
The shafts fits correctly only in one position. Dur-
ing assembly, the longest V--groove is used as a
reference point.
6
2. Start from the front fitting a 2 mm shim (5), com-

plete the assembly and add shims at the back, if
required.
The joint between front axle and final drive disc
must have a max. end float of 1 mm.
3. Fit the lower and upper pins and fasten them with
the corresponding screws (3).
604.64.961.00 - 04 - 2003
4. Assemble the brake caliper. Tighten the screws

(1) to the torque of 460 Nm.
Assemble the wheel and tighten the wheel nuts
to a torque ranging from min. 610 Nm and max.
732 Nm.
TELESCOPING SHAFT GREASING
Place the combine on even ground. Lubricate by the

grease fitting (B) until grease flows out from the whole
pipe (D). If grease flows out only from one quarter of
pipe, proceed as follows:
-- Determine the max. cross levelling of the com-
bine on the left and on the right.
-- Switch the engine off.
-- Lubricate again with the grease fitting (B) until
grease flows out from the pipe (D).
10
-- Place the combine on even ground again.
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WHEEL DRIVE
11
SECTION -- SINGLE STAGE FINAL DRIVE
1. Wheel axle 10. Cover

2. Wheel bolt 11. Pinion
3. Ring bevel gear 12--13. Bearing
4. Bearing 14. Shim
5. Slip ring 15. Gasket
6. Spacer ring 16. Gasket
7. Bearing 17. Dust cover
8--9. Special nut
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SCREW TIGHTENING TORQUE (Nm)

A 96
B 150
C 225
D 460
E 275
F 460
NOTE: During assembly, lubricate the grease hous-

ing (6) with GR75MD grease (N.H. 720A).
12
1 Brake supporting plate

2 Brake caliper
3 Brake disc
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SINGLE STAGE FINAL DRIVE
DISASSEMBLY
DANGER

1. Disassemble the brake caliper (1, page 7) and
support the final drive with the tool 296082 and
the stand 290090.
Remove the cover (2) and the guard (3).
13
2. Straighten the tang (4) of the slip ring between the

special nuts.
14
3. Fit the special tool 51013 (6) with the

tang 296124 (7), keeping the ratio 1:5 (8) 296082
on the pinion (5) (for the dimensions, see
page 16). Loosen the special nuts for the ring
bevel gear fastening.
15
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4. Assemble the special support 51012 (10) (see

figure on page 16) and the brake caliper
screw (11) on the wheel axle.
16
5. Lift the wheel axle (12) with a lifting device having
at least a capacity of 500 kg and a suitable hook.
17
6. Remove the axle wheel (12) and disassemble the
ring bevel gear (9).
18
7. Remove the bearing (14) with a suitable
puller (13). Before carrying out this step, heat the
bearing at about 80_C.
19
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8. Take the bearing rings (15--16) out with a suitable

punch.
20
9. Slightly beat the pinion (5) with a plastic hammer

to release the bearing ring (17), then remove the
pinion.
21
10. Take out the inner bearing ring by the special

tool 291206 (18) and the puller 293450 (19).
22
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ASSEMBLY
DANGER
Suggestions for using Loctite and silicone during the

assembly of the final drive housing.
F Clean and grease the mating surfaces, then lay a
film of Loctite Super--Fast 510.
Y Before assembly, lay some Silmate (silicone
rubber produced by General Electric Co.) on the con-
cerned surface.
j Clean the housing and the metal support of the
gasket; before assembly, lay Loctite 290.
SCREW ASSEMBLY
The screws of blank housings must be oiled. Apply
Loctite 242 on the screws touching oil inside the final
drive.
BEARING ASSEMBLY
Before assemble the bearing on the shaft, heat the
ring at the max. temperature (80 -- 90_C).
1. Assemble the bearings (12 and 13) (see fig. 11,
page 6) on the pinion (1) of the final drive. As-
semble the bearing ring in the final drive housing.
Fit the pinion in the housing and assemble the 23

outer bearing ring (2).
24
2. Lay a film of Loctite 290 on the metal housing of
the rubber gasket (3), then assemble it on the
flange (4).
3. Lubricate all the inner part with Alteflon Gasket
Seal 730 grease.
4. Measure the height of the flange (4) (H) with a
gauge.
25
604.64.961.00 - 04 - 2003
5. Measure the clearance between bearing ring and

the outer surface with a depth gauge. After carry-
ing out the measurements, calculate the shims
required considering that the max. allowed end
float between sleeves (on the thrust element)
ranges from 0 to 0.05 mm.
26
6. Engage the required shims (5) paying attention
they are clean and smooth.
27
7. Lay a film of Loctite Super--Fast 510 on the sur-
face of the mating flange (6).
Assemble the flange. During fitting, protect the
seal.
8. Tighten the screws to the torque of 50 Nm.
The pinion must rotate freely.
28
9. Press the bearing ring (7) in the final drive hous-
ing, with a suitable punch.
29
604.64.961.00 - 04 - 2003
10. Lay a film of Loctite 290 on the metal support of

the rubber gasket (8), then press with a suitable
punch.
11. Lay a film of Silmate on the dust seal ring (9), then
press in its housing.
12. Lubricate the gasket inner surface with Alteflon
Gasket Seal 730 grease.
30
13. Assemble the steering knuckle (10) on the wheel
axle (11) using a hydraulic press. Heat the inner
ring of the sleeve (13) and the spacer ring (14)
at 80 -- 90_C, then assemble them on the wheel
axle (11).
14. Lay the wheel axle on the support 2900090 with
the tool 296082 (15) and fasten with the relevant
nuts (16).
31
15. Assemble the snap ring (18) on the ring bevel
gear (17) and fit it in the housing.
32
16. For lifting, screw in two special tools 51011 in the
two threaded holes located one facing the other
in the final drive.
17. Assemble the final drive housing (19) on the
wheel (11) of the axle, using a suitable lifting de-
vice.
Pay special attention not to damage the dust seal
ring and the gasket.
33
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18. Fit the spacer ring (20) in the wheel axle, with the
groove facing outwards.
34
19. Lubricate the seat and assemble the sleeve (7,
page 6) with a suitable punch.
35
20. Fit the special tool 51013 (21) in the reduction pin-
ion (see figure on page 16).
With the wrench 296124 (22), first of all tighten
the ring gasket (9, page 6) to the torque of 400
-- 500 Nm.
21. Remove the tool (21) and rotate the housing three
or four times. Assemble again the tool (21) and
loosen the bearing ring, then tighten to a torque
ranging from 100 to 300 Nm.
36
22. Assemble the ring with the safety tangs (23).
37
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23. With a ratio 1:5 (24) and a wrench 296124 (22),

tighten the second ring gasket (part 8, page 6)
to the torque of 1000 Nm.
24. Remove the wrench (22) and bend the tangs of
the slip ring (23) previously fit.
38
25. Lay a film of Silmate on the edge of the cover (25),

then assemble it using a plastic hammer.
39
26. Lay the cover (26) surfaces with a film of Loctite

Super--fast 510, assemble the cover and tighten
the screws to the torque of 50 Nm.
Screw in the following plugs:
-- Oil level plug (27), 23 Nm.
-- Oil drain plug (28), 90 Nm.
-- Bleed plug (29), 28 -- 30 Nm.
NOTE: To get a reduction on the right or on the left,
the oil drain plug and the bleed plug must be screwed
in the reverse direction, while the cover must be ro-
tated by 180_, so that the oil level plug is at 15 mm
below the gearbox central line.
40
604.64.961.00 - 04 - 2003
TOOLS
NOTE: To get a safe operation, best performance as

as well as to save time and effort, each assembly
must be fitted using the specified tools. Assembly
must be carried out correctly: for diagrams and in-
structions, refer to this manual.
Tool to be manufactured to remove the wheel axle
(see tool no. 51012).
Make a 20--mm thick disc in Fe42.
41
Tool to be manufactured to fasten the ring gasket as

a support of the final drive (see tool no. 51013).
Make the tool in Fe42.
42
Tool to be manufactured to lift the final drive (see tool

no. 51011).
Make five pieces in 18 NiCr.
UNI 7846
Capacity of 60 kg.
43
604.64.961.00 - 04 - 2003
SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1 1
Chapter 1 -- Hydraulic system (TC)

Page
Hydrostatic system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydrostatic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pump replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Motor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
System filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Charge pump intake pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Input shaft replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
604.64.961.00 - 04 - 2003
2 SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1
HYDROSTATIC SYSTEM DIAGRAM
604.64.961.00 - 04 - 2003
A: pump housing
B: motor housing
1: variable displacement pump
2: charge pump
3: pump supply pressure limiting valve (20 bar)
4: flow divider (manual)
5: pressure limiting servo--controlled valves
6: multifunction valves
6a: calibrate at 420 bar
6b: calibrate at 450 bar
6c: by--pass
6d: supply check valve
7: motor supply pressure limiting valve (20 bar)
8: swinging valve
9: steady displacement motor
10: filter
11: reservoir
12: radiator
13: thermal valve
14: servo cylinder
15: float check valves
16: limiting valve
604.64.961.00 - 04 - 2003
1. Hydrostatic pump
A: drive shaft C: cylinder block

B: charge pump D: swash plate
604.64.961.00 - 04 - 2003
Specifications
The specifications of the pump (fig. 2) are marked on the data plate.
90R075 Na1 A8S3C7DO3NLN424224
90: series 90, closed circuit
R: rotation direction: to the right
075: max. flow: 75 cm3/rev.
NA: mechanical flow adjustment not linear
1: pressure limiter in ports A and B
(1: with overpressure -- 2: without overpressure)
A: opening SAE -- A closed
B: double radial fitting
S: intake filter
3: no mechanical flow limiter
C7: input shaft: 23 teeth, effective pitch 16/32
D: supply pump flow: 17 cm3/rev.
03 pressure duct throttle diameter: 0.81 mm
NLN: low noise
42: pressure difference in A: 420 bar
42: pressure difference in B: 420 bar
24: supply pressure adjustment at 24 bar
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2. Hydrostatic motor
3
E: cylinder block G: motor swash plate
F: main shaft H: swinging valve
604.64.961.00 - 04 - 2003
Specifications
The specifications of the motor (fig. 3) are marked on the data plate.
90M075NCON7NOC7WOONNN000024
90: series 90, closed circuit
M: double--acting motor
NCON: standard version
7: axial openings
NO: standard version
C7: shaft with 23 teeth -- effective pitch 16/32
W: recirculation system pressure washing device
OONNNOOOO: not available
24: supply pressure value at 24 bar
604.64.961.00 - 04 - 2003
3. Pump replacement
Removal
1. Lock the combine so that it cannot move.
2. Drain oil from the hydrostatic oil reservoir
through the hose (A).
3. Remove the electrical cable from the sender (B),
the hydrostatic lines (C) and the control cable (D)
(fig. 5).
4. Prevent dirt inlet inside hydrostatic lines.
5. Remove the four pump fastening screws with the
support (E) (fig. 5).
6. Remove the pump.
Assembly
1. Fasten the pump to the support (E).
2. Connect all hydrostatic lines (C) and (K) and the
control cable (D) to the pump, then connect the
electrical cable to the sender (B).
3. Fill the system (see paragraph 5 ”System filling”).
4. Motor replacement
Removal
1. Lock the combine so that it cannot move.
2. Drain oil from the hydrostatic oil reservoir (fig. 4)
by the hose (A) and the plug under the hydro-
static motor.
3. Remove the hydrostatic lines from the motor. 5
4. Remove the hydrostatic motor from the gearbox.
Assembly
1. Fasten the motor to the gearbox.
2. Connect the hydrostatic lines to the motor.
3. Fill the system (see paragraph 5).
604.64.961.00 - 04 - 2003
5. System filling -- Start the engine and let it run at low idle. The
max. supply pressure must be 20 bar.
-- If a new hydrostatic motor and/or a new hydro- -- Let the engine run at idling speed for 5 minutes,
static pump must be installed, drain oil from both. moving the ground speed control lever forward
and backward, slowly, and leaving the gearshift-
-- Adjust the revolution control cable (fig. 5), then ing lever in neutral position.
place the ground speed control and the gearshift- The supply pressure must be at least 16 bar.
ing lever in neutral position.
-- Remove the pressure gauge in point (G), as-
-- Position a gauge (with scale up to 60 bar) next to semble the sender and connect the electrical
the opening (G) of the pump for the supply pres- cable (B).
sure gauge (fig. 5).
-- Check oil level in the reservoir and add oil until re-
-- Loosen the charge pump line in point (F) (fig. 5) aching the max. level mark on the dipstick, if re-
at the charge pump inlet. quired.
-- Fill the reservoir up to the highest mark on the oil
dipstick, using oil corresponding to the following 6. Charge pump intake pressure
specifications:
DIN51524 HLP 46 -- min. viscosity index 155.
-- Intake pressure 0.7 bar absolute, measured in
-- As soon as oil flows out, tighten the fitting in
point (M) (fig. 5) with a new filter cartridge and an
point (F) (fig. 5).
operating temperature of about 50_C.
-- Loosen the hydrostatic line (K) next to the pump
-- An intake pressure of about 0.5 bar absolute is
housing (fig. 5) and the plug under the hydro-
allowed for a short time interval, with a reservoir
static motor.
temperature lower than 50_C in case of cold
-- Pour in oil through the line (K) until it flows out starting, to heat the system without stressing it.
from the loose plug under the motor.
-- Intake pressure lower than 0.6 bar absolute at
-- Tighten the plug under the motor again and re- operating pressures over 50_C: the filter must be
connect the hydrostatic line (K) to the pump. replaced.
-- Add oil until reaching the highest mark on the dip- -- An intake pressure steadily lower than 0.5 bar
stick. absolute is not allowed. In this case, the filter
-- Let the engine run for 10 seconds with the starter. must be replaced, the temperature is too low or
-- Check oil level in the tank and add oil until reach- oil has a too high viscosity.
ing the max. level, if required.
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7. Input shaft replacement
Disassembly
1. Remove the three screws (A) (fig. 6) and the
cover plate (B) with the gaskets.
2. Position the pump so that the shaft grooved end
is facing upwards.
3. Take out the shaft (C) and the bearing (D) (fig. 7).
Assembly
1. Fasten a new bearing (D) on the shaft (C) (fig. 7).
2. Fasten new gasket on the guard (B) (fig. 8).
3. Fasten the guard (B) to the pump and tighten the
screws (A) to the torque of 13.5 Nm (fig. 6).
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8. Pressures:
2 bar -- to be measured with the ground speed lever

in neutral position.
10
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Chapter 2 -- Hydraulic system (AL)

Page
Hydrostatic system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydrostatic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydrostatic motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pump drive pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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HYDROSTATIC SYSTEM DIAGRAM
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A: Sauer 90 R 100 pump

B: Sauer 90 M 100 motor
1: Vario pump
2: pressure pump
3: pump pressure limiting valve (26 bar)
4: pressure servo--control
5: single--acting valves
6: multifunction valves
6a: adjustment pressure: 420 bar
6b: adjustment pressure: 450 bar
6c: by--pass valve
6d: charge pressure control valve
7: motor drain valve (24 bar)
8: shifting valve
9: steady motor
10: intake filter (up to frame no. 3804026 and 8404009)
11: oil reservoir
12: exchanger
13: by--pass valve
14: servocylinder
15: check valves
16: delivery/return valve
17: pressure filter (from frame no. 3807001 and 8407001)
2 3
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Hydrostatic pump
4
A: input shaft C: multifunction valve
B: pressure pump D: pressure limiting valve
PUMP SPECIFICATIONS
Pump specifications are shown on the data plate.
90R0100Na1 A8L3C7D03GBA424226
90: series 90, closed circuit system
R: pump rotation -- to the right
100: pump max. flow: 100 cm3/rev.
NA: manual control, not linear
1: pressure limiting valve in ducts (A) and (B) (high pressure lines)
(1: with delivery/return valve)
A: opening SAE A with dust cover
8: double duct, radial
S: intake filter (up to frame no. 3804026 and 8404009)
L: pressure filter (up to frame no. 3807001 and 8407001)
3: no limiter
C7: shaft with 23 grooves, rim clearance 16/32 in.
D: pressure charge pump flow: 17 cm3/rev.
03: check diaphragm -- dia. 0.81 mm
GBA: noise limit
42: high pressure duct (A) at 420 bar
42: high pressure duct (B) at 420 bar
26: charge pressure adjustment at 26 bar
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HYDROSTATIC MOTOR
5
E: driven shaft
F: unload valve
G: drive housing
H: motor swash plate
MOTOR SPECIFICATIONS
Motor specifications are shown on the data plate.
90M01OONCON7NOC7WOONNN000024
90: series 90, closed circuit system
M: double--acting motor
NCON: --
7: axial ducts
NO: --
C7: shaft with 23 grooves, rim clearance 16/32 in.
W: purge circuit valve
NNN: standard version
24: charge pressure at 24 bar
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PUMP DRIVE PULLEY
1. Pulley
2. Second grease fitting every 50 operating hours
3. Thrust element
4. Pump shaft
5. Spacer ring
6. Bleed
7. Movable bearing
8. Pump support bearing
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SECTION 33 -- BRAKES & CONTROLS -- CHAPTER 1 1
Chapter 1 -- TC
Page
Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Brake pedal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake master cylinder operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Left circuit bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bleed of the fitting between the two brake master cylinders . . . . . . . . 6
Right circuit bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parking brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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2 SECTION 33 -- BRAKES & CONTROLS -- CHAPTER 1
SERVICE BRAKE
Removal (fig. 1 and 2)
1. Remove the spring (C) and the pins (G).

2. Loosen the nuts (J) and remove the brake
lever (H).
3. Remove the brake guard (B).
4. Remove the outer brake disc (D), the brake
mechanism (E) and the inner brake disc (D).
Assembly
Assemble the parts in the reverse order.
Adjustment (fig. 1 and 2)

1. Remove the spring (C) and the pin (F).
2. Measure the distance X (fully retracted cylinder).
3. Pull the lever (H) upwards to 215 N. Adjust the
nuts (J) to get a clearance = X + 4 mm. 1
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Brake pedal adjustment (fig. 3)

1. Remove the pin (K). Adjust the height of the pedal
Y = 205 mm with the adjusting screw (L).
2. Take out the rod (M) and adjust the fork (N) until
the pin (K) can be fitted easily.
3. Empty travel: 50 to 60 mm.
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Brake master cylinder operation

(fig. 4 and 5)
Both brake master cylinders are reciprocally linked by
the fittings (B) and (C), to the oil reservoir and to (R)
by the pipe (K) and to the brake cylinder through the
pipe (D).
Oil coming from the oil reservoir reaches the brake
master cylinder by the opening (E) (released pedal).
If both brake pedals are pressed, the opening (E) is
closed by the seal (I) and oil is pushed in the brake
cylinder through the opening (F).
The ball (H) is lifted in both brake master cylinders (A)
by the piston (J).
When only one brake pedal is pressed, the open-
ing (E) is sealed as well by the seal (I) and oil is
pressed into the brake cylinder through the open-
ing (F).
In the other brake master cylinder, the ball (H) is
pressed down by the pressure of oil coming from the
first brake master cylinder, through the fitting (B) and
the part (G). Oil flow is stopped by the seal (P).
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BRAKE BLEED
Left circuit bleed (fig. 6)
1. Slide one end of a transparent hose over the air
bleed screw (F) and dip the other end in a con-
tainer partially filled with brake fluid.
2. Open the air bleed screw (F) of the brake cylinder.
3. Press the left brake pedal several times, until oil
starts flowing in the container.
4. Close the air bleed screw (F).
5. Depress the left brake pedal several times to
build up pressure.
6. Keep the pedal depressed.
7. Slightly open the air bleed screw (F) so that oil
and air can come out through the transparent
hose. 6
8. Close the air bleed screw (F).
9. Release the brake pedal.
10. Remove the transparent hose from the air bleed
screw (F).
Bleed of the fitting between the two

brake master cylinders
1. Slide the transparent hose over the right air bleed
screw.
2. Open the right air bleed screw.
3. Press the right brake pedal and hold it pressed.
4. Press the left brake pedal once and hold it
pressed.
5. Release the right brake pedal and then the left
brake pedal.
6. Repeat steps 3, 4, 5.
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Right circuit bleed
TC56
1. After sliding the transparent hose over the right

air bleed screw, press the right brake pedal many
times, until brake fluid flows into the container.
2. Close the right air bleed screw.
3. Press the right brake pedal several times to build
up pressure.
4. Keep the pedal depressed.
5. Slightly open the right air bleed screw so that oil
and air can come out through the transparent
hose.
6. Close the air bleed screw.
7. Release the brake pedal.
8. Repeat steps 3, 4, 5, 6 and 7 until the fluid flowing
out from the transparent hose is free of air
bubbles.
9. Remove the transparent hose from the air bleed
screw.
7
TC54
PARKING BRAKE ADJUSTMENT
Parking brake on differential shaft

(fig. 7 and 8)
With the pedal in the lowest position, adjust the cable

so that the distance X between pedal and pin is max.
4 mm.
8
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Parking brake on input shaft (fig. 9)
1. Adjust the support (A) so that the angle X = 13_ 2. With the brake lever in the lowest position, adjust
when the brake lever is pulled upwards. Tighten the cable (B) so that the angle X = 8_.
the grooved nuts.
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Chapter 2 -- AL
page
Service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Brake pedal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Brake master cylinder operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Brake disc disassembly and replacement . . . . . . . . . . . . . . . . . . . . . . . . 5
Replacement of brake parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brake bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Replacement of brake parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Parking brake disc -- disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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SERVICE BRAKES
1
Brake pedal adjustment
1. Remove the pin (K).
Adjust the height of the pedal Y = 205 mm with the
adjusting screw (L).
2. Fully loosen the rod (M) and adjust the fork (N)
until the pin (K) can be fitted easily.
3. Allowed pedal travel: 50 -- 60 mm.
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Brake master cylinder operation

(fig. 2 and 3)
Both brake master cylinders are reciprocally linked
through (B) and (C).
The line (K) is connected to the oil reservoir and the
line (D) is connected to brake cylinders.
Oil coming from the reservoir reaches the brake
master cylinder through the opening (E) (released
pedal).
If both brake pedals are pressed, the opening (E) is
closed by the seal (I) and pressurized oil is pushed in
the brake cylinders through the opening (F).
The ball (H) of both brake cylinders is lifted by the pis-
ton (J).
If only one pedal is pressed, the opening (E) is closed
through the seal (I) and pressurized oil is sent to the
brake cylinder through the opening (F).
In the second brake master cylinder, the ball (H) is
shifted by the pressure generated by the oil coming
from the other cylinder and passes through the fit-
ting (B) and the part (G). Oil flow is stopped by the
seal (P).
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BRAKE DISK DISASSEMBLY AND

REPLACEMENT
To replace the brake disc, the axle shaft must be re-

moved.
Proceed as follows:
1. Loosen the adjusting screws (1) of the brake cali-
per.
2. Remove the brake caliper, fit a suitable shim to
keep brake shoes separated, so that brake cali-
per can be fitted later on in the brake disc. Do not
bend the brake hose. Oil flow in the hose should
not be interrupted. 4
3. Fasten the brake caliper in the housing.
DANGER
The procedure below must be carried out with the ut-
most care. Fit the corresponding wrench only after
switching the engine off. The combine should stand
on an even ground and be blocked by suitable
wedges. Otherwise, additional staff is needed.
5
4. Remove the brake disc screw (2). Then, press
the brake disc towards the gearbox.
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5. A hole (3) is located on the disc supporting flange;

through this hole the three locking screws of the
supporting bearing (4) can be reached.
6. Slowly drive the combine forwards, to align the
holes with the corresponding screws.
7. Fully remove the axle shaft, check the brake disc
and replace it, if required.
8. Brake disk thickness: 22 mm.
9. During assembly, the larger joint operates as a

stop where the axle shaft fits during the assembly
in the described sequence.
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REPLACEMENT OF BRAKE PARTS
To replace, proceed as follows:

1. Take out the pin (1) fastening the brake parts and
remove the springs (2).
2. Take out the other pin.
3. Remove the brake parts (3) as shown.
10
4. Fully fit the brake cylinder to get clearance

enough to assemble the new brake parts.
5. Assemble the pins (1) and the springs again.
6. If brakes have been opened, air must be bled.
11
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BRAKE BLEED
To bleed, proceed as follows:

1. Check if the brake oil reservoir (1) is full.
12
2. Remove the plug (2) from the bleed valve.

3. Connect a drain hose to the bleed pipe (3). The
other end of the hose must be dipped in a con-
tainer with brake fluid, so that, when the brake
pedal is released, no air can be taken in.
4. Press the brake pedal many times, successively,
then release it slowly. Wait until the pump is filled
by the brake oil reservoir.
5. Repeat this process many times. The reservoir
(1) must be filled regularly.
6. Brakes are fully bled when oil (without bubbles)
flows out from the hose (3).
13
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PARKING BRAKE
REPLACEMENT OF BRAKE PARTS

1. Remove the flexible cable (1) from the parking
brake as shown.
14
2. Take out the fastening screws of the slide gauge
(2) through the hole in the brake disc (3), then
take the slide gauge out.
15
3. Remove the hinged pin (4) from the levers and
take the lever out.
16
4. Remove and replace both brake parts (5).
5. Fit the slide gauge and tighten the corresponding
screws.
6. Connect the flexible cable to the lever again.
17
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7. Leave the flexible cable loose and make sure that

the lever (5) lays on the rubber disc (6) of the re-
turn line.
8. Adjust the nuts (7), until the distance between the
pin of the flexible cable and the disc corresponds
to 5 mm ± 2 mm, as shown in the figure.
9. Manually tighten the screws (9) until they touch
the brake shoes, then loosen by one sixth of
thread and fit the nuts (8).
10. Then, check if the disc slides easily when the
lever is in neutral position and when the brake
does not reach the stop.
18
PARKING BRAKE DISC -- DISASSEMBLY

1. Remove the parking brake slide gauge proceed-
ing as above described.
2. Remove the snap ring (3) and disconnect the disc
from the shaft.
19
604.64.961.00 - 04 - 2003
SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 1
Chapter 1 -- TC
Page
Hydraulic system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Hydraulic valve functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hydraulic adjustment valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Steering valve removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydropneumatic accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Valve stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Adjustment valve repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hydraulic cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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2 SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1
HYDRAULIC SYSTEM COMPONENTS TC54 mech. -- TC56 mech.
1. Steering valve
2. End plate
3. Inching variator 4/3 way valve
4. Loading sensing circuit selector
5. Header lifting/lowering 4/3 way valve
6. Load sensor circuit selector
7. Reel lifting/lowering 4/3 way valve
9. Unload tube swinging 4/3 way valve
11. Reel forward/reverse 4/3 way valve
13. Inlet element
14. Pressure limiting valve
15. Flow adjusting 3--way valve
16. Diesel engine
17. Double hydraulic pump
18. Ventilation with filter and lock valve
19. Filling opening with filter
20. Drain hose
21. Return filter
22. Header cylinder
23. Hydraulic accumulator
24. Reel horizontal adjustment cylinder
25. Multiple clutch
26. Unload tube -- header cylinder
27. Reel vertical adjustment cylinder
28. Pressure gauge for ground pressure
29. Inching variator adjustment cylinder
P: pressure line
R: return line
--: pilot line, load sensing line
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HYDRAULIC SYSTEM COMPONENTS TC54 hydrostatic -- TC56 hydrostatic
1. Steering valve
2. End plate
3. Header side compensation 4/3 way valve
5. Reel lifting/lowering 4/3 way valve
7. Unload tube swinging 4/3 way valve
9. Reel forward/reverse 4/3 way valve
11. Inlet element
13. 3--way pressure gauge
14. Diesel engine
15. Double hydraulic pump 16 + 5.5 cc
16. Ventilation with filter and lock valve
17. Filling opening with filter
18. Drain hose
19. Return filter
20. Header lifting cylinder
21. Hydraulic accumulator
22. Reel horizontal adjustment cylinder
23. Multiple clutch
24. Unloading tube cylinder
25. Reel vertical adjustment cylinder
26. Side compensation cylinder
27. Header lifting/lowering valve
28. Secondary pressure limiting valve
29. Accumulator connection valve
30. Pressure sensor
32. Oil radiator
P: pressure line
R: return line
--: pilot line, load sensing line
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HYDRAULIC VALVE FUNCTIONS
TC54 AND TC56 WITH MECHANICAL

TRANSMISSION
If the power supply to a solenoid valve is stopped,

that is in case of emergency, the valve can be en-
abled by the tappets (6) on the solenoid valve end.
1. Reel forward/backward
2. Unloading auger in and out swinging
3. Reel lifting/lowering
4. Header lifting/lowering
5. Inching variator opening/closing
TC54 AND TC56 WITH HYDROSTATIC

TRANSMISSION
2. Unload tube in and out swinging
TC54 AND TC56 WITH HYDROSTATIC

TRANSMISSION AND AUTO--FLOAT SYSTEM
2. Unload tube in and out swinging
4. Header side sloping lifting/lowering
604.64.961.00 - 04 - 2003
EXPLANATION OF SYMBOLS
Symbol Description
Thermal engine (2100 rpm)
Single acting double hydraulic pump
Open air reservoir

Capacity: 20 liters
Return oil filter, installed in the reservoir upper part

By--pass valve calibrated at 1.14 bar
High pressure filter, assembled next to the adjustment valves
By--pass valve calibrated at 3.5 bar
Ventilation with filter and check valve
Filling opening with filter
Quick release joint connected to check valves with mechanical opening
Hydropneumatic accumulator. The fluid is pressurized by compressed nitrogen

Pressure can be adjusted by different valves
Restriction
Lock valve, with remote--controlled valve opening
Check valve: pressure opening by outlet pressure plus spring tension
Check valve, allowing the flow in one direction and preventing it in the opposite
direction
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Symbol Description
Pressure limiting valve; inlet pressure piloting through the opening of the outlet
hole towards the reservoir.
Differential pressure adjuster. Discharge pressure is decreased by a constant,

linked to the intake pressure.
Fixed displacement motor with two flowing directions (hand pump).
Hydraulic oil flow adjusting valve. It keeps a steady flow of 9 l/minute towards the
steering circuit.
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HYDRAULIC PUMP
PUMP ASSEMBLY AND DISASSEMBLY
Figures from 7 to 10 20
1. Remove the four socket screws (29), so that the
pump can be split in two parts, figure 8.
2. To split the two pump halves, remove the
cylinder screws (20).
3. In this way, the fitting (27) is released.
4. Remove the slip ring (17).
5. Replace all seals (12), (14) and (15). 29
20
6. For the assembly, proceed in the reverse order
40539
of disassembly.
7
IMPORTANT: The seals (12), (14) and (15) must be
fitted so that the oil flow follows the direction of the
arrow. If the mark on the pump housing is in the upper
part, the pump drive shaft is at the bottom.
HYDRAULIC PUMP -- fig. 7 -- 11 20
1 Pump housing
2 Bearing cover
3 Housing cover
4 Gear
5 Gear
6 Bearing shell
7 Bearing shell
8 Cylinder pin
9 Cylinder pin
10 Plug 27
11 Protection plug 40537
12 Flat seal ring
8
13 Supporting ring
14 Seal ring
15 Shaft seal ring
16 Toothed ring 15
17 Slip ring
18 Snap ring
19 Hexagonal nut
20 Cylinder screw
21 --
22 Pump housing
23 Cover
24 Housing cover
25 Gear
26 O--ring
27 Drive pawls 14 17 14
28 -- 40952
29 Long cylinder screw
9
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Torque Torque
43 Nm 50+10 Nm
52445
10
23
20
22
29 10
6 13 12
14
25
7 8 16
11 15 A
9
24 7
26
8 4 9 11 14 13 20
1
14 6
27 13 7 3
A 12 12
5
20
6 8
9 10
6
2
8 4 9
14 7
15 13
17 12
18
19
11
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HYDRAULIC ADJUSTMENT VALVE

The Danfoss adjustment valve is formed by a selec-
tor valve and by a recirculation pump.
While assembling a recirculation pump in the valve
housing, keep a perfect relationship between steer-
ing wheel and steering cylinder, so that the vehicle
can be manually steered even in case of hydraulic
system failure.
Steering wheel operates the selector valve and the
recirculation pump. The valve arm is kept in neutral
position by leaf springs.
During steering wheelrotation, leaf springs allow only
a small movement between valve arm and spool.
Four openings are directed to the valve body:
P: pressure inlet
T: return to the tank 12
L and R: steering cylinder connection, on the left
and on the right
A ball floats between the openings (P) and (T). In

standard operating conditions, the floating ball is
pushed in its housing and seals the connection be-
tween (P) and (T).
When, in the opening (P), pressurized oil does not
come from the pump (for example due to a failure of
the hydraulic pump), steering is always possible as
return oil moves the ball from its seat and flows to the
intake line (P).
604.64.961.00 - 04 - 2003
STEERING VALVE REMOVAL AND INSTALLATION
WARNING
This valve carries out an important safety function.
The repairs of this valve must be carried out by staff
suitably trained to this purpose, with specific instruc-
tions about the valve. Use only genuine NEW HOL-
LAND spare parts.
13
PRELIMINARY REMARKS
1. Make sure to get the special tool no. 80395892

before disconnecting the two halves of the steer-
ing valve.
This special tool must be used for positioning
new gaskets in the valve body.
2. Fit the shaft in the rotor and make sure that the
drive groove is at the same height of the rotor
notches (see arrows) (fig. 13).
3. Before assembling the special screw with the cyl-
inder pin, make sure that the floating ball be-
tween the openings (P) (fig. 12) and (T) is per-
fectly seated.
14
REMOVAL
1. Lock the steering valve in a vise (see fig. 14). Re-

move the cover plate screws (D).
2. Remove the cover plate (E) (fig. 15) with the
rotor and its housing (F), then remove the O--
rings from both sides of the rotor housing.
15
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3. Remove the shim (G) and the input shaft (H).
16
4. Remove the intermediate plate (I) and the

O--ring (J).
17
5. Loosen the lock ring (K).
18
604.64.961.00 - 04 - 2003
6. Take out the floating ball (M) from the rotor hous-
ing, than remove both intake valves in point (E)
(2 pins and 2 balls).
19
7. Press the valve spool body to take it out of the

valve housing.
During this procedure, the valve housing must be
kept vertical.
20
8. One after the other, remove the washer (N), the

needle bearing (O), the sliding ring (P) and the
ring (Q).
Press the crossed pin (S) to take it out of its hous-
ing, then remove the leaf springs (R).
Remove the valve spool body from the valve
arm.
21
604.64.961.00 - 04 - 2003
9. Now, the ring (T) and the O--ring (U) can be re-
moved from the steering valve body. These seals
are located at the inlet of the steering valve body.
22
10. Clean all disassembled parts carefully.

Before assembly, all the O--rings (V), the
washers (W) and the leaf springs (R) should be
replaced.
Before assembly, all parts should also be lubri-
cated with hydraulic oil.
23
INSTALLATION
1. Symmetrically fit the leaf springs (R) in the

spool (X), so that the spring ends open if the
spring is fitted correctly.
24
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2. Assemble again the spool housing (X) and the

valve arm (Y), then fasten them with crossed
pins (S).
25
3. One after the other, install the ring (Q), the sliding
disc (P), the needle bearing (O), and the
washer (N) on the valve spool body.
26
4. Lubricate the ring (T) and the O--rings with ”Esso

Bearing Q” or a similar lubricant. Then, position
the parts of rings (T) and (U) around the spindle
of the special tool (part no. 80395892).
27
604.64.961.00 - 04 - 2003
5. Then, press the handle of the special tool until

feeling some resistance on the seal rings.
28
6. Fit the special tool with the seal rings in the valve
housing bore, until the tool handle touches the
ground.
29
7. Keep the tool handle in this position and press

the spindle, rotating it downwards at the same
time, until the parts of the rings (T) (fig. 27)
and (U) do not fit sturdily in the groove. First of all
take out the spindle, then the handle of the
special tool.
30
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8. Now, tighten the valve body with all its compo-

nents in the valve housing.
31
9. Fit the floating ball (M) in the corresponding hole

and hold it by the locking plugs (K). Fit both intake
valves (2 pins and 2 balls) locating them at 180_
from the floating ball (M).
32
10. Install the O--ring (J) and the intermediate

plate (I).
33
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11. Then, assemble again the rotor housing (F) with

the rotor and the input shaft, with the joint (H). At
the same time, fit the new seal rings. The joint (H)
must be fitted so that the drive groove (Z) is on
the same plane as the rotor notches. Rotate the
rotor housing until the drive groove (Z) engages
with the pin (S) (fig. 25) in the spool body. Then,
fit the washer (G) (fig. 16).
34
12. Assemble again the cover (E) and rotate the rotor
housing until all openings are perfectly aligned.
Check that the floating ball (M) is in the correct
position. Assemble the bolt and the pin with a
new washer, so that the floating ball (M) is still
correctly seated.
35
13. Assemble the remaining bolts with new washers

and tighten the bolts in crosswise direction, to the
torque of 30 Nm. Now, assemble the fitting with
new O--rings.
36
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INTEGRATED ADAPTER
Fig. 37 and 38
Adjustment of the pressure limiting valve: 100 bar

Adjustment of the protection damping valve
(2 valves): 150 bar
Intake valve (2 valves E)
37
38
A Stop plug
B Pressure limiting valve adjusting screw
C Protection valve adjusting screw
D Stop plug
E Intake valves (2)
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HYDROPNEUMATIC ACCUMULATOR
One part of the hydropneumatic accumulator is filled

with nitrogen.
The other part is connected to a circuit of the hy-
draulic system.
FILLING
Required tools:
-- Bottled nitrogen
-- Special tool (valve + pressure gauge)
(Bosch re. no. 0538103004)
Proceed as follows:
39
1. First of all remove the Allen screw from the accu-
mulator.
2. Connect the special tool to the accumulator and
to the nitrogen bottle.
3. Open the valve (B) and read the value on the
pressure gauge. If necessary, add nitrogen by
opening the valve (C). Once the prescribed pres-
sure has been reached, close the valves(B)
and (C), bleed excess pressure by the valve (D)
and remove the special tool.
4. Retighten the Allen screw.
HEADER ACCUMULATOR
MACHINE MODEL GRAIN HEADER WIDTH NUMBER PRESSURE
10 feet 3 70 bar
Combine with
4 straw walkers
12 feet, 13 feet, 15 feet 3 80 bar
Combine with
12 feet, 13 feet, 15 feet
5 straw walkers
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VALVE STACK -- From fig. 40 to fig. 42
The valve stack is formed by two main components:

1. adjustment valve (13):
oil supply and power measurement.
By power measurement, the high pressure in-
side the system is cut--out. Oil heating is thus li-
mited and a flow piloting is ensured independent-
ly of the charge.
2. Adjustment valves (3, 5, 7, 9, 11):
adjustment valves with power measurement:
3 traction variator adjustment valve
5 cutting header height adjustment valve
7 reel vertical adjustment valve
9 unload tube control valve
11 reel horizontal adjustment valve
40
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When all valves are in ”0” position: Operation of the valves (3, 5, 7, 9)
-- The valves (3, 5, 7, 9, 11) are closed, that is oil -- When one (or more than one) pilot spools are en-
cannot pass through these valves. abled, the hydraulic cylinder pressure (pump
-- The pilot line (14) operates the adjustment pressure measured depending on the spool re-
valve (13) connecting the pressure line to the restriction) is over the charge measurement spool
turn line, with a pressure difference of 3 bar. in point (14).
-- This pressure moves the charge measuring
spool (12) with the spring in position ”0”.
-- Pressurized oil does not pass through the open-
ing (R) and flows through the enabled adjust-
ment valve, to the hydraulic cylinders.
41
42
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ADJUSTMENT VALVE REPAIR
When one adjustment valve does not reply to a con-

trol, an electric or hydraulic fault could have oc-
curred.
-- Electric fault: the solenoid does not operate the
valve spool.
Result: no power supply to the solenoid spool or
faulty solenoid spool.
In this case, the valve spool can be manually op-
erated by pressing the rubber plug of the sole-
noid and moving the valve spool to the operating
position.
When there is no power at the solenoid, as a tem- 43
porary solution, connect the electric cables of
another valve (not used) to the faulty solenoid.
-- Hydraulic fault: a single valve cannot be re-
placed. Only the seal rings can be replaced.
IMPORTANT: While assembling the valve stack, pay
attention to the tightening sequence and torque of
the screws (fig. 43).
Screws 1 and 2: 25 Nm
Screw 3: 13.5 Nm
Tighten the screws in this sequence.
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HYDRAULIC CYLINDERS
The gaskets can be replaced in all hydraulic cylin-

ders.
The cylinders listed below are assembled and re-
moved in the same way.
1. Variator control cylinder
2. Grain tank unload tube cylinder
3. Steering cylinder
To remove, proceed as follows:
With a nut wrench or a threaded tool, rotate the cylin-
der head in the direction of the bevelled edge of the
notch (C) until the safety metal wire can be removed. 44
NOTE: In some cylinders, both edges of the notch
(C) are bevelled. In this case, the cylinder head can
be rotated in both directions to remove the safety
metal wire.
After removing the cylinder head, take out the piston
rod and remove all seals. Clean the cylinder pipe and
the piston rod. Lubricate and assemble again the pis-
ton rod, the cylinder tube and the seals. Move the cyl-
inder head (D) on the piston rod and align the groove
of the safety metal wire and of the notch on the cylin-
der tube. Rotate the cylinder head until the notch in
the groove becomes visible. Fit the bent end of the
safety metal wire in the notch and pay attention so
that the other end faces the bevelled edge of the cyl-
inder notch. Now, further rotate the cylinder head (D)
until the safety metal wire completely fits in the
groove.
45
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STEERING CYLINDER
46
A Cylinder F O--ring
B Piston rod G Piston ring
C Plumb cable H O--ring under the piston seal ring (I)
D Oil scraper ring I Piston seal ring
E Seal ring
WARNING
This cylinder carries out an important safety function.
Repairs of this cylinder must be carried out by skilled
staff. Use only genuine NEW HOLLAND spare parts.
604.64.961.00 - 04 - 2003
HEADER CYLINDERS
Remove the cylinders starting from the end (Z): re-

move the oil scraper ring (E) and the slip ring (D).
Then, take the rubber gasket (C) and the plastic
ring (B) out of the cylinder.
For the reassembly, proceed in the reverse order of
removal.
NOTE: The rubber seal ring (C) has a lip on one side.
During reassembly, this side must face the slip ring.
A Cylinder
B Plastic ring
C Rubber seal ring -- position it so that the lip
faces the slip ring
47
D Slip ring
E Oil scraper ring
48
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VARIATOR CONTROL CYLINDER
A Cylinder
B Plumb cable
C Notch for fitting the pump cable
D Cylinder head
E Brown plastic ring
F White plastic ring
G Piston rod
H Rubber O--ring
I Seal ring
K Oil scraper ring
49
M Groove for the pump cable
N Rubber O--ring under the plastic ring (E).
50
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UNLOAD TUBE CYLINDER
A Cylinder
B Plumb cable
C Notch for fitting the pump cable
D Cylinder head
E Brown plastic ring
F White plastic ring
G Piston rod
H Rubber O--ring
I Seal ring
K Oil scraper ring
51
M Groove for the pump cable
N Rubber O--ring under the plastic ring (E)
NOTE: To remove the cylinder head, remove the re-

taining ring of the rings (E), (F) and (N).
52
604.64.961.00 - 04 - 2003
Chapter 2 -- AL 59, levelling and pressure control

Page
Location of the hydraulic system main components . . . . . . . . . . . . . . . . 2
Power steering and hydraulic system line diagram . . . . . . . . . . . . . . . . . 5
Location of the levelling hydraulic system main components . . . . . . . . . 7
Location of the hydraulic system main components . . . . . . . . . . . . . . . . 8
Height compensation line diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Header side compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Header pressure limiting valve stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Oil flow divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Levelling control double pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pump identification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydraulic cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cross levelling cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Longitudinal levelling cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Header cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Header side compensation cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Driving wheel control cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
604.64.961.00 - 04 - 2003
LOCATION OF THE HYDRAULIC SYSTEM MAIN COMPONENTS
PART FIGURE
1 MOTOR 1
2 HYDRAULIC OIL RESERVOIR FOR POWER STEERING AND PRESSURE CONTROL 2
4 OIL FLOW DIVIDER 3
5 BY--PASS CONTROL VALVE ELEMENT 4
10 REEL SIDE CONTROL VALVE ELEMENT 4
11 UNLOAD TUBE CONTROL VALVE ELEMENT 4
13 REEL HEIGHT CONTROL VALVE ELEMENT 4
17 HEADER CONTROL VALVE ELEMENT 4
18 MANUALLY--OPERATED HEADER SIDE COMPENSATION CONTROL VALVE ELEMENT 4
20 SINGLE ACTING THROTTLE VALVE (DIA.: 3 MM) 5
21 HEADER HYDRAULIC SYSTEM PRESSURE GAUGE 6
22 HYDROPNEUMATIC ACCUMULATOR 7
23 PNEUMATIC SYSTEM RETURN FILTER 8
26 PNEUMATIC SYSTEM OIL DRAIN RESERVOIR 9
27 THROTTLE VALVE (DIA.: 3 MM) 10
28 POWER STEERING (OSPC100) 10
31 HEADER HEIGHT CONTROL CYLINDER 11
32 STEERING WHEEL HYDRAULIC SYSTEM CONTROL CYLINDER 12
604.64.961.00 - 04 - 2003
LOCATION OF THE HYDRAULIC SYSTEM

MAIN COMPONENTS
1 2
3 4
5 6
604.64.961.00 - 04 - 2003
LOCATION OF THE HYDRAULIC SYSTEM

MAIN COMPONENTS
7 8
9 10
11 12
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POWER STEERING AND HYDRAULIC SYSTEM LINE DIAGRAM
1 -- MOTOR
2 -- HYDRAULIC OIL RESERVOIR -- PRESSURE CONTROL (20.5 LITRES)
3 -- POWER STEERING AND HYDRAULIC PUMP (39 LITERS/MINUTE)
4 -- OIL FLOW DIVIDER (9 LITERS/MINUTE TO THE STEERING)
5 -- BY--PASS ELEMENT
6 -- CHARGE SENSOR VALVE
7 -- PRESSURE LIMITING VALVE (160 BAR)
8 -- POWER LIMITER (HOLE DIA.: 0.8 MM)
9 -- LOAD SENSOR CLOSING VALVES
10 -- REEL SIDE CONTROL VALVE ELEMENT
11 -- UNLOAD TUBE THROTTLE CONTROL VALVE ELEMENT
(DIA.: 1.4 MM)
12 -- THROTTLE VALVE (DIA.: 1.4 MM)
13 -- REEL HEIGHT CONTROL VALVE ELEMENT
14 -- THROTTLE VALVE (DIA.: 1.2 MM)
15 -- REEL HEIGHT CONTROL CYLINDER FOR 5.18 M HEADERS
16 -- REEL HEIGHT CONTROL CYLINDER FOR 4.57 M HEADERS
17 -- HEADER HEIGHT CONTROL VALVE ELEMENT
18 -- MANUALLY--OPERATED HEADER SIDE COMPENSATION CONTROL VALVE ELEMENT
19 -- COVER SHEET
20 -- SINGLE ACTING THROTTLE VALVE (DIA.: 3 MM)
21 -- HEADER HYDRAULIC SYSTEM PRESSURE GAUGE
22 -- HYDROPNEUMATIC ACCUMULATOR (CALIBRATION 70 BAR)
23 -- RETURN FILTER (25 MICRON, WITH BY--PASS VALVE)
24 -- PLUG WITH FILTER
25 -- BLEED WITH FILTER AND CLOSING VALVE
26 -- OIL DRAIN LINE FROM THE RESERVOIR
27 -- POWER LIMITER (DIA.: 3 MM)
28 -- POWER STEERING
29 -- PRESSURE LIMITING VALVE (110 BAR)
30 -- PRESSURE LIMITING VALVES
31 -- HEADER HEIGHT CONTROL CYLINDER
32 -- STEERING WHEEL HYDRAULIC SYSTEM CONTROL CYLINDER
604.64.961.00 - 04 - 2003
Cylinder pressure control for header

side compensation
13
604.64.961.00 - 04 - 2003
LOCATION OF THE LEVELLING HYDRAULIC SYSTEM MAIN COMPONENTS
NO. FIGURE
7 SIDE COMPENSATION CYLINDER, LEFT SIDE 14

9 LEFT SIDE COMPENSATION CYLINDER CLOSING VALVE 14
12 CROSS LEVELLING HYDRAULIC PUMP 15
13 CROSS LEVELLING HYDRAULIC SYSTEM PRESSURE LIMITING VALVE
16
14 CROSS LEVELLING CONTROL VALVE ELEMENT 16
15 HEIGHT COMPENSATION RETURN FILTER 17
16 LONGITUDINAL LEVELLING HYDRAULIC SYSTEM HYDRAULIC PUMP 15
17 LONGITUDINAL LEVELLING HYDRAULIC SYSTEM PRESSURE LIMITING VALVE
16
18 LONGITUDINAL LEVELLING CONTROL VALVE ELEMENT 16
19 HEADER VALVE STACK COMPENSATION 18
26 OIL DRAIN COMPENSATION RESERVOIR 19
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LOCATION OF THE HYDRAULIC SYSTEM MAIN COMPONENTS
14 15
16 17
18 19
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HEIGHT COMPENSATION LINE DIAGRAM
1 -- PRESSURE DIVIDER HEADER HEIGHT CONTROL ELEMENT

2 -- SINGLE ACTING VALVE FOR HEADER LOWERING SPEED LIMITING (HOLE DIA.: 3 MM)
3 -- HEADER LIFTING HYDRAULIC SYSTEM PRESSURE GAUGE
4 -- HYDROPNEUMATIC ACCUMULATOR (CALIBRATION 50 BAR)
5 -- HEADER LIFTING CYLINDER, LEFT SIDE
6 -- HEADER LIFTING CYLINDER, RIGHT SIDE
7 -- CROSS LEVELLING CYLINDER, LEFT SIDE
8 -- CROSS LEVELLING CYLINDER, RIGHT SIDE
9 -- LEFT CROSS LEVELLING CYLINDER CLOSING VALVE
10 -- RIGHT CROSS LEVELLING CYLINDER CLOSING VALVE
11 -- HEIGHT COMPENSATION OIL RESERVOIR (41 LITRES)
12 -- CROSS LEVELLING HYDRAULIC SYSTEM HYDRAULIC PUMP (30 LITERS/MINUTE)
13 -- CROSS LEVELLING HYDRAULIC SYSTEM PRESSURE LIMITING VALVE
(170 BAR)
14 -- CROSS LEVELLING CONTROL VALVE ELEMENT
15 -- HEIGHT COMPENSATION RETURN FILTER (25 MICRON WITH BY--PASS VALVE)
16 -- HYDRAULIC PUMP FOR LONGITUDINAL LEVELLING HYDRAULIC SYSTEM
(40 LITERS/MINUTE)
17 -- LONGITUDINAL LEVELLING HYDRAULIC SYSTEM PRESSURE LIMITING VALVE (170 BAR)
18 -- LONGITUDINAL LEVELLING CONTROL VALVE ELEMENT
19 -- VALVE STACK
20 -- PRESSURE LIMITING VALVE FOR HEADER LIFTING CONTROL HYDRAULIC SYSTEM,
LONGITUDINAL LEVELLING CYLINDER
21 -- LIFTING HYDRAULIC SYSTEM LONGITUDINAL LEVELLING CLOSING VALVE
22 -- LOWERING HYDRAULIC SYSTEM LONGITUDINAL LEVELLING CLOSING VALVE
23 -- HYDROSTATIC OIL RESERVOIR
24 -- LONGITUDINAL LEVELLING CYLINDER, LEFT SIDE
25 -- LONGITUDINAL LEVELLING CYLINDER, RIGHT SIDE
26 -- OIL DRAIN
604.64.961.00 - 04 - 2003
20
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HEADER SIDE COMPENSATION
HYDRAULIC SYSTEM CHARGE, BLEED AND

PRESSURIZATION
1. Header side compensation control valve

element
Y7. Solenoid valve for right orientation control
Y8. Solenoid valve for left orientation control
CAUTION
• Pressurized escaping oil can penetrate under
the skin and cause severe injuries. To protect
against oil splashes, wear rubber gloves and
safety goggles.
• Before carrying out maintenance or repair works
on the hydraulic system, let hot oil cool down. 21
• Before carrying out repair works on the hydraulic
system, switch the engine off.
• Outflowing oil must be collected in suitable con-
tainers, without forming puddles and preventing
it from penetrating the soil. Before its disposal ac-
cording to legal requirements, it must be stored
safely.
Proceed as follows:
1. Park the machine on level ground and lower the
header to the ground.
2. Stop the engine.
3. Open by two threads the bleed screws (D) of hy-
draulic cylinders (3) and (4) (fig. 24, on page 12),
on the left and on the right, between front axle
and axle support.
4. Start the engine and leave it at idling speed;
press three to four times the direction key (E) on
the left and on the right side, until the hydraulic 22
system is completely bled.
5. Tighten the bleed screws again.
6. Proceed in the same way with the hydraulic cylin-
ders (5) and (6) (fig. 24) of the front lifting device.
7. Now, pressurize the whole hydraulic system and
proceed as below described: press the key (E) to
lift the header. Tilt the header to the right and to
the left, 2 to 3 times, until its end of stroke.
23
604.64.961.00 - 04 - 2003
24
1 -- HEADER SIDE COMPENSATION CONTROL VALVE ELEMENT

2 -- HEADER SIDE COMPENSATION PRESSURE LIMITING VALVE STACK
3 -- RIGHT LOWER CYLINDER
4 -- LEFT LOWER CYLINDER
5 -- RIGHT UPPER CYLINDER
6 -- LEFT UPPER CYLINDER
604.64.961.00 - 04 - 2003
HEADER PRESSURE LIMITING VALVE STACK
1. Control valve lines (1), page 11, for header side

compensation control.
2. Pressure limiting valve calibrated at 205 bar.
3. Lines linked to the header side compensation
cylinders.
25
OIL FLOW DIVIDER
1. Oil supply line from the hydraulic pump for steer-

ing and pressure control.
2. Steering oil supply line
(quantity: 9 liters/minute, steady).
3. Oil supply line to the pressure control valve
(quantity: about 39 litres/minute).
26
604.64.961.00 - 04 - 2003
LEVELLING CONTROL DOUBLE PUMP
27
1. Fastening screws
(dyno wrench setting: 50 Nm)
2. Pump half for the cross levelling pressure control
3. Pump half for the longitudinal levelling pressure
control
4. O--ring
PUMP IDENTIFICATION DATA
LONGITUDINAL LEVELLING PRESSURE CROSS LEVELLING PRESSURE CONTROL

CONTROL PUMP PUMP
SN = product series SN = product series

P = product type (pump) P = product type (pump)
2 = drive line dimensions 2 = drive line dimensions
14 = displacement 11 = displacement
D = rotation direction (D = right) D = rotation direction (D = right)
SC = front input shaft (with wedge toothing) FR = front input shaft (milled)
4 = no intermediate disc 03 = front flat shape
6 = front flat shape (SAE A)
604.64.961.00 - 04 - 2003
HYDRAULIC CYLINDERS
PAGE
1. CROSS LEVELLING 16--17
2. LONGITUDINAL LEVELLING 18--19
3. HEADER LIFTING FROM THE FRAME, FROM NUMBER 3807001/8407013 20
4. HEADER LIFTING UP TO FRAME 20
5. HEADER SIDE COMPENSATION 21
6. DRIVING WHEEL PRESSURE CONTROL 21
7. REEL LIFTING CONTROL Standard version
8. REEL FORWARD MOVEMENT CONTROL Standard version
9. CROP UNLOAD TUBE OPENING/CLOSING Standard version
604.64.961.00 - 04 - 2003
CROSS LEVELLING CYLINDER REMOVAL
CAUTION
• Pressurized escaping oil can penetrate
under the skin and cause severe injuries. To
protect against oil splashes, wear rubber
gloves and safety goggles.
• Before carrying out maintenance or repair
works on the hydraulic system, let hot oil
cool down.
• Before carrying out repair works on the hy-
draulic system, switch the engine off.
• Outflowing oil must be collected in suitable
containers, without forming puddles and
preventing it from penetrating the soil. Be-
fore its disposal according to legal require- 28
ments, it must be stored safely.

1. Park the machine on level ground and operate
the safety latches (1).
2. Loosen the fittings (2) to drain oil slowly, be-
cause, at the beginning, outflowing oil is pressur-
ized. Then, remove the fittings.
3. Remove the pin (3) and the screws with the sup-
ports (4), then remove the cylinder.
29
604.64.961.00 - 04 - 2003
INSTALLATION

1. Fit the cylinder in its housing.
2. Assemble the supports (4) and fasten them with
the relevant screws.
3. Fit the pin with two spacer rings (3) and fasten the
fittings (2).
4. Fill with oil, then place the safety latches (1) in
home position.
5. For filling, move many times and shortly the lever
for the cross levelling manual override, to the left
and to the right.
6. This procedure can be interrupted only if the ma-
chine is moving, to prevent damaging the safety 30
latches (1). Release the latches and fill the reser-
voir up to the max. level notch.
604.64.961.00 - 04 - 2003
CROSS LEVELLING CYLINDER
SEAL REPLACEMENT

1. Loosen the ring nut (1) and unscrew it by about
15 mm.
2. Fit the cylinder head (2) fully in with a plastic
hammer.
3. Remove the ring nut (1) and the snap ring (3).
4. Remove the cylinder head (2) and take the piston
rod (4) out of the cylinder (5).
5. Loosen the nut (6) and take the piston (7) out.
6. Remove the seal support (2) from the piston
rod (4).
7. Take out all seals and carefully clean all the con-
cerned parts.
8. Fit the new seals after lightly oiling them, so that
their fitting can be easier.
9. Fit the cylinder head (2) in the piston rod (4).
10. Fit the piston (7) and fasten it by the jam nut (6).
11. Fit the piston rod (4).
12. Lock the ring nut (1).
13. When the piston rod (4) or the pivoting joint (8)
must be replaced, apply Loctite 270 on the piston
rod thread and fully tighten the pivoting joint (8).
31
604.64.961.00 - 04 - 2003
CROSS LEVELLING CYLINDER REMOVAL

CAUTION
• Pressurized escaping oil can penetrate
under the skin and cause severe injuries. To
protect against oil splashes, wear rubber
gloves and safety goggles.
• Before carrying out maintenance or repair
works on the hydraulic system, let hot oil
cool down.
• Before carrying out repair works on the hy-
draulic system, switch the engine off.
• Outflowing oil must be collected in suitable
containers, without forming puddles and
preventing it from penetrating the soil. Be-
fore its disposal according to legal require-
ments, it must be stored safely.

1. Fit two rectangular shims (1), suitably sized, on
the rear axle.
2. Lower the machine rear side with the suitable
hand lever for longitudinal levelling override until
the weight lays completely on the shims.
3. Loosen the fittings (2) to drain oil slowly, be-
cause, at the beginning, outflowing oil is pressur-
ized. Then, remove the fittings.
4. Remove the pin (3) and the supports (4), then
take the cylinder out.
32
INSTALLATION
1. Fit the cylinder in its housing.
2. Fit the supports (4) and the pin with both
spacers (3), then connect the divider pipes (2).
3. Lift the machine rear side with the suitable hand
lever for longitudinal levelling override until the
shims (1) are unladen. Remove the shims.
33
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LONGITUDINAL LEVELLING CYLINDER
SEAL REPLACEMENT

1. Loosen the cylinder head (1).
2. Take the piston rod (2) out of the cylinder (3).
3. Loosen the nut (4).
4. Take the piston (5) and the cylinder head (1) out.
5. Remove the seals from the piston (5) and from
the cylinder head (1).
6. Carefully clean the concerned parts.
7. Fit the seals in the piston (5) and in the cylinder
head (1), after lightly oiling them, so that their fit-
ting can be easier.
8. Fit the cylinder head (1) in the piston rod (2).
9. Fit the piston (5) and fasten it by the jam nut (4).
10. Fit the piston rod (2) in the cylinder head (3). Fully
tighten the cylinder head (1).
11. When the piston rod (2) or the pivoting joint (6)
must be replaced, apply Loctite 270 on the piston
rod thread and fully tighten the pivoting joint (6).
34
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HEADER CYLINDER
(starting from the frame no. 3807001/8407013)
CAUTION
To prevent injuries due to high temperature oil,
wear rubber gloves!
35
To replace the seal, proceed as follows:
1. Carefully remove the piston rod (1) so that the snap ring (2) aligns with the connection hole (3).
2. Press the snap ring (2) in the notch (4) with a screwdriver.
3. Take the piston rod (1) out of the cylinder (5).
4. Remove the seal (6) and the oil scraper ring (7).
6. Fit the new seal (6) and the oil scraper ring (7) after lightly oiling them, for their easier fitting.
7. Fit the piston rod (1).
8. Place the screwdriver through the connection hole (3), leave the snap ring (2) project from the notch (4) as
shown.
9. Fit the snap ring (2) and the oil scraper ring (1) after lightly oiling them, for their easier fitting.
604.64.961.00 - 04 - 2003
HEADER SIDE COMPENSATION CYLINDER

CAUTION
wear rubber gloves!
36
1. Remove the lower part (1).

2. Remove the rod (2).
3. Remove the seals (3), (4) and (5).
5. Fit the new seals (3), (4) and (5) after lightly oiling them, so that their fitting can be easier.
6. Fit the rod (2).
7. Assemble the lower part (1) again.
604.64.961.00 - 04 - 2003
DRIVING WHEEL CONTROL CYLINDER

CAUTION
wear rubber gloves!
37
1. loosen the ring nut (1) and unscrew it by about 15 mm.

2. Fit the seal support (2) fully in with a plastic hammer.
3. Remove the ring nut (1) and the snap ring (3).
4. Remove the seal support (2) and take the piston rod (4) out of the cylinder (5).
5. Loosen the nut (6) and take the seal support (7) out.
6. Remove the seal support (2) from the piston rod (4).
7. Remove the seals (8--9--10--11--12--13).
9. Fit the new seals (8--9--10--11--12--13) after lightly oiling them, so that their fitting can be easier.
10. Assemble the seal support (2), the seal block (7) inside and the jam nut.
11. Fit the piston rod (4) in the cylinder (5). The seal support (2) must be further pressed inside, so that the snap
ring (3) can snap into position.
12. Counter--lock the ring nut (1). When the piston rod (4) must be replaced, apply Loctite 270 on the piston rod
thread and fully tighten the extension (14).
604.64.961.00 - 04 - 2003
604.64.961.00 - 04 - 2003
SECTION 41 -- STEERING -- CHAPTER 1 1
Chapter 1 -- TC
Page
Steering wheel spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Spindle disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Spindle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering wheel toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fixed steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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2 SECTION 41 -- STEERING -- CHAPTER 1
STEERING WHEEL SPINDLE
13
1. Cover
2. Wheel hub
3. Disc
4. Bearing inner part
5. Protection plug
6. Spindle
7. Nut
8. Bolt
9. Bearing
10. Bearing outer part
11. Grease fitting
12. Axle cylinder
13. Ball joint
604.64.961.00 - 04 - 2003
SPINDLE DISASSEMBLY
DANGER
During disassembly and assembly operations, all
heavy parts must be fastened to suitable lifting de-
vices. Assemblies and parts must be fastened to suit-
able lifting devices.
While lifting the assembly, make sure no one is stand-
ing nearby.

2. Arrange a stand with capacity of at least 8000 kg
2
under the steering axle, on the assembly side.
3. Remove the wheel and the plug (1).
4. Loosen the nut with the special tool (W).
5. Remove the wheel hub (2) with a puller.
604.64.961.00 - 04 - 2003
6. Remove the bearing (4) with a puller.

7. Release the protection cover (5).
8. To replace the spindle (6), release the ball joint

(13) from the spindle steering lever (6) and re-
move the nut (8).
9. Remove the spindle from the bottom.
10. Keep the disc (3) and the bearing (9) for their
further utilization.
13
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SPINDLE ASSEMBLY
To assemble, proceed as follows:

1. Fit the bearing (9) in the spindle lower part.
2. Assemble the spindle (6) and fit the upper disc
(3). Fit the bolt (8).
13
3. Connect the ball joint (13) to the spindle steering

lever (6).
4. Fit the protection cover (5) and the bearing (4).
5. Assemble the hub (2) and the bearing outer part

(10).
6. The protection cover (5) must be correctly fit in
the hub housing (2).
604.64.961.00 - 04 - 2003
7. Tighten the nut (7) to the torque of 90 Nm. Man-

ually rotate the hub (2) with the tool.
8. While tightening, the hub must be rotated and
fitted by hitting it with a plastic hammer, so that
the bearing rings correctly enter their seats.
9. Fully loosen the nut (7).
Tighten the nut to the torque of 45 -- 50 Nm.
10
10. Fill the hub with AMBRA GR 75 MD grease

(N.H. 720 A).
11. Fit the boot of the hub (1) on the hub itself.
12. Assemble the wheel and tighten the screws to a
torque ranging from 304 Nm to 335 Nm.
13. Remove the stand.
11
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STEERING WHEEL TOE--IN
Toe--in--adjustment
Steering wheel toe--in must be adjusted correctly. If

the adjustment is wrong, the tyres could wear before-
hand. The distance between the steering wheels
must be smaller at the front than at the rear (facing the
direction of travel).
Toe--in check and adjustment
1. Pull the parking brake and lift the steering wheels
from the ground. 12
DANGER
Before adjusting the steering axle, the combine must
be supported by suitable stands to be positioned stur-
dily under the combine back.
The steering ball joints, wheel spindles, linkage and
components of the hydraulic steering system should
be checked every 50 operating hours.
2. Set the steering wheels in the straight ahead

position.
3. On both steering tyres, mark spots at 273 mm
from the centre on the front inside part of the
wheel rims at the centre--of--wheel height and
measure the distance (2).
4. Rotate the steering wheels by 180 degrees, until
the marks are at the same height from the wheel
center and are facing backwards. Now, measure
the distance (3).
The distance (3) must be from 8 to 12 mm longer
than the distance (2).
5. To adjust toe--in, loosen the cross link rod (4), re-
move the steering ball joint (6) from the steering
link and tighten/loosen the steering ball joint in the
same way, on both sides of the cross link rod (4).
After adjusting toe--in, tighten the castle nut of the
steering ball joints (6), lock with a new split pin,
then tighten the jam nuts (5) (see further on in this
chapter).
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FIXED STEERING AXLE
ADJUSTMENT
Adjust the toe--in following the procedure described

in the previous paragraph.
STEERING WHEEL STOPS
The steering wheel stops are factory--set and should

normally not require further adjustment. 13
Nevertheless, if they need adjustment, proceed as
follows:
1. tighten the screw (5) to its stop.
2. Rotate the steering wheel to the right or to the left,
to its stop, when the steering cylinder is at its end
of stroke.
3. Retract the steering cylinder 2 mm.
4. Rotate the screw (5) against the rear axle (TC56)
or against the support (TC54) and tighten the jam
nut.
5. Repeat the same procedure on the opposite side. 14
STEERING AXLE BALL JOINT
Check the steering axle ball joint clearance every 50

operating hours, to find out possible damage.
If, for whatever reason, the steering axle ball joint
must be removed, during assembly tighten the castle
nut to the min. torque of 49 Nm and fasten it with a
new split pin.
15
16
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Chapter 2 -- AL
Page
Steering wheel spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Spindle disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Spindle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Steering wheel toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
604.64.961.00 - 04 - 2003
STEERING WHEEL SPINDLE
11
12
1. Cover 7. Nut
2. Wheel hub 8. Slip ring
3. Disc 9. Disc
4. Bearing inner part 10. Bearing outer part
5. Protection plug 11. Grease fitting
6. Spindle 12. Nut
604.64.961.00 - 04 - 2003
SPINDLE DISASSEMBLY
DANGER
During disassembly and assembly operations, all
heavy parts must be fastened to suitable lifting de-
vices.
While lifting the assembly, make sure no one is stand-
ing nearby.

2. Arrange a stand with capacity of at least 8000 kg
under the steering axle, on the assembly side. 2
3. Remove the wheel and the plug (1).
4. Loosen the nut (7) with the special tool no.

293521.
5. Remove the wheel hub (2) with a puller.
604.64.961.00 - 04 - 2003
6. Remove the bearing (4) with a puller.

7. Release the protection cover (5).
8. To replace the spindle, remove the nut (12) and

the slip ring (8). Remove the spindle from the bot-
tom.
9. Keep the upper disc (3) and the lower disc (9) for
their future utilization.
12
6
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SPINDLE ASSEMBLY
To assemble the spindle, proceed as follows:

1. Fit the disc (9) in the spindle lower part.
2. Assemble the spindle (6) and fit the upper disc
(3).
3. Install the slip ring (8).
4. Install the wheel axle link and tighten the nut (12).
12
7
5. Fit the protection cover (5) and the bearing (4).
6. Assemble the hub (2) and the bearing outer part

(10).
7. The protection cover (5) must be correctly fitted
in the hub housing (2).
604.64.961.00 - 04 - 2003
8. Tighten the nut (7) to the torque of 90 Nm.

9. Manually rotate the hub (2) with the tool 293521.
10
10. Fully loosen the nut (11) and tighten it again to the
torque of 45 -- 50 Nm.
11. While tightening, the hub must be rotated and
fitted by hitting it with a plastic hammer, so that
the bearing rings correctly enter their seats.
12. Bevel the nut (7) inner tab according to the two
6
ground contours of the spindle (12).
11
13. Fill the hub with AMBRA GR 75 MD grease

(N.H. 720 A).
14. Tighten the hub boot (2) to its stop.
15. Fill the grease nipple (11) with grease, until it
flows out of the inner part of the protection cover
(5).
16. Assemble the wheel and tighten the screws to a 2
torque ranging from 304 Nm to 335 Nm.
17. Remove the stand.
11
12
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STEERING WHEEL TOE--IN
13
Steering wheels should have the right toe--in to avoid
tyre early wear and combine swerving while driving.
The distance between the front parts of steering
wheels must be lower than that between the rear
parts.
Toe--in is factory--measured, as shown.
When a high tyre wear is detected, toe--in must be ad-
justed as follows:
1. Position steering wheels so that they are parallel.
2. Support both swinging links on the sides, next to
the wheels, in the middle and parallel to the
ground.
3. Loosen the jam nuts (1).
4. Remove the pins (2) so that the swinging links (3)
can be tightened or loosened, if required. 14
5. During fine adjustment, check that the steering
angle on the right and left side ends at the corre-
sponding stroke (4).
6. Otherwise, adjust again.
7. Tighten the nuts (1) to the torque of 600 Nm.
8. Tighten the nuts (2) to the torque of 70 Nm.
9. To adjust toe--in correctly, it is always advisable
to adjust both swinging links (3) at the same
length.
15
604.64.961.00 - 04 - 2003
604.64.961.00 - 04 - 2003
SECTION 50 -- CAB CLIMATE CONTROL -- CHAPTER 1 1
Chapter 1 -- Climate control system

Page
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
A/C system utilization according to the law prescriptions . . . . . . . . . . . . . . 3
Storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
A/C system circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Compressor clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Drying bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Circuit parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Low pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
High pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Drier filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
604.64.961.00 - 04 - 2003
2 SECTION 50 -- CAB CLIMATE CONTROL -- CHAPTER 1
GENERAL INFORMATION
Best comfort
The AMERICAN SOCIETY FOR HEATING, RE- For heat transfer and transmission, three technical
FRIGERATING AND AIR--CONDITIONING EN- procedures are available and used in a perfectly op-
GINEERS (A.S.H.R.A.E) has communicated that the erating A/C system.
ideal temperature for human beings ranges between 1. Convection
22 and 25_C, while the air moisture content should
Heat is conveyed from one point to another through
range between 20 and 60%.
a moving substance: in available NEW HOLLAND
systems, the R134a coolant is used.
Cooling principles
2. Conveying
Considering that there are no special procedures for Heat moves to a cooler point through a given device.
cold generation, the following should be considered: Heat is conveyed by a cooler and a condenser.
• an A/C system transfers heat only from one place 3. Radiation
to another.
Procedure through which heat is transferred in the
• When a liquid absorbs heat enough, it changes its form of waves; in an A/C system, the condenser is the
aggregation status and becomes a gas, that it is most important component for heat radiation.
it evaporates.
The boiling point of a liquid depends on its pressure.
• Giving a sufficient quantity of heat, gas passes For water, the following applies:
again to the liquid state, that is it condensates.
• Heat passes from the hottest substance to the Pressure Boiling point
coldest one, until both reach the same tempera- bar ûC
ture.
0 100
1.4 126
--0.3 4
604.64.961.00 - 04 - 2003
A/C SYSTEM UTILIZATION ACCORDING TO LAW PRESCRIPTIONS
-- Keep the cab door closed. STORAGE CONDITIONS

-- Use the A/C system as much as possible.
-- Use the A/C system only when the fan is in posi- During the combine long storage, operate the A/C
tion I or II. system once a month, for at least five minutes. Let the
-- Control system the wished temperature through engine run at idling speed and place the fan in posi-
the thermostat (A/C system knob). tion II (in this way, the compressor seals are lubri-
Regularly check: cated and non--sealing points are excluded).
-- the conditions of the sight glass IMPORTANT: The A/C system must be operated
only when the temperature inside the cab is equal or
-- the condenser cleaning
higher than 21_C. In addition, the A/C system must
-- the air intake filter cleaning be operated only when the ambient temperature is
-- the exhaust pipe water dripping. over 10_C.
CAUTION
The A/C system should be checked by a skilled
technician at least once a year (before each harvest-
ing season).
Often coolant must be added because the new
R134a coolant is more volatile than R12 gas previ-
ously used. This is the reason why a small coolant
loss should be considered as standard.
CAUTION
After having the system filled by a skilled techni-
cian, the engine rpm should be kept at low idle. Then,
switch the A/C system on and let it work for two (2)
minutes until the system gas and lubrication reach
standard levels.
Now, the system can be started as usual.
604.64.961.00 - 04 - 2003
A/C SYSTEM CIRCUIT (Fig. 1)
Components 5. Cell drier filter

1. Compressor 6. Expansion valve
2. High pressure switch 7. Cooler tube bundle
3. High pressure delivery port 8. Low pressure delivery port
9. Low pressure switch
4. Condenser
TECHNICAL DATA
Coolant
Specifications: R134a
Quantity: 1850 g
Compressor
Type: SANDEN SD7M13KG7303/
SANDEN SD7H15KG7862 (*)
Displacement per revolution: 129.2/154,9 (*) cc
Oil reservoir capacity: 280 cc (Sanden SP--20)
(135 cc in the compressor + 145 cc in the circuit)
IMPORTANT: The use of R134a in an A/C system
compressor for automotive use requires special care
as for its lubrication.
For models SD7H13/SD7H15 (*) a special oil, PAG
type, Sanden SP--20 has been developed.
SP--20 represents the only type of oil approved for
models SD7H13/SD7H15(*). Never use a different
oil, for whatever reason.
Compressor clutch
Rated voltage: 12 V dc
Exclusion torque: 34 Nm
Min. engagement voltage: 7.5 V
Power consumption: 49 W
V--belt type: A
(*) Machine with 5 straw walkers and hydrostatic
transmission
604.64.961.00 - 04 - 2003
604.64.961.00 - 04 - 2003
COMPONENTS
Compressor
The compressor pumps R134a coolant through the
high and low pressure side of the A/C system.
The compressor intake side sucks low pressure

R134a gas from the cooler, where it is compressed,
then the compressor releases it at higher tempera-
ture and pressure.
An inner component, a ”blade valve” allows intake. It
is single acting valve that operates only when the
compressor piston moves on the intake stroke. By
another single acting blade valve, pressurized vapour
can come out of the compressor through the dis-
charge side. In this way, gas is pumped towards the 2
condenser through the discharge line.
The compressor has a specific quantity of coolant oil.
This water--free oil, that can be used with R134a, lu-
bricates the A/C system during operation.
The compressor is driven by a belt through an elec-
tromagnetic clutch.
The Sanden compressor is formed by five different
cylinders, each one equipped with piston, operated
by a swash plate when the crankshaft rotates.
Each of the five cylinders is equipped with blade
valves. Right thanks to the positive, pressurized inter-
nal lubrication system, an oil pump would be super-
fluous.
604.64.961.00 - 04 - 2003
CONDENSER The drying bottle filters the foreign bodies (both liquid
and solid) preventing any passage through the sys-
The condenser is formed by a set of spools, with in-
tem, with possible damage.
take and exhaust threaded fittings, surrounded by
thin cooling fins. A fuse is located at the top of the drying bottle. It burns
at 105_C to prevent inner overpressure.
Gas R134a at high temperature and pressure enters
the compressor at the top of the condenser, flows Thanks to a sight glass, the conditions of R134a in-
downwards through the spools and comes out of the side the system can be checked.
bottom of the condenser as R134a fluid, at high pres- In case of compressor or cooler fault, the drying bottle
sure and temperature. must be replaced.
The air that passes over the cooling fins operates as
a heat baffle.
DRYING BOTTLE
SIGHT GLASS
High pressure and temperature liquid R134a flows di-
rectly from the condenser to the drying bottle, carry-
ing out three main functions.
As a safety factor for the system, drying agent ab-
sorbs and isolates all moisture inside the system. If
mixed to R134a, it produces hydrochloric acid, hydro- OUTLET INLET
fluoric acid and carbon dioxide, all substances ex-
tremely noxious for the system components.
The drying bottle reservoir collects and keeps liquid
R134a, then sends it to the cooler, depending on the
system requirements.
FILTERS AND
DRIER
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EXPANSION VALVE
A = inlet from dry heater and drying bottle
B = outlet towards cooler
On the other side of the diaphragm, a compensation
pipe (6) is linked to the system low pressure side, be-
tween cooler and compressor. The actual pressure
inside the low pressure side closes the expansion
valve.
Both the measuring diaphragm (2) and the housing of
the ball of the expansion valve are very small. The
fast spreading of R134a inside this area can freeze
the moisture in this point of the system and stop the
coolant flow.
A spring under the valve tends to move the valve to-
wards the closing position. The spring is pre--set to
ensure the correct operation of the valve and the cor-
rect temperature differential between cooler intake
opening and outlet.
This temperature differential is an ”over--heating” in-
dispensable so that the vapour coming out of the
cooler does not contain any drop of coolant when it
goes back to the compressor.
4
COOLER
The expansion valve is the partition between the A/C Heat exchanger operates like the condenser and is
system low pressure side and high pressure side. formed by a set of aluminium cooling fins crossed by
a copper coil. The cooler carries out the opposite
Now, the liquid R134a at high pressure and tempera-
function of the condenser.
ture is sprayed in the cooler and becomes gas, that
is it changes the aggregation status. The cooler, receiving R134a at low pressure and tem-
perature, as a spray from the expansion valve, oper-
The embedded capillary tube (8), connected to the
ates as a boiler and a cooler.
upper part of the diaphragm chamber of the valve (9)
holds the liquid/gas mixture. The other end of the cap- Hot air inside the cab is blown on the cooler surface
illary tube (8) forms a spool for temperature measure- by a fan. Considering that R134a coolant in the cooler
ment, installed on the cooler drain opening. The pres- coil has a very low temperature, heat is drawn to-
sure varying inside the capillary tube presses the wards the cooler surface and is absorbed by R134a
diaphragm chamber (9). The diaphragm chamber coolant.
presses the adjustment pin (5) that opens and closes When the R134a coolant comes out of the cooler
the metering valve (3). In this way, the expansion through the outlet opening, it is a vapour at low pres-
valve, depending on the heat load inside the cooler, sure and temperature, drawn back into the com-
measures the exact quantity of R134a in the cooler. pressor inlet opening.
604.64.961.00 - 04 - 2003
Circuit parameters
A/C system Ambient temperature, _C Low pressure, bar High pressure, bar
Not operating 20 4.5 4.5

Not operating 30 6 6
Operating 20 from 0.5 to 1 11
Operating 30 from 1 to 1.5 14
Low pressure switch
Normally open switch:

non--adjustable
Intervention set point: 2.5 bar ± 0.3 bar
Exclusion set point: 0.3 bar ± 0.15 bar
Switch body colour: bronze
High pressure switch
Normally closed switch:

non--adjustable
Intervention set point: 2.8 bar ± 1.5 bar
Exclusion set point: 29 bar ± 1.5 bar
Switch body colour: green
Drier filter (fig. 5)
A sight glass is used to check the conditions of the

R134a coolant.
IF:
-- from the sight glass a milky and bubble--free cool-
ant fluid is visible, the coolant is in good condi- 5
tions;
-- from sight glass bubbles inside the coolant are 1. Outlet port
visible, there is too little coolant.
2. Sight glass with moisture content indicator
NOTE: When the A/C system is opened, the drier
filter must be replaced. 3. Inlet port
604.64.961.00 - 04 - 2003
SYSTEM FILLING
IMPORTANT: Main service operations on the A/C threaded fitting (4) creates a connection with the
system require special tools for coolant recovery and R134a coolant reservoir, to fill or drain the system.
regeneration. The third threaded fitting (3) creates a connection
Strictly comply with the instructions shown in the with the hose on the high pressure side leading to the
documents supplied with the tools. compressor.
The following information should be used only for the The low pressure gauge (7) is studied to measure
more simple maintenance operations and for refer- both vacuum and pressure and is calibrated in cm Hg
ence. (mercury) (76--0 cm Hg) with the vacuum scale and
in bar (0 -- 8.5 bar) for the pressure scale. The scale
INSTRUMENTS AND TOOLS on the high pressure side gauge (1) measures the va-
lues ranging from 0 to 35 bar.
Set of manifold gauges
DANGER
Never open the screw valve on the high pressure side
if the A/C system is operating. If the coolant is
pressed through the pressure gauge towards the
R134a reservoir, the reservoir could be damaged,
with possible severe injuries.
MAIN VALVES
These stem valves have three positions:
1. in the most advanced position (fully closed) the
compressor and the pressure gauge are separ-
ated from the rest of the system.
2. In the intermediate position, coolant R134a can
flow through the compressor, through the main
6 connection line and through the service opening.
This position is valid when the pressure gauges
are connected.
The manifold gauge is formed by a distribution pipe
with two screw valves (2 and 6). One of the intake 3. In opening position, a link is created between
valves is allocated to the low pressure side (6), while compressor and main connection line.
the other is allocated to the high pressure side (2) of Some valves are equipped with a service port at 45_.
an A/C system. They are placed on each end of the This opening shows that the valve houses a Schrader
distribution pipe. Three threaded fittings are located valve. These are considered superfluous for NEW
between the two manifold gauges (5, 4, 3). The first HOLLAND equipment and often cause misleading
threaded fitting (5) connects the hose on the low pres- measurements.
sure side to the compressor intake side. The second
604.64.961.00 - 04 - 2003
A Fully screwed in 1 Valve housings 4 Valve boot

B In intermediate position 2 Connection to the hose 5 Valve stem
C Open 3 Connection to the compressor 6 Service measuring port
Before operating on a NEW HOLLAND A/C system VACUUM PUMP

with stem valves, it is recommend to remove all
Air and moisture intake from the system. The pump
Schrader valves using a special tool.
must have a vacuum capacity of at least 1013 mbar.
604.64.961.00 - 04 - 2003
Coolant 4. Connect the vacuum pump to the remaining hose

(yellow) of the manifold gauge.
R134a.
COMPRESSOR OIL LEVEL CHECK

Electronic leak detector
The oil level should be checked:
It is portable device with a pivoting probe for leak
detection. The leaks are signalled by the buzzer or -- before starting a new compressor;
alarm of the device. Among all leak detectors, the -- after repairing a compressor;
electronic device is definitely the most sensitive one. -- after adding coolant to the system.
For detection a leak, keep the device under a fitting.
NEW HOLLAND uses the following oil in the com-
pressor: B.P. ENERGOL LPT 150.
Tooling
Technical data:
To adjust the compressor valves, a 1/4” wrench is re-
quired for square fittings and a 9/19” wrench for hex- Type: ISO 150
agonal fittings. Specific density at 15_C 0.907 kg/l
Oil Viscosity at 20_C 133 CST

Top--up for vacuum pump. 100_C 11.1 CST
50_C 9.9_E
Top--up for the compressor. For information concern-
ing the allowed oil types, refer to the end of the para- Viscosity index
(ASTM D 2270) 51
graph ”Compressor oil level check”.
Flash point (COC) 231_C
ASSEMBLY OF THE MANIFOLD GAUGE Melting point --27_C
To install, proceed as follows: Hardening point --42_C
1. hang the manifold gauge in a safe place, far from CST Centistoke
the machine rotating parts. _E Engler degrees
2. Connect the low pressure gauge (blue hose) to 1_E= 7.5 CST
the compressor intake side.
3. Connect the high pressure gauge (red hose) to
the compressor drain side.
604.64.961.00 - 04 - 2003
For oil level check, proceed as follows:

1. Tighten the main valves for compressor high and Dipstick
low pressure (fully screwed in).
2. Determine the locking angle. Position the bubble STOP
level on the flat surface of both fastening slots.
Center the air bubble. Determine the locking
angle with precision.
3. Fully unscrew the oil filling plug. Watch through Left assembly
angle
the opening and rotate the clutch front sheet to
Right assembly
position inner parts, as shown in the figure below. angle (looking at the Oil filling hole
clutch)
View with compressor angle to View with compressor angle to

the right the left
Top view
Stem ball joint
9
Stem ball joint
If the assembly angle is to the left, the dipstick angle
must be to the right.
Piston rod
Piston rod If the assembly angle is to the right, the dipstick angle
Ball housing on planetary Ball housing on planetary
plate
must be to the left.
plate
In both cases, the angle lower surface must be facing
the oil filling opening surface.
Oil filling hole 7. Take the dipstick out and count the oil units.
To determine the oil level for the compressor assem-
bly angle, proceed according to the following table.
8
4. Compressor installed to the right (in front of the ASSEMBLE ANGLE ALLOWED OIL LEVEL
clutch). Center the parts when they move to the (degrees) (intervals)
back of the compressor (discharge stroke). 0 4--6
5. Compressor installed to the left (in front of the 10 6--8
clutch). Center the parts when they move to the 20 7--9
front of the compressor (intake stroke). 30 8--10
This step is required to release the dipstick from 40 9--11
the inner parts and to fit it completely. 50 9--11
60 9--12
6. Fit the dipstick up to its lock position. The stop 90 9--12
position is the angle next to the dipstick upper
part. Tighten the oil filling plug again (tightening torque
from 7.8 to 11.8 Nm).
Connect the vacuum pump -- with a set of pressure
gauges -- to the compressor intake and drain pres-
sure gauge.
604.64.961.00 - 04 - 2003
Empty the compressor until reaching 71.1 cm Hg and SYSTEM TEMPERATURE

follow the instructions in the paragraph ”Oil level VACUUM
check” starting from the compressor emptying. (cm Hg) ûC
IMPORTANT: If the system has never been operated 71.0 38
and coolant hoses longer than 5 m are used for its 73.3 27
emptying, add oil in the liquid areas and the intake 74.6 16
areas.
75.4 5
Add about 30 cc of oil for every 2 additional meters of
coolant hose. 75.7 --7
The hose should not exceed the length of 15 m. 75.9 --18
For the system emptying, proceed as follows:
SYSTEM EMPTYING
1. connect the distribution pipe, as described,
IMPORTANT: Every 300 m above sea level you must through the fitting of the pressure gauge set.
add 2.54 cm Hg to the value measured by the vacuum 2. Set the main valves of the compressor in central
meter, to compensate for atmospheric pressure vari- position.
ation.
3. Fully open the low pressure side and the high
Air and moisture are eliminated while emptying. pressure side of the pressure gauge control
When the vacuum pump decreases the system pres- valves.
sure, the boiling point of moisture possibly inside the
4. Operate the vacuum pump and check the gauge
system decreases as well. Thus, during system
low pressure side, to check if the system gener-
emptying, the boiling point of the moisture possibly in-
ates vacuum.
side the system must be lower than ambient tempera-
ture, for a complete moisture removal. If the low pressure gauge does not show at least
71.1 cm Hg after 5 minutes, check the system for
The relationship between system vacuum and boiling
leaks or a loose pressure gauge fitting.
temperature for water vapour to be removed from the
system is the following: After reaching the minimum vacuum pressure of
71.7 cm Hg, let the vacuum pump operate for
further 5 minutes.
604.64.961.00 - 04 - 2003
5. Re--check the system for leaks closing the pres- Proceed as follows:
sure gauge valves, switching the vacuum pump 1. Connect the central hose (yellow) of the pressure
off and reading the value on the gauge low pres- gauge to the coolant reservoir. Overturn the res-
sure side. If vacuum decreases by more than 5 ervoir so that liquid R134a can flow from the res-
cm Hg in 5 minutes, there are some leaks in the ervoir to the system.
system.
2. Open the valve of the R134a reservoir and re-
NOTE: A good way to check if there are leaks when move the threaded fitting of the central hose to-
both screw valves are closed consists in taking out wards the pressure gauge, to bleed the central
the central distribution hose of the vacuum pump and hose.
connecting it to a reservoir filled with coolant. Open
3. Open the valve on the high pressure side of the
both valves on the low pressure side and open the
gauge. Liquid R134a flows to the system drain
coolant reservoir by 1/4 of revolution, so that the sys-
side.
tem gets about 1/2 kg of coolant. Close the coolant
reservoir valve and carry out the test to detect the 4. When the pressure gauge reaches values rang-
presence of leaks, with an electronic leak detector. ing from 3 to 3.5 bar, close the valve of the upper
Empty the system, repair the leaks and repeat the part and put the coolant reservoir vertical again.
emptying procedure. 5. Start the engine and let is work at a speed of 1500
6. If the vacuum continues, proceed with the empty- rpm, set the cab A/C system to ”max. cold” and
ing for at least 30 minutes. rotate the cab fan switch to the second notch.
7. Close the high pressure side gauge valves and of 6. Adjust the vacuum valve so that coolant gas
the low pressure side, then remove the pump going inside the system does not generate a
central hose. Now the system can be filled. pressure higher than 3 bar on the low pressure
side. A pressure higher than 3 bar can damage
the compressor.
SYSTEM FILLING
The value measured by the high pressure side
Fill the system with liquid R134a coolant. gauge varies according to ambient temperature
changes.
Filling the system with liquid coolant is simpler and
more efficient. 7. Pressure--temperature relationship:
CAUTION NOTE:
Never fill the system with coolant while the com- • Engine speed 1500 rpm.
pressor is operating, as the A/C system could be • Ambient temperature is measured at 50 mm from
damaged. the condenser front.
604.64.961.00 - 04 - 2003
VALUE MEASURED 8. Once the required coolant quantity has been ob-
AMBIENT tained, close the low pressure side valve and
BY THE HIGH
TEMPERATURE check the pressure in the system, to make sure
PRESSURE GAUGE
it works correctly.
ûC bar
9. Close the valve of the R134a reservoir.
15.6 6.6 -- 7.9
10. Open both compressor main valves.
18.3 7.2--8.6
21.1 8.0-- 9.3 IMPORTANT:
23.9 9.0--10.3 • When the system is charged while the ma-
26.7 10.3--11.7 chine is operating and the ambient tempera-
ture is over 21_C, check the bubbles of the
29.4 11.4--12.8
drying bottle looking through the sight glass.
32.2 12.1 --13.7
• The system is completely full when there are
35.0 13.0--14.4
no bubbles in the sight glass.
37.8 14.8--16.2
• When the temperature is lower than 21_C,
40.6 16.2--17.6
some bubbles could be present even though
43.3 17.6--19.0 the system has been completely filled.
46.1 18.6--20.0
• The quantity of coolant to be added in the sys-
48.9 19.7--21.8 tem can be determined according to the sys-
tem pressure or the weight of the R134a. The
A/C system of a combine is full when the
quantity of coolant charged in the system
VALUE MEASURED corresponds to 1.9 kg.
COOLER • Sometimes the R134a coolant still present in-
BY THE LOW PRES-
TEMPERATURE side the reservoir must be heated to develop
SURE GAUGE
enough pressure to fill the system. The cool-
ûC bar
ant reservoir must be heated using hot water
--23.9 0.28 or wet cloths, at a temperature not over 50_C,
--21.7 0.41 after connecting the system for the filling
--18.9 0.55 operation.
--16.7 0.69
--14.4 0.83
--12.2 0.97
--10.0 1.10
--7.8 1.24
--6.7 1.38
--5.6 1.52
--4.4 1.66
--2.8 1.79
--1.7 1.93
0 2.07
2.2 2.41
5.6 2.76
8.9 3.10
11.7 3.45
14.4 3.79
16.7 4.13
18.9 4.48
21.1 4.82
604.64.961.00 - 04 - 2003
SYSTEM FILLING WITH R134a GAS 6. Close the high pressure side valve.
Proceed as follows: 7. Start the engine and let is work at a speed of
1500 rpm, set the cab A/C system to ”max. cold”
1. Connect the central hose of the distribution pipe
and rotate the cab fan switch to the second notch.
to the R134a reservoir, keeping the reservoir
vertical. 8. Adjust the vacuum valve so that coolant gas
going inside the system does not generate a
2. Open the reservoir valve and remove the
pressure, on the low pressure side, higher than 3
threaded fitting from the pressure gauge central
bar. At higher pressure, the compressor could be
hose.
damaged.
3. Let gas come out for a few seconds, then tighten
IMPORTANT: If the system intake side is in vacuum
the threaded fitting again.
conditions, the low pressure side could be locked. Be-
4. Open the low and high pressure valves of the fore proceeding, check if this is the case and possibly
pressure gauge, then let coolant flow inside the correct the failure.
system.
9. Add further coolant complying with this pro-
Now, the pressure inside the system should in- cedure, until the system is full.
crease.
The pressure indicated by the pressure gauge
IMPORTANT: depends on the different ambient temperatures
• Do not start the engine. and on the cooler temperature. To this purpose,
• Do not overturn the coolant reservoir, so that refer to the relationship between pressure and
no more coolant flows inside the system. temperature.
5. Add coolant complying with this procedure, until
the pressure gauge shows a pressure ranging
from 3 to 3.5 bar.
604.64.961.00 - 04 - 2003
ELECTRICAL SYSTEM
1. Compressor relay
2. A/C system switch
3. Intake fan switch
4. Intake fan
5. High pressure switch
6. Low pressure switch
7. Compressor clutch
10
604.64.961.00 - 04 - 2003
NOTE: The sensor of the A/C system should be fitted

between the cooler cooling fins, as shown in the fig-
ure below. Proceed according to the dimensions X
and Y between the first and second pipe (front view).
11
X = 160 mm
Y = 120 mm
604.64.961.00 - 04 - 2003
TROUBLESHOOTING
In most cases, the following failures are detected in
the A/C system:
no cooling Insufficient cooling

1. Faulty coolant lines. 1. Fan motor slow operation.
2. Leaks in the system. 2. Fan outlet clogged.
3. Loosen or damaged drive belt. 3. Insufficient air flow over the condenser spools
4. Fuse blown. (clogged cooling fins).
5. Faulty or interrupted ground cable. 4. Clogged cooler cooling fins.
6. Faulty or interrupted power cable. 5. Compressor clutch slipping.
7. The thermostat electric contacts are overheated 6. Air intake filter clogged.
or one element of the sensor is faulty. 7. Outer intake hoods open.
8. Ignition switch or relay burnt. 8. Insufficient coolant in the system.
9. Clutch coil burnt or broken. 9. Expansion valve filter clogged -- it can be found
10. Compressor partly or totally rusty. by a standard pressure or a slightly increasing
pressure reading with low intake pressure and
11. Compressor blade valve not operating -- it can be
high discharge temperature.
found only by a small difference between the re-
adings of both pressure gauges, for each engine
speed.
12. Leaks from compressor shaft seal.
13. Fan motor stopped or burnt.
14. Expansion valve locked in opening position -- it
can be found by a standard outlet pressure and
flow from the cooler.
15. Drying bottle filter or expansion valve filter
clogged.
604.64.961.00 - 04 - 2003
10. Load loss of the expansion valve thermal probe 5. Faulty or badly adjusted thermostat -- it can be
-- it can be found by too high readings and a too found out by a too low or too high reading of the
high transpiration of the intake line and of the low pressure gauge, that does not change even
cooler line. after an adjustment.
11. Drying bottle filter clogged -- it can be found by a 6. Clogged cooler cooling fins.
low pressure gauge reading lower than the stan-
dard values; the drying bottle and the liquid lines Noisy system
are cold and possibly frozen.
1. Loose system lining.
12. Too much moisture inside the system -- it can be
found by a too high reading of the pressure 2. Noisy clutch.
gauge. 3. Loose or worn drive belt.
13. Air inside the system -- it can be found by a too 4. Too low oil level in the compressor -- red--hot com-
high pressure and possible bubbles seen from pressor lower parts.
the sight glass. 5. Noisy compressor.
14. Faulty thermostat or badly adjusted -- it can be 6. Closed high pressure main valve -- the com-
found by a high reading of the low pressure gauge pressor produces a strong slap, the high pressure
or clutch slipping with a too high reading (engage- gauge shows a temperature higher than the stan-
ment and release). dard one.
7. System filled too much -- noise or swingings of the
Irregular cooling high pressure line, compressor creaking, too high
1. Faulty fan or fan motor. pressure and intake pressure, bubbles or liquid
clouding visible from the sight glass, or low pres-
2. Incorrect grounding or loose compressor clutch
sure.
spool fittings.
8. Insufficiently filled system -- howl of the cooler
3. Compressor clutch slipping.
housing, next to the expansion valve, bubbles or
4. Unit freezing -- it can be caused by too much liquid clouding visible through the sight glass, low
moisture in the system, a wrong adjustment of the pressure.
overheating in the expansion valve or a too low
thermostat adjustment.
604.64.961.00 - 04 - 2003
9. Too much moisture in the system -- noisy expan- NO COOLING:

sion valve, low intake pressure.
-- low pressure side low.
10. Noisy fan -- excessively worn motor.
-- High pressure side low.
For an easier troubleshooting of the A/C system, the
following pages make a synthesis of the main causes
for a bad cooling. For each condition, the remedies
are suggested.
During troubleshooting, to determine the individual
conditions for each fault, proceed as follows:
1. connect the manifold pressure gauge.
2. Operate the A/C system.
3. Carry out the operation test and compare the
measured values with those shown in the para-
graph ”Conditions”.
4. Consider the problems listed in the paragraph
”Diagnosis” and carry out additional tests accord-
ing to the description.
5. Carry out the repair works described in ”Actions”.
6. The high pressure values apply for an ambient
temperature of 35_C. If the temperature of the
testing room is not the same, refer to the para-
graph ”Pressure--temperature relationship”.
12
Conditions:
-- Low pressure side too low. The reading must
range from 1 to 2 bar.
-- High pressure side too low. The reading must
-- Bubbles in the sight glass.
-- Air coming from the cooler is not cold.
Diagnosis:
-- insufficient quantity of coolant in the system; this
condition could be due to a small leak.
604.64.961.00 - 04 - 2003
Actions: Conditions:
-- carry out the test for system leak detection. -- low pressure side too high. The reading must
-- Repair the leaks. range from 1 to 2 bar.
-- Check oil level in the compressor. -- High pressure side too high. The reading must
-- Drain the system.
-- Bubbles in the sight glass.
-- Fill the system.
-- Carry out the system operation test.
Diagnosis:
NO COOLING OR INSUFFICIENT COOLING -- air in the system. Air and air moisture contami-
nate the coolant, causing a system faulty oper-
-- Low pressure side high. ation.
-- High pressure side high. Actions:
-- discharge the coolant.
-- Replace the drying bottle.
-- Evacuate compressed air.
-- Fill the system.
13
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NO COOLING OR INSUFFICIENT COOLING Actions:

-- Low pressure side high. -- check if the expansion valve is stuck or if the tem-
perature probe has been installed correctly:
-- High pressure side high.
• let the system operate in max. cooling.
• Spray coolant at the top of the expansion
valve and/or on the temperature probe.
• Check the low pressure gauge. It should de-
tect the presence of vacuum.
-- If the above test shows that the expansion valve
is operating properly, proceed as follows:
• clean the surface of the condenser drain pipe
and the temperature probe, then fasten the
probe to the pipe.
• Operate the system and check its perform-
ance.
-- If the test indicates that the expansion valve is
damaged, proceed as follows:
• drain coolant.
• Replace the expansion valve.
• Relief the pressure.
• Fill the system.
14
• Carry out the system operation test.
Conditions:
-- low pressure side too high. The reading must
-- High pressure side too high. The reading must
-- Air coming from the cooler is hot.
-- High moisture on the surface of the cooler hose
and of intake hose (towards the compressor).
Diagnosis:
-- the expansion valve lets too much coolant flow
through the evaporator spools. The valve is
locked in open position or the temperature detec-
tion probe has been wrongly adjusted.
604.64.961.00 - 04 - 2003
NO COOLING OR INSUFFICIENT COOLING Diagnosis:

(in some cases, engine overheating) -- insufficient cooling due to the overpressure on
-- Low pressure side high. the high pressure side, due to a faulty condenser
operation (standard or excess coolant charge).
Actions:
-- check the belt tension. A loose or worn drive belt
could cause a too high pressure in the com-
pressor head.
-- Check that there are no clogged openings be-
tween cooling fins and condenser spool, or there
are other restrictions that could prevent the air
flow through the condenser.
-- In case of engine overheating, check that the
cooling fan operates correctly. Start the system
and check if the performance are satisfactory.
Check that there is no excess coolant charge.
Proceed as follows:
• let coolant flow out until some bubbles can be
seen through the sight glass and both read-
ings are lower than the standard values.
• Add new coolant until the bubbles disappear
and readings go back to standard values.
Now, add 100 to 200 g of coolant. Start the
15 system and recheck the performance.
-- If the readings are still too high, proceed as fol-
lows:
• drain coolant.
• Remove the condenser, clean and rinse so
Conditions:
that coolant can flow freely. If the condenser
-- low pressure side too high. The reading must is too much dirty or plugged, replace it.
range from 1 to 2 bar. • Replace the drying bottle.
-- High pressure side too high. The reading must • Evacuate compressed air and fill the system
range from 13 to 14 bar. again.
-- Bubbles in the sight glass. • Carry out the system operation test.
-- Red--hot liquid line.
-- Hot air coming from the cooler.
604.64.961.00 - 04 - 2003
INSUFFICIENT COOLING Diagnosis:

(during the hottest part of the day) -- too much moisture in the system. The drying
-- Low pressure side normal agent inside the drying bottle is oversaturated
and releases moisture at high outer temperature.
-- High pressure side normal
This moisture collects and freezes in the expan-
sion valve, preventing a flow of refrigerant
through the evaporator.
Actions:
• drain coolant.
• Replace the drying bottle.
• Evacuate compressed air.
• Fill the system.
16
Conditions:
-- normal pressure on the low pressure side; read-
ing between 1 and 2 bar. During the test, vacuum
is found.
-- Normal pressure on the high pressure side; read-
ing of about 14 bar, that decreases when the low
pressure gauge detects a vacuum condition.
-- Small bubbles through the sight glass.
-- Air coming from the cooler is cool enough until the
low pressure gauge detects a vacuum condition.
Now, air heats.
604.64.961.00 - 04 - 2003
INSUFFICIENT COOLING Actions:

-- Low pressure side low. -- touch the expansion valve intake opening with
your finger. If it is cold, proceed as follows:
• let the system operate in max. cooling.
• Spray coolant at the top of the expansion
valve or on the temperature probe.
• Check the low pressure gauge. It should de-
tect the presence of vacuum.
-- If this test shows that the expansion valve works
correctly, clean the surface of the cooler drain
pipe and the temperature probe, then fasten the
probe to the pipe.
-- If the test indicates that the expansion valve is
damaged, or if a frozen deposit or a high quantity
of moisture are found on the valve intake side,
proceed as follows:
• drain coolant.
• Replace the expansion valve.
• Make sure the temperature probe is fastened
correctly to the cooler drain line.
• Evacuate compressed air.
17 • Fill the system.
Conditions:
-- Low pressure side too low. The reading must
-- High pressure side too high. The reading must
-- Air coming from the cooler is cool, but not cold
enough.
-- Too much moisture or frozen deposit on the sur-
face of the expansion valve intake line.
Diagnosis:
the expansion valve is not permitting a sufficient flow
of coolant. Among the possible causes, we find: valve
locked in incomplete closed position or open position,
valve filter clogged or insufficient coolant in the tem-
perature probe.
604.64.961.00 - 04 - 2003

-- Low pressure side low. -- too few coolant in the system, indicating a major
leak.
Actions:
-- check the system for possible leaks.
-- Pay special attention to the compressor seal
area.
-- Drain coolant.
-- Repair the leaks.
-- Check oil level in the compressor, to make sure
there are no leaks.
-- Evacuate compressed air and fill the system.
18
Conditions:
-- low pressure side very low. The reading must
-- No liquid or bubbles visible through the sight
glass.
-- Hot air coming from the cooler.
604.64.961.00 - 04 - 2003

-- Low pressure side normal. -- non--condensables (air or moisture) inside.
-- High pressure side normal. -- System not completely filled.
Actions:
-- check the system for leaks and pay special atten-
tion to the compressor seal area.
-- Drain coolant.
-- Repair the leaks.
-- Replace the drying bottle.
-- Check oil level in the compressor, to make sure
there are no leaks.
-- Evacuate compressed air and fill the system.
19
Conditions:
-- in case of temperature changes (cooling), the
pressure on the low pressure side does not
change. Pressure should decrease until the com-
pressor starts rotating.
-- High pressure side normal, tending to increase.
The reading must range from 13 to 14 bar.
-- No bubbles or few bubbles visible through the
sight glass.
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INSUFFICIENT COOLING Actions:

-- Low pressure side high. -- insulate the compressor or drain coolant.
-- High pressure side low. -- Replace the compressor.
-- Check oil level in the compressor.
-- Evacuate compressed air from the compressor
or the system and fill.
INSUFFICIENT COOLING
-- Low pressure side low.
20
Conditions:
-- low pressure side too high. The reading must
range from 13 to 14 bar. 21
-- No bubbles visible through the sight glass (com-
pletely full system).
Diagnosis:
-- compressor inner leaks due to leaks of blade
valves or seal. Worn or cut pistons, rings or cylin-
ders.
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Conditions: Conditions:
-- Low pressure side too low. The reading must -- wrong pressure reading on the low pressure side
range from 1 to 2 bar. during the compressor switching on and off, or
-- High pressure side too high. The reading must wrong measuring range between the cycles.
range from 13 to 14 bar. -- The reading should be:
Diagnosis: • during switching--off: 0.85 to 1 bar;
-- there is an obstruction in the liquid line or in the • during switching--on: 2.5 to 2.7 bar;
drying bottle, causing a ”starvation” condition of • between the cycles: 1.7 and 1.9 bar.
the converter (air compressor deviates the cool-
-- High pressure side normal. The reading must
ant from the converter more quickly than the cool-
ant flows to the converter).
Diagnosis:
Actions:
-- faulty thermostat switch.
-- discharge the coolant.
Actions:
-- Replace the liquid lines, the drying bottle or other
obstructed parts. -- stop the engine and switch--off the A/C system.
-- Evacuate compressed air and fill the system. -- Replace the thermostat switch and make sure
that the capillary tube has been fitted correctly
with respect to the condenser core.
IMPORTANT: The tube is filled with pressur-
THE COMPRESSOR ROTATES TOO QUICKLY
ized coolant. Do not break or bend the capil-
(switching on and off)
lary tube too much.
-- Low pressure side high. -- Carry out the system operation test and check if
-- High pressure side normal. the compressor rotates correctly.
22
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SYSTEM FLUSHING
Flushing
Flushing the system is not recommended. In the
event of a major compressor failure, replacing the
compressor output line and the drier filter most of the
debris should be collected.
Some service or repair operations require flushing of
A/C systems to remove dirt or other debris. It has
been common practice to use another CFC, usually
R--11, for this purpose. The Clean Air Act prohibits the
use of any CFC for such a purpose where the CFC
may be released into the atmosphere. Methychloro-
form, a popular flushing agent, is also prohibited.
DANGER
Flushing should never be done with compressed air.
Certain mixtures of air and R134a are combustible.
The use of air to flush R134a systems could result in
combustion. Shop air also contains moisture which
would contaminate the system.
IMPORTANT: Never use CFC--11, R--11, CFC--12,

R--12, CFC--113, R--13 or any other substance to
flush an R134a system. To do so would result in
breakdown of the lubricant and system corrosion.
Use of other flushing solvents may cause other prob-
lems. If a vacuum pump does not remove the solvent,
it could affect the chemical stability of the refrigerant
and lubricant.
604.64.961.00 - 04 - 2003
Chapter 2 -- Compressor
Page
Compressor clutch replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clutch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clutch installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
604.64.961.00 - 04 - 2003
COMPRESSOR CLUTCH
REPLACEMENT
Clutch removal
1. Fit both pins of the nut wrench pins for the cover
plate in any threaded hole of the clutch cover
plate.
2. Lock the clutch plate. Then, remove the screw
with a socket wrench of 19 mm.
3. Remove the clutch plate using a puller, aligning

the puller center bolt with the compressor shaft.
4. Fit and tighten the three puller bolts in the
threaded holes of the clutch plate.
5. Rotate the puller center bolt clockwise, until the
clutch cover plate detaches from its housing.
6. Remove the compressor shaft key hitting it slight-

ly with a screwdriver or a hammer.
604.64.961.00 - 04 - 2003
7. Remove the bearing inner snap ring.
8. Remove the bearing housing outer snap ring.
9. Remove the rotor block:

-- First of all, fit the jaws in the groove of the inner
bearing snap ring.
-- Then, position the rotor shaft puller protection de-
vice on the free rotor shaft.
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10. Align the slotted head bolts to the puller jaws and
tighten manually.
11. Turn the puller center bolt clockwise until the rotor
pulley is free.
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12. Remove the field coil.

13. Remove the coil cable from the clamp on the
compressor protection housing.
10
14. Remove the snap ring and the field coil.
11
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Clutch installation
1. Install the field coil:

the projection of the field coil flange must fit per-
fectly in the hole of the front housing, so that the
field coil has no clearance; the drive cable must
be fitted correctly.
2. Replace the rotor pulley.
12
3. Lay the compressor on the four fastening holes

at the back of the compressor. Using a vise, lock
only the fastening holes, never the compressor
body.
4. Align the rotor assembly squarely on the end
housing hub.
5. Using a hammer or a special tool, hit the rotor until
it touches the compressor end housing hub.
13
6. Fit again the inner bearing snap ring.

7. Fit again the front housing outer snap ring.
14
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8. Replace the end plate assembly.

-- Check that the original junction seals are posi-
tioned correctly on the compressor shaft.
-- Replace the compressor shaft key.
-- Align the V--groove of the end plate with the com-
pressor shaft key.
-- With a shaft protection, press the cover plate
against the compressor shaft, until it touches the
junction seals.
15
9. Replace the shaft, screw and tighten it to a torque

ranging from 35 to 40 Nm.
10. Using a feeler gauge, check that the air gap
ranges between 0.4 and 0.8 mm. If the air gap is
irregular, lift the discs in the area where the differ-
ence is lower and press slightly downwards those
areas where the difference is higher.
16
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604.64.961.00 - 04 - 2003
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 1
Chapter 1 -- GENERAL INFORMATION
CONTENT
Section Description Page

Diagram info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Location of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ground speed calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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2 SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
GENERAL INFORMATION - Orange (or): lighting
- Yellow (ge): lighting
- Purple (pu): to rear direction indicator lights.

DIAGRAM INFO
- Transparent (tr)
WIRES
On the upper part of the page, the + 12 V lines are
The wiring diagram is drawn following the DIN 40719 drawn.
standards.
The line at the top (first line) always is at + 12 V (when
Each page contains a part of the complete wiring dia- the main battery switch is engaged).
gram, not necessarily a complete group.
Lines 2 and 3 have + 12 V when the ignition switch is
engaged.
Colour code On the lower part of the page, a line is marked with
numbers increasing by ten (10 - 20 - 30 - etc).
Ten colours of wires are used on the combine, each
colour having its specific signification. In some locations, an arrow (vertical or horizontal)
and a number is added.
- Red (rd): + 12 V without passing the igni-
E.g.
tion switch
- Black (zw): directly earthed to the frame
- White (wt): connected with the pin of a switch

which engages a system that in-
creases something (e.g. increase
of drum rpm)
820
- Grey (gr): connected with the pin of a switch
which disengages a system that
decreases something
- Brown (br): signal wire from the rpm monitor

to a sensor 60 70 80 90 100 110 120 130
- Blue (bl): earth of sensors through the This means that the line with the arrow and num-
monitor ber 820 is further connected with an item which is
found on the page on which 820 is marked. On
- Green (gn): wire to non rpm sensors (e.g. en- this page, a line with an arrow and number 100
gine oil pressure, temperature, will be found.
etc)
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Wire identification
The wiring diagram is marked as follows:

E.g.
E.g.
X16 p01 893-6 wt X108p02
X16p01: Connector X16, position 01

893: Wire number
6: Wire section is 6 mm2
wt: Wire colour (white)
X108p02: Connector X108, position 02
The other circuits that are protected by the same fuse
This information is printed at regular distances are drawn as follows:
on the wire itself, e.g.
E.g.
X16/01 < - 893 - > X108/02
Thick drawn lines in the wiring diagrams do

not exist as a wire but are lines in the printed
circuit.
(*) The line reference indicates the line on

which all connections (lines) with that par-
ticular fuse are mentioned.
SYMBOLS
Fuses
All symbols used in the wiring diagram are drawn ac-
A fuse can protect one or more electrical circuits. cording to the DIN 40719 standard and are marked
with a letter and a number.
When more circuits are protected, the first time the
fuse is mentioned, the drawing is as follows (really Each letter represents a group of similar compo-
connected): nents.
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The letters used can be found in following list:
Letter Component Example of typical components
A Monitors, prints Radio, CB, displays
B Commutator from non-electrical Sensor, horn, sender elements of water, air, oil
into electrical signals, and vice temperature and pressure, buzzer
versa
C Condensers
D Accumulator equipment Accumulators
E Lighting All lamps, except warning lights, dashboard lights
F Safety components All fuses
G Generators Battery, alternator
H Control components All control lamps
K Relays All relays, flasher unit
L Inductive components Coils in relays
M Motors Variator motors, ventilator, actuators
N Amplifier, controller Voltage controller
P Measuring instrument Fuel and water temperature gauge
R Resistances Potentiometer, preheating
S Switch All switches
T Transformer Ignition coils
U Commutator from electrical Frequence commutator, converter

signals into other electrical
signals
V Semi-conductors Diodes, transistors, thyristors
W Wiring looms, antennas CB and radio antenna, coax wires
X Connectors All connectors, plugs
Y Mechanical components Hydraulic valve, electromagnetic clutches, electrical

electrically energized valve on injection pump.
Z Electrical filter Suppressor
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RELAYS
The plug-in relays which MUST be used are the ones

fitted with a suppressor built inside the relay, parallel
with the coil.
REMARK:
NEVER use relays with a diode parallel with
the coil or without a suppressor.
The relays can be recognized by the drawing on the

relay housing.
USE
DO NOT USE
DO NOT USE
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EXPLANATION OF SYMBOLS USED IN THE ELECTRICAL DIAGRAMS
Symbol Description
Electrical motor, actuator
Lamp
Double-acting lamp
Diode
Led (light emitting diode)
Fuse
Socket (female)
Plug in (male)
Automatic fuse
Buzzer
Inductive sensor
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Symbol Description
Horn
Ignition switch
Solenoid for control valves
Flashing unit
Battery
Gauge
Electromagnetic clutch
Adjustable resistance
Bipolar switch
Loudspeaker
Alternator
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Symbol Description
Wiper motor
Electric starter motor
Normally closed switch, manually controlled
Normally open switch, mechanical control by pedal
Normally open switch, mechanically controlled
Normally open switch, mechanically controlled
Normally closed switch, mechanically controlled
Normally open switch, controlled by a pressure sender
Normally open switch, controlled by under-pressure
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Symbol Description
Normally closed switch, controlled by over-pressure
Normally open switch, controlled by a temperature sender
Normally closed switch, controlled by a level indicator
Normally open switch, controlled by the grain level indicator
Relay
Airconditioning ventilation motor
Mirror motor
REMARK: The switches are drawn in the position as they are removed from the combine.
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LOCATION OF MAIN COMPONENTS
M3
M4
G3
M1 Y23
55651
55650
1 2
B28
Y27 S63 S62 M18

55652 55653
3 4
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Y5 Y6
Y12 Y11
Y14 Y13
Y15 Y16
5 Y18 6 Y17
S49 S48 G2 G1
55656 55657
5 6
G3
7
M1
Y23
55658 55667
7 8
S113 S7 S6 S114 S65 S9 S115 S116 S12

S117
S41
S118
S119
S13
S120
9 S16
E55 S17 S39 S121 A45 A48

55664 55666
9 10
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S24 S22 S20 S25 S19

P
S41 S26
S18
S42 S27
S29
55665 55663
11 (Without lateral flotation) 12
55668
(With lateral flotation) 13 14
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52186
14
52187
15
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52188
16
52189
17
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52190
18
52191
19
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GROUND SPEED CALIBRATION
To obtain a correct ground speed read-out, the dip switches on the rpm control print have to be set in accordance
to the tyre size of the traction wheels installed (see table).
DIP SWITCH SETTING (0 OR 1)
Dip switch
Tyre size 1 2 3 4 5 6 7 8
23.1 x 26 1 1 1 0 1 1 1 1
23.1R x 26 1 1 1 0 0 0 1 0
28LR x 26 1 1 0 1 1 1 0 0
18.4 x 30 1 1 1 1 1 1 0 1
23.1 x 30 1 0 1 1 1 1 1 1
23.1R x 30 1 0 1 1 0 1 1 1
Tracks 0 0 0 0 1 1 1 1
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MISCELLANEOUS
MULTIFUNCTION HANDLE
The wires of the multifunction handle are not coded. If replacement or repair is needed, use the table below.
Function Switch Input + position Output + position
Reel speed up S26 wt/ge 13 bl 6
Reel speed down S27 wt/ge 13 rd 7
Header up S22 wt/gn 1 gn 2
Header down S20 wt/gn 1 ge 3
Reel up S19 wt/rd 22 wt 8
Reel down S18 wt/rd 22 br 9
Lateral flotation left- S24

hand side down br/gn 1 gr 5
(if installed)
Lateral flotation right- S25

hand side down br/gn 1 rose 4
(if installed)
Reversing mechanism S29 wt/gr 22 vt 10
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604.64.961.00 - 06 - 2003
Chapter 2 -- WIRING DIAGRAMS
CONTENT
Section Description Page

Electrical diagrams -- Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
List of symbols and where to find them . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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ELECTRICAL DIAGRAMS -- OVERVIEW
Ref. Line Group / Series
1A 0 STARTER CIRCUIT (HYDROSTATIC DRIVE)

TC54 9262 > .....
1B 0 STARTER CIRCUIT (HYDROSTATIC DRIVE)
TC56 9262 > .....
1C 0 STARTER CIRCUIT (MECHANICAL DRIVE)

TC54 9262 > .....
TC56 9262 > .....
1D 0 STARTER CIRCUIT (AL)

AL59 9262 > .....
2A 510 ENGINE PROTECTION
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
2B 510 ENGINE PROTECTION (FUEL POWER)
TC54 9262 > ..... TC56 9262 > .....
3 860 BLOW-OFF SYSTEM
TC56 9262 > ..... AL59 9262> .....
4 1020 CONTROLS + RPM

TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
5 1700 TACHOMETER
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
6 2040 GAUGES
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
7 2380 GRAIN LEVEL INDICATOR AND REVOLVING FLASH LIGHTS
TC54 9262 > ..... TC56 9262 > ..... AL59 9262> .....
8 2720 STRAW CHOPPER
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
9a 2890 VARIATORS
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
9b 2890 VARIATORS (lateral flotation)
TC56 9262 > .....
10 3230 SIEVE LEVELLING SYSTEM
TC54 9262 > ..... TC56 9262 > .....
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Ref. Line Group / Series
11 3570 UNLOADING, THRESHING AND HEADER ENGAGEMENT

TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
12 3740 REVERSING SYSTEM
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
13 3910 UNLOADING TUBE MOVEMENT
TC54 9262 > ..... TC56 9262 > ..... AL59 9562 > .....
14a 4080 REEL CONTROL
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
14b 4080 REEL CONTROL (lateral flotation)
TC56 9262 > .....
15 4420 LATERAL FLOAT AND STRAW ELEVATOR MOVEMENT
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
16 4930 LIGHTING
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
17 5780 DIRECTION INDICATOR AND HORN
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
18 6290 OPERATING LIGHTS
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
19 6970 PERFORMANCE MONITOR
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
20 7140 CAB
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
21 7650 MIRROR CONTROL
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
22 7820 MACHINE LEVELLING SYSTEM
AL59 9262 > .....
23 8160 MACHINE LEVELLING SYSTEM
AL59 9262 > .....
24 8500 HEADER HEIGHT CONTROLS
TC56 9262 > .....
604.64.961.00 - 06 - 2003
LIST OF SYMBOLS AND WHERE TO FIND THEM
A. Prints and Monitors
Code Description Line
A10. Radio 7440
A18. Printed circuit -- Rotary screen brush 3950
A41. Printed circuit -- Machine levelling system 8240

Printed circuit -- Blow-off timer 950
A42. Printed circuit -- Machine levelling system alarm box 8030
A43. Printed circuit -- Timer 1770
A45. Printed circuit -- Tachometer 1810

1820
A47. Printed circuit -- Performance monitor 7020
A48. Printed circuit -- Sieve levelling system 3360
A49. Printed circuit -- Autofloat module 8680
A51. Printed circuit -- Interface for header height control 8640
B Sensors, limit switches, buzzers, speakers
B1. Engine oil pressure switch 570
B2. Engine water temperature switch 530
B3. Engine oil temperature switch 550
B4. Hydrostatic oil pressure switch 1210
B5. Hydrostatic oil temperature switch 1210
B7. Air filter restriction sender 1310
B11. Engine water temperature sender 2090
B12. Fuel level sender 2150
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B16. Ground speed sensor 1790
B19. Grain elevator speed sensor 1880
B20. Straw chopper speed sensor 1820
B22. Threshing drum speed sensor 1730
B24. Cleaning fan speed sensor 1760
B28. Straw walker speed sensor 1850
B29. Horn 5880
B31. Loudspeaker 1 7420
B33. Straw walker grain loss sensor (right-hand side) 7110
B34. Sieves grain loss sensor 7110
B39. Straw walker grain loss sensor (left-hand side) 7110
B40. Reverse drive buzzer 430
B41. Engine protection buzzer 1800
B42. Sensor position 8870
B43. Sensor pressure 8510
B44. Sensor tracer -- left-hand side 8690
B45. Sensor tracer -- right-hand side 8720
B49. Temperature contact fuel power 600
E. Lighting
E1. Flashing light (left-hand side) 2500
E2. Flashing light (right-hand side) 2500
E3. Direction indicator, left-hand side (rear) 6060

Brake light, left-hand side 5030
Parking light, left-hand side (rear) 5280
E4. Direction indicator on straw hood, left-hand side 6080

Brake light on straw hood, left-hand side 5060
604.64.961.00 - 06 - 2003

Parking light on straw hood, left-hand side (rear) 5300
E5. Direction indicator on straw hood, right-hand side 6010

Brake light on straw hood, right-hand side 4990
Parking light on straw hood, right-hand side 5230
E6. Direction indicator, right-hand side (rear) 6030

Brake light, right-hand side 5010
Parking light, right-hand side (rear) 5260
E7. Direction indicator, left-hand side (front) 6060

Parking light, left-hand side (front) 5200
E8. Additional direction indicator, left-hand side (front) 6090

Operating light on rail, left-hand side (front) 5170
E11. Direction indicator, right-hand side (front) 6030

Parking light, right-hand side (front) 5120
E12. Additional direction indicator, right-hand side (front) 5980

Operating light on rail, right-hand side (front) 5150
E15. Headlight, left-hand side (front) 5370
E16. Headlight, right-hand side (front) 5420
E26. Unloading tube spotlight 6710
E27. Operating light A, left-hand side 6410

Operating light B, left-hand side 6430
E28. Operating light A, right-hand side 6350

Operating light B, right-hand side 6320
E29. Operating light on cab, right-hand side 6490
E30. Operating light on cab, left-hand side 6470
E33. Light in grain tank 6610
E34. Stubble light, left-hand side 6560
E35. Stubble light, right-hand side 6580
E38. Light in cab 7250
E39. Header lighting 5230

5260
E41. Licence plate lighting 5300
E55. Light in header cylinder pressure gauge 2000
604.64.961.00 - 06 - 2003
F. Fuses
F1. 15A Grain level indicator and flashing lights 2420
F2. 10A Horn 5880

Mirror control 7660
Cab switches illumination 1980
2450
2840
2940
3270
4130
5040
5420
6050
7190
Operating lights control 6320
F3. 10A Light in grain tank 6610
Tachometer 1700
F4. 15A Led’s 1030
Reverse drive buzzer 380
Gauges 2090
Reel control 4090
Reel control 4160
Reel variator 3050
Fuse alarm leds 1030
Lateral float control 4440
Unloading tube movement 3980
Header control 4610
Engine protection 530
Reversing mechanism 3770
Performance monitor 7010
Tachometer 1940
Traction variator 430
Autofloat 8740
F5. 10A Grain level indicator 2530
Machine levelling override 3350
Tachometer selector switch 2010
Parking brake 1390
Brake lights 4960
F6. 15A Unloading tube light 6710
Direction indicators 5840
F7. 15A Direction indicators 5850
F8. 25A Engagement switches 3620
F9. 15A Air conditioning 7220
F10. 15A Screen wiper 7170
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F11. 15A Dipped headlights 5400
F12. 15A Headlights 5390

F13. 10A Operating light, left-hand side 6380
F14. 10A Operating light, right-hand side 6370
F15. 10A Cab operating lights 6490
F16. 10A Parking lights, right-hand side 5140

Tachometer 1960
Light in gauges 2070
F17. 10A Parking lights, left-hand side 5180
F18. 10A Stubble lights 6560
F19. 10A Reverse drive light 6590
F20. 25A Levelling system 330

3280
7830
F21. 15A Alarm system 6070
F51. 10A Machine transverse levelling system 7880
F52. 10A Machine longitudinal levelling system 7850
F53. 10A Switches 7830
F61. Automatic fuse 110

5010
F63. 15A Straw chopper 2750
F64. 16A Autofloat 8740
G. Alternators, batteries
G1. Battery 20
G2. Battery 50
G3. Alternator 120
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H. Indicator lights (led’s)
H1. Engine oil pressure led 580
H2. Engine water and oil temperature led 520

H3. Battery voltage led 1330
H4. Excessive hydrostatic oil temperature and pressure led 1210
H6. Air filter restriction led 1290
H8. Parking brake led 1350
H9. Unloading tube open led 1460
H10. Machine levelling operation warning led 1420
H11. Grain tank level warning led 1380
H15. Headlights control led 5350
H16. Direction indicators control led 5830
H17. Trailer direction indicator lights 5800
H27. Straw chopper rpm led 1140
H28. Straw walker rpm led 1100
H29. Grain elevator rpm led 1180
H30. Straw walker protection led 1250
H51. Machine levelling transverse limit led 8090
H52. Machine levelling longitudinal limit led 8110
H53. Transverse levelling alarm led 8090
H54. Longitudinal levelling alarm led 8110
H55. Diagnose led (red) 8580
H56. Status led (green) 8590
604.64.961.00 - 06 - 2003
K. Relays
K1. Threshing mechanism engaged 3650
K2. Header drive engaged 3690
K3. 12 V after contact switch engaged 280
K4. Headlights 6490
K5. Operating lights 6370
K6. Engine protection 1740
K7. Engine protection override 1800
K8. Flashing lights 2420
K9. Air conditioning 7260
K10. Stubble lights 6540
K11. Flasher unit 5910
K32. Straw chopper 2750
K52. Starter relay 210
K66. Cold starter relay 390
K101. Header up 4650
K102. Header down 4700
K103. Lateral float, right-hand side down 4520
K104. Lateral float, left-hand side down 4470
K105. Lateral float protection 4570
K106. Reel forward 4120
K107. Reel rearward 4150
K108. Reel up 4190
K109. Reel down 4220
K110. Reversing mechanism 3800
K111. Machine longitudinal levelling override 7850
K112. Reel variator faster 3000
K113. Reel variator slower 3040
K114. Straw chopper protection 2800
K115. Autofloat system 8850
604.64.961.00 - 06 - 2003
M. Motors
M1. Starter motor 90
M3. Threshing drum variator motor 2920
M4. Cleaning fan variator motor 2960
M6. Sieve levelling actuator motor 3300
M10. Reel variator motor 3030
M11. Air conditioning fan motor 7410
M12. Screen wiper motor 7240
M13. Mirror, right-hand side 7780
M14. Mirror, left-hand side 7780
M16. Reversing system motor 3810
M18. Engine fuel pump 1690
M26. Engine Blow-off 990
M32. Windscreen washer 7150
P. Measuring equipment
P1. Engine water temperature gauge 2100
P2. Fuel level gauge 2160
P5. Engine hour counter 2110
P6. Tachometer 1940

1980
604.64.961.00 - 06 - 2003
R. Resistances
R16. Sieves levelling actuator position potentiometer 3280
R17. Stubble height setting 3280
R18. Ground pressure setting 3280
R19. Transport position 3280
R32. Plug 390
S. Switches
S6. Drum variator 2930
S7. Cleaning fan variator 2970

2980
S9. Straw chopper 2810
S12. Operating lights 6320
S13. Flashing lights 2450
S16. Engine protection override 640
S17. Ignition switch 220
S18. Reel down 4220
S19. Reel up 4190
S20. Header down slow 4690

8560
S22. Header up slow 4640

8600
S24. Lateral float, left-hand side down 4460

8500
S25. Lateral float, right-hand side down 4510

8530
S26. Reel variator fast 2990
604.64.961.00 - 06 - 2003
S27. Reel variator slow 3030
S29. Reversing mechanism 3770
S31. Hydrostatic lever safety switch 310

360
S36. Parking brake on 1370
S37. Air conditioning fan 7360
S38. Screen wiper 7160
S39. Mirror control 7670
S41. Reel horizontal 4120
S44. Clutch pedal 280
S47. Grain level indicator 2500
S48. Threshing mechanism engaged 3640
S49. Header mechanism engaged 3670
S50. Unloading tube movement switch 3930
S51. Swath-forming plate in swath position 2850

2870
S54. Unloading tube open end-of-stroke 4040
S56. Straw walker protection A 1270
S57. Straw walker protection B 1250
S58. Brake pressure 4960
S59. Direction indicator 5830
S61. Air conditioning thermostat 7330
S62. Air conditioning high pressure switch 7410
S63. Air conditioning low pressure switch 7410
S64. Battery main switch 80
S65. Alarm 6040
S72. End-of-stroke -- Traction variator fast 460
S73. End-of-stroke -- Traction variator slow 490
S101. Machine longitudinal levelling override 7950
S102. Automatic machine levelling 8030
S103. Machine automatic longitudinal levelling 7910
S104. Machine automatic transverse levelling 7960
604.64.961.00 - 06 - 2003
S105. Machine transverse levelling override 8380
S106. End of stroke, right-hand side up (machine levelling) 8400
S107. End of stroke, left-hand side up (machine levelling) 8370
S108. End of stroke, rear down (machine levelling) 8370
S109. End of stroke, rear up (machine levelling) 8400
S111. Unloading tube open 4000
S112. Unloading tube closed 3990
S113. Tachometer selector switch 1980
S114. Reel variator 3040
S115. Lighting 5030
S116. Dipped headlights 5400
S117. Cab operating lights 6430
S118. Unloading tube light 6710
S119. Stubble lights 6670
S120. Sieve levelling override 3230
S121. Starter button 190

280
S123. Reverse drive buzzer 370
S124. Manual levelling switch 3290
S125. Reverse drive buzzer (mechanical drive) 370
S126. Screen washer rocker switch 7140

Traction variator fast 460
S127. Traction variator slow 490
490
S128. Straw chopper safety switch 2800
S130. Ladder safety switch (to engine compartment) 520
S131. Header down fast 8570
S132. Header up fast 8610
S135. Automatic header height control switch 8570
S136. Header control selector switch 8510
604.64.961.00 - 06 - 2003
V. Semi-conductors (diodes)
V19. Lateral float 4600
V23. Traction variator 440
V41. Engine oil pressure led 550

560
V42. Engine oil pressure 550
V43. Engine temperature led 520

V44. Engine temperature 530
V45. Returns buzzer 1160
V46. Straw chopper buzzer 1120
V47. Straw walker buzzer 1080
V49. Hydrostatic low pressure buzzer 1200
V50. Sieve levelling buzzer 830
X. Connectors
X9. Dashboard -- Grain tank
X16. Dashboard -- Engine

X18. Engine wiring
X20. Valve connector
X1A. Rpm module
X1B. Rpm module
X20. Valves
604.64.961.00 - 06 - 2003
X25. Header connector 3000

3020
3040
3040
5200
5230
8750
X80. Levelling system
X103. Stop solenoid
X106. Flashing lights
X107. Grain level indicator
X108. Straw chopper clutch

Straw chopper 4 pos.
X109. Swath-forming plate
X111. Drum variator
X112. Cleaning fan variator
X115. Sieve levelling actuator
X118. Unloading tube open
X128. Straw walker protection
X129. Rotary screen brush
X130. Header trailer connector 5080

5220
5320
5980
6100
X131. Operating lights, left-hand side
X132. Operating lights, right-hand side
X133. Unloading tube light
X134. Ground speed sensor

Sensor groundspeed
X137. Grain elevator sensor

Sensor grainelevator speed
X139. Straw chopper sensor
X140. Threshing drum sensor
X142. Cleaning fan sensor
604.64.961.00 - 06 - 2003
X146. Straw walker sensor

Sensor straw walkers
X149. Portable operating light socket 6650
X150. Dashboard 260
X152. Straw walker grain loss sensor, right-hand side
X153. Sieves grain loss sensor
X156. Pressure switch 1
X157. Pressure switch 2
X158. Compressor
X169. Mirror, right-hand side
X172. Mirror, left-hand side
X186. Straw walker grain loss sensor, left-hand side
X201. Mirror control
X202. Dashboard -- Operator’s platform
X203. Dashboard -- Operator’s platform 8750
X204. Dashboard -- Multifunction lever
X205. AL
X216. Levelling box
X217. Steering column
X218. Operating light, right-hand side
X219. Operating light, left-hand side
X220. Stubble light, right-hand side
X221. Stubble light, left-hand side
X222. Dashboard -- Performance monitor
X223. Intermediate cable -- Performance monitor
X226. Performance monitor
X227. Mirror, right-hand side
X228. Mirror, left-hand side
604.64.961.00 - 06 - 2003
X230. Convertor
Tachometer
X233. Dashboard -- cab
X234. Cab
X237. Rpm monitor
X238. Levelling system
X239. Screen wiper
X240. Headlights, right-hand side
X241. Headlights, left-hand side
X243. Grain elevator sensor
X244. Straw walker sensor
X245. Air conditioning
X246. Portable operating light socket
X247. Timer Blow-off

Fuel pump
X248. Straw chopper
X250. Sieve levelling actuator
X251. Straw chopper clutch
X252. Reel variator motor
X253. Timer
X254. Timer
X330. Engine Blow-off
X337. Fuel pump
X673. Joystick connector
X674. Sensors connector
X675. Module EMR-D connector
X676. Operating panel connector
XA. Power module
XB. Power module
XD. Power module
XE. Power module
604.64.961.00 - 06 - 2003
Y. Valves
Y5. Traction variator slow 480
Y6. Traction variator fast 460
Y7. Lateral float, right-hand side down 4500
Y8. Lateral float, left-hand side down 4470
Y11. Header up 4620
Y12. Header down 4650
Y13. Reel up 4180
Y14. Reel down 4210
Y15. Unloading tube open 4000
Y16. Unloading tube closed 3980
Y17. Reel forward 4090

4110
Y18. Reel rearward 4120

4140
Y23. Stop solenoid 590

650
Y24. Straw chopper clutch 2730
Y26. Rotary screen brush solenoid 3930
Y27. Compressor 7370
Y51. Self-levelling system, rear down 8430
Y52. Self-levelling system, rear up 8460
Y53. Self-levelling system, right up 8430
Y54. Self-levelling system, left up 8460
Y55. Blow-off valve 920

Header up 8790
Y57. Lateral float -- right-hand side 8810
Y58. Lateral float -- left-hand side 8830
Y59. Valve accumulator 8500
Y72. Solenoid fuel power 590
604.64.961.00 - 06 - 2003
ELECTRICAL DIAGRAMS
1A STARTER CIRCUIT (HYDROSTATIC DRIVE)

TC54 9262 > .....
F4. 15A Reverse drive buzzer 380
G1. Battery 20
G2. Battery 50
G3. Alternator 120
X150. Dashboard 260
Line: 0 -- 500
604.64.961.00 - 06 - 2003
STARTER CIRCUIT (HYDROSTATIC DRIVE)

TC54 9262 > .....
604.64.961.00 - 06 - 2003
22 SECTION 55 - ELECTRICAL SYSTEM -- CHAPTER 2
1B STARTER CIRCUIT (HYDROSTATIC DRIVE)

TC56 9262 > .....
G1. Battery 20
G2. Battery 50
G3. Alternator 120
K66. Cold starter relay 390
X150. Dashboard 260
Line: 0 -- 500
604.64.961.00 - 06 - 2003
STARTER CIRCUIT (HYDROSTATIC DRIVE)

TC56 9262 > .....
8740
015--1.5rd
X673
509--1wt
X673
046--1,5bl 510--2,5wt
510--1,5wt
K66
X338
X673
PA
R32
M
012--2,6rd
X338
046--1,5bl
PB
X673
604.64.961.00 - 06 - 2003
1C STARTER CIRCUIT (MECHANICAL DRIVE)

TC54 9262 > ..... TC56 9262 > .....
F4. 15A Traction variator 430
G1. Battery 20
G2. Battery 50
G3. Alternator 120
S44. Clutch pedal 280
S72. End-of-stroke -- Traction variator fast 460
S73. End-of-stroke -- Traction variator slow 490
S125. Reverse drive buzzer (mechanical drive) 370
S126. Traction variator fast 460
S127. Traction variator slow 490
V23. Traction variator 440
X150. Dashboard 260
Y5. Traction variator slow 480
Y6. Traction variator fast 460
Line: 0 -- 500
604.64.961.00 - 06 - 2003
STARTER CIRCUIT (MECHANICAL DRIVE)

TC54 9262 > .....TC56 9262 > .....
604.64.961.00 - 06 - 2003
1D STARTER CIRCUIT (AL)

AL59 9262 > .....
G1. Battery 20
G2. Battery 50
G3. Alternator 120
X150. Dashboard 260
Line: 0 -- 500
604.64.961.00 - 06 - 2003
STARTER CIRCUIT (AL)

AL59 9262 > .....
604.64.961.00 - 06 - 2003
2A ENGINE PROTECTION
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
F2. 10A Cab switches illumination 700
F4. 15A Engine protection 530
Line: 510 -- 840
604.64.961.00 - 06 - 2003
ENGINE PROTECTION
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
604.64.961.00 - 06 - 2003
2B ENGINE PROTECTION (FUEL POWER)

TC54 9262 > ..... TC56 9262 > .....
B49. Temp. contact fuel power 600
M18. Engine fuel pump 690
Y72. Solenoid fuel power 590
Line: 510 -- 840
604.64.961.00 - 06 - 2003
ENGINE PROTECTION (FUEL POWER)

TC54 9262 > ..... TC56 9262 > .....
604.64.961.00 - 06 - 2003
3 BLOW-OFF SYSTEM
TC56 9262 > ..... AL59 9262 > .....
A41. Printed -- circuit Blow-off timer 950
M26. Engine Blow-off 990
Y55. Blow-off valve 920
Line: 860 -- 1020
604.64.961.00 - 06 - 2003
BLOW-OFF SYSTEM
TC56 9262 > ..... AL59 9262 > .....
604.64.961.00 - 06 - 2003
4A CONTROLS + RPM
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
B4. Hydrostatic oil pressure switch 1210
B5. Hydrostatic oil temperature switch 1210
B7. Air filter restriction sender 1310
F4. 15A Led’s 1030
F5. 10A Parking brake 1390
H3. Battery voltage led 1330
H4. Excessive hydrostatic oil temperature and pressure led 1210
H6. Air filter restriction led 1290
H8. Parking brake led 1350
H9. Unloading tube open led 1460
H10. Machine levelling operation warning led 1420
H11. Grain tank level warning led 1380
H27. Straw chopper rpm led 1140
H28. Straw walker rpm led 1100
H29. Grain elevator rpm led 1180
H30. Straw walker protection led 1250
S36. Parking brake on 1370
S56. Straw walker protection A 1270
S57. Straw walker protection B 1250
V45. Returns buzzer 1160
V46. Straw chopper buzzer 1120
V47. Straw walker buzzer 1080
V49. Hydrostatic low pressure buzzer 1200
Line: 1020 -- 1520
604.64.961.00 - 06 - 2003
CONTROLS + RPM
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
604.64.961.00 - 06 - 2003
5 TACHOMETER
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
A45. Printed circuit -- Tachometer 1810
B16. Ground speed sensor 1790
B19. Grain elevator speed sensor 1880
B20. Straw chopper speed sensor 1820
B22. Threshing drum speed sensor 1730
B24. Cleaning fan speed sensor 1760
B28. Straw walker speed sensor 1850
E55. Light in header cylinder pressure gauge 2000
F3. 10A Tachometer 1700
F5. 10A Tachometer selector switch 2010
P6. Tachometer 1980
S113. Tachometer selector switch 1980
Line: 1700 -- 2030
604.64.961.00 - 06 - 2003
TACHOMETER
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
604.64.961.00 - 06 - 2003
6 GAUGES
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
B11. Engine water temperature sender 2090
B12. Fuel level sender 2150
F4. 15A Gauges 2090
F16. 10A Light in gauges 2070
P1. Engine water temperature gauge 2100
P2. Fuel level gauge 2160
P5. Engine hour counter 2110
Line: 2040 -- 2200
604.64.961.00 - 06 - 2003
GAUGES
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
604.64.961.00 - 06 - 2003
7 GRAIN LEVEL INDICATOR AND REVOLVING FLASH LIGHTS

TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
E1. Flashing light (left-hand side) 2500
E2. Flashing light (right-hand side) 2500
F1. 15A Grain level indicator and flashing lights 2420
F5. 10A Grain level indicator 2530
K8. Flashing lights 2420
S13. Flashing lights 2450
S47. Grain level indicator 2500
Line: 2380 -- 2540
604.64.961.00 - 06 - 2003
GRAIN LEVEL INDICATOR AND REVOLVING FLASH LIGHTS

TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
604.64.961.00 - 06 - 2003
8 STRAW CHOPPER
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
F2. 10A Cab switch illumination 2840
F63. 15A Straw chopper 2750
K32. Straw chopper 2750
K114. Straw chopper protection 2800
S9. Straw chopper 2810
S51. Swath-forming plate in swath position 2850
S128. Straw chopper safety switch 2800
Y24. Straw chopper clutch 2830
Line: 2720 -- 2880
604.64.961.00 - 06 - 2003
STRAW CHOPPER
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
604.64.961.00 - 06 - 2003
9a VARIATORS
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
F4. 15A Reel variator 3050
Line: 2890 -- 3050
604.64.961.00 - 06 - 2003
VARIATORS
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
P20 P26
P20 P26
604.64.961.00 - 06 - 2003
9b VARIATORS (lateral flotation)

TC56 9262 > .....
F4. 15A Reel variator 3050
Line: 2890 -- 3050
604.64.961.00 - 06 - 2003
VARIATORS (lateral flotation)

TC56 9262 > .....
8840
X673
X673 X673
P20 P26
P20 P26
604.64.961.00 - 06 - 2003
10 SIEVE LEVELLING SYSTEM

TC54 9262 > ..... TC56 9262 > .....
A48. Printed circuit -- Sieve levelling system 3360
F5. 10A Machine levelling override 3350
M6. Sieve levelling actuator motor 3300
R16. Sieve levelling actuator position potentiometer 3280
S120. Sieve levelling override 3230
S124. Manual levelling switch 3290
Line: 3230 -- 3390
604.64.961.00 - 06 - 2003
SIEVE LEVELLING SYSTEM

TC54 9262 > ..... TC56 9262 > .....
604.64.961.00 - 06 - 2003
11 UNLOADING, THRESHING AND HEADER ENGAGEMENT

TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
F8. 25A Engagement switches 3620
K1. Threshing mechanism engaged 3650
K2. Header drive engaged 3690
S49. Header mechanism engaged 3670
Line: 3570 -- 3730
604.64.961.00 - 06 - 2003
UNLOADING, THRESHING AND HEADER ENGAGEMENT

TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
604.64.961.00 - 06 - 2003
12 REVERSING SYSTEM
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
F4. 15A Reversing mechanism 3770
K110. Reversing mechanism 3800
M16. Reversing system motor 3810
S29. Reversing mechanism 3770
Line: 3740 -- 3900
604.64.961.00 - 06 - 2003
REVERSING SYSTEM
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
(X673)
604.64.961.00 - 06 - 2003
13 UNLOADING TUBE MOVEMENT

TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
A18. Printed circuit -- Rotary screen brush 3950
F4. 15A Unloading tube movement 3980
S50. Unloading tube movement switch 3930
S54. Unloading tube open end-of-stroke 4040
S111. Unloading tube open 4000
S112. Unloading tube closed 3990
Y15. Unloading tube open 4000
Y16. Unloading tube closed 3980
Y26. Rotary screen brush solenoid 3930
Line: 3910 -- 4070
604.64.961.00 - 06 - 2003
UNLOADING TUBE MOVEMENT

TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
604.64.961.00 - 06 - 2003
14a REEL CONTROL

TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
F2. Cab switches illumination 4130
F4. 15A Reel control 4090
K108. Reel up 4190
S18. Reel down 4220
S19. Reel up 4190
Y13. Reel up 4180
Y14. Reel down 4210
Line: 4080 -- 4240
604.64.961.00 - 06 - 2003
REEL CONTROL
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
604.64.961.00 - 06 - 2003
14b REEL CONTROL (lateral flotation)

TC56 9262 > .....
F2. Printed circuit -- Cab switches illumination 4130
K108. Reel up 4190
S18. Reel down 4220
S19. Reel up 4190
Y13. Reel up 4180
Y14. Reel down 4210
Line: 4080 -- 4240
604.64.961.00 - 06 - 2003
REEL CONTROL (Lateral flotation)

TC56 9262 > .....
8760
601 -- 1.50
X673
X673 X673
604.64.961.00 - 06 - 2003
15 LATERAL FLOAT AND STRAW ELEVATOR MOVEMENT

TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
F4. 15A Lateral float control 4440
F4. 15A Header control 4610
K101. Header up 4650
K102. Header down 4700
K103. Lateral float, right-hand side down 4520
K104. Lateral float, left-hand side down 4470
K105. Lateral float protection 4570
S20. Header down 4690
S22. Header up 4640
Y7. Lateral float, right-hand side down 4500
Y8. Lateral float, left-hand side down 4470
Y11. Header up 4620
Line: 4420 -- 4740
604.64.961.00 - 06 - 2003
LATERAL FLOAT AND STRAW ELEVATOR MOVEMENT

TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
604.64.961.00 - 06 - 2003
16 LIGHTING
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
E3. Brake light, left-hand side 5030
E3. Parking light, left-hand side (rear) 5280
E4. Brake light on straw hood, left-hand side 5060
E4. Parking light on straw hood, left-hand side (rear) 5300
E5. Brake light on straw hood, right-hand side 4990
E5. Parking light on straw hood, right-hand side 5230
E6. Brake light, right-hand side 5010
E6. Parking light, right-hand side (rear) 5260
E7. Parking light, left-hand side (front) 5200
E8. Operating light on rail, left-hand side (front) 5170
E11. Parking light, right-hand side (front) 5120
E12. Operating light on rail, right-hand side (front) 5150
E15. Headlight, left-hand side (front) 5370
E16. Headlight, right-hand side (front) 5420
E41. Licence plate lighting 5300
F5. 10A Brake lights 4960
F11. 15A Dipped headlights 5400
F12. 15A Headlights 5390
F16. 10A Parking lights, right-hand side 5140
F17. 10A Parking lights, left-hand side 5180
H15. Headlights control led 5350
604.64.961.00 - 06 - 2003
16 LIGHTING
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
S58. Brake pressure 4960
S115. Lighting 5030
S116. Dipped headlights 5400
Line: 4930 -- 5430
604.64.961.00 - 06 - 2003
604.64.961.00 - 06 - 2003
LIGHTING
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
P24 P30
P24 P30
604.64.961.00 - 06 - 2003
17 DIRECTION INDICATOR AND HORN

TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
B29. Horn 5880
E3. Direction indicator, left-hand side (rear) 6060
E4. Direction indicator on straw hood, left-hand side 6080
E5. Direction indicator on straw hood, right-hand side 6010
E6. Direction indicator, right-hand side (rear) 6030
E7. Direction indicator, left-hand side (front) 6060
E8. Additional direction indicator, left-hand side (front) 6090
E11. Direction indicator, right-hand side (front) 6030
E12. Additional direction indicator, right-hand side (front) 5980
F2. 10A Horn 5880
F21. 15A Alarm system 6070
H16. Direction indicators control led 5830
H17. Trailer direction indicator lights 5800
K11. Flasher unit 5910
S59. Direction indicator 5830
S65. Alarm 6040
Line: 5780 -- 6110
604.64.961.00 - 06 - 2003
DIRECTION INDICATOR AND HORN

TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
604.64.961.00 - 06 - 2003
18 OPERATING LIGHTS
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
E26. Unloading tube spotlight 6710

E27. Operating light A, left-hand side 6410
E27. Operating light B, left-hand side 6430
E28. Operating light A, right-hand side 6350
E28. Operating light B, right-hand side 6320
E29. Operating light on cab, right-hand side 6490
E30. Operating light on cab, left-hand side 6470
E33. Light in grain tank 6610
E34. Stubble light, left-hand side 6560
E35. Stubble light, right-hand side 6580
F2. 10A Operating lights control 6320
F3. 10A Light in grain tank 6610
F6. 15A Unloading tube light 6710
F13. 10A Operating light, left-hand side 6380
F14. 10A Operating light, right-hand side 6370
F15. 10A Cab operating lights 6490
F18. 10A Stubble lights 6560
F19. 10A Reverse drive light 6590
K4. Headlights 6490
K5. Operating lights 6370
K10. Stubble lights 6540
S12. Operating lights 6320
S117. Cab operating lights 6430
S118. Unloading tube light 6710
S119. Stubble lights 6670
X149. Portable operating light socket 6650
Line: 6290 -- 6790
604.64.961.00 - 06 - 2003
OPERATING LIGHTS
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
604.64.961.00 - 06 - 2003
19 PERFORMANCE MONITOR
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
A47. Printed circuit -- Performance monitor 7020
B33. Straw walker grain loss sensor (right-hand side) 7110
B34. Sieves grain loss sensor 7110
B39. Straw walker grain loss sensor (left-hand side) 7110
F4. 15A Performance monitor 7010
Line: 6970 -- 7130
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PERFORMANCE MONITOR
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
604.64.961.00 - 06 - 2003
20A CAB
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
A10. Radio 7440
E38. Light in cab 7250
F9. 15A Air conditioning 7220
F10. 15A Screen wiper 7170
K9. Air conditioning 7260
M11. Air conditioning fan motor 7410
M12. Screen wiper motor 7240
M32. Wind screen washer 7150
S37. Air conditioning fan 7360
S38. Screen wiper 7160
S61. Air conditioning thermostat 7330
S62. Air conditioning high pressure switch 7410
S63. Air conditioning low pressure switch 7410
S126. Screen washer rocker switch 7140
Y27. Compressor 7370
Line: 7140 -- 7470
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CAB
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
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21 MIRROR CONTROL
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
F2. 10A Mirror control 7660
M13. Mirror, right-hand side 7780
M14. Mirror, left-hand side 7780
S39. Mirror control 7670
Line: 7650 -- 7810
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MIRROR CONTROL
TC54 9262 > ..... TC56 9262 > ..... AL59 9262 > .....
604.64.961.00 - 06 - 2003
22 MACHINE LEVELLING SYSTEM

AL59 9262 > .....
A42. Printed circuit -- Machine levelling system alarm box 8030
F51. 10A Machine transverse levelling 7880
F52. 10A Machine longitudinal levelling 7850
F53. 10A Switches 7830
H51. Machine levelling transverse limit led 8090
H52. Machine levelling longitudinal limit led 8110
H53. Transverse levelling alarm led 8090
H54. Longitudinal levelling alarm led 8110
K111. Machine longitudinal levelling override 7850
S101. Machine longitudinal levelling override 7950
S102. Automatic machine levelling 8030
S103. Machine automatic longitudinal levelling system 7910
S104. Machine automatic transverse levelling system 7960
Line: 7820 -- 8150
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MACHINE LEVELLING SYSTEM

AL59 9262 > .....
604.64.961.00 - 06 - 2003
23 MACHINE LEVELLING SYSTEM

AL59 9262 > .....
A41. Printed circuit -- Machine levelling system 8240
S105. Machine transverse levelling override 8380
S106. End of stroke, right-hand side up (machine levelling) 8400
S107. End of stroke, left-hand side up (machine levelling) 8370
S108. End of stroke, rear down (machine levelling) 8370
S109. End of stroke, rear up (machine levelling) 8400
Y51. Self-levelling system, rear down 8430
Y52. Self-levelling system, rear up 8460
Y53. Self-levelling system, right up 8430
Y54. Self-levelling system, left up 8460
Line: 8160 -- 8490
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MACHINE LEVELLING SYSTEM

AL59 9262 > .....
13 21 13 21
14 22 14 22
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24 HEADER HEIGHT CONTROLS

TC56 9262 > .....
A49. Printed circuit -- Autofloat module 8680
A51. Printed circuit -- Interface for header height control 8640
B42. Sensor position 8870
B43. Sensor pressure 8510
B44. Sensor tracer -- left-hand side 8690
B45. Sensor tracer -- right-hand side 8720
F4. 15A -- Autofloat 8760
F64. 16A -- Autofloat 8740
H55. Diagnose led (red) 8580
H56. Status led (green) 8590
K115. Relay autofloat 8850
R17. Stubble height setting 8600
R18. Ground pressure setting 8610
R19. Transport position 8560
S20. Header down slow 8560
S22. Header up slow 8600
S131. Header down fast 8570
S132. Header up fast 8610
S135. Automatic header height control switch 8570
S136. Header control selector switch 8510
Y55. Header up 8790
Y57. Lateral float -- right-hand side 8810
Y58. Lateral float -- left-hand side 8830
Y59. Valve accumulator 8500
Line: 8500 -- 8870
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HEADER HEIGHT CONTROLS F04

TC56 9262 > ..... S135
10 240 2980 8550 8540 8560
15A
Y57 Y58
+3
S24 S25
4160 Y56 Y55
S20:131 S22:132 F64
16A
wt/zw
10 10
210 210
718--1zw
719--1zw
720--1zw
716--1zw
717--1zw
717--1zw
715--1wt
716--1gr
wt/gn
br/gn gn
pk gr br/gn wt/br gn wt/br X675 A49 X675

X673 701--1wt 015--1.5rd
P06 P08 P07 P05 X20 P04 P02 P01 P03 X20
P17 + P29
P03 P15 P16 P01 P02 607--1.5zw
P05 P04 P14 702--1wt
P9 GND. - P28
703--1gn 601--1.5br
P36 + P24
704--1wt 720--1gr
P3 VALVES P19
705--1wt 719--1bl A
P33 U+D P35
706--1wt 718--1wt
P27 P37
707--1wt 716--1gr
P32 P15
711 -- 1gn
VALVES
736-- 1bl
685 -- 1wt
712 -- 1gn
708--1wt 717--1wt B
P13 LATERAL P51
B43 8870 8750 8790
P34 715--1wt
1
X674 758--1br 8580 8590
725--1br
P
734--1bl P07 734--1bl 86 87a 87
722--1zw
2 P38 SENSOR P14
U 3
733--1gn P08 733--1gn
P8 P/U K115
758--1br
732--1br P09 C 732--1br
P39
1 731--1wt P02 731--1wt 738--1gn
P46 VALVE P26 85 30
Y59 730--1bl P01 730--1bl

P18 AKUM TRACERS P7
739--1gn
2 735--1br
P2 R+L P41 748--1bl B42
736--1gn 725 -- 1br P12 725 -- 1br
P21 1
737--1gn
P31 OPER.
X203 P
8850 8840 P37 P34 P35 P36
740--1gn
P12
724--1gn P11 724 -- 1gn 2
PANEL SENSOR P6
723 -- 1bl
741--1gn
P22 Q/U P1
723--1bl P10
3 U
712--1gn
711--1gn
742--1gn
P5 X674
758 748
743--1bl
X676 P20 X25
P1 P2 P7 P3 P4 P5 P6 P8 758--1br P05 P23 P06 P25 P01 P02

756--1br
722--1zw
607--5zw
607--5zw
+10V
748--1bl
748--1bl
739--1gn
1
738--1gn
3 2 1 3 2 1
B44 B45 X12
H55 H56
3
2
1 R19 L R
S136 A51
0
R17 R18
8500
8510
8520
8530
8540
8550
8560
8570
8580
8590
8600
8610
8620
8630
8640
8650
8660
8670
8680
8690
8700
8710
8720
8730
8740
8750
8760
8770
8780
8790
8800
8810
8820
8830
8840
8850
8860
8870
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604.64.961.00 - 06 - 2003
CONNECTORS
X115 X240 X241
ZDA0428A
1
X239 X245 X108 X233
1 3
2 4
ZDA0429A
2
X112
3
X254
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X253
5
X80 XF XH
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
ZDA0436A
6
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X230
1
14
2
15
3
16
4
17
5
18
6
19
7
20
8
21
9
22
10
23
11
24
12
25
ZDA0437A 13
7
X1A X1B XA XB XC XD XE XG
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X140 X142
9
X103 X109 X131 X132 X137 X139 X146
X156 X157 X169 X172 X223 X224 X227
X228
10
X106 X107 X111 X118 X128 X129 X133
X134 X152 X153 X158 X184 X186 X218
X219 X220 X221 X225 X234 X246 X247
X252
2 3
ZDA0427A
11
X250
2 3
ZDA0425A
12
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X330
2 1
ZDA0447A
13
X16 X205 X238
14
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X09
X201 X217 X222 X226
X237
15
X20
16
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X229
17
X203
18
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X18 X202 X204 X673
1
3 2
8 4
14 9
19 15
21 20
22
ZDA0443A
19
604.64.961.00 - 06 - 2003
SECTION 60 -- PRODUCT FEEDING -- CHAPTER 1 1
SECTION 60 -- PRODUCT FEEDING
Chapter 1 -- Straw elevator

Page
Straw elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Straw elevator chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Lower shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Upper shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
604.64.961.00 - 04 - 2003
2 SECTION 60 -- PRODUCT FEEDING -- CHAPTER 1
STRAW ELEVATOR
STRAW ELEVATOR CHAIN
IMPORTANT: Before removing the straw elevator,

disconnect the battery.
1. Remove the straw elevator, see paragraph 3 of

the operating instructions.
2. Tension the chain by loosening the nuts (A) on
both machine sides. H
3. Rotate the chain further on until the connection
links are easily accessible (from the shaft upper
part). Open the connection links. Then, to hold
the chain during rotation, fasten a rope on the
lower end of the chain, through the upper shaft. K
Installation (fig. 1 and 2) Only TC 56 H and TC 56 H+
Before fastening the supporting plates (E), move the

straw elevator chain to the right as much as possible, A H B K E
letting the chain rotate some times.
F
Fully tighten the spring (G) on the left side.
Fully tighten the spring (G) on the right side and adjust D
G
it to the length of the indicator plate (H).
C
Adjust the spring (G) on the left side to the length of
the indicator plate (H).
TC--60--2--2
2
604.64.961.00 - 04 - 2003
LOWER SHAFT
TC 54 MODELS
(standard version)
Removal (fig. 1, 2)
1. Remove the plate on the front part of the straw el-

evator.
2. Remove the stud bolts (B) and (C) on both sides.
3. Remove the seal ring (D) of the bearing (F) on
both sides.
4. Remove the plate (E) on both sides. 3
5. Then, remove the lower shaft.
Installation
1. For the reassembly, proceed in the reverse order

of removal.
IMPORTANT: Before tightening the bearing seal
rings (D), put the lower shaft at a distance of 205 mm
from the fastening flange of the chain guide support
and from the right side sheet of the straw elevator
housing (fig. 3).
2. Adjust the compensation springs (K) of the lower
shaft (fig. 1, 2) to a length of 112 mm or 89 mm
for maize.
604.64.961.00 - 04 - 2003
TC 54 -- TC 56 (all versions)
(If maize header)
Removal and installation
Proceed as for the standard version.

IMPORTANT: Before tightening the bearing seal
rings (D), put the lower shaft at a distance of 124 mm
from the fastening flange of the chain guide support
and from the right side sheet of the straw elevator
housing (fig. 4).
• Dimension 394 mm = TC54

• Dimension 524 mm = TC56
604.64.961.00 - 04 - 2003
Adjustment
1. Loosen the stud bolts (R) on both sides.

2. Adjust the lower shaft at the wished height, on
both sides, using the stud bolt (S).
3. Fit the stop (Q) on the supporting plates.
4. Loosen the stud bolts (R).
5. Loosen the stud bolt (S) to get a clearance of
1 mm.
6. For cereal harvesting and in standard harvesting
conditions, adjust the lower shaft at the minimum
height. Make sure the chain rotates freely. Adjust
the spring to the length of 112 mm.
7. For maize, bean or pea harvesting, to prevent
damaging the crop, the lower shaft should be ad- 5
justed as low as possible.
8. For maize harvesting, adjust the spring (E) to the Only TC 56 H and TC 56 H+
length of 89 mm.
9. Chain tension: adjust the spring (C) to the length
of the indicator plate (that is 57 mm). C E
10. To ensure an even crop feeding, adjust the lower
shaft to the same height on both sides.
Q S
R
TC--60--2--6
6
604.64.961.00 - 04 - 2003
UPPER SHAFT
IMPORTANT: Nut (A) is located on the machine left

side.
50362
7
TC 54 -- TC 54 HYDRO PLUS MODELS
(STANDARD VERSION)
(2) TC 56 MODEL (ALL VERSIONS)
(1) TC 54 -- TC 54 HYDRO PLUS MODELS (If maize header)
604.64.961.00 - 04 - 2003
1. Remove the following parts:

a) Straw elevator chain
b) Nut (A) and spring (B)
c) Sliding disc (C) and slip clutch (D)
d) Nut (E)
e) Bolt (F)
f) Key (G)
g) Bolt (H) on the right side
h) Guard sheet (J)
2. Press the shaft to the right, to take it out of the
straw elevator.
3. Remove the bearing and its housing from the
shaft.
Installation (fig. 7 and 8)
1. Assemble the shaft on the straw elevator from the

right side.
2. Assemble the guard sheets (K) on both sides of
the shaft, with the notch (A) towards the front
(fig. 9).
3. Press the gears (J) on the shaft.
4. Assemble the bearing housing/housings on the
shaft and lock with the bolts (H).
5. Assemble the bearings.
6. Assemble the gears complying with the dimen-
sions shown and lock with the bolts (F).
50380
7. Assemble the slip clutch proceeding in the re-
verse order of removal. 9
8. Tighten the nut (A) to 35 daNm.
9. Assemble the safety sheet/sheets (J) on the
shaft, as shown in the figure 10.
The arrow shows the shaft rotating direction.
50381
10
604.64.961.00 - 04 - 2003
604.64.961.00 - 04 - 2003
SECTION 66 -- THRESHING -- CHAPTER 1 1
SECTION 66 -- THRESHING
Chapter 1 -- Drum and Concave

Page
Operating parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Concave types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Concave adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Concave replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dust sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Threshing drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drum variator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drum replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Threshing function adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Threshing drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Concave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Dust sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Stone trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
604.64.961.00 - 04 - 2003
2 SECTION 66 -- THRESHING -- CHAPTER 1
OPERATING PARTS
1
1. Threshing drum 5. Rotary separator (if installed)
2. Concave 6. Rotary separator concave (if fitted)
3. Straw beater 7. Straw walker
4. Beater concave or rake
604.64.961.00 - 04 - 2003
CONCAVE TYPES
Concave type Row distance ”A” Row distance ”B” Row distance ”C” Number of
threshing bars
Concave for
standard
conditions
(cold concave) 14 9 3.5 14
Maize concave 26 10 6 10
604.64.961.00 - 04 - 2003
CONCAVE ADJUSTMENTS
Concave for standard conditions
1. Concave control lever (A) in the second notch

from the top.
2. Adjust to 10 mm at the first bar (at the concave
front).
3. Adjust to 10 mm at the second last bar.
Maize concave
1. Concave control lever (A) in the seventh notch

from the top.
front).
3. Adjust to 31 mm at the last bar.
604.64.961.00 - 04 - 2003
Rice concave
1. Concave control lever (A) in the fifth notch from

the top.
front). Adjust to 25 mm at the last bar.
3. Check that the distance between the tines is the
same.
4. Possibly, move the drum removing the end key.
604.64.961.00 - 04 - 2003
CONCAVE REPLACEMENT
Removal
IMPORTANT: On combines fitted with a starter next

to the straw elevator for reversal, the battery must be
disconnected.
1. Remove the straw elevator, the dust sheet (D)
(fig. 6), the dust sheet (G) and the stone trap (C)
(fig. 7).
2. Remove the rake (E) (fig. 8) and the plate with
rubber canvas (F) at the concave end.
6
3. Loosen both levers fastening the concave.
4. Remove the concave by loosening the screws (A)
(fig. 9) at each fastening rod (B).
5. Remove the fastening rod (B) (fig. 9).
6. Remove both cover plates at the front of the con-
cave suspension.
7. Take the concave out.
7
Assembly
1. Assemble the parts in the reverse order of re-

moval.
2. Adjust the concave to drum clearance depending
on the application.
604.64.961.00 - 04 - 2003
DUST SHEET
Adjustment
1. Adjustment of the dust sheet with fitted straw el-

evator:
rotate the concave and adjust the dust sheet with
the nuts (A) until the sheet touches the drum, then
loosen the nuts by half a turn.
2. Adjustment with removed straw elevator:
adjust with the nuts (A) until getting a clearance
of 2 mm between the drum threshing bars and the
dust sheet.
3. For maize harvesting, remove the dust sheet.
10
604.64.961.00 - 04 - 2003
THRESHING DRUM
Threshing bar replacement
1. The drum is equipped with eight threshing bars

with grooves pointing alternately to the left and to
the right. If all grooves were in the same direction,
the whole crop would be conveyed only to one
side of the machine, with following clogging.
2. The threshing bars are supplied in pairs, that is
two identical bars at a time. The max. allowed
weight difference between two threshing bars of
one set is 25 g.
3. Always change the threshing bars in pairs, select-
ing those bars placed at 180_ one from the other.
11
4. Screws tightening torques:
-- Tighten the nuts to a torque of 6 daNm.
-- Hammer all screws to get a tightening torque
of 10 daNm.
604.64.961.00 - 04 - 2003
5. After changing the threshing bars, the drum must

be statically balanced. To this purpose, belts and
pulleys must be removed from the drum shaft.
Drum discs are supplied with some holes for fit-
ting the weights (A) (fig. 12).
6. Drum discs have a mark. The drum is fitted so
that the marks are aligned. In this position, the
drum is balanced.
7. Threshing bars are worn when:
-- Crop is not fully threshed (drum and concave
are correctly fitted).
-- Crop gets stuck.
-- Crop flows back.
8. Figure 11 shows a threshing bar with left--
oriented grooves and a threshing bar with right--
oriented grooves.
12
604.64.961.00 - 04 - 2003
DRUM VARIATOR
13
604.64.961.00 - 04 - 2003
Variator belt removal (figure 13) Adjustment (figure 13)
1. Set the variator in the max. position [link (C) 1. Check the beater shaft rpm: 875 rpm (0 + 10).
against the nut (D)]. 2. Adjust the belt tension by the nut (A): the spring
2. Loosen the belt tension by removing the nut (A). length should correspond to the length of the slide
3. Remove the variator lower links from the drum gauge (78 mm).
shaft. 3. Adjust the variator in the min. position: beater va-
4. Set the variator in the min. position [link (P) riator links (P) against the stop (Q).
against the stop (Q)]. 4. Check if the distance (N) corresponds to about
5. Remove the lower auger drive chain. 78 mm = 430 rpm.
6. Remove the fan variator upper drive belt. 5. Adjust the variator in the max. position: beater va-
riator links (C) against the nut (D).
7. Remove the variator drive electric motor (L).
6. Check if the distance (O) corresponds to about
8. First of all, remove the variator drive belt from the
78 mm. Adjust with the nuts (D) and (E).
upper pulleys, then remove it from the lower
pulleys. IMPORTANT:
-- In both minimum and maximum position the
Variator belt assembly (figure 13) variator belt should not protrude more than
3 mm beyond the variator sheaves.
1. First install the belt on the lower variator pulleys, -- The distance of 78 mm is valid only if a new
belt is fitted.
then on the upper variator pulleys.
-- The distance between variator links and
2. Adjust the distance (X) to 179 ± 2.5 mm and the
pulleys must be at least 5 mm.
distance (Y) to 67 mm.
3. Proceed in the reverse order of removal.
604.64.961.00 - 04 - 2003
DRUM REPLACEMENT
14
604.64.961.00 - 04 - 2003
Removal
IMPORTANT: On combines fitted with a starter inside

the straw elevator, the battery must be disconnected.
Remove, in sequential order:

1. The straw elevator.
2. The whole dust sheet and both supports.
3. Two centering devices (A) (fig. 15).
4. Sensor (B) (fig. 16), left side.
5. Drum variator belt.
6. Thrust bearing and drum variator links. 15
7. Drum variator pulleys.
8. Drum shaft adjustment keys (E) (fig. 14).
9. Right and left drum bearings with housings (C)
(fig. 14) and (D).
10. Remove the drum shaft (B) (fig. 14) operating
from the right side.
IMPORTANT: To remove the bearing, use the special
tool 434629 (puller).
Assembly
Assemble the parts in the reverse order.

1. First of all, assemble the right bearing (D)
(fig. 14).
2. Fit the ring (F) (fig. 14). Press the ring with the left
bearing and the housing (C) in its seat.
3. Before assembling the adjustment keys, align the
drum in the middle of the frame.
4. Lock the adjustment keys.
16
THRESHING FUNCTION ADJUSTMENT

Threshing drum (4) and concave (5) separate grains
from straw. To get the best performance, the drum to
concave clearance should be as small as possible.
Operate the drum at the max. speed, paying attention
not to damage grains or straw too much.
The beater (6) makes the crop flow from drum to
straw walkers and prevents straw from winding
around the drum.
Straw walkers (7) aid grain separation from the straw
and eject the straw from the combine.
The crop is threshed due to the friction between
threshing bars and concave. Theoretically, threshing
efficiency corresponds to 100% and, in standard
conditions, about 90% of grains fall through the con- 17
cave openings.
604.64.961.00 - 04 - 2003
THRESHING DRUM
The drum threshes the crop on the concave and

moves it from the front to the rear part of the grate.
The drum speed can be adjusted by a mechanical va-
riator.
Drum speed depends on the following factors:
-- the difficulty of separating grains from straw;
-- the brittleness of straw or grains and on the crop
ripeness.
The max. speed is required in case of:
-- crop difficult to thresh (for example in case of oats
or winter barley);
-- partly ripened or green crop;
-- too much straw in the crop (e.g. rye).
The average speed is required in case of:
-- crop with standard ripeness (e.g. grain);
-- easy--to--thresh crop (e.g. barley);
-- crop where straw quantity is almost the same as
grain quantity.
The low speed is required in case of:
-- too much ripened crop and easy to thresh (e.g.
peas, beans, grain, etc...);
-- too much breakage of the straw, with following
sieve overload.
Max. threshing efficiency is obtained with a max.
drum speed and a min. concave clearance.
NOTE: Drum speed can be decreased, while the crop

should be fully threshed in any case.
For a perfect threshing of maize, the cover plates (A)
must be fitted on the concave. They prevent cobs to
fall through the drum.
18
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CONCAVE
The concave can be fitted closer or less close to the
drum through the control lever (A) on the steering
platform.
The concave is factory set parallel to the drum, at a
clearance of 10 mm from the latter; the control lever
is in the second position from the top.
The concave should be adjusted depending on the
crop type, as well as on the crop dimensions and
brittleness.
19
Adjustment
Adjust the concave as close as possible to the drum:
-- in case of small grain (e.g. trefoil) and other diffi-
cult--to--thresh crops;
-- in case of winter barley, hard to shell and when
grains do not break.
Use the standard adjustment (10 mm) in the following
situations:
-- for crops such as grain, rye, oats, etc...;
-- if grains break; first of all, decrease the drum
speed.
Adjust the concave as far as possible from the drum:
-- for brittle, large grains;
-- for pulses such as peas, beans, etc...;
-- when straw is very brittle and sieves are over-
loaded (e.g. rape);
-- when grains break, e.g. in case of grain, when the
drum speed is set at its min. value.
NOTE:
-- If grains break, first of all decrease the drum
speed. Usually straw and grains breakage is
not due to a small clearance, rather to a very
high speed of the drum.
-- The shorter the drum clearance, the higher
the quantity of grains separated from straw in
the concave.
-- When harvesting winter barley, rasping
bars (F) can be fitting under the concave, for
a higher friction on the concave itself, before
grains fall through the grating.
20
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CONCAVE TYPES
21
Concave type Row distance (A) Row distance (B) Wire diameter (C) Number
Grain concave 14 9 3.5 14
Maize concave 26 10 6 10
NOTE: For rice threshing, drum and concave are

equipped with pegs so that rice is separated from
straw. In case of rice threshing with a drum and a con-
cave equipped with conveyor bars, rice can be easily
shelled and broken.
22
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Adjustments
GRAIN CONCAVE
The concave for standard conditions and with dry

crop, as well as the universal concave, are adjusted
as follows:
1. The control lever (A) is in the second notch from
the top.
2. Adjust the concave to drum clearance at 10 mm
next to the first bar, at the concave front.
next to the last but one bar. 23
MAIZE CONCAVE
1. The concave control lever (A) is in the seventh

notch from the top.
next to the rear bar.
RICE CONCAVE
24
1. The concave control lever (A) is in the fifth notch
from the top.
next to the rear bar.
4. Check that the distance between the tines is the
same.
5. Possibly, adjust the drum again by loosening the
set keys and moving the drum.
25
26
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DUST SHEET
The dust sheet prevents any dust and chaff inlet.
The dust sheet is adjusted by the nut (A) so that the
clearance between threshing bars and dust sheet (B)
corresponds to 2 mm.
For maize threshing, the dust sheet should be re-
moved.
STONE TRAP
The stone trap gathers stones and foreign bodies that

could damage the drum and the concave. When the
stone trap is full, these object could go back to the
straw elevator.
27
For maize harvesting, a cover plate must be fitted on
the stone trap.
Stone trap cleaning
1. Clean the stone trap at least once a day.

2. Fully lift the header.
3. Place the safety latch in position (L).
4. Move upwards the lever (C) so that the guard (B)
opens.
28
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SECTION 72 -- SEPARATION -- CHAPTER 1 1
SECTION 72 -- SEPARATION
Page
Beater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Beater shaft, bearing and drive belt replacement . . . . . . . . . . . . . . . . . . . . 4
Straw walker and straw walker shaft replacement . . . . . . . . . . . . . . . . . . . . 6
Straw walker adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
604.64.961.00 - 04 - 2003
2 SECTION 72 -- SEPARATION -- CHAPTER 1
BEATER
The beater allows the flow from the drum to the straw
walker and prevents straw from winding around the
drum.
The beater shaft speed must correspond to 875 rpm.
This speed is extremely important because all other
parts are operated by the beater shaft.
The rasp bar (A) must be fitted as close as possible
to the drum threshing bars. If new threshing bars are
fitted, always check this distance (B). Threshing bars
can be adjusted through the grain tank opening.
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BEATER SHAFT
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BEATER SHAFT, BEARING AND DRIVE BELT REPLACEMENT
Removal
On the right side, remove:

1. The chain (V) (fig. 4),
2. The drum variator belt.
3. Remove the tailing elevator from the tailing un-
load tube. There are eight fastening screws (A)
(fig. 4) at the top and two fastening screws (B)
(fig. 5) of the grain elevator.
4. Remove the three fastening screws (C) (fig. 6) of
the tailing unload tube (left side).
5. Push the tailing elevator to the left, remove the
tailing unload tube and make the tailing elevator
swing to its lowest position.
6. Remove the pulley (D) of the beater variator 4
(fig. 3).
7. Remove the variator links (E) (fig. 3) and the
thrust bearing (F).
8. Remove the set key (G) (fig. 3) and the special
washer (H) (bevelled side towards the bearing).
On the left side, in sequence:
9. Remove the hinged guard.
10. Remove the drive belt of the eccentric shaft (J)
(fig. 3).
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11. First of all remove the pulley (S) (6 screws), then

the pulley (L) (fig. 8). Remove the machine parts
in the following order (from the straw walkers):
-- Both rasp bars of the beater (M) (fig. 7) on
the V--grooved side.
-- The cover plate (N) (fig. 7).
-- The close cover plates.
-- Both head keys (O) (fig. 3).
-- The left bearing (P) (fig. 3).
-- Remove the four fastening screws on the
right bearing housing (R) (fig. 3) and take out
the beater shaft with the bearing, pushing to
the right.
Installation
6
Assemble the parts in the reverse order of removal.

IMPORTANT: Adjust the main drive belt guide with
operating threshing mechanism, at a distance of
8 ± 0.5 mm from the main drive pulley.
Tighten the nuts of the beater shaft at the following
tightening torques:
first nut: 200 Nm
ring nut: 250 Nm
Fit the special washer (H) (fig. 3) with the bevelled
side towards the bearing on the right side of the
beater shaft.
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STRAW WALKER AND STRAW

WALKER SHAFT REPLACEMENT
Straw walker replacement:

1. Remove the sieves.
2. Remove the straw walkers.
Straw walker shaft removal:
• Straw walker rear shaft
1. Remove the guard plug (A) (fig. 13/ 14) and the
safety bracket (B) on the right side.
2. Remove the bearing ring (C) on the left side.
3. Remove the bearing fastening screws on both
sides.
4. Remove both bearings.
5. Take the shaft out of the machine.
• Straw walker front shaft
1. Remove the guard plug (A) (fig. 13/ 14) and the
safety bracket (B) on the left side.
2. Remove the drive pulley (D) (fig. 13/ 14) on the
right side.
3. Remove the bearing fastening screws on both
sides.
4. Remove both bearings. Take the bearing out of
the machine, from the inner side, to the right,
using the special tool (F) (fig. 10).
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Straw walker bearings
When one bearing must be replaced, all the felt

gaskets must be make water--tight with engine oil.
Tighten the nut (P) (fig. 9) to the torque of 105 Nm.
604.64.961.00 - 04 - 2003
Straw walker shaft assembly -- TC 54
• Straw walker rear shaft:

1. Fit the pre--assembled shaft on the machine.
2. Assemble the left bearing and press it against the
stop.
3. Lock the left bearing with the four fastening
screws and fit the bearing ring (C) (fig. 13).
4. Assemble the right bearing and push it against
the frame plate.
5. Lock the right bearing with the four fastening
screws.
6. Further press the bearing against the stop.
7. Install the required number of shims (E) (fig. 13)
and the safety bracket (B) (the distance between 10
shims --E-- and safety bracket --B-- should be
lower than 1 mm).
8. Position the guard plug (A) (fig. 13).
• Straw walker front shaft
Fit the straw walker front shaft like the rear shaft,
starting from the right side.
NOTE: To install the bearing on the right side, use the
special tool (G) (fig. 10 and 12) [to be made locally].
The groove (J) (fig. 11) in the right bearing housing
(front shaft) must be at the bottom, so that grease can
reach the bearing.
The grease fitting (K) (fig. 13) should be positioned at
a 90_ angle with respect to the V--groove. Before as-
sembly, dip all felt rings in oil.
11
12
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TC 54
13
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Straw walker shaft assembly -- TC 56 • Straw walker front shaft

• Straw walker rear shaft Fit the straw walker front shaft like the rear shaft,
1. Fit the pre--assembled shaft on the machine. starting from the right side.
NOTE: To install the bearing on the right side, use the
2. Install the left bearing keeping a clearance of 70
special tool (G) (fig. 10 and 12) [to be made locally].
mm (fig. 14).
The groove (J) (fig. 11) in the right bearing housing
3. Lock the left bearing with four fastening screws (front shaft) must be at the bottom, so that grease can
and fit the bearing ring (C) (fig. 14). reach the bearing. The grease fitting (K) (fig. 14)
4. Assemble the right bearing and push it against should be positioned at a 90_ angle with respect to
the frame plate. the V--groove. Before assembly, dip all felt rings in oil.
5. Lock the right bearing with the four fastening Straw walker assembly
screws. 1. Lock the straw walker front shaft with the drive
6. Further press the bearing against the stop. belt, so that the first crank towards the shaft drive
side is in the highest position.
7. Install the required number of shims (E) (fig. 14)
and the safety bracket (B) (the distance between 2. Assemble all straw walkers on the shafts. Fit the
shims --E-- and safety bracket --B-- should be fastening screws in the front shaft without tighten-
lower than 1 mm). ing them.
3. Place the thinner washers on the front bearing
8. Position the guard plug (A) (fig. 14).
plate and the thicker ones on the rear bearing
plate.
4. Keep an even clearance between the straw
walkers, with a max. distance of 3 mm (measured
at the front shaft and at the end).
5. Tighten the front shaft screws.
6. Fit the screws on the rear shaft and check if all
screws can be tightened easily. Install all the
parts again, proceeding in the reverse order of
disassembly.
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TC 56
14
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Vibrating plate position
TC 54
15
TC 56
16
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STRAW WALKER ADJUSTMENT

STRAW WALKER
Straw walkers aid grain separation from the straw

and eject the straw from the combine.
In case of crop with short and brittle straw, it could be
advisable covering all the straw walker vertical open-
ings. These cover sheets (C) are supplied with the
machine.
17
Between beater and straw walker a straw--retaining

canvas (D) is installed, to slow down the flow of crop
fallen down from the beater onto the straw walkers
and to favour the best separation of grains from
straw.
18
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604.64.961.00 - 04 - 2003
SECTION 74 -- CLEANING -- CHAPTER 1 1
SECTION 74 -- CLEANING
Chapter 1
Page
Fan variator replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Deflector and cleaning fan adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Grain pan and cleaning shoe removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Upper and lower cleaning shoe removal and installation . . . . . . . . . . . . . . 6
Eccentric shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Upper and lower cleaning shoe removal --
Installation with sieve levelling cleaning system . . . . . . . . . . . . . . . . . . . . . . 15
Sieve levelling cleaning system upper sieve adjustment . . . . . . . . . . . . . . 17
Cleaning function adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Grain pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cleaning shoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Self--levelling cleaning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Adjustable sieve types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
604.64.961.00 - 04 - 2003
2 SECTION 74 -- CLEANING -- CHAPTER 1
FAN VARIATOR REPLACEMENT
Mechanical adjustment
The fan variator belts (A) and (B) are tensioned by

moving the whole variator (C).
Adjustment
Loosen the central screw (D) and tighten the nut (E)
until reaching the correct tension. 1
Variator belt replacement
1. Loosen the central screw (D) of the variator (C).

2. Loosen the nut (E) as much as possible and push
the variator upwards.
3. Remove the belts.
4. Install all the parts again, proceeding in the re-
verse order of disassembly.
Adjustment
1. Adjust the nuts (F) so that in the min. and max.

position there is a gap of 1 mm between the
pulley.
2. Place the fan variator in half--open position to ad-
just the belt tension.
Electrical adjustment -- optional

(fig. 2)
The variator adjustment knob has been replaced by

the actuator (G). The variator min. and max. position
adjustment must by carried out by the nuts (F). 2
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DEFLECTOR AND CLEANING FAN

ADJUSTMENT
(fig. 3 and 4)
TC 54 -- TC 56
Two horizontal deflectors
Four deflectors on the fan bottom plate
Measurements: see table and figure.
Model A B C D E F
TC 54 230 430 230 430 40 120

TC 56 205 415 205 415 40 120
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FAN REPLACEMENT
Removal
Remove the following parts on the left side:

1. guards,
2. eccentric drive belt (A) and pulley (B),
3. elevator drive belt (C),
4. drive bar (D),
5. guard (E),
6. 2 screws (F) (fastening the rubber belt),
7. 4 screws (G).
Remove the following parts on the right side:

1. fan variator lower belt,
2. 4 screws (H).
Assembly
Install all the parts again, proceeding in the reverse
order of disassembly.
IMPORTANT: Install the same quantity of shims (K)
previously installed.
604.64.961.00 - 04 - 2003
GRAIN PAN AND CLEANING SHOE

REMOVAL
Grain pan removal
Remove the following parts:

1. straw elevator,
2. stone trap,
3. transition plate (A) (fig. 7) [with the plate (A),
loosen also the fasteners of the hydraulic line and
of the brake line],
4. both sieves,
5. 2 screws (B) (fig. 8) on the front right and left part
of the grain pan,
6. 2 screws (C) (fig. 9) on the rear and left part of the
grain pan (connection to the upper cleaning
shoe).
Take out the grain pan from the front. 7
Grain pan assembly
1. Install the grain pan in the middle of the frame in

line with the upper cleaning shoe (maximum tol-
erance = 3 mm).
2. Tighten the screws (C) (fig. 9) on both sides.
3. Tighten the rubber bushings (1) and (2) without a
high effort and tighten the screws (B) (fig. 8) on
both sides.
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UPPER AND LOWER CLEANING SHOE

REMOVAL AND INSTALLATION
Remove the following parts:
1. left side guard,

2. eccentric drive pulley and eccentric drive belt,
3. right and left drive bar,
4. fan,
5. upper and lower sieve,
6. grain pan,
7. screws (D) and articulation joints (E) (fig. 10) on
both sides, 10
8. screws (G) (fig. 11) and articulation joints (F)

(fig. 10) on both sides,
11
9. screws (H) (fig. 12), (J) (fig. 13) and suspension

links (K) (fig. 12) on both sides,
12
604.64.961.00 - 04 - 2003
10. fastening cable of the performance control sen-

sor of the upper cleaning shoe,
11. upper cleaning shoe,
13
12. screws (P) (fig. 10) and articulation joint (M)

(fig. 10) removing the plate (N) (fig. 14),
14
13. fastening screws of the two U--profiles (L)

(fig. 15) on both sides,
14. lower cleaning shoe.
15
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Assembly and adjustment
The articulation link is formed by two parts (A) and (B)

held together by a rubber bushing. The angle of 22_
is extremely important and cannot be modified any-
more.
16
Assemble the main swinging links (fig. 17) on both

sides. Tighten only the fastening screws (E) (fig. 17)
on the right side.
Assemble the lower cleaning shoe and align it in the
center of the frame.
17
18
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Assemble the suspension links (G) (fig. 19) without

tightening the fastening screws.
19
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Assemble the upper cleaning shoe and align it in the

center following the same procedure used for the
lower cleaning shoe (max. tolerance: 3 mm).
Assemble the rear suspension links (F) (fig. 20) with
the articulation points at (9) and (10). Tighten all the
fastening screws (fig. 21).
Assemble the grain pan and align it in the center of the
frame.
20
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Assemble the supports (H) (fig. 21) on both sides of

the lower cleaning shoe and connect them through
the articulation link (C), without tightening the fasten-
ing screws (6).
Check if the lower cleaning shoe is in the middle of the
frame and tighten the fastening screws.
21
22
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Assemble the front suspension links (fig. 23) on both

sides with the fastening screws (E) (fig. 21).
Check that the grain pan is in the center of the frame,
tighten all the fastening screws of the links (J) (fig. 23)
tightening first the fastening screws (3) on the right
side (fig. 21).
Assemble the upper and lower sieve.
23
Install the eccentric drive bars (L) (fig. 24) on both

sides and fit a spacer with 3 mm thickness in point (X)
only on the right side (fig. 21). Tighten the fastening
screws in point (4) on the right side as well.
Adjust the drive bar (L) (fig. 24) on the left side at half
of its stroke rotating the eccentric shaft (V--groove
with 90 angle with respect to the drive bar).
The distance (Y) (fig. 24) (between the spacer on the
bar and the outside diameter of the articulation point)
corresponds to 10.5 mm.
24
604.64.961.00 - 04 - 2003
Measure the distance (Z) (fig. 25) between the bar

and the outside diameter of the articulation point, on
the left side.
The number of shims to be added is Z --10.5 mm.
Tighten the bar fastening screws with the joint (C)
(fig. 24) on the left side.
25
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ECCENTRIC SHAFT
Removal
Remove the pulleys from the shaft and the drive bars
of the cleaning shoe, on both sides. The eccentric
blocks on the shaft can be removed from the latter
using the two holes in the blocks.
Remove the screws (A) (fig. 26) and (B) of the bear-
ing housing and turn them so that they fit to the frame
holes.
Assembly
Install the shaft with the bearing and the assembled

bearing housing on the frame left side.
Tighten the fastening screws (A) (fig. 27). Install the
housing (C) and the bearing on the right side, until the
housing (C) can be fastened with the screws (B).
IMPORTANT: 26
-- While assembling the eccentric blocks (A)
(fig. 28) and (B), make sure they are pressed
against the tapered side of the eccentric shaft.
-- While assembling the pulleys (C) (fig. 28) and (D)
on the shaft, there should be no gap between ec-
centric blocks and pulleys.
27
604.64.961.00 - 04 - 2003
UPPER AND LOWER CLEANING SHOE

REMOVAL -- INSTALLATION WITH
SIEVE LEVELLING CLEANING SYSTEM
The different positions of sieves and vibrating plates
on the grain pan are automatically adjusted by the
actuator (E) (fig. 29 and 30)
[operated by the electronic box (F)].
28
604.64.961.00 - 04 - 2003
Before removing the grain pan, park the combine on

even ground. Operate the ignition and engage the
threshing mechanism lever. The vibrating plates of
the grain pan should be parallel to the machine frame,
while the sieve sections must be horizontal. Remove
the actuator. Remove the grain pan and the upper/
lower cleaning shoes.
Assembly
Install the shoe and the grain pan as described.

Before connecting the actuator (E) in point (K)
(fig. 29), adjust the electronic box (F) (fig. 30) from
the dashboard.
Proceed as follows: M L
1. Make sure the combine is horizontal.
2. Connect the cables (L) (fig. 29).
3. Operate the ignition in the cab.
N E
4. Move the electronic box (F) (fig. 30) so that the
second of the three lights (G) switches on
(fig. 30).
5. Engage two or three times the threshing mechan-
ism lever.
6. The actuator (E) reaches the correct position de-
pending on the position of the electronic box (F).
7. Release the lever of the threshing mechanism.
8. Switch the ignition off.
K
9. Align the four holes (D) (fig. 33) to position the
sieve sections horizontally.
10. Connect the actuator (K) (fig. 29). 29
If required, rotate the bar (N) inside or outside for
a correct connection.
11. Fit the connector (M) (fig. 29) in the holes (D)
(fig. 33) from the front to the rear part for maize
and in the opposite direction for the other crops.
30
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SIEVE LEVELLING CLEANING SYSTEM

UPPER SIEVE ADJUSTMENT
If any part of the upper sieve must be replaced, the

sieve must be adjusted again.
Carry out the adjustment proceeding as follows:
1. Position the sieve on a flat surface.
2. Fit the rods (A) (fig. 31) on the sieve frame as a
pre--assembled unit. If required, fit some shims in
point (B). Tighten the fastening screws.
31
3. Remove the actuator in point (C) (fig. 32).

4. Position the vibrating plates of the grain pan par-
allel to the machine frame.
The four holes (D) (fig. 33) must be aligned.
32
33
604.64.961.00 - 04 - 2003
5. Install the special tool (E) (fig. 34) as shown in

fig. 35. The pin (F) should just touch the leaf
spring (G) (fig. 35).
6. Measure the distance (X) (fig. 36).
7. Install the upper sieve fully forward.
8. In this position, measure the new distance (X1).
9. The difference between (X) and (X1) should
correspond to 39 mm (± 1).
The distance can be adjusted by adding or re- Nut
moving shims (H) (fig. 35).

The sieve sections must be parallel to the machine O--ring
frame. Thread--locking
Loctite
Carry out the adjustment proceeding as follows:
1. With the special tool (E) (fig. 31) (equipped with
an M13 wrench) remove the screws (F). 34
2. Align the sections so that they are parallel.
Tighten the screws (F) (fig. 31).
Position the combine on level ground. Start the igni-
tion and engage the threshing mechanism lever.
Connect the actuator as shown in fig. 29 [possibly
adapt the length of the bar (N) (fig. 29) by tightening
or loosening it].
35
36
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CLEANING FUNCTION ADJUSTMENT
Introduction
The cleaning process is used to separate threshed

grains from chaff and short straw.
1. The grain pan (9) arranges the crop and conveys
it to the sieves.
2. The sieves (10) separate grains from chaff and
short straw.
3. The fan (11) blows a strong and even air flow
through the sieves, so that chaff and short straw
are blown away.
37
604.64.961.00 - 04 - 2003
The cleaning process is used to separate threshed

grains from chaff and short straw.
Parts
A Grain pan
B Fan
C Upper sieve
D Lower sieve
E Grain auger
F Tailing auger
H Air baffle
l Grate
J Grate
38
GRAIN PAN
The long toothed grain pan starts under the concave
and ends under the straw walkers. An eccentric shaft
moves the grain pan from the left to the right and vice
versa.
A shaft full stroke corresponds to the length of one
level of the grain pan.
Chaff and grains separated from straw fall through
the concave (± 90%) and through the grate (± 7%), on
the grain pan, where grain is fully sieved by shaking.
Toothed extensions are fitted at the end of the grain
pan.
The grain collected by the straw walkers (3%) falls on
the back of the grain pan.
604.64.961.00 - 04 - 2003
FAN
The fan blows a strong and even air flow through the
sieves, so that chaff and short straw are blown away
and clean grain can fall through the sieves.
By the fan variator, the fan speed can be changed de-
pending on the grain type. The air flow direction is de-
termined by air deflectors.
To get a perfect cleaning, the fan must be correctly
adjusted on the machine.
A correctly adjusted air flow operates mainly on the
first fourth of the upper sieve, removing straw and
chaff and letting most grains fall through it.
The remaining sieve surface must be regularly
loaded with chaff and straw.
The best way to control air flow is stopping the ma-
chine after ±30 metres and checking that there is not
too much grain in the tailing conveyor. After this
check, control the sieve load as well.
-- If the clean surface of the upper sieve is too small
and air deflectors are wrongly adjusted, the air
flow is not enough. This situation produces dirty
grains and causes loss of grains.
-- If, instead, the clean surface of the upper sieve is
too large, the air flow is too strong. In this case,
grains are blown over the sieves and then out of
the combine.
-- If the clean surface of the upper sieve is not rec-
tangular, check the fan, the fan housing and the
air deflectors, as one of these parts could be bent
and blow air only in one direction.
During maize threshing, use the cleaning fan protec-
tion plates, so that the fan housing is not damaged by
the cob stems. 39
604.64.961.00 - 04 - 2003
CLEANING SHOE
The cleaning shoe has two adjustable sieves.

The upper sieve, at the back, has an adjustable part
and a grate.
The upper sieve filters all grains and uncompletely
threshed ears (with grains) from the unwished crop
residues falling on the ground through the sieve end.
The lower sieve is the last screen. Clean grain falls
through it and is conveyed to the grain tank. Uncom-
pletely threshed ears move on the sieve, are col-
lected by the tailing system and go back to the drum,
for their final threshing.
Round and heavy grains fall directly through the
upper sieve, onto the lower sieve, where the remain-
ing chaff and short straw are separated from grains. 40
SELF--LEVELLING CLEANING SYSTEM

(optional)
TC combines can be equipped with a self--levelling

cleaning system. The different parts of the upper
sieve remain horizontal even while working hillsides,
on slopes up to 17%.
41
604.64.961.00 - 04 - 2003
ADJUSTABLE SIEVE TYPES
a) Upper sieve
NH, 1 1/8”
-- It is used for the standard European condi-
tions, for cereals and rice.
-- It is adjusted in the lowest position.
42
Hart Carter, 1 1/8”

-- It is used for dry crop (short straws), for cer-
eals and rice.
-- It is adjusted in the lowest position.
43
Hart Carter, 1 5/8” sieve

-- It is used for maize harvesting.
-- It is adjusted in the upper position.
44
604.64.961.00 - 04 - 2003
Graepel extension (only without self--levelling

cleaning system)
-- It is fitted at the rear end of the upper sieve,
instead of the grating.
-- It is used for harvesting grass seeds, rape,
trefoil, beans, soya and dry cereals and with
weeds causing a short straw overload in the
tailing elevator.
45
b) Lower sieve
Hart Carter, 13/16”:
it is used for all crop types and in all conditions.
Round hole sieve:
3.5 mm: small seeds
16 mm: maize and beans
18 mm: maize and beans
46
604.64.961.00 - 04 - 2003
Sieves can be adjusted according to different angles.

The upper sieve has three positions for the non--self--
levelling cleaning system and two positions for the
self--levelling cleaning system. The lower sieve has
only one position.
The sieve angle can be increased if the combines
works with dry crop or if the grain quantity in the tailing
system must be decreased.
The upper sieve extension can be made leaving the
sieves as flat as possible, so that the threshed crop
does not accumulate on the end of the upper sieve.
Usually, the upper sieve is fastened in the lowest
position.
604.64.961.00 - 04 - 2003
Sieve adjustment depending on the crop type
Using the handle, adjust the sieve openings depend-

ing on the grain size. In standard conditions, the
openings must be as small as possible, to get a clean
grain sample.
Check if the opening width is correct by throwing a
handful of grains on the closed sieves and opening
the sieves until grain falls through them.
Starting from this position, open the upper sieve by
one further peg, because clean grain and residues
must fall through the upper sieve.
The lower sieve separates clean grain from the resi-
dues.
In case of units without self--levelling cleaning sys-
tem, the rear part of the upper sieve must be opened
by one more peg with respect to the front part of the
upper sieve, because this extension must collect
again all the grains and unthreshed crop.
To check the sieve adjustments, check the quantity
of material inside the residue conveyor. This con-
veyor should contain a reduced quantity of clean
grain or even no clean grain. A too high quantity of re-
turn clean grain is a clear symptom that the sieve
openings are too small.
A too high quantity of clean grain in the residue con-
veyor can cause the breakage and loss of grains
through the sieves. When, on the other hand, the
sieve openings are too large, the grain tank contains
a too dirty grain sample.
604.64.961.00 - 04 - 2003
SECTION 80 -- GRAIN STORAGE -- CHAPTER 1 1
SECTION 80 -- GRAIN STORAGE
Chapter 1 -- Crop transport

Page
Lower augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Grain tank filling auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tailing distribution auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Unloading auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
604.64.961.00 - 04 - 2003
2 SECTION 80 -- GRAIN STORAGE -- CHAPTER 1
LOWER AUGERS
Removal
1. Remove the elevator chain and the guard (A)

(fig. 1) from the lower gear.
2. Remove the pin (B) (fig. 1).
3. Remove the bearings (C) (fig. 2) and (D), the
seals and bearing plates.
4. Turn the auger by about 120 mm outside and to
the left.
5. Remove the lower gear (E) (fig. 1).
6. Rotate the auger to the left.
Installation

8. While installing the bearings (C) (fig. 1) and (D),
position the gear (E) in the middle of the elevator
housing.
604.64.961.00 - 04 - 2003
GRAIN TANK FILLING AUGER

The filling auger is operated by the chain (A) through
the grain elevator upper shaft gear.
The drive chain (A) is tensioned by the intermediate
wheel (B).
Removal
1. Remove the drive chain (A).
2. Remove the grain elevator filling auger with the

screws (C) , on both sides of the elevator.
3. Remove the fastening screws (D) inside the grain

tank.
4. Remove the filling auger.
Installation
604.64.961.00 - 04 - 2003
TAILING DISTRIBUTION AUGER
The tailing distribution auger is operated by the

chain (A) (fig. 5) through the tailing elevator upper
shaft gear.
The drive chain (A) is tensioned by the intermediate

wheel (B) (fig. 5).
Removal
1. Remove the drive chain (A) (fig. 5).

2. To clear the tailing elevator from the tailing unload
tube, remove the fastening screws (C) (fig. 3) on
both sides of the elevator. 5
3. Remove the fastening screws (D) of the grain el-

evator.
4. Remove the three fastening screws (E) on the left

side of the tailing unload tube.
5. Press the tailing elevator upwards and remove
the tailing unload tube on the right side.
Installation
Proceed in the reverse order of removal.
604.64.961.00 - 04 - 2003
UNLOADING AUGER
Removal and installation of the grain tank unload tube with auger
Remove the screws (A) (fig. 8), (B) and (E) with the
pin (F).
Installation
Proceed in the reverse order of removal.

IMPORTANT: Make sure the augers are positioned
correctly, that is the flights of the augers should be in
the same direction.
Adjust until getting a distance of 66 mm.
If the contour (D) (fig. 8) touches the bracket (C), de-
crease the distance of 66 mm, until getting a clear-
ance of 2 mm.
To remove only the universal joint (G) (fig. 8), rotate
the grain tank unload tube into its operating position.
In this position, the universal joint (G) is fully extended
and the two joint halves can be removed.
604.64.961.00 - 04 - 2003
Adjustment of the grain tank unload tube

bearing
The distance (K) must correspond to 8.0 mm and it

can be adjusted by the shims (K) (fig. 9).
Grain elevator lower auger slip clutch
To adjust the clutch, press the spring (L) and the

nut (M) fully, one against the other, then loosen the
nut (M) by five turns.
10
604.64.961.00 - 04 - 2003
SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1 1
SECTION 90 -- CAB, PLATFORM, BODYWORK AND DECALS
Chapter 1
Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Broken windscreen removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
604.64.961.00 - 04 - 2003
2 SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1
INTRODUCTION
The description below concerns the operations re-

quired to replace a broken windscreen.
Due to the short life of the glass adhesive, its delivery
is the most complicated matter both for producer and
reseller.
For this purpose, we stipulated an agreement with
”Kent Industries”, one of the major glass adhesive
suppliers, with a distribution network spread all over
the world.
This company can give suggestions, recommenda-
tions and, if required, can supply the required tools for
the windscreen removal and installation.
REQUIRED TOOLS
To change the broken windscreen in the operator’s
cab of a TC combine, the following tools are required:
fig. 1: NH locking devices (2 each)

1 and 2: see details
figures 2 and 3
2a: rubber reduction ring
(diameter: 50 mm, thickness: ±17 mm)
2b: screws M10x25
(with welded tab)
2c: screws M8x25
(with jam nut)
604.64.961.00 - 04 - 2003
604.64.961.00 - 04 - 2003
Fig. 4: Kent Industries tools:

-- 1 Kent no. 3 threader
-- 1 no. 4 adhesive cutting wire
-- 2 Kent no. 5 supporting handles
-- 2 Kent glass pullers (not shown).
Other tools required:
-- plasticizer as adhesive component
-- thinner
-- glass cleanser
-- adhesive component
604.64.961.00 - 04 - 2003
BROKEN WINDSCREEN REMOVAL

1. Remove the cab upper part with the cab lights
and the windscreen wiper.
2. Remove the rubber weatherstrips (A) under the
windscreen, inside the cab (fig. 5).
3. Spray the plasticizer (Kent release agent) on the
adhesive between glass and cab frame, then let
it rest for 5 minutes (fig. 6).
The release agent contributes to the lubrication
and simultaneous cooling of the puller wire.
4. Using a Kent no. 3 threader tool, pull the wire (it
should be about 50 longer than the windscreen
height) through the center of the windscreen
upper and lower part.
5. Assemble the Kent no. 5 supporting handles on
both ends of the cutting wire.
6. Cut the windscreen sawing it to the left and to the
right.
604.64.961.00 - 04 - 2003
7. Keep the puller wire at the same height of the

weatherstrip edge to prevent cutting the glass
(fig. 8).
8. Fasten the NH locking device at half the height of
the windscreen, under the latter, to keep the
windscreen in the correct position.
Fig. 9: tool no. 1 (seen from below)
Fig. 10: tool no. 2 (seen from the top).
10
604.64.961.00 - 04 - 2003
9. To this purpose, fasten the NH locking devices

first in point (A) and then in point (C). During the
cutting procedure (fig. 11), in the passage
from (B) to (D) on the opposite side, fasten both
the other locking devices.
11
10. Remove the broken windscreen with the help of

a second operator, using Kent glass pullers
(fig. 12).
11. Before fitting the glass puller, clean the wind-
screen outer part with the Kent glass cleanser
”Glass Kleen”.
12. If the old adhesive is still sticky on the cab edge,
do not remove it. Anyway, remove all the re-
moved adhesive sections. Clear the central fitting
layer of all foreign bodies using an air jet.
12
13. Correctly position the glass and mark the correct

position with a paper band (E) (fig. 13).
14. Cut the paper band in point (F) (fig. 13), then re-
move the windscreen.
15. Fully remove the release agent of the central fit-
ting layer using ”Kent Acrysol”. Before assem-
bling the central fitting layer, ”Acrysol” should be
fully evaporated.
16. Grease the glass black edge with ”Acrysol”. Let
”Acrysol” evaporate fully.
13
604.64.961.00 - 04 - 2003
17. Lay a primer of URP--B, agitating the bottle be-

fore use; let the primer dry (fig. 14). Treat all
badly--painted areas with URP--B and let it dry for
about 10 minutes.
Never lay the primer on an old adhesive!
18. Remove the cartridge metal cover and drill the
cartridge bit before tightening the spraying
nozzle.
19. Cut the nozzle and spray ”Urefix 2000” Kent by a
hand or pneumatic gun.
20. The height (X) of the material should be about
3--5 mm if laid on old adhesive or 10--14 mm on
bare metal (fig. 15 and 16).
14
15
16
604.64.961.00 - 04 - 2003
21. Assemble the windscreen in the correct position

(previously marked) within 10 minutes (fig. 17).
22. Press the windscreen evenly until getting a good
adhesion between windscreen and ”Dreiix 2000”.
23. Apply the special tools no. 2 at the top of the cab
(fig. 17) and the special tools no. 1 at the bottom
of the cab (fig. 7). These tools must be used
only to keep the windscreen in the correct
position. DO NOT FORCE THEM DURING AS-
SEMBLY!
The hardening speed by vulcanization is about

3--4 mm after 24 hours, at the temperature of
20_C and air relative humidity of 50%.
NOTE: At a temperature lower than 5_C ”Urefix”
does not vulcanize. 17
24. Position the paper bands (A) on both sides of the

groove (B) and below the windscreen (fig. 18).
25. Fill the groove (B) with silicone rubber, then polish
it. Remove the paper bands (A).
26. Clean the windscreen using ”Glass Kleen” Kent
(non--silicone cleanser).
27. Remove the special tools (1) and (2) after 4--4.5
hours. Fit a rubber weatherstrip under the wind-
screen, inside the cab, then position the cab
upper side again, with cab lights and windscreen
wiper.
18
604.64.961.00 - 04 - 2003
GENERAL INSTRUCTIONS
Preservation of a closed cartridge: from 9 to 12
months.
Hardening speed by vulcanization: from 3 to 4 mm
after 24 hours (at a temperature of 20_C and air rela-
tive humidity of 50%). At temperatures lower than
5_C ”Urefix” does not vulcanize.
Reaction temperature = 15_C.
Outer layer build up after 15 minutes.
Recommended adhesive quantity:
for the windscreen of a TC series combine: 3 car-
tridges, if the previous adhesive layer has been re-
moved or 2 cartridges in case of standard repair
works.
604.64.961.00 - 04 - 2003

Manual Service New Holland TC54 TC56 AL59

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Manual Service New Holland TC54 TC56 AL59

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REPAIR MANUAL

Print No. 604.64.961.00

NEW HOLLAND IS A BRAND OF CNH.

CHAPTER 2 -- COOLANT FILTER

SECTION 25 -- FRONT MECHANICAL DRIVE

SECTION 29 -- HYDROSTATIC TRANSMISSION

CHAPTER 2 -- HYDRAULIC SYSTEM (AL)

SECTION 33 -- BRAKES & CONTROLS

SECTION 35 -- HYDRAULIC SYSTEMS

CHAPTER 2 -- AL 59, LEVELLING AND PRESSURE CONTROL

SECTION 50 -- CAB CLIMATE CONTROL

SECTION 55 -- ELECTRICAL SYSTEM

SECTION 60 -- PRODUCT FEEDING

SECTION 80 -- GRAIN STORAGE

SECTION 90 -- CAB, PLATFORM, BODYWORK AND DECALS

No reproduction, though partial, of text and illustrations allowed

SHIMMING O--RING SEALS

PROTECTING THE IMPORTANT: if welding must be performed on the

• If welding in close proximity to a computer

This warning symbol points out important personal safety messages.

ACCIDENT PREVENTION • Do not carry out repair operations with someone

UNITS OF MEASURE -- CONVERSION CHART

1 mm -- 3/76” = 0.03937 in 1 Inch = 25.4 mm

1 ha = 2.471 acre 1 acre = 0.4047 ha

1 litre = 0.0063 barrel 1 barrel = 158.987 litre

1 kg = 2.204 pound 1 pound = 0.4536 kg

1 Nm = 0.7376 lbf.ft 1 lbf ft = 1.3558 Nm

1 bar = 14.505 lbf/in2(psi) 1 lbf/in2(psi) = 0.06894 bar

1 _C = ((1.8 x _C) + 32)_F 1 _F = (0.56 x (_C -- 32))_C

MINIMUM HARDWARE TIGHTENING TORQUES

IN NEWTON-METRES -- Nm (FOOT POUNDS -- LBF. FT)

METRIC HARDWARE AND LOCKNUTS

CLASS 5.8 CLASS 8.8 CLASS 10.9 LOCKNUT

NOTE: torque values shown with * are inch pounds.

HEX NUTS AND LOCKNUTS

PROPERTY CLASS CLOCK MARKING

IN NEWTON-METERS -- Nm (FOOT POUNDS -- LBF. FT)

INCH HARDWARE AND LOCKNUTS

SAE GRADE 2 SAE GRADE 5 SAE GRADE 8 LOCKNUTS

NOTE: torque values shown with * are inch pounds.

SAE GRADE 2 SAE GRADE 5 SAE GRADE 8

REGULAR NUTS SAE GRADE 5 SAE GRADE 8

EXPLANATION OF MACHINE SERIAL NUMBERS

809262001: The third digit indicates the product line.

809262001: Product line number (1) and batch toge-

809262001: The last 3 digits are a sequential

Summarizing we can say that this machine is the first

SPEED (high idle)

Combine right side

(1) Only machines with 5 straw walkers and hydrostatic transmission

Cylinder head screws (fig. 1)

4. If the pump needs no inner setting, before disas-

5. Remove the engine adjustment guard (F) (fig. 4).

7. Make a puller referring to figure 5. Fasten the

OIL FILTER -- replace at each oil change.

FILTER -- ENGINE HOUSING AIR BLEED

DESCRIPTION TC54 TC56 TC56+

Mechanical Hydrostatic Mechanical Hydrostatic Hydrostatic

DESCRIPTION TC54 TC56 TC56+

Mechanical Hydrostatic Mechanical Hydrostatic Hydrostatic

Face angle 44515’--44530’ relative to the valve head

Stem diameter Standard: 9.401--9.421 mm

Stem diameter Standard: 9.426--9.446 mm

CAMSHAFT LOBE LIFT